A case study of the effect of lubrication and profile grinding on low rail roll-over derailments at CSX transportation

Abstract Kingsport and Blue Ridge are two subdivisions of CSX Transportation's Corbin Division. Annually they carry 42 million gross tons (MGT) of predominantly 100 ton coal car traffic through Kentucky, Tennessee, and North Carolina. Because of the mountainous terrain, the track has several sharp curves (up to 14°) and steep grades (up to 1.2%). Between the period of January 1990 through October 1991, eight derailments occurred. Some of the derailments were called low rail roll-over derailments and the others, although not listed as low rail rollover derailments, had several common features. Under normal operating conditions the track structure would have been considered good. However, because of the rugged conditions on these two subdivisions, the track structure needed strengthening and upgrading. Factors contributing to low rail roll-over include heavy axle loads, under-balanced train speeds, inadequate lubrication, wide track gauge and poor rail head profiles. During the period of the derailments, maintaining track gauge, line and level was a continuous operation. In the sharp curves, damage occurred rapidly to newly replaced timber ties and premium head hardened rail. The average life of the low rail in a 14° curve was 18 months (60 MGT). These conditions were costly and required a solution. Research and tests carried out by National Research Council of Canada, CSX Transportation and Loram Maintenance of Way, led to the development of a comprehensive lubrication and grinding program. The lubrication emphasized friction control between the low rail-wheel interface. The grinding method was changed from corrective to preventive. NRC/ LORAM asymmetric profile geometry of low and high rails was scrupulously maintained. Since the implementation of these two programs, there has not been a low rail roll-over derailment or a derailment with any feature associated with low rail roll-over derailment.