© U.S. Department Locomotive Crashworthiness of Transportation Federal Railroad and Cab W orking Conditions Administration Report to Congress Office of Safety Assurance and Compliance September 1996 stives THE SECRETARY OF TRANSPORTATION WASHINGTON, D.C. 20590 Septem ber 18, 1996 The Honorable Albert Gore, Jr. President o f the Senate Washington, D.C. 20515 Dear M r. President: I am pleased to submit the enclosed report prepared by the Federal Railroad Administration (FRA) on “Locomotive Crashworthiness and Cab Working Conditions,” as requested by the Rail Safety Enforcement and Review Act, Public Law 102-365. This report responds to the congressional mandate to report on issues related to: • health and safety of locomotive cab working conditions; • effectiveness of Association of American Railroads (AAR) Specification S-580; and • benefits and cost of additional locomotive crashworthiness features. The report summarizes the findings of FRA’s study, which included research on locomotive crashworthiness features, extensive consultations with a wide range of interested parties, and a field survey of actual locomotive working conditions. These findings indicate that a number of the crashworthiness features and working condition improvements identified in the Act merit further action by FRA in cooperation with the private sector. Identified priority safety improvements include implementation of stronger collision posts and fu ll height corner posts, incorporation of a crash refuge, improved fuel tank design, and improved methods to control noise and temperature levels inside the locomotive cab. Consistent with FRA’s emphasis on promoting a collaborative approach to railroad safety, FRA w ill seek the participation of railroads, employee representatives, manufacturers and suppliers, and other interested persons in determining the specific actions that may be appropriate to advance the safety and health of railroad crew members, based on the results of this study and other information that the parties may make available. FRA expects to refer locomotive crashworthiness issues to the newly constructed Railroad Safety Advisory Committee. That committee w ill make recommendations on the best course of action to implement the recommendations of this report, including voluntary initiatives, and regulatory standards where appropriate. 2 The U.S. rail industry has experienced significant growth over the past 15 years. The railroads are using larger, heavier locomotives which are more effective and efficient than the locomotives they are replacing. This growth has already been accompanied by some improvements in locomotive design and crew working conditions. I am confident that further improvements w ill be forthcoming if those most affected work together toward specific objectives that they participate in defining. I look forward to working w ith the Congress to advance our shared objective o f improving safety in the railroad industry. An identifical letter has been sent to the Speaker o f the House o f Representatives. Sincerely, Federico Pena Enclosure THE SECRETARY OF TRANSPORTATION WASHINGTON, D.C. 20590 Septem ber 18, 1996 The Honorable Newt Gingrich Speaker o f the House o f Representatives Washington, D.C. 20515 Dear Mr. Speaker: I am pleased to submit the enclosed report prepared by the Federal Railroad Administration (FRA) on “ Locomotive Crashworthiness and Cab Working Conditions,” as requested by the Rail Safety Enforcement and Review Act, Public Law 102-365. This report responds to the congressional mandate to report on issues related to: • health and safety of locomotive cab working conditions; • effectiveness of Association of American Railroads (AAR) Specification S-580; and • benefits and cost of additional locomotive crashworthiness features. The report summarizes the findings of FRA’s study, which included research on locomotive crashworthiness features, extensive consultations with a wide range of interested parties, and a field survey of actual locomotive working conditions. These findings indicate that a number of the crashworthiness features and working condition improvements identified in the Act merit further action by FRA in cooperation with the private sector. Identified priority safety improvements include implementation of stronger collision posts and full height corner posts, incorporation of a crash refuge, improved fuel tank design, and improved methods to control noise and temperature levels inside the locomotive cab. Consistent with FRA’s emphasis on promoting a collaborative approach to railroad safety, FRA w ill seek the participation of railroads, employee representatives, manufacturers and suppliers, and other interested persons in determining the specific actions that may be appropriate to advance the safety and health of railroad crew members, based on the results of this study and other information that the parties may make available. FRA expects to refer locomotive crashworthiness issues to the newly constructed Railroad Safety Advisory Committee. That committee w ill make recommendations on the best course of action to implement the recommendations of this report, including voluntary initiatives, and regulatory standards where appropriate. 2 The U.S. rail industry has experienced significant growth over the past 15 years. The railroads are using larger, heavier locomotives which are more effective and efficient than the locomotives they are replacing. This growth has already been accompanied by some improvements in locomotive design and crew working conditions. I am confident that further improvements w ill be forthcoming if those most affected work together toward specific objectives that they participate in defining. I look forward to working with the Congress to advance our shared objective of improving safety in the railroad industry. A n identical letter has been sent to the President o f the Senate. Sincerely, Federico Pena Enclosure TABLE OF CONTENTS Executive Summary .................................. i The M a nda te...................................................................................................................... vii Chapter 1 - Introduction .................................................................................................. 1-1 The Starting P oint .............................. .............................................................. 1-2 The Plan................................................................................ 1-3 Railroad Industry Meetings .......... ........................................................................... 1-3 Definitions ............................................................................................................ 1-7 Locomotive Collision Data Base.............................................................................. 1-7 Locomotive Crashworthiness Research Contract ..................................................... 1-7 Locomotive Cab Working Conditions .................................................................... 1-9 Chapter 2 - Locomotive Collision D a ta ........................................................................... 2-1 Establish Collision Data Base................................................................................... 2-1 Analysis of Data Base ............................................................................................. 2-2 Chapter 3 - Locomotive Crashworthiness ...................................................................... 3-1 Background............................................................................................................... 3-3 National Transportation Safety Board.............................. 3-3 Past Studies of Locomotive Crashworthiness .............................................. 3-7 A pproach................................................................................................................. 3-9 Model Development ............................................................ 3-11 Occupant Survivability Measures ............................................................................. 3-13 Model Validation ................................ 3-18 Baseline Crash Scenario.............................. 3-19 Summary of Results ................................................................................................. 3-19 Effectiveness of AAR Specification S-580 ................................................... 3-19 Braced Collision Posts .................................................................................. 3-23 Rollover Protection Devices.................................................. 3-27 Deflection Plates............................................................................................ 3-29 Shatterproof Windows .................................................................................. 3-31 Readily Accessible Crash Refuges ................. 3-35 Anticlimbers/Uniform Sill Heights.................................................................3-42 Equipment to Deter Entry of Flammable Liquids .......................................... 3-48 Other Findings................................................................................... 3-48 Comer Posts ................. 3-48 Fuel T anks ................... 3-49 Emergency Lighting ............................................................................. 3-58 Attachment of Interior Equipm ent.................................................................3-59 Optional Egress .............................................................................................3-59