Document Exx1L0OmboGzYGq16VYp5Dd6b
ASSOCIATION OF AMERICAN RAILROADS SAFETY AND CASUALTY PREVENTION BUREAU OF EXPLOSIVES
ANNUAL REPORT OF HAZARDOUS MATERIALS
TRANSPORTED BY RAIL
YEAR 1993
Report BOE 93-1
JULY 31,1994
CMA110085
SPECIAL NOTICE
Doe to a computer processing error, the information on the number of hazardous materials carloads for the years 1989 through 1991 were overestimated in previous Annual Reports on Hazardous Materials By Rail. AAR detected and corrected this error and has changed the data in this report to reflect the corrected figures. Because of this error, comparisons of data from 1989 through 1991 Annual Reports on Hazardous Materials By Rail and 15193 data from this report is difficult Should you have any questions please see page 20 for a point of contact
i
CMA 110086
The Association of American Railroads, Bureau of Explosives has maintained records on railroad accidents and incidents involving explosives and other dangerous goods since its inception in 1907. It has maintained a computerized data base of railroad hazardous materials incidents since 1975. It is from this database that most of these statistics are derived.
For the purpose of the Bureau's database an accident is a situation in which a railcar of hazardous material derails, catches fire, explodes, suffers a serious sideswipe or involves a death. It does not have to release its contents, meet any dollar damage figure, or any other requirement An incident is classified as the unintentional release of a hazardous material while in transportation (including loading and unloading). This release does not usually involve an accident An incident may also be referred to as a NonAccident Release (NAR). The numbers of incidents found in this report may vary from those reported by DOT'S Reseach and Special Programs Administration (RSPA) and Federal Railroad Administration (FRA) because of the definitions of accident and incident as well as the fact that the Bureau's data base does not record fuel leaks from locomotives.
While hazardous materials are transported by rail in various types of rail cars such as tank cars, covered hoppers, gondolas, box cars, and trailers and/or containers on flat cars (TOFC/COFC), the majority (70%) of hazardous materials move in tank cars. This percentage has varied over the past several years but has generally declined from 82% in 1982 to the present level. This decline has been primarily due to the increasing use of TOFC/COFC and intermodal portable tanks.
Of the 1,205 Non-Accident Releases in 1993,1,077 or 89% were from tank cars. Of the remainder, 120 came from TOFC/COFC service and 8 from all the other car types. Because most hazardous materials continue to be transported in tank cars and the vast majority of leaks are from these containers, this report deals primarily with tank cars.
This report is based on information on railroad hazardous materials releases maintained by the AAR's Bureau of Explosives, and information available from the U.S. Department of Transportation. Railroads are required to report train accidents/incidents to die Federal Railroad Administration (FRA), including those that result in the release of a hazardous material, if they meet or exceed certain reporting requirements. Railroads (as well as all transporters of hazardous materials) are required to report to the Department of Transportation (DOT) any incident involving the unintentional release of a hazardous material or hazardous waste during transportation (including loading, unloading, and temporary storage), even if it is not involved in an FRA reportable train accident (See Appendix for explanation of reporting requirements). The vast majority of U.S. and Canadian railroads voluntarily provide the AAR with copies of the Hazardous Materials Incident Reports filed with DOT. These DOT5800.1 reports, along with on-scene reports from Bureau of Explosives Inspectors and several other sources, are combined, compared, and distilled to produce the information which goes into the Bureau Accident/Incident Database. Because of the multiple sources of data and the finer detail, we feel this
1
CMA110087
V'T
information is more precise than that kept by other sources.
Wmk
ZSif `
All information contained in this report dealing with non-accident releases of
hazardous materials are derived from the AaR's Accident/Incident Database. All
information pertaining to derailments and train accidents is derived from FRA statistics.
Railroad industry statistics for the transportation of hazardous materials show that over the past seven years the frequency of non-accident hazardous materials releases as a percentage of hazardous materials carloads has declined by a very small amount (See Graph #1). This decline is due to increased safety efforts of the railroad industry, increased awareness and concern of chemical shippers, changes in rail car fittings and design, deregulation, and increased spending on railroad physical plant
-
Non Accident Releases (NAR's) of hazardous materials consist of leaks,
splashes, as well as venting from safety relief devices. The majority of the reported
non-accident releases involve relatively small quantities of hazardous materials, usually less
than 100 gallons. Of the 1,077 non-accident releases from tank cars in 1993, 637 or 59%
were due to loose or defective fittings (see BOE Report BOE 93-2). Releases from
pressure relief devices accounted for 401 or 37%.
>r
The number of loaded rail car originations used in this report are obtained from
TRAIN n, the AAR's railcar interchange data base. All of the major freight railroads and
many of the short lines and regional railroads report their waybill information, car
interchanges, and car locations to TRAIN II. Estimates vary as to the extent of the traffic
captured by TRAIN n, but for the purposes of this year's report AAR
it captures
90% of all rail traffic in the U.S.
** -
The railroads use the seven (7) digit Standard Transportation Commodity Code
(STCC) to set rates as well as track the types of commodities moving by rail. All hazardous
material traffic is assigned a Product Class STC Code and a HazMat Code. The HazMat
Code begins with the two digits "49". This "49" designation is intended to flag hazardous
materials, not for rating purposes. Hazardous wastes are assigned a STC Code which begins
with "48". These unique numbers enable the railroads to track their hazardous material and
hazardous waste shipments, electronically prepare shipping papers in accordance with DOT
regulations, and provide required emergency response information, keyed to the STCC number.
Figure #1 is a list of the top 125 hazardous materials transported in tank cars
by rail This information was obtained from TRAIN Q. These commodities
up
approximately 95% of the movements of hazardous materials in tank cars. The list is
ranked by total tank car originations.
2 CMA 110088
FIGURE #1
1993 Top 125 Hazardous Commodities Movements By Tank Car Originations
HAZMAT RANK QE___
COMMODITY
DOT
TOTAL
HAZARD TANKCAR
CLASS ORIGINS
1. 49 352 40 Z 49 300 40 3. 49 457 70 4. 49 057 52 5. 49 205 23 6. 49 042 10 7. 49 092 30
8. 49 302 47 9. 49 057 92 10. 49 057 06 11. 49 057 81 12. 49 045 09 13. 49 072 65 14. 49 302 28 15. 49 057 82
16. 49 057 66 17. 49 15168 18. 49 091 52 19. 49 057 47 20. 49 151 13 21. 49 057 04 22. 49 151 17 23. 49 411 96 24. 49 082 24 25. 49 081 75 26. 49 201 08 27. 49 151 10 28. 49 092 15 29. 49 101 65 30. 49 057 78 31. 49 091 51 3Z 49 057 67 33. 49 151 12 34. 49 212 20
Sodium Hydroxide Sulfuric Add Molten Sulfur **
liquefied Petroleum Gas Chlorine Anhydrous Ammonia ** Methyl Alcohol Phosphoric Add Vinyl Chloride Butane (IPG) Propane (LPG) Carbon Dioxide, Ref. Liq. Styrene Monomer, Inhib. Hydrochloric Add Propylene (LPG) Propane/Propylene (LPG) Fuel Oil Denatured Alcohol Isobutane (LPG) Fuel Oil Butadiene Fuel Oil, #2 Elevated Temperature Material Methyl Tert-Butyl Ether Gasoline Ethylene Oxide Fuel Oil Fuel, Aviation, Turbine Crude Oil, Petroleum Vinyl Chloride Denatured Alcohol Petroleum Gases, liquefied Fuel Oil Phenol, Solid
8 8 9 2.1 23 22 3 8 2.1 2.1 2.1 22 3 8 2.1
2.1 CL 3 2.1 CL 2.1 CL 9 3 3 23 CL
3 3 2.1 3 Zl CL 6.1
82373 64,867 61281 55362 47,057 44353 27,428 21383 20.414 20337 19,921 17,685 15,750 14,746 12332 10,834 10,772 10,414 10318 9353 9,086 8357 8328 8,186 8,065 8,018 7,963 7,731 7,686 6,618
6318 6,112 5,916
3
CMA110089
HAZMAT
RANK COPE__
35. 49 057 68 36. 49 411 39 37. 49 356 45 38. 49 300 42 39. 49 072 70 40. 49 15120 41. 49 066 20 42. 49 081 10 43. 49 093 51 44. 49 152 59 45. 49 072 50 46. 49 352 30 47. 49 064 20 48. 49 302 48 49. 49 313 03 50. 49 081 32 51. 49 08177 52. 49 122 10 53. 49 601 31 54. 49 205 08 55. 49 057 50 56. 49 215 75 57. 49 091 66 58. 49 057 02 59. 49 093 05 60. 49 183 35 61. 49 122 15 62. 49 151 85 63. 49 102 59 64. 49 081 05 65. 49 151 11 66. 49 161 41 67. 49 101 85 68. 49 091 17 69. 49 300 30 70. 49 131 68 71. 49 300 24 72. 49 151 67 73. 49 313 04
FIGURE 1 (cont.)
COMMODITY
Petroleum Gases, liquefied Elevated Temperature Material Hexamethylenediamine Sol. Sulfuric Add, Spent Vinyl Acetate Fuel Oil #6 Propylene Oxide Benzene Xylene Petroleum Naphtha Methyl Methacrylate Monomer Potassium Hydroxide Acrylonitrile Phosphoric Add Acetic Add, Glacial Cydohexane Gasoline Fuel Oil Env. Hazardous Substance, n.o.s. Sulfur Dioxide Isobutane (LPG) Toluene Diisocyanate Ethylene Dichloride Butane Toluene Hydrogen Peroxide Sol Butyl Acrylate Combustible liquid, n.o.s. Petroleum Naphtha Acetone Fuel Oil Phosphorus, White Flammable Liquid, n.o.s. Butyl Alcohol Oleum Formaldehyde Solution Hydrogen Fluoride Fuel, Aviation, Turbine Acetic Anhydride
4
DOT
TOTAL
HAZARD TANKCAR
CLASS ORIGINS
2.1 5,915 9 5,825 8 5,711 8 5,623 3 5,479 33 5,188 FL 5,107 3 4,946 3 4,834 CL 4,432 3 4383 8 4,261 3 4,111
8 4,061 8 4,057 3 3,880 3 3,609 3 3,785 9 3,462 23 3,437 2.1 3^78 6.1 3371 3 3371 2.1 3,198 3 3,139 5.1 3,070 CL 2,918 CL 2,855 3 2,714 3 2,700 CL 2,697 42 2393
3 2380
3 2339
8 2382
CL 2311 8 2309 CL 2,173 8 2,142
CMA 110090
HAZMAT RANK CODE___
74. 49 216 13 75. 49 314 05 76. 49 092 37 77. 49 092 05 78. 49 187 74 79. 49 215 98 80. 49 072 10 81. 49 151 01 82. 49 302 08 83. 48 105 60 84. 49 365 40 85. 49 187 65 86. 49 411 02 87. 49 323 42 88. 49 057 07 89. 49 091 60 90. 49 101 02 91. 49 091 46 92. 49 092 43 93. 49 365 28 94. 49 633 30 95. 49 057 15 96. 49 091 41 97. 49 352 68 98. 49 302 21 99. 49 045 03 100. 49 102 53 101. 49 661 50 102. 49 057 48 103. 49 081 83 104. 49 057 61 105. 49 081 25 106. 49 104 90 107. 49 13194 108. 49 091 28 109. 49 210 27 110. 49 104 44 111. 49 072 15 112. 49 300 26
FIGURE 1 (cont) COMMODra
DOT
TOTAL
HAZARD TANKCAR
CLASS ORIGINS
Organophosphorus Pesticide Liq, Toxic 6.1
Acrylic Add
8
Methyl Alcohol
3
Isopropanol
3
Ammonium Nitrate Solution
5.1
Phenol, Molten
6.1
Acetaldehyde
3
2-Ethyl Hexanol
CL
Corrosive Liquid, n.o.5.
8
Waste Flammable Liquid, n.o.s.
9
Corrosive Liquid, n.o.s.
8
Sodium Chlorate Solutions
5.1
Other Reg. Substances (Capmiactum)
9
Ferric Chloride Sol.
8
Butene (LPG)
2.1
Ethyl Acetate
3
Alcoholic Beverage
3
Ethyl Alcohol
3
Methyl Ethyl Ketone
3
Corrosive liquid, n.o.s.
8
Emr. Haz. Sub. 1LO.S. (contains Creosote) 9
Butylene
2.1
Denatured Alcohol
3
Sodium Hydrosulfide SoL
8
Corrosive Liquid, n.o.s.
8
Argon, Ref. Liquid
23
Methyl Tert Butyl Ether
3
Env. Haz. Sub. (Phthalic Anhydride) 9
Isobutylene (LPG)
2.1
Hexane
3
Methyl Chloride
2.1
Carbon Disulfide
3
Aromatic Concentrates
3
Glycol Ethers
CL
Butyl Acetate
3
Hydrogen Cyanide, Anhydrous
23
Rosin Solution
3
Ethyl Acrylate, Inhib.
3
Hydrofiuorosilidc Add
8
2,068 2,010 1,984 1,952 1,882 1,813 1,754 1,668 1,626 1387 1,571
1,550 1316 1,479 1,477 1,446 1,439 1389 1382 1360 1368 1373 1373 1347 1346 1322
1302 1301 1371 1369 1335 1302 1,164
1,105 1,099 1,067 1,056 1,041 1,020
5
CMA110091
HAZ MAT RANK CODE___
113. 49 122 67 114. 49 152 45 115. 49 403 64 116. 49 102 45 117. 49 323 29 118. 49 103 20 119. 49 613 87 120. 49 205 04 121. 49 411 61 122. 49 055 10 123. 49 057 91 124. 49 187 75 125. 49 081 82
FIGURE 1 (cont)
COMMODITY
Fuel, Aviation, Turbine Oil, n.03. Formaldehyde Solution Oil n.03. Ferrous Chloride Solution Pulp Mill liquid Environmentally Hazardous Sub. Hydrogen Chloride, Ret Liq Maleic Anhydride Dimethylamine, Anhydrous Propane Hydrogen Peroxide Solutions Hexanes
DOT
TOTAL
HAZARD TANKCAR
t'LASS ORIGINS
3 1,081 CL 1,002 9 982 3 964
8 964 3 955 9 953 23 952 9 934
2.1 867 23 842 5.1 839 3 832
wall mha ihlppiS m MUwr a DMatia UrU ulirtaL MsHau
can fee shipped as a DMatea 41 er Class 9. Farthaput]puses at this ivpest we have eaatoaed the MevaueaaisefAahrdiaus Am
under the DMaiaa IS Has Mai Cads and the MaiMasati af Maksa Suite under the Claae 9 Haa Mat Cade).
YEAR 1993 1992 1991 1990 1989 1988
TOTAL TOP-125
907,472 872,643 852342 1,077,124
1,175381 837,985
TOTAL ALLHAZMAT 1,497,464
1361,817 1359373 1,404303 1323,774 1,153^26
Explanation of Hazard Class/Divisions used in Figure #1
2.1 * Flammable Gas 22 Non-Flammable Gas 23 - Poison Gas 3 - Flammable TuyiiH 42 - Spontaneously CimKimiKU
5.1 Oxidizing Material 6.1 - Poisonous Material 8 Corrosive Material 9 - Miscellaneous/ORM CL - Combustible liquid
6 CMA110092
An examination of Figure #1 will show that the same commodity name appears more than once. Due to differing contract rates, product differences, and shipper differentiation, a commodity with the same DOT proper shipping name, i.e., Liquefied Petroleum Gas, may be assigned several different Haz Mat Code numbers. For the purposes of transportation, they all present the same kind of hazard.
Figure #2 takes this situation into account and ranks the top 25 commodities by total rail volume (combining both tank car and other car types) by name, with those commodities with the same (or similar) names grouped together. These 25 commodities account for approximately 74% of all the hazardous materials shipped by rail
There are two columns of numbers used in this figure. The left column provides the number of carload originations for the individual STC Code and the right column provides a total for all of the STC Codes associated with that commodity name.
Figure #2 points out that the highest volume of hazardous material shipped by rail is Freight Rate Shipments/Freight Forwarder Traffic/Shipper Association Traffic. These are loads of hazardous materials which are being shipped under special contract rates, intennodal traffic (trailer or container on a flat car) which may contain more than one type of a hazardous material, and freight forwarder traffic. The amount of hazardous materials in these shipments can vary from a single package to the entire load.
FIGURE 2 1993 Top 25 Hazardous Materials By Rail Volume
HAZ MAT HAZ RANK CODE CLASS COMMODITY NAME
1. 4950150 4950130 4950110
4-- --
Freight Rate Shipments Freight Forwarder Traffic Shipper Association Traffic
z 4905752 2.1 liquefied Petroleum Gas (LPG)
4905781 2.1 Propane 4905706 2.1 Butane 4905782 2.1 Propylene 4905766 2.1 LPG (propane/propylene) 4905747 2.1 Isobutane 4905767 2.1 LPG (butylene/isobutane) 4905768 2.1 LPG (butane/butylene) 4905750 2.1 Isobutane
7
313,751 63,463 3367
55,615 20,104 20353 12333 10,847 10318 6319 5,915 3385
TOTAL
380381
151,688
CMA 110093
FIGURE 2 (cont.)
4905702 2.1 Butane 4905707 2.1 LPG 4905748 2.1 Isobutylene 4905791 2.1 LPG
3. 4935240 8
Sodium Hydroxide (Caustic Soda)
4. 4930040 8
Sulfuric Arid
5. 4945770 9
Molten Sulfur
6. 4904210 22 Anhydrous Ammonia
7. 4920523 23 Chlorine
8. 4909230 3
Methyl Alcohol
9. 4915113 CL Fuel Oil
4915110 CL
H II
4915112 CL
mm
4915111 CL
mm
10. 4905792 2.1 Vinyl Chloride
4905778 2.1
MM
11. 4930247 8
Phosphoric Arid
12. 4904509 22 Carbon Dioxide, Ret liquid
13. 4909152 3 4909151 3
Denatured Alcohol
*m
14. 4907265 3
Styrene Monomer, Inhibited
15. 4930228 8
Hydrochloric Arid
16. 4918310 5.1 Ammonium Nitrate Fertilizer
17. 4915168 CL Fuel Oil, Diesel
18. 4915117 CL Fuel Oil #2
19. 4905704 2.1 Butadiene
20. 4918723 5.1 Sodium Chlorate
21. 4941196 9
Elevated Temperature Material
22. 4908224 3
Methyl Tert Butyl Ether
23. 4908175 3
Gasoline
24. 4909215 3
Fuel, Aviation, Turbine
25. 4910165 3
Crude Oil, Petroleum
TOTAL - TOP 25 COMMODITIES
1,091,629
3,201 1,486 1,271
842
9,669 8,143 6362 3,051 20,429 6,618
10,414 6341
82,631 64,912 61300 44353 44345 27,442
27325
27,047
21,448 17,877
16,655
15,759 14,777 14,010 11306 9,980 9,087 8,851 8328 8,186 8,122 7,731 7,688
8 CMA 110094
Figure #3 takes these same 25 commodities and shows their historic ranking for the past 5 years. As demonstrated in this list, the seven consistently highest volume hazardous materials are Anhydrous Ammonia, Chlorine, Liquefied Petroleum Gas (IPG), Molten Sulfur, Sodium Hydroxide, Sulfuric Add, and Methyl Alcohol. These commodities accounted for 31% of all hazardous materials originated in 1993 and 46% of the tank car
originations.
FIGURE 3 Historic Ranking of Hazardous Materials Carloads
COMMODITY____________
1993
1993 1992 1991 1990 1989
CARLOADS RANK RANK RANK RANK RANK
Shipper/Freight Assoc. Liquefied Petroleum Gas Sodium Hydroxide Sulfuric Add Molten Sulfur Anhydrous Ammonia Chlorine Methyl Alcohol Fuel Oil Vinyl Chloride Phosphoric Add Carbon Dioxide, Ret Liq. Denatured Alcohol Styrene Monomer, Inhibited Hydrochloric Add Ammonium Nitrate Fuel Oil, Diesel Fuel Oil #2 Butadiene Sodium Chlorate Elevated Temperature Material Methyl Tert Butyl Ether Gasoline Fuel, Aviation, Turbine Crude Oil, Petroleum
380,581 151,688 82,631 64,912 61,300 44,553
44,545 27,442 27,225 27,047 21,448 17,877
16,655 15,759 14,777 14,010 11306 9,980 9,087 8,851 8,228
8,186 8,122 7,731 7,688
1 1 11 1
2 2 22 2
3 3 33 3
4 5 55 6
5 4 44 4
6 6 66 5
7 7 77 7
8
8
8 10
9
9
11
10 11
11
10 9
9 9 10
11 10 11 8 11
12 14 12 15 14
13
17
17 20
19
14 15 14 14 13
15
16
16 16
15
16 13 13 13 12
17 12 15 12 16
18 23 -- --
--
19 18 -- -- --
20 19 20 --
--
21 -- -- --
22 --
-- -- .--
23 21 21 18 18
24
----
--
25 20 18 17 17
Figure #4 takes some of the major DOT hazard dasses and portrays the non-acddent leakage frequency for these hazard classes. Where a particular commodity or commodities
9
CMA 110095
are responsible for a majority of the leaks in that hazard class, the commodity(ies) name and individual leak rate is shown. This figure demonstrates that Anhydrous Ammonia, LPG, Sulfuric Add, Hydrochloric Add and Phosphoric Add, the top movers in tank cars, are also the top leakers. The exception to this is Chlorine, which has a leak rate of 0.16 per 1000 (7 out of 44,520 carloads) tank cars shipped. This exception may be due to the hazard of die material, the type of tank car chlorine is shipped in (DOT 105) and the standardized valving arrangement.
FIGURE 4 Leakage Frequency By Hazard Class
1988 1989 1990 1991 1992 1993
(1) (2) (3)
Camedlty/
Car Cart
Car Cars
Car Can
Can Can
Can Can
Can Cart
HAZARD CLASS Laaka Shtpd Rata Laaka Shipd Rata Laaki Shipd Rata Leaks Shipd Rata Leaks Shipd Rate Leaks Shtpd Rate
LPG DIVISION 2.1
(Flaaneble Gas)
61 134 0.46 73 164 0.45
71 175 0.41 133 155 0.85 78 215 0.36 142 190 0.75
64 222 0.29 75 266 0.28
55 148 0.37 60 190 0.36
45 152 0.30 59 196 0.30
Amenta
67 54 1.24
62 67 0.93
68 56 1.21
59 71 0.83
68 52 1.31
80 44 1.82
DIVISION 2.2
135 125 1.08 151 152 0.99 139 134 1.04 107 161 0.66 114 62 1.83 134 66 2.03
Nonflasmble Gaa
Chlortna DIVISION 2.3
(Poison Gas)
l
I
89
R< tgulatod at a non- lasnat>la gat In t!
0 1-
0 2-
0 2-
0 11 -
6 45 0.13 13 67 0.19
7 45 0.1b 12 55 0.22
CLASS 3 (Hwash la Liquid)
Z37 188 1.26 247 214 1.15 246 211 1.17 189 254 0.74 200 188 1.06 228 209 1.09
COMUSTIBLE LIQUID
74 62 1.19
82 91 0.9
74 90 0.82 74 114 0.65
57 92 0.62
74 82 0.90
DIVISION 1.1 (Poison B)
6 12 0.67
1 15 0.07
7 14 0.5 7 17 0.41 12 16 0.75
8 26 0.31
Sulfuric Acid Phoaphorlc Acid
Hydrochloric Acid
110
26 65
51 2.16 27 0.96
11 5.91
CLASS a
394 223 1.77
(Corroslvo Mat'l)
118 71 1.66 66 32 2.06 172 15 11.5
532 273 1.95
148 64 2.31 116 75 31 2.42 65 173 14 12.4 108
575 253 2.27 449
80 1.45 35 1.86 20 5.40
311 1.44
165 58 2.84 74 28 2.64 92 14 6.57
525 230 2.28
159 65 2.45
no 25 4.40
69 15 4.60
511 242 2.11
HAZARDOUS HASTE OTHERS
3 2 0.15 61 81 0.75
10 3 0.33 64 129 0.5
14 4 0.35 13
6 0.22
61 122 0.5 61 179 0.34
8 4 2.0 58 105 0.55
9 4 2.25 42 130 0.32
TOTAL
985 857 1.15 1165 1092 1.07 1258 1018 1.24 975 1308 0.75 1047 954 1.09 1077 1010 1.07
10 CMA 110096
1. Sckcfd co--oditiw art riiirtirt hmd daat took. TOTAL include* Other hazard cki 2. 'Can Shipd' it loaded teak car origination* (ilOOO) m lapoeted to TRAIN II 3. Hate' ie aiunber of Ireking jncirtreti divided by 'Can Shipd'. (Lcaka per lftOO eaia chipped).
Graph #1 plots non-accident hazardous materials tank car leakage frequency between the years 1988 and 1993.
GRAPH #1 Tank Car Leakage Frequency
(per 1,000 carloads)
The AAR, the Rail Progress Institute (RPI) and Chemical Manufactures Association (CMA) have worked together to form several task forces and working groups to address methods of eliminating Non-Accident Releases. These groups have focused on tank car equipment, securement, loading and unloading procedures and operating practices. Many of the ideas and procedures developed by these groups have begun to be implemented. As shown by Graph #1 results from these efforts have had some effect
11
CMA 110097
Graphs #2 and #3 display tank car originations by DOT hazard class and non-accident tank car leaks by hazard class. These two graphs reveal several things: while corrosive materials account for 24% of tank car originations, they are responsible for 51% of the ieaks. This is due to the fact that the extremely corrosive nature of many of these products limits the use of a spring loaded safety relief device, which reseals itself after functioning, to those made of specialized materials. These cars are equipped with rupture disks which function only once and then remain open. These rupture disks are vulnerable to improper installation by shippers and pressure spikes encountered while shifting tank cars into and out of rail yards.
GRAPH #2 Tank Car Movements By DOT Hazard Class
Year 1993
DIVISION 2.3
DIVISION 2.2
CLASS B
24* -----
The AAR Tank Car Committee prohibited the use of lead disks as of January 1, 1989. A comparison of the figures for 1989 and 1990 releases due to rupture disk failures (Figure
12
CMA110098
GRAPH #3 Tank Car Leaks By DOT Hazard Class
Year 1993
5) shows a significant increase in the failure rate for this type of pressure relief device. This may be related to the more brittle nature of some of the materials substituted for lead rupture disks as well as improper installation. Some of these broken rupture disks can be attributed to the shipper overloading the car while others may be caused by train handling.
The second thing these graphs show is the disparity between percentage shipped by hazard class and the percentage leaked by hazard class. Class 3 (Flammable liquids) account for 20% of the originations and 21% of the leaks yet Combustible liquids accounted for 8% of the originations and 7% of the leaks. These materials are shipped in the same type of general service tank car. Division 2.1 (Flammable gas) accounted for 19% of originations and only 5% of the leaks, yet Division 22 (Non-flammable gas) accounted for 7% of originations and 12% of leaks. This is somewhat unusual in that many of the same type of cars are used in both services (LPG in the fall and winter and Anhydrous Ammonia in the spring and summer). Since they are the same car types and have the same valving arrangements the difference in the leakage percentage is difficult to explain. An additional factor in the leak rate for Division 22 (non-flammable gases) is the shipment of Carbon
13
CMA 110099
Dioxide and other refrigerated liquids in tank cars equipped with pressure regulators. These pressure regulators periodically function to release pressure which cools the contents. These releases are captured as Non-Acddent Releases. (For a more detailed description of non-accident releases by commodity and by source of leak see report BOE 93-2).
The information displayed in Graph #4 plots the number of train accidents reported to the FRA for the years 1988 through 1993. This graph shows that the number of train accidents went up in 1988 and 1989 but have genreally declined since then.
GRAPH #4 Train Accidents
YEAR Graph 5 plots the number of train accidents in which hazardous material cars were damaged or derailed along with the number of accidents in which a hazardous materials car released its product as a result of the derailment These releases range from the loss of the entire load due to a catastrophic tank failure to "minor" seepage from otherwise secure tnnlr car fittings when they roll over.
14
CMA 110100
It is interesting to note that while overall train accidents have generally declined over the past several years (see Graph #4), the number of those accidents involving damage to cars containing hazardous materials has gone up. This is partially due to the increasing number of commodities which DOT has chosen to regulate during this period i.e., Molten Sulfur and Elevated Temperature Materials.
GRAPH #5 Train Accidents Involving Haz Mat
Figure #5 is a detailed summary of railroad hazardous materials accidents and incidents for the year 1993.
The major problem these figures portray is the constantly high number of Non-Accident Releases of hazardous materials from tank cars, the majority of which are due to burst rupture disks on tank cars in corrosive material service. The Inter-Industry Task Force, comprised of representatives of AAR, CMA,and RPI has proposed various solutions to this problem and have published their results. Many of their recommendations have been adopted by both the rail carriers and chemical shippers.
15
cMA 110101
Four major changes which could reduce the releases due to burst rupture disks are being implemented without the need to obtain an exemption from DOT. These are (1) increasing the outage in the car, (2) reducing coupling speeds, (3) equipping tank cars in corrosive material service with safety vent baffles and (4) equipping them with safety valves which resist the corrosive effects of the material. Other changes, such as reducing the safety vent orifice size, eliminating the safety vent on tank cars in corrosive material service ("Total Containment") or the use of 1351bs or 1651bs rupture disks require exemptions or regulatory changes by DOT.
FIGURE 5
1993 Detailed Summary
HAZ MAT ORIGINATIONS;
Total Tank Cars (48 A 49 stcc only) Total Haz Mat Cars reported Estimated Total t
(xlOOO for all the above)
1988
857 1153 1268
1282
1092 1523 1675
1990
1018 1404 1615
1221
963 1359 1506
1992
954 1361 1497
1993
1009 1497 1646
NON-ACCIDENT RELEASES;
1988
TOTAL LEAKING TANK CARS 2 Sources of leaks: Safety Device (Valve Functioned) (Disk Ruptured) Bottom Fittings Manway liquid line Other Top Fittings Shell or Head
985
352 (77) (206) 174 280 106 108 50
1989
1165
499 (91) (336) 172 323 126 120 39
1990
1257
563 (79) (388) 152 362 141 144 34
1221
975
441 (56) (334) 139 253
97 98 21
1222
1047
473 (51) (369) 141 285 105 116
31
1993
1077
461 (55) (346) 117 287 129 130 39
DERAILMENTS,:
1988
NUMBER OF TRAIN ACCIDENTS:
- involving Hazardous Material Cars:
475
1989 517
1220
466
1991 525
1992 482
1993 559
Continued on next page 16
CMA 110102
FIGURE 5 (cont.)
1988 1989 NUMBER OF TRAIN ACCIDENTS (continued):
1990
1991
1222
1993
- in which a Haz Mat Car Damaged or Derailed:
- involving a Release:
- resulting in an Evacuation:
number of Cars Releasing Hazardous Materials:
237 251 236 293 230 262 44 55 35 47 27 29 32 28 20 28 11 15 74 84 90 84 33 58
CASUALTIES DUE TO HAZ MAT4: 1988
Injuries Fatalities
36 0
1989
36 0
1990
73 0
1991
75 0
1222
116 0
1993
65 0
NOTES:
t That data havt kata (milryWiif bf a factor to yitU aw ulimamd total. It is tsunami thatfor tht ytart 1964 duoufh 1966 TRAINB ccfoawd
about80%ofactualUS. twifmmiemi (Hrnirintmnf ifrirrJIrriYrjmrT Tf1Tiftnrir|ft ffimTMfTf ITn^pmifrfnjfimiiiiimrifp fiHTi r/trrrrrf T'T
orifbuttkms. ht 1990 TRAIN B taparad iyvonma0 65%.
,aen * "
tftnr it nrfmmrrf rmmiiiiMiwf) TTS
1 Thttt mtmbtn imott rndfidual looks; this mcludts mvhiplt looks from tht lame car.
3. Data obtnimad pva tht Ftdtral RailroadAdministration.
4. Data obtairttdpom Rtstrrck A Sptdal Propams Administration (RSPA) ofDOT.
Figure #6 shows the number of tank car loads, all car type loads, and the number of leaking tank cars for each DOT Hazard Class.
17
CMA 110103
FIGURE 6
1993 Car Loadings by DOT Hazard Class
Hazard Class
Tank Car Loads
All Car Loads
Division 1.1 thru 1.6 (*)
4
Division 2.1 (Flammabk Get)
195,915
Division 23 (Nom-Flammabk Gw) 66,185
Division 23 (m gw)
56,556
Class 3 (flammable U*dd)
209304
Combustible liquid
81395
ClaSS 4 (Flammable Solid)
3384
Division 5.1 (cmum)
9,039
Division 52 (ornc rmuid*)
43
Division 6.1 (foOmb)
25,997
ClaSS 7 (nadtaaoimMamiai)
0
Class 8 (omriMfiftowiar)
242,446
Class 9
96349
6366 196,812 68,096 56,722 216360 86,707
7,409 42,022
94
31353 217
249,725 124,720
Leaking Tank Cars
0 59 135 12 227 74
1 24
0
8
0 511
17
NOTE: - The number of car loads for Freight Rate/ShipperAssociation is not included in this figure because this description can fit one or mote of the DOT Hazard Classes listed above.
** The numbers far HAZARDOUS WASTE are included in the totals for CLASS 9 materials. They art broken out for reference only.
Figure #7 is the railcar originations, terminations and incidents listed by state. The originations and terminations are based on TRAIN II waybill data and reflect only the amount of hazardous materials traffic which originated or terminated in that state. It does not count "overhead" traffic (that traffic which originated or is destined for one state yet passes through another). Leak and splash data is derived from AAR's Accident/Incident Data Base. All figures are for tank car and other types of railcars combined.
18 CMA 110104
*
STATE
FIGURE 7
1993 Hazardous Materials Originations And Terminations By State
ORIGINATIONS TERMINATIONS
57 22,073 5,980 11,007 77,525 12330
94 0 7337 29399 37,701 15,431 7378 182,088 14,979
31,458 17,841 121,414 9,024
6,463 5354 14,953 13,815 14,160 24351 5,973 29,133 4369 6,065
266 40,685
18305 4,091 26,941 35,404
629 24,497 14,797 18,482 111,049 22,769 2,005
34 5347 74,960
43331 11,855 11336 135323 16,485 22,432 27,612 45,012 14310 15372 9,076 24,981 21,836 14349 18,869 16384 41300 7,602 10,485 2353 45,875 10,080 12,423 23,156 35,148
19
INCIDENTS leaks/splashes
0 39 52 18 159 24 1 0 3 20 33 4 6 66 17 17 12 76 2 11 0 28 8 53 6 9 32 2 33 0 9 5 24 12 49
CMA 110105
333g*ssaaBBH*88
STATE
ORIGINATIONS
15,550 10,032 25,059
21 7,309
52 26,119 214,458 10,572
20 7,311 20,734 4,196 16,733 19,763
TERMINATIONS
12^59 19,447 37,373 1,121 26,071
683 34,098 171,821 16,127 3,647 20,774 33,483 9,091 14,839 6,122
INCIDENTS LEAKS/SPLASHES
12 19 23 0 6 0 20 171 36 0 26 8 8 4 20
This is Part One of AAR's Annual Report on Hazardous Materials Transported by Rail (B^ 93*1). Additional information on Non Accident Releases by commodity by source of leak is avail* in Part Two of this report (BOE 93-2). Questions concerning any information eontumeH in this report should be directed to Paul Williams, Manager, Operations Analysis, Bureau of Explosives, Association of American Railroads.
Additional copies of the combined report are available for $25 from:
Association of American Railroads Bureau of Explosives 50 F Street, NW
Washington, DC 20001
20 CMA 110106
APPENDIX
Department Of Transportation reporting requirements:
Research and Special Projects Administration (RSPA) requirements for a hazardous material incident:
Each carrier who transports hazardous materials shall report to the Department of Transportation any incident which occurs during the course of transportation (including loading, unloading, and temporary storage) in which, as a direct result of hazardous materials any one (or more) of the following occurs:
o A person is killed; or o A person receives injuries; requiring his or her hospitalization; or o Estimated carrier or other property damage exceeds $50,000; or o An evacuation of the general public occurs lasting one or more hours; or o One or more major transportation arteries or facilities are closed or shut down
for one hour or more; or o The operational flight pattern or routine of an aircraft is altered; or o Fire, breakage, spillage, or suspected radioactive contamination occurs involving
shipment of radioactive material; or o Fire, breakage, spillage, or suspected radioactive contamination occurs involving
shipment of etiologic agents; or o A situation exists of such a nature (e.g^ a continuing danger to life exists at the
scene of an incident) that, in the opinion of the carrier, it should be reported to the Department of Transportation even though it does not meet the criteria of 49CFR Section 171.15(a)(1), (2), or (3); or o There is an unintentional release of a hazardous material from a package (including a tank car) or any quantity of hazardous waste has been discharged.
Federal Railroad Administration (FRA) reporting requirements:
o Any impact between railroad on-track equipment and an automobile, bus, truck, motorcycle, bicycle, farm vehicle, or pedestrian at a rail-highway grade crossing; or
o Any collision, derailment, fire, act of God, or other event involving operation of railroad on-track equipment (standing or moving) that results in more than $6,300! in damages to railroad on-track equipment, signals, tract, track structure,or roadbed; or
o Any event arising from the operation of a railroad which results in: - The death of one or more persons;
21
CMA 110107
- Injury to one or more persons other than railroad employees, that requires medical treatment;
Injury to one or more employees that requires medical treatment or results in restriction of work or motion for one or more days, one or more lost work days, transfer to another job, termination of employment, or loss of consciousness;
- Occupational illness of a railroad employees diagnosed by a physician.
1 ~ Amount changes every two years by regulation.
22 CMA 110108