Bloomberg
Rail Industry Pushes Sensors Over Brakes After Ohio Train Crash
Thomas Black – February 26, 2023
(Bloomberg) — The train derailment that spilled toxic chemicals into a small Ohio town has revived a long-running debate about railroad safety — and some industry players think they have just the thing to resolve it.
The Feb. 3 crash of the Norfolk Southern Corp. train in East Palestine, Ohio, has renewed a push for railroads to adopt electronic brakes that could help prevent a malfunctioning train from endangering people and property. Electronically controlled pneumatic, or ECP, brakes have been touted for their capacity to bring trains to a halt in shorter distances and prevent dangerous pileups.
The Biden administration has blamed industry stonewalling for blocking regulations that would have mandated use of the systems on some trains — even though it isn’t clear that ECP brakes would’ve done much to mitigate an accident similar to the one in Ohio, and the proposed rules wouldn’t have applied to the train that crashed.
The railroad industry has found itself in a tight spot as the political furor around the accident grows, with former President Donald Trump turning up in East Palestine, and the derailment becoming a talking point on cable news and Capitol Hill. The episode has aggravated fears about the safety of sending chemicals and other hazardous materials over the rails, and raised the specter of new regulation at a time when railroads are coping with restive workers and annoyed customers.
Installing ECP brakes that the Biden administration and safety advocates favor would be expensive and cumbersome for a business beset by complaints about delays and lackluster service. The brakes need to be installed on each car to work properly — a daunting prospect for an industry with some 1.5 million cars on the tracks and little idle capacity.
A coalition that includes railcar makers, shippers and two large railroads say they have a different idea. They want to place sensors on railcars that could flag faulty equipment immediately to a train’s crew and others monitoring remotely. The system is being tested on 400 railcars and could be available commercially by the end of this year, according to the group, which calls itself RailPulse.
Such sensors could potentially catch problems like the overheated wheel bearing that likely caused the East Palestine wreck. Electronically controlled brakes, on the other hand, may not have even done much to mitigate the derailment if they were installed, based on a 2017 study by the National Academy of Sciences.
Notably, a sensor apparatus also would likely be much less expensive for the industry to put into place. RailPulse says its system would cost about $400 to $900 per railcar.
Smart Railcars
The use of remote sensing technology on the railroads isn’t entirely new. Currently, sensors known as wayside heat detectors placed along the tracks screen train cars for defects — and they sniffed out the trouble in Ohio. Wayside detectors were voluntarily adopted by railroads to reduce accidents; Norfolk Southern said it has nearly 1,000 of them.
According to a preliminary report by the National Safety Transportation Board, Norfolk Southern’s wayside detectors in Ohio were working, but caught the overheated wheel too late. The NTSB found that a wayside detector about 20 miles before the crash site measured the wheel bearing at 103 degrees Fahrenheit above ambient temperature — hot, but below a level that calls for the crew to stop and take a look.
However, the next detector, just ahead of the crash site, recorded a wheel temperature at 253 degrees above, a critical level. The sensor sounded an alarm, but it was too late. The wheel failed and caused 38 of the train’s 149 railcars to careen off the rails.
Sensors mounted directly on railcars could diagnose the issue sooner and buy critical time, backers say. Railcars will likely have multiple sensors in the near future that can detect anything from open doors to signs that equipment is in danger of failing, said David Shannon, general manager of RailPulse.
“Our objective is to make railcars smart,” Shannon said.
The group’s pilot program, which is testing five types of sensors, will be on 1,000 railcars by this summer, he said, and should be ready for real-world use by the end of this year. RailPulse plans to provide a subscription service to transmit the data to the cloud, and is counting on manufacturers to design the sensors the industry needs.
ECP Debate
Norfolk Southern was on the forefront of testing ECP brakes before the US Department of Transportation decided to require them on high hazard flammable trains in 2015. The company opposed the mandate because of cost, the brakes’ reliability and the inability to mix locomotives and railcars that didn’t have the system.
One of the biggest drawbacks of ECP brakes is that all the railcars on a train must have them or the system doesn’t work, making it impossible to phase in gradually. The rule followed a spate of derailments by trains shuttling crude oil from fracking hotspots where there were no pipelines to refineries.
As part of an infrastructure bill in 2015, Congress required the transportation department to justify the need for ECP braking. The National Academy of Sciences was ordered to examine computer modeling the department used to support its position that they had a significant safety advantage over conventional brakes.
After tests at a Norfolk Southern rail yard in Conway, Pennsylvania, and the New York Air Brake Facility in Watertown, New York, the academy said in a 2017 report that the department’s efforts to validate its modeling “do not instill sufficient confidence in DOT’s comparison of the estimated emergency performance of ECP braking systems” with other systems. That paved the way for the Trump administration to rescind the mandate.
In a Feb. 19 letter to Norfolk Southern Chief Executive Officer Alan Shaw, Transportation Secretary Pete Buttigieg faulted the industry for opposing ECP brakes. “Rather than support these efforts to improve rail safety, Norfolk Southern and other rail companies spend millions of dollars in the courts and lobbying members of Congress to oppose common-sense safety regulation,” Buttigieg wrote.
However, others in the federal government have pushed back on the idea that the ECP mandate would have prevented the Ohio crash.
“Some are saying the ECP (electronically controlled pneumatic) brake rule, if implemented, would’ve prevented this derailment. FALSE,” NTSB Chairman Jennifer Homendy said in a Feb. 16 tweet. She went on to explain why the Norfolk Southern train wasn’t designated as high hazard flammable. “This means even if the rule had gone into effect, this train wouldn’t have had ECP brakes.”
Uphill Battle
The prospect that regulators would swiftly put the electronic-braking rules in place following the Ohio crash is remote. To reinstate the mandate would be an uphill battle, a senior White House official acknowledged during a Feb. 17 briefing. The rulemaking process takes years and it would be difficult to pull off after Congress weighed in against the technology.
Similarly, persuading the entire railroad industry to go along with RailPulse’s sensors could be a tall order.
Workers are wary of new safety technologies that the industry touts, especially if they are aimed at replacing human inspections, said Mark Wallace, vice president of the Brotherhood of Locomotive Engineers and Trainmen. For the past five years, the railroads’ first priority has been profit, not safety, Wallace said. Operating profit margin for North American railroads increased to 39% last year from 34% in 2017.
“If you’re going to implement the technology, then you have to maintain the technology and you have to have somebody in place to make sure that it’s working properly,” he said.
Additionally, railcars are mostly owned by shippers and by leasing companies. Shippers are pushing to be able to track their freight cars just as they can for trailers on trucks, the railroads’ main competitor for freight. Some large railroads, including CSX Corp. and BNSF Railway, aren’t part of the coalition.