PACIFIC National has increased routine coal train inspections after a fractured bogie that posed a high derailment risk went undetected at Kooragang in 2017 before the train took on a full load at Tahmoor Colliery.
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The loaded Pacific National coal train travelled from the colliery 75 kilometres south west of Sydney to Newcastle on December 12, 2017 before the fracture was detected at Kooragang Coal Terminal, more than 24 hours after it was missed by a Pacific National maintenance worker at Newcastle Coal Infrastructure Group's Kooragang terminal.
In a report today the Australian Transport Safety Bureau said it was probable the fracture was visible on December 11, 2017 but not picked up by the maintenance worker because of his position on the other side of the bogie.
The train travelled empty from Kooragang to Tahmoor on December 11 and returned fully laden the next day. Between December 10 and 12 the wagon operated within the allowable 100 tonne gross limit and "the operation of the train and wagon loading does not appear to have contributed to this occurrence," the ATSB said.
The bogie design "has a history of fatigue cracking which increases the risk of derailment if the cracking is not identified", the ATSB said.
"The fractured bogie was indentified during a roll-by inspection on 12 December, likely preventing a derailment," the ATSB said.
The fracture was on the lead bogie of the train's 35th wagon.
Investigations showed trackside monitoring equipment recorded elevated temperatures and increased bearing angles in the days before the fracture was identified which were "likely a result of the bogie fracture progressing", but the changes did not trigger an automatic alert requiring action.
The ATSB found the Pacific National maintenance worker's primary function on December 11 was to observe the wagon doors close.
"It was not clear if this worker was deemed to additionally be conducting a roll-by inspection. The worker was positioned on the opposite side (to the bogie fracture) of the wagon and did not report any defects. The bogie was probably visibly fractured at the time," the ATSB said.
"The roll-by inspection completed on 12 December was completed by a single worker, with the worker positioned on the same side as the fractured bogie and the defect was identified."
The ATSB noted the train underwent unit train maintenance and a full train examination on December 8, 2017 at the Pacific National Lithgow maintenance depot where no defects were reported.
Pacific National said it revised its maintenance schedule to accommodate the need for a more thorough examination of the bogie area.
