Railcars contain multiple types of seals, gaskets, and o-rings that protect cargo, block moisture, and secure panels, hatches, and other equipment. From self-contained tanker and hopper cars to standard boxcar brakelines and many other applications, high-quality seals to help ensure rail fleet performance, safety, and operational efficiency.
Becoming aware of the signs and signals that a railcar seal may be failing, or has already failed, is critical to keeping rail transport safe, reliable, and within budget and time constraints. Here, we’ll look at some seal failure symptoms and implications, as well as preventive maintenance tips.
Physical Symptoms
Identifying a seal that’s degraded, failed, or approaching the end of its useful life helps reduce product loss, spills, and unplanned delays. Fortunately, there are clear physical signs that point to potential seal failures, including:
- Leaks. One of the most obvious signs of seal failure is leakage. Leaked fluid on, below, or around a railcar can indicate lip wear, improper gasket or seal installation, or material incompatibility. Corrosion due to fluid leaks may also be an indicator.
- Wear. Most seals show signs of wear prior to failure. These may include scoring, pitting, surface damage, cracks, and other physical problems. When a seal’s surface becomes damaged, it can no longer hold a tight seal and must be replaced.
- Pressure loss. Damaged sealing components, particularly on the locomotive, can cause pressure drops in various systems. This can lead to reduced braking performance, engine overheating due to coolant loss, and reduced engine efficiency.
Operational Impacts
Failed seals impact far more than an individual car and its contents. Shipping and travel schedules, crew and passenger safety, and supply chain logistics all get caught in the ripple effect of one train that’s out of service due to a seal failure. In the case of hazardous cargo spills or leaks, the cleanup process adds complexity and time to the process of bringing the train back on line.
Some additional ways failed seals have outsized effects on rail systems include:
- Unexpected downtime. When seals fail suddenly or catastrophically, emergency repairs cannot be delayed. This can result in blocked tracks, missed transfers, and rescheduling of other needed repairs or maintenance throughout the system.
- Product loss. When seals fail on tank or hopper cars, the result is a sudden leak that can spill large volumes of product or expose it to oxygen and other contaminants. Cleanup adds time to the repair process, especially if corrosive or hazardous substances are involved.
- Increased costs. Product loss, service delays from downtime, and reputational damage resulting from reliability issues can lead to significant profit loss and increased costs for rail operators.
Preventive Maintenance Tips
Given the significant operational impacts of rail seal failures, finding ways to prevent them is essential for safety, efficiency, and your company’s bottom line. A few things that you can do to prevent railcar seal failures include:
- Improving installation practices. Proper installation is essential in order to ensure that seals are seated correctly and to extend service life. It’s important to train your maintenance staff to remove, replace, and maintain them according to manufacturer’s specifications.
- Choosing the right materials. Not all materials are suitable for all railcar applications. Always consider the specific sealing application when selecting materials, including temperatures, pressures, exposure to fluids or corrosive materials, and in the case of tanker cars, the physical and chemical properties of the contents. Knowing these details will help determine if PTFE, FKM, Buna-N, silicone, or other polymers and elastomers are suitable.
- Prioritizing maintenance. Perhaps the most important thing that you can do to reduce the risk of seal failure is to create and follow a proactive maintenance schedule to inspect, lubricate, and replace seals. Regular maintenance extends the useful life of most seals and creates an easy opportunity to inspect them and catch problems early.
How MPRC Seals Reduce Failure Risks
To reduce the risk of rail seal failure, it’s also essential that you choose high-quality rail seals that you can rely on, such as those from MPRC. MPRC manufactures static and dynamic seals, gaskets, o-rings, and other custom solutions that meet the needs of the rail transportation industry. We have decades of experience serving this critical industry, and can provide guidance on material selection, seal design, and proper maintenance.
Partner with MPRC Seals for Railcar Applications
Instead of risking safety, operational delays, and product quality to low-quality rail seals or unexpected seal failures, learn to spot the warning signs, then reach out to MPRC Seals for reliable custom seals. Contact us to learn about our capabilities and material selection, or request a quote to start an order.