Fortis_Design_Brief_Appendix_F_06_28_21.pdf
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- Fabrication & Testing of FORTIS 8-Axle Railcar
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- 89243222RNE000025
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This solicitation requests proposals for the fabrication and testing of a prototype FORTIS 8-Axle Railcar. The Department of Energy seeks to award a contract to conduct testing required by AAR S-2043 standards and obtain railcar approval from the AAR-EEC. Offerors must procure necessary documentation from AAR and fabricate a prototype that complies with AAR's Manual of Standards, including section S-2043. The railcar is intended to transport spent nuclear fuel casks in trains consisting of two buffer cars, one to seven cask cars, and an escort car, pulled by two locomotives. The design for the FORTIS 8-Axle Railcar will be provided to offerors. The successful bidder must complete fabrication and testing to verify the railcar meets AAR requirements for transport of spent nuclear fuel over a projected 50-year service life.
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FORTIS 8-AXLE SNF RAILCAR
DESIGN DOCUMENTATION
APPENDIX F – COOPER RATINGS
June 2021
Page F1 DOE 8-Axle SNF Car – EEC Submittal – Appendix F
Cooper E-Rating of DOE Cask Car Trains Given that railcars and locomotives come in various different lengths, weights, and axle load spacings, comparing their loading effects on railroad bridges is not straightforward. Cooper ratings are a mechanism/methodology to present the loading effects of different railcar, locomotive, and train configurations in a common format so that their effects on railroad bridges can be more readily compared. The larger the Cooper rating value for a given railcar/train configuration, the more severe its effect is on a railroad bridge. Most modern railroad bridges1 are designed to carry a load of Cooper E-802; in other words, if a given railcar/train configuration has an rating of less than E-80, a modern railroad bridge would have the capacity to carry it without any concerns.
A Cooper E-Rating was performed for a train consist containing the DOE 8-axle Cask Car.
The train consist is as outlined in the Atlas Report and is detailed in the table below.
Vehicle No. Vehicle Type GRL (lbs.)
1 6-axle Locomotive 415,000
2 Buffer Car 286,000
3 8-axle DOE Cask Car 630,000
4 Buffer Car 286,000
5 Escort Car 177,000
As seen in the results table, the 8-axle car causes the highest ratings for bridges with short spans (under 10 ft.), which are still lower than E-80, and should pose no problem for modern bridges (which likely have a capacity that is at least 25% higher in those span ranges). The expectation is that vehicles be designed to present an equipment rating of E-80 or lower.
1 Older railroad bridges, especially those on secondary lines, may have a capacity of less than E-80; their ability to carry heavy-duty span bolster cars needs to be evaluated on a case-by-case basis.
2 Among modern bridges, shorter bridge spans will have an even higher rating, with spans less than 11 ft., having a rating of E-100 or more.
Page F2
For comparison, Cooper E-Rating was also performed with a train consist containing the DOE 12-axle Cask Car3. This train consist is similar, as detailed in the table below.
Vehicle No. Vehicle Type GRL (lbs.)
1 6-axle Locomotive 415,000
2 Buffer Car 286,000
3 12-axle DOE Cask Car 789,000
4 Buffer Car 286,000
5 Escort Car 177,000
All resulting ratings for the 12-axle car are also less than E-80.
3 Reference: Report # DE-NE0008390, “Design & Prototype Fabrication of Railcars for Transport of HLRM,” AREVA Federal Services LLC, Mar. 6 2018.
Page F3
MOMENT, SHEAR, & REACTION RATING
Train: Locomotive, Buffer Car, One (1) 8-Axle Cask Car, Buffer Car, Escort Car
SPAN MAX. MAX. MAX. MOMENT SHEAR REACTION
LENGTH MOMENT SHEAR REACTION RATING RATING RATING
(ft) (ft-kips) (kips) (kips) 5 98.4 78.7 78.8 78.8 78.7 78.8
6 118.1 79.8 79.8 78.8 68.5 59.9 7 137.8 90.9 101.3 78.8 70.7 64.4 8 157.5 99.3 118.1 78.8 72.2 67.5 9 177.2 105.7 131.3 75.5 73.2 69.5
10 196.9 110.9 141.8 70.0 73.9 70.9 11 231.5 115.1 150.3 70.5 70.4 68.9 12 268.2 118.7 157.5 67.1 67.8 67.5 13 305.4 127.7 169.6 64.3 69.2 68.9 14 354.4 135.5 180.0 64.4 70.2 69.0 15 413.4 142.2 189.0 66.2 70.2 69.3 16 472.5 148.1 196.9 67.5 69.7 69.2 18 590.6 157.9 210.0 69.5 67.6 69.2 20 708.8 172.6 220.5 68.7 69.0 67.3 22 826.9 185.5 229.1 67.3 70.4 65.3 24 973.7 196.3 236.9 68.3 71.4 64.1 25 1051.3 201.1 243.1 68.9 71.2 64.1 26 1129.0 205.5 248.9 69.5 70.9 64.1 28 1284.6 213.3 259.2 70.3 70.6 63.0 30 1440.5 220.1 269.1 70.2 69.8 62.4 32 1596.5 226.0 286.7 70.1 68.8 63.0 35 1830.9 233.6 309.4 70.0 67.5 63.4 40 2222.2 252.0 355.4 67.8 66.8 65.8 45 2614.1 273.1 398.9 65.3 66.9 67.2 50 3049.8 296.5 436.3 64.1 67.9 67.7 55 3540.9 321.2 468.9 63.4 69.3 66.8 60 4122.2 346.9 500.7 63.5 70.7 65.3 65 4784.6 368.7 532.7 63.9 71.1 64.4 70 5558.5 387.4 560.0 65.1 70.1 63.2 75 6334.2 406.8 583.8 65.8 69.1 62.0 80 7148.1 427.3 604.5 66.2 68.8 60.7 85 8051.4 447.7 626.8 66.8 68.5 59.9 90 9012.9 465.7 649.8 67.5 67.9 59.4 95 9974.8 481.9 672.0 67.8 67.1 58.8
100 10937.2 496.5 695.3 67.8 66.2 58.6 110 12933.8 521.6 747.3 66.5 64.4 58.6 120 15171.8 544.9 802.4 65.7 62.7 58.9 130 17450.2 572.3 852.1 64.7 61.8 58.7 140 19730.3 597.6 898.3 63.5 60.9 58.3 150 22011.7 623.9 942.3 62.3 60.1 57.8
Page F4
SPAN MAX. MAX. MAX. MOMENT SHEAR REACTION
LENGTH MOMENT SHEAR REACTION RATING RATING RATING
(ft) (ft-kips) (kips) (kips) 160 24294.2 648.0 990.4 61.0 59.3 57.5
170 26648.7 673.0 1037.7 60.0 58.7 57.2 180 29260.6 696.4 1079.7 59.4 58.0 56.6 190 31937.9 721.7 1117.3 58.8 57.6 55.8 200 34881.3 747.4 1151.1 58.6 57.2 54.8 225 42864.4 801.7 1222.6 58.5 55.8 52.3 250 51672.3 845.1 1279.7 58.6 53.9 49.6 275 61006.2 895.4 1326.5 58.3 52.8 47.0 300 70735.0 953.0 1365.4 57.7 52.2 44.5 325 81511.4 1001.7 1398.4 57.4 51.3 42.2 350 92721.5 1043.5 1426.7 56.9 50.1 40.1 375 103931.7 1079.7 1451.1 56.0 48.9 38.2 400 115142.6 1114.4 1472.6 54.8 47.7 36.4
Page F5
MOMENT, SHEAR, & REACTION RATING
Train: Locomotive, Buffer Car, One (1) 12-Axle Cask Car, Buffer Car, Escort Car
SPAN MAX. MAX. MAX. MOMENT SHEAR REACTION
LENGTH MOMENT SHEAR REACTION RATING RATING RATING
(ft) (ft-kips) (kips) (kips) 5 89.4 72.3 72.3 71.5 72.3 72.3 6 107.3 82.2 82.2 71.5 70.5 61.6 7 125.1 89.2 98.6 71.5 69.4 62.8 8 143.0 94.5 111.0 71.5 68.7 63.4 9 166.4 98.6 120.5 70.9 68.3 63.8
10 197.5 101.9 128.2 70.2 67.9 64.1 11 228.8 107.6 140.5 69.7 65.8 64.4 12 260.4 115.1 156.2 65.1 65.7 66.9 13 296.8 121.4 169.4 62.5 65.7 68.8 14 346.1 126.8 180.8 62.9 65.7 69.3 15 395.3 131.5 190.7 63.3 64.9 70.0 16 444.6 139.7 199.3 63.5 65.7 70.1 18 543.1 153.4 219.2 63.9 65.7 72.2 20 654.2 164.4 236.7 63.4 65.7 72.2 22 783.0 176.3 251.0 63.7 66.9 71.6 24 937.2 189.0 268.5 65.7 68.7 72.6 25 1019.4 194.6 276.2 66.8 68.9 72.8 26 1101.6 199.8 283.2 67.8 69.0 72.9 28 1266.0 209.0 295.9 69.3 69.2 71.9 30 1430.3 217.0 315.6 69.7 68.9 73.2 32 1605.7 228.1 332.9 70.5 69.4 73.2 35 1899.2 242.3 361.6 72.6 70.1 74.1 40 2389.2 263.8 409.3 72.9 70.0 75.8 45 2879.8 286.4 457.4 71.9 70.1 77.1 50 3452.6 311.7 503.1 72.6 71.4 78.1 55 4049.0 337.7 543.7 72.5 72.8 77.4 60 4751.5 364.9 583.6 73.2 74.4 76.1 65 5509.4 392.5 621.4 73.6 75.6 75.1 70 6348.3 419.9 653.8 74.4 76.0 73.8 75 7286.6 444.5 681.8 75.7 75.5 72.4 80 8267.4 466.2 706.4 76.5 75.1 71.0 85 9248.8 489.4 728.1 76.8 74.9 69.6 90 10300.7 513.4 750.7 77.1 74.8 68.6 95 11452.7 535.4 774.8 77.8 74.6 67.8
100 12615.6 555.3 798.2 78.2 74.0 67.2 110 14961.9 589.5 850.8 77.0 72.8 66.7 120 17580.6 618.1 909.6 76.2 71.1 66.8 130 20262.4 645.4 962.6 75.1 69.7 66.3 140 22945.0 675.9 1012.3 73.9 68.8 65.7 150 25628.3 703.9 1059.5 72.5 67.8 65.0
Page F6
SPAN MAX. MAX. MAX. MOMENT SHEAR REACTION
LENGTH MOMENT SHEAR REACTION RATING RATING RATING
(ft) (ft-kips) (kips) (kips) 160 28312.1 732.3 1105.2 71.1 67.0 64.2
170 30996.3 759.9 1154.2 69.7 66.3 63.6 180 33783.7 790.0 1198.6 68.6 65.8 62.8 190 36812.1 817.8 1238.3 67.8 65.3 61.8 200 39938.1 846.0 1274.0 67.2 64.8 60.7 225 48714.9 907.0 1349.5 66.5 63.1 57.7 250 58515.8 955.8 1409.8 66.4 61.0 54.6 275 68796.8 995.8 1459.2 65.7 58.7 51.7 300 79495.9 1034.5 1500.4 64.9 56.7 48.9 325 90858.1 1089.2 1535.2 64.0 55.7 46.4 350 103059.4 1136.1 1565.0 63.2 54.6 44.0 375 115261.0 1176.7 1590.9 62.1 53.3 41.8 400 127463.7 1212.3 1613.5 60.7 51.9 39.8
Appendix_F_Front
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