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News and Views

DOSH releases Big Thunder Mountain Railroad accident report

The State of California Division of Occupational Health and Safety released its report on the September 5 fatal accident on Disneyland’s Big Thunder Mountain Railroad attraction. The timing of the report—released the morning before Thanksgiving, just as the news media turned their attention to the traffic in airport parking lots around the country—could not have been better for Disney officials had they scheduled it themselves. By the time the major news outlets picked up the story, the official report had even disappeared from the DOSH Web site.

Even so, the contents of the report were sufficient to guarantee national headlines on both Thursday and Friday. The investigators determined that Disney’s maintenance and procedures were responsible for the accident, which killed 22-year-old Marcelo Torres, and injured 10 others. The report cited two key mechanical failures that contributed to the accident: an incorrectly installed guide wheel, and a missing safety wire.

The investigator interviewed workers who didn’t know the difference between a “yellow-tagged” ride vehicle, (not yet ready for passengers), and a “green-tagged” ride vehicle. Machinists admitted signing for work that they had not personally performed, and managers admitted signing off on repair work that they did not personally inspect. Ride operators complained that there was no policy explaining what to do when a ride vehicle was making an “unusual sound”; noises like the train involved in the accident was making before it was sent out on its final, fatal trip.

The report concluded that the design of the coaster was not to blame for the accident, saying that “there is no evidence that the design of the Big Thunder Mountain attraction is unsafe.” Once the damaged track is replaced, Disney must demonstrate compliance with the “Corrective Action Specifications” detailed in the report before reopening the ride. These include retraining machinists and managers in proper procedures, and implementing a resort-wide policy for dealing with “unusual noises” from ride vehicles.

Disneyland issued a statement after the DOSH report was released, saying “We agree, as DOSH concluded, that the design of the attraction is safe.” The resort laid the blame for the accident on “…a failure to follow procedures…,” and said that it had already “begun re-training our maintenance personnel on our policies, procedures and guidelines.” The statement concluded by saying “At no time have we ever done anything which we believe would compromise the level of safety required for the safe operation of our attractions”

MousePlanet has a full PDF copy of the DOSH report online (link). The 22-page document provides a detailed description of the events leading up to the accident, and the investigation that took place afterwards.

Timeline of the accident

Analysis by MousePlanet staff Tony Phoenix and Kevin Krock.

On September 5, 2003 at 10:30 a.m., 90 minutes after park opening, BTMRR train #2 was put into service, making it the third operating train of the day. The report indicates that the train had been used for a show check prior to park opening. At some point during its operation, one of two bolts holding the left side floating axle upstop/guide wheel fell out. Fifty minutes after being put into service, at the conclusion of its twelfth trip of the day, the second retaining bolt fell out, causing the wheel to fall off just before it entered the station.

Walt Disney World train, showing key ares of failure. Photo Courtesy Joel Rogers, CoasterGallery.com. Click image for full original image.

This retaining wheel is located under the track tube below the wheel indicated by arrow #1 in the photo above. The Big Thunder Train engine and cars are secured to the track by what can be the visible wheel on the topside of the track, and the upstop wheel underneath, which you can see figures #1 and #2.

These two wheels pinch the track, keeping the car pointed in the correct direction and preventing it from lifting up off the track. The floating axle means that the axle can pivot, allowing the car to swing around curves and bends in the track. Think of a rear-wheel drive car, with a rear axle and wheels that turn.

At this point, the train entered the station and the passengers disembarked. Several cast members say that they heard an unusual noise coming from the train, and decided to remove the train for inspection by maintenance after it completed one last run. At 11:17 a.m., the train was set onto the track with approximately 24 people on board for its thirteenth run of the day.

The train ran normally through the first third of the ride, climbing through the bat cave, up the lift in the rainbow cavern, and through the first drop. It ran under the tree with the swinging possums, through a steep banked right-hand turn, and into the entrance of the long, dark tunnel located before the second lift hill. The second lift hill has a steam engine off to the right hand side, and is commonly known as the location of the goat trick.

The forces encountered by the train in the banked curve caused the axle to shift left, and the remaining upstop wheel on the right side to drop lower. That wheel struck a railroad tie just at the entry to the tunnel. The axle continued to drag and bounce as the train approached the small incline at the mid-point of the tunnel. This incline is also the location of the Zone 1 safety brake—brakes on rides such as Big Thunder operate with two bars covered with a lining that squeeze together. A guide on the train cars are pulled through these two bars, while the lining creates friction, slowing the vehicle.

Figure 3. A rear view of the engine showing the shifted axle.

When the train engine reached the safety brake, the wheel struck the brake, damaging the brake lining and brake sensor. Because of the damage to the brake sensor, the ride computer immediately prevented new trains from leaving the station. For cast members, this “dispatch inhibit” condition was the first indication that something had gone wrong.

The axle assembly then wedged between a brake and a railroad tie, causing the rear of the engine to lift off the track and to strike the first passenger car. The lifting of the engine also caused damage to another brake sensor, triggering another warning in the control center.

Figure 4. A side view of the ride showing the initial collison of car #1 into the back of the engine.

The front—or nose—of the engine car collided with the last brake, shearing the brake completely off. This also caused the towbar (identified as arrow #2 in the photo) to fail. The first passenger car pushed under the engine, wedging the engine between the tunnel roof and the passenger car. The front seat of the first passenger car sustained serious damage, and it was this impact that likely killed Marcello Torres, who was seated on the front right seat of car #1. The impact also caused the rear axle of the second passenger car to derail, and the second car pitched up in the back.

Figure 5. A side view of the ride showing the second collision.

The train continued to drag in this position for a bit longer until the second passenger car struck a brake, bringing everything to a stop. The forward motion stopped, and the train, now without its engine, began sliding back down the incline until a brake caught part of one of its rear cars. The ride computer sensed a train at the brake for a second time, and issued an immediate Emergency Stop command, stopping all motion on the track.

Cause of Failure

The entire accident can be traced back to the upstop wheel that fell off. The DOSH investigator found the two bolts and washers that should have held the wheel in place along the track. Closer inspection (and metallurgy testing) confirmed that the bolts had never been secured tightly. In addition, missing was a safety wire that should have prevented to bolts from coming out. As a result, the wheel fell off, triggering the chain events that led to the crash.

The investigation focused on Yellow and Green maintenance tags. These tags indicate which vehicles are cleared to be used with passengers (Green Tags), and which are still undergoing maintenance (Yellow Tags). Interviews of the machinists assigned to Big Thunder revealed “an inadequate understanding” of how the tag system worked. The machinists also commented that they were shorthanded.

Behind the scenes in the California Screamin’ maintenance bay at Disney’s California Adventure park. Colored tags indicate the status of the vehicle. Photo by Adrienne Vincent-Phoenix.

Managers showed an understanding of the procedures, but admitted that they occasionally signed off on the work without actually reviewing the work or reports.

The investigator found that the maintenance procedures were adequate, so long as they were followed correctly. In this case, they apparently were not.

What DOSH has told Disney to do

Disney has been told to retrain all outside machinists and managers on company policies and procedures, and to establish procedures for ride operators on what to do when they hear unusual noises. In the future, any car added to the ride must complete one full run before passengers can ride. Finally, only the machinists performing the maintenance work can sign off that the work was complete.

What would we call her, Madame Tilly?

USA Today reported that Jennifer Tilly, who plays Madame Leota in the just-released The Haunted Mansion movie, may get a more permanent role. According to the article, Tilly’s contract stipulates that her voice and likeness could replace the voice of Eleanor Audley and the face of Imagineer Leota Toombs as the ride’s resident medium “if the film is a hit.” The paper quotes Tilly as saying, “I hate for tradition to fall by the wayside, but I would rather it was me!”

In a televised interview on a network entertainment program, Tilly said that her contract includes a clause that would let Disney cast her as Madame Leota in the theme park attraction if they were to update it. Fans of Eleanor Audley and Leota Toombs probably have little to worry about.

Preview signs have been added to the Tower of Terror construction wall. Photo by David Michael.

Dining by Candlelight

Visitors hoping to book a Candlelight Processional dinner package for this weekend’s performances need to act quickly. Hook’s Pointe and Storytellers Cafe, two of the participating restaurants, have filled their available Candlelight slots, leaving only these four, more expensive, restaurants available:

Minimum spending of $50 per adult, $15 per child:

• Granville’s Steak House at the Disneyland Hotel
• Yamabuki at the Paradise Pier Hotel

Minimum spending of $75 per adult, $20 per child:

• Napa Rose at the Grand Californian Hotel
• The Vineyard Room in the Golden Vine Winery in DCA

The Fastpass distribution area stands just inside the gates to the new ride. Photo by David Michael.

Sleeping Beauty’s Royal Ball – new and improved!

When Disneyland released the preliminary details of 2004 Valentine’s Day Sleeping Beauty’s Royal Ball, many prospective attendees balked at the $285 per-person price tag. One special event regular said, “Disney has finally found the upper limit on what they can charge for these things, and it’s about $85 less than this. I guess I’m making other plans now.”

Still others say they might attend the event, if only they knew more about it—starting with where the ball is being held. “If it’s inside Disneyland, like the WDW event is inside the Magic Kingdom, I’m there,” wrote another. “But if they are sticking us inside some hotel ballroom, forget it.”

Although tickets went on sale last Tuesday, response has been light—event services cast members say that there is “plenty of room” left for the ball. Late last week, Disneyland’s merchandise event team issued this “royal proclamation”:

We are pleased to announce that as part of the FLORA, FAUNA and MERRIWEATHER event packages for Sleeping Beauty’s Royal Ball we will be including the following event elements:

• One (1) admission ticket for a showing of the Walt Disney Animated Classic film “Sleeping Beauty” on February 14, 2003 at the AMC 12 Theater in the Downtown Disney District.
• Reserved Seating for a Performance of “Disney’s Snow White – An Enchanting Musical”

More details are expected to be announced in the next few weeks, including the location for the ball. Perhaps Disney will just keep adding elements to the event until they get the registration numbers they are looking for.

More art for Mickey

“75 Years of Memories” is one of the murals created for Mickey’s birthday celebration. Photo by Adrienne Vincent-Phoenix.

Six Disney artists have designed murals for the 75 Years with Mickey art exhibit in Downtown Disney. The artists are taking turns painting their panels near the construction wall just erected around the upcoming Tortilla Joes location. You can watch the work in progress most weekdays from noon to 3 p.m. The completed murals will be auctioned on January 31, 2004, along with the 75 Mickey “Big Figs” on display at the World of Disney store.

Current Refurbishments and Attraction Closures

Disneyland

The Mark Twain Riverboat sits in dry dock during its refurbishment. Photo by Adrienne Vincent-Phoenix.

Space Mountain’s transformation continues. Photo by David Michael.

• Mr. Toad’s Wild Ride closed through December 11
• Mark Twain Riverboat closed indefinitely as of November 3
• Sleeping Beauty Castle walk-through closed indefinitely
• Space Mountain closed through 2005
• Big Thunder Mountain Railroad closed indefinitely

The Main Street improvement project continues even into the holiday season. Photo by Adrienne Vincent-Phoenix.

Disney’s California Adventure

• Superstar Limo closed indefinitely
• Francis’ Lady Bug Boogie closed through December 19

Future Attraction Closures

• Indiana Jones Adventure closed January 20 to April 3, 2004

Note: Refurbishment schedules are estimates only. All information is subject to change without notice. To get the most recent updates, call Disneyland at (714) 781-7290.

Park Events

December

• Marie Osmond “Enchanted Tiki Room Hostess” doll release and meet-and-greet at Disneyland. Saturday, December 6.
• Candlelight Processional at Disneyland. December 6 and 7.
• Robert Olszewski “Central Plaza” sculpture release at Disneyland. Saturday, December 13.
• Disneyland Resort Pin Trading Night at the Paradise Pier hotel – Sunday, December 14, 5:00pm – 9:00pm

January

• Disneyland Resort float in 2004 Tournament of Roses Parade, January 1, 2004
• 75 Years with Mickey auction, January 31, 2004.
• Cast Member Create-A-Pin Contest pin release, date not announced. (Moved from November)

February

• Sleeping Beauty’s Royal Ball, details available at the Disney Gallery Web site (link). February 14.

April

• Tower of Terror event, details to be announced at a later date. April 22 & 23, 2004

May

• A Celebration of Walt Disney Art Classics – “A Disney Blast to the Past” Registration open to returning participants through October 15, open registration begins October 16. May 14 to 16.

Current Discounts & Promotions

Live an Artful Life with an OC Arts Card

The Disneyland Resort partnering with Arts Orange County sponsor the OC Arts Card, which provides cardholders with benefits such as savings on tickets, classes, merchandise and memberships at more than 40 nonprofit arts venues in the local Orange County community.

Annual passholders can purchase the 2004 card for $37.50, 25 percent off the regular price. In addition, the first 500 passholders to purchase a card receive a second card for free.

For more information or to order a card, visit the OCArts card Web site (link) or call (888) 556-5160. To receive the annual passholder discount, use offer code C04DIAP. The first card is mailed immediately; those who are among the first 500 will have the second card mailed at a later time.

Disney’s Wildfire Heroes Salute

“Disney’s Wildfire Heroes Salute” entitles active California firefighters, law enforcement and rescue personnel, with proper organization and photo ID, to one free three-day park hopper ticket. They can also make a one-time purchase of up to five three-day park hopper companion tickets for $39 each. Discounted hotel rates are also available at the three Disneyland Resort hotels.

The promotion is valid through March 31, except for blackout dates of November 27 to 29, December 20 to January 3, and February 14 to 16. For more details, visit Disneyland’s Disney’s Wildfire Heroes Salute Web page (link) or call (714) 520-5069.

Disneyland Resort Holiday Getaway offer

Disneyland is offering a holiday-themed variation on its recurring “get 5 days and 4 nights for the price of 3” offer. The promotion is available through January 2, 2004, and includes:

• A 5-day Park Hopper ticket for the price of a 3-day ticket.
• A 4th night free at participating hotels, including the Disneyland Resort hotels and selected “Good Neighbor” hotels.
• A collectible pin and lanyard
• Disneyland Resort Magical Pocket Guide
• A Disney holiday ornament (with arrivals between November 10 – December 31, 2003)

Have a Coke and a pass

Specially marked 12-packs and two-liter bottles of Coca-Cola in Southern California are currently offering a $20-off coupon towards the purchase of a new Deluxe or Premium Disneyland Resort Annual Pass. The coupon is valid through January 31, 2004.

A Nightmare deal at Costco

MousePad member Tiki Junki purchased a copy of The Nightmare Before Christmas at a local Costco store, and discovered a Disneyland Resort offer inside. The $13 Special Edition DVD comes with a voucher for up to four pre–issued Fastpass tickets for the Haunted Mansion, and a voucher for one free cloisonné pin from the Le Bat en Rouge Shop in New Orleans Square. The vouchers are good until March 31, 2004, and are redeemable at Disneyland—there is nothing to mail in, and no four-to-six-week wait for the passes and pin to arrive.

Annual Passholders nights at the Disneyland Resort hotels

• Annual passholder discounts are available at the Paradise Pier Hotel through Friday, December 12. Rates are $79 per night weekdays, and $119 per night weekends. AP rooms are also available at the Disneyland Hotel and Disney’s Grand Californian Hotel at higher rates.
• Annual passholders can also book a room at the Paradise Pier hotel for $59. This offer is valid only on Sunday nights, through March 2004.

Get 5 days and 4 nights for the price of 3

Book a package at the Disneyland Resort for a minimum four-nights through the Walt Disney Travel Company, and the package price includes one night’s free accommodations at participating hotels. Your package will also include a five-day Disneyland Resort park hopper ticket for the price of a three-day Disneyland Resort park hopper ticket. Click here for a list of participating hotels and dates.

Disney’s Armed Forces Salute

Through Friday, December 19, all active members of the United States military (including Coast Guard and activated National Guard and Reservists) qualify for Disney’s Armed Forces Salute and can claim one free 3-day park-hopper tickets. Since the tickets expire on December 19, you must claim them by December 17 to use all three day’s worth. The passes can only be claimed at a park gate ticket booth. To claim the passes, valid military ID must be shown; activated National Guard and Reservists must also show their active duty orders.

In addition to the one free pass, each qualifying person can also purchase up to five 3-day companion passes for $39 each. If the qualifying person cannot visit a park to purchase these companion tickets, a spouse may do so instead.

ESPN Zone discounts for annual passholders

Disneyland annual passholders can get an Season Ticket Frequent Dining Card at the Downtown Disney ESPN Zone. The Season Ticket entitles you to a free soda with your meal purchase of $6.99 or more. Once you have made four meal purchases, you receive the fifth meal and soda free, and get a chance to win a pair of tickets to the ESPY Awards in 2004. See location for more information and details.

City Pass now available with AAA packages

You can now purchase the Southern California City Pass with Walt Disney Travel Company packages.

A Southern California City Pass booklet includes admission to five separate entertainment options:

• 3-day Disneyland Resort Park Hopper Ticket
• 1-day ticket to Sea World Adventure park
• 1-day ticket to the World-famous San Diego Zoo
• 1-day ticket to Knott’s Theme Park.

Instead of the Disneyland Resort Park Hopper Ticket currently included in California packages from the Walt Disney Travel Company, guests can select a Southern California city’s for an additional charge of $47 per pass ($32 per pass for guests ages 3 through 9).

Note: The Southern California City’s does not include the $10 ESPN Zone Arena Game Card, or the California package’s feature that allows guests to collect multiple Fastpass tickets at once for free in advance.

5-Day Park Hopper promotion extended

The “Get a 5-Day Park Hopper ticket for the price of a 3-Day ticket” promotion has been extended through January 5, 2004. These tickets are available when from the Disneyland Web site (link). Restrictions apply—see site for details.

AAA Passport Plus Package

For $122.75, you can get a 5-day park hopper and the following extras:

• Multiple attraction Fastpass (The “Unlimited” option)
• Breakfast in the park (one per person)
• Free ESPN Zone arena game card ($10 value)
• AAA Free parking at the Disneyland Resort Theme Parks

A $13.75 FedEx fee applies to each reservation, (not per person). This package is available without an air or hotel purchase, and must be purchased at your local AAA affiliate office at least 5 days before you plan to use the tickets.

Many readers have experienced difficulties when trying to purchase this package from their local AAA affiliate. Be sure to read this thread on our MousePad discussion boards, for more information about the package and tips on how to help your AAA travel agent book your package.

AAA-Disney’s Resort Magic Package

This package requires a minimum 2-night hotel stay, and includes:

• Accommodations at Disney’s Paradise Pier Hotel, the Disneyland Hotel, or Disney’s Grand Californian Hotel
• Disneyland Resort Hotel self-parking and Fitness Center access
• Disneyland Resort Park Hopper Ticket – valid for entry into Disneyland park and Disney’s California Adventure park with full park-hopping privileges
• Free ESPN Zone Arena Game Card – $10 value (one per person)
• New. Collect Fastpass tickets for multiple attractions at one time. Preferred Seating at a choice of select shows in Disney’s California Adventure
• Exclusive – Walt Disney Travel Company collectible pin and lanyard (one per person)
• Exclusive – Walt Disney Travel Company California Fun Book (one per package)
• Exclusive – Disneyland Resort Magical Pocket Guide (one per package)

You can book this package through your local AAA affiliate travel agent.

Park Hours/Blockout Dates

DL: Disneyland
DCA: Disney’s California Adventure
Annual Pass blockout dates: SoCal – Southern California Annual Pass. DX – Deluxe Annual Pass

Visit our Annual Passholders Blockout Dates 2003-2004 page to see more dates.

Entertainment Schedule