Transcript G&W / BHPB Cost Comparison

Sophisticated
Simplicity
Heavy Haul Operations
Supported by Proven
Technology
Mike Darby
Karribrook WA Pty Ltd
Presentation Overview
 What is “Sophisticated Simplicity”?
 BHP Billiton’s Railway NW Australia
 BHPB’s use of technology
 Example of Sophisticated Simplicity in a
Heavy Haul Railway Operations supported
by proven technology
2
7/18/2015
What is Sophisticated Simplicity?
Traditional Approach
Simple System
Proven Technologies
BHP Billiton Ltd
 Is the worlds largest diversified resources company
(>US$100 billion)
 Global resource development company
 BHP Billiton Iron Ore located in Northern Australia:
• Developed a “Fit for Purpose” Railway
• Operates in a harsh and isolated environment
• Operates the heaviest axle loads/trains in the
world
Operations in ‘Cyclone Alley’
BHP Billiton Iron Ore Railway
History of the BHP Billiton Railway
 Mt Whaleback was the largest single iron ore deposit
in the world (>1 billion tonnes)
 Historically Iron Ore deposits in Western Australia
seen as too far (400 km) from tidewater prior to heavy
haul railways
 Heavy haul rail line built in 1969 by North American
contractor
 In 1970 Oroville Dam Project cars and dumpers
brought from California to Australia / evolved as a
North American Railroad
 Regulated by Mines Department not DOT
BHP Billiton Iron Ore Railway
Operating Philosophies:
 Good Safety Is Good Business
 Continuous Improvement
 Use Assets to Their Full Potential
 Research and Development
Proven Technologies
 High axle load issues
 Hot bearing-Hot/Cold Wheel Detectors
 Wheel Impact Monitor
 “Weigh-in-Motion” Weighbridges
 Acoustic Bearing Detection
 Instrumented ore cars
 Auto Locomotive Downloads
 Video Imaging
 Workshop Initiatives
Axle Load Evolution
Axle Loading
40 tonnes
35.0 tonnes
32.5 tonnes
28.5 tonnes 30.0 tonnes
Wet
tonnes
per
wagon
1970
1974
1986
1996
2005
Issues with 40 tonne Axle Load
 “Thermit” Welds/Flash Butt Welds
- 6000 “Thermit” welds – 2% failure/annum
- 35000 flash butt welds - .008% failure/annum
- Program in place to replace “thermit” welds
 Rail Grinding Program
 Wheel/Rail Interface
 Weekly Rail Ultra Sonic Inspection
Thermit/Flash Butt Welds
Stress Free Temperature (SFT)
 Incorrect SFT leads to:
•Track buckles – when hot
• Rail Breaks – when cold
 1,000 meters rail @ 60°C is 999.386meters @ 5°C
 25°C change causes 92 tonnes of tensile force
 “Thermit” welds
• Sensitive to SFT & lateral loading
 Concrete SFT 33 - 38°C
 Timber & Steel SFT 35 - 40°
Painting Welds
Reduce lateral loading
Hot/Cold Wheel/Bearing Detection
 18 hot bearing wheel detectors
 1 cold wheel detector
 Automated and site activated
Impact Detection & Weigh-In Motion
 1 impact load detector
4 weigh-in motion scales
Acoustic Bearing Detection
Following faults are detected:
 Cone Faults
 Roller Faults
 Audible Wheel Flats
 Cup Faults
 Looseness / fretting
 Noisy Wheel sets (flanging)
Consequence of System
Breakdown
Result of System Breakdown
Instrumented Ore Cars (IOC)
 4 IOC’s in service
 Vertical suspension travel (ride quality)
 Wheel-rail acceleration (rail condition)
 In-train forces
 Lateral stability (hunting)
 Longitudinal acceleration
 Car body/draft gear pocket strains
 Temperature
 Brake pipe pressure
Auto Locomotive Downloads
The “Black-Box” is downloaded at each arrival at port
 Driver education/incident management
 Fuel utilization
Data for automated train operation
 All operating parameters
Video Imaging
Measures:
 Flange Height
 Flange Width
 Vertical Flange
 Hollowing Depth
 Rim Thickness
 Wheel Diameter
Workshop Initiatives
 Component Tracking
 Ultra-Sonic Wheel Testing
 Super Clean Wheel Specs
 Bearing Quality Assurance
 “H” Class Bearings
 40 tonne trucks
 Side Wall Thickness Tracking
 Asset Protection Information Integration
Ultrasonic Wheel Inspection
Shop Facilities
37 Traceable
Components Tracking
for each Ore Cars
Component
Coupler Inspection
 Developed in UK, for in-
situe inspection
 Uses ultrasonic probe
inserted through the
drain hole
 Detect lower pulling lug
cracks which are the
primary mode of failure
for fixed & rotary
couplers
BHP
Iron Ore Railroad
Productivity
Results
R&D into the
rail/wheel
interface
allows for the
useful life of
assets to be
extended
Ore Car Wheel Life
1980
2006
million km
million km
0.34
1.95
Life extension
6.5 fold
increase
Rail Life (Tangent Track)
1980
million gross
metric tonnes
350
2006
million gross
metric tonnes Life extension
1,200
3.4 fold
increase
Employee Productivity Tripled in the last 10 years
353
301
(‘000’s tonnes per employee /yr)
245
258
216
126
1996
148
151
1997
1998
167
1999
179
2000
2001
2002
2003
2004
2005
Heavy Haul Railways of the Future
KIS: Keep it simple
• Train operation designed with minimum interfaces
Implicit safe operation
• Design the operation to avoid train movements
Intense capital utilization
• Use assets to the fullest
Integrated knowledge process implementation
• Proven technology to protect assets
The Knowledge Process
Integrated
data collection
information
knowledge
implementation
System management
What’s in the Future ?
 Continued safety focus
 Human resource efficiency
 Higher axle loads
 Evolution of “Cruise Control”
 Automated trains
 Electric brakes
Electric Brakes
 Handbrakes on grades can be managed
 Ease of train handling
• all brakes on and off simultaneously within 7 seconds
• graduated release
• Faster brake charging time
 Reduced in train coupler forces and less brake shoe wear
 Distributed power (no radio based locotrol)
 End of train monitoring
 Brake system charges while brakes are applied
 Load / empty features not required
Advantages cont.
 Faster train cycle time
• Faster accelerations brakes release sooner
• May be able to increase speed of loaded trains
• Graduated release of train brakes
 Individual wagon brake status monitoring
 Fault finding i.e. train break location
 Faster train brake charging times (uses less air)
 Fuel savings as brakes release faster
 Increased wheel life
• No sticking brakes / hot wheels
 Even wearing brake shoes
“Highway” for future Developments
 Derailment detection
 Hot bearing / hot wheel detection
 Hand brake status
 “GPS” train braking
(individual brakes graduated as loads traverse
undulation)
 Car weights linked to load out facilities
(ensures each car is loaded to maximum)
 Automated trains platform
Objective
“Move 6 million tonnes
of product per annum
a distance of 100 km”
Traditional Approach
Simple Approach
 250 cars/wagons
80 cars/wagons
 7 locomotives
3 locomotives (Push/Pull)
 Rotary/Bottom dump wagons
Side dump cars/wagons
 Rotary or bottom dump station
Flat unloading platform
 80 employees
35 employees
 Extensive track/yard system
Simple track/yard system
 Cost for plant >US$100 million
Cost for plant <US$30 million
 High maintenance costs
Less plant to maintain
Supported by proven technology
The End Result