chris brown manager civil assets network operations ... · level crossing at arduard rd, blackwater...

Commercial in Confidence

Aurizon Network

Chris Brown Manager Civil Assets Network OperationsSeptember 2015


Overview of CQCN


3

Central Queensland Coal Network Overview Managing track access to 2,700km of rail network with 2,000km

electrified

Longest distance between mine and port of 438km

Loading at 40 mines

Delivering to 6 export coal terminals and 7 domestic customers

Communicating with 7 Rail Operators across Coal (4), Freight (2) and Passenger(1) services

Average railings of 612kt per day for FY15

Hay Point Expansion

Cost: $121mAdditional Capacity: 11mtpa

GAPE


Rolleston Electrification

Cost: $163mElectrification of 113km track

Wiggins Island Rail Project


GROWTH PROJECTS

180

230

200

220

170

0

210

190

Mill

ion

Tonn

es

2013/14

227

2011/12

+35.8%

2012/13

211

2014/15

181

223

2010/11 2015/16 Forecast

165 165


4

Organisational Structure

Safety

Volume

Reliability

Cost

People

Maintenance and Renewals Assurance Strategy for Civil, Signals,

Telecoms and Electrical assets

Maintenance

Plant

CQCN Operations

Infrastructure, Signals, Traction, Control and Communications Systems

Extreme weather preparation Preventative maintenance

Resurfacing Ballast Cleaning Maintenance of Plant

Control Centre Management Critical capacity planning Scheduling of access paths Performance analysis

Planning Strategic system planning System planning principles Closure optimisation

Asset Management

NETWORK FINANCE

NETWORK REGULATION

NETWORK OPERATIONS

NETWORK COMMERCIAL


5

Blackwater Moura Goonyella Newlands CQCN

Coal Rail Operators AurizonPacific National

Aurizon AurizonPacific National

BMA Rail

AurizonPacific National

AurizonPacific National

BMA Rail

Average Cycle Time 25.6 17.1 18.4 18.2 20.5

Standard Payloads 8,144 6,234 9,979 6,656 8,573

Average Trains per Day 22.1 5.3 31.9 12.1 71.4

Record Trains in a Day 30 13 43 18 90

Volume in FY15 65.77mt 11.99mt 116.37mt 29.34mt 223.47mt

CQCN Train Services Fast Facts


6

Assets Blackwater Moura Goonyella Newlands CQCN

Track (km) 1,186 260 980 320 2,746km

Electrified Track 1,030 0 980 0 2,010km

Rail 2,296 520 1,960 640 5,416km

Turnouts 394 67 453 89 1,003 T/O

Culverts 1,371 679 1,168 591 3,809

Bridges 134 56 115 32 337

Sleepers 1.94 0.43 1.62 0.53 4.52 million

CQCN Asset Fast Facts


7

Automated remotely monitored rail lubricators installed at key locations on the network reduce rail

wear and improve the rail/wheel interface

Completed trackslab installationCooling Channel Bridge

Infra-red analysis

Innovation in Assets and Maintenance Low Profile Composite Sleepers

Renewing culverts under traffic improves the asset while maintaining

capacity

High definition images

Unmanned Aerial Vehicles

Resin Based Culvert Solution

Completed culvert

Drones reduce the time required on track for inspections while providing data for preventative

maintenance and minimising exposure to working at height for staff.

Ballastless Trackslab

Ballast heavily fouled by coal dust needs replacement every 2 years; high cost, major impact on network

availability and velocity

Improved total cost of ownership and service life with lower maintenance

compared to existing sleepers

Electric Rail Lubricators


8

• Wheel impact detects identify flat wheels which impact rail, increase the risk of rail break and reduce rail life

Reliability & Asset Protection – Protection


9

Safety – Level Crossings

• Lasers detect high loads and alarm driver to stop. • Protects against dewirements at level crossings• Continual safety improvement project for level crossing

Leading edge asset diagnosis is key to improve asset condition knowledge and move to a complete predictive focus

Note: Whole Network complete

Note: Tendering for remote recording equipment for locomotives with automatic download

Ground Penetrating Radar Track Defect Inspection Reporting


11

Level Crossing at Arduard Rd, Blackwater

Level Crossing at Arduard Rd, Blackwater

Delivering Improvements – Safety (Level Crossings)

• Over height Detectors – Blackwater and Dingo• Gracemere Overbridge – removed two level

crossings


12

Reliability & Asset Protection - Reliability

• Installation Points monitoring; the force to move a turnout predicts failure• Being installed at high use turnout• Alarms sent to Fault Control Centre automatically

Measurement and alarm trigger shown below


13

Commercial In Confidence

Delivering Efficiency Improvement - Mt Larcom Vital GE In-sleeper points machine

In-sleeper points machine allows tamping over the points machine. The manufacturer promises increased reliability and decreased maintenance. Trailability of machine should eliminate roddingdamage after run throughs.

Points condition monitors installed handled by the FCC

Jammed

Delivering Reliability Improvements – Points Monitoring

13

Cooling Channel Bridge Ballast-less Track

1

In July 2015, Cooling Channel Bridge was converted from a ballast deck bridge to a ballast-less track bridge in a 94 hour closure.

Previously, ballast on the bridge was required to be replaced every 18-24 months due to coal fouling.

The new track slab has an expected life of 50 years

The project pay back period is 8-10 years compared

Less closures associated with maintaining the track over the bridge will be required.

The design will looked to be implemented on other critical bridges

Design features:

Precast panels encased by super workable high strength concrete

Delkor rail fastenings pre-attached to precast slabs for quick installation

Self cleaning drainage system retrofitted to treat run-off before discharge

For further info contact Reannan Moodie

Innovative Delivery in FY16 - Culvert Solution

1

Current State Culverts are placed in the wettest part of the track formation to direct water flow and prevent

formation damage and washout Corrugated metal pipes have been commonly used for culverts, while cost effective, are only

2mm thick and rust in damp conditions with significant risk of catastrophic failure Culvert replacements are relatively expensive (~$300 – 400k for 3 pipes) and require

significant network closure time due to the impact on formation, ballast and trackFuture State Berolina system is a corrosion resistant fiberglass sock with 12mm thick UV‐light cured

polyester resin that coats the inside of the existing pipe Designed and manufactured in Germany to suit specific pipe geometry, represent a

collaboration between Aurizon and contractor ITS Pipetech Maintains existing hydraulic performance, 50 year design life (RPEQ Certified)

Advantages Track remains undisturbed and lines remain open– no possession

or post work speed restrictions required! At least 30% cheaper than traditional culvert replacement The potential to save Aurizon up to $100 million in direct CAPEX

costs over the next 20 years Supports 30t axle load for potential future load increases

Trains running while resin installation in progress

Culverts after completion of resin and fibreglass liner

Corrugated metal culvert showing extensive corrosion

Network Asset Update

Supersites - Providing real time data collection to better manage below rail assets

A “Supersite” is a strategically selected location that houses a range of wayside equipment in a common on track location. These locations (1 per coal system) are selected due to their position of the rail Network, (relative to traffic task), security of power, strong communications and convenient , safe access.

Designed primarily as a site for co-location of asset protection systems such as mainline weighbridges, wheel impact detectors (WILD) and pantograph defect detection (Pancam), sites are also available for installation of above rail operator’s equipment for further measurement and condition monitoring of rollingstock.

An exhaustive site selection process was undertaken to find sites suitable for the equipment to be installed in terms of speed, topology, access and access to communications and power. All fours sites were identified and project progress is as below:

Wandoo Supersite building and compound

WILD installation at Wandoo 1

Civil works complete WILD Weighbridge Pancam

Goonyella (Wandoo) Jun-14 Jun – 14 2017 2017Blackwater (Kalapa) Feb-15 Oct – 15 Mar-16 2017Moura (Graham) Sep-15 Dec - 15 2017 x

Newlands (Abbot Point) Jul-15 x Apr-16 xApplication of Data (data will be available to operators via the Network assets Portal)• The Mainline weighers will form the missing link in our wagon weighing systems,

allowing direct comparison between sites and automatic detection of accuracy drift• WILD data will be used to identify defective wheels causing impact to the rail and assist

operators to manage their wheel defects below the alarm thresholds• Pancam will provide additional reference information for the interface between the train

pantograph and the overhead at line speedBenefits • Mainline weighing will form the voice of reason for weight disputes, and put an end to

accuracy questions, thereby increasing certainty and reducing delays • Application of WILD will both protect the assets for defective wheels and allow operators

to better plan wheel change outs informed from wear data• Pancan information will held reduce pan related dewirements and allow operators to

better manage the carbon change out schedule on train pantographs


17

Commercial In Confidence

TAS – Track Access System: Innovation through technology

A joint venture with QR, scheduled for field rollout in September 2015. Factory Acceptance Testing underway. Possible delay due to Pluto implementation in Control Centre.

17

• View of the train control screen to the field, allowing personnel to see rail traffic and adjacent work groups.

• GPS location and translation to train control system layouts –providing an engineering control for identification of location (for both field and control centre)

• Electronic communication –provides an engineering control to eliminate human error in communication


18

Reliability & Asset Protection - Protection

• Dragging Equipment Detectors (DED): Detect derailed trains, broken axles and alert train control and driver to stop train and limit damage

• Left if old style required attention after operation (response expense and risk if run trains before reset)

• Right is more reliable, new, resetting DED.

CQCN ION Meter Blackwater

1

2

Safety

Cost

Reliability

Volume

Operational LAN WAN

2

Photo STC HBD new Web Portal

Photo of CMS (WILD and HBD Systems)


24

UAV (Unmanned Aerial Vehicle)

Overview

Automated collection of track condition data for traction assetsHigh Def Imagery and Infra-Red analysis Condition-based maintenance and renewals programsProgress so far:

Proceeding with procurement of 2 systems Training for linesman - completedStart data collection - completedAnalysis Outputs

24


25

UAV Business BenefitsThe project will:Provide detailed asset condition data to inform the investment and maintenance program Maximise reliability by targeting corrective works based on analysisReduce business impact of inspection activities by not requiring track access or HV isolationPreviously imagery acquired with full-sized aircraft (Big $$ 500k+)Total UAV project cost $324k

High Def imagery like this shows great detail of asset condition information

25


26

Innovation in Planning, Scheduling and Day of Operations

Network Forecasts and Planning

Plan and Schedule Generator

Real-Time PlanningSupport

Conflict Resolution & Optimization

Day of Operations (DOO)

Supply Chain Optimisation

Real‐Time Traffic Management

Business rules embedded into solution

Real-time train movement (interactive graphs)

Conflict detection and resolution (manual > automated)

Performance Dashboards (plan v’s actual)

Recovery to Plan with CQCN impacts consideration

Forecasts / Plans (2 years to DOO) ‘What-if’ opportunity analysis Plan to Schedule creation and

optimisation

Advanced Planning and Execution (APEX) is a transformational tool integrating industry proven technologies into a single solution to optimise planning, scheduling and day of operations for the Central Queensland Coal Network

Network Asset Management System (NAMS) is a multi-phase business transformation project. It will provide a single source of comprehensive asset data with In-field mobile devices to support maintenance delivery Standardisation of work delivery processes Asset condition datacapture including photos, design drawings & safety

information Asset level costing, analysis, planning and scheduling.


Network Operations CQCN Transformation and Strategic Focus


28

Network Ops CQCN Transformation Journey

45

Support planning and execution with increasing complexity

• More mine to port combinations• Increased volumes

Better utilisation of capacity and existing asset ‐more trains, maintenance and track activity

Further reduce Day of Operation losses through decision making with full system view vs individual sections

Replace manual processes and legacy in‐house systems

Provide integrated solution from long term planning, to scheduling and day of operations

Platform for ‘auto routing’

Remaining Business Need

Consolidation of Mackay and Rockhampton based Control Centres to form CQCN Control Centre in Rockhampton (2011);

Consolidation of Network Operations North and South to form Network Operations CQCN with restructure of leadership, planning and business system teams (2013);

Implementation of consistent planning tools across CQCN (2014);

Review of Business Execution Rules and implementation across all Rail Operators and Ports;

KPI reporting to Rail Operators and Supply Chain Forums implementation (2014).

Recent Transformation Activities


29

Building a sustainable future through partnering with customers to achieve repeatable excellence in below rail operations through planning, scheduling and execution and supply chain coordination.

We are a disciplined operator of below rail assets and integral to supply chain coordination, using transferrable, repeatable processes to deliver for our customers.

Build and promote our repeatable, transferrable operational skills for below rail planning, scheduling and execution, using reputation for excellence in CQCN to attract growth opportunities both domestically and internationally. This growth may be through direct operations or consultancy opportunities to other rail networks.

Translating Aurizon’s Blueprint for Network Operations CQCN


30

We’re driven by smartprocess, not only smart people.

Disciplined Planning is Key.

Embed a ‘Lift and Shift’Mentality.

Move to portfolio approach for Supply Chain Coordination

Market the Outcomes

and Offering.

Our 5 Year Strategy

Step Change

Step Change to Achieve Our 5 Year Strategy


31

Step Change How will we know when we have achieved each step change?

We’re driven by smart process, notonly smart people.

… when our processes have the rules built into them, and stand‐alone red tape like ‘System Rules’ will no longer exist.

DisciplinedPlanning is Key

… when our smart processes and our tools are widely known and trusted, offering value‐add to supply chains and driving discipline within Network and Supply Chain activities.

Move to portfolio approach for Supply Chain Coordination

… when our processes are packaged into core uniform modules, with checklists/tools that tailor our approach to the needs of individual supply chains (including mine production and shipping considerations).

Embed a Lift and Shift Mentality

… when can ‘lift and shift’ our process modules to grow new opportunities in our existing Supply Chains & also secure opportunities in new Networks and Supply Chains.

Market the Outcomes and Offering

… when our services will be ‘in demand’, with existing and new customers seeking and agreeing to partner with us to provide then with new services because of the value‐add and discipline we offer.

Step

Cha

nge to a Sustainab

le Future


32


chris brown manager civil assets network operations ... · level crossing at arduard rd, blackwater...

Documents