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Taking A Heavy Haul Approach to Rehabilita7on, Opera7on and
Maintenance of East African Railways, November 2012
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• CASE STUDY: Taking a Heavy Haul Approach to Rehabilita7on, Opera7on and Maintenance of East African Rail Infrastructure
• Insights into the Dutwa Nickel Project • Lessons learnt from the Hunter Valley Heavy Haul Coal Chain
Context
HUNTER VALLEY HEAVY HAUL NETWORK NSW, AUSTRALIA
DUTWA NICKEL PROJECT TANZANIA
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The Hunter Valley Network
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A Complex Logis7cs Chain
• 34 Coal Mines
• 14 Producers
• 24 Load Points
• 80 Different Brands of Coal
• 4 Above Rail Operators
• 2 Terminal Operators / 3 Terminals
• Multiple Components per Cargo
• 140 tonne pa Export Target
• 16 independent organisations required to move each tonne of coal
• No control over demand – only two weeks visibility and highly variable volumes
• Avg 5 days clean coal on stock at the mines
“The Hunter Valley is a complex integrated
logistics chain”
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Hunter Valley Operators
‘Open Access’ 8 Minute Headways 10,000 tonne Trains 30 tonne axle loads
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Complex Train Management
• 5 train transit managers
• 59 network controllers
• 5 coal logistics co-ordinators
• 4 train programmers
• 12 control boards
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Efficient Maintenance
7
Maitland PC (39 ARTC Staff)
Muswellbrook PC (24 ARTC Staff)
Scone Sub PC
(7 ARTC Staff)
Carrington Sub PC
(17 ARTC Staff)
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Major Projects
$3 bn of Capacity Projects in the Planning
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East African Railways
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East African Railways
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East African Railways
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East African Railways
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East African Railways
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East African Railways
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Posi7ves
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Posi7ves
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Posi7ves
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Posi7ves
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East African Railways
‘On the surface these Networks look very different….
………..They do however share a common history’
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Hunter Valley History
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Narrow Gauge in Australia
Central Queensland Coal Network: 180 million tonna pa
Brookfield Rail, Western Australia: 50 million tonne pa
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Future Growth in East Africa provides Opportunity
Corridor Upgrade Strategy:
Target reduc7ons in Transit Time
Challenging the standards in rela7on to axle loads
Commercially driven, reliable freight opera7ons
Get the most out of the infrastructure
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Standard Gauge in East Africa?
If East Africa is to one day have a World Class Standard Gauge railway……..
.. it should be as part of a Staged Plan to revitalise rail on the Exis7ng Corridors’……….
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Key Message
‘Pay for future upgrades…..
with the revenue created ……
from running exis7ng railways….
more efficiently’
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• Dutwa is a significant nickel project with around 100 million tonnes at ~ 1% equivalent. The project was discovered in mid-‐2008.
• The deposits are readily accessible and situated on hilltops. The mining method with be open pit, with minimal pre-‐stripping required and a very low ore to waste ra7o
Dutwa Nickel Project
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• To develop this Nickel Mine we must first solve the Transport issues.
• The mining is the easy part
Dutwa Loca7on – Northern Tanzania
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Transport Bulk Volumes
Limestone:
0.75 million tonne pa
Sulphur + other reagents:
0.45 million tonne pa
TOTAL VOLUME:
1.3 million tonne pa
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What is a Corridor Approach
‘The Philosophy of geing the Maximum Opera7onal benefit out of your infrastructure budget……
………not the maximum possible infrastructure’
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Why a Corridor Approach?
‘Because that is what majers to your Customer.
His prime concern is how many tonnes he can haul and how long it will take’
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Take a Heavy Haul Approach
‘The key to reducing maintenance costs and improving opera7ons on low tonnages lines is to study Heavy Haul networks.
‘There is no room for error when running in excess of 200 million Gross tonnes on a single track …….
………so by necessity, the Hunter Valley had to develop efficient ways of maintaining infrastructure’
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Rail – The Highest Priority
Remove impacts from joints, poor welds, and surface defects
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Sleepers – Steel is Fine
Ensure Ballast under the sleepers, especially at fixed points
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Ballast – Regular Resurfacing
Ensure ballast is free draining;
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Forma7on – Well Drained
Use Slot drains or GPR in areas of concern
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Asset Protec7on – Monitoring
Asset protec7on systems include:
• Wheel impact load detectors • Hot bearing detectors • Dragging equipment detectors • In line weighbridges • Geometry recording instrumented to Loco
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Network Control & Signalling
Train Management is cri7cal in Heavy Haul to meet Cycle Times.
Same is true on Low tonnage lines so Operators make profit. Suggest: Independent Network control, with KPI’s and protocol’s in place for management of priority services.
Implement a satellite based Track Warrant System (ideal for single lines)
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Just some sugges7ons:
• Con7nuous welding of rails to improve train speed
• Extension of crossing loops for long freight trains
• Regular and higher produc7on track resurfacing
• Ballast distribu7on system
• A future rail grinding program
• A satellite based Train Order Working system
• A program to improve the skills of the exis7ng workforce
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Final note