saudi arabia railway organisation visit to transnet iron ore line saldanha
TRANSCRIPT
PAGE
Saudi Arabia Railway Organisation Visit to Transnet Iron Ore Line
Saldanha
19 February 2015
Table of Contents
• Overview of Transnet
• Transnet Freight Rail
• Transnet Engineering
• Transnet Port Terminals
1
Transnet State Owned Company Ltd
Operational Divisions
2
PAGE
Transnet Freight Rail
PAGE
Sishen
Postmasburg
Saldanha
Sishen
Kolomela
Khumani
Emerging
Miners
Upington
Springbok
Bloemfontein
De Aar
Kimberley
Cape Town
Iron Ore Export Channel
PAGE
Sishen
Postmasburg
Saldanha
Sishen
Kolomela
Khumani
Emerging
Miners
Upington
Springbok
Bloemfontein
De Aar
Kimberley
Cape Town
Iron Ore Export Channel
PAGE
0
10 000 000
20 000 000
30 000 000
40 000 000
50 000 000
60 000 000
70 000 000
19
76
/77
19
77
/78
19
78
/79
19
79
/80
19
80
/81
19
81
/82
19
82
/83
19
83
/84
19
84
/85
19
85
/86
19
86
/87
19
87
/88
19
88
/89
19
89
/90
19
90
/91
19
91
/92
19
92
/93
19
93
/94
19
94
/95
19
95
/96
19
96
/97
19
97
/98
19
98
/99
19
99
/20
20
00
/01
20
01
/02
20
02
/03
20
03
/04
20
04
/05
20
05
/06
20
06
/07
20
07
/08
20
08
/09
20
09
/10
20
10
/11
20
11
/12
20
12
/13
20
13
/14
20
14
/15
0
150 000 000
300 000 000
450 000 000
600 000 000
750 000 000
900 000 000
1 050 000 000
An
nu
al V
olu
me
Tota
l Vo
lum
e
Export Iron Ore Railed since Start-up (metric tons, per year & accumulated)
6
18mtpa Installed Capacity (1976)
Incremental Optimisation
Phase
Expansion Phase (crossing
loops, RDP trains, new wagons &
locomotives, new mines)
20 Years of Growth & Optimisation
PAGE
Global demand for South Africa’s high quality iron ore outstrip export
capacity since 1994
Through innovative execution and continuous improvement, Freight
Rail increased capacity of 18mtpa to ~28mtpa
A capacity expansion programme launched in 1994, increased
capacity to the current 62mtpa level:
− Existing crossing loops lengthened from 2.5km –4.5km to accommodate
longer trains
− State of the art signalling systems installed along the 861km length
of the line
− Track upgraded from 26 tons per axle to 30 tons per axle,
increasing wagon payload from 85 – 100 tons
− Rolling stock fleet expanded to increase rail capacity
− Introduction of radio distributed power (RDP) technology increased
train length from 216 wagons to 342 wagons during 2007 7
Successes the past 2 decades
South Africa now
operates the longest
production train in the
world – 4km : 342
wagons and 6
locomotives
PAGE
Class 43 Diesel-Electric Class 15 Electric
The Ore Line was commissioned with 31x Class 9E locomotives in 1976 These locomotives were replaced during the past 4 years with a fleet of 76x Class 15E
locomotives – power output 4’500kW or 6’000 hp/tractive effort of 588kN at start and 454kN continuous – the strongest locomotives in South Africa, supplemented by 32x Class 43D locomotives to haul general freight
8
Rolling Stock Modernisation
PAGE 9
Remote 3 (End Of Train)Remote 2
Remote 1
Lead Consist
342-wagon Radio Distributed Power Train
Statistics
Train Length 3,9 kilometres
Train Mass 42 320 Tons
Pay load mass 34 200 tons
Operating speed 60 km/h
Wagons type Gondola CR14 at 30t/axle
Payload per wagon 100 tons
Locomotives 15E Electric = 4410 KW43 D/E = 2050 KW
PAGE 10
Operational Model
System 1: Loading at Mines
National Ports Authority
Berth capacity, Berths, Marine
services
Port TerminalsReclaiming & Ship Loading
4
SALKORCompiling/De-compiling trains, Shunting, NTG, Wagon & Locomotive maintenance
Rail operationsTrain operations, Crews, Traffic Control, Per way, Communication, Signalling, Power supply, Infrastructure- and Rolling Stock maintenance
Halfweg : Re-manning of trainsCrew book off
2
Port TerminalsOff-loading & stacking3
MINE SIDINGS AND LOUD-OUT
STATIONS
Kolomela
Sishen
Khumani
1
System 2: Rail transit
System 3: Off-loading & stacking
System 4: Reclaiming & ship-loading
PAGE
Iron Ore Line PerformanceOperational Efficiencies
11
Performance Area Past Performance Projections
2012/13
2013/14
2015/16
2016/17
2017/18
2018/19
2019/20
Locomotive EfficiencyGTK '000/loco/month
48 429 52 028 55 000 55 000 55 000 55 000 55 000
Wagon Cycle Time hours
94 93 76 76 76 76 76
On Time Departures minutes
73 33 60 60 60 60 60
On Time Arrivals minutes
140 233 120 120 120 120 120
PAGE
Future export volumes
12
Iron Ore Export Volume Growth
52
56,654,3
6062 62
67 67
72
0
10
20
30
40
50
60
70
80
2011/12 2012/13 2013/14 2014/15 (LE) 2015/16 2016/17 2017/18 2018/19 2019/20
Historical Performance (Mt) Projections (Mt)
20 THANK YOU
PAGE
Transnet Engineering
Table of Contents
15
Transnet Engineering: Overview 1
2 Western Region Overview
3 Saldanha Iron Ore Line
4 Challenges
PAGE 16
Continuous technology advancements and improvements
Running Maintenance
Refurbishing &
ConversionsLocos, wagons, coaches,
components
Heavy Maintenance
UpgradesLocos, wagons, coaches,
components
New BuildsLocos, wagons
Leasing
1859 – Landing of the first railway locomotive in South Africa at Cape Town
Running maintenance was first established
TE brings over 150 years of experience in the rail engineering sector and has built substantial expertise...
TE’s evolution and transformation of the SA transport industry1
1950s – Koedoespoort plant established to refurbish steam locos
1970s – Started refurbishing electric locos
1999 – Expanded capability to upgrade locos starting with 6E1 to 17E
2007 – Upgrading of diesel locomotives
2008 – Entered the new build market
1: Evolution of locomotive capability illustrated
SOURCE: Team Analysis
PAGE
TE began its journey in 1860, and is currently a leading Rail Engineering & Manufacturing firm
17
TE journey to dateRevenue
R13.71bn
Depots
150
Employees
~13,0002
Asset Value
R8.4bn
Factories
7
TE Today1
Coaches WagonsLocomotives
FoundryRotating machines
Ports Rolling stockEquipment
Wheels
1850 200919161892 1990 1994
First railway in South Africa established – Natal Railway Company
South African Railways and Harbours was born under the Union of SA
Transwerk branded as a separate entity within Transnet
Links between various Railway Companies started to develop
SA infra-structure management became a company entity, and Transnet was born
Transnet rebranding and structuring completed –Transwerk became TE
First locomotive arrived in SA – beginning of TE
Arrival of the first train at Johannesburg from Cape Town via Bloemfontein
TE produces the worlds most advanced health train (Phelopepa 1)
TE partners with leading international OEMs to create world class products for Africa
Official opening of the first public railway in South Africa, from Point to Durban
1 2013 results
2 Full Time Employees
2013
TE awards R50bn for 1064 locomotives to be produced in partnership with 4 OEMS as part of the MDS
TE plays a vital role in ensuring the success of Transnet’s Market Demand Strategy
SOURCE: TE
Offerings
9 Products
PAGE 18
TE Western Region Management
Operations
Mr Moeketsi JamJamBusiness ManagerSchool of Engineering
Mr Vicky GeldenhuysBusiness ManagerRisk & Safety
Mr Poobalan PillayCentre ManagerWestern Region
Mr Patrick RynhardtBusiness ManagerInformation Technology
Mr Andre DookooBusiness ManagerFinance
Support Services
Mr Arne BakkenePlant EngineerMPE
Ms Veronica van RooyBusiness ManagerProcurement SLD
Mr Bradley BesterBusiness ManagerProduct Development
Mr Roger LawrenceBusiness ManagerProjects
Ms Heena RanchodBusiness ManagerProcurement SRX
Ms Bongiwe MhlalukaBusiness ManagerHuman Capital
Mr Luvuyo RulasheBusiness ManagerWheels
Mr Leon StuurmanBusiness ManagerRSE
Mr Martin EsauBusiness ManagerRotating Machines
Mr Neville SolomonsBusiness ManagerPorts
Mr Bongufefe NtengoBusiness ManagerWagons
Ms Karen DamonBusiness ManagerCoaches
Mr Sedick van der Schyff Business ManagerLocomotives SLD
Mr Dirk EygelaarBusiness ManagerLocomotives BLV
PAGE
Western Region
19
Saldanha
Bellville
SaltRiver
PAGE
HISTORY
1909 Sawmill 1915 Early Carpenter Shop on the right
1934 First imported mainline passenger coach
1946 New Wagon Shop 1979 Aerial View of Salt River plant
150 Year Celebration
Salt River 150 Years Old
20
PAGE
Western Region - Saldanha
21
End of train @ 4.1 kilometres
Key insights
Longest train in the world –
▪ 4.1 kilometres
▪ 342 Wagons
▪ 5 Locomotives (4 electric and 1 Diesel)
▪ 1.2 million tonnes per week
Provide Maintenance for:
▪ 130 Locomotives per annum
▪ 6700 Wagons per annum
▪ 8000 Wheels per annum
PAGE
Iron Ore Line – Availability and Reliability
22
Sishen
Postmasburg
Saldanha
Upington
Springbok
Bloemfontein
De Aar
Kimberley
Cape Town
Locomotives91%
93%
Budget Actual
Availability15
7
Budget Actual
Reliability
15
0
Budget Actual
Reliability
98%
99.3%
Budget Actual
Availability
Wagons
Availability Reliability (FPMKM)
Budget Actual Budget Actual
Locomotives 91% 93% 15 7
Wagons 98% 97% 0.07 0.03
PAGE
Customer Facing Businesses - Western Region
23
LOCOMOTIVES
Description
Class 15E Class 9E Class 43D Class 34D Class 36D
Fleet size 76 8 29 16 4
WAGONS
Description
CR 17 CR 13/14 DBR FMKJ CALJ
Fleet size 504 6120 75 60 80
COACHES
Description
MetroShosholoza
MeylPremier
ClassAfrica Phelophepa
Fleet size 45 30 14 29 36
WHEELS
Description
Class 15E Class 9E Class 34D APS APD
Fleet size 612 18 636 6000 1500
PAGE
TE has a clear outlook of the broader developmental agenda, driving both Growth and Transformation
24
Key focus elements
▪ Industrialisation
▪ Export promotion
DTI – B-BBEE elements CSDP/ SD and B-BEEE elementDPE – CSDP/ SD elements
National objectives
▪ B-BBEE spend
▪ Investment in plant
▪ Intellectual Property transfer
Description
▪ Localisation of production
▪ Development of BO, BWO, YO, EME’s and QSE’s
▪ The growth and development objectives aim to:– Contribute toward competitiveness by
leveraging large-scale SOE procurement to develop a local supplier base and in doing so create decent jobs, decrease inequality and eliminate poverty
– Influence foreign organisations towards initiatives that lead to the development of local suppliers
– Transfer of skills and IP to local companies through ESD initiatives
– Development of local capability
▪ The transformation and empowerment objectives aim to:– Promote an equitable socio-economic
society through the integration of historically disadvantaged persons into the main stream economy
– Focus on “broad-based transformation impact”
– Focus on “changing the ownership patterns of the economy”
– Enable increase in black owned businesses (BWO, YO, Disabled)
“Growth & development”
“Transformation & empowerment”
▪ Small business promotion
▪ Preservation and creation of jobs
▪ Skills development
SOURCE: Team analysis
PAGE
Taking this into consideration TE has developed an over-arching strategic end state view of the business by 2024
25
TE in 10 Years
Core Business
Segments
African Success
Story
People Company of
Choice
Centre of Operational Excellence
SA Rail Development
Leader
World Class OEM
Leading Contributor to the local economy and region by promoting localization, skills transfer, job creation and sustainability
Promoter of BO, BWO, BYO, Disabled EME and QSE Businesses
Partake in Regional Development Discussions (not only in SA) Reduce any inefficiencies throughout all
business units Ensure maximum capacity utilization and
demand management Best in class Lean, Cost, Delivery and Quality
performance
Identify, attract, select, develop, and retain the best talent
Employer of Choice with attractive Employee Value Proposition
TE ‘One Culture’ High focus on Talent
Management
Rail OEM of choice for African customers
TE viewed as a partner and not only as a Supplier
TE TransAfrica locomotive aimed to be #1 seller in SSA markets
Refined Business Model to enhance Competitiveness to support SSA needs
Focused and fine-tuned operating activities and businesses
Enabler to TFR and PRASA by providing: Rolling stock manufacturing Rolling stock maintenance.
TE operating at the levels of World Class OEMs in its regions (SSA, SA)
Move towards delivering higher volume (units p.a.), standardized base product offerings with high tailoring potential
Clear Differentiators to other OEMs
SOURCE: TE
Thank you
27
TRANSNET PORT TERMINALS
WESTERN CAPE REGION
TABLE OF CONTENTS
28
SALDANHA TERMINALS OVERVIEW
TECHNOLOGY USED
BULK IRON ORE PROCESS
SALDANHA TERMINALS SHEQ
SALDANHA TERMINALS OVERVIEW
The port consists of the following:
o A reclaimed area on which approximately 5.1 million tonnes of iron ore can be stockpiled
o A causeway 2,3 km long from the reclaimed area to the ore/tanker quay
o An ore quay with two berths
o The MPT with 3/4 berths (depending on vessels’ LOAs)
o MPT capacity of 6.5mt per annum
The port of Saldanha is South Africa's main iron ore export harbour. A highly mechanizedore-handling plant remains the largest facility at the port.
Multi Purpose Terminal (MPT) supporting iron ore exports as well as a variety of harbor bound industries. The terminal has added Manganese exports to its service offering during 2014.
Saldanha Terminal is South Africa's largest natural anchorage and port with the deepest water.
The first deliveries of iron ore were exported on the vessel Fern Sea during September 1976.
SALDANHA TERMINALS SHEQ
Safety, Health and Environmental accreditations:
Saldanha – Occupational Health & Safety Management Systems OHSAS 18001:2007
Saldanha – Environmental Management System ISO 14001:2005
Saldanha – Quality Management System ISO 9001:2008
Bulk – NOSA 5 Star
MPT – NOSA 4 Star
Saldanha – Rail Safety Regulator (Valid License)
Statistics for Saldanha Terminals:
BULK MPT
Target Actual (LE) Target Actual (LE)
DIFR 0.78 0.65 0.78 0.66
Cost of Risk 2.81 1.80 1.30 1.30
TECHNOLOGY USED
Multi Purpose Terminal
• General Cargo Operating System (GCOS3)
• GCOS is highly beneficial to the customer because all to cargo handling is recorded; from
where the cargo leaves the client to port entry and ultimately shipping. Each and every move
is recorded. During this time, the client is also informed of each event taking place with their
cargo.
Bulk Terminal
• Supervisory Control And Data Acquisition (SCADA) which runs the whole plant.
• SCADA interfaces to CommTrac which provides various reports (operational efficiencies,
delays, tonnages loaded etc.) and sent to clients daily.
BULK IRON ORE PROCESS
Rail offloading
• 2 x Tandem, Dual Wagon, Rotary Tipplers
• Rate Capacity =8000 t/hr.
• Cycle Time=90 seconds
• Fully Automated
• Supplemented by dust extraction system
• Bag-house facility and air emissions control/recording
• Brake Wagons-Noise control
Ore Stacking
• 4 x Bucket Wheel type stacker reclaimercombinations
• Semi-automated, operator controlled
• Rated capacity = 10 000 t/hr
• Covered conveyance system
• Supplemented, dust fogging and demisting sprays
Ore Stockpile
• Stockpile capacity is 5.1 million tons
• Current provision, 13 ore grades
• MTS System -Support materials load/offload tracking
• Water/stockpile spraying system
• Conveyor belts: 26 km
Ore Reclaim
• 4 x bucket wheel type stacker reclaimercombinations
• Semi-automated, operator controlled
• Rated capacity = 10 000 t/hr
• Covered conveyance system
• Supplemented, dust fogging and demisting sprays
Ore Loading• 2 x boom ship
loaders• 4 operating
modes i.e. single, staggered, dual & direct loading
• Rated capacity-10 000 t/hr
• Inline product sampling
• Covered conveyor systems
• Dust suppression system, online dosing and moisture analysis and control
• Dual Berths, maximum 21m draft
MULTI PURPOSE TERMINAL
MULTI PURPOSE TERMINAL
MULTI PURPOSE TERMINAL
BULK TERMINAL SALDANHA
BULK TERMINAL SALDANHA
THANK YOU