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Justin Angove, Rio Tinto: Delivering exceptional track maintenance strategies in heavy haul rail
 

Justin Angove, Rio Tinto: Delivering exceptional track maintenance strategies in heavy haul rail

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Justin Angove, Maintenance Execution Superintendent, Rio Tinto delivered this presentation at the 2013 Heavy Haul Rail conference. The highly anticipated event is the annual meeting place for mining ...

Justin Angove, Maintenance Execution Superintendent, Rio Tinto delivered this presentation at the 2013 Heavy Haul Rail conference. The highly anticipated event is the annual meeting place for mining and rail representatives from around the country to discuss all the latest rail projects in the heavy haul sector. For more information about the event, please visit the conference website: http://www.informa.com.au/hhrail14

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    Justin Angove, Rio Tinto: Delivering exceptional track maintenance strategies in heavy haul rail Justin Angove, Rio Tinto: Delivering exceptional track maintenance strategies in heavy haul rail Presentation Transcript

    • Rio Tinto Track Maintenance
    • RTIO– Railways Division
    • 2013 safety focus for railways division • Quality pre starts • Quality safety interactions • Quality pre-task hazard assessments • Leadership span of control Safety Leadership • SQRA & CCMP • HSEQ compliance • Align HSEQ and regulatory requirements • Fatigue Safety System Compliance • Hazard awareness • Focus on Line Of Fire • Mechanisation of repetitive tasks Hand Safety
    • Railways community safety campaign Rio Tinto’s focus of 2013 Rail Safety Week is ‘Safety at level crossings’. Rio Tinto supported this key safety message through an extensive Community Awareness Campaign titled Look, Listen, Live.
    • Integral part of the production network Rail is the key to the logistics chain • Ore is railed from 10 mine locations to 6 dumpers (3 at Dampier and 3 at Cape Lambert). • The current schedule (~249 Mtpa) is – Pooled fleet: 19 - 24 trains per day – RV J: 5 - 7 trains per day A 360 Mtpa system means; • 23% increase in tonnes, 20% increase in cars, 13% increase in loco’s, 7% increase in track • Railing from 12 mine locations to 7 dumpers (3 at Dampier and 4 at Cape Lambert) • 1 Mt per day, 40 loaded trains per day • Train movement every 20 minutes in dual track
    • Locomotives • A current total of 163 locomotives: - 72 x Dash 9 - 4 x Dash 8 - 87 x Evolution • Planned loco deliveries: - 10 x DC Evolution (mid 2013) - 6 x AC Evolution (early 2014) - 3 x DC Evolution (early 2014) 0 50 100 150 200 250 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 DC Traction - 72 GE Dash 9's - balance GE Evolution Series AC Traction ? Dash 9 replacements due to start ~2015
    • Train configuration • Very long, heavy trains. Operating at quartile 1 power to weight ratio of class 1 Heavy Haul rail operations • Pooled Fleet = 3 locomotives hauling 236 ore cars, Robe Valley = 3 locomotives hauling 166 ore cars • Banker locomotives (2 or 3) used for uphill gradients from mines • Average payload of 114 tonnes of ore per car = 33.9 tonnes average axle load. Upper control limit is 36 tonne axle load (governed by infrastructure) • Each train has a gross mass of approx. 32,300 tonnes and is 2.25 km long • A round trip to Yandicoogina is approx. 900km’s and uses 20,100L of fuel
    • Track equipment - Fixed Plant Flashbutt Welder and associated rail gantry system - 50 ballast hoppers including 7 side tippers with two plough cars - 2 Rail Train capable of carrying 48 by 400 m long rail strings - 1 x 64 stone & 1 x 56 stone Rail Mainline Grinding and 2 Switch Grinders (also 3 x 32 stone units on order) - 6 x Tamper machines for surfacing including turnouts - 3 x Ballast Regulators for shaping of the ballast section - 7 x Mobile Flashbutt Welders
    • Electronically Controlled Pneumatic (ECP)Brakes and Driver Assist ECP - Consistent and rapid braking to facilitate smoother train running - Retrofit of fleet commenced November 2011. Driver Assist – Advice to drivers on optimum throttle and brake setting to achieve the optimal run – Anticipated cycle time and fuel saving benefits
    • ECP – Verification of benefits
    • Summary •RTIO Railways is the largest privately owned heavy haul railway - “Traditional” heavy haul railway with large technology changes in progress - Rapid increases in rolling stock assets offset by minimal investment in track infrastructure - Complex logistics operation reliant on optimised planning, scheduling, execution and deviation management - Legacy infrastructure challenges managed through operational discipline - Efficiency opportunities with modernisation and mechanisation
    • Track Maintenance Defect Management 12
    • Track Reliability 2012 Broken Rails 25 7 6 2 1 0 5 10 15 20 25 30 PLK Open Rail MFBW FBW Turnout Blade 2012 Broken Rails by Type To 31 Dec Major focus for improvement work
    • 2012 Broken Rails 17 6 5 3 3 2 2 1 1 1 0 2 4 6 8 10 12 14 16 18 2012 Broken Rails by Failure Type To 31 Dec
    • Rail Defects 2012/2013 BRTDXBHCHSHHSWVSHTDUHRDW 140 120 100 80 60 40 20 0 DEFECT TYPE Count Chart of 2012 DEFECT TYPE BHVSHHSWHSHUHRTDBHCDW 70 60 50 40 30 20 10 0 2013 DEFECT TYPE Count Chart of 2013 DEFECT TYPE
    • UHR
    • Welding Improvement Activities •Improved welding procedures •Increased welder surveillance •More stringent standards •Equipment compliance •Major NDT improvements
    • 2013 Broken Rails Cumulative Count 9
    • •Zero UHR broken rails YTD 2013 •Zero aluminothermic weld broken rails YTD 2013 •On target YTD 2013 with broken rail KPI 2013 Broken Rail Situation
    • Defect Management •Statistical analysis of fatigue defects •Statistical analysis of non fatigue defects •Step change process improvement in defect management guidelines •Use of statistical tools to classify and manage defects •Step change in defect detectability and classifications •65% and 45% of rail defects were “saved” for the months of March and April respectively 2013 •Best estimate for Jan-Apr 2013 is a cycle time benefit of 76.5 hrs or an additional 1.9 trains
    • 131118105927966534027141 4000 3000 2000 1000 0 -1000 -2000 Data Points = Individual Welds WeldLifeinDays _ X=154 _ X=747 _ X=210 UCL=413 UCL=3029 UCL=647 LCL=-105 LCL=-1536 LCL=-228 Confirmed Historical Data NDT Contractor Data New Process Data 1 1 1 7 1 1 Control Chart of Confirmed Historical Data/NDT Contractor Data and New Process Data Statistical Analysis of Failures
    • 11110000000 450 300 150 0 Confirmed Welds WeldLifeInDays _ X=149.3 UC L=391.6 LC L=-93.0 11110000000 300 200 100 0 Data Source MovingRange __ MR=91.1 UC L=297.6 LC L=0 1 1 UHR Control Chart Use of Control Charts for Defect Management/Identification
    • Inclusion V’s UHR Statistical analysis used to differentiate where UT operator is unsure Where applied – 100% reliability
    • Questions