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HEAVY HAUL RAILWAYS of AUSTRALIA

HEAVY HAUL RAILWAYS of AUSTRALIA. Mark Baxter EGM Rail Technical Services. Presentation Outline. Introduction to Heavy Haul Heavy H aul regions in Australia World’s heaviest haul railways Technologies that enable Heavy Haul Locomotives in Heavy Haul Applications in Australia.

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HEAVY HAUL RAILWAYS of AUSTRALIA

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  1. HEAVY HAUL RAILWAYS of AUSTRALIA • Mark Baxter EGM Rail Technical Services

  2. Presentation Outline • Introduction to Heavy Haul • Heavy Haul regions in Australia • World’s heaviest haul railways • Technologies that enable Heavy Haul • Locomotives in Heavy Haul Applications in Australia

  3. About the Companies • UGL Rail • Founded in 1902 • Designer, manufacturer and maintenance provider of railway rolling stock including locomotives, passenger cars and wagons • GE licensee in Australia • Top 100 Australian Blue chip company • Texmaco • By House of Birla • 1 out of every 4 cars in Indian Railways built by Texmaco • leaders in railcar innovation • Reputation for quality, on-time delivery and ethical practices • UGL Rail / Texmaco JV • Founded in 2010 • Combining skills and strengths of both companies

  4. Heavy Haul Railways of Australia • This presentation profiles the heavy haul freight railways of Australia • Describes Australia’s unique heavy haul operations and how they have developed over time, driving railway technology to new limits and in doing so establishing new benchmarks and standards. • The presentation will also focus on the key technologies that are utilised to enable efficient railroad costs to achieve these remarkable applications.

  5. Pilbara Region • Australia is a world leader in heavy haul freight railways with the Pilbara region of Western Australia dispatching the longest and heaviest iron ore trains in the world, operating at 40 tonnes axle load. Pilbara Region

  6. Heavy Haul Coal in Australia • Extensive heavy haul freight operations in the coal areas of the Hunter Valley in New South Wales and the Bowen and Surat Basins in Central Queensland Bowen and Surat Basins Hunter Valley

  7. World’s HEAVIEST Haul Railway • The world record for the heaviest and longest train is held by BHP Billiton in the Pilbara Region iron ore area. The train was 7.4 km long comprising of 682 loaded ore wagons hauled by 8 AC6000’s with distributed power control of the remote locomotives within the train and ONE driver!!! • The gross weight of the train was 99,734 tons This is not the actual train but does give a perspective of the size and terrain

  8. Heavy Haul Iron Ore Operations • Iron ore wagons with a rotary coupler one end of each wagon to permit tippling when emptying them at the port storage area. • Axle loads have grown from 30 tonnes in early 80’s to current 40 tonnes in 2000’s and plans to extend to 45 tonnes by FMG in the near future. • Track laid on concrete sleepers with good ballast depth for track stability.

  9. Iron Ore Locomotives • Initial iron ore locomotives were 3600 HP DC traction (predominantly ALCO’s) The current iron ore locomotive designs include; • 4400 traction HP • AC traction • 196 tonnes service mass • Built to US domestic rolling stock gauge • Distributed power • Microprocessor controls for engine, power generation and traction • Screen based crew information systems • GPS locators and radio download capability for locomotive health • Slow speed control to enable “in motion” loading at nominal 1 kmh.

  10. ES44ACi/ ES44DCiDiesel Electric Locomotive (DEL) Iron Ore Locomotives

  11. Iron Ore Wagon Development Current iron ore wagon designs features include; • Bogie mounted brake equipment (More efficient and lower cost) • AAR specification ABD brake control • 3 piece freight bogies with constant contact side bearers and split friction wedges for improved damping control • Load to tare ratios approaching 8:1 • Stainless steel hoppers (5CR12) • Drawbar connection to form 2 pack or 4 pack wagon groups with standard AAR auto couplers at one end and AAR standard rotary auto coupler at the other end. • Conversion to Electronic Control Pneumatic (ECP) brakes for better train control

  12. Iron Ore Wagon Development Gross 160+ tonnes Tare 22 Tonnes Capacity 138+ Tonnes Volume 62 Cubic Metres Length Overall 10,360 mm Width 3,200 mm wide Height 3,352 mm high Structural Material 12% ferritic stainless steel Ti stabilised Max Operating Speed 100 km/h Rotary wagon dumper,, indexer positioning Brake System Bogie mounted Consist Configuration Major OEMs control valves (ECP Option)

  13. Coal Trains in Hunter Valley Coal train of the Hunter Valley of NSW being hauled by 3 x 134 tonnes 4,400 HP AC traction GE/UGL locomotives 92 x 120 tonnes wagons

  14. Coal Locomotive Hunter Valley C44ACiDiesel Electric Locomotive (DEL)

  15. Coal Wagon Development Current coal wagon features include; • Bogie mounted brake equipment (More efficient and lower cost) • Mechanical hand brake operating on one bogie per wagon • Electronic Control Pneumatic brake system (ECP). Better train operation with almost no slack action when applying brakes. Brakes are graduated on and off. • Non metallic composition brake shoes give better life and less noise than cast iron shoes. • 3 piece freight bogies with frame bracing & constant contact side bearers • Load to tare ratios approaching 6:1 • Stainless steel hoppers (5CR12) • Fixed drawbar connection to form 2 pack or 4 pack wagon groups with auto couplers at each end. • Operational speeds of 80 kmhrloaded and 100 kmhrempty.

  16. Coal Wagon Development • Tare 21.8 Tonnes • Capacity 98.2 Tonnes • Volume 108 Cubic Metres • Gross Weight 120 Tonnes • Length Overall 1 5,600 mm • Max Operating Speed Empty 100 km/h • Max Operating Speed Loaded 80 km/h • Bottom Door Operation KwikDrop • Consist Configuration Single or multiple pack • Brake System Body or Bogie mounted (ECP option)

  17. Coal Wagon Development Early 4 wheel coal wagons manufactured in Newcastle for use in the Hunter Valley coal fields and hauled by steam locomotives

  18. Coal Wagon Development Current design coal wagon at 120 tonnes with lateral “Kwik Drop” doors and sequential operation by trackside mounted cam to enable “in motion” unloading at 1 kmh. Solid drawbar connection between wagons to create 2 pack or 4 pack wagons dependent upon customer requirement.

  19. Narrow Gauge Locomotives PH37ACmai Locomotive

  20. Narrow Gauge Locomotives PH37ACmai Locomotive

  21. Conclusions • Heavy Haul operations in Australia are pushing the envelope of technology and innovation. • Technologies that enable Heavy Haul operations • High axle weight • AC locomotives • High capacity wagons • ECP brakes • Distributed Power • Tippler or Bottom Dump facilities • Competition continues to drive innovation

  22. Conclusions Thank You

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