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Rail Transport Optimisation Project Update

Summary of key business requirements, delivery timeframe, fleet issues rectification, station schedules, performance stats, and outstanding issues for the Rail Transport Optimisation Project as of July 2012.

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Rail Transport Optimisation Project Update

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  1. DL Gen I UpdateJuly 2012

  2. DL Gen I - Summary • Key Business Requirements - recap • Delivery Timeframe » Urgent. Increase in Freight & Passenger1 demand • Supplier » Existing supplier, capability, specification, warranty. • Two cabs » 2-for-1 replacement, reduces need to turn (but option for “recovery”) • Homogenous » Reduce range of “train-specific” locos, maintenance, inventory • Horsepower » 2700kW for timetable performance (especially 2-for-1). • Weight » 108t (maximise to 18t axle load limit). • Engine » MTU 20V4000R43, Electronic Fuel Injection, EU Stage IIIA emissions. • Pricing » Competitive pricing to match specification • Reliability » High reliability (but this has not been achieved yet). • Key Stats (as at 13 July 2012) • Kilometres » 1.9 Million km • Freight Trips » 14,800 • 1 DFT’s for ARTA

  3. Fleet Issues – 1st Rectification Program • Program Period » December 2011 – May 2012 • Rectification Items» Covered under warranty. • Control System (DLoco)» Loss of amps/loss of power/screen freezes. • » Control system card upgrade (MCU, ACU). • » Control system software upgrade. • Traction Motor (Yongji)» SKF bearing failure (rivets loosened, leading to failure). • » Fleet-wide replacement program (replaced with same bearing). • Water pipes (MTU)» Cracked pipes (water leaks). • » Turbo vent pipes modified. • Exciter Base (DLoco)» Cracking, causing excess vibration. » Re-welded exciter. • Vibration (MTU/Yongji)» Axial vibration on alternator end-plate, resulting in excessive brush wear. » 3 DL’s with very short brush life (9089, 9170 & 9193). » Engine-Alternator realigned. » Alternator Brush Holder improved across fleet. » Further investigations.

  4. Fleet Issues – 1st Rectification Program – cont’d • Items – cont’d • Compressor aux (DLoco)» Shutting down » Regulator change, inductor change, control system changes. • Silencer(Dloco’s sub-supplier)» Cracking, sets off fire alarm. » 20 silencers remanufacture (& rejected). » Sub-supplier refused to rectify again under warranty. » New supplier sourced and 21 silencers manufactured. • Basin Pump (DLoco’s sub-supplier)» Burns out when left on. » Replaced with continuous duty pump. • Adhesion (KR/DLoco)» Configure to NZ conditions (normal requirement for new loco) • » Performance across a range of loads, track, climate, driving styles. » Contributed to the required control system upgrade. • DL9089 (DLoco)» Alternator vibration (very short brush life) • » Waiting spare parts. • » Due for release – end July. • Other » TC radio (Tait) • » Portable radio (Motorola) • » Headstock cocks (Wellington).

  5. Fleet Issues – 2nd Rectification Program • Program Period » June 2012 – August 2012 • Items» Covered under warranty. • Control System (DLoco)» Various faults. • » ACU card upgrade (factory modified). • » Control system software upgrade & rewiring. • Traction Motor (Yongji)» Repeat SKF bearing failure. • » Fleet-wide replacement program (upgraded NU326 bearing). • Water pipes (MTU)» Cracked pipes, results in water leaks. • » MTU coolant pipes modified. • Exciter Base (DLoco)» Exciter based failed again – original repairs inadequate. » Enhanced support beam being fitted & improved security. • Vibration (MTU/Alt) » Axial vibration on alternator end-plate. » Some improvement, but investigations continuing. • Silencer (Dloco’ sub-supplier)» Cracking, sets off fire alarm. » New silencers are being installed. • “MDBF”» Various. » MDBF failures review. » Rectifications applied as necessary.

  6. 3 Rectification Stations - 3-7 days per station Station 1 (3 days) Exciter Base Welding Traction Motor Bearing Exciter Base Welding Traction Motor Bearing Exciter Base Welding Traction Motor Bearing Station 2 (3 days) Exciter Alignment Silencer Install MTU Pipe mod Exciter Alignment Silencer Install MTU Pipe mod Exciter Alignment Silencer Install MTU Pipe mod Station 3 (3-7 days) ACU install Eng-Alt alignment check “MDBF” rectifications ACU install Eng-Alt alignment check “MDBF” rectifications ACU install Eng-Alt alignment check “MDBF” rectifications

  7. 10 Week Rectification Plan

  8. Individual DL MDBF Performance

  9. Fleet Utilisation & Performance

  10. Main Outstanding Issues • Alternator Vibration » Axial Vibration. • » Identification of Cause. • » Investigation ongoing. • Alternator Fan » Cracks and failure of Fan Blade on 9135. • » Interim fix applied. • » Possible replacement of all fans? • » Engine-Alternator removal and realignment? • » Solution being developed by Yongji. • Drive-train gearbox » Overheating, leading to breather pipe failure • »Incorrect oil used (on advise from Mobil).» Breather pipe hose modification and oil change.

  11. DL Gen II UpdateJuly 2012

  12. DL Generation II - Status • Contract in place » 20 DL’s. • » Pre-dominantly the same loco. • » Required by 2013 peak season. • Gen II Prototype » Assembly completed. • » Functional testing completed. • » Scheduled to run on rolling-road for 3 weeks. • Main Production » Has been “paused”. • » Enables Gen I mods to be applied prior to Production. • » Potential re-start of 1st October 2012. • » Expect delivery mid-2013.

  13. DL Generation II - Changes • Gen I Rectifications » Gen I “learnings” applied to Gen II. • Compressor » Atlas Copco, France (was Knorr VV450 , Germany). • Front Window » Lowered by 60mm. • Drivers Footstep » Re-design (switch position, adjustment range). • Console Desk (right hand side) » Re-design (improved access). • Head light switch » Re-arrangement proposed. • Emergency egress » Above-window hand-grab, modified first foot-step.

  14. IAB UpdateJuly 2012

  15. IAB - Summary • Key Business Requirements - recap • Delivery Timeframe» Urgent. Increase in Freight demand • Key Stats (as at 17 July 2012) • Configurations » 439 IAB’s • » 59 ZXT’s • » 2 ZXM’s • Kilometres » 26.4 Million kms • Trips » 81,000 trips

  16. Key Issues • Camber »Difficulty with loading some empty 40’ containers. • » Too much underframe camber. • » Supplier developing proposal for evaluation. • Wheel-skids » Running with hand-brakes on. • » Number of incidences reducing. • Brake system performance » Compliance achieved. • » Required modifications as part of commissioning (brake block). • » Further modification are being considered. • Dynamic ride » Compliance achieved. • » Required modifications as part of commissioning (friction wedge). • Brake Beam » Damaged during lift-offs. » Brake lever setup modification changed to prevent damage.

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