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So… You Want to Have a Steel Mill on Your Layout…

So… You Want to Have a Steel Mill on Your Layout…. JMRI Operations Part III. Today’s Agenda. Not about “Steel Mill Modeling” per se That can be a life commitment… But you must be interested or wouldn’t be here! Is about “rail operations” serving a Steel Mill How can one:

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So… You Want to Have a Steel Mill on Your Layout…

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  1. So… You Want to Have a Steel Mill on Your Layout… JMRI Operations Part III

  2. Today’s Agenda • Not about “Steel Mill Modeling” per se • That can be a life commitment… • But you must be interested or wouldn’t be here! • Is about “rail operations” serving a Steel Mill • How can one: • Represent the steel mill complex • Represent the mill rail traffic • Might be the Theme of the model railroad • A GREAT way to tell a story & reason to run trains • So, we’ll talk about Steel Mills & Rail Operations

  3. Steel Mills & Rail Operations • Steel Mills are big, noisy, fascinating places • What are the parts and pieces? • How much space • Does it take? • Do you have…? • What about • Raw materials? • In plant materials? • Finished products? • What about the bigger context of a city’s railroad(s)? • Operations can be the “tie that binds” this together…

  4. Steel Mills & Rail Operations • Can I apply JMRI to Steel Mill Operations? • YES! • JMRI Operations Software: • Powerful • Flexible • Limited only by your ideas/imagination • Hmmm… (might be a “life commitment”...) • How can I use JMRI Operations software? • Raw materials in • In Plant switching • Finished products out • Tying to the rest of the model RR…

  5. Let’s Take a Little Trip to Birmingham • Birmingham, AL • Didn’t exist in the Civil War… • Founded at the junction of two railroads (1871) • Developed as an industrial city • The New South • Continuing the Industrial Revolution • “Railroad Reservation for Mechanical Enterprises” • Unique natural resources • Iron ore • Coal • Limestone • All “within a rifle shot of each other”… • Known as the “Birmingham District” in the iron trade Make Iron Make Steel

  6. An Entire Industrial District • Everything in one place! • Can I do that? • What do I need? • Where can I learn? • What are the parts? • How does it work? • What is “required” Coal Birmingham Limestone Iron Ore Bessemer = 1,100 ft. in HO say 28 acres in HO 18 Miles

  7. Birmingham District Model RR • Birmingham Steel “District” • Iron & Steel Industries • 8 Trunk RR’s + Industrials • Interchange + passenger • Yards • Main “staging” • Downtown pocket yard • Steel Works yard • Steel theme – “mine to mill” • Iron ore • Coal to coke • Limestone • Related industries • Scrap, iron pipe, cement • By-product (chemicals) • Downtown industries 18 Miles

  8. A view of the heart of the Birmingham industrial area including TCI / USS Ensley Works and Fairfield Works – 2 fully integrated steel mills and much, much more…

  9. How Do I Model a Steel Mill? • Lemme’ tell ya’ what’mgonna do! • EVERYTHING you need in one place… • Typical Steel Mill • Birmingham • Lots of other places

  10. Limestone Limestone Iron Ore Raw Materials Primary Rolled Shapes Coal Steel Making Secondary Products Coke Blooming Hot Rolled Products Typical Steel Mill Components Steam Era Birmingham District

  11. Blast furnaces for iron (BF’s) • 1928 - #5, #6 • 1942 - #7 • 1000 tons/day/BF (by 1950’s) • Recipe per 1 ton iron • 2.5 tons iron ore • 1 ton coke • ½ ton dolomite • Cars @ 2000 tons/day/2-BF’s • 72 ore cars • 66 coke 34’ hoppers • 16 dolomite 34’ hoppers • Car ratios to (our) stock trestle • 6 -- 22’ ore jennies • 5 -- 34’ hopper coke • 1 or 2 -- 34’ hopper limestone • Coal to (our) coke plant • 1.7 tons coal/1 ton coke • 60 -- 34’ hoppers coal We have 2 BF’s Times 2,000 tons/day 13 Trains per Day! 8 Trains per Day!

  12. Open Hearths for Steel • 1928 – 8 OH’s • 1942 – add 4 OH’s • 400 tons/day/each OH • About 2 heats per day • Cars from BF to OH’s, say: • 8 @75 ton hot metal cars • 5 @125 ton hot metal cars • To 600 ton mixer • Plus scrap loads to floor • Plus dolomite & misc. • Plus slag cars to dump • Output for 3 OH’s/day, say: • 1,200 tons per day • 150 @ 8 ton ingots (varies) • 40 small 4 ingot flat cars • More slag cars to dump We have 3 OH’s

  13. Blooming Mill(s) -- pick one • Ingot cars “in” • Ingot mold stripping • Overhead crane to soaking pits • Ingot buggy to mill line • Blooms or slabs out • Move along to rolling mills

  14. Have to make tough choices… • How much room? • What to “show” • Building flats? • Sidings? • Your choice… • And there’s MORE!

  15. Coal Mine Iron Ore Mine Coke Plant Bessemer Converters In the 1950’s lots of school kids in Birmingham visited the Steel Works at Fairfield… Power Plant Rolling Mills

  16. Resources • Aerial Photos & Maps • Historical? • Current • Local History • Plant layout drawings? • HABS-HAER • Library of Congress • Books at library • Online “groups” • Google Books online • Process • Concept drawings • Don’t plan forever… • Need to run trains… BF’s #5, #6, #7 Ingot Soaking Pit Open Hearth Charging Floor Teeming (Casting Ingots) Blast Furnace #7 Blooming Mill Ingot Stripping Pouring Slag at BF Pouring Hot Metal at BF Charging Open Hearth

  17. Things to Think About… • How much room do I have/need • You can’t do it all… • What do I want to include? • Suggest starting with steel making • Then consider processing = “big buildings & spurs” • Don’t forget raw material sources/processing • Whole buildings or flats? • Some great operating layouts model “fronts” • Consider “mock ups” to get started and check fit • My main goal is to get a spur to a “place” • Don’t be afraid of “imagination” & mockups • Run trains now, build fine models later…

  18. Now back to the reality of… available space! September 28, 2008

  19. Downtown Birmingham Coke Plant AISLE AISLE AISLE Quarry • Birmingham District Model Railroad • Overall space • 13 x 33 • 10 x 14 • Large folded dog-bone mainline • Branch lines Small Yard Red Mountain AISLE AISLE Coal Branch AISLE Steel Works Main Yard = 550 sf +/- AISLE AISLE Coal Branch

  20. Downtown Birmingham REACH Coke Plant Switching Lead Quarry Crossing Red Mountain Small Yard Switching Lead REACH REACH REACH REACH Coal Branch Main Yard Steel Works Parts Coal Branch

  21. Raw Materials • = Branch Lines Primary Rolled Shapes ??? • Steel Making Secondary Products ??? ??? • Blooming Hot Rolled Products ??? Typical Steel Mill Components Steam Era Birmingham District

  22. Things to Think About… • Operations changes your point of view • Focus may change from buildings to trains • Train length perspective • What looks good? 10 car trains – good goal • What fits? 10 car siding – 5 feet log • Yard tracks for trains 7’ minimum (5’ + eng. & cab) • Each “stop” requires room Lots of spurs! Lots of cars! • Steam era = shorter cars! 34’ hoppers vs. 60’ • Where can I park this thing? No need to run if you can’t park • Start thinking in “modules” of cars • Maybe 4’s and 8’s – based on spur length, materials required • Moving a train with purpose is fun regardless of length! • More switching spots = larger car fleet! • Remember: Switching takes R-E-A-L T-I-M-E!

  23. Industrial Development • Recruiters have landed a steel mill • Site selection is complete • Railroad coordination is in progress • Surveyors are ready • Engineering folks are busy “head scratching”… • So, how does it all fit?

  24. Loads OUT RM #1 Out TCI Fairfield Works c. 1928 Birmingham, AL Schematic RM #2 In OH #1 Teem OH #2 Pour BM In OH Charge OH Mix OH Lead Coal Branch Blooming Mill Open Hearth BM Out Scrap Yard Slag Scrap #2 Plant BF Stock Trestle Scrap #1 Out Hot Metal BF #5 Slag Blast Furnaces Steel Works Lead Hot Metal BF #6 Main Downtown Siding BF Lead Downtown Lead #2 Slag Dump Lead Fairfield Yard Lead #1 Slag Dump Quarry & Cement Plant Loads In Passing Siding Steel Works Yard Main Empties Out To Downtown Yard & Industries Joint Use Engine Terminal Downtown Siding

  25. Rolling Mill OH Teeming Coal Br. OH Charging Fairfield X’g. OH Mixer SW Lead Blooming Mill Fairfield Yard (FY) & Engine Terminal Quarry 18’ Slag Dump #5 Blast Furnace Atlas Cement FY Lead (curves to left) Stock Trestle #6 Blast Furnace

  26. Where do the raw materials come from? How do they get to Fairfield Yard? Fairfield X’g. Fairfield Yard Lead Downtown Siding SW Lead Main Line Yard Lead joins Downtown Siding

  27. Where’s JMRI Come In? • Plan your work… • See JMRI Part I & II • Name each location • Decide work to be done • Decide cars required • Consider process “loads” • “Custom loads” needed? • Location “schedules”? • Take one material • Make it work • Work your plan… • Start simple with JMRI • Take baby steps • Try it • Test it • Repeat it • Go to next step • Ask for help • Use Yahoo Group • Work with a friend

  28. JMRI Tools • Help Manual (“RTFM”) • Online part of JMRI • Can print to pdf • Keep it handy • Currently about 40 pages • Not always clear • Use Yahoo Groups • JMRI Users Group • Follow the rules • Subject “Operations” • Step by step • Be ready to copy files • VERY helpful folks • “Detailed” Build Report • LEARN to read the report • Recipe to build a train • Learn to read it • Always the same parts • Read in pieces • SCAN for parts • Your problem is there! • See what program does • Often becomes clear • Think like a computer • See left side of Screen!

  29. Learn JMRI While You Have Fun! • K.I.S.S. Rule • Don’t try “all at once” • Start out simple • Use Random switching • Then pick ONE… • Industry • Process • “Next step” • Get that to work • Then do ONE more • Birmingham District MRR • Focused “random" switching • Passenger trains • Interchange trains • Downtown Industries • Staged trains • Local Switchers • Intermediate Yards • Build & break yard work • Multiple train logistics • Complex processes

  30. Consider an Example • Coal mine service • Could use “random” E/L’s • Mine is a “location” • Set it as a “spur” • Spur will “swap” loads • Empties in, loads out??? • Set up a Mine Turn • From a (say) power plant • To your mine • Back again • Should do the job… • BUT, What about… • Different grades of coal? • Multiple mines? • A “next step” process? • Add a coke plant • Material flows one way • Keep it moving? • Requires “restrictions” • Conditions on cars • Conditions on loads • Schedules for cars/loads • JMRI can do it!

  31. JMRI Example – Get Started Coal Mine #1 SW Power • Download software • Setup software • Set preferences • Set File Locations • Add Ops to Menu

  32. JMRI Example – Create Coal Train • Power House to Coal Mine • Create Locations • Coal Mine #1 • SW Power House • Create Cars • Create Route for “Turn” • Place Cars • 3 at Mine • 3 at Power House • Set Loads “Prime Pump” • Loads at Mine • Empties at Power House • Restrict Loads • Mine services “Empties” • PH services “Loads” • Create Train • Name train • Assign Route • Build Train • See what happened? SW Power Coal Mine #1 • Train Sheet • PwrHse Coal Turn • Depart PwrHse w Empties • Work Coal Mine • Depart Coal Mine w Loads • Arrive PwrHse S/O Loads

  33. JMRI Example - Locations SW Power Coal Mine #1 • Power House to Coal Mine • Create Locations • Coal Mine #1 & Spur • SW Power House & Spur • Create Cars

  34. JMRI Example – Create Cars • Power House to Coal Mine • Create Locations • Coal Mine #1 & Spur • SW Power House & Spur • Create Cars • Create Route for “Turn”

  35. JMRI Example – Create Route Coal Mine #1 SW Power • Power House to Coal Mine • Create Locations • Coal Mine #1 • SW Power House • Create Cars • Create Route for “Turn” • Place Cars

  36. JMRI Example – Place Cars & Loads • Power House to Coal Mine • Create Locations • Coal Mine #1 • SW Power House • Create Cars • Create Route for “Turn” • Place Cars • 3 at Mine • 3 at Power House • Set Loads “Prime Pump” • Loads at Mine • Empties at Power House • Restrict Loads

  37. JMRI Example – Set & Restrict Loads • Power House to Coal Mine • Create Locations • Coal Mine #1 • SW Power House • Create Cars • Create Route for “Turn” • Place Cars • 3 at Mine • 3 at Power House • Set Loads “Prime Pump” • Loads at Mine • Empties at Power House • Restrict Loads • Mine services “Empties” • PH services “Loads” • Create Train

  38. JMRI Example – Create & Build Train • Power House to Coal Mine • Create Locations • Coal Mine #1 • SW Power House • Create Cars • Create Route for “Turn” • Place Cars • 3 at Mine • 3 at Power House • Set Loads “Prime Pump” • Loads at Mine • Empties at Power House • Restrict Loads • Mine services “Empties” • PH services “Loads” • Create Train • Name train • Assign Route • Build Train • See what happened?

  39. JMRI Example – Create & Build Train • Successfully built train • Imagine we ran the train • WE moved cars • WE might swap loads • BUT the computer hasn’t • YET… • Have one more step • TERMINATE TRAIN!

  40. Let’s Review • Planned “reason” for train • “Work” for train to do • “Locations” with “spurs” • “Load options” on spur/loads • “Cars” & placed them • “Loaded” some of them • “Route” • “Train” • “Built” and “terminated” • Observed the results! • Coal for power at SW’s • Haul empties, loads, switch • Places with “right” track • Move coal in right direction • Set up the game board • Prime the pump • Define “railroad” for JMRI • A way to move “cars” • Puts database to work • Database moves cars/loads

  41. Birmingham District MRR • HO Scale • Digitrax Control • 33’x12+’ + 10’x14’ = 550 sf • Folded dog-bone w/ 5 branches B

  42. Typical Delivery Scenario Mine to Mill Quarry DT Coal Br. (CB) (DT) Train Source Downtown Yard (DT) Fairfield Yard (FY) Steel Works (SW) Trains per day? (L&N) DT Switch MTs In TCI Dolomite Out DOLOMITE Switching Time MTs In Coal Out Switching Time COAL Trains per day? (L&N) CB Turn Fairfield Yd (FY) Coke Pl. (CP) DT DT Trains per day? Trains per day? Coke Plant Switching DOLOMITE COKE (TCI) FY Turn Session Time (“A Day”) COKE (L&N) CP Turn Switching Time Switching Time Coal In TCI Coke Out Red Mtn. FY MTs In Processed Ore Out Switching Time Trains per day? PROCESSED IRON ORE Iron Ore Mines Process Plant (TCI) RM Switch, then RM Turn Steel Works (SW) Fairfield Yd. (FY) Switching Time Trains per day? (BF) Slag, Hot Metal (OH) Scrap, Ingots, Slag LDs In MTs Out • Amount needed per train: • 6 cars iron ore • 1 car dolomite • 5 cars coke (BF) Iron Ore, Coke, Dolomite (BM)Slabs from Bl’mg Mill (TCI) SW Turn (TCI) SW Switch Raw Mat’l In Slabs Out Ingots In Slabs Out

  43. DT YARD • Coal Branch Turn (L&N) • Requires “long route” • Switches coal branch • 3 mines • Wye COAL BRANCH

  44. DT YARD • Coke Plant Turn (L&N) • Downtown Yard • Switches coke plant • Coal in (via Downtown Lead) • Empties in plant • Coke out (via Main Line) • Returns to Downtown Yard COKE PLANT

  45. Scrap DT YARD • FY to DT Turn • Precedes SW Turn • Coke and dolomite at DT • Loads to FY • Empties to DT • Products out of Steel Works • Products for market to DT FY YARD Slabs Rails

  46. Red Mtn. Turn • Requires trackage on L&N • Iron ore to FY • Follows RM Switch • Mines • Processing (sinter) Plant RED MTN MINES YD Track FY YARD

  47. Steel Works Turn • Serves Blast Furnaces • 3 grades ore, coke, dolomite • Clears stock trestle • Fills stock trestle • Classify at FY by type/load • Precedes Red MtnTurn FY YARD BLAST FURNACES

  48. Steel Works Switch (TCI Plant RR) • Advances materials thru plant • BF Hot Metal to OH Mixer • Scrap to OH • Ingots to Blooming Mill • Slag to dump • Blooming Mill to Rolling Mill STEEL WORKS

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