bob vanselow - rail consultant - heavy haul issues

Midnight  at  Jabiru  --10 years on--

How  a  Major  Heavy  Haul  Derailment  challenged  the  

Pilbara’s  biggest...      

                                                                             Bob  Vanselow,  for  RISSB’s  Major  Rail  Occurrence  Forum  2014  

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North

INDIAN

DAMPIER

KARRATHA

Nanutarra

Witt

enoo

m

BROCKMAN DETRITALS

West

ROEBOURNE

OCEAN

WICKHAM

Millstream-ChichesterNational Park

PARABURDOO

CHANNAR

PARABURDOO

RosellaSiding

MOUNTTOM

PRICE

TOMPRICE

Coastal

MARANDOO

KarijiniNational

Park

Road

PORT HEDLAND

Great

Hwy.

Highway

Northern

YANDI (HIY)

0

Kilometres

25 50

66  mta*  +  31  mta  Robe  

 350  km  Haul*  

Hamersley  Iron’s  Rail  network  

 (c.  2000)  

Rail  Task:  240  >>  360  mta  (by  2017)  

Secondary  Task  (fuel  the  mines)  

Parker  Point      (Diesel  in;  Blended  Ore  out)  

Supply  Chain  Link  =  Ore  TransportaDon:  Deplete  Mine  Stockpile  >>>>>>>>>>>>>>>>>>>  >>>>>>>>>>>>>>>Build  (&  Blend)  Port  Stockpile  

Suggested  'TransportaYon'  System  for  Mine  to  Port  movement  of  Lump  and  Fine  Ore: RG  Vanselow

  Lump*  Ore  'TransportaYon'  System:  Moves  Batch  B  from  Mine  Stockpile  to  Port  Stockpile

*  A  similar  system  applies  to  Fine  Ore,  but  has  been  omi]ed  for  clarity.

Mine Stacker 'TransportaYon'

Stacker

Mine 'TransportaYon' Port Ship  

Plant Reclaimer Reclaimer

Loader

'TransportaYon'  by  

Trains:  

Lump  Batch  B    >>>>

  Mine  to  Port  Railway   Car  Dumper

Lump  &  Fine  Ore  'TransportaYon'  System: Its  funcYon  is  the  Ymely  and  efficient  transportaYon  of  each  ore  product's  Batch  from  its  'depleYng'  Mine  stockpile  to  its  'building'  Port  stockpile.

Lump Batch B

Lump Batch C

Train Loadout Bin

Lump Batch A

Lump Batch B

<  Rail  >>  

Ore  TransportaDon  (Ore  Flow)  >>  

Eight  ‘Roads’  Vacant  (Ore-­‐Flow  flowing)  

Pay Load Rise

Control  the  Unexpected:  Fortescue  

River’s  Dual-­‐  Tracked  Weir  Crossing  

survives,  yet  again  …  

Western  Creek  suffers,  Feb  2009  

Harding  River’s  Twin  Bridges,  Feb  2009  

Planned  Ahead:  Starter  Bars  on  the  Higher  Bridge’s  Abutments    (1970’s  era)  

ExisYng  SFD’s                ‘Drop  the  Block’  

Modern  Stream  Flow  

Detectors  (transmit  to  Train  Control)  

Track  Integrity  Threat      (early  warning)  

Work  Train:  Side-­‐dump  ballast  &  Rerail  

Loaded  Ore  Car’s  Loose  

Wheel  Damaged  6  km  of  Concrete  Sleeper  

Fastenings  

Loaded  Ore  Train  Collided  into  Empty  Train  WaiYng  inside  Passing  StaYon  

Turnout  Control  Failure      (Example  No.  1)  

Neighbour’s  Mid-­‐Train  Units  caught-­‐up  in  Loaded  Train  Derailment  

Not  healthy!  

Loco  Recovery    (Difficult  at  Fmes)  

Turnout  Control  Failure  (Example  No.  2)  

Turnout  Control  Failure  (Example  No.  3)  

Delicate  handling  respects  Loco  value.  

Turnout  Control  Failure  (Example  No.  4)  

Rotary  Coupler  (Advantage)  

Yard  Loco  waiYng  near  ‘Trailable  Points’  that  Face  Incoming  Loaded  Trains      (unwise  risk)  

                                                         Ouch  $$++  

Rotary  Coupler  (Disadvantage)    

Turnout  Reliability  

Train-­‐  Transparent  Turnouts  

Rugged,  Reliable,  

Transparent  to  Trains  

Safe  in  every  circumstance  

Hancock  JuncYon    (trial)  

Rolling  Contact  FaYgue    (Rail  Surface  FaYgue)  

Rail Strength, Hardness

Pushing the Boundaries: •  Payloads UP •  Speeds UP •  Frequencies UP • Rail Surface

Fatigue UP • Ultrasonic

Blind Spots UP

•  Inspection Time DOWN

• Grinding Time DOWN

• Rerail Time DOWN

•  $$’s DOWN

Evolution of Rail Grinding:

• Corrugations • Rail Profiles

• Surface Fatigue

6,000 track-km passes p.a. (48 stones) x 2

‘Hollow’ Wheels

Wheel Profiles

410

430

450

470

490

510

-50 0 50 100 150

profileL7R7

Rail  Strain-­‐Gauging  in  Curves  

Wheelset  Angle  of  ASack  in  Curve  

Wheelset  ‘HunYng’  in  Tangent  

Bogie Behaviour

Extra 9% volume. Axle loads to 35.7 tonne.

Surface Fatigue Cracks

Rail  Surface  FaYgue  Measurement  

Making it Work - Step 4

0

2

4

6

8

10

150 160 170 180 190 200

Surf

ace

Fatig

ue S

ever

ityEast RailWest RailStart of TangentStart of Left Hand CurveStart of Right Hand Curve

0

2

4

6

8

10

200 210 220 230 240 250

Surf

ace

Fatig

ue S

ever

ity

PTRO

PTPE

0

2

4

6

8

10

250 260 270 280 290 300Location /km

Surf

ace

Fatig

ue S

ever

ity

PTSW

MLE MLPARA

Map of Worst Surface Fatigue: 150 - 300 km

Business  Brief      12th  August  2004  

Business Brief 12th August 2004

Ore car derailment Yandicoogina line

Last night just before midnight a mainline derailment occurred at the 377-kilometre on the Yandicoogina line near the Jabiru siding. No one was injured in the incident, however about 80 loaded ore cars were derailed and extensively damaged. The derailment is currently under investigation. This incident has not resulted in any harm to the environment, but we do have a large task ahead to clean up the derailment site and restore rail access to the Yandicoogina mine. Recovery crews from Pilbara Rail’s 7 Mile facility are on site to access and coordinate the cleanup. Supporting equipment including dozers, front end loaders, cranes and personnel have been sent from West Angelas, Tom Price, Yandicoogina and Major Projects’ site on the Yandicoogina line to assist. The Yandi spur is likely to remain closed for about a week. The incident has not impacted rail access for other mines. Rescheduling is being carried out to try to make best use of stockpiles at other mines and to minimise the losses as much as possible.

Dave Smith Managing Director

‘B’  end  

‘Jabiru’    Culprit  

Twin  ‘Jabiru’  Culprits  on  the  one  Day  

Rail  Integrity  Team  AcDons,  23  Nov  2004  Pilbara Rail – Immediate Actions following derailment, additional items included following 1st Meeting of Rail Integrity Team at 7 Mile on 13/10/04, and items arising from Investigation into Yandi Derailment by PRC – amended 23/11/04 Action Required to be Completed Responsible Person Current Status/Responsibilities Due Date (1) Two thermit welding trainers/assessors to be trained and accredited by Railtech for internal thermit welding training and validation

Michael Bailey (CMM) Greg Francis (CMM) and Leigh Twigg (CMM) assessed as competent thermit welding trainers/assessors by Railtech on 8/10/04

Completed

(2) Railtech to individually audit the thermit welding practices of each CMM gang in accordance with Railtech’s procedures

Michael Bailey (CMM) Audit undertaken during the week commencing 4/10/04 – written report provided by Railtech

Complete

(3) Railtech to provide certificate of attainment to each welder assessed as competent

Michael Bailey (CMM) Certificates received Complete

(4) All thermit welds to be completed by or in conjunction with an accredited CMM welder

Michael Bailey (CMM) 17 Welders now trained – process ongoing

Complete

(5) CBP for Thermit welding to be amended to reflect accreditation requirement

Michael Bailey (CMM) Draft document prepared – document system update now reqd

Complete

(6) Railtech Audit of CMM welders to be undertaken at 6 monthly intervals

John Gurney (PRC) To arrange standing order with Tony Brown

Complete

(7) Standing Work Order to be placed in SAP for recurrent Railtech audits of CMM thermit welders

Tony Brown (PRC) JG to arrange with Tony Brown Complete

(8) SPENO to provide additional (PERMANENT) hand testing crew so as to complete hand testing of outstanding in field thermit welds

Richard Nolan (SPENO) Crew on Site – backlog to be completed by end Nov 04 -

End Dec 04

(9) SPENO to provide advice concerning ability to detect underhead radius defects on PLK welds

Richard Nolan (SPENO) Have developed method of using finger to examine underhead radius defects – procedure to be trialled and CBP modified when

Complete

Possum      30th  January  ‘09  

Mobile  Flashbu]  Welding  

Tonnage Rise

Crossing  Paths  at  Yandicoogina  

Old  Friends,  now  CompeYtors  

H.I    Yandi    Doubles-­‐Up  

Doing  what  we  do  best  (no  worries!)  

Questions ??