bob vanselow - rail consultant - heavy haul issues
DESCRIPTION
Bob Vanselow delivered the presentation at 2014 Major Rail Occurrence Forum (Derailments). The RISSB Major Rail Occurrence Forum (Derailments) has been designed to build on and continue the analysis of major occurrence reports and to seek Industry learning from them. By reviewing major occurrence reports, Rail Organisations have the opportunity to learn from the lessons without having to suffer the same occurrence. For more information about the event, please visit: http://www.informa.com.au/derailments14TRANSCRIPT
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 ??