Akshaya Malaviya, ARTC: Examining track and signalling design approach for the Hunter Valley Coal...
-
Upload
informa-australia -
Category
Business
-
view
534 -
download
3
Transcript of Akshaya Malaviya, ARTC: Examining track and signalling design approach for the Hunter Valley Coal...
Akshaya Malaviya
Engineering Manager Major Projects
Hunter Valley ARTC
ARTC 31/07/2013 Heavy Haul Rail 2013 1
First train on the 3rd track in Area A.B
Maitland to Minimbah 3rd Track Project
31/07/2013 Heavy Haul Rail 2013 2 ARTC
HV Network Capacity Enhancement Program ◦ ARTC Business Overview ◦ Hunter Valley – Key Customer Expectations ◦ Demand and Capacity ◦ HV Strategy ◦ Projects Delivered ◦ Current Projects ◦ HV Infrastructure Plan ◦ Heavy Haul Guidelines
Broad Design Criteria ◦ Track & Civil ◦ Signalling ◦ ARTC/Industry initiatives
Maitland to Minimbah 3rd Track Project – Case Study ◦ About the project ◦ Design approach – Civil & Signalling ◦ ARTC cost reduction initiatives on the Project
ARTC 31/07/2013 Heavy Haul Rail 2013 3
ARTC
Primarily supports general freight
transport
Primarily supports coal transport Our Business Network
ARTC is a federal Govt owned company leasing HV network from NSW Govt; owns or leases over 10,000 rkm of track.
ARTC does not operate trains - charges access fee from train operators for use of ARTC network 31/07/2013 Heavy Haul Rail 2013 4
Key customer expectations
Minimise ARTC impact on Coal throughput
Ensure network capacity stays ahead of the demand
Divisional infrastructure supports and remains safe &
sustainable, cost effectively, under forecast tonnages
ARTC 31/07/2013 Heavy Haul Rail 2013 6
Corridor Capacity Strategy
Corridor Infrastructure
Plan
The expectations from the network form the basis of the corridor strategies for infrastructure and projects
in the form of:
ARTC 31/07/2013 Heavy Haul Rail 2013 7
Strategy identifies infrastructure upgrade projects designed to ensure capacity stays ahead of contractual demand
2013-2022 Strategy just released; it’s the seventh edition
Coal volumes increased by about 50% in the last five years
ARTC 31/07/2013 Heavy Haul Rail 2013 8
The Corridor Capacity Strategy identifies projects to be
delivered to augment network capacity by way of:
Increasing train loads
•increase in size of train consists;
Increasing speeds at turnouts
•use of longer turnouts e.g. 1:18.5
Improving operational flexibility and headways
•new crossing loops with simultaneous entry facility; additional tracks
Reducing congestion
•holding & park up tracks
ARTC 31/07/2013 Heavy Haul Rail 2013 9
ARTC
Additional Tracks
•Maitland to
Minimbah 3rd Track
($360m)
•Minimbah Bank 3rd
track ($145m)
•Nundah Bank 3rd
Track ($95m)
•Antiene to
Grasstree
Duplication ($40m)
•St Helliers to
Muswellbrook
Duplication ($30m)
Crossing Loops Ulan
•Mangoola,
Murrumbo,
Baerami, Wollar,
Bylong, Radio Hut,
Bengalla and
Wilpinjog Crossing
Loops (≈$15m+
each)
•Bylong Loop
Extension ($30m)
Crossing Loops
North
•Braefield, Willow
Tree, Togar,
Murulla, Ardglen,
Werris Creek,
Koolbury, Burilda,
Bells gate,
Parkville, Chilcotts
Creek, Pages River
and Watermark
Crossing Loops
(≈$15m+ each)
Other
•Sandgate
Separation ($80m)
•Maitland –
Branxton Bi-
Directional
Signalling ($45m)
•Ulan Line CTC
($15m)
•Maitland CBI
($12M)
•Drayton Junction
Renewal ($20m)
•Kooragang island
Bypass Re-
alignment ($2m)
Total investment
over a billion dollars
31/07/2013 Heavy Haul Rail 2013 10
Drayton Relief Hub ($33m)
Whittingham Relief Hub ($42m)
Kooragang Island Arrival Roads ($90m)
Kooragang Island Departure Roads ($32m)
Hexham Relief Roads ($163m)
Scone Reconfiguration ($8m)
Widden Creek Crossing Loop ($45m)
Gunnedah yard upgrade ($15m)
Train park up facilities (to be developed, $300m)
Prospective volume projects if required
ARTC 31/07/2013 Heavy Haul Rail 2013 11
The Corridor Infrastructure Plan envisions the corridor
requirements to meet forecast coal tonnages, an
associated growth in asset base and increased daily
train movements.
The Plan also takes into account the mixed type of
traffic operated on the corridor.
The requirements for new infrastructure based on
the Infrastructure Plan have been incorporated in
what is referred to as Heavy Haul Infrastructure
Guidelines (formerly Hunter 200+).
ARTC 31/07/2013 Heavy Haul Rail 2013 12
•Heavy Haul Guidelines form the basic design framework for the
Hunter Valley Major Projects.
Guidelines
in designs
•These guidelines are not intended to replace any ARTC standards
but to provide a link between the Heavy Haul requirements of the
network and the existing ARTC standards.
•The Guidelines requirements are over and above the standards.
Standards v
Guidelines
•Meet operational reliability targets;
•Meet infrastructure availability targets;
•Achieve prudent capital expenditure; and
•Ensure no unnecessary or overly complicated designs.
Objectives
ARTC 31/07/2013 Heavy Haul Rail 2013 13
ARTC
Design is not just what it looks like and feels like. Design is how it
works. Steve Jobs
31/07/2013 Heavy Haul Rail 2013 14
Track
Item Adopted Comments
Design axle load and speed
(Ports to Ulan)
30 Tonne
60kph loaded
80kph empty
Design axle load and speed
(Gunnedah basin)
25 Tonne 80kph loaded
80kph empty
30T for new infrastructure
Min vertical clearance 5.150m With a design provision to lift
any structure to 7.1m
Min horizontal clearance 4.3m from track centreline
Track centres Min 4.5m Min 7.5m if infrastructure
located between the tracks
Track 60kg head hardened (HH) Mainline
Turnout Type SNX drives with 75kph turnout
speed, generally 1 in 18.5
1200R tangential
FNX with 50kph turnout
speed, generally 1 in 12 or 15
1200R tangential
Ports to Ulan (in bearer drives
preferred)
Gunnedah basin
ARTC 31/07/2013 Heavy Haul Rail 2013 15
•In accordance with the standards
•Superelevation biased for coal traffic as much as
possible
Track Geometry
•200mm capping layer, CBR≥50
•500mm structural fill layer, CBR ≥30
•For subgrade CBR <3 add 500mm structural layer CBR ≥8
•For subgrade CBR >20 install 400mm capping only.
Formation/subgrade
•Cut and fill batters to be designed with a long term Factor of Safety ≥1.5.
•Drainage - generally designed for 50yr ARI, sometimes 100yr ARI
•For drainage blanket exiting into a cess - a min 20 year ARI freeboard
Earthworks and
drainage
•Generally in accordance with the standards for 350LA rail loading.
•Underbridges to have ballasted track decking system.
•Overbridges to be single span over the rail tracks including any access
roads.
Structures
ARTC 31/07/2013 Heavy Haul Rail 2013 16
•For 3 or more tracks continuous both Up and Down sides
•For single or double track continuous on one side
•Where cuts or fills are <1.5m at grade access roads
•At turnouts min shoulder width 7.5m
Access Roads
•Grade separation for more than two tracks
•Any project impacted level crossing to be upgraded to the required standard.
•Active or passive protection based on ALCAM assessment
•Private roads crossings – risk assessments drive the requirement
Level crossings
•All signalling infrastructure is shown on the civil IFC (Issued For Construction)
drawings including GPS coordinates.
Signalling civil
design integration
ARTC 31/07/2013 Heavy Haul Rail 2013 17
Crossing loops ◦ Are designed for 1,543m train length from Ports to Ulan and 1,329m train length in
Gunnedah basin.
◦ Allowances for signal sighting and loco recovery
◦ Total standing room (CP to CP) - min. 1,634m (Ports to Ulan) and 1,420m (Gunnedah basin).
◦ An additional 300m for “simultaneous entry facility”
ARTC 31/07/2013 Heavy Haul Rail 2013 18
ARTC
The Mantras
Maintainability – Minimise exposure of
maintainers at track
Use low maintenance equipment such
as in-bearer point motors
Avoid signals on steep rising grades
Design for double green headways
Minimise GIJ’s, avoid them on curves
Heart transplant of relay interlockings
to facilitate current/future upgrades
31/07/2013 Heavy Haul Rail 2013 19
Item Adopted Comments
Interlocking New interlockings – CBI
type
Train detection Axle counters on points and
Jointless track circuits on
straight portions
Jointless track circuits used
to minimise GIJ’s
Signalling Four aspect colour light
signalling
Fourth aspect is a ‘pulsating
yellow’
Crossing loops Simultaneous entry facility
Headways Generally 8minute max. Ports to Muswellbrook
Train control CTC with an OCS system Phoenix Control System
Predictive features of
equipment
Via alarm management
systems
ARTC 31/07/2013 Heavy Haul Rail 2013 20
ARTC
There are reviews underway to determine the benefits of various upgrades to the infrastructure
32.5TAL (Tonne Axle
Load) for Ports to Ulan
30TAL for Gunnedah
basin
All new infrastructure
to be designed for
30TAL
31/07/2013 Heavy Haul Rail 2013 21
•Radio communication links for vital &
non-vital
•Hybrid interlockings
Cost reduction
initiatives
• Higher axle loads, longer train consists
• Train park up strategy
• Relief roads
Operational
initiatives
• Network Control Optimisation
• Split point detection, Cooperative sweep
release for axle counters, Emergency power
operation of points
Technological
initiatives
ARTC 31/07/2013 Heavy Haul Rail 2013 22
ARTC
Network control optimsation
•ARTC intends to investigate options for a decision support system
integrated into network control system
Split point detection
•Maintain signalling on the other track when one side of a crossover
is under maintenance
Emergency power operation of points
•In point failure situations, manual operation using push buttons
instead of crank handles
Cooperative sweep release
•Removes the requirement of sweep by trains reducing the reset
time significantly
These initiatives will help in improving
fluency of train operations leading to smoother throughput
31/07/2013 Heavy Haul Rail 2013 23
The Project
The Maitland to Minimbah Third Track comprised of approximately 22km new track, divided into
2 areas (A.B and C), 10km reconditioning of existing track, 1.5mil m3 earthworks, 6 bridges, 1
station upgrade and Interaction with F3 link project and 53 properties requiring acquisition.
The project excludes the 7km between Branxton and Greta stations and 1km from the Farley
end.
Included re-signalling of existing Up & Down Main from Branxton to Minimbah and significant
enabling works.
Completion Date: November 2012 ARTC
Project cost circa
$360m
Objective - Minimise maintenance impact and provide 8min headways to ports
31/07/2013 Heavy Haul Rail 2013 24
Site visit by Prime Minister Julia Gillard,
Federal Member for Hunter Joel
Fitzgibbon MP and ARTC Executive GM Alec
MacKenzie, 19th July 2011
Official ‘Sod
Turning’ by Federal
Member for Hunter
Joel Fitzgibbon MP
and ARTC Executive
GM Tim Ryan, 27th
May 2011
Heavy Haul Rail 2013 ARTC 31/07/2013 26
Area A, B
• Lochinvar station upgrade
• Drill and blast
• 700 000 m3 earthworks
• 15 month duration
• Commissioning November 2012
• 14km track
• Farley to Greta
• 3 bridges – Station Lane Overbridge. Lochinvar
• Allandale Rd underbridge, Allandale
ARTC 31/07/2013 Heavy Haul Rail 2013 28
Area C
• Drill and blast
• 15 month duration
• Commissioning August 2012
• 8 km track
• Branxton to Minimbah
• 800 000 m3 earthworks
• 3 bridges
• Hermitage rd. Overbridge, Belford,
• Black Creek Underbridge
• Jump Up Creek Underbridge
ARTC 31/07/2013 Heavy Haul Rail 2013 29
Track Centres ◦ Increased from 4.5m (required by standards) to
7.2m to address future maintenance requirements
◦ Increased further to 7.5m for signalling
◦ Gantry option found to be less cost effective.
ARTC 31/07/2013 Heavy Haul Rail 2013 30
• Level crossings • 2x grade separated • 1x closed
• Structures - new bridge works
• Reinforced earthwalls, reinforced concrete piers/abutments and precast pre-stressed concrete (PSC) bridge beams
ARTC 31/07/2013 Heavy Haul Rail 2013 31
• Access Tracks
• The width of the access track 6.5m from the centre of the adjacent track to the outside shoulder of the track.
• Stations • Lochinvar station was
upgraded; Railcorp standards followed; new pedestrian bridge and access ramps constructed; and entry from one side only.
ARTC 31/07/2013 Heavy Haul Rail 2013 32
Headways ◦ Combined 8min headways in both directions
Turnout configuration ◦ New track main road, existing Up Main turnout road
ARTC 31/07/2013 Heavy Haul Rail 2013 33
Signalling
New Microloks
for Area C,
existing ones
for Areas A.B
New Railcorp
fibre route
Diverse
communication
link
Commissioning
in three stages
Signalling
designs
integrated
with civil
CSEE track
circuits on
straight
portions,
Frausher axle
counters on
points
ARTC 31/07/2013 Heavy Haul Rail 2013 34
General ◦ Safety in design
Workshopping, discussions, independent reviews and independent design verification
◦ Design standards ARTC, Australian & other applicable standards
ARTC’s Heavy Haul Guidelines
◦ Standards challenged Track centres 7.2m instead of 4.5m - Accepted
Bridge clearance standard of 7.1m, reduced to 5.15m with provision of lifting structure to 7.1m - Accepted
Formation over & above ARTC standards - Accepted
ARTC 31/07/2013 Heavy Haul Rail 2013 35
ARTC
Farley retaining walls
avoided services
relocation & major
property acquisition
Non at grade access on
Down side and at some
locations on Up side
Lochinvar station –
access from only
one side
Continuous beam
structure on Black
Creek Bridge
Scope reduction
•Branxton to Greta 3rd track deleted
•Terminating the 3rd track short of
Wollombi Road
•Bridge upgrade & major services relocation
avoided
•Need for grade separation at Greta
avoided
Cost
reducti
on init
iati
ves
31/07/2013 Heavy Haul Rail 2013 36