HEAVY HAUL RAILWAYS of AUSTRALIAMark Baxter EGM Rail Technical Services

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• Introduction to Heavy Haul• Heavy Haul regions in Australia• World’s heaviest haul railways• Technologies that enable Heavy Haul• Locomotives in Heavy Haul Applications in Australia

Presentation Outline

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About the Companies

• UGL Rail- Founded in 1902- Designer, manufacturer and maintenance provider of railway rolling stock

including locomotives, passenger cars and wagons- GE licensee in Australia- Top 100 Australian Blue chip company

• Texmaco- By House of Birla- 1 out of every 4 cars in Indian Railways built by Texmaco- leaders in railcar innovation- Reputation for quality, on-time delivery and ethical practices

• UGL Rail / Texmaco JV- Founded in 2010- Combining skills and strengths of both companies

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• This presentation profiles the heavy haul freight railways of Australia

• Describes Australia’s unique heavy haul operations and how they have developed over time, driving railway technology to new limits and in doing so establishing new benchmarks and standards.

• The presentation will also focus on the key technologies that are utilised to enable efficient railroad costs to achieve these remarkable applications.

Heavy Haul Railways of Australia

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• Australia is a world leader in heavy haul freight railways with the Pilbara region of Western Australia dispatching the longest and heaviest iron ore trains in the world, operating at 40 tonnes axle load.

Pilbara Region

Pilbara Region

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• Extensive heavy haul freight operations in the coal areas of the Hunter Valley in New South Wales and the Bowen and Surat Basins in Central Queensland

Bowen and Surat Basins

Hunter Valley

Heavy Haul Coal in Australia

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• The world record for the heaviest and longest train is held by BHP Billiton in the Pilbara Region iron ore area. The train was 7.4 km long comprising of 682 loaded ore wagons hauled by 8 AC6000’s with distributed power control of the remote locomotives within the train and ONE driver!!!

• The gross weight of the train was 99,734 tons

This is not the actual train but does give a perspective of the size and terrain

World’s HEAVIEST Haul Railway

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• Iron ore wagons with a rotary coupler one end of each wagon to permit tippling when emptying them at the port storage area.

• Axle loads have grown from 30 tonnes in early 80’s to current 40 tonnes in 2000’s and plans to extend to 45 tonnes by FMG in the near future.

• Track laid on concrete sleepers with good ballast depth for track stability.

Heavy Haul Iron Ore Operations

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Initial iron ore locomotives were 3600 HP DC traction (predominantly ALCO’s)

The current iron ore locomotive designs include;• 4400 traction HP • AC traction• 196 tonnes service mass• Built to US domestic rolling stock gauge• Distributed power• Microprocessor controls for engine, power generation and traction• Screen based crew information systems• GPS locators and radio download capability for locomotive health• Slow speed control to enable “in motion” loading at nominal 1 kmh.

Iron Ore Locomotives

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ES44ACi/ ES44DCiDiesel Electric Locomotive (DEL) Specifications

  ES44ACi/ ES44DCi

Gross Power 3356 kW

Traction Power 3281 kW

Traction Motors GEB13Ô/ GE752Ô

Tractive Effort – Starting 801 kN/ 632 kN

Tractive Effort – Continuos 739 kN/ 485 kN

Mass 188 Tonnes/ 186 Tonnes

Axel Load 31.3 Tonnes/ 31 Tonnes

Power per driving Axle 547 kW

Bogie C-C GE HiADÔ cast bogies

Maximum Speed 121 km/h/ 113 km/h

Fuel Capacity 18,927 Litres

Length 22,301 mm

Height 4,699 mm

Engine GEVO -12

12 cylinder

  4 stroke turbo charged rated at 3,356 kW

Alternator5GMG192, combined traction and auxiliary alternator

Cab Resiliently mounted comfort cab design

Iron Ore Locomotives

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Current iron ore wagon designs features include; • Bogie mounted brake equipment (More efficient and lower cost) • AAR specification ABD brake control• 3 piece freight bogies with constant contact side bearers and split

friction wedges for improved damping control • Load to tare ratios approaching 8:1• Stainless steel hoppers (5CR12)• Drawbar connection to form 2 pack or 4 pack wagon groups with

standard AAR auto couplers at one end and AAR standard rotary auto coupler at the other end.

• Conversion to Electronic Control Pneumatic (ECP) brakes for better train control

Iron Ore Wagon Development

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Gross 160+ tonnesTare 22 TonnesCapacity 138+ TonnesVolume 62 Cubic MetresLength Overall 10,360 mmWidth 3,200 mm wideHeight 3,352 mm high

Structural Material 12% ferritic stainless steel Ti stabilisedMax Operating Speed 100 km/hRotary wagon dumper,, indexer positioningBrake System Bogie mountedConsist Configuration Major OEMs control valves (ECP Option)

Iron Ore Wagon Development

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Coal Trains in Hunter Valley

Coal train of the Hunter Valley of NSW being hauled by 3 x 134 tonnes 4,400 HP AC traction GE/UGL locomotives 92 x 120 tonnes wagons

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C44ACiDiesel Electric Locomotive (DEL) Specifications

Gross Power 4,500 Hp

Traction Power 4,356 Hp

Traction Motors 5GEB30

Tractive Effort – Starting 565 kN

Tractive Effort – Continuous 453 kN @ 21km/h

Mass 134 – 139 Tonnes

Axle Load 22.5 – 23.133 Tonnes

Power per driving Axle 726 Hp

Bogie UGL Rail high adhesion, fabricated bogie

Maximum Speed 115 km/h

Gear Ratio 85:16

Fuel Capacity13,500 Litres (limited to 7,400 Litres in 134 Tonnes configuration)

Length 22,000 mm

Height 4,242 mm

Width 2,930 mm

Engine

GE7FDL16

16 cylinder

4 stroke turbo charged EFI rated at 3356kW

Alternator5GMG192, combined traction & auxiliary alternator

Brakes – Air Webtec Fastbrake or NYAB CCB II

ECP & Distributed Power Capable

Coal Locomotive Hunter Valley

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Current coal wagon features include; • Bogie mounted brake equipment (More efficient and lower cost)• Mechanical hand brake operating on one bogie per wagon• Electronic Control Pneumatic brake system (ECP). Better train

operation with almost no slack action when applying brakes. Brakes are graduated on and off.

• Non metallic composition brake shoes give better life and less noise than cast iron shoes.

• 3 piece freight bogies with frame bracing & constant contact side bearers

• Load to tare ratios approaching 6:1• Stainless steel hoppers (5CR12)• Fixed drawbar connection to form 2 pack or 4 pack wagon groups

with auto couplers at each end.• Operational speeds of 80 kmhr loaded and 100 kmhr empty.

Coal Wagon Development

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Tare 21.8 TonnesCapacity 98.2 TonnesVolume 108 Cubic MetresGross Weight 120 TonnesLength Overall 1 5,600 mmMax Operating Speed Empty 100 km/hMax Operating Speed Loaded 80 km/hBottom Door Operation KwikDropConsist Configuration Single or multiple packBrake System Body or Bogie mounted (ECP

option)

Coal Wagon Development

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Early 4 wheel coal wagons manufactured in Newcastle for use in the Hunter Valley coal fields and hauled by steam locomotives

Coal Wagon Development

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Current design coal wagon at 120 tonnes with lateral “Kwik Drop” doors and sequential operation by trackside mounted cam to enable “in motion” unloading at 1 kmh. Solid drawbar connection between wagons to create 2 pack or 4 pack wagons dependent upon customer requirement.

Coal Wagon Development

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Narrow Gauge Locomotives

PH37ACmai Locomotive

Specifications

Gross Power 3700 Hp

Traction Power 3300 Hp

Traction Motors 5GEB37

Tractive Effort – Starting 600 kN

Tractive Effort – Continuous 460 kN @ 21km/h

Mass 120 Tonnes

Axle Load 20 Tonnes

Power per driving Axle 550 Hp

Bogie High adhesion, Flexi Curve fabricated bogie

Maximum Speed 115 km/h

Gear Ratio 85:16

Fuel Capacity 8000 litres

Length 21,800 mm

Height 3,900 mm

Width 2,930 mm

Engine

PH3700

16 cylinder

4 stroke turbo charged EFI

Alternator Combined traction & auxiliary alternator

Brakes – Air Webtec Fastbrake or NYAB CCB II

ECP & Distributed Power Capable

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Narrow Gauge Locomotives

PH37ACmai Locomotive

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• Heavy Haul operations in Australia are pushing the envelope of technology and innovation.

• Technologies that enable Heavy Haul operations– High axle weight– AC locomotives– High capacity wagons– ECP brakes– Distributed Power– Tippler or Bottom Dump facilities

• Competition continues to drive innovation

Conclusions

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Conclusions

Thank You