BHP Billiton Iron Ore Railroad
Presentation to Analysts June 2005
Mike Darby, Vice President Rail
Iron Ore
Rail System Location Map
The Nelson Point Newman Railway is
426km
Port Hedland-Yarrie
Railway is 208km
Yandi spur line is
30km
Area C spur line
extension from
Yandi is 38km
Jimblebar spur line is
32km
Page 2
Safety Performance - Rail Classified Injuries
Classified Injury Frequency Rate for Rail (including contractors)
50 47.3
45
40
35
28.1
30
25
17.2
20
15
12.6
10.5
10.4
7.8
10
11.6
11.6
10.5
9.5
10.5
10.5
9.5
8.2
5
Historical
Page 3
Actual CI
Actual
Ma
y-0
5
-0
5
Ap
r
Ma
r-0
5
Fe
b05
-05
Ja
n
De
c-0
4
No
v04
Oc
t-0
4
Se
p- 0
4
-04
Au
g
4
Ju
l -0
4
03
/0
3
02
/0
2
01
/0
00
/0
1
0
Page 4
P
Rapid
RG
FY
04
FY
02
FY
00
FY
98
FY
96
FY
94
FY
92
FY
90
FY
88
FY
86
FY
84
FY
82
FY
80
FY
78
FY
76
FY
74
FY
72
FY
70
FY
68
FY
66
Tonnes Railed
110
Growth
Period
61
Page 5
r-0
Ma 1
y-0
1
Ju
l-0
1
Se
p- 0
1
No
v -0
1
Ja
n- 0
2
Ma
r-0
2
Ma
y-0
2
Ju
l-0
2
Se
p- 0
2
No
v -0
2
Ja
n- 0
3
Ma
r-0
3
Ma
y-0
3
Ju
l-0
3
Se
p- 0
3
No
v -0
3
Ja
n- 0
4
Ma
r-0
Ma 4
y-0
4
Ju
l-0
4
Se
p- 0
4
No
v -0
4
Ja
n- 0
5
Ma
r-0
5
Ma
1
0
v -0
n- 0
0
l-0
0
p- 0
Ja
No
Se
Ju
Rail KPI’s - Long Trains (300-336 Cars)
Number of Train Runs
Apr 05
3,642
3,642
YTD
1,053 Trains
Long Trains
Yandi & MAC
Newman
Million Tonnes Railed Per Employee
Employee Productivity Tripled in the last 10 years
0.353
0.301
0.245
0.258
0.216
0.126
FY96
Page 6
0.148
0.151
FY97
FY98
0.167
FY99
0.179
FY00
FY01
FY02
FY03
FY04
FY05
Railroad Manning
375
362
297
FY99
Page 7
FY00
288
290
FY01
FY02
302
FY03
322
FY04
339
FY05 Actual
FY05 Plan
Rolling Stock Fleet Expansion Program
Rakes
Ore Cars
4,000
Original
50
Arrival of 13 SD70
3,410 45
3,5008 AC600 Locos
40 Dash 8 Locos
Arrival of 6 SD40
3,203
2210 Ore Car
40
2,971
3,000
Arrival of 6 SD40
Arrival of 5 SD40
2,500
2,484
2,210
Arrival of 3 SD40
2,000
21 21 21
22 22 22 22
23 23 23
24 24
25 25
26 26
27 27
28 28
29 29 29 29 29
30 30
31 31
32 32 32
33 33 33 35
30
25
20
1,500
12 Train Schedule
15
1,000
10
10 Train Schedule
500
Page 8
Dec-05
Nov-05
Oct-05
Sep-05
Aug-05
Jul-05
Jun-05
May-05
Apr-05
Mar-05
Feb-05
Jan-05
Dec-04
Nov-04
Oct-04
Sep-04
Aug-04
Jul-04
Jun-04
May-04
Apr-04
Mar-04
Feb-04
Jan-04
Dec-03
Nov-03
Oct-03
Sep-03
Aug-03
Jul-03
Jun-03
May-03
Apr-03
Mar-03
Feb-03
0
5
0
Locomotive Fleet
Dash 8
Number
40
Traction Horsepower 4,000
AC6000
8
20
6,000
SD40
Dash 8
AC6000
Page 9
SD40
3,000
SD70ace
13
(Oct05)
4,300
Automatic Train Protection - ATP System
Page 10
Current Train Operations
Newman Line
• 12 ore trains per day / 14 trains 1 July 05
• Flexibility of One / Two / Three Rake Trains
• Train configuration:
1 rake = 104 ore cars = 12,480 tonnes of ore
2 rakes = 208 ore cars = 24,960 tonnes of ore
3 rakes = 312 ore cars = 37,440 tonnes of ore
•
Goldsworthy Line
• 4 ore trains per day
• Train configuration:
90 ore cars = 7,650 tonne of ore
Page 11
Asset Protection
9 12 Hotbox / Hot Wheel Detectors
Page 12
9
1 Cold Wheel Detector
9
1 Wheel Impact Monitor
9
3 in Motion Weighbridges
9
Acoustic Bearing Detection
9
Dragging Equipment Detectors
9
Auto Locomotive Downloads
9
Video Imaging
Instrumented Ore Cars (IOC)
• Vertical suspension travel (ride quality)
• Wheel-rail acceleration (rail condition)
• In-train forces
• Lateral stability (hunting)
• Longitudinal acceleration
• Car body / draft gear pocket strains
• Temperature
• Brake pipe pressure
Page 13
IOC Reporting
Automatic data downloading
Dumping Forces Measured
Page 14
Car side wall strains
IOC Other Applications
• Bearing Temperature & Brake Pressure
• Track Assessment Sensors
• Improve Car Body Life
Strain Gauge on Sidewalls
Measure Car Body Dumping Strains
Control Service Dumping Peaks
Strain Gauge on Draft Gear Pocket
Measure Longitudinal Train Forces
Control Service Loading
Peaks & In Train Forces
Page 15
Acoustic Bearing Detection
The following bearing faults are detected:
•
Cone Faults
•
Roller Faults
•
Audible Wheel Flats
•
Cup Faults
•
Looseness / fretting
•
Noisy Wheel sets (flanging)
Page 16
Video Imagining Technology
• Flange Height
• Flange Width
• Vertical Flange
• Hollowing Depth
• Rim Thickness
• Wheel Diameter
Page 17
Video Imaging Reporting
1. Tabulated
2. Pictorial
3. Graphical
Page 18
37 Traceable Components for each Ore Cars
Page 19
Wheels Ultrasonic Testing
Page 20
Train Driving Simulator
Used To Define
Driving Strategy
&
Training Needs
Page 21
Aluminothermic / Flash Butt
Page 22
In Track Flash Butt Welder
Page 23
Rail KPI’s Broken Rails
69
64
62
56
49
37
36
34
29
27
25
23
4
'93
'94
'95
'96
'97
'98
'99
'00
Calendar Year
Page 24
'01
'02
'03
'04
'05
April
Best Practice
R&D programme since 1970, combination of ‘in-house & Monash University
It focuses on four main areas:• Rail / Wheel Interface
• Higher Axle Load
• Train Lengths / Cycle Time
• Components Life
Page 25
Higher Axle Load
Operating Improvements
Axle Load
40.2 tonnes
37.5 tonnes
35.0 tonnes
32.5 tonnes
28.5 tonnes 30.0 tonnes
Wet
tonnes
per
wagon
89
1970
Page 26
96
1974
107
116
Yandi
1986
1996
126
Yandi
99-04
Rail / Wheel Interface
1.9
Ore Car Wheel Life
Million Tonne Kms
0.34
1980
2005
1,800
Rail Life (Tangent Track)
Million Gross Tonnes
350
Page 27
1980
2005
Train Lengths / Cycle Time
312
208
180
Train Lengths
Train Length
131
Cars per Train
Cars / Train
1972
1984
1992
Current
40
36
Train Cycle Time
30
Hours
Page 28
1972
1984
Current
Environmental & Efficiency
Contributing Factors
1.45
¾ Rail / Wheel profile
0.68
Fuel Savings
¾ Aerodynamic Ore Cars
¾ Efficient Locomotives
¾ Distributed Power
¾ Higher Axle Load
¾ Longer Trains
1978
Page 29
2005
¾ Driver Strategy
What’s in the “Future”
• Continued Safety Focus
• 40 tonne axle loading
• “Cruise Control”
• Train Automation
• Electric Brake Trials
• Increased Tonnage (16 train schedule arrival based)
Page 30