INCREASING AWARENESS OF MINING AND SUPPLY CHAIN … Handouts/RIMS 16/IND014/IND014 Mining... ·...
Transcript of INCREASING AWARENESS OF MINING AND SUPPLY CHAIN … Handouts/RIMS 16/IND014/IND014 Mining... ·...
INCREASING AWARENESS OF MINING AND SUPPLY CHAIN RISK MANAGEMENT IN THE
DOWNTURNIND014
Speakers:
• Matt Newman, Head of Casualty, Apollo Syndicate 1969
• Diann Morshead, Senior Manager – Risk Management, Norfolk Southern Corporation
Learning Objectives
• To increase the awareness of how associated industries can have a positive impact on reducing the risks relating to the Mining Industries supply chain
• To understand the importance of Rail Transportation in the Mining Industry
• To understand some of the technologies used by Railroads to reduce losses.
AGENDA
• Railroads and the Mining Industry
• Accident Data
• Addressing Derailments• Track
• Equipment
• Human Error
• Transportation Technology Institute, Inc. (TTCI)
• Immense pressure on margins
• All costs are under the microscope
• Continued & unchanged commitment to a safety culture
• A focus & drive towards zero injuries for staff and contractors
• A drive to minimize contractual liabilities with third parties
• A commitment to maximizing mine efficiency
Common themes from our Mining Industry renewal meetings – from a Casualty perspective
External exposures have the potential to:
• Seriously disrupt the operation of the mine
• Delay the arrival of crucial spare parts or equipment
• Block the departure or product from the site
What about external factors that are'out of your control' ?
All adding pressure those precious margins…..
Similarity to Class 1 Rail meetings
• Similarly focused on a number of topics:
• Margin management
• Driving a safety culture
• Maximizing efficiency
• Minimizing the risk of system failure
• Significant annual investment in infrastructure
Are these investments communicated outside their own industry?
• It is important to that associated industries share information on the structural investment they make, which has a positive impact on the risk profile of others
• This is a demonstration of how one industries investment helps to de-risk the supply chain of another
• Helping to reduce and quantify external risk factors
• Has a positive impact in that these investments help to maximize the business relationship of both sides in tough economic times.
Railroads and the Mining Industry -Coal
• Railroads deliver approximately 70 percent of coal delivered to coal-fueled power plants.
• Railroads are used to deliver coal to ports for export.
• In 2014, Coal comprised 38.8 percent of total tonnage hauled and 18.8 percent of total revenue for U.S. Class I railroads.
Railroads and the Mining Industry - Crude
• Railroads have been used to deliver crude oil to refineries as U.S. oil production increased.
• In November 2015, railroads moved 41 percent of oil produced in North Dakota.
• Railroads have also been used to deliver materials used in Fracking.
FRA Reportable Train Accident Rate By Cause
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Data Source: FRA Web Site March 2016
Track Equipment Human Factors OtherRep
ort
able
Tra
in A
ccid
ents
per
Mill
ion
Tra
in-M
iles
Measuring CracksWith a Draisine
• The Rohmann(Germany) “Draisine”
• Walk-Behind
• Measures one rail at a time
• Knowing crack depth can improve the effectiveness of grinding program
Drasiene, Rail HeadCross-Section Exam
Draisine on-site EloRail Scan evaluation software results
Surface of rail
Damage depth of 1.850mm at 21 degrees (Mag. = X25)
Exception Type
Look For: Examples
CBV Carbody Vertical
Look for repeated vertical profile dips in track
Look for mud and pumping conditions
CBL Carbody Lateral
Look for lateral alignment irregularity in track
AXV1 and
AXV2 Axle Vertical
Impact
Dent
Break
Look for broken rail, broken joint, broken frog, battered joint, engine burn, crushed rail head, loose/missing bolts.
MCO1 and
MCO2 10-Foot Mid-Chord Offset
Vertical Profile
Look for mud and pumping conditions.
Look for pumping joints
Bridge Tie Research• In-service monitoring
• NS, UP, TTCI
• Materials• Glue-laminate (glu-lam)
• Fiber reinforced Foamed Urethane (FFU)
• Use• New AREMA 30 (industry
committee) guidelines for engineered composite ties in 2012 manual
• Both FFU and glu-lam ties can meet guidelines with reasonable tie sizes
Installation of FFU Bridge
Ties on Norfolk Southern
FFU Bridge Ties Installed on Norfolk
Southern near Princeton, West Virginia
Coupler Pin Plate• Captures images of coupler
pin plate from underneath the train
• Max train speed 70 mph
• Can recognize:• Plate type
• Missing bolts and nuts
• Displaced and rotated plates
• Missing plates
Coupler Pin PlateDefect Validation
Good Plate, All Bolts Present Good Plate, One Bolt Missing
Plate Cocked, 3 Bolts Missing Plate Missing, 4 Bolts Missing
Coupler View - Key• Captures Images of coupler cross key
• Max train speed of 80 mph
• Can recognize:• Missing cross key
• Missing retainer-pin
• Missing cross key retainer washer
Acoustic Bearing Detector
• 2 manufacturers• TTCI (1 detector)
• TrackIQ (2 detectors)
• Defects – Running Surface• Cup
• Cone
• Roller
Acoustic Bearing DetectorDefect Validation
• Early-stage and advanced defective freight car bearings• Real time at track speed
• ID bearings before they overhead or seize in service
• Defects have specific acoustic signatures• High risk defects (multiple components)
• Cup defects (spalling, brinelling, water etch)
• Cone defects (spalling, brinelling, water etch)
• Roller defects (spalling, brinelling, water etch, seams)
Acoustic Bearing DetectorDefect Validation
MISSING ROLLER & BROKEN CAGE
6 in2 SPALLING CONE RACE 10 in2 SPALLING CUP RACE
Wheel Profile Detector
• 3 manufacturers• Beena Vision
• IEM
• KLD
• Defects• Flange Width
• Flange Height
• Rim Thickness
• Tread Hollow
• Back-to-back
• Other Users• BNSF, UP,
CSX
• Europe, Middle Eastern RRs
Wheel Impact Load DetectorWILD detectors use a series of vertical and
lateral strain gage force measurements to
identify wheel and truck anomalies
WILD Electronics with AEIlink to identify suspect cars
High Wheel Impacts Imbalanced Loads Overloads Truck Hunting Skewed Trucks
Truck Hunting DetectorTwo Methods
• TBOGI-HD evaluates the changes in wheel set orientation through the TBOGI detector array.
• WILD-HTD evaluates the lateral and vertical forces through the WILD detector array.
Truck Hunting DetectorTest Equipment Validation Run
Transfer of energy from forward motion into a sustained lateral oscillation of the wheelset(s), causing the truck to weave down the track
The lateral motion (energy) associated with the “truck hunting” phenomena is transferred into the freight car body and the track
Norfolk Southern Training Center
• Opened in December 1974.
• Located in McDonough, GA.
• Classroom space of 50K square feet.
• State-of-the –art technology.
• 21 Staff members
• Over 3,000 students annually.
Norfolk Southern Training• Learning areas
• American Welding Society-certified welding and testing facility
• Dispatch Center
• Locomotive Engineer Training
• Signal-Training area
• Signals
• Locomotive Maintenance and Repair Shop
• Four-Track Freight Yard
• Conductor training in virtual rail yard
TTCI – Transportation Technology Center, Inc.
• Wholly owned subsidiary of the AAR.
• Located in Pueblo, CO.
• Operates on behalf of the Federal Railroad Administration.
• Focus on research, development and training for the rail industry.
• 270 employees.
• 52 Square mile facility with 48 miles of track.
TTCI – Security and Emergency Response Training Center (SERTC)
• In operation at TTCI since 1985
• Hazmat response for Surface Transportation
• Approximately 60,000 students trained• Railroad
• Chemical and petroleum
• Local, State, Federal and Tribal First Responders
• Emphasis on preparedness and response.
TTCI – Engineered Facilities for Dynamic Testing
• High Tonnage Loop (HTL)
• Wheel/Rail Mechanism Track (WRM)
• Transit Test Track (TTT)
• Railroad Test Track (RTT)
• Precision Test Track (PTT)
Tight
Turn Loop
Tran
sit Te
st T
rack
Substation #2
WRMTrain
Dynamics
Track
Precision Test
Track
Balloon
Loop
Substation #1
Impact
Tra
ck
HTL
Railro
ad
Test
Tra
ck