1 The New Rail Technology System for BHP

1 The New Rail Technology System for BHP Billiton Iron Ore – A Case Study Aus. RAIL PLUS 2005 Presented by: Andreas Rottmann Business Development Manager Siemens Transportation Systems Communications Automation Buildings Power Transportation Healthcare

2 The New Rail Technology System for BHP Billiton Iron Ore – A Case Study Agenda • • Communications BHP Billiton Iron Ore Railroad RTS Intro and Project Approach Software Architecture System Architecture Train Control Operation (TCS) Train Information Management System (TIMS) Intelligent Train Scheduling System (ITSS) Automation Buildings Power Transportation Healthcare

3 BHP Billiton Iron Ore Railroad BHP Billiton Iron Ore is one of the world’s leading suppliers of iron ore products, shipping millions of tonnes of iron ore to steel mills around the globe. The Railroad is the connecting link between various mine sites in the Pilbara and the port located in Port Hedland. Newman Line (426 km) • Fully Signalled & Circuited Goldsworthy Line (210 km) • ATP node & Paper Train Orders Marshalling Yards at Nelson Point & Finucance Island Communications Automation Buildings Power Transportation Healthcare

4 Rail Technology System • Operation Control Centre • Back-Up Control Centre • Training & Replay Centre • Development Centre Communications Automation Buildings Power Transportation Healthcare

5 Project Approach Stage 1 • • Replacement of the existing train control system for the Newman and the Goldsworthy Line Existing Functionality for TCS • Some Enhancements - TIMS Stage 2 • Replacement of the existing train control system for the Hedland Yard • Extended TCS function ARS, Electronic Train Order • Full ITSS online – rescheduling function Communications Automation Buildings Benefits: ü Eliminate current system constraints ü Minimisation of implementation risk ü Gradual change of the operational environment Power Transportation Healthcare

6 Software Architecture Vicos®OC 501 Core System • Unix Operating System - Solaris • Siemens Sinaut®Spectrum Operational Database • Oracle® Real Time Database Management System Communications Automation Buildings Power Transportation Healthcare

7 Software Architecture RTS Train Control System Function Stage 1 • Alarms and Logs • Train Monitoring and Tracking • Interlocking Control • Record and Playback • Maintenance Function Stage 2 • Timetable Manager • Automatic Route Setting • Train Order Function Communications Automation Buildings Power Transportation Healthcare

8 Software Architecture RTS Interface Modules • Distributed Network Protocol • Westinghouse based S 2 Protocol • Southern Technology Cooperation (Hotbox Detection) • Wheel Impact Monitor • AEI tag readers • Locomotive Messaging Communications Automation Buildings Power Transportation Healthcare

9 RTS System Architecture MMI 2 MMI 1 MMI n Maintenance MMI Ethernet LAN Man Machine Interface • • • 6 Operator Consoles in the OCC 6 Operator Consoles in the BCC 2 Maintenance Consoles 2 Offline ITSS Consoles Flexible assignment of control areas to all MMI’s in the network Communications Automation Buildings Power Transportation Healthcare

10 RTS System Architecture MMI 1 MMI n MMI 2 Maintenance MMI Communicator (COM) Process Server COM 1&2 Hot Stand-By Communications Automation Buildings Spare COM Cold Stand-By • The COM servers are the actual process servers • They process all external data and generate all control function commands • 2 COM’s run in Hot-Standby Mode • Additional COM in Cold-Standby Power Transportation Healthcare

11 RTS System Architecture MMI n MMI 2 MMI 1 Maintenance MMI Administrator (ADM) • Manages all statistical system and configuration data Spare Process and Server • Archive management storage COM • Spare - Redundancy Concept COM 1&2 Hot Stand-By Communications Automation Buildings Administrator ADM Server (ADM) Spare Cold Stand-By Power Transportation Healthcare

12 RTS System Architecture MMI n MMI 2 MMI 1 Maintenance MMI Independent Front End Server Line Splitter Communications ADM Independent Server Process Server Front End Administrator Server (ADM) Spare Communicator • (COM Interface 1 & 2)to the external systems • Hot Redundant Stand-By Server Pair Automation Buildings Power Transportation Healthcare

13 RTS System Architecture Maintenance MMI Redundant Server Pairs MMI n • ITSS Offline • TIMS MMI 2 MMI 1 ITSS Offline Independent Front End Server Line Splitter Communications Process Server Communicator (COM 1 & 2) Hot Stand-By Automation Buildings Spare Administrator ADM COM Server (ADM) Spare Cold Stand-By Power TIMS Spare TIMS Transportation Healthcare

14 TCS Operational Principle Main Line Overview (Fixed) Working Screen Communications Detailed Views Automation Buildings Detailed Overview ITSS Train Graph Power • Mouse & Keyboard • Drag & Drop • Point & Click • Multiple windows can be opened • Multiple function are performed simultaneously Transportation Healthcare

15 TCS Operational Functions Rail Network Views Maintenance Function • MLO/GML – Main Line Overview • IFS – Status and Control • GEO – Geographical Overview • ILD – Interlocking Diagnostics • SYS – System Overview • STC – STX Set-up Data Dialog • SDM – Source Data Management Control Function • TMT – Train Tracking and Monitoring • IC – Interlocking Control Communications Automation Buildings Administrative Function • A&R – Authority & Responsibilities • UAC – User Administration Control Power Transportation Healthcare

16 TCS Operational Functions Archive Log Special • • A – Alarms • WEB – Web-Interface • W – Warnings • CAM – Camera • N – Notifications • VER – Version • OD – Operation Diary • MO – Manual Operation • SS – Signal to Stop ARR – Archive Reconstruction • ARM – Archive Management • R&P – Record & Playback Communications Automation Buildings Power Transportation Healthcare

17 TCS - Overviews Rail Network Views Geographical Overview Main Line Views Station Views Communications Automation Buildings Power Transportation Healthcare

18 Control Function Operational Example Route Setting – Option 1 Dialog • Select Entry and Exit Point – Left Mouse click 1 Communications • Select Operation Command (highlighted in bold) 2 Automation • Execute Buildings Power Transportation Healthcare

19 Control Function Operational Example Route Setting Option 2 • Select Entry Point – Left Mouse click • Select Exit Point – Right Mouse click • Route is set 1 Communications 2 Automation Buildings Power Transportation Healthcare

20 Train Information and Management System Reports Process Interface Indication and Control TIMS Train Control System Train Location Management Railing Variance Data Train Consist Management Hotbox Data GPS Data Timetable Data Storage and Distribution BHP Billiton Iron Ore Business Systems Railing Requirements Track Possession Data Vehicle Maintenance Planning Data Warehouse Communications Automation Buildings Power Transportation Healthcare

21 Intelligent Train Schedulling System Maintenance Infrastructure Railing Requirements Output Daily Schedules Master Schedules for predefined period Communications Automation Buildings Power Transportation Healthcare

22 Intelligent Train Schedulling System Process Interface Indication and Control Offline Master Timetable ITSS - Online Conflict Detection & Network Image Resolution Train Monitoring & Tracking Interlocking Control Re-scheduling Option Manual Train Location Automatic Routing Semi Automatic Timetable Train Orders Advanced User Interface Fully Automatic Daily Operational Constraints Communications Train Control System Optimisation of the Railway Operation Daily Business Objectives Automation Buildings Power Transportation Healthcare

23 Summary • Provide BHP Billiton Iron Ore with a user friendly train control system • Eliminate the impediments on infrastructure expansion • Alleviate the train controller of its manual workload • Minimisation of disruptions during daily operation • Greater flexibility in capacity planning • Overall increase in train running performance Improvement of delivery capacity of the Rail System Communications Automation Buildings Power Transportation Healthcare

24 Acknowledgements Thanks to: BHP Billiton Iron Ore Siemens Transportation System and to the Project Team, John Lamberti, BHP Billiton Iron Ore Niels-Henning Madsen, Siemens Transportation Systems Communications Automation Buildings Power Transportation Healthcare