Teknis: Port Hedland

Port Hedland Port Hedland, West Australia

A wheel condition monitor system was installed on the main line 39km from the port of Port Hedland in 1996. This site was used by BHP Materials Laboratories during its original research 1990 to 1992 and today it still has a comprehensively strain gauged section at the monitoring site. Today the Melbourne Research Labs use the site for ongoing research.

Operating trains in excess of 45,000 tonne at lengths of 1400 axle using 190 tonne 6000 hp locomotives within the consist and with 40+ tonne axle loads requires very careful process control. In order to trend wheel defects and do proper machine condition monitoring it was critical for BHP-Billiton to have a system that output wheel condition metrics independent of the axle loads (4 tonne tare, 40 tonne gross).

BHP-Billiton monitors wheel condition, bearing and wheel temperatures and the dynamic forces in the consist and applies formal statistical methods to ensure that the process remains in control. WCM is integrated into the BHP-Billiton operation and is one of the major systems used to help BHP-Billiton identify ore wagons that require maintenance. The BHP-Billiton site has been presented some unique challenges over the years and solving those has been instrumental in Teknis’ ongoing development of the WCM. The system is fully integrated with Train Control and the Locomotive and Wagon workshops and all defects are scheduled for service and monitored until removal.

BHP Billeton Iron Ore

Rolling stock and train operations monitoring

68kg rail, standard gauge

40 tonne axle loads

1400 axle consists

Full vehicle tagging

Co-located with HBD and research array

Telemetry radio communication

Solar powered

Maximum rail temperatures 70°C (160°F)

Periodic seasonal cyclones and flooding