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Commercial in Confidence
Aurizon Network
Chris Brown
Manager Civil Assets
Network Operations
September 2015
Commercial in Confidence
Overview of CQCN
Commercial in Confidence
Central Queensland Coal Network Overview

+35.8%
Managing track access to 2,700km of rail network with 2,000km
electrified
230
223
227
220
Longest distance between mine and port of 438km

Loading at 40 mines

Delivering to 6 export coal terminals and 7 domestic customers

Communicating with 7 Rail Operators across Coal (4), Freight (2) and
Passenger(1) services
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Average railings of 612kt per day for FY15
211
210
Million Tonnes

200
190
181
180
170
165
165
2010/11
2011/12
0
2012/13
2013/14
2014/15
2015/16
Forecast
GROWTH PROJECTS
Hay Point Expansion
Cost: $121m
Additional Capacity: 11mtpa
GAPE
Cost: $1100m
Additional Capacity: 33mtpa
Rolleston Electrification
Cost: $163m
Electrification of 113km track
Wiggins Island Rail Project
Cost: $858m
Additional Capacity: 27mtpa
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Commercial in Confidence
Organisational Structure
Asset
Management
 Maintenance and Renewals
 Assurance
 Strategy for Civil, Signals,
Telecoms and Electrical assets
Safety
 Infrastructure, Signals, Traction,
NETWORK
COMMERCIAL
NETWORK
OPERATIONS
NETWORK
FINANCE
NETWORK
REGULATION
Maintenance
Control and Communications
Systems
 Extreme weather preparation
 Preventative maintenance
Plant
 Resurfacing
 Ballast Cleaning
 Maintenance of Plant
Planning
 Strategic system planning
 System planning principles
 Closure optimisation
CQCN
Operations




Control Centre Management
Critical capacity planning
Scheduling of access paths
Performance analysis
Volume
Reliability
Cost
People
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Commercial in Confidence
CQCN Train Services Fast Facts
Blackwater
Moura
Goonyella
Newlands
CQCN
Coal Rail Operators
Aurizon
Pacific National
Aurizon
Aurizon
Pacific National
BMA Rail
Aurizon
Pacific National
Aurizon
Pacific National
BMA Rail
Average Cycle Time
25.6
17.1
18.4
18.2
20.5
Standard Payloads
8,144
6,234
9,979
6,656
8,573
Average Trains per Day
22.1
5.3
31.9
12.1
71.4
Record Trains in a Day
30
13
43
18
90
65.77mt
11.99mt
116.37mt
29.34mt
223.47mt
Volume in FY15
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Commercial in Confidence
CQCN Asset Fast Facts
Assets
Blackwater
Moura
Goonyella
Newlands
CQCN
Track (km)
1,186
260
980
320
2,746km
Electrified Track
1,030
0
980
0
2,010km
Rail
2,296
520
1,960
640
5,416km
Turnouts
394
67
453
89
1,003 T/O
Culverts
1,371
679
1,168
591
3,809
Bridges
134
56
115
32
337
Sleepers
1.94
0.43
1.62
0.53
4.52 million
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Innovation in Assets and Maintenance
Commercial in Confidence
Low Profile Composite
Sleepers
Electric Rail Lubricators
Resin Based Culvert Solution
Completed
culvert
Renewing culverts under traffic
improves the asset while maintaining
capacity
Automated remotely monitored rail lubricators
installed at key locations on the network reduce rail
wear and improve the rail/wheel interface
Unmanned Aerial Vehicles
Improved total cost of ownership and
service life with lower maintenance
compared to existing sleepers
Ballastless Trackslab
High
definition
images
Infra-red
analysis
Drones reduce the time required on track for
inspections while providing data for preventative
maintenance and minimising exposure to
working at height for staff.
Ballast heavily fouled by coal dust
needs replacement every 2 years;
high cost, major impact on network
availability and velocity
Completed trackslab installation
Cooling Channel Bridge
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Commercial in Confidence
Reliability & Asset Protection – Protection
• Wheel impact detects identify flat wheels which impact rail, increase the risk
of rail break and reduce rail life
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Commercial in Confidence
Safety – Level Crossings
• Lasers detect high loads and alarm driver to stop.
• Protects against dewirements at level crossings
• Continual safety improvement project for level crossing
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Leading edge asset diagnosis is key to improve asset condition
knowledge and move to a complete predictive focus
Ground Penetrating Radar
Track Defect Inspection Reporting
Note: Whole Network complete
Note: Tendering for remote recording
equipment for locomotives with
automatic download
Commercial in Confidence
Delivering Improvements – Safety (Level Crossings)
• Over height Detectors – Blackwater and Dingo
• Gracemere Overbridge – removed two level
crossings
Level Crossing at Arduard Rd, Blackwater
Level Crossing at Arduard Rd, Blackwater
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Commercial in Confidence
Reliability & Asset Protection - Reliability
• Installation Points monitoring; the force to move a turnout predicts failure
• Being installed at high use turnout
• Alarms sent to Fault Control Centre automatically
Measurement and alarm trigger shown below
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Commercial In Confidence
Commercial in Confidence
Delivering Efficiency Improvement - Mt Larcom Vital GE
In-sleeper points machine
In-sleeper points machine allows
tamping over the points machine.
The manufacturer promises
increased reliability and decreased
maintenance. Trailability of
machine should eliminate rodding
damage after run throughs.
Delivering Reliability Improvements – Points Monitoring
Jammed
Points condition monitors installed
handled by the FCC
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Cooling Channel Bridge Ballast-less Track
In July 2015, Cooling Channel Bridge was converted from a ballast deck bridge to
a ballast-less track bridge in a 94 hour closure.
Previously, ballast on the bridge was required to be replaced every 18-24 months
due to coal fouling.
The new track slab has an expected life of 50 years
The project pay back period is 8-10 years compared
Less closures associated with maintaining the track over the bridge will be
required.

The design will looked to be implemented on other critical
bridges

Design features:

Precast panels encased by super workable high strength
concrete

Delkor rail fastenings pre-attached to precast slabs for quick
installation

Self cleaning drainage system retrofitted to treat run-off
before discharge
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For further info contact Reannan Moodie
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Network Asset Update
Innovative Delivery in FY16 - Culvert Solution
Current State
 Culverts are placed in the wettest part of the track formation to direct water flow and prevent formation damage and washout
 Corrugated metal pipes have been commonly used for culverts, while cost effective, are only 2mm thick and rust in damp conditions with significant risk of catastrophic failure
 Culvert replacements are relatively expensive (~$300 – 400k for 3 pipes) and require
significant network closure time due to the impact on formation, ballast and track
Future State
 Berolina system is a corrosion resistant fiberglass sock with 12mm thick UV‐light cured polyester resin that coats the inside of the existing pipe
 Designed and manufactured in Germany to suit specific pipe geometry, represent a collaboration between Aurizon and contractor ITS Pipetech
 Maintains existing hydraulic performance, 50 year design life (RPEQ Certified)
Corrugated metal culvert showing extensive corrosion
Culverts after completion of resin and fibreglass liner Trains running while resin installation in progress
Advantages
 Track remains undisturbed and lines remain open– no possession or post work speed restrictions required!
 At least 30% cheaper than traditional culvert replacement
 The potential to save Aurizon up to $100 million in direct CAPEX costs over the next 20 years
 Supports 30t axle load for potential future load increases
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Supersites - Providing real time data collection to better
manage below rail assets
A “Supersite” is a strategically selected location that houses a range of wayside equipment in a common on track location. These locations (1 per coal
system) are selected due to their position of the rail Network, (relative to traffic task), security of power, strong communications and convenient , safe
access.
Designed primarily as a site for co-location of asset protection systems such as mainline weighbridges, wheel impact detectors (WILD) and
pantograph defect detection (Pancam), sites are also available for installation of above rail operator’s equipment for further measurement and
condition monitoring of rollingstock.
An exhaustive site selection process was undertaken to find sites suitable for the equipment to be installed in terms of speed, topology, access and
access to communications and power. All fours sites were identified and project progress is as below:
Civil works
complete
Jun-14
Feb-15
WILD
Weighbridge
Pancam
Jun – 14
Oct – 15
2017
Mar-16
2017
2017
Moura (Graham)
Sep-15
Dec - 15
2017
x
Newlands (Abbot Point)
Jul-15
x
Apr-16
x
Goonyella (Wandoo)
Blackwater (Kalapa)
Wandoo Supersite building and compound
Application of Data (data will be available to operators via the Network assets Portal)
• The Mainline weighers will form the missing link in our wagon weighing systems,
allowing direct comparison between sites and automatic detection of accuracy drift
• WILD data will be used to identify defective wheels causing impact to the rail and assist
operators to manage their wheel defects below the alarm thresholds
• Pancam will provide additional reference information for the interface between the train
pantograph and the overhead at line speed
Benefits
• Mainline weighing will form the voice of reason for weight disputes, and put an end to
accuracy questions, thereby increasing certainty and reducing delays
• Application of WILD will both protect the assets for defective wheels and allow operators
to better plan wheel change outs informed from wear data
• Pancan information will held reduce pan related dewirements and allow operators to
better manage the carbon change out schedule on train pantographs
WILD installation at Wandoo
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Commercial in Confidence
TAS – Track Access System: Innovation through technology
A joint venture with QR, scheduled for field rollout in September 2015. Factory Acceptance Testing underway. Possible delay due to
Pluto implementation in Control Centre.
• View of the train control screen to
the field, allowing personnel to
see rail traffic and adjacent work
groups.
• GPS location and translation to
train control system layouts –
providing an engineering control
for identification of location (for
both field and control centre)
• Electronic communication –
provides an engineering control to
eliminate human error in
communication
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Commercial in Confidence
Reliability & Asset Protection - Protection
• Dragging Equipment Detectors (DED): Detect derailed trains, broken axles
and alert train control and driver to stop train and limit damage
• Left if old style required attention after operation (response expense and risk if
run trains before reset)
• Right is more reliable, new, resetting DED.
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CQCN ION Meter Blackwater
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Operational LAN WAN
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Safety
Cost
Reliability
Volume
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Photo STC HBD new Web Portal
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Photo STC HBD new Web Portal
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Photo of CMS (WILD and HBD Systems)
Commercial in Confidence
UAV (Unmanned Aerial Vehicle)
Overview
Automated collection of track condition data for traction assets
High Def Imagery and Infra-Red analysis
Condition-based maintenance and renewals programs
Progress so far:
Proceeding with procurement of 2 systems
Training for linesman - completed
Start data collection - completed
Analysis Outputs
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Commercial in Confidence
UAV Business Benefits
The project will:
Provide detailed asset condition data to inform the investment and maintenance program
Maximise reliability by targeting corrective works based on analysis
Reduce business impact of inspection activities by not requiring track access or HV
isolation
Previously imagery acquired with full-sized aircraft (Big $$ 500k+)
Total UAV project cost $324k
High Def
imagery like this
shows great
detail of asset
condition
information
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Innovation in Planning, Scheduling and Day
of Operations
Commercial in Confidence
Network Asset Management System (NAMS) is a multi-phase business
transformation project. It will provide a single source of comprehensive asset
data with
 In-field mobile devices to support maintenance delivery
 Standardisation of work delivery processes
 Asset condition datacapture including photos, design drawings & safety
information
 Asset level costing, analysis, planning and scheduling.
Advanced Planning and Execution (APEX) is a transformational tool integrating industry proven technologies into a single solution to optimise
planning, scheduling and day of operations for the Central Queensland Coal Network
Network Forecasts
and Planning
Plan and Schedule
Generator
Real-Time Planning
Support
Conflict Resolution &
Optimization
Day of Operations
(DOO)
Supply Chain Optimisation
 Forecasts / Plans (2 years to DOO)
 ‘What-if’ opportunity analysis
 Plan to Schedule creation and
optimisation
Real‐Time Traffic Management  Business rules embedded into
solution
 Real-time train movement
(interactive graphs)
 Conflict detection and resolution
(manual > automated)
 Performance Dashboards (plan v’s
actual)
 Recovery to Plan with CQCN
impacts consideration
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Network Operations CQCN
Transformation and
Strategic Focus
Commercial in Confidence
Network Ops CQCN Transformation Journey
Recent Transformation Activities
 Consolidation of Mackay and Rockhampton based Control Centres to form CQCN Control Centre in Rockhampton (2011);
 Consolidation of Network Operations North and South to form Network Operations CQCN with restructure of leadership, planning and business system teams (2013);
 Implementation of consistent planning tools across CQCN (2014);
 Review of Business Execution Rules and implementation across all Rail Operators and Ports;
 KPI reporting to Rail Operators and Supply Chain Forums implementation (2014).
Remaining Business Need
 Support planning and execution with increasing complexity
• More mine to port combinations
• Increased volumes
 Better utilisation of capacity and existing asset ‐ more trains, maintenance and track activity
 Further reduce Day of Operation losses through decision making with full system view vs individual sections
 Replace manual processes and legacy in‐
house systems
 Provide integrated solution from long term planning, to scheduling and day of operations
 Platform for ‘auto routing’
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Commercial in Confidence
Translating Aurizon’s Blueprint for Network
Operations CQCN
Building a sustainable future through partnering with customers
to achieve repeatable excellence in below rail operations through
planning, scheduling and execution and supply chain
coordination.
We are a disciplined operator of below rail assets and integral to
supply chain coordination, using transferrable, repeatable
processes to deliver for our customers.
Build and promote our repeatable, transferrable operational skills for below rail
planning, scheduling and execution, using reputation for excellence in CQCN to
attract growth opportunities both domestically and internationally. This growth
may be through direct operations or consultancy opportunities to other rail
networks.
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Commercial in Confidence
Step Change to Achieve Our 5 Year
Strategy
Disciplined Planning is Key.
Our 5 Year Strategy
Step Change
We’re driven by smart
process, not only smart people.
Market the Outcomes and Offering.
Embed a ‘Lift and Shift’
Mentality.
Move to portfolio approach for Supply Chain Coordination
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Commercial in Confidence
Step Change to a Sustainable Future
Step Change
How will we know when we have achieved each step change?
We’re driven by smart process, not
only smart people.
… when our processes have the rules built into them, and stand‐alone red tape like ‘System Rules’ will no longer exist.
Disciplined
Planning is Key
… when our smart processes and our tools are widely known and trusted, offering value‐
add to supply chains and driving discipline within Network and Supply Chain activities.
Move to portfolio approach for Supply Chain Coordination
… when our processes are packaged into core uniform modules, with checklists/tools that tailor our approach to the needs of individual supply chains (including mine production and shipping considerations).
Embed a Lift and Shift Mentality
… when can ‘lift and shift’ our process modules to grow new opportunities in our existing Supply Chains & also secure opportunities in new Networks and Supply Chains.
Market the Outcomes and Offering
… when our services will be ‘in demand’, with existing and new customers seeking and agreeing to partner with us to provide then with new services because of the value‐add and discipline we offer.
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Confidence
Commercial
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