BHP Billiton Iron Ore Railroad
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1 BHP Billiton Iron Ore Railroad Presentation to Analysts June 2005 Mike Darby, Vice President Rail Iron Ore
2 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
3 Safety Performance - Rail Classified Injuries Classified Injury Frequency Rate for Rail (including contractors) /01 01/02 02/03 03/04 Jul-04 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05 Historical Actual CI Actual Page 3
4 Page FY66 FY68 FY84 FY86 FY88 FY90 FY92 FY94 FY02 FY04 RGP FY96 FY98 FY00 Tonnes Railed Rapid Growth Period FY70 FY72 FY74 FY76 FY78 FY80 FY82
5 Jul-04 Sep-04 Nov-04 J an-05 Mar-05 Rail KPI s - Long Trains ( Cars) Number of Train Runs Apr 05 3,642 Long Trains YTD 1,053 Trains Yandi & MAC Newman Sep-00 Nov-00 J an-01 Mar-01 M ay-01 Jul-01 Sep-01 Nov-01 J an-02 Mar-02 M ay-02 Jul-02 Sep-02 Nov-02 J an-03 Mar-03 M ay-03 Jul-03 Sep-03 Nov-03 J an-04 Mar-04 Jul-00 M ay-04 Page 5 3,642
6 Million Tonnes Railed Per Employee Employee Productivity Tripled in the last 10 years FY96 FY97 FY98 FY99 FY00 FY01 FY02 FY03 FY04 FY05 Page 6
7 Railroad Manning FY99 FY00 FY01 FY02 FY03 FY04 FY05 Actual FY05 Plan Page 7
8 Rolling Stock Fleet Expansion Program 4,000 Original 3,500 8 AC600 Locos 40 Dash 8 Locos Rakes Ore Cars Arrival of 6 SD40 3,203 Arrival of 13 SD70 3, Ore Car 2,971 3,000 Arrival of 6 SD Arrival of 5 SD40 2, , , Arrival of 3 SD , ,500 1, Train Schedule Train Schedule 0 Feb-03 Mar-03 Apr-03 May-03 Jun-03 Jul-03 Aug-03 Sep-03 Oct-03 Nov-03 Dec-03 Jan-04 Feb-04 Mar-04 Apr-04 May-04 Jun-04 Jul-04 Aug-04 Sep-04 Oct-04 Nov-04 Dec-04 Jan-05 Feb-05 Mar-05 Apr-05 May-05 Jun-05 Jul-05 Aug-05 Sep-05 Oct-05 Nov-05 Dec-05 Page
9 Locomotive Fleet Dash 8 AC6000 SD40 SD70ace Number (Oct05) Traction Horsepower 4,000 6,000 3,000 4,300 Dash 8 SD40 AC6000 Page 9
10 Page 10 Automatic Train Protection - ATP System
11 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
12 Asset Protection 12 Hotbox / Hot Wheel Detectors 1 Cold Wheel Detector 1 Wheel Impact Monitor 3 in Motion Weighbridges Acoustic Bearing Detection Dragging Equipment Detectors Auto Locomotive Downloads Video Imaging Page 12
13 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
14 IOC Reporting Automatic data downloading Dumping Forces Measured Page 14 Car side wall strains
15 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 Page 15 Strain Gauge on Draft Gear Pocket Measure Longitudinal Train Forces Control Service Loading Peaks & In Train Forces
16 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
17 Video Imagining Technology Flange Height Flange Width Vertical Flange Hollowing Depth Rim Thickness Page 17 Wheel Diameter
18 Video Imaging Reporting 1. Tabulated 2. Pictorial 3. Graphical Page 18
19 37 Traceable Components for each Ore Cars Page 19
20 Wheels Ultrasonic Testing Page 20
21 Train Driving Simulator Used To Define Driving Strategy & Training Needs Page 21
22 Aluminothermic / Flash Butt Page 22
23 In Track Flash Butt Welder Page 23
24 Rail KPI s Broken Rails '93 '94 '95 '96 '97 '98 '99 '00 '01 '02 '03 '04 '05 April Page 24 Calendar Year
25 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
26 Higher Axle Load Operating Improvements Axle Load 40.2 tonnes Wet tonnes per wagon 28.5 tonnes tonnes 32.5 tonnes tonnes 116 Yandi 37.5 tonnes 126 Yandi Page 26
27 Rail / Wheel Interface 1.9 Ore Car Wheel Life Million Tonne Kms ,800 Rail Life (Tangent Track) Million Gross Tonnes 350 Page
28 Train Lengths / Cycle Time Train Lengths Train Length Cars per Train Cars / Train Current 36 Train Cycle Time Hours 30 Page Current
29 Environmental & Efficiency 1.45 Contributing Factors Rail / Wheel profile Page Fuel Savings Aerodynamic Ore Cars Efficient Locomotives Distributed Power Higher Axle Load Longer Trains Driver Strategy
30 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
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