Interlocking system upgrade future-proofs AutoHaul™ heavy haul rail network

Hitachi Rail will soon commence the third and final phase of the interlocking system upgrade of Rio Tinto’s autonomous heavy haul rail network in Western Australia.

In the state’s Pilbara region, Rio Tinto operates an integrated system of 17 iron ore mines and four port terminals – all linked by a vast railway network.

In 2019, Hitachi Rail worked with Rio Tinto to develop and launch , AutoHaul^™the world’s first fully autonomous heavy-haul rail operation, capable of moving about one million tonnes of iron ore a day. Today, these 2.4-kilometre-long trains, monitored remotely from an operations centre in Perth, travel across a more than 1,900 kilometres of track to deliver iron ore from mine to port.

At the same time that AutoHaul^™ pioneered across the Pilbara and into the history books, a major project to replace the Integrated Control and Supervision System (ICSS) that supports the network’s operation was also launched.

Program Director, Mazahir Yusuf said the massive and complex task of replacing Rio Tinto’s interlocking system aimed to eliminate potential safety, operational and efficiency risks .

“Our focus is on supporting Rio Tinto to future proof their network with an innovative, scalable and flexible solution,” Mr Yusuf said.

The three-year, eight-staged project replaces the existing ICSS MicroTrax interlocking system with a Hitachi Rail-designed MicroLok II interlocking to optimise network throughput, on-time operations and life cycle costs – all while minimising faults and failures.

Central to the network’s operation, the ICSS is the technology platform that allows for integrated, centralised and local train control and monitoring – as well as supervision of subsystems located trackside.

The computer-based interlocking system performs key wayside functions, both in the field and remotely, such as train detection and track circuit integrity – and can “self-diagnose” and send alerts back to the control centre.

MicroLok II’s advanced technology can monitor multiple lines of railroad track and crossings to safely and efficiently move freight to its destination. The system’s functions including train detection, track circuit integrity, coded track circuit communication, cab signalling code generation and event recording. It also includes a vital interlocking code and a code system for nonvital control and indications.

The completed ICSS Phase 1 and Phase 2 projects replaced the existing interlocking system and supporting wayside equipment across a 100 kilometre stretch of the Tom Price line and 200 kilometres of the Yandi line.

Phase 3 will now focus on the Paraburdoo Line and is expected to go live in 2025.

ENDS

EDITOR’S NOTES

• Rio Tinto operates a fleet of heavy haul locomotives on its 1,900km rail network in the Pilbara, Western Australia. The average return journey of the 2.4 km long trains is 800km, taking approximately 40 hours including loading and dumping.
• AutoHaul^™ is the result of a multi-year collaboration between Rio Tinto and Hitachi Rail. Hitachi Rail was the signalling, telecommunications and traffic management system (TMS) systems integrator on this groundbreaking project.
• A total of 221 locomotives have been retrofitted with AutoHaul^™ technology which enables them to travel the return journey without a driver on board.
• AutoHaul™ was officially recognised as the “heaviest robot in the world” by the Guiness Book of Records in 2021.
• The locomotives are fitted with on-board cameras allowing for constant monitoring from an Operations Centre in Perth. All public rail crossings on the network are fitted with CCTV cameras and an obstruction detection system (ODS). All locomotives are fitted with safety systems including collision detection, automatic train protection which controls train speed, and automatic train operations technology.
• The AutoHaul™ project saw one of the first installations of the European Train Control System Level 2 (ETCS L2) in Australia. Hitachi Rail is now delivering ETCS L2 as part of the Cross River Rail project in Queensland
• AutoHaul™ is estimated to have removed Around one million driver kilometres off the road each year including emissions and fuel - as driver change overs are no longer required.
• Hitachi Rail’s tech pioneering continues to support Rio Tinto carbon reduction target of 15% emissions reduction by 2025 and 50% by 2030, and zero by 2050.
• More than 200 wayside signalling stations are located across the network, the majority of which are entirely solar powered, and can handle internal temperatures higher than 60 degrees celsius.