81 Coal Export Line: 81 MTPA Rail capacity expansion program
Project
81 Coal Export Line: 81 MTPA Rail capacity expansion
program
Background

The coal line currently delivers close to 70 million
tonnes per annum (mtpa) of export coal, from about
48 mine loading sites situated mainly in Mpumalanga,
to the Richards Bay Coal Terminal (RBCT). The 81
mtpa rail expansion program is designed to meet the
increasing international market demand for export
coal. The program involves increasing the rail capacity
of the coal line and addressing operational bottlenecks
which impact on the stable flow of train traffic.
Scope

The program provides for increases in the wagon and
locomotive fleets to cater for the higher volume, and
consists of 35 infrastructure work packages which are
designed to:
Generally improve the overall availability and reliability
of the integrated rail capacity system on a sustainable
basis.
Streamline train operations in yards.
Improve locomotive operational and maintenance
effort efficiencies.
Strengthen the traction power supply on both the
Eskom delivery side and within Transnet’s substation
and overhead Track Equipment (OHTE) network.
Improve yard security.
Enhance the integrated condition assessment system
for the infrastructure and rolling stock.
Enable an increase in capacity for long trains from the
Waterberg coal fields.
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Project
Description
The program covers the following improvements, which were
identified after a thorough feasibility study involving a range
of quantitative analysis techniques, including an operational
and an electrical simulation
1. Line and Yard Expansion
There are 4 yard upgrades to streamline train operations in
the Blackhill, Saaiwater, Ermelo and Vryheid yards. The
capabilities and the operating efficiencies of the yards are
being improved, in order to reduce the amount of time the
trains stand. Speeding up of the compiling and de-compiling
processes, enables quicker deployment of the empty trains
into the mining areas by providing for slip loads at a strategic
location, and also provides facilities to enhance operations by
enabling synchronization with the train plan. Extension of
some of the loops will enable easier and quicker coupling and
de-coupling of the wagons, which is done on a loop rather
than on the main line, to accommodate smaller trains coming
from the mines. The Matlabas loop extension between
Lephalale and Thabazimbi increases the slot capacity for long
trains from the Waterberg.
2. Efficiency Work Packages
2.1 Workshops
The Ermelo body – lifting workshop has been extended and
upgraded to enable loco body lifting for repairs, in order to
accommodate the expected growth in the locomotive fleet on
the coal line. A locomotive preparation depot is being built at
Ogies to prepare locomotive consists for service at an
accessible location, as opposed to having them travel back to
the maintenance depots, which is time consuming.
2.2 Turntable
A 25m diameter locomotive turntable in Richards Bay is to be
used to turn the single cab locomotives around, when they
are required to operate as a lead locomotive. Turning
locomotives around was previously achieved on a track
configuration called a triangle or balloon track. The turntable
offers a faster method of turning the single cab locomotives,
thereby improving efficiency by reducing turnaround times.
2.3
Security Enhancement
A 16.5 km fence is being erected around the Ermelo Yard
complex, to increase security, improve access control, and
enhance the safety effort.
3. Electrical traction power upgrade
The coal line is composed of two electrification systems,
namely the 3kV DC network from Blackhill to Ermelo, and the
25kV AC network from Ermelo to Richards Bay. 100 wagon
trains operate between Blackhill and Ermelo, and 200 wagon
trains operate between Ermelo and Richards Bay. At Ermelo
yard there is a changeover of supply voltage from 3kV DC to
25kv AC, and vice versa. The changeover is done using diesel
– electric haulers around balloon lines linking the 4 yards,
which enables the compilation of the 100 wagon into 200
wagon trains, vice versa, and arrival and departure yards
respectively.
The electrical power upgrade projects are designed to
strengthen the traction power supply on both the Eskom and
the Transnet sides, to reduce thermal overloading of some of
the single unit transformers, and to ease maintenance and
isolation during abnormal conditions. Most of the double and
single unit Transnet substations are powered from an 88kV,
three phase distribution line owned by Eskom, which is
dedicated to power the traction network. The remaining
double and single unit power stations are powered from a
132kV three phase distribution line from Eskom.
Transnet’s electrical upgrades for the 81mtpa include: 7 new
DC substations; 6 DC existing substation upgrades; 2 new AC
substations, 2 AC existing substation upgrades and
transformer replacements. The electrical upgrades that are to
be conducted on Eskom’s electrical system include: the
upgrade of the distribution system supplying traction power
to the DC section of the coal line north of Ermelo, and an
upgrade on the 88kV electrical backbone supplying traction
power to the AC section of the coal line between Ermelo and
Richards Bay. The latter involves 3 new Eskom substations
stepping down from its 400kV transmission line to the
dedicated 88kV transmission line, and a major upgrade of the
88kV Eskom backbone which dates back to 1976.
4. Condition Assessment Systems (CAS)
A number of additional CAS’s are to be added to the current
infrastructure and rolling stock health monitoring system, and
these include the:

Way in Motion – Wheel Impact Monitor (WIM-WIM)
which monitors impact load from flat wheels and
wagon overloading, to prevent damage to the rail
track.

Hot Box Detector which monitors the temperature of
the axles and prevents derailments resulting from
broken axles.
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Dragging Equipment Detector which detects the
presence of equipment hanging below the train to
prevent infrastructure damage.

Broken Rail Detector which detects rail breaks in the
track, and prevents derailments.
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Load Profile Monitor which detects whether the entire
product has been removed from the wagon after
unloading.
5. OHTE – The Feeder line projects
The traction power supply is being improved over the 3kV DC
section by installing 800mm2 aluminum additional feeder
cables over four different critical sections where the trains
experience steep uphill gradients. This is to improve the
delivery of current to the locomotives in a substation section,
and to improve on the thermal characteristics of the OHTE.
An additional feeder has already been installed over a critical
section of the AC traction power network.
Train speeds are affected by fluctuating and low voltages. In
the event of a loss of a substation due to vandalism or theft
of the return circuit, the feeding sections become too long
and it becomes impossible to move full length trains. The 5
identified feeder wire projects are between Kameel and
Savannah; Midpoint and Halfgewonnen; Geluksplaas and
Broodsnyersplaas; Rietvleirus and the Ermelo substation; and
over the entire 34km of the Dumbe deviation near
Paulpietersburg between Ermelo and Richards Bay.
Status of Project

Most of the work packages are scheduled for
completion by 2016.
Benefits of Project

Transnet operates the train service between the mines
and RBCT, and from which it earns revenue that
provides returns that are invested in maintaining the
asset base and expanding the rail capacity. On
completion of all the packages in the 81mtpa rail
expansion program, a stable flow of train traffic to
Richards Bay will be maintained which will have many
benefits for the South African economy.
Milestones

Most of the infrastructure work packages are currently
in execution. Five of the substation projects are
subject to land acquisition and environmental
processes, which are underway. All of the coal line
upgrades are carried out in a manner that causes
minimal disruptions to current train operations.
EPCM

Transnet Capital Projects
Client/Who will the
project serve

Transnet Freight Rail
Capacity creation

To improve the overall availability and reliability of the
integrated rail capacity system on a sustainable basis.