South Africa-based rail technology provider On Track Technology (OTT) is installing its Dynatrack train safety system at a South African platinum mine, in Rustenburg, where the seven-month R8.5-million project is in its final phase.

The mine’s train fleet collects raw material at the loading source and transports it to one of the on-site processing plants.

OTT director Francesco Costella explains that Dynatrack is an interactive collision avoidance and speed-monitoring system specifically designed for closed-rail-network systems. It is based on an advanced global positioning system and “provides real-time, accurate position information used for train operation management, speed control and collision avoidance”.

He notes that OTT was first approached by the platinum miner toward the end of 2016, explaining that transmitters have been attached to the miner’s ten-strong locomotive fleet to relay positioning data to the central monitoring system. This is where train controllers are able to monitor train movements, ensure adherence to safety protocols and can remotely override train operation.

OTT operations manager Sean Fielding stresses that the system’s primary function is collision avoidance and speed adherence. “Should trains be within a predetermined distance, the system will warn the drivers of the hazard. Should the driver not take the appropriate action by slowing down, the system will intervene if necessary, removing excitation and applying the brakes. “Similarly, speed adherence is ensured first by warning and then intervention.”

He notes that the various system parameters and algorithms are designed to intelligently limit unnecessary impact on production, while maintaining safe operating conditions. “Further, the logged real-time data provides a detailed history of train movements, thereby providing valuable data in terms of turnaround and performance, as well as a source for safety review.”

Costella says, with regard to the platinum project, the specific safety and operational requirements of the mine, as well as continual system optimisations for performance improvement were the main challenges. “They weren’t big challenges as such, but they were customisations that we provided so as to enable the client to extract the maximum benefit from the system.”

OTT designed and developed Dynatrack, Costella points out and “it took us roughly eight months to design the system. Thereafter we spent about six months testing and industrialising the system to be ready for use in operations”.

Dynatrack works alongside the locomotive driver, continually monitoring the situation and warning of any potential hazards, and taking action when the hazards are confirmed. “The adoption of this independent, intelligent fall-back system provides an additional, but significant, safety layer,” Costella notes, adding that Dynatrack has also been installed at a mine in Orkney, in the North West.

Comparing Dynatrack to other locomotive safety systems, Fielding states: “Of all the offerings, we are the most cost effective. This is a direct result of our design approach. We’ve designed the system specifically for this purpose. Therefore, we’ve been able to reduce production costs. Many other systems are catalogue-engineered, creating high reliance on third-party components whose procurement often has significant cost implications.”

This design, along with the fact that the system was developed and is owned by OTT, ensures that the life cycle costs are contained. “We are able to effectively manage the life cycle of subcomponents – microprocessors, for example – as we own the entire design. This allows us to guarantee the availability of spare subcomponents at a reasonable cost to our clients,” says Fielding.

Dynatrack also provides an added level of safety when people are working on the railway track through a mobile beacon unit. “When the beacon unit is activated – adjacent to the people on/near the track – it informs them of the presence of approaching trains. The beacon and the train systems warn track workers and train drivers respectively, using audible and visual signals. Should the train driver not slow down to the permitted speed, the on-board system will intervene, reducing the train’s speed to a safe crossing level.”

Diversification
Costella notes that, while the specialised nature of OTT products has enabled it to continue relatively unaffected by commodity crashes and mining downturns, the company has identified its reliance on the sector as a “potential threat” to its business and looks to address this weak point by diversifying into new markets.

“OTT is focused on gaining offshore exposure. Over the last two years, the company has installed about 10% of its weighbridge base into Africa and a further 10% into Australia. OTT is also investigating and designing alternative technology products [for] industries such as renewable energy and intelligent housing,” Costella concludes.