BHP Iron Ore now operates only one railway line with the Goldsworthy line suspended and a motive power fleet of 178 SD70ACe locomotives in the Pilbara.
And the rail line is 426km long running from Nelson Point (Port Hedland) and Finucane Island to Newman (or Mt Whaleback Mine). With junctions at Yandi Junction, where the mainline continues on towards the MAC™ or Mining Area C (a former GML lease) mine, past the spurs to both Yandi One and Yandi Two mines, with the other at Jimblebar Junction which includes a marshalling yard, with branches heading east out past Orebody 18 to Wheelarra Hill, (formerly McCamey's Monster, then Jimblebar) iron ore mines and to the south west to Mt Whaleback (Newman) past Ore Body 23/25 iron ore mines.
BHP are currently running 18 trains a day on the Newman line.
Train lengths are based on two 134 car rakes for 268 waggons, with the mid-train units controlled via radio link from the lead unit in a system known as 'Locotrol' or 'Distributed Power'.
The Golynx bottom discharge cars (8400 series) that were used on the Goldsworthy system between Finucane Island and Yarrie/Nimingarra have been converted to rotary dump cars and now see service system wide, including 8400, which still carries the stencils 'GML ONLY'.
Expansion of the operation to 205 million tonnes per annum (Mtpa) is well under way with BHP Billiton and the Macmahon Leighton Joint Venture in the process of duplicating the Newman mainline between Bing South (21 km) and Yandi Junction in a project called RGP 5.
There are currently two sections already duplicated between Coonarie and Spring sidings and Turner South to Turner North. With the addition of a rotary car dumper (CD4) at Finucane Island this has allowed increased tonnages to the Western and Eastern Yards of Yandi and MAC™ DSO or Direct Shipped Ore with the continued use of the under harbour tunnel. Extensive duplication works have been carried out in the Hedland area as in Nelson Point Yard is now dual track all the way to Bing South, with the south leg of the Goldsworthy Triangle duplicated and called the 'avoidance road' which avoids the GML leg of the triangle being added to the once former diamond.
Trains are now regularly made and broken up at Bing Siding, which has an Up and Down mainline along with the siding, which is also the access point to the Flashbutt Yard. This occurs due to the length limitations on the line to Finucane Island being only capable of single (112 car) rakes. Normal operation is for empty rakes to leave both Nelson Point and Boodarie yards and be marshalled into a single train in the siding at Bing. With loaded trains splitting apart on the Down mainline before continuing onto either Boodarie or Nelson Point.
Train movements are controlled from the Train Control centre located in Perth at the Intergrated Remote Operations Centre with five control desks, being:
Communications and all track devices are controlled across an extensive VHF radio system with solar powered microwave linked repeaters. All track side infrastructure as in signals, switch motors and monitoring devices are solar powered and are monitored and controlled out of Nelson Point via a computer controlled Siemens' Vicos Train Control System.
A trunking style scanner is required for the BHP system as they use a P25 based unencyted system.
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