Presentation on theme: "Not about “Steel Mill Modeling” per se – That can be a life commitment… – But you must be interested or wouldn’t be here! Is about “rail operations”"— Presentation transcript:
Not about “Steel Mill Modeling” per se – That can be a life commitment… – But you must be interested or wouldn’t be here! Is about “rail operations” serving a Steel Mill – How can one: Represent the steel mill complex Represent the mill rail traffic – Might be the Theme of the model railroad – A GREAT way to tell a story & reason to run trains So, we’ll talk about Steel Mills & Rail Operations
Steel Mills are big, noisy, fascinating places – What are the parts and pieces? – How much space Does it take? Do you have…? – What about Raw materials? In plant materials? Finished products? – What about the bigger context of a city’s railroad(s)? – Operations can be the “tie that binds” this together…
Can I apply JMRI to Steel Mill Operations? – YES! – JMRI Operations Software: Powerful Flexible Limited only by your ideas/imagination Hmmm… (might be a “ life commitment ”...) How can I use JMRI Operations software? – Raw materials in – In Plant switching – Finished products out – Tying to the rest of the model RR…
Birmingham, AL – Didn’t exist in the Civil War… – Founded at the junction of two railroads (1871) – Developed as an industrial city The New South Continuing the Industrial Revolution “Railroad Reservation for Mechanical Enterprises” – Unique natural resources Iron ore Coal Limestone All “within a rifle shot of each other”… – Known as the “Birmingham District” in the iron trade Make IronMake Steel
Everything in one place! – Can I do that? – What do I need? – Where can I learn? – What are the parts? – How does it work? – What is “required” 18 Miles = 1,100 ft. in HO say 28 acres in HO Birmingham Bessemer
Birmingham Steel “District” – Iron & Steel Industries – 8 Trunk RR’s + Industrials – Interchange + passenger Yards – Main “staging” – Downtown pocket yard – Steel Works yard Steel theme – “mine to mill” – Iron ore – Coal to coke – Limestone Related industries – Scrap, iron pipe, cement – By-product (chemicals) – Downtown industries 18 Miles
A view of the heart of the Birmingham industrial area including TCI / USS Ensley Works and Fairfield Works – 2 fully integrated steel mills and much, much more…
Lemme’ tell ya’ what’m gonna do! EVERYTHING you need in one place… Typical Steel Mill – Birmingham – Lots of other places
Typical Steel Mill Components Steam Era Birmingham District Raw Materials Steel Making Blooming Primary Rolled Shapes Hot Rolled Products Secondary Products Limestone Iron Ore Coal Coke
Blast furnaces for iron (BF’s) #5, # # tons/day/BF (by 1950’s) Recipe per 1 ton iron 2.5 tons iron ore 1 ton coke ½ ton dolomite 2000 tons/day/2-BF’s 72 ore cars 66 coke 34’ hoppers 16 dolomite 34’ hoppers Car ratios to (our) stock trestle ’ ore jennies ’ hopper coke 1 or ’ hopper limestone Coal to (our) coke plant 1.7 tons coal/1 ton coke ’ hoppers coal 13 Trains per Day! We have 2 BF’s Times 2,000 tons/day 8 Trains per Day!
Open Hearths for Steel 1928 – 8 OH’s 1942 – add 4 OH’s 400 tons/day/each OH About 2 heats per day Cars from BF to OH’s, say: ton hot metal cars ton hot metal cars To 600 ton mixer Plus scrap loads to floor Plus dolomite & misc. Plus slag cars to dump Output for 3 OH’s/day, say: 1,200 tons per day 8 ton ingots (varies) 40 small 4 ingot flat cars More slag cars to dump We have 3 OH’s
Blooming Mill(s) -- pick one Ingot cars “in” Ingot mold stripping Overhead crane to soaking pits Ingot buggy to mill line Blooms or slabs out Move along to rolling mills
Have to make tough choices… How much room? What to “show” Building flats? Sidings? Your choice… And there’s MORE!
Coal Mine Iron Ore Mine Coke Plant Bessemer Converters Rolling MillsPower Plant In the 1950’s lots of school kids in Birmingham visited the Steel Works at Fairfield…
Resources Aerial Photos & Maps Historical? Current Local History Plant layout drawings? HABS-HAER Library of Congress Books at library Online “groups” Google Books online Process Concept drawings Don’t plan forever… Need to run trains… BF’s #5, #6, #7 Blast Furnace #7 Pouring Hot Metal at BF Pouring Slag at BF Open Hearth Charging Floor Charging Open Hearth Teeming (Casting Ingots) Ingot Stripping Ingot Soaking Pit Blooming Mill
Things to Think About… How much room do I have/need – You can’t do it all… What do I want to include? – Suggest starting with steel making – Then consider processing = “big buildings & spurs” – Don’t forget raw material sources/processing Whole buildings or flats? – Some great operating layouts model “fronts” – Consider “mock ups” to get started and check fit My main goal is to get a spur to a “place” – Don’t be afraid of “imagination” & mockups Run trains now, build fine models later…
Now back to the reality of… available space! September 28, 2008
AISLE Main Yard Coal Branch Red Mountain Downtown Birmingham CokePlant Steel Works Small Yard Quarry Coal Branch Birmingham District Model Railroad Overall space – 13 x 33 – 10 x 14 Large folded dog-bone mainline Branch lines = 550 sf +/-
Red Mountain Downtown Birmingham Main Yard Coal Branch Coke Plant Quarry Coal Branch Steel Works Parts Small Yard REACH Switching Lead Switching Lead Crossing
Typical Steel Mill Components Steam Era Birmingham District Raw Materials = Branch Lines Steel Making Blooming Primary Rolled Shapes ??? Hot Rolled Products ??? Secondary Products ??? ???
Things to Think About… Operations changes your point of view – Focus may change from buildings to trains – Train length perspective What looks good?10 car trains – good goal What fits?10 car siding – 5 feet log Yard tracks for trains7’ minimum (5’ + eng. & cab) Each “stop” requires room Lots of spurs! Lots of cars! Steam era = shorter cars!34’ hoppers vs. 60’ Where can I park this thing?No need to run if you can’t park – Start thinking in “modules” of cars Maybe 4’s and 8’s – based on spur length, materials required Moving a train with purpose is fun regardless of length! – More switching spots = larger car fleet! Remember: Switching takes R-E-A-L T-I-M-E!
Industrial Development Recruiters have landed a steel mill Site selection is complete Railroad coordination is in progress Surveyors are ready Engineering folks are busy “head scratching”… So, how does it all fit?
Coal Branch Downtown Lead Downtown Siding Steel Works Lead Passing Siding To Downtown Yard & Industries Quarry & Cement Plant TCI Fairfield Works c Birmingham, AL Schematic Main BM Out BM In Blooming Mill RM #1 Out RM #2 In Loads OUT OH Mix OH #1 Teem OH #2 Pour OH Charge OH Lead Open Hearth Scrap #2 Plant Scrap #1 Out Scrap Yard #2 #1 Blast Furnaces BF Stock Trestle Slag Hot Metal BF Lead Slag Dump Lead Slag Hot Metal BF #5 BF #6 Slag Dump Joint Use Engine Terminal Fairfield Yard Lead Loads In Empties Out Steel Works Yard
Main Line Downtown Siding Fairfield X’g. SW Lead Fairfield Yard Lead Yard Lead joins Downtown Siding Where do the raw materials come from? How do they get to Fairfield Yard?
Where’s JMRI Come In? Plan your work… – See JMRI Part I & II Name each location Decide work to be done Decide cars required Consider process “loads” – “Custom loads” needed? – Location “schedules”? – Take one material – Make it work Work your plan… – Start simple with JMRI – Take baby steps Try it Test it Repeat it – Go to next step – Ask for help Use Yahoo Group Work with a friend
JMRI Tools Help Manual (“RTFM”) – Online part of JMRI Can print to pdf Keep it handy Currently about 40 pages Not always clear – Use Yahoo Groups JMRI Users Group Follow the rules – Subject “Operations” – Step by step – Be ready to copy files VERY helpful folks “Detailed” Build Report – LEARN to read the report Recipe to build a train Learn to read it – Always the same parts – Read in pieces – SCAN for parts – Your problem is there! – See what program does – Often becomes clear – Think like a computer – See left side of Screen!
Learn JMRI While You Have Fun! K.I.S.S. Rule – Don’t try “all at once” – Start out simple – Use Random switching Then pick ONE… – Industry – Process – “Next step” Get that to work Then do ONE more Birmingham District MRR – Focused “random" switching Passenger trains Interchange trains Downtown Industries – Staged trains – Local Switchers – Intermediate Yards – Build & break yard work – Multiple train logistics – Complex processes
Consider an Example Coal mine service Could use “random” E/L’s Mine is a “location” – Set it as a “spur” – Spur will “swap” loads – Empties in, loads out??? Set up a Mine Turn – From a (say) power plant – To your mine – Back again Should do the job… BUT, What about… – Different grades of coal? – Multiple mines? – A “next step” process? Add a coke plant – Material flows one way – Keep it moving? – Requires “restrictions” Conditions on cars Conditions on loads Schedules for cars/loads JMRI can do it!
JMRI Example – Get Started Download software Setup software Set preferences Set File Locations Add Ops to Menu Coal Mine #1 SW Power
JMRI Example – Create Coal Train Coal Mine #1 SW Power Power House to Coal Mine Create Locations – Coal Mine #1 – SW Power House Create Cars Create Route for “Turn” Place Cars – 3 at Mine – 3 at Power House Set Loads “Prime Pump” – Loads at Mine – Empties at Power House Restrict Loads – Mine services “Empties” – PH services “Loads” Create Train – Name train – Assign Route Build Train See what happened? Train Sheet Pwr Hse Coal Turn Depart Pwr Hse w Empties Work Coal Mine Depart Coal Mine w Loads Arrive Pwr Hse S/O Loads
JMRI Example - Locations Coal Mine #1 SW Power Power House to Coal Mine Create Locations – Coal Mine #1 & Spur – SW Power House & Spur Create Cars
JMRI Example – Create Cars Power House to Coal Mine Create Locations – Coal Mine #1 & Spur – SW Power House & Spur Create Cars Create Route for “Turn”
Coal Mine #1 SW Power JMRI Example – Create Route Power House to Coal Mine Create Locations – Coal Mine #1 – SW Power House Create Cars Create Route for “Turn” Place Cars
Power House to Coal Mine Create Locations – Coal Mine #1 – SW Power House Create Cars Create Route for “Turn” Place Cars – 3 at Mine – 3 at Power House Set Loads “Prime Pump” – Loads at Mine – Empties at Power House Restrict Loads JMRI Example – Place Cars & Loads
JMRI Example – Set & Restrict Loads Power House to Coal Mine Create Locations – Coal Mine #1 – SW Power House Create Cars Create Route for “Turn” Place Cars – 3 at Mine – 3 at Power House Set Loads “Prime Pump” – Loads at Mine – Empties at Power House Restrict Loads – Mine services “Empties” – PH services “Loads” Create Train
JMRI Example – Create & Build Train Power House to Coal Mine Create Locations – Coal Mine #1 – SW Power House Create Cars Create Route for “Turn” Place Cars – 3 at Mine – 3 at Power House Set Loads “Prime Pump” – Loads at Mine – Empties at Power House Restrict Loads – Mine services “Empties” – PH services “Loads” Create Train – Name train – Assign Route Build Train See what happened?
JMRI Example – Create & Build Train Successfully built train Imagine we ran the train WE moved cars WE might swap loads BUT the computer hasn’t YET… Have one more step TERMINATE TRAIN!
Let’s Review Planned “reason” for train “Work” for train to do “Locations” with “spurs” “Load options” on spur/loads “Cars” & placed them “Loaded” some of them “Route” “Train” “Built” and “terminated” Observed the results! Coal for power at SW’s Haul empties, loads, switch Places with “right” track Move coal in right direction Set up the game board Prime the pump Define “railroad” for JMRI A way to move “cars” Puts database to work Database moves cars/loads
B Birmingham District MRR – HO Scale – Digitrax Control – 33’x12 + ’ + 10’x14’ = 550 sf – Folded dog-bone w/ 5 branches
Typical Delivery Scenario Mine to Mill Session Time (“A Day”) Red Mtn. FY MTs In Processed Ore Out Switching Time COAL Raw Mat’l In Slabs Out Trains per day? Steel Works (SW) Fairfield Yd. (FY) Trains per day? Ingots In Slabs Out (BF) Iron Ore, Coke, Dolomite (BM)Slabs from Bl’mg Mill (BF) Slag, Hot Metal (OH) Scrap, Ingots, Slag LDs In MTs Out Amount needed per train: 6 cars iron ore 1 car dolomite 5 cars coke Coal Br. (CB) (DT) MTs In Coal Out Switching Time Trains per day? (L&N) CB Turn (TCI) RM Switch, then RM Turn (TCI) SW Turn (TCI) SW Switch Source Downtown Yard (DT) Fairfield Yard (FY) PROCESSED IRON ORE Trains per day? DT MTs In TCI Dolomite Out Switchin g Time DOLOMITE (L&N) DT Switch Quarry Train Steel Works (SW) Iron Ore Mines Process Plant Coal In TCI Coke Out Switching Time DT Trains per day? COKE (L&N) CP Turn Coke Pl. (CP) Coke Plant Switching Fairfield Yd (FY) Switching Time DT Trains per day? DOLOMITE COKE (TCI) FY Turn
Coke Plant Turn (L&N) – Downtown Yard – Switches coke plant Coal in (via Downtown Lead) Empties in plant Coke out (via Main Line) – Returns to Downtown Yard COKE PLANT DT YARD
FY to DT Turn – Precedes SW Turn – Coke and dolomite at DT Loads to FY Empties to DT – Products out of Steel Works Products for market to DT DT YARD FY YARD Scrap Slabs Rails
Red Mtn. Turn – Requires trackage on L&N – Iron ore to FY – Follows RM Switch Mines Processing (sinter) Plant FY YARD RED MTN MINES YD Track
Steel Works Turn – Serves Blast Furnaces 3 grades ore, coke, dolomite Clears stock trestle Fills stock trestle – Classify at FY by type/load – Precedes Red Mtn Turn FY YARD BLAST FURNACES
Steel Works Switch (TCI Plant RR) – Advances materials thru plant BF Hot Metal to OH Mixer Scrap to OH Ingots to Blooming Mill Slag to dump Blooming Mill to Rolling Mill STEEL WORKS
Birmingham District MRR Logistics work sheet What trains need to run? Set up Ops Session – Status of materials – Loads & empties – Status of hopper fleet Blast Furnace Supply Coal to Coke Lime- stone Hopper Car Status
Birmingham District MRR Passenger Trains Interchange Trains Material Trains Sequence of material trains varies depending on need for materials at time of ops session For Ops Session
Birmingham District Operations TRAINS CARS LOCATIONS MAIN LINE TURNOUTS
What’s Next for YOU… Develop your steel story What to “include” – Space available – Interest/time frame – Be creative – What’s the train crew “see” At plant Away from plant Tie to rest of world Expect to run trains Expect to make changes Engage your friends Where, what, how Defines operations – Techniques of our hobby – Make your story fun for YOU – Operation goals are “different” – Track, “walls”, cars… Plant work Materials in, products out Check your “story” Fun as you go! Learn as you go! You will enjoy their fun, too!