Case Study: BHP Billiton achieves optimized, automated train loading with Honeywell

BHP Billiton Optimizes Train Loading Performance at Australian Coal Mine

BHP Billiton’s Mt. Arthur coal operation needed to move from a manual, operator‑controlled Train Load‑Out (TLO) process to a fully automated, unmanned system that improved loading consistency, reduced safety risks and met SIL2 safety requirements. Honeywell was engaged to deliver an upgraded, SIL2‑rated Train Load‑Out solution (TLO) integrating with existing site infrastructure and sub‑systems such as SCADA/HMI, train speed and weight detection, wagon monitoring and rail operator interfaces.

Honeywell implemented an inline, largely automated TLO control system—adding and replacing third‑party equipment and providing HMI/SCADA control, automated conveyor magnet cleaning and coal sampling, video monitoring and safety‑rated wagon under‑load/spill detection. The solution required minimal operator intervention, was deployed with only short outages, and delivered measurable benefits: loading accuracy improved to about 0.5% (vs typical 2–5% manually), penalties from the rail operator were avoided, manning and operating costs were reduced, and overall safety and productivity were increased.

BHP Billiton