Don Thompson - Drill Monitoring & Guidance Systems

Don Thompson - Drill Monitoring & Guidance Systems

18-12-2012

The Mining Forum – Mastering Drilling and Blasting 1

12/18/2012

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Mastering Surface Drilling & Blasting Cuzco

12/18/2012

DRILL MONITORING AND GUIDANCE SYSTEMS

Don Thompson,

Thunderbird Mining Systems


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12/18/2012

Topics

• The Mining Sequence and why drilling and blasting are critical

• Drill Monitoring and guidance systems

• Reporting

• Cost analysis and benefits

• Future developments

• Conclusion

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The Mining Sequence


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Drill the Pattern

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Load or Charge the Holes


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Fire & Blast

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Load or Move Ore/Overburden


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Why Drilling & Blasting are critical?

• Start of the mining sequence:– Can have a positive or negative impact on entire mining

sequence including:• Cost of explosives

– Over or under fragmentation impacts

» Loading and hauling rates

» Crushing—additional energy

• Bench conditions:– Additional shovel, truck and tire maintenance

– Bench preparation

– Future drilling and blasting results

• Total mine throughput and costs

If you don’t measure it and provide data,

how are you going to improve it

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Who Needs the Data & Information

• Operators: How can you expect him to improve if he has no idea what he is doing—drilling by the ‘seat of his pants’

• Drilling supervisors/managers: monitor performance and take corrective steps to improve performance

• Blasting engineers: use drill data to more accurately load and improve blasting

• Senior management: better visibility on D&B


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Types of Drilling Systems

• Drill Monitors: provide information to operators

• Data-loggers:– Above features

– Records information for analysis

– Data can be stored in an open database

– Application Software provides management and analysis of data

• HPGPS Guidance systems:– Above features

– Pattern maps for tramming between holes

– Calculates target depth based on drill elevation

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Drill Monitors

ROP Depth


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Drill Monitors

• Operator Display:– Depth

– Average ROP

– ROP Graph

– Drill Time

– Time to Complete

– Distance from Bottom

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Other Features

• Shift & Production Statistics:– Total holes

– Total depth

– Average depth

– Average ROP

– Average drill time

• Alarms for depth & ‘pipe in hole’


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Drill Data Logger

• Logs:– Drilling and sensor information

– Operator ID

– Hole and pattern numbers

– Delays

– Drill stem/consumable information

– Pre-shift inspections

• Off-loading:– Radio, USB stick, PDA

• Office database for reporting

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COTS--Components off the Shelf

• Benefits:

– Multiple sources

– Not a proprietary design

– Quicker delivery

– Don’t become obsolete

– Lower cost components


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Sensor Manager

• Sensor Manager Option:

– Pull-down pressure

– Torque

– RPM

– Air pressure

– Relays & switches

• Provide accurate gauges

• Record drill KPIs

• Used to calculate specific energy or

other drilling/blasting indexes for

blasting, etc.

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Operator GUI

• Better graphics

• Easy to customize

• Multi-languages

• Warnings:

– Overdrilling

– Pipe-in-the-Hole


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Other Product Features

• SQL database for reporting

• Standard suite of drill reports and the ability to create custom

reports or inquiries

• Remote support and troubleshooting over the internet

• Supports uploading of pattern maps to display hole locations,

target depths, etc. Will then log actual hole data against the

planned holes

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Remote System Support

• System capabilities:

– View the operator GUI

– Text operator

– Take control of system

– Interrogate the system

– Troubleshooting

– System upgrades

Mine

Corporate

Office

Server

Mine

Corporate

Office Server

Mine

Office

Server

Internet

Mine’s

Dedicated

Network

Mine’s

Wi-Fi

Network


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Remote Access

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Drill Pattern Design


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Ore Identification & Hardness Data

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Drill Bit Information


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Load Holes Based on Drilling Data

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Blasting Data

Soft

20’ stemming

0.657#/Ton

Medium

18’ stemming

0.714#/Ton

Hard

16’ stemming

0.771#/Ton

SOFT

0 7000MEDIUM

7000 9500

HARD

9500 >1100

Specific Energy:

Energy required to crush a given volume of rock.

(ft-lb/ft-in2)


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Fire

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Cameras for Better Safety &

ProductivityCameras Strategically Located

Integrated into Operator Display


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Radio Remote Drilling

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Integration with Fleet

Management SystemsBenefits:

• One database for reporting

• One configuration table:• Equipment

• Operators

• Delays

• Pre-shift checks

• Real-time feedback to dispatcher• Status of drills

• Location of drills

• Status of patterns—Number of holes

remaining to be drilled


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Drill Guidance Systems

• Includes all features and options of the monitoring & data logging systems

• Uses HPGPS for navigation between holes and patterns

• Pattern and drill data transferred via mine’s Wi-Fi network

• Provides cm accuracy

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GPS Receivers & Antennas• Single HPGPS Receiver

– Reduces cost— save one receiver

– Employs 31 USGPS and 24 Glonasssatellites

• GPS Antenna Location

– No longer on top of mast

• No custom masthead brackets

• Reduce installation time

• Less maintenance

• Easier to service

• GPS signal while tramming

with mast down

Cab Handrail Mount

Cab Roof Mount


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Hole Position (X & Y)

• Pattern maps provide X-Y position of all the holes on bench or ramp

• No surveying required

• Provides any special instructions for each hole, i.e. redrill

• Hole data shared between drills

• Shows no entry or danger areas

• Benefits:• Faster tramming between holes

• More accurate hole positioning

• No limitation due to darkness or weather

• Logs actual drilled positions & depth

• Improved blasting

• Save cost of surveying

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Drill to Elevation (Z)

• System calculates elevation of drill bit

• Pattern maps provide elevation of new bench

• System then calculated the drill depth (meters or feet)

• Provide a target depth to operator

• Benefits:

• No guessing on depth—spelled out for the operator

• Benches are drilled to the design elevation

• More accurate blasting

• Bench are leveling

• Less wear & tear on equipment—lower maintenance costs

Calculated

drill depth

New Bench


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Drill Azimuth/Mast Angle

• Critical in angle drilling or cast blasting to

have the correct mast angle & to have

the drill aligned or oriented properly

• If holes are not drilled parallel & at

proper angle, major impact on blast

• Pattern map shows azimuth and mast

angle for each hole

• Benefits:– Displays very accurate compass heading

– Helps operator to align drill

– Insures holes are drilled parallel

– Improves blasting

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Multiple Languages


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Pattern Viewing

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Section View of Pattern--Drilling


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3D View of Pattern

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Drilling, Reaming and Moving


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Standard Database Reports

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Validation of Hole Positions

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Non Conformance in Drilling

Drilled short

Drilled long

Price of non conformance includes

• Cost of wasted drilling

• Cost to back fill

• Damage/lost coal

• Cost of extra dozing to expose coal Toe

• Potential for redrills

• Poor Fragmentation

DrilledDesign

Source : DBS Production Reporter

Dri

lle

d D

ep

th –

De

sig

n

De

pth

Drilled Short =1,195 meters

Drilled Long = 262 meters

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Parameter Controlled By CommentCollar Horizontal Position (X,Y) Driller Horizontal distance and direction from Design

collar location

Collar Vertical Position (Z) Topography/Pad

Preparation

Vertical distance from Design Collar elevation.

Drill Depth Driller Affects Drilling and Blasting on Current and Future

Benches.

Drill Angle (Dip) Driller

Drill Bearing (Azimuth) Driller

Bit Diameter and Condition Driller

Drill Productivity Driller Pulldown Force

RPM’s

Feed Rate

Delay Times

Perceived Productivity Driller Accuracy of Reporting (Manual Records)

Drill Production Parameters

Drill Hole Parameters


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How to Improve Drill Hole Accuracy

• Provide operators with the tools to allow him to do his job better:– Well designed patterns

– Accurate surveying

– Monitoring systems

– Navigation systems

• Monitor & improve the drillers’ performance:– Measure & evaluated with reporting tools

– Training

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Corrective Actions when Variations

Detected—Short-term• Hole not within tolerance--location or depth:

– Re-drill the blasthole

– Adjust the blasthole firing time based on the actual hole position relative to the firing plan. This approach may require electronic timed detonators

• Encounter unexpected rock type or hardness:

– Adjust the explosive type and quantity based on the rock type encountered within the blasthole

– Other techniques (such as decking) may be utilized if the rock type varies significantly within the blasthole or across the pattern


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Corrective Actions—Long-term

• Design blast with final topo data: clean bench (HPGPS can compensate for bench elevation—drill target elevation)

• When angle drilling: understand limitation on locating drill

• Improve quality of models used for blast design

• Train drillers on need for accurate drilling

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Drilling Performance

Pen Rate

(m/hr)

Tracking the trend of drilling penetration rate may be an indicator of process

improvement , easier drilling, or an indicator of a non-conformance

Date


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Drill Bit Performance

When should a drill bit be retired? Is the trend curve

an indicator of expected performance? Can better drill

bits be developed using this data?

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Cost Benefit Analysis

• Assumptions:– No. of drills: 4

– Days of operation: 365

– Availability/capacity: 70%

– Operating costs: $150/hour

– Production rate: 100 ft./hour

– Average bit cost: $3100

– Bit life: 15000 ft.

– TOTAL DRILLING COST: $1.71/ft


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Increase Drill Productivity

• How: Less delays, higher ROP, less time trammingbetween holes, etc.

• Assumptions:– Total ft./year: 613,200

– Drilling cost: $1.71/ft.

– Increase in production: 5%

– New drilling cost: $1.62/ft. ($.09 savings)

– Total savings: $55, 188/drill

– Fleet savings (4 drills): $220,752/year

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Reduce Overdrilling

• How: Provide operator with depth gauge, target depth alarm, drill to elevation with GPS

• Assumptions:– No. of shifts per year: 730

– Average hole depth: 46 ft.

– Avg. no. of holes/shift: 18

– Overdrilling per hole: 2 ft.

– Overdrilling per shift: 36 ft. (26280 ft./year)

– Savings per drill: $44,940



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Reduce Surveying Costs

• How: Eliminate need to survey blasthole locations with the use of HPGPS guidance systems

• Assumptions:– Avg. daily man hours surveying: 4 hours

(based on 100 holes/day)

– Cost of surveyor: $100/hour

– Cost per hole: $4.00

– Holes drilled per year: 13,140

– Total savings: $52,560


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Lower Explosive Consumption

• How: Eliminate overloading and enable more accurate charge placement using strata information from drill monitors

• Assumptions:– Explosive used: 19 million pounds/year

– Cost @ $0.20/lb.: $3.8 million/year

– Savings of 3%: $114,000

– Savings per drill: $28,500/year


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Saving Summary

Drill Fleet

• Increase production: $55,188 $220,752

• Reduce overdrilling: $44,940 $179,760

• Eliminate surveying: $52,560 $210,240

• Reduce explosive costs: $28,500 $114,000

TOTALS: $181,188 $724,752

• Other potential savings: lower maintenance costs, longer bit life, or elimination of a drill

• Radio remote operation, and semi-autonomous or autonomous offer in greater potential savings

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Bingham Canyon Drill Productivity—

Ft/Drill/Shift

+53%


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Bingham Benefits--Summary

• Measure, record, and report on all drilling parameters: pull-down, torque, RPM, rate of penetration, etc:

– increase drilling rate

• Log and track all time and delays:

– drills spent more time drilling

• Increase total feet/meters drilled per shift

• Drilling Index for blasting

– Optimized powder distribution

• Monitor bits and all other consumables:

– reduce costs

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Minntac Productivity Increases

• Managing of delays:– Improved maintenance delay and fault information for

maintenance planning

– Decreased watering from twice to once a shift

– Service vehicle uses extra time to ready relief drills-drillers get drilling faster

– Relief drillers used during lunch when short on drills

• Increased average footage from 575 to 750 feet per 24 hours per drill


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Minntac--Benefits

• Improved drill productivity: 30% over 5 years (Combination of Drill Monitoring, Improved Drill Design, Drill Replacement Program)

• Improved fragmentation by optimizing powder distribution.

• Reduced number of blast complaints due to air blast: close to populated area

• Reduced number of labor grievances: drillers know what is expected of them

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Increased Drill Productivity-Navajo Mine

How:

• Increased ROP

• Reduced tramming time—more holes are drilled per shift

• Drill availability:

– Track delays and downtime

– Increased number of drilling hours

• Additional benefit—dramatically reduced surveying costs

Annual Drill Footage Changes

-10%

0%

10%

20%

30%

40%

50%

2002 2003 2004 2005 2006

Annual Change

CumulativeChange

Linear (CumulativeChange)

Overburden Drill Footage

0

500000

1000000

1500000

2000000

2500000

2002 2003 2004 2005 2006 2007

2007-- Annualized based upon 1st Qtr


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GPS System for Draglines or

Shovels

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Diggability Index


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Drilling Index Combined with

Digging Index

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Benefits of Better Analysis &

Integration of D&B Data• Reduced under/over-drilling;

• Increasing the accuracy of drilled hole locations;

• Identification of coal seams, and weak or strong strata & rock types;

• More accurate blasting, resulting in:– Less fly rock and lower vibration

– Better fragmentation and diggability

– Lower energy costs in digging and crushing

– Improvements in bench quality

– Reduced explosives costs

Bottom-line—increased production and lower mining cost


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Conclusion

• Significant improvements have been made in software and hardware:

– Standard data formats such as SQL

– Components of the shelf

– Data Radio systems

– GPS Systems

• Electronic collection of drill data can provide accurate information that can be used for making solid business decisions.

• Integrating applications provide for cost, productivity and quality control improvements.

• Product development continues.


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QUESTIONS??

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Thank you!

Don Thompson - Drill Monitoring & Guidance Systems

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