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Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 1
12/18/2012
Listen, Learn, Discuss, Share, Experience, Practice… and Enjoy!
Mastering Surface Drilling & Blasting Cuzco
12/18/2012
DRILL MONITORING AND GUIDANCE SYSTEMS
Don Thompson,
Thunderbird Mining Systems
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 2
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
12/18/2012
The Mining Sequence
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 3
12/18/2012
Drill the Pattern
12/18/2012
Load or Charge the Holes
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 4
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Fire & Blast
12/18/2012
Load or Move Ore/Overburden
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 5
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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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 6
12/18/2012
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
12/18/2012
Drill Monitors
ROP Depth
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 7
12/18/2012
Drill Monitors
• Operator Display:– Depth
– Average ROP
– ROP Graph
– Drill Time
– Time to Complete
– Distance from Bottom
12/18/2012
Other Features
• Shift & Production Statistics:– Total holes
– Total depth
– Average depth
– Average ROP
– Average drill time
• Alarms for depth & ‘pipe in hole’
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 8
12/18/2012
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
12/18/2012
COTS--Components off the Shelf
• Benefits:
– Multiple sources
– Not a proprietary design
– Quicker delivery
– Don’t become obsolete
– Lower cost components
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 9
12/18/2012
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.
12/18/2012
Operator GUI
• Better graphics
• Easy to customize
• Multi-languages
• Warnings:
– Overdrilling
– Pipe-in-the-Hole
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 10
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 11
12/18/2012
Remote Access
12/18/2012
Drill Pattern Design
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 12
12/18/2012
Ore Identification & Hardness Data
12/18/2012
Drill Bit Information
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 13
12/18/2012
Load Holes Based on Drilling Data
12/18/2012
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)
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 14
12/18/2012
Fire
12/18/2012
Cameras for Better Safety &
ProductivityCameras Strategically Located
Integrated into Operator Display
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 15
12/18/2012
Radio Remote Drilling
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 16
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 17
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 18
12/18/2012
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
12/18/2012
Multiple Languages
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 19
12/18/2012
Pattern Viewing
12/18/2012
Section View of Pattern--Drilling
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 20
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3D View of Pattern
12/18/2012
Drilling, Reaming and Moving
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 21
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Standard Database Reports
12/18/2012
Standard Database Reports
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 22
12/18/2012
Standard Database Reports
12/18/2012
Standard Database Reports
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 23
12/18/2012
Validation of Hole Positions
12/18/2012
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 24
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 25
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 26
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 27
12/18/2012
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?
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 28
12/18/2012
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
12/18/2012
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
– Fleet savings (4 drills): $179,760/year
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 29
12/18/2012
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
– Fleet savings (4 drills): $210,240/year
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 30
12/18/2012
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
12/18/2012
Bingham Canyon Drill Productivity—
Ft/Drill/Shift
+53%
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 31
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 32
12/18/2012
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
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 33
12/18/2012
GPS System for Draglines or
Shovels
12/18/2012
Diggability Index
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 34
12/18/2012
Drilling Index Combined with
Digging Index
12/18/2012
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
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 35
12/18/2012
12/18/2012
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.
Don Thompson - Drill Monitoring & Guidance Systems
18-12-2012
The Mining Forum – Mastering Drilling and Blasting 36
12/18/2012
QUESTIONS??
12/18/2012
Thank you!