Blasthole Drilling

in Open Pit Mining

Third edition 2012

www.atlascopco.com/blastholedrills
Drill all day long

We wont even break a sweat

Your job is the first step in supplying the world with the power it needs.
And to do your job, you need to keep your mines safe and productive.
Atlas Copco designs and builds the blasthole drill rigs that help you reach
your goals.
More drilling time!
Our multi-pass rotary blasthole drills are well known for their durability,
mobility and speed. We make it possible to reduce time tramming, leveling
and changing pipe so you have more time to drill.
Providing the right balance of bit load,
rotary head performance, air flushing and
depth capacity results in economical and
high performance production. A variety
of options like angle drilling and cold
weather packages are available. But even
more important is how Atlas Copco can
improve your safety. Ask about the safety
enhancements and automation features you
can get from our Rig Control System (RCS.)

For more information visit:

www.atlascopco.com/blastholedrills
Facebook.com/AtlasCopcoRotaryDrills
Twitter.com/AC_RotaryDrills
Contents
Foreword
129 Penasquito powers up Gold/Mexico
2 Foreword by Brian Fox 133 Secoroc hammers go for gold Gold/Turkey
137 Advanced iron ore mining in Ukraine Iron/Ukraine
Talking technically 141 Steep wall open pit mining at Zhelezny Iron/Russia
145 Mining industrys new beginnings in Mongolia
3 From gunpowder to Pit Viper Coal/Mongolia
11 Ergonomics and safety 149 Coal mining in eastern Australia Coal/Australia
13 Personnel rig protection 155 The fuel cost killer of Queensland Coal/Australia
17 An introduction to surface mining 157 Boosting Siberian energy Coal/Russia
23 Putting rotary drilling into perspective 159 Hidden treasure beneath America's western prairie
29 Automated surface blasthole drilling Coal/USA
35 Taking advantage of single-pass drilling 163 Finding a perfect balance Coal/USA
37 Drilling at high altitudes 165 Moving mountains Coal/USA
41 Drilling in Arctic conditions 169 Cost busting Coal/USA
43 Tricone rotary blasthole drilling 171 Mining in Kazakhstan Coal & Gold/Kazakhstan
47 Optimizing the rotary drill string 173 Drilling for coal in Vietnam Coal/Vietnam
49 Increased productivity with DTH drilling
53
59
Selecting the right DTH drilling tools
Blasting in open cut metal mines
Product specifications
69 Fuel saving clutch 175 Drilling methods guide
71 The mid-range Pit Viper 235 179 Specifications guide
75 Development through interaction 180 Blasthole drill rigs
79 The large Pit Viper 310 series 211 Drill rig options
83 Large diameter drilling 236 Compressors and boosters
87 The economic case for routine bit grinding 239 Tricone rotary blasthole drilling
91 Secoroc Jazz 246 Bit selection
250 Sealed bearing
Case studies 255 When to change a bit
256 How a rock bit drills
93 Aitik eyes top three efficiency Copper/Sweden 258 Importance of records
99 Asarcos choice: both diesel and electric Copper/USA 260 Air practices
101 Reopening of Copper Mountain Copper/Canada 270 Rock formation & drillability
103 Radomiro Tomic prioritizes service Copper/Chile 273 Guides for best bit performance
105 Automation at Escondida Copper/Chile 276 DTH hammer specifications
107 Ambitious target at Esperanza Copper/Chile 280 Secoroc grinding tools
109 Raising to the altitude challenge Copper/Chile 288 Service and training
115 Innovation through interaction Gold/USA 295 Glossary of terms
117 Unforgiving ground Gold/USA 300 Where to find us
119 Community-friendly mining Gold/Canada For latest updates contact your local Atlas Copco Customer
123 Drilling reliability at Veladero Gold/Argentina Center or refer to www.atlascopco.com/blastholedrills

Produced by: Atlas Copco Drilling Solutions LLC, PO Box 462288, Garland, TX 75046, USA, Phone +1 972 496 7400.
Publisher: Ulf Linder, ulf.linder@us.atlascopco.com
Editing team: Cecilia Einarsson, Diane Norwood, Elisa Davidson, Gunilla Lindberg, Justin Cocchiola, Marino Wallsten, Matthew Inge,
Torbjorn Viberg, Ulf Linder.
Adviser: Dustin Penn, dustin.penn@us.atlascopco.com
Contributors: Brian Fox, Clarence Zink, Bo Persson, Dustin Penn, Gunnar Nord, Jim Langford, Tyler Berens, Jon Torpy, John Stinson, Leif Larsson,
Maureen Bohac, Morgan Penn, Rick Meyer, Sverker Hartwig, Ted Aikman, Tyler Berens, all name.surname@country code.atlascopco.com
William Hustrulid, Hans Fernberg, Kyran Casteel, Scott Ellenbecker, James Lawrence, Mark Stewart, Adriana Potts, Joseph Bradfield, Sara Schmuck.
Digital copy of Atlas Copco reference edition can be downloaded at www.atlascopco.com/blastholedrills.
Reproduction of individual articles only by agreement with the publisher.
Layout: Rafaella Turander, ahrt informationsdesign, rebro, Sweden, turander@ahrt.se
Printed by: Executive Press, Richardson, Texas, www.executivepress.com

Legal notice
Copyright 2012, Atlas Copco Drilling Solutions LLC, Garland, Texas, USA. All rights reserved.Atlas Copco is committed to comply or exceed all
applicable laws, rules and regulations. Photos in this publication may show situations which complies with such laws, rules and regulations in the
country where the photo has been taken but not necessarily in other parts of the world. In any case think safety first and always use proper ear,
eye, head and other protection to minimize risk of personal injury. This publication, as well as specifications and equipment, is subject to change
without notice. All Atlas Copco product names (including but not limited to Pit Viper, ROC, COPROD, TEAMALLOY, SmartRig, SmartROC, COP and
Secoroc) are registered trademarks or trademarks of one or more Atlas Copco Group companies.

Blasthole Drilling in Open Pit Mining 1

 Foreword

Blasthole Drilling
Open pit mining technology continues its evolution, as seen everywhere
at MINExpo 2012 in Las Vegas. Atlas Copco prides itself in being at the
forefront of blasthole drill automation with our proven Rig Control System
in Open Pit Mining (RCS). We have many of the building blocks in place for autonomous drilling,
and extensive plans to tie everything together for a safe, reliable solution that
is designed to be a integrates seamlessly into the mines communications infrastructure. We will
comprehensive refe- stay on target and execute these plans.

rence on the applica- We will also stay on target with our efforts to continually improve the safety
of our machines. Safety First is our approach within our factory and engi-
tion of rotary drills neering teams. One such example is our project to fit a multitude of local
in surface mining Australian options (known as J4) at our facility in Texas; this is proving very
successful. These options are designed to yield improved operation and main-
applications, plus tenance of the machines, with the goal of further improving safety perfor-
mance. We anticipate that more markets will adopt these options in the future.
an overview of the
current product Despite economic uncertainty in the world as this Third Edition is released,
we find the mining industry running at a high level. We are proud to be a part
offering from of it, and are working hard to introduce new products such as the Pit Viper
311 and continually improve our sales and support capabilities worldwide.
Atlas Copco. Our singular focus is blasthole drills for open pit mining. Its all we do.

We hope you enjoy this third edition.

Brian Fox
Vice President, Marketing
Atlas Copco Drilling Solutions LLC
brian.fox@us.atlascopco.com

2 Blasthole Drilling in Open Pit Mining

 Talking Technically

From gunpowder to Pit Viper

Drilling and blasting
The rotary blasthole drilling rig
was a long time coming. Gun-
powder was invented in China
about 1000 A.D. But in Europe at
least it took another 500 years or
more before miners started to use
it for blasting and a further three
centuries for the introduction of
mechanized drilling in surface
mines. Mobile blasthole drilling
rigs have been in use for only
some sixty years.

Gunpowder
The application of blasting agents
apparently began in Hungarian mines
sometime during the sixteenth cen-
tury. To make better use of the explo-
sive force, miners started to place the
powder in holes and it is certain that
drilling and blasting were used in sev-
eral German and Scandinavian mines
early in the seventeenth century, for
instance at the Nasafjll silver mine in
Lappland in 1635, and in 1644 at the
Rros mine in Norway.
One-man drilling with the help of
a drill steel and sledgehammer was
the established technology used in the
Drilling with sledgehammer was the established
method before the development of the rock drill.
The Pit Viper is designed for production drilling of large holes in hard rock conditions.
eighteenth century. This physically
demanding technique evolved only
slowly but, despite the mechanization
of other industries, remained in quite
widespread use until well into the
twentieth century. However, powered
drills did start to mount a challenge in
the 1800s, the competition in the USA
being symbolized by John Henry who
in 1870 hammered through 14 feet in
35 minutes while the steam drill only
completed nine feet.
The first patented rock drilling ma-
chine was a steam driven percussion
drill invented by J. J. Couch in Phila-
delphia in 1849 but it may have been
preceded by a machine manufac-
tured by the Scottish engineer James
Nasmyth ten years earlier. This patent
spurred a period of rapid development,
accelerated in the 1860s by Nobels
inventions of the blasting cap and
safe dynamite explosives. From 1850
to 1875 some 110 rock drill patents
were granted to American inventors
and seven for drill carriers while 86
patents were issued in Europe during
this period.
In 1851 James Fowle, who had
worked with Couch, patented a rock
drill that could be powered by steam
or compressed air and could rotate the
drill steel by means of a ratchet wheel
controlled by the piston's back-and-
forth movement. In the 1860s large
scale rock drilling machines were built
for tunnelling by engineers in Europe
and the United States. One of the most
successful of these early rock drills
was the second refined version of the
Burleigh rock drill, which was put into
service in October 1866 at the Hoosac
tunnel in Massachusetts. The perfor-
mance at this tunnel project showed
that rock drill development had taken
the step from an experimental product
to a proven and rather reliable technol-
ogy.
In 1871 the American inventor Simon
Ingersoll patented a steam powered rock
drill, later to be operated on compressed
air. Ingersoll formed the Ingersoll Rock
Drill Company in the same year. During
the following year Ingersoll purchased
the Fowle-Burleigh patents and also
merged with the Burleigh company.

Blasthole Drilling in Open Pit Mining 3

 Talking Technically

In 1871, a number of patents were issued to the

inventor Simon Ingersoll, who started the Inger-
soll Rock Drill Company The machine produced
by Ingersoll was at this time regarded as the best
rock drill yet produced, and it was followed in
the mid 1880s by another success, the famous
Ingersoll Eclipse machine. The Ingersoll rockdrill was a simple and strong design with few moving parts.

The new compact rock drill launched by
Ingersoll was a simple and strong design
with few moving parts. The designers
had kept in view the tough conditions
in which the rock drill had to work, and
the contemporary technical opinion
regarded his new rock drill as the best
yet available on the market. During the
years to come Ingersoll bought out many
small firms and expanded his company.
The Ingersoll Rand name came into
use in 1905 through the combination of
Ingersoll-Sergeant Drill Company and
Rand Drill Company.
The AB Atlas enterprise had been
founded in February 1873 at a time
when the Swedish railway net was
being rapidly expanded. Three years
later, now with 700 employees and the
Stockholm shops completed, AB Atlas
had delivered more than 600 railway
wagons. Diminishing demand from the
railroad sector, combined with years of
losses, led to a reconstruction in 1890.
During the years to follow new product
lines were added, including compressed
air tools, compressors, diesel engines
and the first Atlas rock drill which was
launched in 1905.
it was very heavy for manual use.
Immediately and for the next 25 years
Atlas focused on light weight hand
rotated drills like the Cyclop, Rex,
and Bob. The real Atlas winner among
lightweight hand-held rock drills was
the RH 65 from the year 1932. This
machine had more efficient shank and
chuck designs for better steel guidance
and longer shank life. Used with the
new pusher leg feed system developed
in the 1930s, the RH 65 was the most
important element in what was later
to become known as the "Swedish
method" of underground drilling.
In the United States Ingersoll-Rand
expanded into pneumatic tools in 1907
by acquiring the Imperial Pneumatic
Tool Company of Athens, Pennsylvania.
In 1909 the company bought the A.S.
Cameron Steam Pump Works and en-
tered the industrial pump business.
Ingersoll Rand also acquired the J.
George Leyner Engineering Works
Company. This firm had developed a
small, pneumatic hammer that could be
operated by one man. This Jackhamer
introduced in 1912 became a popular
item, and the company progressively
developed the design as well as sup-
plying compressors to the expanding
construction and mining industries in
North and South America
Rock drilling tools
The parallel improvement of drill steel
quality had started during the 1890s

Further development
The design of the first Atlas rock drill
featured an advanced rifle bar rota- The first drill made by Atlas "pneumatic rock drill No. 16" had a weight of 280 kg (617 lb) and was heavy
tion but with a weight of 280 kg (617 lb) and difficult to handle - at least two men were needed to move it.

4 Blasthole Drilling in Open Pit Mining


with development of heat treated drill
steel that could better resist deformation.
But sharpening the tips required exten-
sive haulage of tons of drill steel between
drilling sites and the work shops. The
detachable drill bit was developed in
1918 by A L Hawkesworth, a foreman
at the Anaconda copper mine in Butte,
Montana. The first versions used a dove-
tail joint to the drill steel while later ver-
sions were threaded or tapered. The rods
were retained at the workings and used
with new or re-forged bits.
In Europe during the German col-
lapse in 1918 a team was formed at
the Osram lamp factory to develop
cemented tungsten carbide as a substi-
tute for industrial diamonds. In 1926 the
first cemented tungsten carbide became
available as a magical machine tool
for turning and milling operations. Early
tests were made in 1928 trying to use
tungsten carbide bits for rock drilling in
German mines and before World War
II promising results were obtained. By
this time the research team had scattered
and some members had been forced to
leave the country. One of these, Hans
Herman Wolff, found refuge in Sweden
where he worked at the Luma lamp fac-
tory. Dr Wolff manufactured a number
of bits according to designs provided by
Erik Ryd at Atlas.
The bits were tested in the Atlas
test mine. In 1942 Atlas, Sandvik and
Fagersta signed a cooperative agree-
ment and it was not until 1945, after a
long improvement process, that the new
cemented tungsten carbide drill bits
were as economical to use as conven-
tional steel bits.
The post-war years saw Atlas achieve
further major advances. In 1948 the com-
pany introduced an RH 65 upgrade, the
RH 656, which was designed to use the
new cemented carbide tipped drillsteels.
The superior performance of the Light
Swedish Method was exploited world-
wide and culminated in 1962 with the
completion of the Mont Blanc tunnel.
With development of highly mecha-
nized drill rigs and with the introduc-
tion in 1973 of the COP 1038 hydraulic
top hammer drill Atlas Copco laid the
foundation to become a world leader in
top hammer drilling technology. (See
article from wagon drill to SmartRig,
Surface drilling, Fifth Edition 2012).
Blasthole Drilling in Open Pit Mining 5
Talking Technically
The US patent for a dual roller cone bit was issued to Howard Hughes Sr. in 1909.
Rotary bits the best alternative. However, as drillers
sought to use the rotary system for pro-
Rotary drilling with drag bits was the gressively harder rock formations so
common method used in oil drilling. the feed force (pulldown) available had
These bits were suitable when drill- to be increased. Roller cones with long
ing in soft formations like sand or steel teeth were used in softer forma-
clay but not in rock. The solution for tions for gouging the formation while
drilling large diameter holes in rock roller cones with shorter teeth were
was by using rotary crushing technol- used for crushing and spalling harder
ogy instead of trying to cut hard rock formations.
with drag bits. The roller cone bit was
developed by Hughes and Sharp, and
the US patent for a dual roller cone
bit was issued to Howard Hughes Sr.
in 1909. This new type of bit had two
interlocking wheels with steel teeth,
and penetrated the rock by crushing
and chipping. The success of the new
bit led to the founding of the Sharp-
Hughes Tool Company, and after
Sharp's death in 1912 the name was
changed to Hughes Tool Company.
The company continued develop-
ment of the roller cone bit and in 1933
The Secoroc Omega sealed bearing tricone bits
two Hughes engineers invented the
are now regarded as the ultimate blasthole bit
tricone bit. This bit had three conical solution.
rollers equipped with steel teeth.
Drilling was accomplished by trans-
ferring a pulldown force to drive the A parallel development of the tri-
teeth into the hole bottom. The three cone bits made it possible to use these
roller cones turned as the drill string high loads on bits. To extend the life of
was rotated, and the teeth crushed and the bits in hard and abrasive rock the
spalled the rock. steel teeth were replaced by cemented
While tophammer drills could be tungsten carbide inserts. Tungsten car-
used for small blast holes in rock, this bide inserts have significantly in-
method was not suitable for large hole creased the number of blast holes that
diameters; for these rotary drills were the roller cone bits are able to drill.
 Talking Technically
Big picture; Airpowered DM-3 with a DRD-2 Rotary head from the late 1950's. Inset; Tractor mounted
Drillmaster, air powered with a DRD Rotary Head from the early 1950's.
Improvements in materials have con-
tinued to increase the life of the bear-
ings so the cutting structures can be
fully utilized. While the geometry of
the roller cone bit is much the same as
the original bit patented in 1933, the
material and technology currently uti-
lized is cutting edge.
Downhole drilling
technology
Meanwhile, manual lightweight pneu-
matic drills had also underpinned the
expansion of bench mining in open cut
mines and quarries. But in the 1930s
The Quarrymaster from 1948 was equipped with a huge 8" bore drifter.
6 Blasthole Drilling in Open Pit Mining
downhole drills (DHDs ) were intro-
duced for drilling deeper holes. The
main initial development of this tech-
nology took place in Belgium and the
United States. Atlas designed a down-
hole unit in the mid-thirties that was
used with good results in two Swedish
limestone quarries until the 1950s but
the company then ceased further DHD
development, only re-entering the
market in 1969 with the COP 4 and COP
6 down-the-hole hammers. Followed
by the valve less COP 32 42,52 and 62
from 1978, where still COP32 is in use.
In 1955 Ingersoll-Rand introduced a
new downhole drill design and started
to establish downhole drilling on a truly
commercial basis. The Tandematic,
which at the time was claimed to pro-
vide the highest drilling speed ever
attained by a downhole drill, was sup-
plied in two standard sizes the DHD
275 for 4* inch and 5 inch holes and
the DHD 1060 for 6 and 6 inch . This
later enabled the company to build drill
rigs adapted to be used either for rotary
drilling or with downhole hammers. The
main difference is that downhole drill-
ing requires more air, and consequently
these drill rigs had to be equipped with
a larger capacity compressor and a more
powerful diesel or electric engine.
Downhole drill technology went
through rapid change in 1960s and 70s.
In fairly rapid succession I-R developed
the DHD 325 ( their first 6" hammer),
DHD 325A, DHD 16, DHD 1060,
DHD 1060 A and B models, DHD 360
(all 6" drills) and corresponding larger
and smaller models, up to the current
line of DHDs. Probably the most sig-
nificant change in DHD technology
was the advent of the valveless DHD.
Drill efficiency and life dramatically
improved with the elimination of the
flapper valve. During the 90s the QL
series of hammers came with the unique
QL (Quantum Leap) design , a still valid
patent. This features makes it possible to
have the piston stroke pressurized 80%
of its distance compared with 50% for
other hammer design. The QL feature is
also used in the TD hammers series for
deep hole drilling.
Of course higher pressure and vo-
lume air from the air compressor advan-
cements produced the performance one
sees today. Re-entry to the downhole
drill market at 6 bar** in 1969 also ena-
bled Atlas Copco to take advantage of
improved air compressors and develop
more and more powerful downhole
hammers, reaching 18 bar in the early
1980s and more recently 25 bar and 30
bar in the larger current hammer sizes.
In the early 90s COP44, 54 and 64
where introduced by Secoroc. A series
of high performing hammers operating
at high air pressure. They were unbeaten
in blast hole drilling applications until
replaced by the COP Gold series in the
beginning of 2000nds.
*1 inch = 25.4 mm, **1 bar = 14.5 psi

Secoroc COP64 Gold downhole hammer.
Drill rigs
The mobilization of rotary and down-
hole drills was linked to significant
post-war changes in rotary drilling tech-
nology. Up until then rotary drilling
had been used in water well drilling and
surface mining using fluid circulation
to clean cuttings from the hole. Coal
mines were using rotary drilling in
soft overburden, removing the cuttings
with augers. In the late 1940s it was rea-
lized that air was an effective flushing
medium with considerable advantages
over water, doing a better cleaning job,
protecting the bits and eliminating the
difficulties of supplying water.
Experience also proved that air flu-
shing improved the penetration rate of
rolling cutter bits such as tricone bits
and extended their life. By using effi-
cient air flushing to keep the bottom
of the drill hole free from cuttings the
rock breaking process became more
efficient.
In 1948, Ingersoll-Rand entered the
large-diameter blast hole market by
launching the Quarrymaster. It really
was not a rotary drill, but a large self
propelled mounting in the 40,000 lb*
weight range, designed with on board
air and a long drill tower to drill 6 inch
to 8 inch diameter holes for mining
and quarry applications. The original
Quarrymasters were equipped with a
huge 8" bore drifter, know as the QD8.
This was a piston drill with the drill
steel attached directly to the drifter
piston. The blow frequency was in the
range of 200-300 blows per minute.
The drifter used a large rifle bar rota-
tion system. Achieving decent wear life
between the rifle bar and rifle nut was
sometimes a problem in tight ground.
This was a single pass drill system,
hole depth was limited by the tower
length. The steel system was a heavy
wall tubular product, in the range of 4"
Blasthole Drilling in Open Pit Mining 7
OD, and was extremely heavy. Since
there was no steel change, the weight
didnt seem to be much of an issue.
Quarrymasters were used in some
large iron mines in Canada and the
Atlantic City Iron Ore Mine in Wyoming.
Numerous Quarrymasters were used in
the rock excavation for the St Lawrence
Seaway in Canada.
In the same year also Atlas intro-
duced its first mobile rubber tired drill
wagons for top hammer drilling, but
these were not equipped with any tram-
ming machinery and were intended for
considerably smaller hole diameters.
I-R development work with downhole
drills in the early 1950s brought about
changes to the drill mounting business.
First, the Quarrymaster was equipped
with the newly developed QRD rotary
head, and this along with the new DHD
325 down hole drill, made for a produc-
tive but heavy and bulky package.
The Drillmaster design, a somewhat
smaller rotary drill, was introduced about
1955. It produced the same performance
as the Quarrymaster in a smaller and
less costly package. Upgraded versions
of the Drillmaster, the DM-1, DM-2
and DM-3 followed in quick succes-
sion. Originally equipped with sliding
vane air compressors up to 900 cfm**,
all were updated to the screw compres-
sor design. The Drillmaster line was
equipped with the DRD and later DRD 2
rotary head to provide drill string rota-
tion. As with the QRD rotary head the
DRD was powered by a vane air motor
and several steps of gear reduction.
All of these drills only used hydraulic
power, from an engine driven hydrau-
lic pump off the cam shaft, to oper-
ate the jacks, tower raising cylinders,
break-out wrench, and dust collector
drive motor. Neither rotary head was
*1 lb = 0.45 kg, **100 cfm = 42.2 l/s
Talking Technically
very useful in supplying straight rotary
power for tricone bits, hence the future
development of the T-4 and DM-4
with hydraulic powered rotary head for
straight rotary drilling. I-Rs first truck
drill was called the Trucm package.
The drill frame package was mounted
on a customer provided truck, often a
used Mack truck. However, none of the
standard truck designs proved very
successful. The normal channel truck
frames were not sturdy enough, result-
ing in many cracked and broken truck
frames. I-Rs answer to this problem
was to join hands with Crane Carrier
Corp of Tulsa, OK, and mount the drill
components and tower directly on an
I-beam chassis frame, often used for
mounting construction cranes. This
product became the TRUCM-3 and the
same style mounting carried over to the
T-4 and T4W introduced in 1968.
A major new stimulus for blasthole
drilling rig development generally was
the introduction in the 1950s of mil-
lisecond delay blasting. This allowed
blasters to design multi-hole large
volume blasts that could be used for
mass production techniques in open
The truck mounted T4BH was introduced in 1968.
 Talking Technically
The DM50 could use bit loads up to 50,000 lbf
and was launched in 1970.
cut drill and blast mines. In turn this
required the introduction of large,
mobile drilling rigs able to drill large
diameter holes using tricone bits, as
well as the formulation of cheap bulk
mining explosives based on ammonium
nitrate and nitro-glycerine. These and
other developments helped the mining
industry to keep the costs of bench
drilling substantially unchanged during
the 1950s and 1960s, despite increasing
wage costs.
The Quarrymaster and TRUCM ma-
chines were made progressively more
self-contained through the 1950s. By
the end of the decade the air supply was
up to 10 bar and the marketing slogan
Pressure is Productivity was promot-
ed. The drill rigs and rock drills were
sold together to maximize revenue but
this did encourage other manufacturers
to build competing rock drills.
Hydraulics technology
adds to drillers options
The similarities between the air requi-
rements of rotary and downhole drill-
ing made the design of rigs able to
do both an economically attractive
proposition. In 1965-66 Ingersoll-Rand
started work on the switch to hydraulic
powered rotation for rotary and down-
hole drilling, launching first the truck-
mounted T4W for water well drilling
in 1968. In the same year this rig was
modified to make a truck-mounted
blasthole rig with a 5-rod carousel,
the Drillmaster T4BH, which could
drill holes of up to 7 inch diameter
and was successfully offered for coal
mine drilling throughout the 1970s.
8 Blasthole Drilling in Open Pit Mining
The designers also used the power unit,
tower and other components to create
the crawler-mounted Drillmaster DM4
blasthole drilling rig. This machine
was designed from the ground up
for both rotary and downhole drill-
ing. A 36 ft* high tower incorpo-
rated a hydraulically indexed carousel
housing seven 25 ft rods. The rotary
head featured an axial piston hydrau-
lic motor and single-reduction worm
gear for rotation, providing 5.6 kNm
of torque and rotation speeds from 0
100 rpm. There was a choice of diesel
engine or electric motor for the spring
mounted f loating power pack and a
range of diesel or electric compres-
sors, enabling use of either rotary or
downhole drilling with the companys
DHD-15, -16 or -17 downhole drills.
The excavator style crawler undercar-
riage had tracks with 22 inch triple bar
grousers driven by hydraulic motor
through a planetary gear drive and
chain reduction.
In the marketplace the DM4 com-
peted with the more powerful electric
top drive blasthole drilling rigs. The
late 1960s and 1970s saw heavy take-
up of the DM4 rig by the Appalachian
coal mines in the United States. And
the combination of patented rig, drill
and drill rod technology was very
profitable for Ingersoll-Rand. The use
of hydraulic power for rotation and
non-drilling functions meant that more
air could be made available for rotary
and, especially, for downhole drilling.
This engendered an air race in the
late 1960s and 1970s. The independent
downhole drill manufacturers were
able to build machines that could drill
at 130 ft/hour in the 6 8 inch diameter
hole range faster than a rotary drill
could achieve in this hole size range,
particularly when drilling in harder
rock types.
The development of screw compres-
sors to supply air for drilling rigs at up
to 20.6 bar led to the 1970s introduction
of an airend to supply both low pres-
sure and high pressure air. These units
were used in portable air compressors
and also onboard drilling rigs, where
they enabled downhole drills to outper-
*1 ft = 0.304 m
**1,000 lbf = 4.44 kN = 453 kilogram-force
Rotary table and Kelly bar concept.
form rotary drills in the 6 - 8 inch
hole sizes in hard rock mines. However,
rotary drills were still better for rock
compressive strengths up to medium
hard limestone.
The higher pressures were also very
beneficial for water well drilling, in
which air pressure must be sufficient
to evacuate the ground water pressure
from the hole while drilling.
Expansion of the
Drillmaster range
Significant corporate developments and
one major product launch impacted the
Ingersoll-Rand drilling business in the
mid-1970s. Firstly, in 1973 the company
acquired DAMCO (Drill And Manu-
facturing Company) in Dallas, Texas,
who built mechanically driven pre-split
drilling machines for quarrying and
light coal stripping. These expanded
the Drillmaster range down to the
20,000 lbf* bit weight class. The rigs
also used the rotary table drive and kelly
bar concept, which lightened the tower
structure sufficiently to accommodate
rod long enough to drill 40 50ft holes
in a single pass if required. Ingersoll-
Rand added their own compressors to
create the DM20, DM25, DM25-SP
(single-pass), DM35 and DM35-SP
rotary rig models. Then, in 1975, the
company bought the Sanderson Cyclone
Drill Company in Ohio, USA, adding
12 models designed for the water well
market.
The next extension of the size class
range came with the launch of the
Drillmaster DM50 with 50,000 lbf of
weight on the bit. In this machine the

diesel engine drove the hydraulic power
pack from one end of the crankshaft and
the compressor was directly coupled to
the other. This concept was also used on
the next two drills to be launched. The
first one was a new crawler mounted
rig for rotary or downhole drilling, the
DM45 with 45,000lbf weight on bit.
This was followed by a conceptually
similar top drive rotary or DHD model,
the DM30 and a specialized rotary table
variant, the DM-35I, which was intro-
duced in the 1980s for drilling underwa-
ter in phosphate mines. It featured a dual
kelly system that allowed explosives to
be charged through the annulus between
the outer and inner kelly. The inner kelly
would then be removed for blasting.
Later the DM 40SPi was developed for
drilling and shooting deeper holes.
Development of large
blasthole drills
Towards the end of the seventies, the
company started designing drill rigs
more specifically aimed at the base
metal mining market, using power
pack concepts developed for deephole
drilling. So far, neither air-powered nor
hydraulic drive rotary nor downhole
drills had challenged the electric motor
top drive rotary rigs manufactured in
the United States for the 12 15 inch
diameter hole market.
These machines by now had very
high weights on bit in the range
100,000 120,000 lbf, partly due to
the weight of the electric motor for the
rotary head, but were not suitable for
live tower operation. Ingersoll-Rands
first response was in 1979 with the
development of the Drillmaster DM70,
able to drill 10 inch diameter holes in
metal mines and up to 12 inch holes
at coal mines using 8.6 bar air for
rotary drilling. And in 1979 the com-
pany launched the DM-H (Drillmaster
Heavy), the first truly modern large
blasthole drilling rig to be used for
low pressure rotary drilling of 9 7/8 -
12 1/8 inch holes with bit loads up to
90,000 lbf.
The DM-H used hydraulics for both
drilling and non-drilling functions
and featured a hydraulic propel exca-
vator type undercarriage with easily
replaceable grouser pads and in-line
Blasthole Drilling in Open Pit Mining 9
Talking Technically
components on the deck. It was equip-
ped with a rotary screw compressor
and a live tower with patented angle
drilling system. The tower pivot point
was flush to the drill deck and within
the dust curtain, reducing the length
of unsupported drill rod. It was an
all-purpose machine, with a single-
pass version added in the mid-1980's.
The machine has been upgraded over
the years although replaced by the Pit
Viper 351 for hard rock applications.
At much the same time the company
started to offer electric powered ver-
sions of the DM 45 and other models
if customers wanted them, for instance
for use in open pits where the other The DM-H, launched in 1979, could be used with
key equipment was electric powered. bit loads up to 90,000 lbf (400 kN).
However, although these machines
had electric motor power packs they
retained the hydraulic rotation system.
The first electric drill rig was the
DM7B delivered to Clarksburg in 1977,
followed a year later by the DM100
delivered to Rock Springs.
After recovery from the recession
of the early 1980s, Ingersoll-Rand
launched a medium range Drillmaster,
the DM-M designed for rotary drill-
ing of 9 7/8 inch holes with bit loads up
to 60,000 lbf. Three of the first four
DM-M's went into operation at Peabody
Energy's new Nor th Antelope &
Rochelle Mine in the Wyoming Powder
River Basin, now one of the two larg-
est coal mines in the world. Now, over
25 years later, the prototype DM-M is
still in operation. The machine featured The DM-M3 launched in 1992 is used for multi-
a carriage feed system with wire rope pass drilling in coal mining.
cables, resulting in a lighter tower and
lower center of gravity. Milestones in development
In 1989 this model was upgraded
Year Model Load on bit
to the DM-M2 on which maximum bit
load was increased to 75,000 lbf and 1948 Quarrymaster drifter
the hole size capability extended up to 1955 DM3 30,000 lbf
10 5/8 inch. Stability was improved as 1968 T4BH 30,000 lbf
well. In 1990-91 the company intro- 1969 DM4 40,000 lbf
duced the DML for multi-pass drilling 1970 DM50 50,000 lbf
to 180 ft hole depth.
1979 DM-H 90,000 lbf
This new model could drill from
6 to 9 7/8 inch (200 250 mm) diam- 1983 DM-M 60,000 lbf
eter holes in rotary mode, and 6 8 1990 DML 60,000 lbf
7 / inch using a downhole hammer.
8 1992 DM-M3 90,000 lbf
Following a development project based 2000 PV-351 125,000 lbf
on a customer consultation exercise the 2004 PV-270 75,000 lbf
DM-M3 was launched at MINExpo
2008 PV-235 65,000 lbf
1992. Designed primarily for deep
2012 PV-311 110,000 lbf
drilling of overburden for cast blasting
 Talking Technically
The first Pit Viper 351 was launched in 2000 and
used at the Morenci copper mine in Arizona.
in large coal mines, the first production
DM-M3 went into operation in 1993 at
Arch Coal's Black Thunder Mine, one
of the largest coal mines in the world.
For this new model, the designers rai-
sed bit load to 90,000 lbf and the hole
diameter range up to 12 inch while a
new patented cable feed allowed the use
of 40 ft long drill rods.
The launch of the Pit Viper
Although difficult market conditions
restricted investment in the mid-1990s,
during 1997 the company started work
on a new generation blasthole drilling
rig design.
To differentiate this new range from
the Drillmaster series, which initially
was designed for drilling large holes
in coal mining and soft rock, this new
series was - from the very beginning
- specified and designed for produc-
tion drilling of large holes in hard rock
conditions.
The first one out was the Pit Viper
351, which was successfully launched at
MINExpo 2000. Weighing 170 tonnes,
measuring 53 feet long, and equipped
with a CAN-bus control system with
seven on-board computers, the new Pit
Viper 351 was at that time the largest
and most advanced drill rig of its kind.
The advanced control system allowed
the drill pattern to be transmitted to
the drill rig via a radio network, and it
also featured production monitoring,
10 Blasthole Drilling in Open Pit Mining
The Pit Viper 235 was launched at MINExpo 2008.
rock recognition and a GPS navigation
system. A few months after the Minexpo
show, in April 2001, the PV-351 was put
to work at the Morenci copper mine
in Arizona for final testing and evalu-
ation. The mine had a fleet of 16 drill
rigs from a variety of manufacturers, so
in addition to the new rig being used for
drilling in the hard igneous rock condi-
tions, this was an excellent opportunity
for benchmarking the PV-351 with the
other brands.
The application required 12 inch
diameter single pass drilling of 57 ft
deep blastholes using up to 90,000 lbf
weight on bit (of the 125,000 lbf
capacity). The test was successful: the
PV-351 drilled some 2.2 million feet by
August 2004 at a recorded average rate
of 60,000 feet per month and in some
months even more than 80,000 feet per
month.
Later the same year the multi-pass Pit
Viper 275 was launched at MINExpo
2004. Based on the experience from the
PV-351, combined with customer con-
sultations, a project had been initiated
for development of the PV-270 series.
These drills were specified for a 75,000
lbf bit load capacity and were featured
a similar cable feed system and auto-
matic cable tensioning to that on the
larger PV-351. The multipass version
PV-275 with a 195ft depth capacity was
delivered for a test in December 2003 at
Peabody's Kayenta coal mine in Arizona
where it was used for cast blast drilling
The new Pit Viper 311.
for removal of the overburden. This first
machine is still in use there and, as a
result of the good performance, the mine
decided to invest in several additional
units. One of these was prepared for
quick change between a multi-pass and
a single-pass tower as an option to be
adapted for different applications at the
mine.
The first mine to use the single pass
version, the PV-271, was the Barrick
Goldstrike mine near Elko, Nevada.
Since the PV-271 arrived at the mine in
April 2004 it has been problem-free, and
holds an impressive track record with
an average penetration rate of 199 ft per
hour. The long component life and also
the automatic tensioning adjustments for
the cables are much appreciated by the
mine.
Following this tradition of product
launches in Las Vegas the PV-235
was introduced in 2008 followed by
the PV-311 at MINExpo in 2012. These
new drill rigs are automation ready, fea-
turing the RCS (Rig Control System) as
standard.
Acknowledgements
Editors: Kyran Casteel and Ulf Linder
Contributions: Guy Coyne, Ron Buell,
Kenneth Moffitt, Brian Fox, John
Stinson, Dustin Penn, Gunnar Nord,
Sverker Hartwig, Jim Langford, Diane
Norwood, Darwin Hollar, Ewald Kurt.
 Talking Technically

Ergonomics and safety

Machine
developments in
a new decade
Ergonomics today has taken on a
broader meaning with the advent
of safer work rules, higher work
efficiencies and superior design
tools. Today engineers can study
and design machines that are effi-
cient to operate, maintain, build
and transport. Engineering tools,
new materials, improved indus-
try standards and new technol-
ogy allow a designer to model a
machine and actually simulate
operation under safer operating
conditions.
During this decade not much has
changed with the technical perfor-
mance of drilling as cutting struc-
tures remain the same. Rather the
design emphasis has been on effi-
ciency, fewer accidents and ease
of operation. Globalization of mi-
ning to a higher level is also driv-
ing changes. The HIV epidemic in
Africa is reducing the workforce at
an unheard of rate. New deposits Reference dust management improvement.
in arctic regions require a new
emphasis. This article highlights
the advances Atlas Copco Drilling
Not only does the manufacturer look Operator cabins and
at drilling as the sole function of an
Solutions engineers have made to
operator. A multi-skilled operator may
machine interfaces
meet these new challenges.
also manage drilling consumables, com- A rotary drill is recognized as one of
plete basic maintenance and report de- two pieces of surface mining equipment
Ergonomics and safety for tails of bench conditions. These new that sits and works in its waste, heat and
operators roles also must be designed into the ma- dust. The other piece is the shovel or ex-
chine interfaces. cavator. The operators cabin, or cab, is
Today much has changed with regard to Also with regard to improved ergo- the device used to protect the operator,
operators, machines and machine inter- nomics and safety, Drilling Solutions a design factor not seriously considered
faces. Twenty years ago the industry engineers work to design systems that as late as 1995.
took a macro view of an operators abil- eliminate or reduce the hazards. In the Nearly everyone would agree todays
ity to complete a shift without tiring or late 1990s when the United States Mining automobiles are safer, quieter, offer a
having an accident. Today designers and Safety Administration imposed stric- smoother drive and are very user fri-
work to a micro requirement; neither ter silica exposure limits for operators, endly. The automobile is becoming the
a hand nor a finger must be injured engineers found that improved air qu- acceptable standard in industry when
over a 30-year career doing the same ality could not be achieved without re- looking at operator cabins. The visual
function. moving the concentration levels in cer- look of an operator cab has also become
In the past the requirements were for tain applications. The drive then became a design criteria, as personnel equate past
gauges and levers to be properly placed to manage the dust rather than improve operator cabs with a metal box that
to avoid human strain during the work air quality through expensive filtration. induces high fatigue. An automotives
shift. Now engineers analyze site paths, The goal of Drilling Solutions is to al- structure and safety systems keep
a process of ensuring that natural hand low the operator to do what comes na- passengers safe. Likewise todays drills
motions are used to operate equipment. turally and to create a work environ- are engineered to protect an opera-
The drive for safety and efficiency are ment that provides superior comfort tor against hazards that once injured or
integrated. and safety. killed operators.

Blasthole Drilling in Open Pit Mining 11

 Talking Technically
Operator survived rock fall.
The image shows a digital leveling device
on which the background can change colors,
sound an alarm or remove power when an
unsafe angle of operation is
experienced.
The image shows digital readouts of weight
on bit, rotation speed, torque and rate of
penetration. It also can be programmed to
give an operator visual feedback.
The image above shows a rock fall
that the operator survived without in-
jury. Using proper de sign techniques
and better materials. Atlas Copco en-
gineers have delivered an operator cab
that reduces interior noise levels signif-
icantly below the industry benchmark
12 Blasthole Drilling in Open Pit Mining
Comfort combined with ease of operation in one
package.
of 80 dBA. For example, the Pit Viper
351 with 1500 hp was measured below
70 dBA when drilling.
Like automotive climate control sys-
tems are developed to maintain opera-
tor comfort more efficiently, todays
systems direct the cooling effort on the
operator. The systems are also used to
defrost windows in cold weather cli-
mates just as automobiles do. Drilling
Solutions engineers also are working to
advance the cleanliness of the air the
operator breathes.
Engineers can use computer models
to quickly improve line of site. Cabs
now feature more window space, which
improves visibility, due to glass and in-
sulation technology. Camera technology
allows an operator to watch the areas
where visibility is restricted. The com-
bined effect is to give operators a full
view from the operators chair.
The operator chair and flooring play
active roles in reducing drilling vibra-
tions, which add to operator fatigue.
Now an operators chair is often referred
to as an operators pod, and is adjust-
able to fit a variety of shapes, sizes and
weights. All machine interfaces are now
within the operators reach.
Technology can also play a role in
protecting the operator from dangerous
work conditions. Drilling Solutions en-
gineers, working with suppliers, are
creating a system that allows limits of
operation to be defined and to give
an operator feedback when an unsafe
condition exists. As drilling conditions
change within the pit, the machine can
be easily reprogrammed to fit the new
situation.
The result of this combined effort
is to deliver a safe, comfortable work
environment that is suited for the long
shifts required in surface mining.
Maintenance ergonomics
Nearly unheard of a decade ago, in-
dustry standards now require safe, rou-
tine and easy access to all maintenance
points. In the 1990s the Australian New
South Wales MDG-15 Act gave guide-
lines for maintenance ergonomics that
have become the accepted standard in
industry today, and these standards, in
addition to factors such as fatigue and
safety, drive the machine design effort.
For example, Australian studies sho-
wed a very high incident rate for person-
nel getting on and off machines. These
results drove the international market to
look at alternatives. As a result, place-
ment of key maintenance points could
only be in a zone from waist to shoul-
ders, based on measurements for 90
percent of the population. Until fairly
recently, operator comfort and safety
were only afterthoughts if they were
considered at all. Now, what was once
out of sight, out of mind, is a critical
requirement at the forefront of design
innovation.
John Stinson
 Talking Technically

Personnel rig protection

Built-in safety
features
For drillers, the safest place to
be is the cabin of the drill rig.
Our equipment has many built-
in features and options that help
to increase operator safety such
as ROPS and FOPS protection.
Moreover todays cabins are all
designed with smooth edges
and without protruding com-
ponents that could conceivably
injure an operator who omits to
wear a hardhat. But the fact is,
the moment the operator steps
outside, he or she is immediately
exposed to dangers. Over the
years, technological advances
have done a great deal to reduce
the number of accidents and inju-
ries. Atlas Copco is committed
to this task and will continue to
identify risks and improve safety
through our product design.
The safest place to be is the cabin of the drill rig.

Mining safety In order to facilitate what we should means of conducting maintenance in

Since the implementation of the Mining
Safety and Health Act of 1977, a lot has
changed in the past 35 years. More spe-
cifically, a lot of lives have changed or
been saved. Safety is the obligation of
every single individual in every single
step of the entire mining process.
As taught in the MSHA training
class SLAM Risks (Stop Look
Analyze and Manage) helps us dimin-
ish workplace risks. SLAM was initiat-
ed to focus the mining industry on the
human factors in accident prevention.
At Drilling Solutions, risk assessments
and design simulations are involved
in mitigating risks to the operator and
maintenance personnel. We should
constantly be assessing our surround-
ing environment and risks that might
be involved. It is something that we
should consider in every action we take
on a daily basis, from climbing off the
machine, to walking out through the
parking lot, to driving home that even-
ing, to walking in that front door; safe
and sound and fully intact.
be doing on a daily basis versus what
we actually do, this is a niche where we
as the OEM are able to further develop
safety into our products. We at Atlas
Copco Drilling Solutions have spent the
past year researching different scena-
rios and situations to find areas that
can further enhance the safety of per-
forming a specific function or task.
We have conducted open-floor meet-
ings with major mining corporations,
spent time on a wide-range of different
mining sites, and coordinated with
various teams world wide in order to
fully understand develop, and offer you
a multitude of Personnel Rig Protection
opportunities for your machines. Our
ultimate aim is to lead the industry by
changing equipment designs to mini-
mize the risk to all parties involved in
the mining process.
Tower access restraint
system
This option provides the mine with a
dedicated resource providing a safe
our towers. The Tower Access Restraint
System meets OSHA Standards 1926
and 1910, as well as Australian and New
Zealand Standards 1891.2:2001.
Drilling Solutions engineers have
designed a set of stairs for access to
the Tower while in the horizontal posi-
tion. Each step is made of sturdy steel
grating. The Stairway also consists of
a signed gate at the bottom, as well as
the top of the stairs in order to prevent
accidental entry. There is a continuous
handrail that goes up both sides of the
stairway and then a spacious work plat-
form once you reach the top.
Once you have reached the top and
you are ready to enter the tower to per-
form maintenance, you open the gate,
clip onto each of the shuttles that are
attached to two stainless steel cables
that run the length of the Tower. The
cables are permanently anchored to
the Tower cords and include a shut-
tle on each side on which to hook the
harness. These shuttles are an integral
part of the structure and include a
double-locking mechanism for safety

Blasthole Drilling in Open Pit Mining 13

 Talking Technically
PV-270 tower access stairs.
(Part of tower fall restraint system)
Tower fall restraint system with infill.
Hydraulic ladder option.
PV-230 standard ladder option.
PV-230 spring assisted ladder option.
14 Blasthole Drilling in Open Pit Mining
purposes and are specially designed to
withstand the vigors of a mining envi-
ronment. They also allow the opera-
tor full access to the Tower, as well
as being able to smoothly move over
transition pieces without the hazardous
practice of having to unhook from the
cable, allowing the individual to keep
their hands free for tools and the task
at hand.
In addition to the Tower Access Re-
straint System, the bottom of the Tower
is also filled with fiberglass grate deck-
ing. This is a continuous slip-resistant
and sturdy surface for the individual to
stand on while performing their duties.
The final result of combining the
above components is a safe and secure
tool to utilize during regular Tower ser-
vice intervals. In addition, this system
provides improved safety and mobility
for mine personnel.
Access and egress
A lot of emphasis and design hours
went into the multiple options we now
provide for getting on and off the ma-
chine, always keeping ease and safety
in mind. Atlas Copco now provides a
number of different means to access
the deck and cab on the cab side of the
machine. These include your Standard
Ladder, a Hydraulic Ramp, a Hydraulic
Ladder, Hydraulic Stairs, and emer-
gency ladders. Each individual step on
the above ladders is comprised of either
sturdy, slip-resistant steel or fiberglass
grating. One more added benefit to
some of the ladders mentioned is the
safety interlock that is built into the
RCS control system. This interlock
will not allow the rig to move while the
ladder is in the down position.
Some of the above options are obvi-
ously more intricate than the Standard
Ladder, but they do provide a more nat-
ural means of accessing the machine.
They can allow the operator or main-
tenance personnel an easy approach
onto the machine, opposed to having
to hoist themself up a vertical ladder.
This ease enables hands to be free for
other needs, such as carrying tools.
Even more so, the Hydraulic Ramp
that we offer provides a flat surface
that, can be utilized as an easy surface
for dollies to be pulled up and, for
example loaded down with a bucket
of grease. When you need to climb on
the machine from the non-cab side you
can either have a Standard Ladder or no
ladder at all with a handrail in its place.
And in the event of an emergency we
now also offer one or two Emergency
Ladders on the Non-Drill end of the
machine. These ladders flip out with a
quick release and provide a swift means
of escape if need be. When they are not
in use they fold up onto the rig and re-
latch.
The main emphasis of these new
ladder options is not for aesthetics, but
instead to further ensure that there is
a safe means of getting on and off the
rig. The new options above allow for
front or backwards ascent or descent
from the machine. We want to try to
get away from having to climb on the
rig, but rather be able to easily access
the decking in a more natural form.
Decking
A main concern of all mines is working
in a confined space. Drilling Solutions
is currently exploring the balance of
opening up workable areas as well as
keeping the machines overall size in
mind for transportation purposes and
still allowing the mine to access those
holes that might bring an operator close
to the highwalls.
We have developed options that will
allow complete 360 access around the
machine. This includes an option for
complete walk-around access of the
cab. This added selection can be used
for inspection and for cleaning the win-
dows for further visibility.
Another part of the 360 access is
a decking option that includes a built
in bit basket on the Drill-End of the
machine as well as a spot to store
hammer subs. By adding this decking
option, you not only gain complete
access to the machine, but also have a
safe, secure, and dedicated spot to store
bits and hammers. This option inhibits
bits from being laid unsecured on the
deck, opening up a possibility for them
to shift and move during tramming.
One more part of the 360 access
option that is available is an Extended
Cooler decking. Prior to this option
the only way to access the back of

the coolers was by using a man-lift or
some other similar means. By adding
on this decking you add approximately
2 feet (61 cm) to the non-cab side of
the machine. This allows unconstrained
access to the back of the coolers for
cleaning, maintenance or a walkway
to other areas of the machine.
Energy isolation
When working on any piece of machin-
ery this size, there is the constant con-
cern about isolating any energy, whe-
ther it be electrical, hydraulic, or pneu-
matic. The engineers at Drilling Solu-
tions spend numerous hours designing
and configuring different options with
the goal of being able to give anyone
with access to the machine a safe and
secure piece of equipment to work on,
complete with fail-safes when applica-
ble. We know that the easier we make
the machine to work on, the happier
and safer all entities involved will be.
One of the new options offered is a
Ground-Level Battery and Starter Iso-
lation box. Inside this box are lockable
turn switches that either engage or dis-
engage the power or the starter. There
are also long-life LED lights that are
color coded to designate whether it is
receiving power, or if the power is off.
The front cover on this box is comprised
of a strong plexiglass piece so that you
can see what energy state the machine
is in without having to physically open
the front cover. Again we are of the
mindset that the quicker and easier it is
to use, the more it will be used.
Another example of how we are iso-
lating hydraulic energy is by utilizing
a series of Hydrau-Flo Valves. These
valves are specially designed to prevent
fuel spillage, in the event of over-filling
or tank rupture. Not only is this design
a safe way to transfer fuel, but it is also
environmentally friendly.
Ease of maintenance
There are many new options offered
straight from the factory that have
greatly enhanced the ease of working on
our machines. Keeping confined spa-
ces in mind, as well as the idea that the
less often a component needs to be ser-
viced, the more production the machine
Blasthole Drilling in Open Pit Mining 15
Talking Technically
does in the dirt. When you choose the
above option for cooler access decking,
you also then have the opportunity to
pick the Cooler Access Ladder. The
Cooler Access Ladder is a stepladder
integrated onto the decking and hand
railing that provides a safe approach to
accessing the radiator tank on top of the
cooler for filling, checking, or mainte-
nance. As a side note pressure-relief
safety caps are standard on all machine PV-270 new decking and access options.
radiator tanks. These caps allow the
pressure that naturally builds up in the
tank to safely be released without the
danger of spraying out hot coolant onto
the individual.
In regards to the powerpack, we now
offer a dipstick for the gearbox. Prior
to this the sight glass for the gearbox
was in a hard to see area. Now it is easy
to access and it provides a means to ea-
sily check the gearbox oil level daily PV-230 bit basket option.
or as required. We also have the new (Will be located on drum deck)
oil-centrifuge option that extends the
life of the engine oil. It achieves this
without filters to change or clean.
We are providing new ground le-
vel service options in addition to the
Ground-Level Battery and Starter
Isolation. The first of these is a new
ground level Live-Oil Sampling option.
This option provides the ability to take
samples for Hydraulic Oil, Engine Oil,
and Compressor Oil. The oil continu- PV-270 ground level battery and starter
ally circulates through this area so that isolation.
all samples taken are fresh.
Two more ground level service
options that are available are the Quick-
Fill Box and the Quick-Drain Box.
These two boxes located on the non-drill
end of the rig provide a simple means to
either fill or drain the machine of its
fluids. Each connection point is clearly
labeled and consists of a safe quick
connect, each differing in size to avoid PV-270 overview of location of live sampling
cross contamination of fluids. quickfill and quick drain.
Design teams at Atlas Copco are
constantly getting feedback from cus-
tomers or our own field service person-
nel. They let us know if something is
working great, what can be improved,
or if something needs to be completely
redesigned. One of the steps that we
are taking as a company is trying to
phase out welding, and instead use
bolt-in parts. This facilitates in both
making it easier to change out parts From left: Close up view of live sampling,
quickfill and quick drain.
and cuts down on possibly challenging
 Talking Technically

Options PV-230 RCS PV-270 SEOH* PV-270 RCS PV-310 PV-351

Respa Filters
XIR Glass
Hydraulic Hedweld Ladder
Hedweld Spring Ladder
Atlas Copco Hydraulic Ladder
Emergency Ladders
New Cab
Tower Access
Cable Reel
Additional Tower Rest Water Tank
Tropical Engine Roof
Stainless Steel Battery Boxes
Staniless Steel Electrical Boxes
Ground Level Battery Isolation & Jumpstart
Live Sampling
Under the Deck Misting
Secondary Rod Catcher
Autcrane Option
Wormald Fire Suppression
Drum Deck Bit Holder
Protective Hose Sleeving
Dynaset Water Injection Pump
Secondary Air Conditioning Unit
Buddy Seat With Seatbelt
Cooler (Radiator Tank) Access
Engraved Hydraulic Schematic
Centrifuge Engine Oil Filter
Gearbox Dipstick
Hydra-Flow Fuel System
360 Walk-Around Decking
Housing Option
Quick Fill Box
Quick Drain Box
Led lights
*SEOH = Non RCS, Standard Electric Over Hydraulic

the integrity of the material by weld-
ing and cutting. As an added bonus, the
more components that we design to be
bolted in rather than welded results in
a more modular machine that can be
customized specifically to the custom-
ers orders.
One of these newly redesigned bolt-
in options is the sheave and cable
retainers that are on the PV-270 and
PV-351 towers. Previously, when it was
time to change out the cables, these pins
and sheaves had to be removed. Now it
is just a matter of loosening a few bolts,
changing out the cable, and rebolting
the roller back in. Another design that
has been modified is the feed cylinder
supports on the PV-351s. Again it
used to be that you would have to
remove the feed cylinders to replace
the worn guides. The guides now bolt-
in as well. By constantly keeping ease
of maintenance in mind, Atlas Copco
Drilling Solutions are hopeful that it
will result in more productivity hours
for you and your mine; less down time
means more drilling time.
Regardless of what drilling rig you
may own, or what piece of equipment
you may work on, we here at Atlas
Copco Drilling Solutions want you
to always be conscious of your every
action on or around the mine site.
Mining is not the safest in-dustry out
there, but with everyone putting forth a
little more effort towards always think-
ing SAFETY FIRST we feel that this
will make a monumental difference
in everyones life. As long as you do
your part of ensuring that you are con-
stantly thinking of your safety, you can
rest assured that Atlas Copco Drilling
Solutions will do all within its power
when designing a machine to keep you
just as safe.
Maureen Bohac

16 Blasthole Drilling in Open Pit Mining

 Talking Technically

An introduction to surface mining

The wealth
of nations
A well-accepted principle is that
the wealth of a nation comes from
the earth. In the world of mining, a
corollary to this is that If it cant
be grown, it must be mined.
Surface mining techniques are the
principal means used to extract
minerals from the ear th. The
yearly rock production yielding
metals, non-metals and coal in the
world totals 16.6 billion tons*. Of
this, the production from surface
mines is about 70% or 11.5 bil-
lion tons. Crushed rock, sand and
gravel - the fundamental materi-
als required for construction - are
largely produced using surface
mining techniques. Their yearly
production rate totals 23.5 billion
tons. To this must be added the
materials needed for the produc-
tion of cement, another 2.3 billion
tons. Finally, the amount of waste
that must be moved in the process
of extracting the valuable materi-
als is estimated at 30 billion tons.
Summing, one finds that the total
amount of material extracted per Photo: Copper mine in the southwest USA.
year using surface mining tech-
niques is of the order of 67.3 bil-
lion tons (Bagherpour et al, 2007). in the future, the actual estimate of ma- engineering and technology for meet-
*1 ton = 907 kg terials mined using surface mining tech- ing todays requirements and especially
niques in the year 2038 is 138 billion those of the future. Atlas Copco is at
An increasing demand tons (Bagherpour et al, 2007). the forefront in producing the equip-
The ability of the earth to meet this ment and technologies required today
Today, the population of the world type of demand is not really a question and for addressing the challenges of the
stands at about 6.5 billion people. In of resources, since they are clearly future.
simple terms, this means that every there, but rather a matter of price and
year approximately 10 tons of material cost. In looking at the mineral resource A brief synopsis of
is extracted using surface mining tech- base, one must conclude that, in gener- quarrying and open pit
niques for every person in the world. al, the mining conditions will be sign- mining
If one looks to the future, the UN esti- ificantly more difficult than today. In
mates that in 20 years (2038) the worlds addition, ever-increasing environmen- This introductory chapter will focus
population will have reached about 8.5 tal and health and safety conditions are on those surface deposits that require
billion people. By simply applying expected to be in place. This means that the application of drilling and blasting
the current utilization rate of 10 tons/ the entire mining process from pro- techniques as part of the overall extrac-
person, one would expect the amount specting to exploration to development tion process. Excluded from the discus-
of material extracted yearly by surface to extraction and finally to reclama- sion will be strip mining, the mining of
mining techniques to climb to 85 billion tion will have to become much more sand and gravel deposits and the quar-
tons. One must keep in mind, however, advanced. In many places of the world rying of dimension stone.
that today about 95% of the population today, mine closure must be fully and As indicated, large quantities of raw
growth is in the developing countries satisfactorily addressed before a surface materials are produced in various types
of the world. Based on their expecta- mine can be opened. This translates of surface operations. Where the pro-
tions for improved living standards into requirements for applying first rate duct is rock, the operations are known

Blasthole Drilling in Open Pit Mining 17

 Talking Technically

is obtained. By adding the desired pro-

Financial duction rate into the model a production
optimization schedule is generated. Based on the
1. Capital and operating schedule, one determines the required
summation
2. Revenue equipment fleet, staffing, etc. to satisfy
3. Cash flow statement
4. Marginal ore utilization
the schedule. This leads allows one
5. Rate of return to calculate the capital requirements
and the operating costs. With these
now-estimated rather than assumed
Refined ore Ore reserve costs, the ore reserves are re-examined
reserves analysis and design alternatives evaluated.
1. Cutoff grade 1. Break-even analysis
2. Drill-hole evaluation
Eventually, an overall financial evalu-
2. Marginal analysis
3. Design alternatives 3. Pit design ation is performed. The double-headed
4. Marginal analysis
arrows indicate the highly repetitive
nature of the process.

Equipment and
facilities
1. Capital intensive
2. Equipment selection
3. Operating costs
4. Capital depreciation
5. selective mining
Figure 1. Financial optimization using circular analysis (Dohm, 1979).
as quarries. Where metallic ore or non-
metallic minerals are involved, they are
called open pit mines. There are many
common parameters both in design and
in the choice of equipment.
When examining a deposit for poten-
tial mining and even when expanding
a current operation, one often employs
a process called circular analysis. As
Figure 2. A diagrammatic representation of a quarry operation.
Production
scheduling
1. Preproduction costs
2. Working room
3. Stripping ratios
4. Sequencing
5. Reclamation
6. Operating schedules
7. Financial
8. Constraints
shown diagrammatically in Figure 1,
the process consists of five components.
Although the figure applies specifically
for the open pit mining of ore depos-
its, a similar procedure is followed for
quarries.
One naturally begins with a descrip-
tion of the deposit and using some as-
sumed costs a preliminary pit design
Quarries
A rather simple but useful definition of
a quarry is a factory that converts solid
bedrock into crushed stone. Quarries
can be either of the common pit type
or, in mountainous terrain, the hillside
type. Pit type quarries are opened up
below the level of surrounding ter-
rain and accessed by means of ramps
(Figure 2). The excavation is often split
into several benches depending on the
minable depth of the deposit. When the
terrain is rough and bulldozers cannot
provide a flat floor, a top-hammer con-
struction type drill rig can be used to
establish the first bench. Once the first
bench is prepared, production drilling
is preferably carried out using DTH- or
COPROD techniques.
The excavated rock is crushed, scre-
ened, washed and separated into differ-
ent size fractions, for subsequent sale
and use. The amount of fines should be
kept to a minimum. Not all types of rock
are suitable as raw material for crushed
stone. The material must have certain
strength and hardness characteristics
and the individual pieces should have
a defined shape with a rough surface.
Igneous rock such as granite and basalt
as well as metamorphic rock such as
gneiss are well suited for these purposes.
Soft sedimentary rock and materials
which break into flat, flaky pieces are
generally unacceptable. The final prod-
ucts are used as raw material for chemi-
cal plants (such as limestone for cement
manufacturing, the paper and steel
industries), building products, and for
concrete aggregates, highway construc-
tion, or other civil engineering projects.

18 Blasthole Drilling in Open Pit Mining

 Talking Technically

Quarries are often run by operators who

sell their products to nearby contractors
and road administrators. Because the
products are generally of relatively low
value, they are transport cost sensitive. Waste
Hence, wherever possible, quarries are
discreetly located as close as feasible to Bench
the market. Special measures are requi- slope 72o
Good slope stability
red to minimize adverse environmental
impacts such as noise from drilling, Pit slope 45o
vibrations from blasting, and dust from
crushing and screening to the neighbor-

y
od
ing areas.

eb
Good fragmentation needed

Or
Open pit mines
Two major differences between open pit
mining and quarries are the geological
Figure 3. General principles of open pit mining.
conditions and the demands placed
on the characteristics of the blasted
material. For quarries, a majority of is of prime importance to keep the pit favorable, continuation may proceed us-
the rock products eventually delivered slope angle as steep as possible, thereby ing some type of underground method.
to the customers has only undergone keeping the excavated waste to a mini- Figure 4 shows the Aitik copper/gold
crushing and screening in order to ob- mum. There becomes a point where the mine in northern Sweden. It is Europes
tain the desired size fractions. An open quality of the material contained in the largest copper mine producing 18 Mton
pit metal mine, on the other hand, next ore bench is not sufficiently high of ore per year. Currently at a depth of
attempts to deliver the ore as pure as to pay the costs of the associated waste. 480 m it is expected to reach of depth
possible via crushers to a concentrator At this point in time either the open of 800 m before decommissioning. The
consisting of mills, separators, flota- pit mine closes or, if conditions are Bingham Canyon mine in Utah (Figure 5)
tion and/or biochemical systems, etc.
The resulting concentrates/products
are eventually sent for further process-
ing before emerging as a final product.
For certain metals, this latter process
involves smelting and refining. The
deposits mined using open pit meth-
ods have a variety of sizes, shapes and
orientations. Sometimes the distinction
between the valuable material and the
waste is sharp such as shown in Figure
3 and in other cases the distinction
is more subtle - based upon econom-
ics. As in quarries, the minerals are
extracted using a series of benches. If
the orebody does not outcrop, the over-
lying material must first be stripped
away to expose the ore. As the initial
pit is deepened, it is widened. The pit
geometry is controlled by a number of
factors including orebody shape, grade
distribution, the stability of the slopes,
the need to provide access, operating
considerations, etc.
For the geometry shown in Figure
3, a significant amount of waste must
be removed (stripped) to access the
next bench of ore at the pit bottom.
Without jeopardizing slope stability, it Figure 4. The Aitik mine in northern Sweden (www.boliden.com).

Blasthole Drilling in Open Pit Mining 19

 Talking Technically
Figure 5. The Bingham Canyon copper mine near Salt Lake City, Utah, USA. (www.kennecott.com)
has been in production since 1906 and
is one of the largest man-made struc-
tures in the world, measuring 1200 m
Photo: Blasthole drilling of 40 ft (12 m) benches at Newmont's Phoenix mine, Nevada, USA. See page 117.
20 Blasthole Drilling in Open Pit Mining
deep and 4400 m across the top. It
has produced more copper than any
other mine in history and has many
Orebody
Drilling
Blasting
Overall fragmentation system
Loading
Hauling
Primary crushing
Mine
Mill
Secondary crushing
Grinding
Further treatment
Figure 6. Diagrammatic representation of the
overall mine-mill fragmentation system and the
mine and mill subsystems (Hustrulid, 1999).
years remaining. With respect to waste
removal, the fragmentation demands
are simple. Since, the material is not
required to pass through a crusher, the
maximum size is controlled by the li-
mitations imposed by the equipment
used to load and haul the material to
the waste dump. On the other hand,
good fragmentation of the blasted ore
offers great savings in the total costs of
the mineral dressing process.
Some forward thinking
Extraction of the valuable mineral whe-
ther in quarries or open pits requires a
number of unit operations. Generally,
the rock is drilled, blasted, loaded,
hauled to a primary crusher and then
transported further to a plant of some
type for further processing. Figure 6
shows a schematic of the process.
Often, mines are organized so that
the individual unit operations are se-
parate cost centers. Although there are
advantages to this approach, one result,

Insitu
Drilling
Blasting
Loading & Haulage
Primary crushing
Fragmentation
Conveyor
Secondary crushing
Transport
Grinding
Further treatment
Figure 7. The mine-mill system represented as
fragmentation and transport unit operations
(Hustrulid, 1999).
unfortunately, can be that the individual
managers look at minimizing the cost
of their center rather than on the overall
objective of overall cost minimization.
In reviewing the components in Figure
6, it can be shown that they can be
replaced by two operations, fragmen-
tation and transport. In the simplified
view shown in Figure 7, there are five
different stages of fragmentation each
with a different energy product pro-
file.
One must carefully examine the best
opportunities for applying fragmenta-
tion energy in the various stages on
the final product cost. For example, in-
creased fragmentation energy can be
relatively easily introduced in the mine
by modifying the drill patterns and
explosive characteristics. This action
may provide an inexpensive alternative
to adding the fragmentation energy in
the grinding circuit. This process of
considering all elements of the frag-
mentation system, logically dubbed
mine-to-mill is a recognized part of
Blasthole Drilling in Open Pit Mining 21
Internal environment
Minimum wall damage
crushing & grinding
Figure 8. Simplified view of the five different stages of fragmentation, each with a different energy -
product profile.
mine-mill optimization. In addition
to production, there are some other
important customers for blast engi-
neering. One is termed the Internal
Environment and the other the Ex-
ternal Environment. These are shown
in Figure 8.
Both for safety and economic rea-
sons, it is important to preserve the
integrity of the pit wall. Large diam-
eter blast holes, energetic explosives
and wide patterns will be used in the
production blasts which will be subse-
quently loaded out using large excava-
tors and haulage units. Near the pit wall,
much more precise techniques involving
smaller diameter holes, specially de-
signed explosives, and special timing
procedures are employed to minimize
wall damage (Figure 9). Unless great
care is taken, large loading equipment
can easily spoil the results of the trim
blasting. The result is that special loa-
ding and hauling fleets may be requi-
red. Failure to protect the pit walls,
translates into the need for flatter slopes
Talking Technically
Drilling
Specified Drill Pattern
External environment
Blast Engineering Minimum: Flyrock, noise,
airblast, ground vibration
Loading & Haulage
Good: Fragmentation,
Pile shape, diggability
Primary crusher
High throughput and
bridging preventation
Secondary
Efficient crushing and
grinding feed
and additional waste removal and/or the
loss of reserves. These, in turn, translate
into higher overall costs for the mining
operation. In carrying out an evaluation
of the appropriate drilling and blasting
practices, emphasizing mine-to-mill
aspects without taking into account
the care of the slopes can result in lo-
wer production costs but at the sake of
higher investment (capital) costs due
to greater stripping or lost reserves.
Therefore care must be taken to include
all the costs when making the analysis.
The external environment component
falls into the category of a potential
show-stopper since if proper meas-
ures are not taken to fully comply with
standards, the operation could very well
be shut down.
Final remarks
Atlas Copco has the advantage of long
experience in all types of surface drill-
ing operations, with a product range to
match. With its history of innovative
 Talking Technically

Figure 9. Near the pit wall more precise tech-

niques are employed to minimize wall damage.

engineering, the company tends to

think forward, and is able to advise the
user on improving design elements of
the operation that will result in overall
cost savings.

William Hustrulid
Hans Fernberg

References
Bagherpour, R., and Tudeshki, H.
2007. Material handling in world-
wide surface mines. Aggregates
International. Pp 10-14. June.

Dohm, G.C., Jr. 1979. Circular ana-

lysis Open pit optimization.
Chapter 21 in Open Pit Mine Plan-
ning and Design (J.T. Crawford, III
and William A. Hustrulid, editors).
AIME. Pp 281-310.

Hustrulid, William. 1999. Blasting

Principles for Open Pit Mining.
A.A. Balkema, Rotterdam.

Fernberg, Hans 2002, New trends in

open pits, Mining and Construction
1-2002
Photo: Blasthole drilling and haulage at a mine in the southwest USA.

22 Blasthole Drilling in Open Pit Mining


Putting rotary drilling
into perspective
Atlas Copcos largest drill, the Pit Viper 351E, operates on a blast pattern at an open pit copper mine. Rotary blasthole drills are the predominant method of drilling
9 inch (229 mm) diameter holes or greater.
Mining prosperity
Atlas Copco offers a complete range
of rotary as well as DTH and top-
hammer drill rigs for most types
of open pit mining and quarrying
applications. But how do these
technologies complement each
other and how do drillers know
which method to choose, and
when?
A complete range
With the acquisition of Ingersoll-
Rands Drilling Solutions, Baker Hughes
Mining Tools (BHMT) and Thiessen
Team businesses, Atlas Copco has a
complete range of products to offer to
large quarries and open pit mines. Much
of the worlds mining output begins
through drilling of holes with rotary
Blasthole Drilling in Open Pit Mining 23
drills. Ingersoll-Rand built air-powered
rotary drills for many years prior to the
introduction of their first fully hydrau-
lic unit, the T4, in 1968.
About rotary drills
It is important to note that rotary drills
are capable of two methods of drilling.
The majority of the units operate as
pure rotary drills, driving tricone or
fixed-type bits. The fixed-type bits,
such as claw or drag bits, have no mo-
ving parts and cut through rock by shea-
ring it. Thus, these bits are limited to
the softest material. The other method
utilized by rotary drill rigs is down-the-
hole (DTH) drilling. High-pressure air
compressors are used to provide com-
pressed air through the drillstring to
drive the DTH hammer (See illustra-
tion next page). The primary difference
Talking Technically
between rotary drilling and other meth-
ods is the absence of percussion. In
most rotary applications, the preferred
bit is the tricone bit. Tricone bits rely
on crushing and spalling the rock. This
is accomplished through transferring
downforce, known as pulldown, to the
bit while rotating in order to drive the
carbides into the rock as the three cones
rotate around their respective axis.
Rotation is provided by a hydraulic or
electric motor-driven gearbox (called a
rotary head) that moves up and down
the tower via a feed system. Feed sys-
tems utilize cables, chains or rack-and-
pinion mechanisms driven by hydraulic
cylinders, hydraulic motors or electric
motors. The preference at Atlas Copco
is to use cables for pulldown, as they
are lightweight and inexpensive, and
allow easier detection of wear to help
avoid catastrophic failures.
 Talking Technically
The tower supports the drill string during drilling as well as the rotation head and feed system.
Down-The-Hole method
Principle:
The hammer is situated
down the hole in direct
contact with the drill
bit. The hammer piston
strikes the drill bit,
resulting in an efficient
transmission of the
impact energy and
insignificant power
losses with the hole
depth. The method is
widely used for drilling
long holes, not only for
blasting, but also for
water wells, shallow
gas and oil wells,
and for geo-thermal
wells. In mining it is
also developed for
sampling using the
reverse circulation
technique (RC drilling).
24 Blasthole Drilling in Open Pit Mining
Pulldown
Pulldown is the force generated by the
feed system. The actual weight on bit,
or bit load, is the pulldown plus any
dead weight such as the rotary head,
drill rods and cables.
More weight with rotary
It only takes one look to see that the
biggest DTH and tophammer drill rigs
are very different than the biggest rotary
blasthole rigs. In fact, the PV-351
rotary drill rig weighs in excess of nine
times that of Atlas Copco's largest DTH
hammer drill rig, the SmartROC D65.
Yet the PV-351 is drilling a hole that is
generally only twice the diameter. Take
a typical medium formation tricone bit
with a recommended maximum load-
ing of 900 kg/cm of bit diameter
(5000 lb per inch of diameter). With a
200 mm (7-7/8 in) bit, you could run
about 18,000 kg (40,000 lb) of weight
on the bit. The laws of physics dictate
that for every action, there is an equal
and opposite reaction, meaning that if
you push on the ground with 18,000 kg
(40,000 lb), the same force will push
back on the unit. Therefore, the weight
of the machine must be over 18,000 kg
Rotary drilling method (40,000 lb) at the location of the drill
string to avoid the machine lifting off
the jacks. To achieve a stable platform
TONS
through proper placement of the tracks
and levelling jacks, the distribution of
weight results in an overall machine
weight that approaches or exceeds twice
Principle: the bit load rating. This weight does add
Rotation is provided
by a hydraulic or
cost to the machine, but the size of the
electric motor components also translates to long life.
driven gearbox, Even smaller rotary blasthole drills are
called a rotary head,
that moves up and
built to run 30,000 hours of operation,
down the tower and some of the large blasthole drills
via a feed system, have clocked over 100,000 hours of use.
generating the
pulldown required
to give sufficient Rig design
weight on the bit.
Flushing of drill With the exception of one model, the
cuttings between
the wall of the hole rubber-tire mounted T4BH, Atlas Copcos
and the drill rods is rotary blasthole drills are mounted on
normally done with excavator style undercarriages. Power-
compressed air.
ful hydraulic-drive systems allow the
machine to tram over a variety of ground
conditions, though rotary blasthole
drills should always operate on firm,
flat benches.
 Talking Technically

The key component of a rotary blast-

hole drill is the tower, which is some-
times referred to as the derrick or mast.
Atlas Copco towers are four main mem-
ber, open front structures in which the
rotary head slides up and down via a
guide system. The length and weight
of the tower ultimately dictates the size
of the mainframe and undercarriage.
Most drilling functions are hydrauli-
cally driven. Powering these hydraulic
systems, along with the air compressor
is a diesel engine or electric motor.
Most rotary drills are diesel powered for
good mobility. Electric powered units
offer some advantages such as lower
power cost (in most areas), no diesel
emissions, no refueling requirement
and less maintenance. However, some
operations are not setup with the pro-
per electrical infrastructure or staffing
to run electric units. Even when elec-
tric power is available, many custom-
ers avoid electric drills as the trailing
cable used to provide power makes it
harder to move the unit between holes
or patterns. Generally, electric power
is preferred on large single-pass units
used in major open pit metals mines
where electric shovels are employed, The drilling platform is supported by a crawler undercarriage except during drilling when it is raised up by
though electric power is now available hydraulic jacks.
on smaller units such as the Atlas Copco
PV-271, PV-275 and DML. excess dust and accelerated wear on the
bit and drill rod.
The importance of air
Bailing velocity
A key parameter of rotary drilling is
flushing the cuttings from the hole. In A traditional rule-of-thumb is a mini-
most rotary blasthole drills, cuttings mum of 1,525 m 3/min (5000 cfm) of
are lifted between the wall of the hole uphole velocity, the speed at which air
and the drill rods by compressed air. exits the hole. The actual amount of air
Sufficient air volume is required to lift required will vary widely based on the
these cuttings. Many types of tricone density of the material and the size of
bits have been developed to meet vari- the cuttings. Dense cuttings as found in
ous drilling needs. Softer formation iron ore mines will settle much quicker
bits are built with long carbides with than lightweight overburden in coal
wide spacing on the face of the bit. mines and thus need more air coming up
This design yields large cuttings which the hole to lift them; 1,525 m3/min (5000
increase drill speed and reduce dust. It cfm) may not be enough. However, har-
is important to have sufficient clearance der material is generally drilled with
between the wall of the hole and the hard formation bits that utilize shorter
drill rods in order for such large cuttings cutting structures, thus yielding smaller
to pass. If this clearance, known as an- chips. Conversely, some soft material
nular area, is not sufficient, the cuttings can be drilled effectively with only 915
will be ground between the wall of the m 3/min (3000 cfm) uphole velocity.
hole and the rods or by the bit itself Unfortunately, many operations have
(called regrinding) until they are small tried to increase uphole velocity by in- The ability to carry long drill rods up to 70 feet
enough to exit the hole. This results in creasing the diameter of the drill rod. provides more time for drilling.

Blasthole Drilling in Open Pit Mining 25

 Talking Technically

This is obviously much easier than get-

ting a larger air compressor by retrofit-
ting or purchasing a new machine. In
some conditions, this strategy works,
but more often, the reduced annular area
results in increased wear and dust and
the drill rate may even drop. Whatever
the application, it is critical to have pro-
per bailing air.

Dust control
A necessary evil created by the air com-
pressor in drilling operations is the ge-
neration of dust. To control the dust,
the area surrounding the hole is en-
closed by a dust hood. Dust hoods are
sealed on the sides by dust curtains,
Rotary drilling with tricone bits is the most cost efficient method for large hole diameters.
and where the rod comes through the
deck by a rod wiper or dust seal. A dust
control system must be used in con-
junction with the dust hood and cur-
tains. The two most popular types of
dust control are dry dust collectors and
water injection. Dust collectors are es-
sentially large vacuum cleaners that
pull the dust away from the dust hood
and run it through a collection of filter
elements. Water injection systems
inject a fine amount of water into the
air stream. Water injection is the more
effective solution for ensuring dust is
minimized, but the introduction of
water into the hole can slow down the
drilling process by increasing the den-
sity of the cuttings at the bottom of the
hole that the air compressor must move.
To control the dust, the area around the hole is surrounded by a dust hood. Water injection systems require fre-
quent refilling of the water tanks, and
in freezing conditions, elaborate heat-
ing systems must be used. Dust collec-
tors offer a productivity advantage, but
they can become plugged if not turned
off when wet material is encountered.
This is particularly a problem if the wet
material freezes in the system.

When rotary is better

Every drilling application is different,
so we cannot say that there are parti-
cular breakpoints where you should
transition between drilling methods.
Generally, drilling below 152 mm (6 in)
is best accomplished with tophammer
units. Above this diameter, it is typi-
Large diameter holes produced by rotary drills, such as this Pit Viper 351, yield blast patterns with wider cally done with a rotary rig, although
burden and spacing, resulting in fewer holes. tophammer units are doing some of this

26 Blasthole Drilling in Open Pit Mining

 Talking Technically

PRODUCT RANGE DIAGRAM

Dimension stone industry
Construction
APPLICATIONS

Aggregate (Cement and Limestone)

Industrial minerals (Cement & Limestone)
Gold and precious metals
Coal
Copper and base metals
Iron and ferrous metals
1" 2" 3" 4" 5" 6" 7" 8" 9" 10" 11" 12" 13" 14" 15" 16"

25 mm 51 mm 76 mm 102 mm 127 mm 152 mm 178 mm 203 mm 229 mm 254 mm 279 mm 305 mm 330 mm 356 mm 381 mm 406 mm
Pit Viper 351
Pit Viper 311
ROTARY DRILLING PRODUCTS

DM-M3
Pit Viper 275
Pit Viper 271
Pit Viper 235
DML
DML-SP
DM45/50
T4BH Atlas Copco Drilling Solutions division
DM30 II
DM30
DM25-SP
SmartROC D65
FlexiROC D65
FlexiROC D60
AirROC D65 Atlas Copco Surface Drilling Division
PowerROC D55
FlexiROC C65
FlexiROC D55
ROC L7
FlexiROC T50
AirROC D55
AirROC D50
PERCUSSIVE DRILLING PRODUCTS

FlexiROC D50
ROC F6
AirROC D40
AirROC D45 SH
ROC F9CR
ROC F9
SmartROC T45
SmartROC T40
FlexiROC T40/R
SmartROC T35 Rotary
AirROC D35
FlexiROC T35/R Rotary / DTH
PowerROC T35/E
AirROC T35 DTH
ROC D3 RRC
ROC D3 COPROD
PowerROC T25/E
AirROC T25 Tophammer
AirROC T25 W
FlexiROC T20R
FlexiROC T15R

Rotary drilling with tricone bits is the most cost efficient method for large hole diameters.

work effectively with the introduction power of the rock drill itself limits the 686 41 m3/min (1,450 cfm), the pressure
of larger platforms and more pow- ability to transmit adequate force to will only build to 23 bar (325 psi), thus
erful rock drills. For harder material, larger diameter bits, especially at dee- providing less impact energy. In real
say above 100 MPa (15,000 psi), uncon- per depths when percussive energy is terms, each blow of the piston is about
fined compressive strength (UCS), successively reduced with each new rod 45 kg (100 lb) less than it is designed
DTH is often faster than pure rotary connection. Down-the-hole (DTH) tools for. In some cases, this method will
drilling if provided there is enough air solve this energy loss problem, but their still outperform rotary drilling.For
pressure on board. Simply looking at maximum hole diameter is limited by the most large diameter blasthole drilling,
our product range (see above) gives an volume of air. To build the air pressure there is simply not enough air on-
indication of which methods are com- that translates directly to impact energy, board for a DTH to be as cost effective
monly used for the different diameters a certain volume of air is required. Take as rotary drilling with a tricone bit.
found in construction and mining. for example a Secoroc QL80 203 mm Rotary drilling is still the predomi-
There are certain limitations im- (8 in) DTH hammer that is designed nant method of drilling 230 mm (9 in)
posed on each method of drilling. to operate at 25 bar (350 psi). Even with diameter or greater. This is driven pri-
With tophammer percussive drills, the our largest high pressure compressor marily by the current limitations of

Blasthole Drilling in Open Pit Mining 27

 Talking Technically
Total Drilling Cost (TDC) related to bit life and productivity
14,000
12,000
Footage/24 Hours & Average Bit Life
10,000
8,000
6,000
300 ft/hour,
1500' bit life
High Production
4,000
2,000
0 $0
tophammer units and rig air systems.
Tricone bits also become more cost ef-
fective as the larger bits are equipped
with larger bearings which in turn can
handle higher loads. These higher loads
translate to improved drill rates. An-
other advantage of rotary rigs is the
length of the drill rods that can be car-
ried on board. Longer rods mean fewer
connections. Smaller rotary blasthole
machines utilize 9.1 meter (30 ft) length
rods, while larger units are capable of
running 10.7 meter (35 ft) or 12.2 meter
(40 ft) rods. By comparison, topham-
mer or DTH crawler drills use drill
steel that is generally 6.1 meters (20 ft)
or less in length. Further, some rotary
rigs are large enough to handle a long
tower that enables drilling of the entire
bench height in a single pass. At the
largest open pit mines, rotary units are
drilling 20 m (65 ft) deep holes in a
single pass to match the bench heights
dictated by the large electric shovels
that can dig a 17 m (55 ft) bench.
Productivity versus cost
Studies have shown that pure penetra-
tion rate will increase linearly with
increased pulldown. The same has also
28 Blasthole Drilling in Open Pit Mining
Footage/24 Hours
Bit Life (ft)
Overall Cost/Ft
215 ft/hour,
5500' bit life
Lowest Cost
75 ft/hour,
12,000' bit life
Great Bit Life
Bit Life vs Production 2012 update (1) (Cost vs. Bit Life & Production)
been said of rotation speed. So why
doesnt every operation use more of
each? Unfortunately, higher pulldown
and rpm usually results in increased
vibration and lower bit life. The vibra-
tion causes increased wear-and-tear on
the rig, but more importantly, it creates
a very unpleasant environment for the
operator. What invariably happens is
that the operator reduces the weight
or rpm until the vibration returns to
a comfortable level. Some operations
limit bit load and rpm even if there is
no vibration in order to improve bit life.
This is often the wrong strategy as the
overall drilling cost per unit, also known
as Total Drilling Cost (TDC), should be
considered. TDC is calculated using the
bit cost per meter/foot and the total rig
cost per hour. The unit cost per hour
includes labor, maintenance and po-
wer, and possibly capital cost. The
drilling speed really doesnt impact
this cost-per-hour figure. What it does
impact though is the cost per unit
produced (cost/meter/foot, cost/ton,
etc).
You generally want to push the rig
harder to reduce the cost/foot, but there
will be a point where the rig overloads
the bits (see diagram).
$ 9,00
$ 7,50
$ 6,00
Overall Cost/Foot
$ 4,50
$ 3,00
$ 1,50
Large versus small
There are some drawbacks to rotary
rigs. Smaller crawler rigs are more
flexible with many advantages such as
articulating and extendable booms and
guides that allow drilling at many dif-
ferent angles. Unlike crawler rigs, the
components on rotary rigs are often not
enclosed. They are mounted onto the
frame in an open layout that makes
them extremely easy to service. Large
electric units normally have a machi-
nery house to protect the electrical drive
components, and newer midrange sized
blasthole units such as the PV-235 have
the option of a machine enclosure. The
general trend for 165 mm (6-1/2 in) or
less is towards the smaller, more flex-
ible units. However, many large scale
quarries and small mines still favor
the durability, life and simplicity of the
larger rotary rigs for these small diam-
eters. For the large scale open pit opera-
tions that yield a high percentage of the
total worldwide mineral production, it
is anticipated that rotary drilling will
remain the primary method for years
to come.
Brian Fox
 Talking Technically

Automated surface blasthole drilling

Utilizing the RCS
technology platform
The current series of Atlas Copco
Pit Viper drill rigs is based on the
latest, well proven computer and
information technology. These drill
rigs are of modularized design in
both hardware and software, so
upgrades of the latest technology
are available for older models. Se-
veral options are available to faci-
litate quality drilling. Atlas Copco
has applied the same new automa-
tion technology for other under-
ground drilling equipment such as
Simba production drill rigs, Boltec
rockbolting rigs, and ROC surface
crawler rigs. For the customer, this
means commonality of compo-
nents and training, leading to a
better understanding of both the
capability and the maintenance
of Atlas Copco products. For the
company, it allows continuous pro-
duct development, which can be
applied straight across the range.

Introduction RCS is Atlas Copcos technology platform.

Atlas Copco has introduced a number of
new drill rigs for the Drilling Solutions
Division using a common technology
platform. This approach allows devel-
opment of new functionalities for the
drill rigs, which experience has shown
in both underground drilling and haul-
age as well as surface drilling. The cur-
rent generation of machines is designed
for high productivity, quality drilling
and a comfortable working environment
for the operator. Drilling a hole consti-
tutes a small amount of the direct cost
and time of mining, but has a major im-
pact on the other production processes
because it affects fragmentation, back-
break, underbreak, wall control, load-
ing, haulage and processing. Although
great attention is paid to penetration
rate and wear of drill steel and bits,
Atlas Copco is also interested in what
drilling can do to improve rock excava-
tion overall. The inputs to this ongoing
process come from customers and from
research projects where new technol-
ogy is applied to drilling operations. PV-275 cabin with RCS provides an excellent operators environment and improved drilling performance.

Blasthole Drilling in Open Pit Mining 29

 Talking Technically
RCS cabin on a PV-351.
Rig Control System
The automation platform for Atlas
Copco blasthole drilling equipment is
the Rig Control System (RCS), which is
based on standard PC-computer tech-
nology. The new generation of RCS rigs
has taken a quantum leap forward with
respect to logging capabilities, service-
ability and drilling accuracy. CAN-bus
technology provides the backbone of this
new rig control system. It is flexible and
easily expandable, allowing new units
to be added anywhere along the data bus
by cable.
The electronic modules are all deve-
loped solely for the RCS rigs, and are
ruggedized and protected from external
magnetic and electric influences. For
RCS cabin on a PV-270 series.
30 Blasthole Drilling in Open Pit Mining
The control system replaces the electric/hydraulic joystick and console layout pictured here.
surface blasthole machines, the flex-
ibility of the system is highly utilized
and can be adapted and configured for
all different types of products. Cus-
tomers can start at a low level of auto-
mation and, as their requirements
change, can upgrade. New functionality
can be added without major rebuilding
of the machines.
Common automation
All Pit Vipers can be equipped with
RCS Basic, which provides a number of
safety and interlock features and a series
of options Autolevel, Autodrilling, GPS
hole navigation, Rig Remote Access
(RRA) and communication, wireless re-
mote tramming, Measure While Drilling
(MWD) data log files, and International
Rock Excavation Data Exchange Sy-
stem (IREDES).
Safety features
The RCS Basic provides the machine
with additional standard interlocks
compared to the electric-over-hydraulic
machines. A few of the interlocks cre-
ated with the software are:
Hole depth indicator displays the
rotary head position as well as the
depth of the hole drilled;
Pipe in hole tram interlock rotary
head must be in a safe position to
allow tramming;
Jack interlock pipe in the hole will
disable jack functions to protect the
machine and reduce bending of rods;
Rod support interlock prevents
damage of the rotary head and rod
support by not allowing feed with rod
support not in the stowed position;
Carousel no-bump prevents damage
to the carousel by limiting pulldown
pressure with the carousel not in the
stowed position;
Breakout wrench protection pre-
vents damage to the breakout wrench
by disabling pulldown with wrench
not in the stowed position;
Engine and electric motor informa-
tion displayed over the touch screen
maintenance screens;
Low fuel, lube and water level mes-
sages; and
Tram interlocks, so a trigger must be
activated to allow tram function.
 Talking Technically

On the panel structured and integrated fault handling

1. Auto interlock button.
Press and hold this first
and then choose one
of the following auto
functions.
2. Using multilever
rocker switch. Auto-
levels up for switch up.
Autodelevels for down
in drill mode.
3. Autodrill. Drills to
predefined depth and
returns head to propel
safe position. Anti-jam,
void detection and so on
in drill mode.
4. Future option.
Auto tramming or auto-
nomous operation.
RCS Automated Function Buttons.
Autolevel/Autodelevel
To increase the quality in setup of the
drill, leveling the machine on the jacks
is performed automatically. This will
help an average operator to close the
gap to the skill level of an expert opera-
tor. Installation of this feature will
reduce wear and tear on the machine
structure by limiting torsional effect
on the mainframe and tower while
leveling. This function's performance,
of course, depends on ground condi-
tions, but for a normal bench flatness,
the results are that leveling is done in
less than 35 seconds with an accuracy
in pitch and roll to 0.2 degrees. Well
is vital for Autolevel/Autodelevel. This
is to avoid unwanted tip over of the drill
in case of uneven ground conditions or
internal component faults.
Autodrilling
In many cases there are several types
of rock conditions within one blasthole,
and an operator must be alert at all times GPS navigation screen.
to react to these varying ground con-
ditions. With Autodrilling, computers
are now the operators reacting to feed-
back from the machines gauges.
Atlas Copco's autodrill feature has
reproduced the expert operator's reac-
tions into an automatic drill control.
When activated, this function will de-
tect the rock when the bit touches the
ground, and start your air, water, rota- Drill dashboard - drilling screen.
tion and feed to collar the hole. After
the collared distance has been met, then
this module will adjust air, water, rota-
tion and feed to a drilling setting. This
feature will apply optimal pulldown
and rotation to try and drill as fast as
possible without stalling the rotation or
getting stuck. Once the target depth has
been hit, the autodrill feature will clean
the hole or flush the hole, shut off the Leveling screen.
air and water and then return the bit to
a tramming-safe position.
This feature provides the consistency
of drilling to the correct hole depth, and
a consistent water flow to maintain the
hole so it does not collapse. Currently
this is available for single pass drill-
ing and multi-pass drilling, although
a manual rod change must be made at
this time. Settings screen.

Autodrill diagram

Hole building

Start Rock contact detection Collaring Drilling Hole cleaning Finished

Anti-jamming / vibration control

This diagram is valid for a single-pass drill. For multi-pass drills a rod handling system sequence is added to the Autodrill sequence, which is currently not
developed for rotary drills.

Blasthole Drilling in Open Pit Mining 31

 Talking Technically
RCS shows its flexibility through mine integration and diverse options.
GPS hole navigation
To ensure the blasthole is precisely po-
sitioned where the mine engineer has
designed the blast pattern and is dril-
led to the correct depth, GPS hole navi-
gation has been developed for the RCS
platform. This hole navigation system
uses antennas mounted on the tower
rest and radio antennas on the cab to
produce an accurate bit position. Drill
plans designed with the local mine co-
ordinates are imported to the system,
and the bit position is provided in real
time. The bit position is very accurate
and is calculated by taking into con-
sideration the variability on the bench,
providing the operator with the correct
depth to drill each specific hole. This
feature also provides a moving map
display with zoom functions as the rig
is trammed closer to the desired blast-
hole location. The dominant system for
positioning of a rotary drill on a blast-
hole drill plan is with satellite naviga-
tion based on GPS or GPS and Glonass.
Accuracies up to 10 cm are possible to
reach depending on installation and
number of available satellites. The inte-
gration of the GPS receiver to the con-
trol system is via a standard RS serial
link. Protocol used is preferably the stan-
dardized NMEA0183. The advantage of
having the GPS system as a positioning
sensor enables customers to choose pro-
ducts of any brand (Trimble, Leica,
Topcon) depending on the preferred
standard in the actual mine.
32 Blasthole Drilling in Open Pit Mining
Rig Remote Access
and communication
The Rig Remote Access (RRA) system
from Atlas Copco gives a customer the
ability to connect the drill rigs to a
standard computer network on a work
site. The RRA system allows access in-
formation on the drill rigs from any
authorized point in a network. The RRA
system basically consists of a commu-
nication server onboard the drill rig and
a network adapter. The server supplies
the user with three functions: a web
server that can connect to any standard
web browser, an FTP server to enable
transferring of data (files) to and from
the drill rig, and a server process that
enables any data to be integrated into
the user's administrative systems.
If a commercially available "office"
network is used on the work site, which
is easy to install into the existing in-
frastructure, it restricts the RRA func-
tionality to only remote access, and does
not permit remote control. Standard
communication equipment is also used
that makes the RRA easy to upgrade
and adapt to new and more effective
equipment when available.
The system also utilizes standard
communication protocols such as PPP
or TCP/IP. With a wireless network
connection to the drill rig, a number
of working procedures in the mine are
simplified and several new features
are available to the mine planning
organization. The basic mine planning
and control functions can be simplified
substantially by having a direct link to
the machines. Advanced work orders
that previously were distributed at the
beginning of each shift can now be
distributed instantly.
This leads to a more flexible and
adaptable production organization.
Computer designed drill plans and
work orders that earlier had to be
loaded manually with a PC card can
now be downloaded directly from the
office computer where they were cre-
ated. This saves time and personnel and
also allows last minute changes in order
to adapt to variations in geology and ore
geometry. Log files generated during
drilling, also previously transferred
from the rig with a PC-card, can now be
collected from any computer connected
to the network.
This means that information carried
by the log files, e.g. production data,
geological and geomechanical data
(strata recognition) is available for the
entire organization as soon as the drill
completes its hole/pattern. Manual shift
reports stating number of holes, drilled
depth, etc. can now be completed auto-
matically from data logs without human
involvement. RRA is also a tool for
more advanced service and mainte-
nance procedures.
The operation of the rig can be fol-
lowed remotely and monitoring of drill
rig status can be made online using
a standard web browser on a remote
PC. Web pages are set up similar
to the native RCS display on the rig.
Troubleshooting can be done remotely
using the built-in menus in the RCS
system. This can also be done by spe-
cialized technicians and engineers at
Atlas Copco's product companies.
Furthermore, entire replacement
of the RCS software has been done
remotely from rebro, the Rocktec
office. The RRA system has been
introduced to a number of underground
mines and construction sites since
2003, which has eased implementation
in surface mining operations.
Wireless remote tramming
The wireless remote tramming function
allows the operator to tram a Pit Viper
from the bench within a 60-meter

distance. This will allow an operator to
walk all the way around the machine
and tram the rig to avoid any blind spots
or next to a highwall or berm to prevent
damage to the machine. This controller
is also equipped with safety triggers, so
the operator must have control of the
unit with his hands to tram the machine.
The function has an emergency stop
button and engine speed control as
well, and can be equipped with addi-
tional functions when available.
IREDES
The data that is transmitted to and from
a drill rig or any other mining equip-
ment is arranged in a specific format.
Often different equipment suppliers use
their own specific format, allowing data
communication only between their own
equipment. For a mining company or a
contractor, an industry standard will
simplify integration of equipment from
different suppliers. Atlas Copco was one
of the originators of the International
Rock Excavation Data Exchange Stan-
dard (IREDES) initiative in 2000. A
positive and open attitude between the
IREDES members has led to data pro-
files for the different processes in the
rock excavation process drilling, loa-
ding and blasting. Atlas Copco is fully
committed to the IREDES standard
and the rotary drilling product line is
IREDES compliant.
Measure While Drilling
Measure While Drilling (MWD), strata
logging, logs several drill parameters
during production drilling, and the
data can be used for prediction of
geological and geochemical variations
within drill patterns on a bench. This
can help determine the strength of that
specific rock type. A rock mass is also
intersected by fractures and faults that
strongly influence the conditions of the
rock mass and, therefore, engineering
aspects such as charging and blasting of
the drill pattern. This data, when inte-
grated with the blasting plan, should
influence the explosive charging and
specific density applied throughout the
pattern, which will in turn influence
the loading, hauling and processing of
the ore.
Blasthole Drilling in Open Pit Mining 33
Teleremote office installation. Inset: Wireless remote control, compact portable package.
Teleremote operation
This feature uses the mine's wireless
network, either 2.4 or 5.2 GHz frequen-
cy, and allows an operator to utilize
the machine functions from a remote
location including, drilling leveling,
tramming, and GPS hole navigation.
A dedicated communication channel
that guarantees bandwidth and latency
times for real time control of the drill is
required. The package can be equipped
with a four-camera system that is com-
pressed to limit bandwidth for viewing
of the machine from remote locations.
This module also includes a dedicated
safety system independent of the RCS
package. If communication is lost be-
tween the remote station and the ma-
chine, it will shut down. Additional
safety systems like personnel detection
systems or systems detecting when
people enter the working area should
be combined with the mine's specific
safety instructions.
Autotramming
Autotramming is a feature in the deve-
lopment stages and has been tested
on a machine at the Garland, Texas,
factory. This component utilizes the
GPS hole navigation system or can be
deployed with an augmented GPS using
the standard NMEA string to tram a
machine between holes on a blasthole
pattern. This pattern is interpreted by
the path planner, which is in communi-
Talking Technically
cation with the drill regarding direction
and track speed to tram the machine
at an ideal speed to the exact location.
This module can reduce wear and tear
on the machine structures as well as
undercarriage by reducing spot turn-
ing and planning a correct path to the
next hole.
The current requirement for this fea-
ture is a "flat" bench, which must be
verified by a mine engineer, to allow
this machine to stay within its limits.
A combination of any or all of these
features are available for deployment to
fulfill a specific mine's needs for auto-
mation.
Additional feedback will be required
in the future to further enhance the
automation package, but the RCS is
Atlas Copco Drilling Solutions' plat-
form for automation.
Autonomous Pit Viper
Operations
Automating Pit Viper functions have
been the backbone of RCS. Since its
inception on ADS drills in 2006, the
RCS product portfolio has grown
through a planned evolution. This
growth in RCS options has focused on
creating autonomous drill elements,
network integration, streaming data,
precise navigation, and remote control.
Capitalizing on this proven platform
provides a solid foundation for the
Autonomous Pit Viper. A multifac-
eted approach was taken to define the
 Talking Technically
A cold winter day (-36 C) at the Aitik mine in Sweden, a perfect place for automation testing.
The newly developed client offers drill fleet awareness in an autonomous environment.
autonomous capabilities with respect
to Pit Vipers. This twofold definition
provides the outline of a complete solu-
tion; documenting machine control and
data exchange.
Machine: Propelling between holes
and rows on a single bench, obstacle
detection/avoidance, positioning, level-
ling, and drilling to target depth (cor-
rected elevation) for vertical and angle
drilling of blastholes.
Data Exchange: Data transfer to and
from the drill to a centralized machine
server. Server to compute internal data
for use and transfer external data to 3rd
parties in a standardized format.
A complete solution
The autonomous Pit Viper has been
engineered for productivity, designed
34 Blasthole Drilling in Open Pit Mining
Integration
around safety, and compatible for inte-
gration directly impactingefficiencies
in the drill and blast process
Safety
Moving drill operations from the drill
to an operations center creates an
added layer of safety for a mine and
its personnel. The unmanned Pit Viper
drill maintains safety through obstacle
awareness, visual and switched safe
to board process and a precautionary
staged approach to degradations that
could be encountered in GPS and
communication networks. All current
safety interlocks will remain in RCS
along with the addition of autonomous
specific interlocks such as geofences.
Productivity
Automated drilling functions provide
predictable, reliable, and repeatable
drill operations where human operators
deal with fatigue, breaks in the sche-
dule (operational delays), along with a
list of additional variables. The auto-
nomous Pit Viper combines the pro-
ven existing automated functions into
a complete drilling process to include
AutoNavigation and Auto Rod Chan-
ging (ARC). The drill is prepared to
take on the challenges of completing a
pattern.
Autonomous mining breathes efficien-
cy by definition. A major component
to that is proper and flexible means
of integration in subsystems. The Pit
Vipers software and hardware have
been engineered around f lexibility
where each meets mine processes and
physical integration points. Standard
data flows, hardware standards (not
brands) and network integration vs
independent networks are each keys
to success. Each integration point was
designed around public/universal stan-
dards or where none exist, adaptable
solutions were created using standard
protocols.
Efficiency
A majority of the items captured in
the safety, productivity and integration
sections have direct contributions to
efficiency. In addition, the autonomous
operations center has monitoring and
control components building efficien-
cies. Maintaining awareness of the fleet
is accomplished through both actively
selected or default drill mounted
and controllable cameras as well as
a unique Pit Viper f leet monitoring
tool. This tool provides the responsi-
ble person the precise data needed for
each autonomous Pit Viper operating in
the fleet. Should a Pit Viper encounter
issues, the person is alerted and can
take action to include direct control
utilizing the teleremote station at their
desk.
The Pit Viper with the integrated
RCS platform will remain on the lead-
ing edge of autonomous drilling.
Dustin Penn and Tyler Berens
 Talking Technically

Taking advantage of
single-pass drilling
The easy way to get 100
more blastholes 90
40' Single-pass,
(12.2 m)
per day 80 1
2
40 ft
50 MPa Rock*

Large rotary drills have been in 30 ft

Overall production rate in metres/hr

use for years around the world 70 30' Multi-pass,

in mining applications. In many
open pit operations, these large
drills were equipped with electric
power and long towers for drilling
benches in a single pass. Today,
these features are being added to
smaller equipment. Lets look at
the benefits of single-pass.
Longer towers
The drilling of large diameter holes,
generally considered to be greater than
9 inches in diameter, is done predomi-
nantly with rotary blasthole drills. One
of the reasons for this is that larger dia-
meter tricone bits allow for large bea-
rings to handle high pulldown forces to
drill through hard rock quickly. These
high pulldown loads require a heavy
tower structure to transmit these pull-
down forces to the drill bit. Further,
this high pulldown must be offset by
sufficient mass to keep the drill rig
from lifting off the ground. The resul-
ting rig is therefore quite heavy.
With a heavy, durable rig already
dictated by a large hole diameter, drill
designers are able to take advantage of
the large platform to offer longer towers
capable of drilling benches in one pass.
This often drives a change in structural
design and supporting components such
as undercarriages, but the basic rig en-
velope doesnt change. Drilling a hole
in one pass has many advantages.
60
50
40
30
20
10
0
0 2
Fig 1. Comparison of single-pass and multi-pass drilling, = Time lost for rod adding and rod removal,
= Lost productivity for multi-pass drilling.
Elimination of rod
changing time
Adding a rod may take 45 to 60 sec-
onds depending on the size of the rig,
and taking the rod back off may take
60 to 90 seconds. The extra time for
removing a rod is due to the extra cycle
required to lower the head to pick up
the next rod.
The effect of rod changing time is
more dramatic in soft material, as shown
in Fig 1. Surprisingly, it is the large
metals mines that pioneered the use of
single-pass drills, even though they may
see limited productivity benefit. In ex-
tremely hard rock such as that encoun-
tered in taconite, the single-pass be-
nefit might only be 3 percent. At the
(9.1 m)
50 MPa Rock*
2 40' Single-pass,
40 ft (12.2 m)
1 100 MPa Rock*
30 ft
30' Multi-pass,
(9.1 m)
100 MPa Rock*
* Compressive strength
4 6 8 10 12 14
Drill depth in metres
other extreme would be very soft coal
overburden. This material can be drilled
with claw-type bits at rates of 400 meters/
hour or more. In this situation, a single-
pass drill would yield an overall pro-
ductivity gain of over 25 percent.
Simplified operation
Even in situations where the productiv-
ity gain from eliminating rod changes
is relatively small, there are benefits.
Operators dont have to worry about
the rod changing operation, which con-
sists of 10 actions to add a rod and 13
actions to remove a rod. Eliminating
these tasks during each hole reduces
the chance for errors such as cross-
threading the tool joints on the drill

Fig 2. Single-pass Pit Viper rigs

Rig PV-235 PV-271 PV-311 PV-351
Hole range 152-251 mm (6-978") 171-270 mm (6-105 8") 229 - 311 mm (9 - 12 ") 270-406 mm (10 5 8 -16")
Single pass 12.2 m (40 ft) 16.8 m (55 ft) 19.8 m (65 ft) 19.8 m (65 ft)
depth

Blasthole Drilling in Open Pit Mining 35

 Talking Technically
Committed to superior productivity. The PV-271 is perfect for single-pass drilling of a 40 ft bench and has a
maximum single-pass capacity of 55 ft (16.8 m).
rods or dropping a rod. Tasks such as
changing a bit in the middle of the hole
or reaming the hole to clear out cuttings
are much simpler when you dont have
to add or remove rods. These factors
could increase overall productivity by
a few more percent.
Less maintenance
The carousel and wrench systems used
routinely in multiple-pass operation are
high wear items due to the nature of
their operation. While they may still be
used on single-pass drills, especially
for changing drill bits, they see a much
lower duty cycle. As mentioned above,
tight drill tool joints can be a problem.
Improvements in breakout wrench sys-
tems have helped address these issues,
but it is still common to see joints that
cant be broken by onboard wrench
systems.
Given the advantages above, why
wouldnt every drill be built as a single-
pass? Obviously, it isnt practical to
36 Blasthole Drilling in Open Pit Mining
build a unit to support a 70 meter hole
in coal overburden. It may be possible,
but youd end up with a unit with a mast
as long as a dragline boom. The expen-
se of such a unit would probably never
be recovered with the operating cost
savings.
Safety factors
As towers grow in length, the support-
ing mainframe and undercarriage must
grow as well. To maintain the structural
life and reliability of smaller multiple-
pass units, proper safety factors must
be used in the design. The result is a
larger and more expensive machine
than customers are willing to buy. An
example would be the move from the
DM-M2, a multiple-pass unit with
35-foot drill rods and a gross weight
of about 57 tons, to the single-pass Pit
Viper 271 for 16.7-meter holes. The Pit
Viper 271 weighs in at around 80 tons.
Many smaller rotary drills operate
on slopes that could not be considered
firm and flat. While single-pass drills
might be capable of operating on a
minor slope (less than 10 percent), they
will generally have a higher center of
gravity than their multiple-pass equiva-
lent, reducing the stability of the unit.
This is often the operators perception
as the unit may be capable of slopes
that might be substantially more.
However, many factors must be
taken into account when determin-
ing whether to operate on a particular
slope. Ground conditions are rarely a
single plane. Instead, they are com-
pound angles of widely varying rock
size and type. Most operators err on
the side of limiting the slope they will
attempt to navigate. Thus, single-pass
drills are viewed as being limited to
flat benches only.
As we say at Atlas Copco, we are
committed to our customers superior
productivity. We will continue to deve-
lop single-pass units for smaller diam-
eter operations. While we have several
smaller units already capable of single-
pass (the DM25SP and DML-SP), they
are rotary table drive units. They utilize
lightweight towers on relatively small
base units by locating the feed and rota-
tion mechanisms towards the bottom of
the tower. The drawback of this design
is that rotation is accomplished through
a rotary table drive that engages a
fluted kelly bar, driven mechanically
by drive pins. The kelly bars are very
expensive due to the fluting milled into
them, and if the material is abrasive,
they wear quickly and result in high
operating costs. However, in soft appli-
cations, they are a great option.
We continue to develop tophead-
drive units with longer towers. Adding
to our fleet of large single-pass units, as
outlined in Fig 2, we are testing the new
Pit Viper 311. It is set up for single-pass
drilling of 65 ft (19.8 m) holes, which is
demanded by many metal mines. This
unit will operate in the same diameter
range as the DM-M3, which has 40-foot
drill pipes and a 11.3-meter capability.
We encourage our customers to look at
single-pass drilling as it is one of the
easiest ways to get more holes per day.
Brian Fox

Drilling at high altitudes
Challenging
locations
Easily accessible, high grade ore
is becoming scarce. To meet glo-
bal mineral demand, mining com-
panies must look to challenging
locations for economically viable
deposits. Naturally, this includes
mountainous regions at high
elevations. While some opera-
tions are already producing at
altitudes exceeding 5,000 meters
(16,405 ft), high elevations can
have adverse effects on people
and machinery starting as low as
1,500 m (4,922 ft).
Reduced density of air
The primary problem with high altitude
is the decreased mass density of air.
To understand this concept, you must
first look at the composition of air. Air
molecules consist of nitrogen (78%),
oxygen (21%) and other gases, and have
a given molecular weight. As grav-
ity pulls the air towards the ground,
these air molecules are subject to the
additional weight of all the molecules
above. This additional weight means
the air pressure is highest at sea level,
and diminishes with increases in eleva-
tion. This is much like water pressure
in a swimming pool. At the surface, the
water pressure is relatively low. As you
dive lower, the pressure increases due
to the weight of the water above.
The reduced mass density of air
poses two problems. First, the air mol-
ecules and their associated density are
what carry the drill cuttings out of the
hole. If there are fewer molecules per
cubic foot of air, there is less carrying
capacity. Second, while the oxygen
content is the same (21%) at sea level
at high elevations, there are fewer
molecules available and therefore less
total oxygen available for humans or
engines.
Blasthole Drilling in Open Pit Mining 37
The entrance to the Collahuasi mine is located 3800 meter above sea level.
Altitude and temperature
It must be noted that temperature and
humidity also factor into the density
of air. Humidity has little impact and,
counter-intuitively, actually reduces the
air pressure as moisture increases. This
is because water vapor (in gas state,
not liquid) is lighter than the nitrogen
and oxygen molecules it is displacing.
Temperature, however, has a signifi-
cant effect. Air, like most substances,
expands when heated and contracts
when it cools. The molecules move
further apart with an increase in heat,
and thus reduce the density of the air.
The majority of heat carried by air
molecules is via conduction from the
earth, which is heated throughout the
day by the suns rays. The air tempe-
rature becomes colder at a fairly uni-
form rate as it moves further from the
heat source, and there are fewer air
molecules to transfer heat at high alti-
tudes. This is called the environmental
lapse rate. The normal lapse rate is
3.5F (1.94C) per 1,000 feet (304 m)
of altitude, though it can range from
3F (1.66C) for saturated air (100%
humidity) to 5.5F (3.05C) for dry
Talking Technically
air. Therefore, 59F (15C) at sea level
(which is often referred to as the stand-
ardized condition) would drop to 7F
(-14C) at 15,000 ft (4,572 m). The alti-
tude has now created a situation where
cold weather provisions are needed for
proper operation of the drill.
Air compressors & bailing
At sea level, an air compressor will
compress a certain volume of air at
atmospheric pressure to a higher pres-
sure, yet lower volume. It is often mis-
stated that compressors produce less
CFM at high altitude. As an example,
lets start with a 1,900 cubic feet per
minute (CFM) compressor rotary drill-
ing at sea level. The compressor rating
is the intake CFM, meaning it can pull
1,900 cubic feet of air into the compres-
sor every minute. What comes out the
outlet of the compressor is determined
by the downstream restriction, which
well assume are the nozzles of a tri-
cone bit. If small nozzles are used, or
the bit becomes plugged, the pressure
will increase back to the compressor,
up to the maximum pressure allowed by
the system (e.g. 110 PSI). The concept
 Talking Technically
When moving from sea level up to high altitudes the density of air will decrease, and the temperature will
drop at a fairly uniform rate.
is similar to water running through a
garden hose. Running unrestricted, a
large volume of water comes out, but
at a low pressure. If you put your thumb
over the end of the hose, the pressure
will increase but the volume will be
reduced. In our example, if the nozzles
are sized properly, the pressure at the
bit might be 60 PSI. At this lower pres-
sure, the volume would be higher than
at 110 PSI, but still much lower than
the intake volume. As the air moves
through the bit and up the hole, the
pressure will eventually drop to atmos-
pheric pressure again, at a high volume.
At 15,000 ft (4,572 m), the same
compressor is still taking in 1,900 cubic
feet of air per minute. However, the
number of molecules of air is reduced
by approximately 42%, calculated by
comparing the air pressure at sea level
Uphole Velocities
At Sea Level/15 C (59 F)
Rating: 1900 cfm
Hole Drill Rod
Effective Vol. 1900 cfm
(in) (in)
10 7 58 6 434 ft/min
10 8 9 149 ft/min
9 7 58 8 946 ft/min
9 8 15 232 ft/min
Comparison of compressor performance at high altitude vs sea level and subsequent effect on uphole velocity in rotary drilling using a Pit Viper 271 drill rig.
38 Blasthole Drilling in Open Pit Mining
(14.7 PSI or 101 kPa) to the pressure
at elevation (8.6 PSI or 59 kPa). To
compensate for the lower density, cor-
rection factors are used to calculate
the effective, not actual, intake CFM
required to produce the same perfor-
mance as at sea level. In this case, the
reduced air pressure effectively cuts
the compressor to an equivalent intake
capacity of 1106 CFM (assuming the
same temperature as sea level). Taking
into account the lower temperature and
corresponding increase in density, the
intake capacity would move up to 1,221
CFM at 7F (-14C).
To determine how much air is re-
quired, a calculation of uphole velocity
is required. Uphole velocity is calculat-
ed from the intake air volume and the
annular area, which is the gap between
the wall of the hole and the drill rod.
Compressor
At 15 000 ft/ 14 C (7 F)
Rating: 2 600 cfm Rating: 1 900 cfm
Effective Vol. 2 600 cfm Effective Vol. 1 221 cfm
8 804 ft/min 4 087 ft/min
12 520 ft/min 5 812 ft/min
12 242 ft/min 5 682 ft/min
20 855 ft/min 9 675 ft/min
A minimum uphole velocity is often
stated as 5,000 ft/min but in reality is
affected by the density, size and shape
of the chips, and factors such as the
pressure of cuttings or water in the hole
and the condition of the borehole wall.
Using a Pit Viper 271 as an example,
the table below shows a comparison at
various elevations.
At sea level, 1900 CFM for a 10-
bit with 7- rod works well, even
as the rod wears down. At high alti-
tude, the large reduction in air den-
sity requires either a larger compressor
(2600 CFM in the example) or a larger
(10-) diameter drill rod. The pre-
ferred option is a larger compressor,
as using larger rods cuts the clearance
between the wall of the hole and the
rod to such a small gap that larger cut-
tings must be reground to a smaller size
before exiting the hole, thus accelerat-
ing bit wear. Going to a smaller diam-
eter bit will improve uphole velocity as
well, though this is not always feasible
given the blasting requirements.
Power drain
Diesel engines face considerable dif-
ficulty at high altitude as they rely on
the oxygen in the air for proper com-
bustion. Engines have varying alti-
tude limits and power de-rate curves.
Manufacturers are able to maintain full
power to the altitude rating by changing
the engine timing, turbocharger con-
figuration and compression ratios. This
altitude rating is the point where horse-
power begins to decrease. As a rule
of thumb a diesel engine will de-rate
1900 cfm = 53.8 m3/min
1000 ft = 304 m
5000 ft/min = 25.4 m/s
Rating 2 600 cfm
Effective Vol. 1 670 cfm
5 592 ft/min
7 953 ft/min
7 776 ft/min
13 240 ft/min

its output by 3% per 1,000 ft (304 m)
above altitude limit.
For example, an 800 HP diesel en-
gine might have an altitude limit of
8,000 ft (2,438 m). At 15,000 ft (4,572 m),
the power would be 21% less, or 632
HP. At full power assuming maxi-
mum compressor and rotary head
power, this unit would approach 90%
load, or 720 HP. If this unit operated
with mechanical or hydraulic drive
systems that do not de-rate, there
would be insufficient power to operate
at this elevation. However, because the
air compressor is working with lower
density air, its power requirement is
reduced by 1.5% per 1,000 ft (304 m).
The 1,900 CFM compressor itself
requires approximately 430 HP to pro-
vide full flow and pressure. At 15,000
ft (4,572 m), the load drops by 22.5%
to 333 HP, effectively cutting the total
load from 720 HP to 623 HP, safely
below the de-rated power.
For best results, it is preferable to
go with a larger displacement engine
with a higher output to offset the
reduction due to altitude. However, it
is not always possible to provide larger
engines as the drills are sized to handle
a particular size engine from the begin-
ning and space is not available.
Another alternative is electric power.
Electric motors do not rely on combus-
tion for power, and are not subject
to power loss due to lack of oxygen.
However, there are two issues which
can impact the operation of electrical
components such as motors, starters
and transformers. One is the decreased
cooling capacity at altitude. Higher
capacity components may need to be
specified to achieve the same rating
as lower altitudes, though the cold air
at altitude generally ensures stand-
ard components do not overheat. The
second issue is that lower air density
reduces the di-electrical strength of air
gaps in components, thus reducing the
insulation capacity of these components
and increasing the risk of electrical
breakdown, or flashover. At extremely
high elevations, special electrical com-
ponents may be required.
The decision to go with electric po-
wer has to consider other factors like
how electricity is generated and the
demand for mobility of the rig. In
Blasthole Drilling in Open Pit Mining 39
Atmospheric Pressure vs. Altitude
110
Atmospheric pressure (kPa)
100
90
80
Computed for 15 deg. C and 0% humidity
70
60
50
40
30
20
10 2 000 4 000 6 000
-10 5 000 10 000 15 000
The primary problem with high altitudes is the decreased mass density of air. There are fewer molecules
for carrying drill cuttings out of the hole and less oxygen available for humans and engines.
remote areas, the only alternative to
produce electricity might be by diesel
powered generators. In such a case, the
power generation will also suffer from
the power de-rating at high altitude,
and a diesel powered rig can still be
the best alternative if it can be config-
ured to meet the required performance.
Electric power may offer higher capac-
ity, but this might be offset by the
mobility and higher utilization of a
diesel powered rig.
Cooling requirements
With fewer air molecules available,
the ability to remove heat from the
engine, compressor and hydraulic
system is reduced. Limiting Ambient
Temperature (LAT) is the temperature
at which the cooling system becomes
marginal; the design standard is 125F
(52C) rating. For the engine and com-
pressor, cooling is not a problem as
they are also de-rating; the LAT essen-
tially remains the same. As the hydrau-
lic oil density does not change, the LAT
rating is reduced to approximately
90F (32C) at 15,000 ft (304 m),
though temperatures at this altitude are
unlikely to approach that level.
Human impact
Aside from the engine, compressor
and cooling systems, there is little
impact on the drill simply from the
altitude. Excluding the extremely cold
Talking Technically
Air Mass Density vs. Altitude
4 800 m 50 %
15 750 ft
8 000 Altitude (m)
20 000 Altitude (ft) Sea level 100 %
temperatures that may be present,
structures and gearboxes perform as if
at sea level. Hydraulic components are
unaffected except for the charging of
pumps, which may require a change in
the charging circuit. An example would
be using a pressurized hydraulic tank.
The biggest impact of high altitude
is on the operators and technicians
working on the drills. The human body
compensates for the decreased amount
of oxygen with higher respiratory
and heart rates along with a gradual
increase in red blood cells that carry
oxygen (known as acclimatization).
Every person is different, and many
can contract acute mountain sickness
(AMS) beginning at 8,000 ft (2,438 m).
AMS symptoms are similar to a
hangover, but this is minor compared
to much more dangerous problems
such as cerebral and pulmonar y
edema. Mining companies are very
careful when it comes to ensuring the
safety of their employees and contrac-
tors. Examination by medical experts
is required before allowing work in
these tough conditions, and full onsite
medical services are available to deal
with problems. Ultimately, autonomous
drilling will play a significant role as
mining companies push to higher
elevations.
By Brian Fox
 Talking Technically

In 2007, Barrick Gold installed the world's

highest-situated wind turbine at the Veladero
mine at nearly 4,200 m elevation.

40 Blasthole Drilling in Open Pit Mining

 Talking Technically

Drilling in Arctic conditions

Coping with
climatic extremes
The spread of mining to inhospi-
table parts of Mother Earth has
posed a major challenge for mining
equipment design engineers in
terms of both basic machine func-
tions and operator well being. Ope-
ration at high latitude or high alti-
tude requires a significant degree
of redesign. Available coal and
mineral resource geography has
intensified, first with exploration
and then mining activity, in the
Arctic and sub-Arctic central con-
tinental regions of North America
and Asia. In parallel the ability to
build equipment that can operate
economically at temperatures
around -55C has become increas-
ingly important. Similarly, the
development of mines at high alti-
tudes requires machines that can
cope with low atmospheric pres-
sure as well as low temperature.

The Russian experience
For rotary drill rigs the key base mate-
rials adversely affected by low tempe-
rature operation are steel, rubber and
lubricants.
At lower ambient operating tempera-
tures steel becomes brittle, creating
possible earlier fatigue failures. For
heavy equipment designers, the task
is to select steel with proper material
properties, to reduce the load or to
reduce the loading cycles. Through
the combination of the three factors,
structural integrity can be equalled
to equipment running in non-arctic
conditions.
Exposure and constant ground contact subject the crawler undercarriage to particular abuse in low tem-
perature, icy conditions, requiring careful selection of materials. Some applications may require heating
the drive elements to keep them working.
With any rotating equipment, seals
and hoses are used to retain fluids.
Like steel, the newer generation syn-
thetics lose f lexibility, becoming
brittle. With arctic conditions, the
key is again through material selec-
tion to keep equipment doing its pri-
mary function without the aid of
artificial heat sources. In an arctic
application the use of natural rubber
or silicon is better than synthetics.
To maintain acceptable component
life in arctic conditions effective lub-
rication is essential. Typically this
will require using the standard addi-
tives with a base lubricant that will
flow at the ambient temperatures
and at the viscosities specified for
the application.
Beyond making necessary changes
to base materials, subsystem rede-
sign may be required to meet the low
temperature challenge. Engineers must
decide if the material can be changed,
heat be added or in some cases the part
be eliminated to achieve 5,000 to 6,000
operational hours per year.
Exposure and constant ground con-
tact subject the crawler undercarriage
to particular abuse in low temperature,
icy conditions. Many components either
rotate or articulate (rollers, idlers, drive
sprockets and track chains). Again the
driver is to upgrade the base mate-
rial, steel and rubber, where necessary.
Some applications may require heating
the drive elements to keep seals soft
and pliable.
Similarly, for a diesel engine powe-
ring the rotary rig in these conditions,
special attention must be given to
start-up and lubrication. Atlas Copco
has designed a series of heater pack-
ages for lubricants, the engine block
and batteries. All these packages are

Blasthole Drilling in Open Pit Mining 41

 Talking Technically

powered by 110, 240 or 380 V AC elec-

tricity provided by the mine electrical
grid or a diesel generator. If getting
electrical power to the drill is impos-
sible, a diesel-powered block heater is
another option available. Likewise if
low ambient fuel is not available use
of 24 V DC fuel heaters is yet another
option available.
Lubrication systems pumping grease
over long distances can be impossible,
and it may be best to redesign with a
component that has impregnated oil
bushings or closed bearings. To prevent
the pump from cavitating, the lubricant
will either have to be heated or replaced
by a special blend that maintains vis-
cosity through the ambient temperature
range.
Dust suppression is most difficult
in low ambient climates. The synthetic
rubber normally used in dry dust col-
lectors becomes brittle in extreme cold,
and articulated components such as
hoses and dust curtains will fail. If the
drop out chute does not close properly
the system fails to back flush. Also moi-
sture entering the collector will freeze Atlas Copco has designed a series of heater packages for lubricants, the engine block and batteries.
when it enters the cold dust collector
chamber. Vibrators can be used to pre-
vent material collecting on the dust
collector body.
Another option under development
is a wet dust control system. To keep
the system from freezing is a design
challenge. In this case short hose con-
nections with diesel fired pre-heaters
create enough energy to keep the Watermist closed. Watermist open.
system in operation.The benefit with
wet systems is the reduced number of
moving parts.
Given that the time limit for human
exposure to very cold air is 15 min-
utes, the cab for artic rigs must be big
enough for two operators and their cold
weather clothing. Additional insulation,
heating and defrosting capability are
also essential. Proheat closed. Proheat open.
The marriage of low temperature
solutions and advanced technology on
Atlas Copco Drilling Solutions rotary
blasthole drills has been successful.
Today over 150 Drillmaster and Pit
Viper class rigs work in coal, gold,
copper, diamond and iron mines where
temperatures can drop below -40C.

John Stinson Wiggins closed. Wiggins open.

42 Blasthole Drilling in Open Pit Mining

 Talking Technically

Tricone rotary blasthole drilling

Rotary tricone
bit elements
Rotary tricone bits consist of se-
veral basic parts: Three roller
cones with the bit cutting struc-
ture (tungsten carbide inserts or
milled steel teeth) on their exter-
nal surfaces; bearing races ma-
chined inside each cone bore;
three sets of bearing elements con-
sisting of small inner rollers, ball
bearings, and large outer roll-
ers; and three lugs, each having
inner, ball, and outer bearing races
that match the cone bore races
and hold the different bearing
elements.

Rotary tricone bit

fundamentals
Rotary tricone bits consist of several
basic parts:
Three roller cones that hold the
cutting structure on their external
surface, and the bearings in their
interior
The cutting structure consisting of
either Tungsten Carbide Insert teeth,
or milled steel teeth.
Three lugs, each of which has the
bearing journals which match up
with the cone bearing bore.
Inner and outer roller bearing ele-
ments.
Ball bearing elements.
These basic parts are then assembled
into bit thirds, and three thirds are
then assembled into a tricone (three
cone) bit.
Once completely assembled into a
finished bit, the bit pin connection is
threaded with the appropriate connec-
tion size and type for the bit diameter.
The figure at right illustrates the as-
sembled components of a tricone bit
and presents a cut away of one lug/
cone assembly to show the internal
component arrangement.
Note that this figure shows air pas-
sages from the bit interior into the bit
bearing areas. This is an air bearing
Elements of a rock bit.
bit. Other types of bearing configura-
tions are open (or fluid) bearing, and
sealed bearing.
Open bearings do not have any in-
ternal air passages, and the back of the
cones are open to the external drilling
environment.
Sealed bearings are completely
enclosed, with no internal air passages.
The bearings are sealed off from the
external drilling environment, and are
filled with pressurized grease.
Rock breakage
Contrary to popular opinion, rotary tri-
cone bits do not drill by crushing rock.
Instead, they actually drill by a mecha-
nism called spalling. A European
gentleman named Hertz originally de-
fined this method of rock breakage
back in the 1880s. If a force is applied
to an indenter in contact with a rock
surface, stress fields are set up under
that indenter. As the loading force on
the indenter is increased, the stress
fields extend outward and downward
from the point of contact and loading.
The applied load creates fractures
(cracks) that propogate along the stress
field vectors, seeking a free surface.
When these stress vectors find the free
surface, the crack is completed, and the
rock above the stress vector breaks free.
A rock chip or cutting is created,
and must now be removed.
Because tricone bits apply this force
to several inserts simultaneously on
each cone, the cones must constantly
be rotated to new indenting positions
in order to advance the hole. It would
do no good to simply continue to apply
weight to the bit without rotation.
Nothing would happen. The bit must be
rotated to bring new teeth into position
for loading and rock breakage.

Blasthole Drilling in Open Pit Mining 43

 Talking Technically
Air circulation through nozzles and bearings.
44 Blasthole Drilling in Open Pit Mining
Drillhole cleaning /
cuttings evacuation
Once the cuttings are created, they
must be evacuated. If the cuttings are
not removed from the hole, the bit will
be eroded by the abrasiveness of the
rock chips, and the teeth will quickly
wear down and/or fall out, rendering
the bit ineffective. In blasthole drilling,
hole cleaning is done with compressed
air.
The rotary bit is either attached di-
rectly to the drill pipe, or one of a num-
ber of other drilling accessories, (bit
adaptor subs, bit stabilizers) are used to
attach the rotary bit to the drill pipe.
The exact attachment method depends
upon the drilling situation.
In any case, a large volume of com-
pressed air is directed down through the
drill pipe (also called the drill string)
into the bit. The flow of compressed
air is intentionally restricted at the tri-
cone bit by the use of jet nozzles, in
order to create back pressure and a
pressure drop through the bit. This
back pressure forces air into the bear-
ings of an air bearing bit, to keep the
bearings cool and clean, and to prevent
contamination from entering the bit.
Secoroc wants to achieve an actual
pressure inside the bit of 45 psi (3.1 bar)
or higher. This will direct from 15%
to 25% of the air into the bearings for
bearing maintenance, while the remain-
ing majority of the air creates a jet blast
against the face of the hole to blow newly
formed cuttings away from the bit.
The following figure shows the bits
internal air path in yellow. Jet nozzles
are shown in purple.
Rock density (specific gravity) varies
greatly, depending on what material is
being drilled. Coal for instance has a
SG of around 1.6, while some iron ores
have a SG greater than 3.8. Most rock
we drill has an in situ SG of between
2.4 and 2.8. If there is a lot of natural
ground water, this can wet the cuttings,
increasing the cuttings SG by about 0.1
SG. Secoroc recommends a minimum
air Bailing Velocity of 5,000 - 7,000
feet/minute (1524 - 2134 meters/minute)
for light and dry materials, and 7,000 -
9,000 feet/minute (2134 - 2744 meters/
minute) for rock materials that are wet
or have a high density.
Drilling parameters
Secoroc tricone bits generally conform
to the IADC rock type classifications.
IADC is the International Association
of Drilling Contractors, who set many
standards and conventions for the
general drilling industry. Secoroc has
adapted certain IADC concepts to its
tricone bits.
Tungsten Carbide Insert bits fall into
five IADC classes:
4-1 to 4-4 - very soft to soft
5-1 to 5-4 - soft to medium
6-1 to 6-4 - medium to medium hard
7-1 to 7-4 - hard to very hard
8-1 to 8-4 - very hard to extremely
hard
In general, decades of bit manufac-
turing, and product development and
application experience gives us the
following operating guidelines:
For 4-1 to 4-4 IADC type bits:
50 to 150 RPM
1000 to 5000 pounds of applied load
per inch of bit diameter
For 5-1 to 5-4 IADC type bits:
50 to 150 RPM
3,000 to 6,500 pounds of applied
load per inch of bit diameter
For 6-1 to 6-4 IADC type bits:
50 to 120 RPM
4,000 to 7,000 pounds of applied
load per inch of bit diameter
For 7-1 to 7-4 IADC type bits:
50 to 90 RPM
4,000 - 8,000 pounds of applied load
per inch of bit diameter
For 8-1 to 8-3 IADC type bits:
40 to 80 RPM
6,000 - 9,000 pounds of applied load
per inch of bit diameter
As the rock gets harder, it is adviseable
to apply slower RPM. As more load is
applied to a bit it is adviseable to apply
slower RPM.
Strong rocks may need time for
the indenting teeth to create sufficient
stress in the rock fabric to cause it to
crack, and the crack propagate. Thus,
in strong or hard rock it is suggested
that lower RPM is used. Weak rock
does not need as much time to react to
the indenting teeth. Higher RPM can
be used effectively in softer ground.
These are general guidelines, and
are intended as suggestions only. Every
rock type is different, and every specific
 Talking Technically

IADC vs. Rock UCS

48000
8-1 to 8-4
70000
36000

7-1 to 7-4
56000
IADC Class

22000

6-1 to 6-4 42000

6000

5-1 to 5-4 28000

1000

4-1 to 4-4 10000

0 10000 20000 30000 40000 50000 60000 70000

Rock UCS (PSI)

IADC vs. Rock UCS Chart showing comparison of IADC classifications to rock hardness.

rock type exhibits a wide variation in cost. Considering that the cost of
mechanical properties at an individual owning and operating a modern rotary
site. Individual mines should determine drill rig can approach US$400 or more,
optimum operating parameters for each bit performance needs to be judged on
rock type and drill type at that specific what the total cost of operating the drill
site. is. This then, goes hand in hand with a
high penetration rate, and is accompa-
The value of a bit nied by a good service life.
Consider this example:
What is the value of a bit? What de- Drill operating cost per hour =
termines how good a bit is? Ask US$300
around, and you will probably get one Penetration rate of Competitors bits
of these four answers to the question of = 30 meters/hour
value: Penetration rate of Secoroc bits = 45
Low price meters/hour
Long service life Hole depth = 15 meters
High penetration rate The Operating Cost per Meter is
Low operating cost calculated by:
Secoroc believes the highest value a tri- OC/m = Drill Operating Cost /
cone rock bit can have is low operating Penetration Rate
Thus, it is easy to see that for a 15
meter drilled depth hole:
Competitors Operating Cost / meter
is US$300 / 30 = US$10.00
Secorocs Operating Cost / meter is
US$300 / 45 = US$6.66
The faster drilling Secoroc bit saves
the mining company US$3.37 for every
meter drilled. That is value.
Bit record keeping
Without keeping track of bit perform-
ance, there can be no way to measure
one bit type against another, and one
bit supplier against their competition.
Secoroc can provide the templates for
two types of Bit Record Book to re-
cord bit performance.
Compilation of product performance
histories creates a valuable tool for the
sales person and bit manufacturer. Dif-
ferent bits can be compared at a mine-
site. Performance of the same bit at dif-
ferent minesites can be compared. How
does one drill type compare against an-
other drill type? If a new mine is being
opened, you need to have an idea of
what products to offer, and what per-
formance can be expected.
Secoroc has a global product per-
formance database available in Lotus
Notes. Product performance from
mines around the world can be com-
pared. Sales people easily generate a
variety of reports for their monthly bu-
siness reviews and sales calls. Below
is an example of a report generated by
Perform v6, for two bit types compared
over a five month period:

Performance comparison for distance, of two bit types, over time. Clarence Zink

Blasthole Drilling in Open Pit Mining 45

 Talking Technically

46 Blasthole Drilling in Open Pit Mining

 Talking Technically

Optimizing the rotary drill string

Money in the bank
In rotary drilling, the careful selec-
tion of every drill string component
is vital to achieve accurate holes,
optimal rock fragmentation and
operational efficiency parame-
ters which affect total operational
costs.

Close attention
When developing a rotary drilling
system, most of the attention is usually
given to the drill rig, the capital equip-
ment that requires significant invest-
ment and hence a planned payback. The
second priority in the system tends to
be choice of rotary tricone drill bit
the Tricone. However, to utilize the full
power and capacity of the rig and the
bit, and at the same time increase serv-
ice life and productivity, consideration
should also be given to the entire drill
string. The optimal drill string includes
a shock absorber at the top, a rotary deck
bushing to centralize the drill string
as it passes through the deck of the rig,
strong and straight drill pipes and final-
ly a hole stabilizing roller stabili-zer
or bit sub-adaptor to optimize the per-
formance. Giving the necessary atten-
tion to every part of the drill string will Giving the necessary attention to the drill string components will pave the way for quality drilling and
lead to the lowest total operating costs lower total operating costs.
in rock excavation and fragmentation.
reduce wear and tear on the drill rig Shock absorber
The rotary drill string absorb damaging vibrations travelling
back up the drill string At the very top of the drill string
The primary purpose of the drill string improve transmission of energy from between the rotary head and drill pipe
is to transmit the rotational torque and the rotary head to drill bit a shock absorber is commonly used.
weight from the power source the centralize the drill bit within the hole As the name indicates, the intention of
rotary head of the rig to the rock longer bit life this tool is to reduce the negative effects
breaking drill bit. As for every rock reduce friction as the drill string of harmful vibrations that travel back
drilling method, the power must be passes through the drill rig deck up the string as a result of the drilling
transmitted as efficiently as possible, stabilize the hole wall to prevent hole process.
and return as few vibrations as possi- caving The benefits of using a shock absor-
ble, as these cause unnecessary wear on increase penetration rates and lower ber include:
the rig and reduce penetration rates. drilling costs improved torque control
When selecting components for the achieve blast hole accuracy for im- increased drilling penetration rates
drill string, attention must be given to proved blasting efficiency better drill rig availability and exten-
the different roles of the support tools improve the end result the frag- ded drill rig drive head and mast life
in the string. The aim can be to: mentation of the blasted rock. longer service life of drill bits

Blasthole Drilling in Open Pit Mining 47

 Talking Technically
Smoothdrive
shock absorbing
sub
Square drive
Welded strap
method flange method
WLS
EZ-Drill Duralloy
roller stabilizer bit sub adaptor
The optimal drill string includes a shock absorber, a rotary deck bushing, strong and straight drill pipes and
finally a hole stabilizing roller or bit sub-adaptor.
Deck bushing
To guide the drill string and reduce the
risk of wobbling, a rotary deck bushing
is utilized at the drill rig deck opening.
The deck bushing guides the pipes to
prevent reduction of rotary head torque
and assists with the final straightness
of the hole.
The deck bushing contains an outer
housing with a top flange that allows it
to fit perfectly into the deck opening. A
series of roller bearings allow the inner
sleeve to rotate with the drill string.
Wear of the deck bushing occurs pri-
marily on the inner sleeve as cuttings
are blown upwards, between the drill
pipe and the inner sleeve.
Drill pipe
The role of the drill pipe is to transfer
sufficient amounts of rotational torque
and weight to the drill bit. The goal is to
establish an optimal rate of penetration
48 Blasthole Drilling in Open Pit Mining
Smoothdrill
shock absorbing
sub
Threadsaver
sub
Full length repairable
Teamalloy
body drill pipe
(box-box optional)
OD
ID
Centeroll
rotary deck bushing
(repairable)
Duralloy bit sub
Secoroc Tricone bits
while still achieving an acceptable life
of the Tricone bit. The use of a strong
and straight alloy drill pipe is one of
the best ways of preventing wobbling
of the drill string and hole deviation.
Drill pipe is subjected to a severe and
abrasive environment, due to the rapid
evacuation of drilling cuttings through
the annulus of the hole, causing a sand-
blasting effect on the drill pipes. It is
logical, therefore, to utilize only the
best alloy steel for both the threaded
connections and the body of the drill
pipe. Special wear protection material
is applied to the most critical areas of
erosion at the bottom of the drill pipe.
The drill pipes can, in most cases, be
refurbished to prolong service life.
Bit sub adaptor or stabilizer
To connect the bit to the drill pipe, a
wearprotected bit sub adaptor is gener-
ally used when the rock formation is
relatively competent, and not in need
of stabilization within the hole. In some
softer, fractured rock formations, it is
worthwhile to consider the use of a sta-
B
bilizer as an alternative. The roller sta-
bilizer contains three roller assemblies
which provide support against the hole
A
walls, serving to both guide the drill bit
in a straight direction and pack the wall
D
of the hole to prevent caving in. The
use of either straight or spiral-bladed
C
stabilizers is strongly discouraged as
this causes excessive friction when
E
these blades are at full gauge diameter,
while they also lose gauge diameter
rapidly rendering them virtually useless
as a stabilizer after only a few shifts. In
addition, the spiral-bladed stabilizer
slows down the evacuation of the cut-
tings. So, to achieve improved hole
straightness, hole wall integrity, and at
the same time increase the effective life
of the stabilizer, only stabilizers with
rollers fitted with cemented carbide
inserts are recommended.
All in all, when you consider the
significant amount of capital invested
in a rotary blasthole drill rig and the
annual investments in Tricone drill bits,
the selection of the best quality rotary
drill string tools that are suited to the
application, is critical to the eventual
success of the drilling program. The
rotary drill string tools should not just
be considered as mere support tools, but
rather as an essential, integrated part of
the total rotary drilling system.
The following basic criteria should
be considered when deciding which
rotary drill string tools will best opti-
mize overall drilling performance and
cost effectiveness:
are quality materials and innovative
design used to address specific drill-
ing problems?
can the tools be refurbished for an
economical second run?
does the supplier of the tools offer
application and follow-up service?
In conclusion, straight blast holes
drilled exactly to the pre-planned hole
bottom positions, pave the way for
lower total operating costs, taking into
account the entire process drilling,
blasting, secondary breaking, loading,
haulage and crushing/screening.
Rick Meyer
 Talking Technically

Increased productivity with

DTH drilling

Cutaway section of Secoroc COP 64 Gold.

in joints; and efficient energy transmis- to the sales of hammers. The flexibility,
DTH growing sion, with the piston striking directly productivity and manoeuvrability of
in popularity on the bit. The COP 34-64 series of
hammers was introduced from 1992,
these rigs, when equipped with a COP
hammer, make them the most produc-
The DTH drilling method is grow- and immediately became the bench- tive combination on the market today.
ing even further in popularity, with mark for productivity within DTH
increases in all application seg-
ments, including blasthole, water
drilling. Over the years, the increase in COP Gold series
well, foundation, oil & gas, cool- average drilling pressure, from 17 bar
ing systems and drilling for heat to a current market standard of 30 bar, The increase in drilling pressure also
exchange pumps. DTH competes has improved hammer performance, had some negative impact on the inter-
favourably with rotary drilling in and productivity has increased pro- nal components of the DTH hammer,
open pit mines, mainly thanks to
portionally to air pressure. The intro- as the increased stress promoted the
increased productivity and flexibil-
ity. Open pit mining has adopted duction of the Atlas Copco ADS and risk of premature failures. So, in 1998,
smaller holes where rotary drilling SDE series of high-performance, high- Atlas Copco Secoroc decided on a long-
has either been replaced by DTH, pressure DTH rigs gave another boost term strategy to improve reliability,
or where DTH has been introdu-
ced to create a better finish to the
pit wall, as the method is also per-
fect for pre-splitting and smooth
blasting, which avoids back-crack-
ing. DTH drilling offers increased
productivity, and is fa-voured by
contractors for production drill-
ing. In larger quarries, the opti-
mum hole size is 110-171 mm.
With todays demands for strict
hole control for safe blasting in
populated areas, DTH drilling is a
popular choice among quarry
operators.

Quality holes
In the hole range 100-254 mm, DTH
drilling is the dominant drilling method
today. The main features of DTH drill-
ing in this hole range are: excellent
hole straightness within 1.5% devia-
tion without guiding equipment; good
hole cleaning, with plenty of air for
hole cleaning from the hammer; good
hole quality, with smooth and even hole
walls for easy charging of explosives;
deephole drilling capacity, with con-
stant penetration and no energy losses New Secoroc hammer and bit ready for action on an Atlas Copco drill rig.

Blasthole Drilling in Open Pit Mining 49

 Talking Technically

extended. And finally a new 12 spline

COP 64.2 steel COP 64 Gold steel Improvement
bit shank with 19% more area than
Yield point ReL(Mpa) 700 1400 100% DHD340A minimize shank failures in
Breaking strength Rm(Mpa) 1000 1950 95% soft or unconsolidated rock.
Hardness (HRc) 32 42 31%
Table 1 reveals not only that the yield point for the new steel grade is twice as high, but Hammer cylinder
also that breaking strength has been almost doubled.
The new cylinder has been redesigned
Table 1 Comparison of COP 64.2 and COP 64 Gold steel. in a number of important ways. COP
Gold boasts a cylinder made of low
while retaining the benchmark status Durability improvements, thanks to alloy wrought and toughened steel, a
of the COP DTH hammers. the higher tensile strength of the new new grade with a higher combined
Stage One of this strategy was the steel grade, are especially noticeable Molybdenum and Vanadium content
development of the second generation when the cylinder approaches mini- (4.8%) than its predecessor. The result
six-inch hammer, COP 64.2, introduced mum thickness limits. COP 64 Gold is greater impact strength and higher
in October, 2000, which incorporated enjoys a greater durability margin than wear and temperature resistance. All
newly-designed steel disc spring and its predecessor. in all, this means greater resistance
lower buffer. Performance was vastly The high demand for COP 64 Gold to breakage, impact, temperature and
improved, thanks to a drastic reduction hammers, particularly in applications wear for the new hammer cylinder.
in the number of internal failures. It where performance and reliability are Thanks to the new steel grade, cylinder
was also possible to rebuild the hammer major considerations, has led Atlas properties have been greatly improved.
without diminishing its performance, Copco Secoroc to add the COP 54 Gold Wear has been reduced, both internally
making it even more attractive. and COP 44 Gold to this increasingly and externally. Cuttings and moving
Stage Two was the introduction of successful range. parts no longer cause the problems
the third generation COP 64 hammer, In July 2004 COP 54 Gold was re- they once did. In effect, the service life
COP 64 Gold, which was unveiled in leased with the same features as the of the cylinder has been extended con-
August, 2001. This version offers su- COP 64 Gold and improved perfor- siderably.
stained performance and improved mance thanks to a heavier and modi-
longevity of the external parts. The fied piston and a 12 spline bit shank. Rebuilding
COP 64.2 resolved internal component The COP 44 Gold was released in
reliability, while the COP 64 Gold has Q3 2009. As the other hammers in With the introduction of COP Gold
experienced a dramatic drop in the nu- the Gold Series It will have improved Series, hammer life will increase sub-
mber of cylinder failures. longevity of the external parts thanks stantially. Less internal and external
COP 64 Gold also boasts improved to the Gold cylinder. Internally it is wear, together with a reduced minimum
sustainable efficiency, maintaining an improved with a heavier piston that cylinder wear limit, are key contribu-
average of 96% of original performance will increase the performance and ting factors. As a rule of thumb: If the
throughout its service life, which is a with modified buffers and a steel disc hammer has reach its external wear
further improvement on COP 64.2. spring the lifetime of internal parts is limits before 5000 drill meters use an

Secoroc COP 54 Gold.

50 Blasthole Drilling in Open Pit Mining

 Talking Technically

Total improvement

Due to wear resistance

Due to wear limit change

Due to less cylinder failure

Increase in service life of COP 64 Gold, which has a 50% longer life than its predecesssor.

Economy Kit and rebuild the hammer,
between 5000 and 10 000 drill meters
consider to rebuild the hammer and
with more than 10 000 drill meters the
internal parts could be subject to fatigue
failures. Ultimately, this means custom-
ers can look forward to increased drill
rig availability.
The sum total of these improve-
ments shows COP Gold Series to have
more than 50% greater service life, in
abrasive rock conditions, than its pre-
decessors.The customer benefits from
lower cost/metre drilled, thanks to less
downtime and greater abrasion resis-
tance, and 30-50% longer life of exter-
nal parts. Higher availability results
from less breakage in the threads of top
sub and chuck-ends of the cylinder, and
there are fewer stoppages for service
and maintenance. Improved penetration
rate and higher efficiency are a result
of reduced friction of the piston, and a
greater life cycle penetration rate is the
overall reward.
To sum up, the customer can drill
more holes per hammer than previ-
ously.
Applications
COP Gold Series is high-pressure ham-
mers, where performance is related to
air pressure. A lower limit of 12 bar for
deep hole applications is a good rule
of thumb.
In abrasive formations, performance
will be up to 15-50% better than old
COP STD, in what is an ideal applica-
tion for COP Gold hammers.
In soft unconsolidated rock drilling,
the 12-spline chuck concept and the
improved durability make COP Gold
the perfect hammer. High pressure
yields higher productivity, and drilling
pressures of 28-30 bar are not unusual.
The COP Gold hammer concept
offers customers a tool to meet the most
demanding requirements with sus-
tained productivity.
Leif Larsson

16 000
14 000
12 000
10 000
Drill metres

New Material
8 000 Old Material
6 000
4 000
2 000
0
146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128
Cylinder OD (mm)

Results of comparative tests with COP 64.2 and COP 64 Gold. The COP 64 Gold drilled 50% further.

Blasthole Drilling in Open Pit Mining 51

 Talking Technically

52 Blasthole Drilling in Open Pit Mining

 Talking Technically

Selecting the right DTH drilling

tools
Covering every
application
Atlas Copco Secoroc now has the
most comprehensive range of DTH
hammers, bits, and related equip-
ment of any supplier in the world,
backed by the strongest support
network in the industry. Whether
the call is for reliable hammers to
keep investment to a minimum,
or for the highest productivity to
ensure maximum rig output, Atlas
Copco Secoroc has the solution.
The company is the only manufac-
turer to offer both first and second
choice solutions in almost all typi-
cal DTH applications on a price vs
performance basis. For premium
performance and advanced tech-
nology, QLX (replacing TD) and
COP Gold hammers are offered.
For an optimum blend of features
and cost, the QL (Quantum Leap)
can be the solution for high reli-
ability at economical price. QLX,
COP Gold, and QL hammers are
also energy efficient, consuming
less fuel and with lower energy Quarrying application.
cost per drilled metre than other
DTH hammers. This wide choice
of DTH drilling tools is backed by
a reliable network of distributors
and customer centres that offer a
complete range of parts, service
and support.

Relevant applications
Quarrying
Companies producing in non-abrasive
rock formations should consider ham-
mers such as Secoroc QL series, a
time-tested and field-proven design
offering good productivity and ease
of service. Customers demanding the
highest productivity and/or drilling in
abrasive formations should consider
either the QLX or Secoroc COP Gold
hammers.These incorporate the latest
technology and are the most reli-
able and productive hammers on the
market. Changing a Secoroc bit.

Blasthole Drilling in Open Pit Mining 53

 Talking Technically
ROC L8.
Dimensional stone quarrying demands
consistent hole straightness, and such
operations typically use smaller size
holes of 90-105 mm in limestone,
granite and marble. Here the QLX 35
hammer is the best choice.
Mineral exploration
Mineral exploration generally occurs in
very remote locations, requiring robust
hammers capable of running high pres-
sures, in sometimes dirty environments.
54 Blasthole Drilling in Open Pit Mining
For true reverse circulation drilling with
face collection in mineral exploration
and in-pit grade control, the Secoroc
RC50 Reverse Circulation Hammer, in-
corporating the Quantum Leap cycle,
performs particularly well. Geotechnical
Environmental monitoring applications
will appreciate the Secoroc Quantum
Leap or COP hammers. Drilling of
holes for foundation, anchoring or
drainage also demands reliable, works
horses like the QL range of hammers.
Open pit mining
Mining operations typically have high
equipment utilization, drilling up to
80% of the working day with DTH. The
typical applications are normal 130-203
mm-diameter blast holes, 140-171 mm
buffer holes, or 115-140 mm pre-split
holes. Companies should consider
either the QLX or Secoroc COP Gold
hammers. These incorporate the latest
technology, and are the most reli-
able and productive hammers on the
market. For customers who are happy
with rebuilds, Secoroc COP Gold is re-
commended, while for those who typi-
cally run hammers until they wear out,
QLX will be the first choice.
Selecting the right hammer
The optimum hole range of blast holes
for DTH drilling is 90 mm to 254 mm.
Smaller holes are generally drilled
using top hammer, and larger holes ge-
nerally use rotary machines. As a rule
of thumb, the smallest hole diameter a
DTH hammer can drill is its nominal
size. A 4 inch hammer will drill a 4
inch (102 mm) hole. The limiting factor
is the outside diameter of the hammer,
because, as hole diameter reduces,
airflow is restricted. Maximum hole
size for production drilling is the no-
minal hammer size plus 1 inch, so for
a 4 inch hammer the maximum hole
size is 5 inch (127-130 mm). Choosing
the right hammer is largely determi-
ned by hole size and type of rock for-
mation. Ideally, the size of the ham-
mer should match the required hole di-
mension as closely as possible, leaving
just enough space for cuttings to eva-
cuate the hole. Secoroc hammers are
purpose-matched for all rock types and
applications. Where high performance
is the main criterion, Secoroc COP
Gold and Secoroc QLX hammers are
recommended. In deep hole drilling
applications, the QLX hammer has
proven superior performance and ad-
aptability to different air requirements,
thanks to the Air-Select System. Where
proven technology is required, the
Secoroc QL series of hammer are
known for their reliability and lon-
gevity, and for a reliable workhorse.
The Standard design for COP 54 and
COP 64 Gold hammers can be used

DM45 Blasthole Drill.
down to a depth of 330 ft (100 m) using
a Standard bit size, making it use-
ful for production drilling in quarries,
shallow waterwell drilling, and under-
ground blasthole drilling. QM (quarry
mining) is similar to Standard, but with
heavy duty chuck and wear sleeve, and
a backhead fitted with tungsten carbide
buttons for wear protection in harsh
and abrasive conditions. These also pro-
tect the top sub from excessive wear
when rotating out of the hole through
broken rock
Soft rock
Convex/Ballistic
Rocket bit ballistic
Bit designs and rock types.
Blasthole Drilling in Open Pit Mining 55
Highest performance
The Secoroc COP Gold and QLX
hammers are designed for the most
demanding drilling conditions and for
those applications requiring premium
performance.
These hammers feature state-of-the-
art technology and deliver both maxi-
mum productivity and profit.
Secoroc COP Gold
Superior longevity and reliability.
Easy to service and rebuild.
Medium hard rock (220 Mpa/32000 psi)
Flat front HD
SpeedBit
Concave
Concave DGR
Rocket bit spherical
Talking Technically
Best suited for production drilling
because of its excellent external wear
resistance and longevity.
Internal components coated for wear
and corrosion protection. Permits
multiple rebuilds.
Three start chuck thread for easy bit
changes.
Bit replacement possible without
using drill rig break-out chains and
wrenches.
Unique air cushion reduces wear and
tear on drill string and rig.
Hard rock
 Talking Technically
Bit designs Facts
Convex/Ballistic front design
Convex front with large cutting grooves and ballistic gauge
and centre buttons. For soft to medium hard non-abrasive
formations. The bit is designed for maximum penetration
rate. Also, an alternative in hard abrasive formations, if
high penetration rate is called for.
SpeedBit
Flat front design/ballistic centre buttons. Flat front with
spherical gauge buttons and ballistic centre buttons. For
high penetration in medium hard to hard abrasive formations.
Flat front design HD
Flat front with large spherical gauge buttons for hard and
abrasive formations. Also, front flushing grooves for effi-
cient cuttings removal.
Concave front design
Concave front with spherical buttons Perfect choice for
medium hard to hard, less abrasive, fractured formations.
Minimizes effect of hole d eviation.
Concave front design HD
Concave front with spherical buttons, with larger gauge
buttons. Ideal for medium hard to hard, abrasive and frac-
tured formations.
Concave DGR front design
Concave front with double rows of spherical gauge but-
tons. Only available for 8 in bits and larger. The rein-
forced gauge gives superior protection in medium hard to
hard, abrasive and fractured formations.
Rocket bit
Super high penetration in soft to medium hard formations
with low silica content. The Rocket bit also handles diffi-
cult formations with clay intrusions where other bit designs
will not work.
The Secoroc range of DTH bits ensures that every driller
can demand a solution for every application.
56 Blasthole Drilling in Open Pit Mining
Secoroc QLX
Provides the industrys highest
power output.
Best suited for deep hole applications.
Industry-leading simplicity and
serviceability, resulting in very low
operating costs.
Features modular components,
snap-in cylinders, a reversible
casing, backhead saver sleeves, and
many options.
The hybrid valved/valveless design
maximizes air compressor
productivity.
Selecting the right bit
Atlas Copco Secoroc has a comprehen-
sive range of DTH drill bits to match
all conceivable applications. Each bit
is made from quality alloy steel, and
has been precision machined to pro-
duce a perfect body, heat treated to the
required hardness, given surface com-
pression for fatigue resistance, and
fitted with precision buttons manufac-
tured in-house. Five basic designs are
available: CV Bit, FF Bit, SpeedBit, CC
Bit, and Rocket Bit.
These are designed for specific appli-
cations for all rock types, hardnesses
and conditions. Bit life and rate of pen-
etration are the most important criteria
in selecting the right bit for a particular
application. In most cases, the focus is
on productivity, so the fast cuttings
removal features of the SpeedBit and
Convex/Ballistic designs are preferable,
to ensure the buttons are cutting clean,
with the minimum of re-crushing. In
hard and abrasive formations, however,
the flat front (FF) HD design offers
best bit life, having strong gauge rows
with large spherical buttons which
are easy to regrind and maintain. The
SpeedBit offers improved productivity
with the same gauge as the FF HD, but
with ballistic buttons in the front for
faster penetration. An alternative is the
Concave design with spherical buttons.
The Rocket Bit can be dressed with bal-
listic buttons for use in soft to medium
hard formations where fractured rock
can be expected, or can be supplied with
spherical buttons for hard and abra-
sive formations. Bits are manufactured
to match all diameters of all Atlas
Copco Secoroc hammers.
 Talking Technically

Selecting the right tube

Key features of a high quality DTH
tube are durability, accuracy and man-
ageability. Atlas Copco Secoroc tubes
are made from cold drawn tubing, pro-
viding a superior surface finish and to-
lerance compared to conventional tu-
bes made from hot rolled tubing. This
drastically reduces the risk of scaling
from the tubes entering the hammer,
a major cause of premature hammer
failure. The joints are friction welded
to achieve maximum strength, and the
threads of the end-pieces are heat trea-
ted for optimum durability and stre-
ngth of the thread profile. This not only
ensures long thread life, but also ma-
kes coupling and uncoupling quick
and simple, reducing drilling time.
Tube diameter should be close to the
hammer diameter to provide optimum
flushing, reducing the chances of get-
ting stuck. In most applications, Atlas
Copco Secoroc standard API threads
will be the best choice. Atlas Copco
Secoroc also offers a wide range of
subs and crossover subs to meet an
array of demands, all manufactured to
the same standards as the tubes. Secoroc COP 54 Gold - the production drillers best friend.

COP Backhammer
Quality Standard End pieces
The COP Backhammer is a tool that
API grade N-80 tubes and adapters
can save and recover a drill string stuck
in a hole. It can be easily fitted in a sui- Lower yield limit N/mm2 min 550 min 550
table tube joint between the drill sup-
Tensile strength N/mm2 min 650 min 700
port and the rotation head to provide
an effective combination of backward Elongation A5 min % 18 21
hammering and vibration to loosen Core hardness HB 190230 210250
stuck drill strings.
Surface hardness HRC 5862

Service and support

Atlas Copco Secoroc service, support
and training follows every purchase,
to ensure that customers extract maxi-
mum productivity from their drilling
operations. Having a knowledgeable
and available Secoroc drilling engineer
on site or on-line makes the difference
between going it alone and tapping the
experience and know-how of a world-
class partner. For example, Secoroc
knows that using higher productivity
bits reduces the cost of each drilled
hole, and the simplest way to cut costs
is to drill holes faster. This has been
Drill tube Wall 23/8" 23/8" 27/8" 27/8" 31/2"
OD (mm) (mm) RD 50 API Reg API IF API Reg API IF API Reg
70 3.6
76 3.6
76 5.6
89 3.7
89 5.7
102 5.7
114 4.3
114 5.7
114 7.9

Blasthole Drilling in Open Pit Mining 57

 Talking Technically

With on-site support, the choice of DTH equipment is even easier to make.

a focus of product development, and
is at the core of Secoroc technology,
ensuring that every generation of prod-
ucts drills faster and more efficiently.
It takes a support team to apply this
knowledge, so that customers can be
assured they run a profitable and effi- dedicated manufacturer of DTH drill-
cient drilling operation in an increas- ing tools in the world.
ingly competitive business climate.
The bottom line is that the customer Leif Larsson
can count on Secoroc service and
support, supplied by the largest, most

58 Blasthole Drilling in Open Pit Mining

 Talking Technically

Blasting in open cut metal mines

Explosives
Since blasting was introduced in
mining as part of the production
process, blasting technology and
blast management have been inter-
connected. Explosives have been
the primary method of break-
ing and loosening rock since the
introduction of black powder.
Over the years, however, blast-
ing technology such as the physi-
cal properties of explosives and
types of detonators has evolved.
The same holds true for the pro-
cess of blast management from
design principles for production
blasts that are cost-effective and
optimize mining operations, to
safety and accident prevention
during every step of the drilling
and blasting process. Drilling
and blasting results have a major
impact on many processes in a Bulk explosives are loaded using an Orica Mobile Manufacturing Unit (MMU ).
mine. Therefore, it is important
to find the right combination of
drill pattern, explosives and blast An oxidizer: a chemical which pro- syrup to firm putty. There are also vari-
design to contribute to the eco- vides oxygen for the reaction. Am- ous blends of emulsion and ANFO type
nomic success of the total mining monium nitrate is the most common explosives, notably so-called heavy
operation. oxidizer; ANFOs. Watergel (slurry) explosives
A fuel: which reacts with oxygen to are also used in some countries.
produce heat. The physical properties of the explo-
Principles A sensitizer: which provides voids sive can dictate the handling system
that act as hot spots where the reac- used to charge the explosive into blast-
When properly initiated, commercial tion starts during detonation. Sen- holes.
explosives are rapidly converted into sitizers are generally air or gas in the
gases at high temperature and pressure. form of very small bubbles, some- Water resistance
When detonated unconfined, a liter of times encapsulated in glass micro- The water resistance of explosives va-
explosive expands to around 1000 litres balloons (GMBs). ries considerably. Emulsions have ex-
of gas in milliseconds. When confined cellent water resistance; heavy ANFOs
by rock, expanding explosion gases re- An explosive is classified as detonator- have some water resistance while ANFO
sult in extremely high stresses in the sensitive if it can be reliably initiated has negligible water resistance.
rock. The gas energy released during in an unconfined state by a #8 strength
detonation acts equally in all directions detonator (which has a base charge of Density
but tends to escape through any path 0.46 g of PETN). Detonator-sensitive The in-hole density of explosives has
of least resistance. Therefore, blastholes explosives may or may not contain in- a significant effect on the energy per
should be charged and stemmed so that gredients that are themselves explo- meter of charge length. Higher-density
the gases are confined for sufficient time sives. explosives generate more energy. Ex-
to provide optimum breakage, displace- plosives are supplied in different densi-
ment and looseness of the blasted rock. Properties of explosives ties to enable the shotfirer to control the
The majority of explosives used in total energy released in a blasthole to
todays surface metal mines are primer- The physical characteristics of the vari- suit the particular blasting conditions
sensitive explosives. Under normal con- ous types of explosives differ markedly. and to achieve the desired result.
ditions of use, a primer is required to For example, ANFO type explosives are
initiate them reliably. loose, free-flowing, granular composi- Sensitivity
All primer-sensitive explosives cotain tions, whereas emulsion explosives have Sensitivity is a measure of the ease with
the following essential components: a consistency that varies from that of which an explosive can be initiated by

Blasthole Drilling in Open Pit Mining 59

 Talking Technically
Drilling at the Aitik Mine, northern Sweden.
heat, friction impact, or shock. The
trend in commercial explosives is
towards lower sensitivity to initiation
without detracting from detonation
efficiency.
Critical diameter
The critical diameter of an explosive is
the diameter below which a stable deto-
nation does not occur. To ensure reli-
able initiation under normal conditions
of use, explosive suppliers recommend
a minimum diameter for each of their
products. To ensure reliable results under
most conditions, the recommended mini-
mum diameter is larger than the critical
diameter.
Desensitization
Most explosives become less sensitive
at higher densities. Desensitization can
occur at excessive hole depths due to the
static head of pressure. It is also possi-
ble for explosives to be dynamically
desensitized by nearby earlier firing
charges.
Velocity of detonation (VOD)
VOD is the speed with which the deto-
nation propagates through a column of
explosive. Two explosives having the
same strength but different VOD may
perform quite differently in a blast. As
a general rule, the higher the VOD,
the greater the shock energy and the
lower the heave energy. However, it is
important not to correlate shock energy
directly with fragmentation energy.
60 Blasthole Drilling in Open Pit Mining
The VOD of explosives used in sur-
face metal mines vary between about
3000 m/s and 7500 m/s. The VOD of
many explosives increases with charge
diameter and confinement. Because of
their high degree of refinement and effi-
ciency, emulsion explosives can main-
tain very high VOD even with poor con-
finement and in small diameters.
Energy/strength
The energy of an explosive expresses
the ability of the explosive to do work.
An explosive with greater energy will
be able to do more work on the surroun-
ding rock. Energy produced by an ex-
plosive can be calculated using thermo-
dynamic codes and measured using a
variety of techniques.
Shock energy, gas energy and
heave energy
Following detonation, high-pressure
gases compress and crush the rock im-
mediately surrounding the explosives.
This results in an increase in the size of
the blasthole and will vary according
to the characteristics of the rock. The
energy that is released by the explosive
can be partitioned into two main types,
the shock energy and the heave energy.
The shock energy that is delivered to
the rock is related to the extent and the
rate of the borehole expansion to a so-
called equilibrium state and includes
the effects due to sub-optimal initiation.
The energy delivered thus far is termed
shock energy, which is primarily
responsible for conditioning the rock
and initiating mechanisms that gener-
ate fractures.
The gas energy or heave energy
is delivered during the later expansion
of the explosive products into the crack
network of the rock. Once a fracture
network is established the gas is able to
expand into the network, both extend-
ing the fracture process and causing
movement of the rock. As this happens,
the gas pressure drops until it vents to
the atmosphere.
Primer-sensitive explosives
Primer-sensitive explosives have rela-
tively low sensitivity to shock, friction
and impact, resulting in excellent safety
and handling characteristics. The reli-
able detonation of primer-sensitive ex-
plosives requires initiation by a primer
(e.g. Pentex) that is in good contact
with the charge. Ammonium nitrate is
the major ingredient of most primer sen-
sitive explosives.
Detonator-sensitive explosives
Detonator-sensitive explosives include
Pentex boosters and Senatel pack-
aged emulsions, which can be reliably
initiated by a single #8 strength detona-
tor or by a strand of 10 g/m detonating
cord.
Initiating systems
Initiating systems are used to safely
initiate charges of explosives at pre-
determined times by carrying a firing
signal from one place to another, using
chemical or electrical energy.
 Talking Technically

Modern initiating explosives incor-

porate various explosive and inert
components, which are partly or wholly
consumed in the blast. Small quantities
of signal tubing or wire often remain in
the muckpile.
Non-electric initiating explosives use
pyrotechnic compositions or explosives
to store and transmit energy by control-
led shock waves, detonation or burning.
Electric initiating systems require an ex-
ploder to generate an electrical charge,
which is transmitted along wires. Blast
timing is usually controlled by pyro-
technic (burning) delay elements lo-
cated inside detonators.
Non-electric initiating systems ba-
sed on a signal tube are currently the
most widely used for blasting in surface
metal mines. Most mines now use non-
electric detonators inside blastholes,
with remote initiation of blasts using a
non-electric firing system. Examples of initiating systems produced by Orica.
Electronic blasting systems are be-
coming more common, and differ from
electric and non-electric delay systems
in that the delay time is controlled by
a programmable integrated circuit, re-
sulting in very precise timing. The ac-
curacy and programmability of elec-
tronic detonators allows for blast timing
to be tailored to the geometry, geology
and unique requirements of any blast-
ing operation to more effectively use
explosives energy.

Bulk explosives
Specialized equipment and tools are
required to safely and effectively mix
and charge explosives in surface metal
mines. Most of the equipment and tools
used in blasting operations are subject
to statutory regulations.
A Mobile Manufacturing Unit
(MMU) is designed to produce and
deliver specif ied bulk explosives
from a manufacturing unit based on
a conventional truck chassis. Orica
MMUs are able to carry large quan-
tities of non-explosive raw materials
to the mine site, avoiding the need to
carry explosives on public or mine
roads. The bulk explosives are manu-
factured at the blasthole collar and
accurately delivered into blastholes at
high discharge rates. MMUs are pro-
duced in a variety of configurations to Electronic Blasting Systems can enable a mine to more efficiently achieve its productivity, safety, and
meet specific needs. The complexity of environmental performance objectives..

Blasthole Drilling in Open Pit Mining 61

 Talking Technically
The Mobile Manufacturing Unit on site (MMU).
the onboard manufacturing facility de-
pends on the type and number of explo-
sives required. The truck on which this
is mounted is selected to suit the ma-
terial to be carried and the terrain on
which it will operate.
Explosives selection,
priming and charging
Priming and charging of blastholes is
one of the most important parts of a suc-
cessful blast. Blastholes must be accu-
rately primed and charged to the design
specified by the blast designer.
The objective when selecting a com-
bination of explosives is reliable per-
formance, which will ensure the lowest
overall operating costs without sacri-
ficing safety. When selecting explosives,
the first considerations are the site geol-
ogy and the end objectives of blasting.
Once assessed, there are other important
considerations such as:
Ground water conditions;
The properties of the rock being bla-
sted, i.e. strength, structure, etc.;
The diameter and depth of blast-
holes;
Drilling costs and drilling capacity;
The relative explosives cost per unit
of effective energy;
The fragmentation and heave char-
acteristics of the explosives;
Shelf life;
Desired results.
ANFO has often been selected when
blasting dry blastholes. Wet blastholes
62 Blasthole Drilling in Open Pit Mining
ideally should be charged with a water-
resistant explosive, either an emulsion
or a watergel. The explosive will dis-
place the water up the hole, which may
flow into adjacent dry blastholes. While
ANFO is considered somewhat of a ref-
erence point, there has more recently
been an increased emphasis on both
lower and higher energy bulk explo-
sives to meet the evolving demands of
the mining industry.
Other options that may be considered
are:
Dewater the holes using in-hole
pumps, compressed air or other
means, and then treat them as blast-
holes containing nuisance water by
charging with water-resistant bulk
or packaged explosives to above the
original water level, then continuing
with ANFO.
Charge the wet blastholes with pack-
aged explosives until above the water
level. Then charge with ANFO.
Blast design
When starting to work a new mine or
a new area of an existing mine, it is ne-
cessary to develop one or more initial
designs for production blasts. In this si-
tuation, some rules of thumb, derived
over many years of relevant practical
experience, should be used for develop-
ing these designs. If a detailed assess-
ment of rock mass properties has been
carried out, computer modeling can
be used to assess the suitability of the
designs developed, and possibly to
indicate alternative superior designs.
Initial blast designs must then be pro-
gressively improved to optimize mining
operations and costs. Optimum designs
help to produce the required fragmenta-
tion, muckpile looseness, muckpile pro-
file, toe conditions and grade control.
In some cases, blast designs must also
minimize flyrock and control ground
vibrations and air overpressures.
Design variables
Bench height normally lies in the range
of 5-18 meters The selected bench
height is influenced by:
Statutory regulations (excessively
high benches are unsafe and, there-
fore, not permitted);
Rock mass properties;
The type and size of digging equip-
ment;
Grade - control requirements;
The need to maximize the overall cost
efficiency of drilling and blasting.
Increasing bench height decreases to-
tal drilling consumption of primers and
initiators, the labor required for firing,
and the number of mining cycles. Op-
timum blasthole diameter increases with
bench height. In general, an increase in
blasthole diameter decreases the total
cost of drilling. Drilling accuracy be-
comes more critical in higher benches
and drill deviation can produce costly
consequences.
Blasthole diameter
Optimum blasthole diameter is greater
for higher benches and for larger dig-
ging, hauling and crushing equipment.
Large diameter blastholes are less suit-
able in strong, massive rock; when mini-
mal broken rock movement is required;
or where it is very important to control
blast vibrations. At large surface mines,
the total cost of mining is usually mini-
mized by drilling large diameter blast-
holes. Larger diameter blastholes reduce
costs for drilling, primers and initiators
and labor. They usually need higher
powder factors than small diameter
blastholes to give the same fragmenta-
tion, especially in strong rocks. Smaller
blastholes give better distribution of
energy in the rock mass.
 Talking Technically

Free faces
Effective free face
Forward displacement of blasted rock
occurs if a blast shoots to a free face
(Figure 1). Some movement of the rock
mass is necessary to allow for crack pro-
pagation. Increased movement assists
crack propagation and can improve frag-
mentation. This may not be the main
objective in some operations (e.g. blast-
ing in ore) so free faces may be limited
(choked) to restrict ore dilution.

Blasthole angle
Vertical blastholes are usually used in
surface metal mines because: Fig 1. Effective free face.
Angled blastholes are more difficult
to set up and drill;
Some drills do not have an angled
drilling capability; and Caution!
Drilling accuracy is greater with
Excessive
vertical blastholes.
Burden Airblast
In free-face blasting, vertical front- Flyrock
row blastholes often leave variable and
excessive burdens between the top and
bottom of the charge (Figure 2). This Required
Burden
variation is greater in high- or shallow-
dipping faces and can cause hard,
immovable toe. Front row blastholes Fig 2. Variable burdens, vertical holes. Fig 3. Excessive blasthole angles cause problems.
collared near the crest to control the
toe burden can cause explosion gases to
blow out prematurely in the face. (See
Figure 3 and 4) Airblast
This blow out has the potential to
create noise, airblast and flyrock and Flyrock
reduces blasthole pressure near the bench
floor level, which may prevent adequate
breakage and movement of the toe. This Caution!
may necessitate the use of some angled
blastholes in front rows. (Figure 5) Correct
Burden
Subdrilling and drilled length of
blasthole
Fig 4. Problems with variable burdens. Fig 5. Angled holes increases rock breakage.
Efficient excavation needs toe condi-
tions that suit the digging equipment.
Toe conditions are affected strongly Priming Bottom priming has several advan-
by the amount of effective subdrilling. The overriding concern in priming is tages over top priming. They include:
Subgrade or subdrilling is the length to locate the primer in the explosives Improved fragmentation, displace-
of the explosive charge, which lies column and ensure operational safety ment and muckpile looseness;
beneath the designed bench floor level. and efficiency. The primer is generally Reduced toe problems, better floors,
Unavoidable fallback of drill cuttings placed at or near grade level. Some ope- and cleaner faces;
and small rock fragments reduces the rators place the primer at a known dis- Reduced noise, airblast, flyrock and
effective subdrilling to less than that tance above or below bench floor level surface overbreak; and
originally drilled. It is good practice to ensure that, should a misfire occur, Fewer cut-offs and misfires.
to drill a certain extra distance (which the excavator operator does not dig di-
is longer for higher benches and weaker rectly into a primer. Charge distribution
rocks) to allow for unavoidable fall- This may be a valid reason for not Distribution of the explosive char-
back. placing the primer at bench floor level. ges in the rock mass is an important

Blasthole Drilling in Open Pit Mining 63

 Talking Technically

consideration when determining blast

geometry. Crater blasting to a horizon-
tal rock surface has a less efficient
charge distribution but is preferred in
shallow ore deposits where quality con-
trol dictates low benches, despite a higher
explosives consumption.

Blasthole pattern
Blasthole patterns depend on blasthole
(a) diameter, rock properties, explosive pro-
(a) Paddock
Paddock blast
blast staggered
staggered perties, bench height, and the results
needed. Operating experience and blast
modeling results have shown that, in
massive rocks, better fragmentation and
productivity are obtained with staggered
patterns than with either square or rec-
tangular patterns. Equilateral triangu-
lar patterns provide optimum distribu-
tion of explosion energy in the rock.
While staggered patterns give the best
theoretical performance, the initiation
sequence can alter the geometry and re-
(b)
(b) Paddock
Paddock blast
blast square
square sults of blasts on square or rectangular
patterns.

Spacing-to-burden ratio
Burden and spacing are related to blast-
hole diameter, depth, rock type and
charge length. Blasthole spacings con-
siderably smaller than the burden tend
to cause premature splitting between
blastholes and early loosening of the
stemming.
This can cause premature release of
(c)
(c) Paddock
Paddock blast
blast rectangular
rectangular explosion gases to the atmosphere and
considerable overbreak. Loss of heave
energy reduces breakage and produces
large rock slabs in the muckpile.
On the other hand, a spacing-to-bur-
den ratio that is too large can cause the
face midway between back-row blast-
holes to remain intact, especially near
bench floor level. This results in tight
digging and possibly unbroken toe.

Front-row blastholes
Special attention should be paid to the
position of front-row blastholes. If the
burden on front-row charges is exces-
sive, it will not be broken by the time
second-row charges detonate. Restric-
tion of motion at the beginning of the
blast can prevent optimum blasting
results throughout the blast. Where
burden is too small, explosion gases
d) Square Fired on Echelon burst rapidly through the face, causing
Fig 6. Blasthole patterns. noise, airblast and flyrock.

64 Blasthole Drilling in Open Pit Mining


Changing burden and spacing
Changes in burden generally affect
fragmentation, muckpile looseness and
toe much more rapidly than changes in
spacing. If enlarging a blast pattern for
improved economy, it is more common
to increase the blasthole spacing in
steps before altering the burden.
Stemming
Stemming enhances fragmentation and
rock displacement by reducing prema-
ture venting of high-pressure explosion
gases to the atmosphere. (Figure 7)
Dry granular materials are best for
stemming because they have inertial
resistance and high frictional resistance
to ejection. Materials that behave pla-
stically or that tend to flow are not suit-
able for stemming, e.g. water, mud, wet
clay. Stemming length can be reduced
significantly if effective stemming is
used, resulting in better explosive dis-
tribution and improved overall frag-
mentation. Optimum stemming length
depends mainly on blasthole diameter,
stemming material, and surrounding
rock properties. Inadequate stemming
increases collar rock breakage, but de-
creases overall fragmentation and dis-
placement because explosion gases vent
to the atmosphere more easily and ra-
pidly. It also creates more flyrock, sur-
face overbreak, noise and airblast.
Long stemming lengths ensure good
confinement of explosion gases, but
fragmentation of collar rock becomes
coarser.
Size and shape of blasts
Most oversize rocks come from the
back, sides and top of blasts. Boulders
are created by open fractures in the free
face, irregular burdens and by back-
break around the perimeter. Damage
from previous blasting around the peri-
meter opens fractures which define
rocks isolated from the rock mass.
These rocks are not fragmented by ex-
plosion-generated strains and cracks,
but are merely pushed forward into the
muckpile. In addition, large rocks that
have been torn loose or dislodged can
slide from the new faces into the muck-
pile. Increasing the blast size reduces
the proportion of large rocks from the
blast perimeter, and therefore improves
overall fragmentation.
Blasthole Drilling in Open Pit Mining 65
(a) Excessive
Airblast & Flyrock
(b) Good
breakage &
displacement
Fig 7. Effect of correct and incorrect stemming.
Allocation of delays
The sequence in which blastholes are
initiated and the time interval between
successive detonations has a major in-
fluence on overall blast performance.
The performance of production blasts
can only be optimized when charges de-
tonate in a controlled sequence at suit-
able discrete, but closely spaced, time
intervals.
Optimum delay allocation for a
blast depends on many factors, which
include:
Rock mass properties (strength,
Youngs modulus, density, porosity,
structure, etc.);
Blast geometry (burden, spacing,
bench height, free faces, etc.);
Diameter, inclination and length of
blasthole;
Explosive characteristics, degree of
coupling, decking, etc.;
Initiating system (surface or in-hole
delays, type of downline, non-electric
or electronic, etc);
Type and location of primer;
Environmental constraints (air and
ground vibration levels and fre-
quency); and
The desired result (fragmenta-
tion, muckpile displacement and
profile etc.).
It is not possible to determine optimum
delay allocations from first principles,
but blast monitoring, analysis and inter-
pretation have led to a greater under-
standing of the mechanisms and signi-
ficance of blasthole interaction.
Talking Technically
(c) Poor fragmentation
Delay along rows
The delay time between adjacent blast-
holes in a row is sometimes called the
intra-row delay. Firing a single row of
blastholes with the optimum delay be-
tween holes produces:
Optimized fragmentation for that
particular blast geometry;
Forward displacement, which is less
than that for an instantaneous single-
row blast; and
Reduced overbreak.
Delay between rows
The delay time between the initiations
of rows of blastholes is sometimes
termed the inter-row delay. The delay
between rows can be as important as
the delay along rows in controlling over-
all blast performance. Multi-row blasts
are fired using a time delay between
the detonations of successive rows of
blastholes. The burden on each blast-
hole needs time to move after the deto-
nation to create an effective free face.
Dependent blastholes then fire towards
this new free face developed during the
blast. (Figure 8)
Hole-by-hole initiation
In many situations the simplest method
of blast initiation hook-up is to fire
blastholes row by row or simultane-
ously along echelons. This will rarely
produce optimum blast performance,
especially in terms of fragmentation or
ground vibrations. The end result can be
improved by introducing hole-by-hole
 Talking Technically
3 2
(a) Good "Relief"
1 2
(b) Insufficient "Relief"
Fig 8. Burden relief.
firing, where every blasthole is ini-
tiated in sequence at a unique time.
Where appropriate delays are selected,
hole-by-hole initiation exploits the
positive benefits of blasthole interac-
tion while avoiding most of the nega-
tive effects. This leads to improved
fragmentation and muckpile looseness,
reduced overbreak, lower ground vibra-
tions, and better control over the final
muckpile position and profile.
Final wall blasting
At most open pit mines, the final slope
of the pit affects profitability appreci-
ably. Steep stable pit walls can be for-
med by smoothwall blasting tech-
niques, which include cushion blasting,
presplitting and postsplitting. But with
each of these techniques, the combined
cost of drilling and blasting is relatively
high. In some cases, stable pit walls
can be formed without smoothwall
blasting.
66 Blasthole Drilling in Open Pit Mining
1 aged. Sufficient standoff distances
3 on a correspondingly smaller pattern.
Careful blast design is the key to pro-
ducing clean, safe pit walls at minimum
cost. The blast design needs to consider
the rock conditions in the area, the
likely amount of backbreak from this
blast, and the design location of the
final pit limit. Key factors to consider
in final wall blasting are:
Geology Rock properties have the
greatest influence on the effect of
blasting on pit walls. Heavily jointed
rock often produces overbreak along
joint planes.
Blasthole location The location of
the back row of blastholes is critical
to the location of the final pit limit.
The back row of blastholes needs
to be drilled in front of the final pit
limit to allow for backbreak behind
the blastholes. The correct location
depends mainly on previous experi-
ence in the pit and trial and error, par-
ticularly if the amount of backbreak
is variable. If the standoff distance
between the back row and the pit
limit is too small, there will be too
much overbreak into the final face.
If the standoff distance is too large,
digging back to the design final face
will be difficult, expensive and may
need a bulldozer. (Figure 9)
Blasthole depth If blastholes are
drilled into the berm below then
the succeeding wall will be dam-
need to be maintained to designed
crests.
Smoothwall blasting techniques
Cushion blasting, postsplitting and pre-
splitting are the three common blast-
ing techniques used to produce stable
final walls. Postsplit and presplit blasts
are often used alone to produce stable
walls.
Cushion blasting is frequently over-
looked when designing final-wall
blasts, but can be the most versatile and
useful method of the three techniques.
The back-row blastholes in a cushion
blast contain lighter charges than the
production blastholes, and are drilled
Cushion blastholes are usually the same
diameter as the production blastholes in
front of them.
Charge weight is commonly reduced
by about 45 percent, and both burden
and spacing by about 25 percent. The
energy factor is therefore essentially the
same throughout the final wall blast.
A postsplit blast consists of a row
of parallel, closely spaced blastholes
drilled along the final face. These blast-
holes are charged with a light, well-
distributed charge, and fired after the
production blastholes in front have
detonated. Postsplit blastholes split the
rock web between the blastholes to pro-
duce a sound smooth face with minimal
overbreak.
Presplitting requires a row of closely
spaced blastholes drilled along the de-
sign excavation limit, charged very
lightly, and detonated simultaneously
before the blastholes in front of them.
Special blasting
techniques
While the main emphasis in surface
metal mines is on production blasting,

there are times when special blasting
techniques are required. These include:
Opening up new benches using
either drop cut or ramp blasting
Mining of weathered and fresh rock
Dilution control
Choke blasting
Blasting ore and waste together
Steeply dipping multi vein orebodies
Shallow dipping narrow vein ore-
bodies
Flat or bedded orebodies
Selective ore blasting
Separate ore and waste blasting
Deck charging
Secondary blasting and popping
Plaster blasting
Floor and toe blasting
Safety and accident prevention
Safe and cost-efficient blasting requires
all mine operators and supervisors to
understand and follow correct proce-
dures for handling and using explosives.
Most mines now have on-site induction
training to develop skills for specific
jobs, including blasting. Many mines
have written work procedures, which
specify the method, tools and equip-
ment to be used for each job. These pro-
cedures, combined with local mine rules
and statutory regulations, are designed
to maintain the health and safety of
all people working in the mining en-
vironment.
Blasting requires the use of special
tools and equipment, which are usually
subject to statutory regulations. All
tools and equipment used for charging
and firing explosives should be prop-
erly maintained, regularly checked and
correctly used.
There should be no improvisation or
substitution, as this can cause injuries
and accidents.
There are many hazards when work-
ing in and about a mine. The additional
hazards associated when using explo-
sives that need to be mitigated are:
Electrical hazards that can affect the
use of electric detonators. The sour-
ces of electrical current are static,
stray currents from machinery, light-
ning and radio frequency energy.
Heavy impact on initiating explo-
sives
Vehicles driving over explosives
Hot and reactive ground
Blasthole Drilling in Open Pit Mining 67
Production
Blastholes
Final Limit
Reduced
Energy per m
No Subgrade
Fig 9. Placement of blastholes along final pit limits.
Misfires
Fume
Walking on rough ground and
around blast holes
Vehicle and pedestrian congestion
on the bench
Charging blastholes safely
Before charging commences, the bla-
sting area should be barricaded and
marked with cautionary signs and
lights. All unnecessary tools, equip-
ment and people not involved with bla-
sting should be removed from the area.
Smoking must not be permitted near
explosives or charging operations.
The quantity of explosives deliv-
ered to the job should not far exceed
immediate requirements, and any
unused explosives must be returned to
the magazine when charging has been
completed.
Explosives and detonators must be
kept apart in separate containers until
charging commences. These containers
should be located in a safe place, clear
of equipment, and marked by appropri-
ate signs or lighting.
Electric detonators must be kept
clear of all sources of electricity and all
Talking Technically
Could be Presplit
Maybe Smaller
Diameter
Final Limit
potential conductors of stray currents.
Electric detonators should be kept coi-
led, with the lead wires shorted toge-
ther, until they are used.
All blastholes should be cleared of
obstructions and checked for length
before charging. Drilling sludge and
loose rocks should be washed or blown
out before charging.
Economics and benefits
Cost effectiveness of drilling and blast-
ing can be defined in many ways, but
the bottom line is that these opera-
tions must contribute to the best overall
economic result for the total mining
operation. Drilling and blasting influ-
ences many different processes in a
mine, with the benefits of a cost-effec-
tive blast being felt anywhere from dig-
ging to maintenance, hauling, crush-
ing and milling, ore recovery to labor
utilization and secondary breakage.
Therefore, decisions on drilling and bla-
sting need to be made in the overall con-
text, and should not generally be based
on short-term economic factors.
The development and introduction of
bulk explosives and efficient delivery
 Talking Technically

Cost per
Tonne Total
Costs
Zone of
Minimum
Total Costs
Load & Haul

Crushing
Unit Costs ($)

A Secondary
Drill
B C
& Blast

Fragmentation
Fig 10. Costs versus fragmentation.

systems has provided a quantum step operations. The optimization criteria

forward in blasting efficiency and has for mine production operations can be
allowed cost reduction through econo- expressed as finding the right combi-
mies of scale. nation of activity costs, and managing
The factors contributing to economic them in order to minimize the overall
production in mines include: production costs (Note: this does not
mean that reducing any particular
Productivity parameter in isolation will necessarily
Overburden/waste removal result in a lowering of overall costs).
Primary raw feed/mine production/ Figure 10 schematically represents the
sales tonnage activity costs as a function of maxi-
Mobile equipment capacity/type and mum fragmentation size. The relation-
availability ship between these activity costs varies
Fixed plant capacity/type from mine to mine.
Ore grade control factors The curve is divided into three zones
Maximizing reserves through struc- A, B and C. Zone B is where the total
tural stability costs are minimized within a control-
Minimizing stripping ratio: waste/ lable and acceptable range. In zones
ore A and C the unit costs of one or more
activities make the overall production
Mine conditions cost excessive. In this case, the cost
Type and extent of overburden/ effectiveness of blasting does not ne-
waste cessarily increase with a decrease in
Rock type and geology blasting costs, and changes can often
Height and inclination of operating be counterproductive.
benches The best time to break rock is
Ground water conditions undoubtedly during the primary blast
Environmental constraints the aim being to achieve desired and
predictable fragmentation, muckpile
Labor force competence looseness, and a suitable muckpile
Training profile for ease of digging. During the
Motivation and numbers evaluation, other key issues may be:
To modify fragmentation to suit
Operating costs vs excavator or crusher specifications;
To make blasting more environmen-
fragmentation tally acceptable;
Drilling and blasting results have a To improve labor utilization allo-
major impact on each part of a mine's cated to blasting;
The PV-351 can drill blastholes up to 16 inches in
diameter.
To reduce blasting costs, particularly
in wet areas;
To protect pitwalls or control over-
break damage; and
To maximize recovery of product
ore.
The process of optimizing blasting
must be done in a controlled manner
so that the inf luence of changes on
blast performance can be measured
and evaluated. It is most important that
changes are made one at a time, and
that a thorough analysis of the total cost
and the blast performance are made to
enable any benefits to be identified and
quantified.
Acknowledgements
Article provided by Orica, the world's
leading provider of commercial explo-
sives, blasting systems and blast based
services. Read more at:
www.oricaminingservices.com

68 Blasthole Drilling in Open Pit Mining

 Talking Technically

Fuel saving clutch

Automatic
clutch system
With rising diesel and electricity
costs, reducing fuel consump-
tion is vital to stay competitive in
todays market. A new innovative
solution to reduce the fuel con-
sumption in drilling applications
is the patent pending automatic
hydraulic clutch. It disengages
the compressor from the diesel
engine during non-drilling opera-
tions.

Turning the compressor off

Atlas Copco is once again taking the
industry lead by introducing and imple-
menting the patent-pending automatic
clutch system on selected surface drill-
ing machines. Although this is new to
the mining market, it is a time proven
technology that has been used in other
industries. Through an integrated
clutch-control unit that activates the
clutch, our engineers have developed
this option to help mines save on the
fuel costs and maintenance, and to con-
tribute in helping the environment by
drastically reducing the amount of fuel
consumed by our machines.
Typically, if you were to study a
drill in a surface mine, you would find
it performing one of the following
tasks: drilling, propelling/tramming,
leveling and rod handling. Today, both
the engine and compressor run at all
times for all five functions, although
the compressor is only required for one
of these tasks: to get the cuttings out of
the hole during the drilling cycle.
Wouldnt it be advantageous, though,
to only use the compressor during drill-
ing and not for the other four phases?
For example, turning the air compressor
on-and-off when deemed necessary and
saving horsepower drawn on the engine
would be greatly beneficial. Even with
the air switched off the compressor still
uses approximately 30% of the rated
horsepower even in standby mode.
This action alone could ultimately save
The automatic clutch system was first introduced for the Pit Viper 235 series and is now also available for
the PV-271, PV-275 and PV-311.
a mine thousands of dollars in fuel and
maintenance costs not to mention the
vast impact that less fuel usage would
have on the environment.
No change to rig operation
With the addition of the clutch system,
it is important to note that the operation
of the machine will remain the exact
same; the clutch integration is minimal
(which also means the clutch can easily
be retrofitted to a machine already
in the field) and will not require any
additional inputs from the operator (See
Figure 1). Once the operator is ready
to drill another hole, they set up the
machine as usual and then turn the air
ON. At this moment a signal is sent
to the clutch control unit and the engine
speed automatically drops to around
900 rpm and the clutch begins feather-
ing the engagement.
Once the speed of the compressor
matches the speed of the engine, the
engine automatically ramps back up
to full speed, the air is now ON and
the compressor has already started
to generate air. All of this happens
within three seconds, so there is no
visible delay. Once the hole is drilled,
the operator then turns OFF the air,
disengaging the compressor, and moves
on to the next hole.
Lets look at a scenario that utilizes
the exact same machine drilling both
single-pass and multi-pass, with and
without a clutch.
If two machines are compared, one
with the clutch system and one without

Blasthole Drilling in Open Pit Mining 69

 Talking Technically
working in the exact same rock forma-
tion, it is easy to visualize the immedi-
ate fuel savings from one single-drilled
hole.
Extending out the fuel savings of
one hole over a mines yearly produc-
tion can greatly assist in increasing the
bottom line. As we can see from the
chart (Figure 2), the fuel savings tend
to increase during multi-pass drilling
since the machine spends more time
performing non-drilling functions when
compared to a single-pass machine.
Furthermore, the fuel savings are also
higher in soft rock formations when
compared to a hard rock formation.
The reason for this lies in the fact
that in order to drill hard rock, the
machine typically spends more time
drilling the rock compared to handling
the drill pipe, ultimately consum-
ing more horsepower and fuel than a
machine used purely for rotary drilling.
Regardless of whether a mine is multi-
pass drilling or single-pass drilling in a
soft or hard rock formation, the reality
is that there is potential for sizeable
cost savings. In fact, with some pre-
liminary studies of this option, we have
seen some increasingly high fuel sav-
ings that could make a significant dif-
ference in any mines operating budget.
Added advantages
Combined with Atlas Copcos large
capacity fuel and water tanks, the
clutch system can greatly increase pro-
duction time while reducing the amount
of time that fuel and water trucks spend
making trips down to the machine at
the bottom of the pit. For example, a
11 14 35
35 75 115
Figure 2: Fuel Consumption based on Depth Drilled . An indication of fuel savings when drilling at different depths in soft formations. Savings with the clutch
increase with the depth of the hole and number of pipe changes and will also be greater when drilling in soft rock where the rate of penetration is high. Actual
savings must be estimated for each drill rig and application.
70 Blasthole Drilling in Open Pit Mining
mine can maximize the fuel capacity
on a PV-275 up to 2,365 liters (625 gal-
lons), and still have a 3,100 liter (822
gallon) water tank. The combination of
the large fuel and water tanks would
allow the machine to run for over 24
hours of operation without the fuel
truck needing to make a visit, as well
as provide the machine with over 24
hours of water. Figure 1: Clutch system, the patent pending auto-
As an ISO 14001 certified company, matic clutch system supplied as an option for se-
Atlas Copco continually strives to lected rotary blasthole drill rigs. Below: A rig
ensure that the highest environmental equipped with this system only uses compressed
air for drilling and hole cleaning (yellow arrows).
standards are adhered to during the
design, assembly, and utilization of
our machines. This additional and wel- Leveling
comed option is just one item in a large
ng
portfolio of options that we offer on our
Dr
ni
tio
illi
machines, all catered toward design-
Posi
ng
ing and manufacturing enviro mentally
conscious equipment. The clutch system
nin g
not only contributes to reducing a mines
le a
Tr a
operating budget, but more importantly
ec
m
we are able to support the mine through
mi
g
ol
H
n
a wide range of safety and environmen- Pip e g
h a n d li n
tal options. Our ability to do this ulti-
mately helps our customers to pursue Working cycle.
their goal of responsible mining, which
benefits not only the environment but
their personnel as well. meter and therefore the service inter-
val and rebuild time was dependant
Three benefits of the clutch on when the engine had to be ser-
option viced or rebuilt. With the clutch, the
compressor has its own hour meter
The clutch omits the parasitic load of and its own service interval based
the compressor on the engine during only on hours of actual use.
start-up, specifically in cold weather The advantage of getting the job
environments. This ultimately increa- done with less fuel is an added bene-
ses engine and compressor life over fit in itself, not just for the mine but
the life of the machine. for the environment as well.
On previous configurations, the com
pressor did not have a dedicated hour Maureen Bohac
WITHOUT Clutch
WITH Clutch
Bench
Height
47 53 m
155 175 ft
 Talking Technically

The mid-range Pit Viper 235

The star of
MINExpo 2008
The new ultra class haul trucks
in the Central Hall arguably may
have achieved the greatest visual
impact at MINExpo 2008, but sur-
face mine drillers attending the
record-breaking Las Vegas show
in 2008 hailed their own new
star in the North Hall the Atlas
Copco Drilling Solutions Pit Viper
235 at the Atlas Copco display.
This PV-230 class machine thus
followed in the tracks of the first
Pit Viper model, the PV-351, which
was launched at MINExpo 2000,
and the PV-270 series models in-
troduced at MINExpo 2004.

Efficiency and productivity

The PV-235 has a weight on bit of up
to 65,000 pounds (29,500 kg) and is
designed for rotary or downhole (DTH)
drilling of 6-inch to 9 -inch (152 251
mm) diameter holes. Competitive per-
formance and excellent long-term reli-
ability have been key marketing points
for the Atlas Copco Drilling Solutions
range of drilling rigs for a long time.
The PV-235 is specified and fabricated
to maintain this reputation, with parti-
cular attention having been paid to the
reduction of horsepower demand and
non-drilling time. The cab and control
technology have been significantly
upgraded and the diesel engine options
are Tier II and Tier III units. Pit Viper 235 is capable of dilling a single pass 40 ft clean hole.
Atlas Copco Drilling Solutions has
again placed great emphasis on flex- hydraulic systems, including the rotary 40 ft tower is fitted. The dimensions for
ibility in application, and the PV-235 is head, that have consistently been pre- the PV-235 version with tower up is 34
available with two towers to drill 35 ft ferred by the Atlas Copco design and feet 2 inches long and 14 feet 6 inches
(10.7 m) or 40 ft (12.2 m) clean 230 mm engineering team for many years. wide (10.4 x 4.4 m). The high-speed
holes. The new machine can be con- tram operates with the tower lowered.
figured in a surprising number of ways Less mass, more options The plate steel frame is new to blast-
to offer an optimal match to a mines hole drill construction and was desig-
particular operating method and envi- Starting at ground level, the PV-235 ned using finite element analysis. The
ronment. has a newly designed platform. It is material thickness is one third that of
Like the PV-351 and the PV-270 built with two-speed hydraulic exca- an equivalent welded plate construction
models, the PV-235 will be available vator style Caterpillar 330 undercar- and has a better fatigue life. The frame
with either a choice of diesel engines riages the 330L for units with the accommodates the 450, 600, and 1050
or an electric motor. And it retains the 35 ft tower, and 330EL when the gallon fuel and water tanks, which are

Blasthole Drilling in Open Pit Mining 71

 Talking Technically

isolation mounted. An additional 400-

gallon water deck tank can be fitted if
no dust collector is used. Another 200
gallon belly tank is now offered with
the non-drill end deck extension.
For safer, easier and quicker trouble
shooting and maintenance, the Grip Strut
open mesh deck provides excellent ac-
cess to the superstructure elements, in-
cluding ground level battery and starter
isolators, deck level access for the service
points on most systems, and quick fills
at waist level. The deck hose and cable
trays manage the routing and clean up
the decking. An optional bolt-on drum
The enclosure option will reduce noise and provide cold weather protection; full-length doors offer easy
deck on the drill end adds extra space
service access.
for lube and other fluids storage tanks,
and cleans up the deck area to allow
300 of access and improved service-
ability. Other optional fittings include a
central lubrication system, fire suppres-
sion equipment, a jump start receptacle
and a spring assisted emergency ladder.
For mounting on this platform, Atlas
Copco Drilling Solutions has decided
to offer customers a wider choice of
power system options than on previous
models. The structure is similar to that
designed for the Pit Viper 351, with an
The hydraulic automatic cable tensioning cylinder is a time saver for maintenance . independent sub-structure and three-
point isolated mounting. But there is a
wider choice of Cummins or Caterpillar
engines, covering the range 600 800
hp at 1,800 rpm with the Cummins
QSX 15 to QSK 19 or Cat C18 to C27
engines, all meeting Tier II, III or IV
regulations.
There is also a wider choice of air
compressors, as either single-stage as-
ymmetrical oil flooded Atlas Copco
or Ingersoll-Rand rotary screw units
are available for low pressure (1,600
1,900 CFM, 100 psi) rotary drilling,
and the two-stage equivalents for high
pressure (1,250 or 1,450 CFM @ 350
psi or 1,300 CFM @ 435 psi) downhole
drilling. An Electronic Air Regulation
System (EARS) allows low load starting.
An Atlas Copco patent pending
automatic hydraulic clutch between the
engine and the air end has been intro-
duced during 2010 as a new option for
the Pit Viper 235 series. The benefit of
this clutch is that it will disengage the
air compressor from the engine when
For angle drilling the PV-235 uses a pivot at the base of the tower with adjustments from vertical to the air end is switched off. In a tradi-
30 degrees in 5-degree increments, while keeping the deck level. tional power package, the compressor
consumes approximately 30% of its

72 Blasthole Drilling in Open Pit Mining

 Talking Technically

rated power at standby. Installation of

this clutch eliminates fuel being used
for this standby power consumption
and allows for a low idle speed. While
changing rods, levelling, or moving
between the holes, the air compressor
is disengaged allowing for horsepower
savings during those cycles as well
as increasing the service interval and
life on the air compressor. The clutch
removes parasitic engine loads at start
up as the compressor is not engaged,
therefore decreasing engine load and
increasing engine compressor life.
The hydraulic system has been fur-
ther refined with load sensing pumps
and other features to reduce horsepower
demand. The heavy duty Funk gearbox
is driven by a drive shaft from the front
of the engine. There is one piston pump
for rotation; one load sensing piston
pump for the feed, set-up and auxiliary
functions; and one pressure-compen-
sated piston pump for the fan circuit.
The propel function uses the feed and
rotation pumps and there is an in-cab
switch to select the diverter valves. The The RCS provides various levels of automation.
valve rack is centrally located for easy
service access, at the same time sim-
plifying hose runs and control wiring. and the updated four-rod carousel, the head delivering either 4,900 lbf-ft
The pressurized hydraulic fluid tank 40 ft tower can be used to multi-pass (6.6 kNm) at 110-190 rpm, or 8,200 lbf-ft
has a capacity of over 100 gallons and drill to a maximum depth of 200 feet (11.1 kNm) at 0-110 rpm. The options
the filters are serviced at waist level. (61 m). direct drive rotary head tends to require
To allow operation at ambient tem- The PV-235 is fitted with a standard less maintenance than the standard spur
peratures up to 125 F (52 C) the cool- spur gear head design that is also used gear head. Both of these rotary heads
ing system features oversized radiators. on the DM45 and DML. Alternatively are fitted with adjustable wear guides
Variable speed control helps to reduce there is the option to chose a two-speed that follow the length of the tower. The
fuel consumption and noise and impro-
ves cold weather performance. The low
fan speed also lowers noise emissions. Output-side
Clutch coupling
Available as an option is a very smart
enclosure that further reduces noise, pro- Bolts
vides cold weather protection and has
full length doors for service access.

Towers
The open front structure of the two Input-side
torsional
towers available is similar to that used coupling
on the other Pit Viper models fabri-
cated from rectangular steel tubing by
certified welders and having four main
vertical members. The 40-foot (12.2 m)
and 35-foot (10.7 m) hole depths men-
tioned previously are the distance from
ground level to the bottom of the hole,
while the top of the bit basket is 5 feet
above ground level. Using a starter rod The optional fuel saving clutch will disengage the compressor when not drilling.

Blasthole Drilling in Open Pit Mining 73

 Talking Technically
The FOPS designed cab offers excellent visibility and comfort.
single cylinder cable feed designed
for the PV-235s 40 ft tower provides
a hydraulic pulldown force of 60,000
pounds and a further improvement in
non-drilling speeds. The sheave diam-
eter: cable diameter (D/d) ratio is 22:1
and reverse bending of the cables, which
can create excess fatigue and shorten
cable life, is eliminated. The pulldown
rate is 140 ft/min with the 40 ft tower
and 193 ft/min for the 35 ft tower.
Retract is 202 ft/min with the longest
tower and 195 ft/min for the other.
Auto-tensioning of the cable, necessary
to counter the loss of tension caused
by cable stretch is by means of a single
cylinder with exclusive balancing yoke.
For angle drilling the PV-235 uses
a pivot at the base of the rig tower,
proven on the earlier Pit Vipers, with
adjustment from vertical to 30 in 5
increments. But the rear telescopic sup-
port legs provided on the larger rigs
are unnecessary. This single pivot de-
sign reduces non-drilling time signi-
ficantly, with tower raising and lower-
ing improved. The rig has a new two-
cylinder impact slide wrench for drill
string breakout that has replaced the
single-cylinder deck fork used on pre-
vious models. The new patented Atlas
Copco twin cylinder break out-wrench
is standard on the PV-235. Breaking the
pipe joint is done below the table and
74 Blasthole Drilling in Open Pit Mining
allows the deck fork to be used while
clamping the upper rod and allowing
for adjustment from 4 " - 8" (115-203
mm) OD drill pipe allowing for wear.
The rear jacks are incorporated into
the new tower rest, as are the exhaust
mounts, air cleaners and lights. The
arch-shaped tower rest adds torsional
stiffness to the frame and riser arms
secure the tower when it has been low-
ered, reducing wear during tramming.
The optional non-drill end deck exten-
sion is provided with an integrated
tower access, a fall restraint system and
an extended tower infill for accessing
the tower for service and maintenance
while it is in horizontal position.
Even better cab
Together with the power system en-
closure, if fitted, the most distinctive
feature of the latest Pit Viper is the cab.
The cantilevered pod-type FOPS de-
sign is a further advance on the pro-
gress achieved with the PV-270 series
machines in terms of both capabilities
and appearance. Visibility is enhanced
not only by the shape of the cab and
large glass area, but also by tinted
windows, improved wiper/washers and
six Nordic integral lights (which also
consume less power than conventional
ones). The integrated air conditioning
system, with a hydraulically powered
compressor, evaporator and condenser,
is mounted under the cab rather than
on the side. The Atlas Copco engineers
worked with the cab supplier to achieve
further noise reduction and have tested
at 70 dBa. For easier housekeeping
there are fitted floor mats and a sweep-
out door at the non-drill end. Optional
offers are a safety camera system and a
radio/CD player for the cab, as well as a
Roll Over Protection Structure (ROPS).
The standard controls are the proven
Atlas Copco RCS computerized net-
work rig control system, which pro-
vides various levels of automation, in
common with the rigs manufactured by
the companys surface and underground
teams in Sweden. For the PV-235 these
options include remote tramming, auto
leveling and GPS navigation, all of
which can help minimize non-drilling
time, and also measure while drilling
logging technology (See page 29 for
RCS explanation). Prospects for the new
Atlas Copco Drilling Solutions model
are good as the PV-235 enjoys the same
level of success as its predecessors.
Dustin Penn
 Talking Technically

Development through interaction

Single- or multi-pass
drilling
The large range Pit Viper 270 se-
ries drilling rigs provide 75,000
lbf (340 kN) force on bit and can
be equipped for either rotary or
down-the-hole (DTH) drilling.
The automation platform for the
Pit Viper series is the Rig Control
System (RCS) and many PV-270
machines have been provided
with RCS. The new PV-270 RCS-
series is built with a new larger
cabin and RCS-Basic as standard.
The PV 270 series combine struc-
tural features of the PV-351, and
components successfully used
on the DM45, DM-M2 and DM-M3
models, and some new ones,
including Tier II engine options.
These features were incorporated
as a result of extensive discussions A PV-270 RCS-series used for blasthole drilling in an American mine.
with customers already using the
Drilling Solutions equipment range
larger than the one used on the DM-M3 radiator cooler package. The Ingersoll-
Low center of gravity rig. The structure achieves a low cen- Rand compressor options are a 1,900
ter of gravity for good stability and CFM (900 l/s) unit or a 2,600 CFM
Clearly an essential quality for this mar- reduces drilling vibration. Single pass (1230 l/s) supplying 110 psi (760 kPa),
ket is f lexibility, though the design stability ratings, adjusted for dynamic plus a 1,450 CFM (680 l/s) air compres-
engineering team could not ignore the conditions, are 5 with cab facing sor delivering air at 350 psi (2,400 kPa)
across-the-board industry requirement downhill and 8 tramming across the for downhole drilling. The CAT C32
for maintenance convenience and cost slope, both with tower up, and 10 with engine is fitted on those rigs using the
effectiveness. These two characteristics tower down, cab facing uphill. The eq- 2,600 CFM compressor.
are evident from the PV-270 crawler uivalent multi-pass figures are respec- The Atlas Copco patent-pending
tracks through to the choice of single- tively 11, 13, and 16. The rigs also automatic hydraulic clutch, between the
pass or multi-pass drilling. offer the customer a choice between a engine and the air end that was intro-
The PV-270 machines offer a choice standard three jack configuration and duced during 2010 as a new option for
of proven Caterpillar and Atlas Copco four, with the rear jacks tied as on the the Pit Viper 235 series, is now availa-
undercarriages to enhance their com- Pit Viper 351. ble on the PV-270 series. The benefit of
patibility with other mine fleet members. this clutch is that it will disengage the
The PV-271 is built with the extended Power options air compressor from the engine when
version of either the CAT 345XL or the air end is switched off. In a tradi-
the Atlas Copco GT3400, while the The power system setup for the PV-270 tional power package, the compressor
PV-275 can have either the standard series machines is structurally similar consumes approximately 30% of its
19-foot 6-inch (5.9 m) CAT 345XL with to that on the Pit Viper 351 but includes rated power at standby. Installation of
GFT110 final drive or the ACGT 3400 a choice of matched engines and com- this clutch eliminates fuel being used
tracks. pressors suitable for the rotary or down- for this standby power consumption
The design and testing process used hole drilling options. The engines offe- and allows for a low idle speed.
for the PV-270 main frame was gener- red, which are Tier II compliant, are While changing rods, levelling,
ally similar to that for the Pit Viper 351. the 760 hp (567 kW) Cummins QSK or moving between the holes, the air
To ensure long frame life without re- 19, the 800 hp (597 kW) Caterpillar compressor is disengaged allowing for
builds, the I-beam used is 24 inches C27, and the larger 950 hp (709 kW) horsepower savings during those cycles
thick with a cross section of 162 lb./ft. Cater-pillar C32. There is a single as well as increasing the service inter-
smaller than the PV-351 frame but side-by-side hydraulic/compressor/ val and life on the air compressor. The

Blasthole Drilling in Open Pit Mining 75

 Talking Technically

clutch removes parasitic engine loads

at start up as the compressor is not
engaged, therefore decreasing engine
load and increasing engine and com-
pressor life.
The electric power pack option com-
prises alternatively a 700 hp (520 kW)
WEG 6808 motor running on 6,000 V
AC/50 Hz current and coupled with
an 1,800 CFM/50Hz Ingersoll Rand
air compressor, or a 900 hp (671 kW)
WEG 6811 motor running on 4,160 V
AC/60 Hz power that is coupled to the
Ingersoll Rand 2,600 CFM/60 Hz air
compressor. An electric powered ver-
sion for downhole drilling is available
for the PV-270 machines, albeit limited
to 1,070 CFM and 350 psi for 50 Hz
application. The motor is completely
enclosed and is cooled by a fan with
the highest rating in the industry, which
allows the unit to operate without a ma-
chinery house. An oil-immersed non-
flammable 40 kVA transformer pro-
tects the motor, providing 380 V AC
for the extensive heating package used
for all the reservoirs. The high voltage
safety circuit and the operator controls
run on 110 V AC that is converted to
24 V DC so that the electric machine
can use the same components as the
diesel-driven rigs.
Experience shows that electric mo-
The PV-271 RCS is fitted with a larger cab. The computerized network rig control system (RCS) provides
tors typically last 20,000 30,000 hours
varoius levels of safety interlocks and automation.
before replacement or rebuild in this ap-
plication, as compared with the 10,000
14,000 hour life usually attained by
diesel engines. This is one reason why
there is growing interest in the electric
Pit Vipers, to which Atlas Copco has
also responded by matching the electric
power pack to a mines available power
supply. For example, four PV-275 rigs
have been delivered to the Moroccan
phosphates producer Office Chrifien
des Phosphates (OCP) for operation at
5,500 V AC.
Like that on the PV-351, the hydrau-
lic system for the 270 series utilizes a
leak-free, clean specification. However
it has the single gearbox and three
pumps configuration used on the
DM-M3 rig, albeit with larger units;
using fewer components has proved to
reduce operating cost. There are two
main pumps for feed, rotation and pro-
The PV-271 live tower is dimensioned for 55-foot single-pass drilling, there is also a 65-foot clean hole single pel, while the double pump supplies the
pass drilling tower option where a pipe must be racked when levering the tower. auxiliary functions.

76 Blasthole Drilling in Open Pit Mining


The PV-271 Rotary head.
The air cleaners are similar to those
on the PV-351, with one provided for
the Cummins engine, two for the CAT,
one for the 1,900 CFM air compressor
and two for the 2,600 CFM unit. These
and the other serviced units are easily
accessed from the PV-270 deck, which
is designed on similar lines to that of
the PV-351, while retractable ladders
are also available.
Three towers
The two machines comprising the Pit
Viper 270 series are primarily differen-
tiated by their towers. These are of sim-
ilar construction to those on the PV-351
but are new designs, not stretched or
lighter weight versions of the existing
design.
The PV-271 live tower is dimen-
sioned for 55-foot (16.7 m) clean hole
single-pass drilling. Like the PV-351
it does have a two-rod changer, in this
case for 25-foot rods enabling drill-
ing to a total depth of 105 feet. With
a four-rod carousel holding 40-foot
pipe, the PV-275 is designed for multi-
pass drilling to a maximum depth of
195 feet. There is also a 65-foot clean
Blasthole Drilling in Open Pit Mining 77
The PV-271 RCS and PV-275 RCS are fitted with a new state of the art cabin, featuring visibility and comfort
for the operator while undertaking complete machine control.
hole tower option, but with this unit
one drill pipe must be racked and the
rotary head brought down in order to
lower the tower for relocation. Like the
power pack, the variable displacement
rotary head for the PV-270 rigs is very
similar to the proven design used on
the DM-M2 machine. The rotary head
also has a filtered lubrication pump
to keep the motor splines lubricated.
Equipped with two motors, the 188 hp
(252 kW) rotary head delivers up to
8,700 foot pounds (11.8 kNm) of torque.
Maximum speed is 150 rpm. Internal
spur gear speed reduction gives better
torque on rough ground, and in other
circumstances where the head stalls are
later than other designs.
The hydraulic rod support with
automatic actuation is essentially the
same as that proven on the DM-M3 rig.
There is also an upper fixed rod catcher.
Again like the PV-351, the Pit Viper
270 series drilling rigs use the cable
feed system introduced on the DM-M3,
however with some redesign to achieve
faster feed speeds. The feed rate is 127 ft.
/min. (38 m./min.) and the retract
rate is 158 ft./min. (48 m./min.). The
automatic tensioning is derived from
Talking Technically
the PV-351 system which has proved
problem-free to date. The pipe handling
system on the PV-271 is similar to that
on the PV-351, and the PV-275 is simi-
lar to the DM-M3. The PV-270 series
machines also use the same patented
system for angle drilling as the Pit
Viper 351, with 0 - 30 adjustment in
5 increments for the multi-pass PV-275
and 0 - 20 adjustment in 5 increments
for the single pass PV-271. These rigs
are quite widely used for angle drilling,
both in coal mines and in metal mines
for toe blasting.
Cab commonalitys
There are two different cab options
available for the PV-270 series. With
the development of the RCS option,
we have incorporated the new state
of the art cabin into the PV-270 RCS
machine design. While rigs without the
RCS control system are fitted with the
same single piece cab as that used for
concurrent DM45, DML, and PV-270
machines. It meets the FOPS require-
ments of ISO 3449 Level 2, is thermal-
ly insulated and pressurized, and has
adjustable vents for climate control. The
 Talking Technically

air conditioning unit is side mounted,

which, along with other detailed fea-
tures, makes this cab easier to service
so no roof access is required. The sound
damping has been tested down to 70
dB(A) on the new cabin. The opera-
tor enjoys excellent visibility over the
ergonomically designed wrap-around
console. The controls are predomi-
nantly electric-over-hydraulic sticks.

Options
As well as the four jack system, options
available for the PV-270 series rigs when
they were introduced included a dry
dust collector with 9,000 CFM blower,
four-camera system with LCD monitor,
buddy seat, water injection, fire suppres-
sion, cold weather package, a central fast
service system, high intensity Nordic
lights, and a hydraulic test station (that
is now standard). The integrated tower
access ladder, a fall restraint system and
an extended tower infill for accessing the
tower for service and maintenance while
it is in horizontal position is an available
option. There is also an option for
non-drill end tower access ladder, fall
restraint system, and extended tower
infill for accessing the tower while in
horizontal position, as well as a number
of ground level service options.

Rapid acceptance
The Pit Viper 270 series rigs were rapidly
accepted since its launch at MINExpo
2004. It was a machine that got it right in
terms of all the parts working together
perfectly, and customers seem to agree.
In only four years the sales of the PV-270
series sur passed the accumulated
14-year sales record of its predecessor,
the DM-M2.
Barrick was one of the first mines to Pit Viper 271 working in a copper mine.
use a PV-271 at their Goldstrike ope-
rations, and the company now has nine Many of the PV- 270 series rigs have drilling, mainly single-pass drilling of
of them. Newmont was another early been ordered for coal applications 8-inch diameter holes at gold mines.
customer, buying four PV-271 machines mainly in South Africa, Russia and Since the first PV-275 was shipped
for the Yanacocha gold mine in Peru, the USA. The other major applications for testing at Peabodys Kayenta coal
and now has 17 of these rigs. Copper are in copper and gold, mostly in the mine in 2003 and the 2004 MINExpo
mining customers include Freeport- Americas, and iron ore mines in Africa, launch of the new models, more than
McMoRan which now has over 20 ma- Latin America, Russia and Ukraine. 250 units of the PV-270 series rigs have
chines. Almost all of the PV-275 machines been shipped to customers.
Most recently, the PV-270 series has are equipped for rotary drilling, but a
broken into the Australian coal and me- significant number of the PV-271 units Dustin Penn
tals markets. have ben configured for downhole

78 Blasthole Drilling in Open Pit Mining

 Talking Technically

The large Pit Viper 310 series

Launched at
MINExpo 2012
Following tradition, Atlas Copco
Drilling Solutions extends its
blasthole drills range at a fourth
straight MINExpo. At MINExpo
2012 the company will exhibit
both the PV-235 and a new rig,
the PV-311, that is slated to be the
first model in a new PV-310 series.
Like the PV-351 this is a rotary
rig set up for single-pass work,
but able to drill deeper holes if
required. However, it is a more
compact machine designed to
drill in soft and hard rock forma-
tions using a narrower range of
large hole sizes at the lower end
of the PV-351 range and the upper
side of the PV-270 models capa-
bility. As with the PV-270 series,
the second model will be a multi-
pass version the PV-316.

Firmly family The Pit Viper 310 series can drill a 65-foot clean hole in a single pass.

Market-driven, but staying with pro-
ven and preferred design concepts,
the Atlas Copco Drilling Solutions
team in Garland have developed the
crawler-mounted Pit Viper range using
an iterative process. These rigs have
established a reputation for excellent
performance and reliability and offer
a full complement of state-of-the-art
features. No surprise then that the new
PV-310 series are conceptually and
visually Pit Vipers. By utilizing a very
high proportion of proven technology
from previous Pit Viper series, trends
of greater energy efficiency and safety
continue.
The standard undercarriage is an
Atlas Copco 375 class extended unit,
a robust frame and tower structural
engineering and fabrication are similar
to the previous models, along with four
jacks. Once again, a choice of diesel or
electric power supply is offered, as are
Ingersoll Rand or Atlas Copco com-
pressor model options. The fuel saving
automatic clutch introduced in 2010 for
the PV-235 is also available as an option
on the PV-310 series, and the hydraulic
system again includes load sensing
technology for auxillary uinctions.
The hydraulic top-head drive drill
rotation system that our Garland engi-
neers have always preferred is retained.
So is the automatically tensioned
hydraulic cable feed, which is much
lighter (and less noisy) than a chain
feed system, which enables production-
time while maximizing live tower
operation. Hydraulic powered break
out tools are once more provided.
The new large cabin is again insu-
lated, pressurized, air conditioned
and FOPS certified with high quality
seating, and provides the operator with
excellent visibility, touch screen and
joystick controls. The computerized
Rig Control System (RCS) is time
proven, but, at the same time, remains
sufficiently agile to support new devel-
opments in control technology.
However, size matters to both pre-
sent and potential Pit Viper customers,
so the new models bring to the market-
place a new combination of power and
hole diameter/ hole depth ranges. The
other key new features are a choice of
diesel engines with Tier 4 compliance
for those who need it and the even more
spacious cab design.
Nimble versatility
The first PV-310 series rotary blast-
hole drilling rig provides a maximum
weight-on-bit of 110,000 lbf (490 kN),
while the machines operating weight
ranges from 310,000 340,000 lb
(140,600 154,000 kg) depending on
specification. The rig is 25 ft wide and
is 98.5 ft long with the tower down.
With the tower up it is 47 ft long (almost
6 ft shorter than the PV-351 and only
5 ft 9 ins longer than the PV-271). With
the tower up the machine is 100.5 ft
high, and 28.5 ft long when the tower

Blasthole Drilling in Open Pit Mining 79

 Talking Technically
Atlas Copcos patent-pending clutch (left) is designed to significantly save on fuel costs. The new Atlas Copco heavy duty, high torque undercarriage. (right)
is down. The optional Caterpillar 350
custom undercarriage has a hydraulic
propel system, hydraulic track tension-
ing, and a 162,000 lbf-ft (220 kNm)
final drive. Alternatively, the standard
heavy duty Atlas Copco 375 undercar-
riage can be fitted as on the machine
displayed at MINExpo. With this latter
platform the power supply system pro-
vides a choice of two tramming speeds,
either 1.0 or 1.6 mph, as on the PV-235.
The main frame is made with wide
f lange structural steel I-beam, like
that on the PV-351, but with newly
developed cross members designed
to increase frame fatigue life. For the
power pack frame the engineering team
has used large rectangular tube that is
very strong in torsion. There is a three-
point mount which prevents the transfer
of torsion forces.
The rig has four levelling jacks, each
with a bore of 8 ins (203 mm)] and a
stroke of 72 ins (1,830 mm). There are
two staircase-type boarding ladders
and tow hooks.
The power pack may have either
an electric motor or a choice of diesel
engines. The two Tier 4 compliant
engine options are the Caterpillar C32,
rated at 1,125 HP/840 kW @ 1,800 rpm,
or the MTU 16V Series 2,000 which
80 Blasthole Drilling in Open Pit Mining
delivers 1,300 HP/970 kW @ 1,800
rpm. Alternatively, there is a choice of
three Tier 2 compliant engines the
Cummins QSK 38 rated at 1,260HP @
1,800 rpm , the Cat C32 rated at 1125
HP @ 1,800 rpm or the MTU 16V2000
unit delivering 1,205HP @ 1,800 rpm.
The standard diesel fuel tank has
a capacity of 700 U.S. gallons (2,650
liters) and provides sufficient fuel
for 12 operating hours. It is normally
teamed with a 1,200 U.S. gallon water
tank. Alternative fuel/water tank com-
binations are 1,400 gallons and 1,200
gallons, providing sufficient fuel for
24-hour operation, or 700/1900 gallons
which provides sufficient water if the
rig is fitted with a water injection and
dust collection option. Diesel machines
also come with a ground level battery
disconnect switch, battery equalizer
and jump start hook up.
The hydraulic system has the same
main pump drive set-up as the PV-351
with P14 closed loop feed and rotation.
But, like the PV-235, it has a load sens-
ing piston pump serving the auxiliary
units which increases machine efficien-
cy. Load sensing should not only yield
a reduction in fuel consumption but
also deliver increased speed for aux-
iliary functions. As well as improving
life and cleanliness, it reduces the risk
of system failure. The valve rack and
I/O modules, together with the central
hydraulic test station, are now located
at one central station above deck. Hoses
are tagged with a part number and ref-
erence number on both fitted ends and
the reference number matches the hose
number on the hydraulic schematic.
The hydraulic oil tank has a capacity
of 350 U.S. gallons (1325 liters).
The required 3,000 CFM of com-
pressed air at 110 PSIG (84.9 m 3/min
@7.6 bar) can be supplied by either an
Ingersoll Rand compressor with a 2 x
285 mm air end as used on the PV-351,
or an Atlas Copco Twin S3 air end
similar to the Single S3 available for
the PV-235. The automatic hydraulic
clutch introduced as an option for the
Pit Viper 235 during 2010 has proved
very beneficial. It disengages the air
compressor from the engine when the
air end is switched off; in a traditional
power package the compressor uses
perhaps 30% of its rated power when
on standby. As well, this clutch allows
for a low idle speed. The air compres-
sor is also disengaged during rod
changes, levelling, or moving between
holes, so horsepower is saved during
these cycles too.

The PV-311 offers a dual acting hydraulic cylinder feed system that raises and lowers the rotary head by way of cable for pulldown and pullback, while integrating
Atlas Copcos patented cable tensioning system.
The engine and air compressor have
separate air intake filters located at the
non-drilling end of the machine. The
filter rack has engine, compressor and
hydraulic system filters. The cooling
package, rated at up to 125F (52C),
incorporates oil coolers for the hydrau-
lic and compressor oils and an engine
charge air cooler.
One area of particular concern to
mine engineering management is the
speed and convenience of servicing and
maintenance work. The PV-310 offers
an optional 360 access decks with
standard full deck service Fibergrate
catwalks and railings, and there is 20
inches of service room between the
power pack and the coolers. On the
deck, hose and cables are located in
trays as on the PV-235 and there are
also dedicated runs in the frame with
improved access.
The fast service system provides
ground level, quick connect fitting for
filling and evacuation of fuel, hydrau-
lic oil, engine oil, engine coolant and
compressor oil.
Going deep
The Pit Viper 310 series is designed
to offer drilling flexibility. The tower
Blasthole Drilling in Open Pit Mining 81
is an interchangeable unit structur-
ally similar to that on the PV-351, but
deeper in order to accommodate larger
sheaves and to be suitable for use on
both the single and multi-pass drilling
versions. In addition, the weldments
have been improved. When the tower
is horizontal, a ladder from the deck
provides access to decking in the tower
above the rod changer. The new tower
rest design allows replacement of a
non-drilling end jack cylinder without
removing the rest.
Like the massive PV-351, the PV-311
model is set up for single-pass drill-
ing 65 ft (19.8 m) clean holes, with bit
changing above the deck. As with the
larger machine, using the carousels
two 35 ft (10.67 m) drill pipes, the
rig can drill a maximum hole depth
of 135 ft (41.1 m). However, the hole
diameter range is quite different, 9-12
inch (229-311 mm), covering the upper
sizes offered by the PV-270 models and
the lower end of the PV-351s hole size
range. We anticipate the new model
may particularly be used for single
pass drilling 270 mm or 311 mm holes,
depending on rock conditions.
The upgraded and well proven two-
speed hydraulic motor rotary head,
already used for the DM-M3, provides
Talking Technically
drill rotation. It delivers 13,800 lbf-ft
(17.5 kNm) rotation torque at 140 rpm
And 7,500 lbf-ft at 240 rpm. Hydraulic
pulldown is 100,000 lbf and pullback
is 50,000 lbf. Hydraulic cylinders
drive the cable feed system, which
has the patented Atlas Copco Drilling
Solutions automatic tensioning of the
pulldown and pullback cables. The
auto-tension power screw is like that on
the PV-351, the tension cylinder as on
the PV-271 but with a larger diameter
rod, and the valve and hydraulic design
is as per the PV-235 which extend cable
life. The thread greasing system uses
a electric driven pump similar to that
on the PV-270 series and PV-235 rigs.
There are improved rotary head guides
and, as on the PV-351, rod support is
provided when the head is close to the
top of the tower. The carousel works
with a no-bump rod changer and
there is an 8,000 lb (3,630 kg) capacity
auxiliary hoist for handling rods.
The breakout tools are those now
standard across the Pit Viper range.
There is a hydraulically powered break-
out slide wrench, the fork chuck having
an improved deck bushing, and a hands-
free auxiliary hydraulic wrench with a
6-inch clamp cylinder. Dust curtains are
hydraulically retractable.
 Talking Technically
The PV-311 offers a spacious cab, as well as maintenance friendly enclosed filter rack and ground level service access.
The drilling angle can be varied in
5 increments from 0-20 on the PV-311
and 0-30 on the PV-316.
In control, in comfort,
in safety
The PV-310 series continues our quest
to provide the rig operator with every
facility needed to achieve maximum
machine productivity all shift long.
Designed with assistance from the
Atlas Copco Rocktec team in Sweden,
the cabin is larger than that used on
the PV-351 (or any other Atlas Copco
Drilling Solutions rig) and has been
further improved over the PV-235.
In conjunction with the elevated
cabin, three large tinted windows on
three sides, each fitted with windshield
wipers and washers, give excellent vis-
ibility from the operators suspension
seat. The Atlas Copco Rig Control
System (RCS) display and joystick
controls are integrated with the seat.
The backlit electrical cabinet has been
integrated to provide easy, secure
access and the size has been increased
to provide flexibility for changes in the
electrical specification during the rigs
lifetime. There is a buddy seat installed
on the front-left side of the cab, and
both the buddy seat and the operator's
82 Blasthole Drilling in Open Pit Mining
suspension seat come installed with
retractable seat belts. The operator's
seat and buddy seat are both installed
with retractable seat belts. While the
work surface above the spaces for the
optional refrigerator and microwave
can seat other visitors; during the rig
build the cabin has hosted up to 10
people. The air conditioning system has
12 kW of cooling power that includes a
hydraulic compressor and a condenser
fan that reduces overall machine elec-
trical requirements.
For operation at night, a High Inten-
sity Discharge (HID) lighting package
and a cabin dome light are standard.
The rigs presence is indicated by LED
strobe lights, amber on the cab and
blue on the tower. Elsewhere there are
the usual emergency shut-down but-
tons, propel alarm, attention horn and
ground level cable for horn activation.
Options
As well as the Atlas Copco 375 under-
carriage, engine and fuel/water tank
options there are other additions or
alternatives available to suit operators
specific circumstances. These include:
an engine enclosure similar to that
introduced with the PV-235, a wrap-
around cabin deck, hydraulic boarding
ladders, a water injection and dust col-
lection system, an LED lighting pack-
age and a fire suppression system that
can be mounted on the non-cab side of
the tower.
In addition to a number of standard
safety and interlock features, the RCS
Basic control system can offer a series
of options Autolevel, Autodrilling,
GPS hole navigation, Desktop Viewer
and communication, wireless remote
tramming, Measure-While-Drilling
data log files, and the International
Rock Excavation Data Exchange Sy-
stem (IREDES).
Multi-pass drilling
Development of the PV-316 multi-pass
drilling model is well advanced. On
this rig the tower will allow drilling to
a depth of 295 ft (90m) using a five-rod
carousel with 50 ft (15.25m) drill pipe.
This is a substantial increase over the
PV-275, which offers multi-pass drill-
ing to 195 ft (59.4 m)*. The PV-316 is
expected to be launched during 2013
and to replace the DM-M3 model.
*For full Pit Viper 311 data see Speci-
fication page 207.
Dustin Penn
 Talking Technically

Large diameter drilling

Pit Viper 351
The giant Pit Viper 351 is a flexible
rotary drill rig with a weight on
bit of 125,000 pounds (56,700 kg),
and the ability to drill 10 5/8 -inch
to 16-inch (270-406 mm) diameter
holes to a maximum depth of 135
feet. However, at MINExpo 2000
many customers commented:
Its set up to single-pass drill a
65-foot-deep hole. The PV-351
is ruggedly constructed with an
operating weight of 385,000-
415,000 pounds (175-188 tons).
However, it takes only touch
screen controls and a joystick to
operate.

Power platform
From the ground up, the PV-351 is a
robust and highly capable drilling rig.
The undercarriage is a hydraulically
driven custom version of the Caterpillar
385 excavator unit. At 26 feet 10 inches
(8.18 m) in length this is the largest
undercarriage used for a rotary drilling
rig. Maximum tramming speed is 1.1
mph (1.77 km/h).
The main frame was designed using
finite element analysis and was subjec-
ted to dynamic strain gauge testing. To
ensure long frame life without rebuilds,
the I-beam used is 30 inches thick with
a cross section of 326 lbs/ft It supports
three inboard mounted tanks one
900 gallon (3,407 liter) water and two
600 gallon (227 l) fuel, as well as the for-
ward jacks and rear tower support and
jacks assembly. There are four levelling
jacks with 10 inch (254 mm) bore and
72 inch (1,829 mm) stroke. The rear
jacks are cross linked to minimize
frame twisting.
Power for the multiple hydraulic sy-
stems and air compressor used on the The diesel powered PV-351 can be offered with Cummins or CAT 12-cylinder engines.
PV-351 comes from either a diesel
engine or an electric motor. Either dri- ambient temperature of 125F (52C). the Caterpillar 3,512, rated at 1,650 hp
ves the hydraulic power pack via a drive Two 12-cylinder diesel engines with (1,230 kW) at 1,800 rpm.
shaft and the air compressor directly. electronic monitoring systems that The 1,400 hp (1,044 kW) electric po-
A floating power pack sub-base iso- meet the EPA Tier I standard are wer unit comes with a rear access plat-
lates the components from vibration. offered; the Cummins QSK 45, rated form and, optionally, a 1,500 ft (457 m)
Two coolers allow operation up to an 1,500 hp (1,119 kW) at 1,800 rpm, and capacity cable reel for a 2 inch (51 mm)

Blasthole Drilling in Open Pit Mining 83

 Talking Technically
cable. The WEG 6811 squirrel cage motor
normally runs on a 50 or 60 Hz, 4,160
7,200 V AC power supply. The machi-
nery house for the electric unit, contai-
ning the majority of the main compo-
nents, is hydraulically pressurized and
has two access doors and removable
roof panels. Some 8085 percent of the
components used in the rig are the same
in the diesel and the electric versions.
The hydraulic system has a 350 gallon
(1,325 l) tank with three-micron filtra-
tion. To ensure reliable operation, the
designers made extensive use of hard
piping with Stauff clamps for hoses,
O-ring face seal fittings and two
quick change filters. There is a single
gearbox and five pumps. The main
Parker Denison variable displacement
pumps control the propel motors and
drill feed/rotation. Other pumps run
various auxiliary functions. The use
of integrated circuit blocks reduces the
number of hose connections.
Pit Viper 351 live tower. The well proven Ingersoll-Rand asym-
metrical screw compressor features twin
rotors in parallel, variable volume elec-
tronic control and lubrication pumps
that minimize load during startup. It
delivers up to 3,800 CFM (107.6 m 3/
minute) of air, which is the highest rate
ever available on a blasthole drill. At
110 psi (758 kPa), its a pressure that
ensures improved bit life. The air clean-
ers employ an innovative three-stage
system in which the elements are easy
Weg motor 1400 hp.
to access and easy to change. Quick
release co-vers make for easy operator
maintenance.
The PV-351 is designed to be a
maintenance friendly machine. The su-
perstructure is laid out to allow safe, easy
movement and good access to service
points. The rig has standard Wiggins
Quick Fills for programmed maintenance
and daily refilling. The spool valves are
located above the deck and all the filter
elements are easy to reach. The stand-
ard decking to the rear of the tower and
the tower access ladder enable service
personnel to inspect the rotary head and
other tower components while the tower
is down.
Versatile tower
Valve stand offering excellent accessibility for Like the main frame, the tower for the
maintenance. PV-351 was designed with the aid of
84 Blasthole Drilling in Open Pit Mining
finite element analysis and tested by
dynamic strain testing. The tower is
of open front construction, fabricated
by certified Drilling Solutions weld-
ers using rectangular steel tubing, and
has four main vertical members. The
design retains the unique live design
used for the Drillmaster towers, which
enables the operator to raise and lower
the tower with the rotary head at the
top and the rods in place; a capability
that typically saves 4 10 hours of
work when moving a rig.
The tower is dimensioned for drill-
ing 65 feet (19.8 m) in a single pass.
Using a longer starter rod, the operator
can drill 70 feet (21.3 m) in a single pass
but the tower cannot be used live. There
is also a two-rod carousel with key lock
retention for a 35 ft (10.7 m) long and
8-inch to 13-inch (219 340 mm)
diameter drill pipe, so the PV-351 can
drill to a depth of 135 feet.
Drill rotation uses the hydraulic drive
rotary head system that the Garland
team has preferred to an electric motor
drive for a long time. It is the compact
size and light weight of this design that
makes possible live tower operation
of the PV-351 and preceding Drillmaster
rigs. The variable displacement rotary
head on the big Pit Viper has two 14-
cubic inch motors that deliver 340 hp
(254 kW) and a maximum torque of
19,000 foot-pounds (25,759 Nm). Maxi-
mum speed is 170 rpm. Simply adjusted
extended head guides maintain align-
ment during descent and a separate
lube pump improves motor spline life.
A rod support system, actuated auto-
matically by detection points at the
rotary head, supports the pipe at its
mid-point whenever the rotary head is
near the top of the tower.
Another important feature of the
Atlas Copco Drilling Solutions rig de-
sign is the patented cable feed pulldown
and pullback system developed in-house
and introduced on the DM-M3. It is
low-cost, four times lighter and much
quieter than a chain feed, but offers good
buckling resistance. The cables absorb
the loads transmitted by drilling before
they reach the rotary head so that drill-
ing is smoother and bit wear is reduced.
As well as providing 120,000 pounds
(54,446 kg) of pulldown and 125,000
pounds (56,700 kg) of bit load, the dual

The variable displacement rotary head and the
automatically actuated rod support.
Automatic cable tensioning pull-down cables
jack screws.
cylinder system delivers 70,000 pounds
(31,752 kg) of pullback and retract speed
is 140 FPM (42.7 m/min). The system
also improves rig safety as the operator
can detect dangerous amounts of wear,
whereas a chain feed can fail catastro-
phically. The downside is that stretch-
ing in use results in a loss of cable ten-
sion, but this has been countered by an
automatic tensioning system that uses
independent hydraulic motors and jack
screws to tension the pulldown cables
and hydraulic cylinders to tension the
pullback ones. The system maintains
tension, ensuring accurate rotary head
alignment, and eliminates maintenance
hours for tensioning.
The break out system may not be the
most technically sophisticated piece of
equipment on a rotary drilling rig, but
from the operators point of view, its ef-
fectiveness is very important in terms
of the physical effort required and the
non-drilling time involved. On the
PV-351 primary break out is achieved
simply and effectively by a sliding
fork and reverse rotation. A patented
self-adjusting hydraulic tong wrench,
already proven on the DM-M3 rigs,
Blasthole Drilling in Open Pit Mining 85
The optional cable reel for 1600 feet of 2-inch cable.
is used for auxiliary break out. Neither
operation transmits shock loads to
the tower. The PV-351 has a patented
system for angle drilling between
vertical and 30 in 5 increments. The
same system is used on the DM-M3 rig.
There is a short, independently sup-
ported pivot point and hydraulic cylin-
der at the base of the tower, and two
telescoping rear legs are attached to the
tower close to the rotary heads upper-
most position and to the tower rest at
the rear of the rig. Locking pins are
remotely activated. This configuration
allows the tower to pivot at deck level,
minimizing the amount of unsupported
drill pipe, which gives the operator a
better view of the deck. The hole to be
drilled can be collared within the Pit
Vipers dust hood.
New generation cab
The new large operators cab is the
same as the one designed for the Pit
Viper 310 series, and has been further
improved over the original PV-351
cabin. In conjunction with the elevated
cabin, three large tinted windows on
Talking Technically
three sides, each fitted with windshield
wipers and washers, give excellent vis-
ibility from the operators suspension
seat. The Atlas Copco Rig Control
System (RCS) display and joystick con-
trols are integrated with the seat. The
electrical cabinet has been integrated
to provide easy, secure access and the
size has been increased to provide
flexibility for changes in the electrical
specification during the rigs lifetime.
There is a buddy seat installed on the
front-left side of the cab, and both the
buddy seat and the operator's suspen-
sion seat come installed with retract-
able seat belts. The air conditioning
system has 12 kW of cooling power that
includes a hydraulic compressor and
a condenser fan that reduces overall
machine electrical requirements.
The PV-351 is equipped with the
Atlas Copco computerized Rig Control
System (RCS). RCS is time proven
yet remarkably agile to continually
support current technology advances.
Based on the highly reliable and well
proven CAN-bus (Controller Area
Network) system, RCS uses a single
main cable through the rig intercon-
 Talking Technically
Inside and outside view of the new PV-351 cab. The RCS control system provides a number of safety and interlock features and a series of automation options.
necting a series of modules control-
ling the drills sensors and actuators.
This simplistic modular design allows
upgrades to higher levels of automa-
tion with little machine downtime. The
RCS touch screen displays a selection
of data, including all pertinent drill
information using internationally rec-
ognizable symbols. The screen is not
affected by dirt and can be used by
operators wearing gloves. The PV-351
rigs being supplied to Bolidens Aitik
copper mine in Sweden are equipped
for Remote Rig Access, enabling Atlas
Copco to check the drilling perfor-
mance, maintenance requirements, etc.
from distant locations. Aitik already
uses this technology to good effect
for other major equipment units. This
includes the RCS (Computerized Rig
Control System page 29), GPS posi-
tioning, MWD (Measurement While
Drilling) data collection functionality,
Autodrill, Auto levelling and wireless
data transfer.
Options
A number of equipment options are avai-
lable for all the Pit Viper models. These
include fire suppression systems and
computer-controlled central lubrication.
Specific options developed for the
PV-351 include a cold weather package
86 Blasthole Drilling in Open Pit Mining
for operation in ambient temperatures
down to -40 C, a four-camera LCD
vision system and attention horn, and a
wireless remote propel control. Remote
controlled tramming with the operator
off the rig is mandatory in certain situ-
ations under some regulatory authori-
ties. Additional options are a Hiab crane
for loading and unloading bits and ac-
cessories, hydraulic retractable stair-
case, tower ladder and much more. Op-
tional equipment for electric Pit Vipers
includes a 5-by-8-foot cable reel for
1,600 feet of 2 inch cable, a load break
switch, a power factor correction system,
a machinery house pressurizer, and a
2,100 gal (7,950 l) water injection system.
Extensive experience
It is now almost 12 years since the
first PV-351 started drilling at the then
Phelps Dodge Morenci copper mine.
A second field follow machine went to
Northgates Kemess mine in May 2003.
Atlas Copco decided to invest consider-
able amounts in production facilities,
and this enabled the Drilling Solutions
division to step up marketing efforts
as mining industry investment in new
equipment began to increase.Commer-
cial deliveries of the Pit Viper started in
2005-6 and the first PV-351 units hea-
ded south to Codelcos Chuquicamata
copper mine in Chile and to the Anglo
Platinum Potgietersrust operation (now
called Mogalakwena) in South Africa.
Codelco reported excellent results with
the first machine and ordered a second
rig that arrived at Chuqui in September
2006. Soon after, another PV-351 start-
ed operating at Codelcos Radomiro
Tomic mine and Andina ordered elec-
tric powered machines. The first two
PV-351 rigs at Anglo Platinum now
have a fleet of nine electric machines.
There are now PV-351 fleets work-
ing for Vale at Sossego in Brazil, at the
Penasquito precious metals mine in
Mexico, and at the Los Pelambres and
Spence copper mines in Chile. Anto-
fagasta chose a mix of diesel and electric
rigs for Los Pelambres and Rio Tinto
has done the same at the Rssing ura-
nium mine in Namibia, southern Africa.
Antofagasta minerals has invested in
electric PV-351 units for its Esperanza
project in Chile, while BHPs Escondida
mine is building up a fleet of diesel
PV-351s. A fleet of machines are oper-
ating at Newmonts Batu Hijau mine in
Indonesia and Atlas Copco has also sup-
plied 5 PV-351E drilling rigs to Boliden
in Sweden for their Aitik 36 project.
Dustin Penn

The economic case for routine
bit grinding
Cutting hole costs
The button bit was originally de-
veloped to do the job of an insert
bit, without any grinding at all.
However, it was soon found that
the service life of a button bit
increased considerably if the
cemented carbide buttons were
ground.
Nowadays, it has become ex-
tremely important to grind button
bits at proper intervals, in order to
extend the service life of the rock
drilling tool, maintain penetration
rates, and drill straight holes.
In all rock excavation opera-
tions, the cost is usually expressed
in cost per drilled metre (cost/dm),
in cost per cubic metre (cost/m3),
or in cost per tonne.
The cost to produce a hole de-
pends on how fast it can be drilled,
and how many tools will be con-
sumed. The cost to produce a cubic
metre of rock is dependent upon
the cost of the hole, and the cost of
blasting. If the blasthole is of poor
quality, then more explosives will
be consumed in blasting the rock.
Unsharpened bits very often give a
poor quality hole with deviation.
Grinding constitutes around
2% of the costs of the entire drill-
ing operation. To run the business
without grinding could multiply
this cost, with up to 100% added
when production losses are taken
into account. Labour and mate-
rial are the highest costs, while
the machine investment cost
is low when u tilization is high,
with a large number of bits to be
ground.
Grinding methods
There are two different methods of
bit grinding to restore the buttons.
The preferred method uses a diamond
coated profiled wheel, and the other, a
grinding cup.
The profiled wheel provides a smooth
and efficient grinding operation, which,
Blasthole Drilling in Open Pit Mining 87
Talking Technically
throughout its life, maintains the cor-
rect button shape and prot rusion. It
features correct centring on all buttons,
producing a high quality cemented car-
bide surface, with no risk of cemented
carbide nipple. Long bit life, and higher
penetration rates, will result from good
grinding quality.
Disadvantages of using the grinding
cup are that it may produce an incorrect
button shape and protrusion, and a lower
penetration rate. It is difficult to centre
the grinding cup over the gauge button,
and there is also a risk of producing a
sharp cemented carbide nipple on the
button. Reduced bit life will result from
poor grinding quality.
Several tests have been carried out
to find which method gives the best
bit performance. The grinding wheel
gives the correct shape to the button,
regardless of the amount of wear on the
The Secoroc BQ3 grinding machine can handle
drill bits up to 127 mm in diameter.
wheel, ensuring that the bit will achieve
standard penetration rate throughout its
Total bit life
drill metres
700
600
10 regrindings
per drill bit
500
400
300
200
Grinding interval
100 drill metres
0
10 20 30 40 50 60
Diagram 1: Typical bit life grinding at different intervals.
 Talking Technically
Diagram 2: Risk of total loss when a bit is overdrilled.
Diagram 3: Penetration rate drops as the button profiles flatten.
entire life. It has also been shown that
bit life is increased considerably when
grinding wheels are used, rather than
grinding cups. Wheels also excavate
steel around the button, simplifying the
grinding task, and giving the bit a more
exact profile.
88 Blasthole Drilling in Open Pit Mining
Bit life
With so many parameters involved, it
is difficult to estimate bit service life.
First, a proper grinding interval must
be established, preferably at the stage
when the button has a wear flat of one
third of the button diameter. When
the number of drilled metres to reach
this stage has been established, then a
calculation of bit life can be made, by
multiplying by the number of times it
can be reground. As a general rule, a bit
can be reground 10 times, but smaller
bits may achieve slightly less than this
figure, while larger bits may achieve
more. So, if the grinding interval has
been established as 60 drill metres,
then the bit life can be 660 drill metres
(diagram 1). If a bit is overdrilled, and
the wear flat is more than half of the
button diameter, there is a tendency
towards cracked buttons.T here is
always a sharp edge created on the
button, and this becomes sharper the
more the bit is overdrilled. This sharp
edge, especially on ballistic buttons,
is very brittle. Once the edge cracks,
pieces of cemented carbide break away
and circulate in the hole, causing sec-
ondary damage to the buttons.
When a bit doesnt show any vis-
ible wear and the buttons are shiny
like a mirror, it may be suffering from
micro cracks on the cemented carbide
surface. This is known colloquially
as snakeskin, and can be clearly seen
when using a magnifier. In this case,
the surface has to be ground away, oth-
erwise the micro cracks lead to more
severe damage on the buttons.
Likewise, buttons which protrude
too much must be ground down to
avoid damage (diagram 2).
Penetration rate
When the right bit has been chosen
for the rock condition, it will provide
maximum penetration rate, along
with acceptable hole straightness. In
rock conditions like Swedish granite,
with a compressive strength of around
2,200 bar, the bit gets a wear flat after
just 10-20 drill metres, accompanied by
a small drop in penetration rate. When
it has a wear flat equivalent to one-third
of the button diameter, the penetration
will have dropped by 5%. If the bit is
used further until it has a two-thirds
wear f lat, the penetration will have
dropped more than 30% (diagram 3).
When a bit has a heavy wear f lat it
tends to deviate, and, by the time it
reaches the bottom of the hole, it will

Secoroc Manual B.
have deviated far more than planned.
As a result, the blast will produce
coarse fragmentation, and much sec-
ondary blasting may be required.
In slope hole drilling, it is of utmost
importance that the holes are straight.
If the holes deviate, the slope walls will
be uneven, making rock reinforcement
more difficult than expected.
Rock formations with different lay-
ers and joints are often characterized
by heavy hole deviation, putting extra
5
4 Grinding material cost
3 Machine cost
2
1 Figures on the left side of the diagram
0 show cost per button in SEK.
5 000
10 000
25 000
50 000
75 000
100 000
Cost of grinding reduces dramatically with volume.
Blasthole Drilling in Open Pit Mining 89
stress on the remaining rock tools in
the drillstring. A sharp bit always cuts
better, and will prevent both deviation,
and its disadvantages.
Grinding machines
Two parameters guide the selection of
the right grinding machine: the number
of bits or steel to be ground; and wheth-
er the machine should be portable or
stationa ry. Several kinds of grinding
machines are available to satisfy these
parameters. In most cases, a simple
machine will suffice for a small opera-
tion, grinding only a few bits.
The semi-automatic machines are
more suitable for larger operations,
such as mines and construction sites,
where the machine can be stationary,
and the rocktools can be brought to it.
Secoroc HG is a water or air-cooled
handheld machine for grinding cups.
Both spherical, ballistic and steel cut-
ting cups are available. The machine
is driven by up to 7 bar compressed
air, and is suitable for a small grinding
operation.
Secoroc Manual B is an air-driven
portable grinder using diamond-coated
grinding wheels for spherical, ballistic
and full-ballistic buttons. The machine
is mounted in a box fitted with wheels
and handles for easy set up. This is
made for threaded button bits. A steel
spring is mounted in the profile of the
Labour cost
Annual grinding volume buttons.
Talking Technically
grinding wheel, where it functions as
a centring device, allowing for easy
grinding.
Secoroc Manual B-DTH is similar
to the Secoroc Manual B. It is mainly
intended for DTH bits and COPROD,
but can also be used for threaded bits
with a special bit holder.
Secoroc Jazz is a very flexible grin-
der that can grind both threaded,
tapered, DTH- and COPROD bits, in
spherical and ballistic versions. The
hole range is from 35 mm to 254 mm.
Secoroc BQ3 is the latest semi-
automatic machine, with many features
such as more efficient working light,
better cooling nozzle, soft start of
grinding table, water filter, sleeve cou-
pling for ventilation plus all features
the previous version had.
These features, coupled to an ergo-
nomic design, ensure high productivity,
and the machine is designed to handle
large volumes of threaded button bits.
Cooling water is recycled after the
waste product has been separated in a
container.
Secoroc BQ3-DTH is the latest grin-
ding machine for mainly DTH and
COPROD bits. It can also be used for
threaded bits with a special bit holder.
The machine has the same features as
Secoroc BQ3, and can grind bits up to
178 mm (7 in) diameter. Secoroc Senior
and Swing are grinders for integral
steel.
Diamond grinding wheels.
 Talking Technically

Secoroc Manual B-DTH. Secoroc BQ3-DTH.

Grinding advice
The Secoroc grinding machines secret
of success is that both the grinding
table and the diamond grinding wheel
rotate. The result is perfectly ground
button surfaces, regardless of whether
the buttons are spherical, ballistic or
full-ballistic.
In addition, the machines unique
diamond grinding wheel is designed
to ensure even wear on its grinding
surface, while still retaining its profile.
This, in turn, guarantees the button
shape throughout the life of the wheel.
Secorocs advice is to use Secoroc
grinding machines, with profiled dia-
mond grinding wheels, for grinding
button bits. It is the only solution able
to consistently deliver perfectly shaped
buttons on customers bits, which gives
longer service life to all rock drilling
tools, rock drills and drill rigs.
Correct grinding is important for
every drilling operation, particularly
in these days of cost consciousness and
fierce competition. It can make a world
of difference to the bottom line.

Bo Persson

Comparison of grinding wheel with grinding cup.

90 Blasthole Drilling in Open Pit Mining


Secoroc Jazz
Secoroc Jazz for correct and professional grinding.
Rig mounted
grinder
In todays world of professional
rock drilling, where ever more
powerful drill rigs and hammers
are used, it has become extremely
important to give the drill string
all the necessary care and mainte-
nance needed if optimum drilling
productivity is to be achieved.
Regrinding the cemented car-
bide buttons of the bit at proper
intervals increases the service life
of the whole drill string. This, in
turn, helps maintain penetration
rates, while ensuring that holes
are drilled straight and true.
Quick and efficient grinding
of button bits in surface drilling
applications, where the rig is con-
stantly on the move from one job
site to another, has been an elu-
sive goal. However, Atlas Copco
Secoroc has now come up with
the solution, by developing a rig-
mounted semi-automatic grinder.
The Secoroc Jazz, equipped with
a profile d diamond grinding
wheel, achieves the same quality
of grinding onboard the rig as that
previously associated with static
workshop models.
Blasthole Drilling in Open Pit Mining 91
Development
Atlas Copco Secoroc has gained exten-
sive knowledge and experience of re-
grinding large volumes of button bits
with stationary grinders, such as the
Secoroc BQ3 and Secoroc BQ3-DTH.
These, together with previous genera-
tions of similar grinders, have all used
profiled diamond grinding wheels for
working on spherical, ballistic and full-
ballistic buttons. However, onboard
grinding machines have always been
fitted with diamond grinding cups,
which have proved to be less efficient
than profiled diamond grinding wheels.
The new Secoroc Jazz grinder, which
is equipped with profiled diamond
grinding wheels, will consistently deliv-
er the same perfectly shaped spherical
and ballistic buttons after regrinding.
This is increasingly important in rela-
tion to ballistic buttons, which are
becoming more and more popular.
Secoroc Jazz
The air-driven Secoroc Jazz helps opti-
mize the performance of the rock drill
and drill string, without the bit leaving
the rig. It is user friendly, is designed
Talking Technically
for economy of air consumption, and
can easily be retro-fitted to most rigs
in current use. It is delivered with an
attachment for bolting on to existing
rigs, which allows the operator to fold
away the grinder when not in use. It
will also be available through the sales
companies as an option on new Atlas
Copco drill rigs. To make the grinder
ready for work, it is simply a matter of
hooking up the air hose, connecting the
electricity, and filling up the water tank
for the mist cooling.
The low air consumption of the
Secoroc Jazz makes it possible to grind
bits without interrupting drilling opera-
tions. The grinder is semi-automatic,
and features an automatic centring
device for placing each button in the
correct position under the grinding
wheel. An indexing bit holder is used for
the gauge buttons, and there is a handy
time relay for setting grinding time.
Secoroc Jazz is a very flexible grin-
der that will have a beneficial influ-
ence on drilling economy. It will grind
spherical and ballistic buttons, on threa-
ded or tapered button bits, as well as big
DTH - and COPROD bits from 35 mm
(13 8 in) to 254 mm (10 in) in diameter.
 Talking Technically

Grinding instructions for button bits

When to regrind

Button bits should be reground when the penetration

rate drops, or if any of the cemented-carbide buttons are
damaged (fractured buttons should be ground flat). It is both
practical and economical to redress the buttons when the
wear flat reaches about 1/3 of the diameter of the button.
Look out for snake skin

If microscopic fatigue cracks so called snake skin

begin to appear on the cemented carbide buttons, the
cracks must be ground away. In any event, bits should be
reground after 300 metres of drilling at the most.
This should be done even if there are no visible signs
of wear and the penetration rate continues to be good.
If snake-skin is not removed, the cracks will deepen and
ultimately result in button fracture.
Do not grind away too much cemented carbide

Secoroc Jazz can easily be set up on the drill rig, here the machine is ready for grinding.

Do not grind too much on the top of the buttons. Let a

few millimetres of the wear flat remain on top of the
button.
Always grind broken buttons flat
Grinding the button bit in a profes- drilling output and product ivity will
sional way makes sense, because grind- be significantly lower, and costs may
ing accounts for only a fraction of the escalate.
cost of the entire drilling operation.
When a drilling programme is carried Bo Persson
on without correct service of the bits,

A drill bit can remain in service as long as the gauge but-

tons maintain the diameter of the bit. Fractured buttons Secoroc Jazz
must always be ground flat to prevent chips of cemented
carbide from damaging the other buttons. Technical Data

Avoid grinding the gauge Air pressure, maximum 7 bar (102 psi)
Air pressure, minimum 6 bar (87 psi)
Air consumption 25 l/sec
Coolant container 3l
Air tool oil consumption 1.8 cl/hour
1 Output, spindle motor 1 kW
Speed, spindle 15,000 rpm
Gauge button anti-taper has to be removed by grinding,
although excessive reduction of the bit diameter should Voltage 24 V (D.C.)
be avoided. Leave about max 1 mm of the wear flat.
Weight, exclusive of packing 90 kg (198 lbs)
Transport dimension 800 x 500 x 700 mm
Grinding Capacity
Maximum distance between bit holder
250 mm (9 78")
and grinding wheel

If necessary, remove some of the bit-body steel below

Maximum diameter of drill bit 254 mm (10")
the gauge buttons, so that a clearance (taper) of 0.5 mm Minimum diameter of drill bit 35 mm (138")
is maintained. If the flushing holes start to deform, open
them up with the aid of a rotary burr or steel file. Minimum distance between buttons 3.5 mm ( 964")

92 Blasthole Drilling in Open Pit Mining


Aitik eyes top three efficiency
The Aitik 36 project has increased ore production, and has put Aitik on pace to reach 36 Mt/y by the end of 2012.The investment will make Aitik one of the most
cost-efficient mines in the world.
Boliden on course
With the Aitik 36 expansion com-
pleted in 2010 mining is now sche-
duled to continue until 2029. The
latest technology including Atlas
Copco Pit Viper and SmartROC
drilling rigs is helping Boliden to
double concentrator throughput of
low-grade copper ore and deliver
a competitive concentrate to its
Swedish smelting and refining
complex.
High-tech strategy
Since 1968 Boliden AB has sought to
supply a competitive copper and pre-
cious metals concentrate to the Rnn-
skr smelting and refining complex at
Skelleftehamn, from the Aitik open pit
mine. The company has periodically
Blasthole Drilling in Open Pit Mining 93
upgraded the mining and treatment of
low-grade ore to maintain financially
viable production.
In 2010 the Aitik 36 Project was com-
pleted, extending Aitiks mine life
from 2016 to 2029. Drill Supervisor
Nils Johansson is optimistic for the
future. The new plant is a big reason
for the large increase in production,
and Nils Johansson says that 45 mil-
lion tonnes can easily be handled by the
new processing plant. The only work to
be done is to coordinate the waste and
the rock. Acting Mine Manager and
Drill Superintendent Supervisor Peter
Palo also emphasizes the increase in
production: Were looking forward to
produce 45 million tons of ore and 45
million tons of waste. Thats the next
step. The earliest will be in five years.
As with previous expansions at
Aitik, Boliden has opted for the most
cost effective appropriate technology
Sweden, gllivare
available: one result was the mines
expansion included adding four Atlas
Copco Pit Viper rigs to the production
drilling fleet.
Securing copper supply
Located near Gllivare and 60 km
north of the Arctic Circle, Aitik rails
material 400 km to Bolidens Rnnskr
complex at the Baltic port of Skel-
leftehamn. It is the facilitys largest
copper concentrate supplier although
Rnnskr treats a range of concentrates
and scrap to yield refined copper, lead,
precious metals and zinc clinker. The
company operates four more primary
metal production facilities and is the
third largest copper and zinc metals
supplier in Europe.
In 2006 Boliden concluded that,
whereas the existing 18 Mt/y operation
was scheduled to close in 2016, a new
 Aitik eyes top three efficiency
Boliden undertook a thorough evaluation before deciding to invest in four new Pit Viper 351 rotary drill rigs.
Bolidens criteria included the ability to drill 311 mm holes to a depth of 19 meters.
state-of-the-art and larger scale con-
centrator would be technically and
economically able to continue recov-
ering concentrate from significantly
lower grade ore reserves at Aitik. The
available tonnage would allow Aitik to
process 36 Mt/y by 2014 and continue
production until 2029. Concentrate
sh ipment to Rn nsk r could be
improved by building a rail spur from
the mine site to the main line instead of
trucking the material to the station at
Gllivare. The 600 million ($845 mn)
Aitik 36 Project was launched in 2007;
the new transport and processing sys-
tems came fully on-stream in April
2010 and the official opening by King
Carl XVI Gustaf was held on August
1, 2010.
The mining operation in Aitik is ba-
sed on proven and probable reserves of
710 Mt. As of December 2011 proven
reserves totaled 486 Mt, grading 0.25%
copper, 0.15 g/t gold, and 1.6 g/t silver,
while probable reserves were 224 Mt.
Although the grade is low, Aitik does
get a little help from nature due to the
good rock conditions that enables the
mine to have really steep slopes 47
94 Blasthole Drilling in Open Pit Mining
Drill Superintendent and acting Mine Manager.
on the footwalls and 52 on the hang-
ing wall. This means they dont have to
mine too much waste rock. For the Life
of Mine the waste-ore strip ratio is as
low as 0.5:1.
To achieve the required ore extrac-
tion rate the Aitik 36 project team
decided to cut back the pit boundary in
a number of places and to mine down to
600 meters. A supplementary open pit
has been developed at Salmijrvi, one
kilometer southeast of the main mine.
Currently, Salmijrvi is at 60 meters
depth with plans to reach 210 meters
depth in approximately 10 years. Nils
Johansson said, Today were mining
the southern part [of the mine] for ore
and the northern part for waste, head-
ing for ore. And then there are two
levels active in Salmijrvi as well, so
we have two main fronts and two sec-
ondary fronts."
In all more than 80 Mt/y of rock
will be moved and Aitik 36 included
a largely new in-pit crushing and con-
veying system to contain mine site rock
haulage costs as well as additional new
shovels and trucks. Boliden under-
took a thorough evaluation of available
Top: Nils Johansson, Drill Supervisor. Bottom: Peter Palo,
options in 2007 and decided to continue
primarily with electric-powered equip-
ment. Loading and haulage capacity
would be raised by buying new models
from the suppliers of the existing
fleets. But the drilling rigs evaluation
persuaded Boliden to switch suppliers.
Drill fleet build-up
Aitiks primary blasting requirement is
to produce a fragmentation suited not
only to the loading, hauling, crushing
and conveying equipment but also to
the grinding system Boliden favors.
Theyre doing so using auto-genous
milling, which means its important to
get the drilling and blasting right.
The blasthole drilling effort at Aitik
has been shared between Boliden per-
sonnel doing the bench production drill-
ing and an NCC team contracted to do
the pre-splitting. Aitik chose to retain
this division of labor so NCC was able
to continue using its Atlas Copco ROC
L8 machines for downhole drilling
straight contour holes. Boliden, on the
other hand, needed to upgrade their
fleet of large rotary drill rigs with four

The PV-351, installed with RCS, offer features like finger-tip joystick controls, a comfortable cabin, ability to drill angled holes, and ease of raising and lowering the tower
for tramming.
new units. The project teams primary
criterion was the ability to single pass
drill 311 mm diameter holes to a depth
of at least 19 m: drilling big 311 mm
holes going 16 to 17 m deep eliminates
the risk of deviation, points out Peter
Palo, Bolidens acting mine manager
and development superintendent. Also
extremely important for the fragmenta-
tion is the positional accuracy of each
hole; the more accurate the holes, the
wider the pattern can be. That way
Aitik can actually save drill meters
and drill fewer holes. Ability to drill
the right hole depths is also important,
with smooth blasting to yield good
flat surfaces for the large loaders and
trucks.
Drilling to the right depth also
means there will be less loose rock to
drill through on the next level down.
Consequently, the team looked for
features such as finger-tip joystick con-
trols, programmable automatic drilling
modes and GPS-based hole naviga-
tion. Other major considerations were
good built-in safety and productivity
enhancing features such as an opera-
tor-friendly cabin, ease of raising and
Blasthole Drilling in Open Pit Mining 95
Aitik eyes top three efficiency
lowering the tower for tramming, and
the ability to drill angled holes.
However, operators opinions regar-
ding the merits of the various models
available were therefore particularly
important and Boliden was able to
take some of them to the Atlas Copco
Drilling Solutions (ADS) premises in
Garland to check out the Pit Viper rigs.
Palo says the feedback was clear; the
operators preferred the ergonomics of
these machines, especially the joystick
control. Equally, the electric version
of the hydraulic drive rotary head Pit
Viper (PV-351) met the Boliden manag-
ers requirements as to drilling capa-
bility and ease of operation. Indeed,
commented Peter Palo, the team was
convinced that the Pit Vipers were the
most advanced rigs of their kind on the
market. I can tell you that if we looked
at the market today, theres little com-
petition, said Johansson. Its the most
modern machine on the market, and its
been proved in the availability as well.
According to Johansson, the Pit Viper
351s availability is 95%. Its really,
really extreme, he said. As of July
2012, the four PV-351s have logged
between 11,000 to 15,000 drilling hours
since they arrived on site in 2009.
Striving for automation
Atlas Copcos Rig Control System
(RCS) technology has a number of
benef its, and Bolidens technical
department took notice. Johansson said,
The probability of being able to use the
autonomous functions in the future is a
big reason that they wanted to buy Atlas
Copco rigs. Using automated features,
such as drilling, tramming, and leveling
is an attractive option for Aitiks mine
personnel, but its something they wont
fully implement until the future.
Boliden and Atlas Copco agreed to
operationally test the Pit Viper 351s
automation software back in 2009.
The products were put under testing
and development dating back to 2009
and the operational testing began in
April 2012. The culminating test is to
put a full drill plan in and to have the
rig achieve predictable and repeatable
results consistently.
Due to the overwhelming success
of the new expansion, more focus on
 Aitik eyes top three efficiency
One of the four Pit Viper 351 drill rigs at the Aitik Mine: The Atlas Copco Rig Control System (RCS) offers a
wide range of features for automation, safety and communications.
the drills autonomous capabilities has
been implemented by mine personnel.
According to Johansson, all full-time
drill operators have been trained on the
autonomous functions, auto-drilling
and auto-leveling, but auto-leveling
seems to be favored by the drillers.
The drillers are using it more and a
lot of drillers like to drill manually; the
older ones, said Palo. The younger
ones drill automatically. But, how
fast and how a fully-autonomous rig
will be utilized remains in question
among mine personnel. Depending on
who you ask, the goal to become fully
autonomous will be within the three
and ten year range.
When asked about how automation
will improve productivity at Aitik Palo
responded, Id really like to see it,
96 Blasthole Drilling in Open Pit Mining
because we can drill on a shift change
and dinner breaks and so on, and we
can speed up production by at least
10-15%. Johansson has set-up five
shifts during the week running eight
hours each, with 12-hour shifts on the
weekend. That makes for a 24-hour
day in which the rigs are being utilized
65% of the time. We have downtime
when we change the shifts, but its not
something that we worry about, said
Johansson. We do pay the operators
to have the opportunity to change
shifts at the rig, but today we dont
have to because of the uptime on the
machines, and also the planning ahead
and everything is at a level where we
dont actually have to worry. Drilling
during 80% of the shift is the goal for
Aitik, and using a fully-automated rig
is how they plan to get there. Aitik will
be using its Pit Viper 351s fully autono-
mously at different points throughout
the day in the future. Johansson states
that one of the biggest benefits of run-
ning a rig autonomously is less down
time for shift changes and dinner
breaks. Using the rigs autonomously
during shift changes and dinner breaks
could increase drill time to 80% each
day. Many people relate fully-autono-
mous functionality to staff reduction,
but Johansson states thats not the case.
They see [drill operators] autonomous
drilling as a huge part as theyre partici-
pating in a project where well eliminate
their jobs, but we dont have any plans
to eliminate their jobs, said Johansson.
If anything well add to our staff and
its a way to increase safety.
Not only does the RCS enable drill
and blast plans to be loaded directly
into the rigs computers, the system
also provides a high level of automa-
tion, such as GPS hole navigation a
major contributor to hole depth qual-
ity plus remote tramming and auto-
drilling as well as auto-leveling. The
Desktop Viewer allows remote mainte-
nance problem-solving. Moving about
the PV-351 is safe and four cameras
provide good visibility where there
is no sight line. The 65ft tower can
be lowered in eight minutes or less,
enabling much quicker relocation times
than some competing rigs can achieve.
The angle drilling option is relatively
expensive, but Aitik calculated that
having it fitted to just two of the four
rigs would achieve the degree of opera-
tional flexibility required.
Preparations for delivery of the
PV-351 machines star ted dur ing
2008, including training at the fac-
tory in Garland, TX for Swedish Atlas
Copco rig assembly and maintenance
personnel and for Boliden operators.
Assembly of the first machine was
completed in January 2009.
The local Atlas Copco team worked
with Aitik engineering personnel under
the guidance of Atlas Copco experts
from Garland. The rigs are maintained
by Aitik staff assisted by an Atlas
Copco technician, with servicing after
each 250 hours of operation.
In June 2012 Boliden reported 95%
availability. Atlas Copco has also

The drill rigs drill 200-300 holes for one blasting round and the penetration rate can vary between 0.4 m/min in the upper part and 0.1 m/min in the harder rock
types. Forcit is contracted to charge each hole with about a ton of Fortis Advantage emulsion. Drilling patterns are transmitted from the mine office to the Pit Vipers
using the mines W-LAN network.
continued to provide training for new
operators, and plans to continue run-
ning culminating tests to drill an entire
drill plan in a predictable, repeatable
form. Atlas Copco engineers continue
to create interfaces for autonomous
operation, but are working with mines
to define a new role of what an operator
actually is.
Pit Vipers in practice
The Pit Viper 351 is very heavy, with
an operating weight of 185 t, and very
large: 16.4 m long, 8.1 m wide and 31.4
m high with tower up. Even so, single
pass drilling with the Pit Viper is a one-
person job, although the operator of a
hired-in wheel loader does the power
cable shifting. The hydraulic drives,
cable feed system and rig control
technology also make the PV-351 quite
Blasthole Drilling in Open Pit Mining 97
Aitik eyes top three efficiency
different to operate from the rigs pre-
viously in use at Aitik. Nevertheless,
according to an experienced driller,
Gerd Martinsson, the PV-351 is rather
easy to handle. Drill operator Hanna
Wikman agrees: It seemed pretty
complicated at first but I soon got the
hang of it. The controls are well placed
and the screen quickly displays all the
drilling data you need, engine hours,
drill speed, rpm, pull-down pressure
etc.
Hanna says she uses the GPS to
locate her position in relation to the
drill plan sent by the mines control
center via the Wireless LAN and finds
the auto de-levelling system helpful,
though she prefers manual levelling.
The mine works five shift groups: three
8-hour shifts daily Monday Friday
and two 12-hour shifts each day over
the weekend.
Equipped with 9.9 m drill pipe and
311 mm bit (at the lower end of the
machines 270-406 mm range), the
Pit Vipers typically drill blastholes to
a depth in the 17-18 m range, but in
some locations down to 19.50 meters,
close to the rigs 19.8 m maximum. For
standard 15 m high bench drilling the
typical hole spacing is 8 x 9 meters
in waste rock, 7 x 9 m in ore, and the
rigs drill 200-300 holes for a blasting
round designed to yield around 700,000
t rock. Penetration rates vary consid-
erably with rock type but by October
2010 the net rate was 33 m/hour 144
m/8-hour shift, higher than Aitiks pro-
jected 27 m/h target. Bit life is around
1200 m, sometimes less. Forcit is con-
tracted to charge each hole with about a
ton of Kemitti 600 emulsion explosive.
The company has built a matrix fac-
tory on the mine site and delivers the
 Aitik eyes top three efficiency

Aitik open pit mine, Sweden.

constituents to the blasting site. Now

that management and operators have
a clear idea of the Pit Vipers capa-
bilities and characteristics in ope-ration
various tests are underway at Aitik to
further boost efficiency in the future.
These include using Secorocs new
PARD (Percussion Assisted Rotary
Drilling) low impact DTH hammers
combined with specially designed
Tricone Rotary drill bits to increase
penetration rate. Aitik reports that the
system increased drilling rates by an
impressive 48 %. Drillers are also using
the rigs auto-tramming feature to tram
to the next drilling position on the
planned path so they can auto-locate Pre-splitting on the Aitik benches:This SmartROC D65 is a highly productive and comfortable rig to operate in
each hole. The Atlas Copco Orealyser these harsh conditions where temperatures can drop to -35 degrees in winter. Together with a ROC L8 it drills
launched at Bauma 2010 has also been 140 and 165 mm holes to depths of 3335 m.
tested at Aitik.

Smart pre-splitting DTH
While Boliden was evaluating produc-
tion drilling options NCC ordered a
new ROC L830 Mk II rigs to replace
older machines. During 2009, when
a new SmartROC D65 came to Aitik
for testing, the contractor was suffi-
ciently impressed to buy the unit for
the pre-splitting contract. NCC Site
Manager Stig Fredriksson says the
main reason for this purchase was that
the SmartROC delivers all the benefits
of the Atlas Copco RCS technology.
The new rig and one ROC L830 are
successfully drilling both 140 mm and
165 mm pre-split holes to depths of
33-35 m, typically at a 1.5 m spacing,
using Secoroc COP54 and COP64 DTH
hammers and spherical button bits. The
NCC team maintains the rigs and the
on-site workshop houses two Secoroc
Grind Matic regrinding machines.
Typically the bits drill about 65 m
before they need a regrind and can be
reground 10 times.
NCC says the SmartROC has been
working two shifts daily, drilling about
6,000 to 7,000 meters/month and aver-
aging about 90% availability. The rigs
Full Drill Cycle Automation option
allows the operators to prepare mate-
rial on the bench while the rig finishes
the hole by itself, enabling high produc-
tivity.
Also much appreciated in this tough
environment, where winter tempera-
tures can drop to -35C, both the DTH
rigs have warm and comfortable cabins
that make life as easy as possible. A
second SmartROC D65 with some ser-
viceability enhancements suggested by
NCC arrived on site during November
2010.
Drilling with confidence
Now that the expansion has been com-
pleted and mine personnel know how
much the new processing plant can
handle, Johansson and Palo are confi-
dent that they will be able to amp up
production in the coming years, despite
a low ore-to-waist ratio.
Automation figures to play a vital
role in the production increase, and its
something Atlas Copco and Boliden
plan to implement-fully in the future.
Potentially, it will be a must for this
mine within 10 years, said Johansson.
Acknowledgements
This story first appeared in Mining &
Construction 3-2010, and was updated
by Justin Cocchiola who visited the Aitik
mine in June 2012.

98 Blasthole Drilling in Open Pit Mining


Asarcos choice:
both diesel and electric
Adding a diesel-powered PV-271 not only met the bench and drilling requirements that Arsarco sought from a single-pass drill rig but also offered versatile mobility.
The rig moves freely about in any of Mission Complex mines pits.
Single pass drilling
with PV-271
Efficient, profitable operations
rely on the right equipment for
the job at Asarcos Mission Com-
plex mine, one of the largest mi-
ning operations in the United
States. Mine management at
Mission Complex combined the
cost-effective production of an
electric Pit Viper 271 drill rig
with the independent mobility
and time-saving capability of its
diesel counterpart. The result was
a more efficient, more profitable
operation.
Mission Complex Mine
Mission Complex, located 18 miles
south of Tucson and operated by the
Grupo Mexico subsidiary Asarco Inc.,
is one of the largest copper mines in
Arizona, a state that produces 65% of
the nations raw copper. On average
the total Mission Complex produces an
Blasthole Drilling in Open Pit Mining 99
average of 160,000 tons of rock daily,
equating to 53,000 tons of ore. Annual
production in 2009 was 56.2 million
tons. The mines ore-to-waste cut off
is 25 percent copper.
When they were selecting rigs to
replace their aging fleet, Asarco man-
agement looked for those that could
provide cost-effective, high produc-
tion management of the mines 40-foot
benches with an additional 7 feet of
sub-drill. Missions bench patterns
vary by formation, from limestone to
wollastonite with many variations in
the middle.
The softer rock is a 30 by 35 foot pat-
tern. They pull it in to 18 by 22 feet in
the harder formations. In the past this
presented them with problems with
pipe, because the rock is so abrasive.
To meet the demanding conditions of a
mine of this size and of rock this hard
on tools, mine management combined
the features of diesel and electric rigs.
They focused on two Atlas Copco Pit
Viper blasthole drill models, ultimately
choosing the single-pass capability of
the PV-271 over the 351s.
USA, TUCSON, ARIZONA
They are now running two PV-271s.
One is a diesel model, just under three
years old. The second, the electric mo-
del, entered service in December 2009.
They purchased the diesel model to
extend the drill reach from the existing
power capacity and to add versatility to
their drill fleet. At the time, they were
operating vintage electric-powered
rigs and one fairly new diesel-powered
DM-M2 in three pits.
Adding a diesel-powered PV-271
met the bench and drilling require-
ments in a single-pass drill rig that also
offered versatility and could move in
any of the pits.
To make the 47-foot holes they run
the PV-271 with two 25-foot and one
8-foot section of Atlas Copco 8 -inch
Teamalloy pipe. Below that they use a
41-inch bit sub adapter above a Secoroc
air-bearing 10 -inch tricone bit.
Comparable performance
Aside from one having a power cable,
The drills operate identically, said
Juan Salido, a Mission mine driller.
 ASARCOS MISSION COMPLEX MINE
The diesel powered PV-271 moves with ease back and forth on the bench increasing productivity by redu-
cing setup time.
The electric drill came with a larger
compressor, 2,600 CFM, whereas the
diesel Pit Viper has a 1,900 CFM com-
pressor. In regard to drilling produc-
tivity, both average 8,000 to 10,000
meters per month.
Mine manager Hal Galbraith said
the diesel PV-271 worked great for his
mine. I wouldnt say we ran the tracks
off the rig, because we did haul it on
our lowboy too, but it went everywhere
in the mine. Since then, the mine has
focused operations to just two of the
pits, but the diesel Pit Viper still moves
wherever needed within the mine.
Time on task favors diesel
Drill and blast manager Larry Maddox
noted that the diesel rig offers a sig-
nificant advantage, working well at
moving into tight spots on the bench to
allow drilling to continue before power
is moved into the working area for the
shovels. Moving an electric drill just
takes more time compared to a diesel
rig: having the cable crew available,
cutting the power, moving the cable,
planning the cable drops. You just
cant put a value on the mobility you
get from a diesel drill.
Salido added that it may only take
20 minutes to move the cable but 40
minutes or more for the crew to get
there. Anything that slows a cable mo-
ving crew stops operations. For exam-
ple, if the cable needed to be moved for
100 Blasthole Drilling in Open Pit Mining
an afternoon blast and the crew got a
flat tire on the cable truck, everything
would be held up until the tire could be
changed.
The diesel model obviously maxi-
mizes time spent drilling. Softer rock
at the mine may take only 20 to 30 min-
utes to drill each 47-foot hole. Other
formations that contain more garnet-
tectite and wollastonite, however, may
require as much as two hours for the
same hole requirements. Maddox said,
I think if you had plenty of time, elec-
tric would be better because of the cost
to operate and maintain, but mobility
more than makes up for it with the
diesel drill.
Comparing operating costs
One exception to this preference for
diesel is in operating cost. The electric
drill currently operates at 61 percent
of the energy costs of the diesel drill.
There is a point when this advantage
outshines the time-saving, independ-
ent mobility of the diesel rig. For
instance, when diesel fuel edged up to
$4 a gallon, the electrical rig was more
attractive.
Galbraith listed some of the addi-
tional, indirect costs to factor in with
use of an electric drill before making a
decision. Each electric rig requires four
4,000-foot cables at $100,000 each.
A 138- 4160 substation to power
the drill costs $250,000. Additional
manpower required to build the infra-
structure and to move the cable during
each relocation must be included in the
comparison.
Outfitting the rigs
Efficient drilling operations at Mission
are the result of strategically match-
ing pipe and bits to these PV-271s.
Teamalloy pipe has a much higher cost
per piece price than other pipe but its
durability and longevity mean cost per
foot is less in the long run.
A 25-foot section of Teamalloy
pipe lasts 6 weeks at Mission. Initial
outside dimension of the pipe is 8.65
inches. They will run it down to 8 or
7.9 before replacing it. The pipe shows
its wear at the lower end of the joint, in
what operators refer to as a penciling
effect. They rotate these sections, since
sections closer to the bit wear faster.
This distributes wear evenly among the
sections to increase longevity overall.
As for bits, the air-bearing works the
best in this formation with an average
life for a bit at 7,500 to 8,000 feet. Each
drill will go through about two bits a
week, depending on the ground.
Bottom line
For Larry Maddox the choice is simple,
I want to keep them both. He says
each has characteristics that make the
operation more efficient and produc-
tive. For the company, that means
greater profitability. Electric may be
cheaper, but the mobility with diesel is
better.
Galbraith said the decision to buy
the right equipment for the drill and
blast process is justified by the bottom
line: For every dollar more you spend
up front on drilling, youll make $10 on
the back end.
Acknowledgements
This article first appeared in Atlas
Copco Mining & Construction maga-
zine No 1 2011. Story and photos
by Scott Ellenbecker, Ellenbecker
Communication, who visited the mine
in June 2010.

Reopening of Copper Mountain
The diesel PV-271s independent utility enabled it to set up quickly in any part of the Superpit, especially
beneficial during pit push backs.
High-tech pays off
In spite of extreme cold weather
arriving earlier than expected,
Copper Mountain Mining Corpo-
rations careful planning, perse-
verance and high tech investment
in reopening a 15-year dormant
copper mine remains on track to
achieve full production by June
2011. This was achieved by com-
bining the benefits of both diesel
and electric-powered Pit Vipers
in their blasthole fleet. Their suc-
cess has inspired interest in other
regional mines abandoned de-
cades ago when mineral prices
fell. Intelligent fleet choices are
proving that revisiting these
mines can be a promising venture.
Promising outlook
Its a full six months before startup, yet
an historic mine being reopened by the
Blasthole Drilling in Open Pit Mining 101
CANADA, PRINCETON, BRITISH COLUMBIA
Copper Mountain Mining Corporation
is already rewarding the Princeton,
British Columbia, region with new
jobs and a promising outlook for an
economic windfall from the billions of
dollars of copper, silver and gold the
mine will generate. It comes none too
soon for this area of British Columbia,
whose forest industry has suffered
from both pine beetle devastation and a
downturn in the forest industry overall.
During its previous life, the open-
pit porphyry mine had already yielded
770,000 tonnes of copper, 258 mil-
lion grams of silver, and 20.7 million
grams of gold from 23 years of con-
tinuous production before it closed in
1996, when copper prices were low.
Exploration in 2006 by its new owner,
however, promised that the mountain
would reward the company with ano-
ther 17 years worth of production from
its untapped mineral deposits.
Data-based confidence in
projections
Combined evidence from past drilling
and modern exploration convinced
stakeholders that there are still at least
680,000 tonnes of copper left, with pre-
cious metal credits of more than 12.8
million grams of gold and 127.6 million
grams of silver.
Earlier this year, Copper Mountain
Corporation President and CEO, James
ORourke, said the company anticipates
full production to reach 32,000 tonnes
per day, amounting to over 45,000
tonnes of copper a year and reaping
significant amounts of gold and silver
as by-products. With operational and
financing costs totaling about $1.30
(USD) per pound, the copper will sell
at about $2.80, which ORourke notes
is a significant margin.
The overwhelming evidence that
there are significant resource deposits
yet to mine come from nearly 5,000
historical drill holes combined with
more than 400 of the companys own.
Continued exploration of the deep-
seated porphyry in the fall of 2010
further confirmed extrapolated predic-
tions. And the life of mine strip ratio is
estimated to be just 2:1.
High profitability, low risk
Although reopening a mine of this size
is a formidable task, the project did
come with some built-in benefits, such
as a ready, skilled workforce from pre-
vious mining operations in the area, as
well as a pre-existing infrastructure at
this site. Only 15 miles from the town
of Princeton, a paved highway runs past
the mine, and the site has ample water
resources with an ideal location for
processing the extracted ore. Copper
Mountain partnered with Mitsubishi
Materials early on, who provided ideal
security for the venture both in finan-
cial backing and by ensuring the mine
a reliable buyer for the ore.
The conscious effort to reduce oper-
ational risk has been evident in every
 Reopening of Copper Mountain
The diesel rigs components arrived on site in September.
component of the enterprise, including
choice of equipment. For instance, to
move the 22.7 million tonnes of mate-
rial by May 2011 in preparation for full
startup in June, and then to move the
additional 54.9 million tonnes anticipat-
ed during the first production year, all
blasthole drilling has been awarded in
a three-year agreement to Altas Copco
and its Pit Viper series, as well as all
drilling rig parts, ancillary equipment
and tools.
Gary Wright, the Atlas Copco sales
representative for southwestern Canada,
said, Its good for startups because it
creates a partnership with the manufac-
turer and the mine. It includes every-
thing from service to the steel and bits
and allows everyone to work together.
The first rig, a diesel-powered
PV-271, which had been in operation
since September, was joined by its elec-
tric counterpart in November. A second
electric model, a PV-351, completed the
trio of Pit Vipers at the site in January
2011.
Alastair Tiver, Copper Mountains
Chief Engineer, said a mix of electric
and diesel is working well. Use of
electric allows us to lower operating
costs, he said. The pit will be deve-
loped with a series of push backs, so
having a diesel rig affords us some
additional mobility to move a rig
from one mining area to another,
102 Blasthole Drilling in Open Pit Mining
should additional drilling capacity be
required.
Strategy for reaching the
metals
Peter Holbek, Vice President of Explo-
ration and leader of the mines explora-
tion teams, explained the three-pronged
approach the company is undertaking
to realize the companys production
goals. They have incorporated and ex-
panded all three pits of the mine under
one all-encompassing Super Pit.
First the company will drill in areas
of known mineralization from the
previous operation. Second, they will
drill in outer target areas that, although
they were drilled previously, were not
fully explored. And third, they will go
after deeper targets, confident in the
corroborative data from the new and
historical information.
The company purchased the origi-
nal, diesel-powered PV-271 for its
ability to move quickly into other areas
without the need to relocate power. The
decision to purchase electric-powered
Pit Vipers was based on economy.
Although they would have purchased
a third PV-271, Mine Manager Art
Pratico said the PV-351E was immedi-
ately available.
The current PV-271s, with their
ample 2,600 CFM (73.6 m 3/min) air
By December, the rig had already logged more than
1,200 hours.
compressor packages, are well-matched
to 270 mm (10 ") Epsilon rotary bits,
which will allow quick clearing of the
holes.
Pratico said the rigs are working
well driving 7.62 meter (25 ft) drill pipe
while smoothly operating on the mines
15-meter (49 ft) benches to stay ahead
of scheduling goals. The electric model
does give them the benefit of lower
operating costs. Other than that, the
diesel and electric perform comparably.
One-source logistics
Copper Mountain Mining teamed with
Atlas Copco for the complete supply
of all required rock drilling tools. This
provides not only the convenience of a
one-source supply but also means Atlas
Copco is in frequent contact with the
company, maintaining instant access
to customer support. Service is instan-
taneous.
So how has the PV-271 been perfor-
ming overall? Pratico said he is pleased
with the machine. The diesel rig had
already logged 1,200 hours of operation
by December. It not only performs well,
but it is also being used as a trainer.
The PV-271s high-tech upgrades give
operators rich options without alienat-
ing those who are new to the series. It
operates just like any other drill rig,
Pratico said, meaning it doesnt require
a steep learning curve to train an opera-
tors skills to proficiency on a Pit Viper.
That drillers can acquire proficiency
with the rigs quickly is just one more
contribution to helping the mine keep
on track for the June 2011 deadline.
Acknowledgements
This article first appeared in Atlas Copco
Mining & Construction USA No. 1, 2011
Story by Joseph Bradfield. Pictures by
Gary Wright.
 CHILE, Andes Mountains, antofagasta

Radomiro Tomic prioritizes service

Chilean mines suc-
cessful strategy
combining exper-
tise of drillers,
technicians.
Proper care of machinery and
tooling directly contribute to the
success of Chilean mines, which
lead the way in mining efficien-
cy and safety in Latin America.
A prime example is Codelcos
Radomiro Tomic Mine in north-
ern Chile, located 3,000 meters
above sea level in the Atacama
Desert. The mine entered into a
10-year service agreement with
Atlas Copco that not only facili-
tates high production but frees
up the company to focus solely
on mining.

Planning for long term
operation
In 1997 the National Copper Corpo-
ration of Chile, or Codelco, named the
Radomiro Tomic mine after a politi-
cal reformer who was a primary force
behind the nationalization of the copper
mining industry in Chile. Known local-
ly as RT, Radomiro Tomic is located
1,670 kilometers from Santiago, in the
Andes Mountains of northern Chile.
Although the oxide copper porphyry
there was discovered in 1952, Coldecos
operations did not begin until 1995,
when improvements in technology
made mining the resource profitably
feasible. The Radimiro Tomic deposit
lies beneath approximately 100 meters
of alluvial material and extends over 5
by 1.5 kilometers by 200 meters.
Operations at RT show a strategy
for long-term success and the mine is
expected to become the model for other
mines. RT features a service solution
that frees its miners to focus on mining
and ensures support of expert techni-
cians in a highly efficient maintenance
program.
The Pit Viper 351 at work in the Radomiro Tomic Mine at 3 000 m in the Atacama Desert in northern Chile, known
as the dryest in the world. Here, Atlas Copco takes care of all service and maintenance of the drill rigs.
To fulfill the 10-year agreement for
service and maintenance of RTs drill
rig fleet, Atlas Copco has established
an onsite service team of about 50
people who will take care of 11 drill
rigs including the Pit Viper 351, ROC
L8, DMH and DML models. Three
additional Pit Viper 351 rigs are due
to be delivered at the end of 2011. By
that time the service team will have
increased to more than 60.
Two programs in force
Two different service programs are in
operation at the minea labor-plus-
parts program (LPP), which supports
older drill rigs, and a maintenance and
parts replacement contract (MARC) for
all new rigs.
Since the history of each part or
activity of the used equipment is uncer-
tain, it is not efficient to apply a fully
comprehensive service program. This
makes an LPP more suitable for this
part of their fleet. Parts are provided
by the mine in accordance with their
consumption and the labor is provided
by Atlas Copco at a predetermined rate.
The MARC program, on the other
hand, is a complete maintenance and
repair service program that applies to
all new rigs as they arrive. A clear his-
tory can be tracked from the first hole
drilled.
The contract consists of all mainte-
nance and repair routines required to
secure high availability and reliability.
This includes preventive, planned and
corrective maintenance as well as con-
dition monitoring. All necessary parts,
repairs and labor are provided by Atlas
Copco at a guaranteed rate.
A predetermined performance level
defined by Key Performance Indicators
(KPI) has also been established, using
a maintenance-balanced score card as
a measurement tool. For example, it is
expected that the Pit Viper rigs will be
available 90 percent of the time. The
mean time between failures (MTBF) is
44 hours and the mean time to repair
(MTTR) is 3.5 hours. This translates
to an average of 44 hours of straight

Blasthole Drilling in Open Pit Mining 103

 Radomiro Tomic prioritizes service
Controlling dust is an important function at all mines. Here water is being pumped into the ROC L8 for
collaring the hole, which controls surface dust.
operation before the rig is shut down
for no more than 3.5 hours before its
up and running again.
The DMH, an older, used rig, has
an availability rate of 78 percent while
its MTBF is 29 and its MTTR is 3.5.
Each drill rig is covered by the con-
tract independently and record keep-
ing is meticulous. The system requires
considerable management expertise
as well as technical skill, and in this
region of Latin America Atlas Copco
is well equipped to provide both. The
service team is part of the its overall
Atlas Copco Service Technician Juan Bustamante
takes a break from working on the electrical
Pit Viper for a photo.
104 Blasthole Drilling in Open Pit Mining
customer support effort in Chile, which
has also resulted in the creation of a
Competence Development Center in
Santiago.
The onsite Atlas Copco team is di-
vided into three categories: planning,
execution and logistics. The planning
team, the smallest group, works on
short term and long term planning
needs for parts and fluids. The execu-
tion team, the largest group, is dedi-
cated to maintenance and repair tasks.
The logistics group is responsible for
administration, warehousing and pur-
chasing.
The purchase of capital equipment
is a small part of the overall demands
at RT, whereas having the qualified
people to keep the equipment opera-
tional is a large part of the mines
success, said Eduardo Fajardo, Atlas
Copcos administrator on the site. As
equipment becomes more technical and
qualified labor becomes more difficult
to hire, mines are looking to companies
that can provide the total package.
The Atlas Copco Competence Deve-
lopment Center was designed to put
more than 100 skilled technicians at the
disposal of its clients. These open pit
and underground equipment specialists
provide training in maintenance and
skills required in such areas as RCS,
electronics and hydraulics.
The Centers mission is to develop
every entrant into a master technician.
Operator Fernando Acua finds automation relaxing
as he waits for completion of the hole on his
Pit Viper 351.
Total focus on drilling
Fernando Acua, an operator at RT
who has ten years of drilling experi-
ence and many more as a loader opera-
tor and truck driver, said learning to
handle the computerized Pit Viper was
not difficult. He pointed to a display
screen showing an rpm of 78 and an
indicator showing a penetration rate
of 0.5 m per minute. The rig keeps its
operator informed of everything that is
happening during the drilling process.
Normally the rig operates at 1 meter
per minute and takes about 20 minutes
to drill an 18-meter hole with an 11-by-
11 meter burden and spacing pattern.
The rig that day was running with a
weight-on-bit of 27 tonnes. It is capable
of 54 tonnes weight-on-bit.
With an an nual production of
300,000 tonnes of cathode copper, the
Radomiro Tomic mine continues its
steady growth by combining the expe-
rience of its drill rig operators with the
service and maintenance experience of
Atlas Copco, leaving each to their area
of greatest expertise.
Acknowledgement
Article and photos by Scott Ellenbecker.
Originally published in Atlas Copco
Mining & Construction magazine,
No. 2/2011.
 CHILE, Atacama Desert, antofagasta
Automation at Escondida
The Pit Viper 351 working in the Escondida pit..
Blasthole Drilling in Open Pit Mining 105
Company triples
mine life with high
tech drill rigs
A l t h o ug h E s c on d i d a M i n e r a
literally translates as hidden
mining, its no secret that it can
maintain its position as the larg-
est copper producer in the world
by stepping up its investments in
automation. The largest copper
mine in the world is updating its
fleet with units that feature Atlas
Copcos rig control system (RCS).
Growth strategy
Escondidas growth plan emphasizes
four basic principles: be safe, put people
first, do things right the first time and
think to the future. These are the prin-
ciples that guide the management in
developing the operation and planning
equipment purchases.
For Escondida, doing things safe,
right and with the future in mind means
their drilling equipment must be mobile
and offer autonomous capabilities both
in the cab and for mine planning.
Growth to us means autonomous
high production drilling, said Juan
Carlos Fuentealba, who is the mines
drill and blast manager.
The mine has strategically moved
its drilling operation toward greater
automation with the recent introduc-
tion of units built upon Atlas Copcos
RCS platform. The fleet so far consists
of 120 haul trucks, 18 shovels and 18
drill rigs.
Anticipating its future drilling ne-
eds, the mine will phase out its aging
fleet of Bucyrus 49R electric rigs for a
mixed fleet of Atlas Copco diesel rigs.
The main production model will be the
Pit Viper 351, of which two are cur-
rently in operation. Three DM45s, a
DM-M2 and a PV-271 are also on site.
Two additional PV-351 rigs are sched-
uled for delivery in the third quarter
2011.
 Automation at Escondida

Escondida operates two open pit copper mines in the Atacama Desert, 170 kilometers southeast of Antofagasta in northern Chile. Escondida produces mainly copper concen-
trates, which are piped as a slurry down to the port of Coloso where they are dewatered before shipping, and a smaller proportion of cathode copper from the leaching
of both oxide and low grade sulfide ore. It also produces gold and silver.

The smaller rigs drill 200 mm (7
-inch) holes while the PV-351 rigs
drill either 276 or 318 mm (10 - or
12 -inch) holes, depending on the ma-
terial. The benches are 15 meters high
with additional 1.5 to 2 meters of sub-
drilling.
Focus on mobility
The mine produces about 300,000
meters per month from its two pits,
Escondida and Escondida Norte, with
the smaller drill rigs primarily drill-
ing buffer holes. Two rows of small
diameter holes are used between the
production holes and the final pit slope
to optimize rock fragmentation. At
Escondida, Atlas Copco ROC L8 rigs
drilling 165 mm (6 -inch) holes are
used for presplitting work.
The mobility of the PV-351 is a key
contributor as it moves from bench
to bench and pit to pit. The Pit Viper
can also be moved with the tower up,
or with a live tower on the bench,
something that could not be done with
the old fleet.
Production in the pits has also in-
creased, mainly due to the new rigs
availability, and to the penetration rate
of the Pit Viper, which is also better
compared to the fleets older units that
the Atlas Copco rigs are replacing.
Other benefits of
automation
As the mine moves forward, the man-
agement is also looking forward to
using the new training simulator that
the Atlas Copco Customer Center is
bringing to the country. Hugo Reales
Trigo, Drill and Blast Superintendent
and General Operations Manager, no-
ted one advantage of using a simula-
tor is that training does not take a drill
out of production. It is also safer, as it
reduces the number of people working
on the bench. He added that automation
increases safety even while eliminating
or reducing the need for many time-
consuming safety procedures.
A big advantage of the Pit Viper for
Escondida is the rigs GPS navigation
capability. This allows the drill pattern
to be located via computer and down-
loaded to the rigs onboard computer.
All operational data is also stored to
make the rigs performance and service
record easy to monitor.
Such automated features as these in
Escondidas fleet will ensure that this
operation remains the most productive
copper mine in the world, with the
safest operation possible.
Acknowledgement
Article and photos by Scott Ellenbecker.
Original article published in Atlas
Copco Mining & Construction maga-
zine, No. 2/2011.

106 Blasthole Drilling in Open Pit Mining


Ambitious target at Esperanza
Esperanza has proven and probable copper reserves of 583 million tonnes with an expected average
annual production of 714,000 tonnes of concentrates containing 190,000 tonnes of payable copper and
230,000 ounces of payable gold over the first 10 years.
Rotary and
DTH drilling
Esperanza mine was from day
one designed to use sea water as
a conservation measure and is
aspiring to become Chiles next
big mining operation by using
even more of the latest in tech-
nology and equipment. Utilizing
Atlas Copco drill rigs, the mine is
using PV-351 rotary rigs for pro-
duction drilling, DMM3 rotary
rigs for buffer holes and DTH rigs
such as the Atlas Copco ROC L8
for pre-splitting the benches.
Large scale mining
The Esperanza mine in the Antofagasta
region is a young mine with big ambi-
tions. Opened in 2008, the first blast
took place in March. The initial blast-
ing, ending in July 2010, included the
largest removal of overburden in the
mining industrymore than 150 mil-
lion tonnes.
Blasthole Drilling in Open Pit Mining 107
CHILE, sierra gorda, Antofagasta
The mine plan considered that the
pit will reach dimensions of 2,100
meters long, 1,750 meters wide and
770 meters deep. The main metal is
copper, but the ore also yields gold and
molybdenum.
The Esperanza project is one of the
few high-profile development copper
projects remaining globally, under
joint ownership of Antofagasta PLC
and Marubeni Corporation.
The groups mining division is one
of the largest international copper
producing companies in the industry.
Its activities are mainly concentrated
in Chile, where it now owns and oper-
ates four copper mines: Los Pelambres,
Esperanza (in start up), El Tesoro and
Michilla, with a total production of
521,100 tonnes in 2010.
As a new mine, Esperanza has had
the opportunity to adopt the most mo-
dern mining practices right from the
beginning. That willingness to embrace
innovation has included the latest up-
dates to its Atlas Copco Pit Viper drill
rigs and a conservative use of water.
Antofagasta focus for exploration in Chile remains
in the Sierra Gorda District. The group owns or
controls a number of properties there: Esperanza
(and the concentrator plant) and the El Tesoro op-
eration, which means Antofagasta is well placed
to develop this area as a wider mining district.
The Telgrafo deposit could be used to extend the
life of Esperanza, or increase its size of operation.
Water is a scarce commodity in
northern Chile, home of the Atacama
Desert. In one of the driest climates in
the world, Esperanza is a pioneer in the
use of seawater without desalination in
large-scale mining processes. To get
the water from 145 kilometers away,
the mine pumps water at 630 liters per
second to an altitude of 2,300 meters
(7,500 feet). To avoid excessive electric-
ity use, Esperanza does not desalinate
the water before using it.
Atlas Copco is supplying blasthole
rigs in a variety of sizes for this mine
to work at peak efficiency. The practice
is to drill 16-meter holes with a 1.5 to
2 meters subdrill. The drilling pat-
tern varies with the type of rock being
drilled. In sulfides the pattern is 6.5 by
7.5 meters, and in oxides the pattern is
7.5 by 8.5 meters. Waste is drilled at 9
by 11 meters.
For safer pit slopes, an Atlas Copco
ROC L8 drills a line of 165 millimeter
(6 -inch) holes along the wall for pre-
splitting. The blast creates a clean crack
between 2-meter spaced holes. The line
 Ambitious target at Esperanza

ROC L8
One of the four
Pit Viper 351 rigs.

DM-M3

Pre-split Holes
165 mm (6 in.)
PV-351 diameter holes
Buffer Holes
269 mm (10 58 in.)
diameter holes

Be
Production Blast Holes
269 mm (10 58 in.)

2m

rm
diameter holes for ore
and 311 mm (12 in.)
diameter holes m
4.5

2.8
m

for waste
4.5
m

sulfi
m
6.5
des 4.5
m

m
6.5
7.5
m

In oxides the drill pattern is

7.5
m

7.5 by 8.5 meters. Waste is

drilled at 9 by 11 meters.

16 m

The operator gets more done with this rig. It is easy

to operate and positioning is faster with RCS. The
Chosen for its advanced technology the majority of the production drilling is done with four Pit PV-351 was chosen by Esperanza for its weight
Viper 351 rigs, drilling 16-meter holes with a 1.5 to 2 m subdrill. Drilling of the buffer holes are
in relation to drilling capacity and also because of
done by two DM-M3 rigs and the holes for pre-splitting with a ROC L8.
its advanced technology.

is drilled 2.8 meters from the closest
blast pattern holes. Almost all of the
benches are presplit for safety reasons
but especially when they are near a
haul road.
A buffer zone is drilled next in the
pattern, preventing the impact of the
main blast from transmitting its full
energy into the wall. It consists of a
double row of 1,269 mm (10 58 inch)
holes drilled with two Atlas Copco
DM-M3 drills. The buffer zone is shot
after the main blast with only a slight
delay. The DM-M3 rigs are also used
for production drilling when necessary.
Progressive mine and
drill rigs
The majority of the production drill-
ing is done with four Atlas Copco Pit
Viper 351 rigs drilling 269 mm (10 58
inch) holes in ore and 311 mm (12-inch)
holes in waste. The PV-351 is capa-
ble of drilling blastholes up to 406 mm
(16-inch) diameter to a maximum depth
of 135 feet.
The PV-351 was chosen by Espe-
ranza for its weight in relation to hole
size, pattern size and bench height, and
also because of its advanced technol-
ogy. The mine converted to the latest
version equipped with the Pit Vipers
Rig Control System (RCS).
Operator Herman Gospochetic said,
Positioning is much faster with RCS,
and I feel I get more done, he said.
The remote control upgrade on the
system is also more user-friendly.
Other Pit Viper options include fire
suppression systems and computer-
controlled central lubrication. Options
specific to the PV-351 include a cold
weather package for operation in ambi-
ent temperatures down to -40 C, a
four-camera LCD vision system and
attention horn, and a wireless remote
propel control. Remote control tram-
ming with the operator off the rig is
mandatory in certain situations under
some regulatory authorities. Additional
options are a Hiab crane for loading
and unloading bits and accessories,
hydraulic retractable staircase, tower
ladder and much more.
Esperanza is at the beginning of its
life. With modern methods and equip-
ment, it is aiming for a long and pros-
perous future through its estimated life
to 2027, possibly longer.
Acknowledgements
Article and photos by Scott Ellenbecker.
Originally published in Atlas Copco
Mining & Construction International
magazine, No. 2/2011.

108 Blasthole Drilling in Open Pit Mining

 Chile, iquique, Tarapac Region

Raising to the altitude challenge

Diesel rigs drill fast
The newest drilling machines at
the Collahuasi open pit mine in
Chile are two snakes from Texas
impressing with their power, ver-
satility and superior technology
in extreme conditions - The Atlas
Copco Pit Viper rigs claim their
territory.

In the northernmost part of Chile, high

in the Andean plateau of the Tarapac
Region, sits the giant Collahuasi mine,
one of the worlds largest copper resour-
ces. Here, mining operations take place
at altitudes of between 4,000 and 4,800
metres above sea level, making this one
of the most challenging work environ-
ments for any mining equipment.
The mine is operated by a joint
venture company - Compaa Minera
Doa Ins de Collahuasi owned by
Anglo American and Xstrata (44%
each) and a group of Japanese compa-
nies headed by Mitsui (12%).
Collahuasi extracts and processes
sulphide ores to produce copper and
molybdenum concentrates and oxide
ores to produce copper cathodes. Of
these, copper concentrate is the main
product, accounting for over 90% of the
mines output of contained copper.
Commissioned at a cost of US$1.76
billion (which turned it into the mine
with the largest single investment in
Chilean history), commercial opera-
tions at Collahuasi started in April
1999. After a US$584 million expansion
in 2004, the mine now has an installed
copper production capacity of 500,000
tonnes per year. Even this figure was
comfortably exceeded in 2009 when
Collahuasi produced a record 535,853
tonnes of contained copper.
In mid 2011, a prefeasibility study
was started to see whether a second
expansion would be economically
viable. The study contemplates two
options: a fourth mill line, which would
take production to 800,000 tonnes per
year or a fourth and fifth lines together, The PV-351 and the PV-271 are the only diesel units in a fleet of 11 production drill rigs at the Collahuasi
which would take production to over mine. Both rotary machines are drilling vertically an to a maximum depth of 18 meter.

Blasthole Drilling in Open Pit Mining 109

 Raising to the Altitude Challenge
Above: Carlos Correa Echeverria. Top right: operator of the PV 351. Bottom right: The PV-351 and PV-271 at Collahuasi copper mine.
1 million tonnes per year. According
to an official press release by Anglo
American, the study is focused on ev-
aluating both options and whichever
option is taken; the project would be
commissioned in 2017. The expansion
project, which will be for the produc-
tion of copper concentrates, is in line
with the companys vision of being
amongst the leading copper producers
by 2020.
Collahuasi currently accounts for
about 9.3% of Chiles total copper out-
put, which positions it as one of the
countrys main producers and a leading
international player. The mine has an
expected life of over 30 years and the
company has production plans in place
up until 2040. According to the com-
pany official figures, mineral resources
total 7.1 billion tonnes at an average
grade of 0.82% copper. This includes
ore reserves of 3.1 billion tonnes, 2 bil-
lion tonnes of which is accessible.
There are approximately 5,500 peo-
ple currently working at Collahuasi,
including contractors. The mine works
110 Blasthole Drilling in Open Pit Mining
non-stop 365 days a year with a pattern
of two 12-hour shifts a day; from 8am
till 8pm and 8pm till 8am. We would
only stop if we are badly affected in
winter, says Carlos Correa Echeverra,
Superintendent Drilling & Blasting
at Collahuasi, referring to the harsh
weather conditions in the Andean high
plateau.
We need all our equipment to su-
stain consistent and reliable perfor-
mance while operating at maximum
production capacity, says Correa. This
is easier said than done when that
equipment has to operate at very high
altitude, at very low temperatures and
during occasional electric storms. This
is the environment in which the two
new Atlas Copco Pit Viper blast hole
drilling rigs, a PV-351 and a PV-271,
have had to prove their worth.
Mining & processing
Located in an area of historical copper
mining, Collahuasi consists of three
major copper deposits: Ujina, Rosario
and Capella. Lying at an altitude of
4,100 metres, Ujina contains second-
ary sulphides and oxides. This deposit
(plus a smaller oxide deposit called
Huinquintipa) was the first to be
mined; representing the first stage of
Collahuasi. Currently a total of 50,000
tonnes per day of rock is extracted from
Ujina and a total of 45,000 tonnes per
day is extracted from Capella, which
contains oxide copper ore.
Still higher, at an altitude of 4,600
metres is Rosario, a deposit that con-
tains secondary enriched sulphides
and oxides with a relatively high
copper grade of 1.1%. Stripping at
Rosario began in 2002 and this has
now become the principal source of ore
at Collahuasi; currently over 600,000
tonnes per day of rock are mined.
Rosario Sur 1, a new area where work
has only just started, is contributing
another 10,000 tonnes per day for a
grand total of 705,000 tonnes per day
of extracted rock.
Most of the mining equipment is
deployed at Rosario, including the
 Raising to the Altitude Challenge

drilling fleet and some large capacity

loading and hauling units. Collahuasi
boasts over 40 ultra class haul trucks
from different suppliers, with a rated
capacity of between 240 and 370 ton-
nes. These are loaded by a fleet of elec-
tric rope shovels, supplemented by a
few hydraulic shovels.
After drilling and blasting, the Run-
of-Mine ore is hauled to the processing
area. Because of the presence of both,
sulphide and oxide ores, Collahuasi
employs two processing methods.
Sulphide ore is crushed, ground and
treated by flotation and oxide to yield
a concentrate whereas oxide and mixed
ores are treated by heap-leaching, sol-
vent extraction and electro-winning
(SX-EW).
The sulphide ore enters a primary
gyratory crusher prior to transport to
two parallel grinding circuits, each
consisting of a SAG mill and a ball
mill. Secondary closed circuit grind-
ing includes cyclone classifiers, from
which the overflow feeds the flotation
circuit. Flotation concentrate is thick-
ened to 50% solids for slurry transport
in a 200 km-long pipeline to the port of The Collahuasi mine, one of the worlds largest copper resources, is located high in the Andean plateau
Punta Patache, 60 km south of Iquique, and operations take place at altitudes of between 4,000 and 4,800 metres above sea level.
where it is thickened and filtered before
shipment to smelters worldwide. are chalcocite, chalcopyrite and bor- low quality of the rock mass. Blasting at
The oxide ore is reduced to -10mm nite. Oxide mineralisation occurs Collahuasi is carried out once a day and
by three-stage crushing. The fine ore mainly as chrysocolla with minor four different drilling patterns are used
is agglomerated before being conveyed brochantite, native copper, and copper- depending on the area. Some areas
to the leach pads where it is leached iron-manganese oxides and hydroxides. contain ground water so we have to
using sulphuric acid. Copper is recov- The rock here has special charac- take this into consideration. Depending
ered from the pregnant leach solution teristics; its altered with quartz so its on the presence or not of water, we use
in the electro - winning plant, where harder, says Correa, explaining that heavy ANFO or ANFO & emulsion,
the copper is stripped using organic the rock at Collahuasi has an average says Correa, adding that they employ a
solutions; the stripped liquor is then strength of 100 megaPascal (MPa), with remote electronic initiation system.
returned to the leach pads for re-use. some sectors reaching even 250 MPa.
The strip solution is cleaned using For comparison, the rock at other local Drilling & Vipers
dilute acid and flotation and is filtered mines has a typical strength of 60 MPa.
prior to the electro-winning phase, Nevertheless, there are some geo- On the drilling front Collahuasi
where the copper is plated onto cath- logical faults. Some areas can be un- currently employs a fleet of 19 rigs of
odes. These are stripped by the Kidd stable with the risk of wall collapse, which 11 are used specifically for blast-
process on a seven-day cycle and the says Correa, explaining that this, how- hole production drilling including the
cathode copper is then transported by ever, does not happen abruptly. A radar two Pit Viper units. They are the only
road to Iquique for export. system is used to scan the walls so the diesel drilling rigs working in produc-
Hard Rock Geologically speaking, risk of collapse can be controlled. tion as the other nine are electric rigs.
Collahuasi is a por phyr y copper The stripping ratio at Collahuasi There are three other rotary diesel
deposit. Approxi-mately 50-60% of varies depending on pushback develop- machines from another supplier, which
the worlds copper and 95% of molyb- ment but the average is 4:1 (waste: ore). are being used to drill 7 buffer
denum comes from porphyry deposits Bench heights are a standard 15 met- holes. These are the holes positioned
and indeed, the greatest concentration res with 1 and 2 metres of subdrilling on the last two or three rows close to
of large copper porphyrys is in Chile. depending on the drilling pattern. the walls. These holes must be drilled
The major ore minerals at Collahuasi There are no double benches due to the with a smaller diameter than production

Blasthole Drilling in Open Pit Mining 111

 Raising to the Altitude Challenge
Once they arrived in Collahuasi, the Pit Vipers went straight to the Rosario deposit to work in production
drilling. Some areas in this deposit are narrow and have water but this is not a problem for the versatile
diesel rigs.
holes as they require a smaller explo-
sive charge in order to minimize
damage to the wall or the slopes, ex-
plains Correa, adding that normally,
these holes are drilled to the height of
the benches, without subdrill.
For pre-splitting, Collahuasi em-
ploys four smaller diesel rigs, which are
drilling 4 diameter holes to a depth
of 16 metres and at an angle of 70.
The Pit Vipers were delivered in
April and May 2011 and both went
straight to Rosario to work on produc-
tion drilling. The PV-271 unit is drill-
ing 10 diameter blast holes and the
PV-351 is drilling 12 diameter blast
holes. Both rotary machines are drill-
ing vertically and to a maximum depth
of 18 metres.
According to Correa, the diesel
machines have proved ideal for work
at this deposit: Weve hit a phase in
the Rosario deposit where the working
area is narrow and there is water, he
explains. It is very convenient for us
not to have to deal with the cables of
the electric machines in that area.
112 Blasthole Drilling in Open Pit Mining
Also important is the machines
versatility: Moving electrical cables
about results in lost time, and thats
why we decided to go for a diesel ver-
sion. We like the versatility of the Pit
Vipers as we can move them around
quickly and without problems.
However, the high altitude and con-
sequent reduction in oxygen, means a
loss of power in any diesel machine.
This makes the rigs less efficient and
so we had to compensate for this by
fitting them with higher-powered en-
gines and compressors, says Paulyn
Espindola, Product Manager, Atlas
Copco Drilling Solutions (ADS), ex-
plaining that the Pit Vipers at Colla-
huasi are f itted with a compres-
sor giving a low pressure rotary of
3,800 cfm @ 110psi instead of 3,000,
which would have normally been
enough. Equally, the rigs feature a
more powerful engine, in this case one
delivering 1,650hp @ 1,800rpm.
T he high altit ude also means
extreme low temperatures, especially
in the South American winter (July to
September), when temperatures can
reach -40C. That means that the rigs
also have to be fitted with a heater
and an on-board generator, continues
Espindola, explaining that elements
such as the water pump, fuel, battery
and oil can all be affected by the very
low temperatures.
Pit Viper 351
Although both rigs have had a good
general performance, it is the larger
unit that has stolen the show: The
PV-351 is drilling about 10% faster
than the electric rigs, roughly 58 metres
per hour, whereas the electric machines
are drilling an average of 50 metres per
hour, informs Correa.
This was confirmed on site by
Eduardo Macheo, the operator of the
PV-351: I like this machine; its fast.
Ive been able to drill 780 metres with it
in one shift of 12 hours (thats including
a one hour break). But I can do better;
my personal record is 800 metres in
one shift and Im sure I can reach that
with the 351! he laughs confidently.
Macheo felt familiar with the rig
from the start as he used to work on
another Pit Viper unit before, albeit the
smaller 271 and not one equipped with
the Rig Control System (RCS). Before
I came here I worked at another large
copper mine and there I had the oppor-
tunity to operate the 271 machine. I
had a console for operation though, not
joy sticks, so the whole computerised
system and the joy sticks were a new
experience for me, he says.
The RCS computerised system
comes as standard on all PV-351 rigs
and provides a high level of automa-
tion, including autodrilling, GPS hole
navigation, rig remote access with com-
munication, remote tramming, measure
while drilling and tele-remote opera-
tion amongst other advanced features.
All the rig functions are controlled
through a touch screen, two joy sticks
and push buttons on the operators seat,
so when the seat swivels, the joysticks
and screen swivel in conjunction. When
the two Pit Vipers arrived, Atlas Copco
provided two experienced instructors,
to train approximately 20 people at
Collahuasi. The technical training was
completed only in January this year.
 Raising to the Altitude Challenge

Macheo admits it has been a learn-

ing curve but an easy and enjoyable
one: Oh, it wasnt a problem at all
to learn to operate it. It did help that I
had already worked on the 271 but the
controls are very straightforward, he
says, praising the cabin and its great
visibility. Its easy for me to work in
here, it feels safe and Im happy.
Featuring a powerful hydraulic pull-
down, the PV-351 has also impressed
Collahuasi with its great capacity:
Before, there wasnt a diesel machine
with this capacity and for us this results
in greater availability in time, says
Correa.

Atlas Copco inside

Collahuasi
Before the Pit Viper units arrived, Atlas
Copco did not have a significant pres-
ence in Collahuasi in terms of large
equipment so, commercially speaking,
these machines represent a coup for the
supplier. Of course were very proud
to have got into Collahuasi but whats
more important for us is the opportuni-
ty to be able to show our new customer
how we can help, especially when it
comes to advanced technology.
Of the 40 Pit Viper units in the
country, 21 of them feature the RCS sy-
stem. says Fernando Depix, Business
Manager ADS in Chile.
Atlas Copcos advanced technology
was, in fact, one of the major reasons
why Collahuasi decided to go with the
Pit Viper units: Atlas Copco offered
us the possibility of automated drill-
ing and this is very important for us,
confirms Correa.
Complete automated drilling is the
way the company would like to go in
the future and so it needs to get ready
for it: We have been looking at several
alternatives and ideally, in the future,
well reach a stage where drilling can
be carried out without the operator
inside the machine. We have been
watching the results at Aitik mine,
where theyve been drilling remotely,
with the operator placed at a distance
from the machine he says referring to
the Swedish copper mine, one of the
most cost-efficient mining operations
and where four Pit Viper 351 rotary
drill rigs are currently working.
Top left: Fernando Depix, Business Manager, Atlas Copco Drilling Solutions, Atlas Copco Chilena
Top right, Paulyn Espindola, Paulyn Espndola, Atlas Copco Product Manager near a blasthole produced by
the PV-351 at Collahuasi. Above: (Group of men from ADS Chile). From left to right: Jean Olivares, Rodrigo
Muz, Paulyn Espndola, Fernando Depix, Felipe Ortega, Julio Acevedo and Hugo Moyano.
Continuous improvement and inno- In a full year, Collahuasi drills about
vation through the use of new tech- 925,000 metres in 12 " diameter,
nology is another important strategic plus 420,000 metres in 10 " diameter
objective for Collahuasi. From the and 220,000 meters in 7 diameter.
drilling point of view, autonomous All the drill rigs are dressed up with
technology would mean being able to TEAMALLOY drill strings from top
standardise our drilling operations and to bottom and SMOOTHDRIVE shock
thus help increase our production, absorber sub. The contract, which was
confirms Correa. recently renewed until October 2014,
is based on rate of penetration (ROP)
Drilling steel with Collahuasi paying for the amount
of metres drilled by the machines in a
Collahuasi and Atlas Copco did have a specific month. We pay for the metres
relationship before the Pit Viper units drilled, not for the steel, confirms
arrived at the mine last year. In fact, Correa, explaining that if the total drill
this relationship started in 2004 and bit run in a certain month reaches an
came about through a Cost-Per-Metre- average ROP over a given base, the
Drilled Contract. The agreement entails cost per metre increases in a percent-
the supply by Atlas Copco of the whole age according to an agreed formula. On
drilling column: rotary bits (includ- the other hand, if the ROP reached is
ing Secoroc Tricone bits), rotary drill below the base, the cost per metre is
pipes, bit adaptors, top sub adaptors decreased accordingly. If we manage
and CENTEROLL rotary deck bush- to get a better drilling rate, well share
ings amongst others. the savings with Atlas Copco, says
The contract covers a total of 12 Correa.
drill rigs and different drill diameters, The cost saving is produced by the
independently of the rock hardness. machines achieving a high penetration

Blasthole Drilling in Open Pit Mining 113

 Raising to the Altitude Challenge
The PV-351 is drilling 12 and the PV-271 is drilling 10 5/8 diameter blastholes.
rate, which generates an important
reduction in the total drilling cost for
the mine, says Espindola, adding that
tests though the PARD system (per-
cussion assisted rotary drilling), show
a 35% higher penetration rate when
compared with the conventional rotary
system.
Maintenance & service
Collahuasi prefers to have control over
its maintenance operations and there-
fore these are carried out by its own
specialist team. However, when the
Pit Vipers arrived, a technical mainte-
nance agreement was struck for Atlas
Pre-split holes
4 "
15 m
Drilling pattern at Collahuasi mine.
114 Blasthole Drilling in Open Pit Mining
for retirement. Ill be looking for the best
Copco to oversee the machines for the
first three months. This included two
Atlas Copco drilling experts assigned
to Collahuasi to support in this area.
Despite the fact that there is no Full
Service Contract, we try to be proac-
tive and see to Collahuasis needs,
says Eduardo Fajardo, Atlas Copcos
Service Manager MEL CMDIC.
He adds: We have to be strong in the
service area, in technical and customer
support, to differentiate ourselves from
other equipment providers.
At the moment, Collahuasi would
like to have more support with the
availability of critical spare parts. We
cant have a warehouse full of parts, so
Buffer holes Production holes
7 7/8" 10 5/8" or 12 "
we need the supplier to hold some key
parts in stock for when we need them,
says Correa, adding that this possibility
is currently being discussed. If an ag-
reement is reached, it would be for fast
moving critical spare parts; those that
the mine would need to use more often.
Future plans & why
Atlas Copco
Next year, in 2013, it is planned that
work will start in another new area,
Rosario Sur 2, which means that a
second machine of the same capacity as
the PV-271 would be needed. In fact,
next year we have to replace two of the
older drilling rigs as theyre coming up
machine for our needs, says Correa.
More Pit Vipers for Collahuasi?
Judging by the reasons why the mine
decided to go with these rigs last time
around, there is a fair chance: One of
the reasons was the machines reli-
ability and prestige. There are a great
number of Pit Viper rigs operating in
the Chilean mining industry, which
proves that the machines work in our
conditions and that theres enough
appropriate support from Atlas Copco,
says Correa.
Another reason was capacity; We
couldnt find another manufacturer that
could offer us a diesel rig with such a
great capacity as that of the PV-351.
Finally, theres the subject of tech-
nology. These rigs are now able to
drill in automatic mode and in the not-
too-distant future we can upgrade to a
full autonomous mode. This was not
offered by other manufacturers, says
Correa.
When it comes to surface drilling
rigs, Atlas Copcos advanced technol-
ogy and know-how is setting it apart
from the rest. As Depix says: Its one
of our main advantages, and well use
it to help our customers achieve their
targets.
Acknowledgments
Article & photographs by Adriana
Potts. Technical drawing by Greenwood
Communications. With thanks to Colla-
huasi mine and Atlas Copco Chilena
.
 USA, Elko, Nevada

Innovation through interaction

First PV-271
ever built
When the Pit Viper 271 drill was
developed, Atlas Copcos engine-
ering and marketing staff worked
closely with customers to design
a rig for greater efficiency when
the truck and shovel mining me-
thod is used. Jim Owen works at
Barrick Goldstrike Mine near Elko,
NV. He is not a driller or mechan-
ic, but his day-to-day responsi-
bilities give him the experience
to know the PV-271 better than
just about anyone.

Product development
Atlas Copco has a creed that is stated
in most internal and external commu-
nications. We are committed to your
superior productivity through interac-
tion and innovation. These are not just
marketing words tossed about lightly,
but rather a promise of conviction to
each customer. However, unlike most
marketing statements recited to custo-
mers, this statement is also a reminder
for employees as to why they are here
and what makes Atlas Copco better.
If you have looked at purchasing a
PV-271, you may have met or talked
with Jim Owen. Atlas Copcos Western
US district manager, Jon Torpy, said
that just about every company that has
purchased a PV-271 in the United States,
and several outside of the US, has first
visited with Jim Owen about the drill.
Jim has been a great resource for other
mines dealing with similar drilling
conditions. For Barrick Goldstrike,
Owen is an important part of the rigs
daily operation. Owen said, Im re-
sponsible for everything below the
tophead: shocks, subs, steel, bits, bush-
ings, and preventative maintenance on
the drills whatever is needed. I just
keep the drills moving.
Barricks Goldstrike mine has four
PV-271 rigs and holds claim to the first
PV-271 ever built. After 27,113 hours,
two compressors and two rotary heads,
After consulting with customers, Atlas Copco developed the PV-271 to meet their requirements to increase
productivity in open-pit, hard rock mining.
Owen said, it is still our best perform-
ing rig with no cracks in the tower or
frame. Where it counts, all is good.
Since it arrived at the mine in 2004,
the original rig has been problem free.
Other than the replacement of wear
items and preventative maintenance,
the first rig went to work the day it
was taken off the lowboy and has been
drilling ever since, said Owen.
To put that in perspective, thats a
whopping 58,856 holes for a total of
2,671,217 drill ft. Over that period of
time the PV-271 has had an average
penetration rate of 199 ft per hour. The
rate has stayed constant over the life of
the rig, faster when starting a layback
and reducing when we go deeper, said
Owen.
Owen is impressed with component
life, too. On the first rig he got 10,000
hours totaling 1.2 million drilled feet
on the first rotary head and so far
17,000 hours on the second rotary head.
Design has had much to do with this.
I really like these drills, said Owen,
emphasizing his personal reason that,
they save me so much work! He com-
plimented the rigs smooth operation
stating, It is even easier on bits because
not having to add a rod, there is no air
loss which sometimes results in back
reaming.
One of the features that Owen really
likes is the Automatic Tensioning Ad-
justment for the cables. As you drill the
cable stretches and slackens up. With
a smaller drill youre manually adjusting

Blasthole Drilling in Open Pit Mining 115

 Innovation through Interaction
Jim Owen, Drill Supervisor, plays an important role in the rigs' daily operation and is responsible for
everything needed to keep the drills moving.
about once a month or so, said Owen,
who is glad this is not necessary with
the longer cables on the PV-271. The
task of manually adjusting the tension
requires lowering the tower which takes
time. With the automatic tensioning
feature on the PV-271 the work is done
automatically.
Interaction from the
beginning
The PV-271 was developed to increase
productivity in open-pit, hard rock mi-
ning. Not only was the entire drilling
process examined, but also how it fit
with mining operations as a whole. To
ensure they hit the mark, Atlas Copco
turned to Goldstrike and worked clo-
sely with the Goldstrike operations team,
which included Jim Owen. Interacting
with Goldstrike and other customers
during the development of the PV-271
ensured that Atlas Copco developed a
drill that met the mining industrys
exact requirements, not just what they
THOUGHT was required. For Goldstrike
116 Blasthole Drilling in Open Pit Mining
that meant the drills needed op-timum
footage, but they also needed to
drill to the shovels optimum perfor-
mance. A 50-ft bench would work great
for the shovel, but this size drill is per-
fect with a 40-ft bench, said Owen.
Increasing the footage rate was a re-
sult of completing a full hole without
adding or removing drill steel. Effi-
ciencies came with more time over
the hole and reduced setup and tram-
ming time. Goldstrike uses two 25-ft
steel and one 10-ft sub for a total of
55-ft. Including the ground to rotary
head space when jacked up, this gives
Goldstrike the required 40 to 46 ft of
clean, straight hole.
Production drilling at Goldstrike is
done with 9- and 8- inch bits for
trim and presplit work. Owen said, We
changed the breakout wrench because
the drill was designed for 7- inch
pipe, but we use 7-inch pipe because
its a better fit for the 9- and 8- inch
bits and its also cheaper. Pipe could
be an expensive item but because they
are not making connections, drill steel
lasts them about eight months. He said
when they are finished with the pipe,
there is nothing wrong with it other
than its diameter is reduced. The wall
thickness on the bottom of the 10-ft sub
is 2 inches for extra strength above
the bit.
Owen said he doesnt know a guy
who would complain about the PV-271
including drillers and mechanics.
Mechanics can be intimidated with
electronics over hydraulics, but its so
much easier to work on. And once a
guy works on it, they find its better,
not much more difficult than the wiring
on your boat trailer, he said with a
chuckle.
I have no problem bragging up the
PV-271, said Owen. Its faster, more
reliable and the factor of safetyevery-
thing just came together on this rig.
When talking about the rate of drilling,
Owen said, Ive seen one driller get
5,500 ft in one shift. Today Goldstrike
is all rotary drilling with a tricone bit.
Owen said, 13,000 ft on a bit is not
uncommon and hammer drilling isnt
necessary. Because the rigs at Gold-
strike use tricone bits, a 1900 cfm
110 psi low pressure compressor is all
that is needed. Many compressor options
are available on the rig, depending on
the type of drilling.
Innovation through interaction are
big words describing how the PV-271
came to be. It was mostly guys who use
drills sitting down with guys who make
drills and saying, We need a drill that
is perfect for what we do. For those at
Barrick Goldstrike, that started with a
hole size, required depth and a need to
mine gold more efficiently. A couple of
years ago, Goldstrike reached a mile-
stone of 30 million ounces of gold
mined. Thats the largest gold removal
from any one pit in the world and weve
mined a couple million since then,
commented Owen. So its safe to say
the PV-271 is doing its job.
Acknowledgements
This article first appeared in Atlas
Copco Mining & Construction maga-
zine No 2 2008. Story and pictures
by Scott Ellenbecker, Ellenbecker
Communications.

Unforgiving ground
Improvement and
teamwork are the
keys to success
at Phoenix Mine
The formation in Newmonts Pho-
enix Mine near Battle Mountain,
NV, contains high levels of abra-
sive quartzite but also contains
precious gold, copper, and silver.
Newmont started mining opera-
tions at Phoenix (formerly Battle
Mountain Gold) three years ago
and the planners knew they were
working with a challenging geo-
logical formation. But as it turned
out, it was more challenging than
anticipated.
Hammer drilling
with PV-271
Mine manager Mark Evatz said, Any-
thing that touches Phoenix rock wears
fast. The rock fights back here. The Pit
Viper is big and bad and can take it.
Evatz is talking about Atlas Copcos Pit
Viper 271 (PV-271) blasthole drill.
Because of the hardness of the rock,
drilling at Phoenix requires hammer
drilling and the mine uses tough Atlas
Copco TD65 hammers with 6-inch
bits. The mines PV-271s are outfitted
with a single 1450 cfm, 350 psi oil-
flooded air compressor.
Phoenix has six Atlas Copco PV-271
drill rigs plus an Atlas Copco DML
and a DM45 midrange blasthole rig. The
mines goal is to keep four million tons
of muck in inventory to stay ahead of
the shovels and support needed opera-
tional flexi-bility (ore control related).
Drilling efficiency has been a contin-
uous point of improvement since ope-
rations began at the mine. The single-
pass depth capability of 55 ft (16.5 m)
on the PV-271 helped with that. Origi-
nally, the plans called for 20-ft bench
heights, supported by 23-ft drill depths,
but time spent moving from hole to hole
was eating up productivity. Drilling on
Blasthole Drilling in Open Pit Mining 117
USA, Battle Mountain, Nevada
Biting through the hard and abrasive quartzite in the Nevada desert, the single pass Pit Viper 271 gives the
Phoenix Mine a clean, 45-ft hole.
that plan resulted in drilling an aver-
age of 47 ft an hour. When depths were
changed to 44-ft drill depths, support-
ing blasting of 40-ft benches, they were
able to utilize the single pass capacity
of the PV-271, and performance increa-
sed to over 60 feet an hour. Although
the drill depth change largely suppor-
ted the improvement, other aspects of
continuous improvement associated
with increased knowledge of the Pit
Viper drills helped as well.
We are below our budgeted drill
costs, said Evatz. This is partially
because the best cost- per- foot comes
from hammer drilling when in hard
rock. Pat McAmis, maintenance plan-
ning general foreman, concurred with
this. You can try to put more drills on
the bench, but space and costs dont
make that practical. The mine focuses
on maximizing blast-induced fragmen-
tation while maintaining the integrity
of the ore zones (minimal dilution).
Although the cr usher can handle
30-inch boulders, McAmis said, The
goal is to maximize what youre dig-
ging keeping a methodical approach.
At the Phoenix mine, drills are top
priority machines and we mine to feed
the mill, said McAmis. He is pleased
with the performance of the PV-271 and
has no major concerns, complimenting
the support from Atlas Copco and his
distributor, Cate Equipment. Were all
in it to make money and you have to
be fair, but I would say we work well
together.
Time per hole
Drill operator Clinton Riddle started in
mining in 1976 and has seen a lot of tech-
nology advancements over the years.
For me, things really started to change
the last couple of years. He cited that
these advancements include the speed
of drilling with air, computerized con-
trols, and automation on the rigs.
Depending on the formation and area
of the mine, Riddle said a 45-ft hole can
take 5 to 45 minutes. As he drills, he
watches his computer monitor, which
tells him the hardness of the rock, the
drilling rate, and performance statistics
such as time per hole, torque and rota-
tion. The color-coded block on the right
of the screen shows red for harder rock
formation and yellow or green for softer
formation. This helps him anticipate
 NEWMONTS PHOENIX MINE
Single pass drill of 40-ft benches with PV-271 rigs.
what changes may be required in the
hole. He said the color bar is nice to
have, but its still just a guide.
Riddle said the average shift com-
pletes about 18 45-ft holes, but there
are some eight- to 12-hole days and hes
seen as many as 50 a day. Atlas Copcos
Western Region manager, Jon Torpy,
has been in mines all around the world.
About the rock at Newmont, Torpy said,
We, as Atlas Copco, have only seen a
handful of locations that have the diffi-
cult drilling conditions found at Phoenix,
and the PV-271, coupled with the TD65
hammers, are the best tools for the job.
Maintenance superintendent Walt
Holland is responsible for the entire
mines equipment maintenance at New-
monts Phoenix Mine. He said that he
looks at mining equipment like a three
leg stool drills, shovels, trucks and
all have to be working to keep things
moving. Because of the hardness of
the rock, drill maintenance is very
important at Phoenix, said Holland.
Other Newmont properties may drill
120 to 130 ft an hour, but at Phoenix,
they are now up to 60 ft per hour. The
rock hardness at Phoenix is unique to
the world, he pointed out. What I like
about the Pit Viper rig is its quality. I
am getting 92.5 percent availability and
that is really good. The operators were
given additional training required for
the single pass rig and they feel very
comfortable operating them now. We
have a great history with Atlas Copco
118 Blasthole Drilling in Open Pit Mining
and have worked right through any
issues that have come up, Holland
said.
Maximum productivity
In recent months, productivity at
Phoenix has increased and Holland
credits this in part to good communica-
tion between operations, maintenance,
and engineering. Phoenix is success-
ful because we dont get conflicting
missions. We work well together and
challenge each other. The ground is
unforgiving at Phoenix and it takes a
team approach to be successful. When
mechanics and operators are talking,
you know youre winning, he said with
conviction.
Mark Evatz echoed this sentiment.
There had to be a steep learning curve
at Phoenix, he said. Since operations
began, the most recent quarter was
the best at Phoenix from an operation
standpoint. More revenue at a reduced
cost has had a lot to do with technol-
ogy and the application of the Pit Viper
rigs, said Evatz.
For Evatz, continuous improvement
is a large part of the success at Phoenix.
We had 96 of 100 points right when
we started up Phoenix, he said. A lot
of the original planning decisions came
from the best practices used at other
Newmont Nevada mines, such as the
Lone Tree Mine. We looked at the har-
dest rock at Lone Tree as a comparison
when beginning operations. Basing eq-
uipment estimates and mining prac-
tices on Lone Trees numbers, our drill
production was half of Lone Trees,
Evatz said. For another equipment
example, Evatz said dozer grousers
require replacement three to four times
faster at Phoenix than Lone Tree.
Although the overall mining rates were
comparable at ~150k tons per day, the
rock hardness/abrasion at Phoenix is
substantially greater.
Major consumption items such as
down-the-hole hammers and bits are a
large ticket item when hammer drilling,
but necessary in very hard rock. The
mine uses about a dozen TD65 ham-
mers a month and hundreds of 6-inch
bits. To maximize performance, Atlas
Copco has placed a full-time Product
Support Sales Representative (PSSR)
in the mine to support and develop
the use of consumables. Jim Wheeler,
Atlas Copco senior area manager for
consumables in the Intermountain
Region, said, Having someone on-site
is all about continuous improvement.
An example of this was a recent insert
change on the 6-inch hammer bits
gauge row, which has increased bit
performance. Having someone there
watching the performance of all con-
sumables ensures that all pieces are
working together, reducing drilling
costs and improving productivity.
About 150 bits are used per month,
and in these extraordinarily abrasive
conditions, regrinding is not considered
an option. However, in order to reduce
bit consumption as much as possible,
Secoroc has changed the carbide in the
buttons to a tougher grade.
Evatz said that incorporating some-
one from Atlas Copco onto his team
has allowed them to share the successes
and failures, and has helped fix issues
as they come up the first time. There
is no finger pointing, just solutions for
Evatz.
Acknowledgements
This article first appeared in Atlas
Copco Mining & Construction maga-
zine No 2 2008. For this edition the
article has been edited and condensed.
 canada, VAL D'OR

Community-friendly mining
Smaller rigs
and holes mean
patterns that
limit vibration,
noise and dust
The mining industry has become
increasingly conscientious of the
environment and comunities where
they operate. Change is driven by
mine ownership and management
striving to create a better work-
place for their employees and de-
velop good working relations with
their operations neighbors. As
manufacturers increase the focus
on operator comfort, fuel econo-
my and ease of maintenance, they
also contribute to better commu-
nity relations by engineering pro-
ducts that control noise, dust and
vibration.

The Malartic mine

In 2011 Osisko Mining Corporation
started production in the Canadian
Malartic mine in Northern Quebec, just
40 kilometers west of Val d Or in the
Abitibi Gold Belt. The open pit proven
and probable reserve estimate is 10.71
million ounces of gold.
In January 2005 Osisko initiated a
detailed compilation of the extensive
historical database, including data from
over 5,000 surface and underground
drill holes. Osisko commenced its own
drilling program on the property and in
2007 started open-pit excavations. Full
production started in 2011. The mine is
expected to produce 250,000 ounces of
gold in 2011 and over 700,000 ounces
in 2012.
The placement of the new working
mine is unique because it sits within
the community of Malartic. During
exploration, core rigs were set up on
lawns of residential property. Almost
200 homes needed to be purchased or
Integrity of the hole is maintained with a cardboard tube: Hole depth is 11.7 m (38 ft 4 inch). moved before push-back could begin.

Blasthole Drilling in Open Pit Mining 119

 Community-Friendly Mining
The PV-235 drill rigs are used for drilling of 8.5 inch (216 mm) blastholes with a spacing of 6.3 x 6.3 m.
Osisko Director of Communications
Hlne Thibault can recall knocking
on peoples doors to let them know
when they could expect drilling in their
lawns.
Starting out, sound and dust pre-
sented a problem, mining in such close
proximity to the community. An earth
berm built to separate the town from
the mine did much to solve that prob-
lem. Equipment choice also played a
crucial role in creating the total com-
munity relations solution.
The PV-235 cab is offering phenomenal visibility and comfort.
120 Blasthole Drilling in Open Pit Mining
The R in PR
so the community knows what we are
If the community did not already em-
brace the vision of restarting the mine,
choice of equipment would be a moot
issue.
Thibault attributed some of the ease
in creating a shared vision to mine
personnel themselves. Of the mines
500 employees, 45 percent of them
come from the community.
She said, The employees are our
ambassadors to the community. They
take the message home with them daily
doing.
For the first time in the history of
Quebec mining, and even though it is
not required by law, Osisko deposited
$22 million with the Quebec govern-
ment, which is half of the future cost
of rehabilitating the Marlartic site. The
balance will be paid by 2013. Osisko
took the initiative as a part of its social-
ly responsible attitude and in order to
assure local residents the mine would
not be abandoned for the government
to clean up.
Reducing vibration and dust
The company chose the newest Atlas
Copco Pit Viper model available, the
PV-235, to drill 8.5 inch blastholes.
These smaller holes are placed closer
together in a blast pattern that has less
impact on the environment. The idea
is to have no dust or vibration outside
the mine, said Mine Manager Franois
Vzina.
The mine has purchased 300 blast
mats to reduce noise, shock and debris
and expects to purchase 100 more.
Vzina appriciates the automation
and precision advantages that come
with the RCS system on the rig. The
 Community-Friendly Mining

auto-drilling system starts off slower

when collaring the hole, which also
reduces ambient noise. Planning each
day starts with the weather forecast,
especially wind direction. The mine
cannot have dust carried into town, yet
the crusher needs to be fed. The wind is
also a factor in carrying noise.
The PV-235 size reduces both of
these problems. The mine was blast-
ing 150,000 tons per day and expected
with increases in equipment to be up to
250,000 tons a day by the beginning of
2012. Osisko operates with a 2:1 waste
to ore ratio. The pit is projected to be
3.2 kilometers by 1 kilometer with a
400 meter depth. To assist in control-
ling the blast, the pattern is 6.3 meters
by 6.3 meters by 10 meters. The goal Driller Mathew Leeker said it took him just one to two weeks to catch on with the operator friendly drilling system.
is to create the smallest rock possible Previously he was diamond driller. Like all drillers on the PV- 235, Leeker very much enjoys the cab's comfort.
using a smaller pattern.

Rebirth of a town
The opening of the Malartic mine has
been a boon to the small community.
Although the town is on the main road
leading to Montreal, it was just a town
to drive by. With the investment from
the mine of new neighborhoods and
a $16 million elementary school con-
struction, the town of 3,000 is now
growing again. Thibault said, We
consider ourselves guests, and we want
to leave the town better off.
Originally the budget was $15 mil-
lion for the school, but because the
architect said $16 million would give
us so much more, we spent $16 million.
These are our future miners. We want
to give the kids the best quality of life
and education.
The mine also committed to an
annual improvement fund of $50,000.
Thibault said, We dont think of this
as buying the communitys apprecia-
tion; we want the community to win
from the gold found here, too.
Safety was also a long-term con-
sideration. Once a neighborhood of
depreciated housing because of the
abandoned underground workings,
homes have been moved to accom-
modate the new mine workings. The
homes were purchased at fair market
value and are now in a healthy area
where kids ride bikes and play in the
streets safely. Adding to the four PV-235 rigs already working, the mine has purchased three additional rigs.

Blasthole Drilling in Open Pit Mining 121

 Community-Friendly Mining

Equipment decision
While making their equipment deci-
sions, they kept one focus in mind:
Choose technology for the future. We
knew we were taking a chance with
new-model equipment, but we are in
this for the long term and going with
Atlas Copcos experience was impor-
tant to us, said Vzina.
In total there are nine drills work-
ing onsite, with many exploration
drills doing reverse-circulation and
core drilling. It is expected the mine
has a 16-year life, but the exploration
is continuing and there is hope that it
will go further.
Adding to the four PV-235 rigs al-
ready working, the mine has just pur-
chased three additional rigs.
Recently Vzina signed a three-year
service contract with Atlas Copco
to maintain the drills. Those Atlas
Copco service techs really do a good
job and know what they are doing.
The commitment from Osisko is
not just for 16 years, though. This is a
partnership, said Vzina. I think we
need to have a partnership philosophy
with suppliers and the community. We
learn from our partners. Im proud of
what we are doing here. And we are
going to have a lot of fun.

Acknowledgements
Photos and story by Scott Ellenbecker,
first published in Atlas Copco Mining &
Construction magazine, No. 3, 2011

The Rig Control System (RCS) makes life easier for The Pit Viper 235 has a weight on bit of 65,000 pounds and is designed for rotary or DTH drilling of 6 9 7/8 inch
Mathew Leeker. (152 -251 mm) diameter holes. Two tower options are available to drill 35 ft (10.7m) or 40 ft (12.2m) clean holes.

122 Blasthole Drilling in Open Pit Mining


Drilling reliability at Veladero
Operations at Veladero take place at altitudes of between 4,000 and 4,850 metres above sea level.
Heroes of Veladero
Working amidst some of the
harshest weather conditions and
where maximum reliability is par-
amount, the PV-271 drilling rig is
proving its worth at the Veladero
gold mine in Argentina.
As mining operations go, you would
be forgiven for thinking that Veladero
is just another conventional, low grade
open pit gold mine. This is true to a
point. However, look closely and you
will find a fascinating history and some
amazing logistics, making you marvel
at the everyday challenges faced by
workers and machinery to make this a
successful mining operation.
The Veladero Mine is operated by
Minera Argentina Gold S.A. (MAGSA),
a subsidiary of Barrick, one of the
worlds leading producers of gold.
Blasthole Drilling in open pit mining 123
argentina, andes mountains, San Juan Province
Located in San Juan Province, about
350 km northeast of the city of San
Juan, Veladero is in the high Andes at
an altitude between 4,000 and 4,850
metres above sea level. It is very close
to the Chilean border and immediately
south of the Pascua Lama gold project,
which straddles the border between
Chile and Argentina and is currently
also being developed by Barrick.
Veladero is accessed by a purpose-
built 156 km road which passes eleva-
tions of over 5,000 metres above sea
level. Depending on the weather con-
ditions, it takes about seven hours in
a 4x4 vehicle to drive from San Juan,
the nearest city, to the mine. Conditions
can be so severe that special shelters
have been built every 20 kilometres
along the access road to safeguard
workers and travellers in extreme
weather.
At this altitude, the temperature
is highly variable and drops 2 for
every 300 metres in elevation. During
winter, which takes place between July
and September, the average daily tem-
perature is -10, dipping as low as -16
during the night. Add to that the wind
chill factor and the night time tempera-
ture can drop to -40, a figure that has
been recorded several times.
Winds blow from west to east and
can be very strong, sometimes 80-100
km/hour. Even extreme winds of up to
220 km/hour have been recorded by the
weather station, says Jose Luis Forns,
Mining Superintendent at Veladero,
explaining that the average winds are
20-30 km/hour during the day but that
this increases substantially as the day
wears out.
Weather conditions can be very
hard, especially in winter, to the point
where the access road can be blocked
and us having to declare an alert,
says Forns, explaining that among its
facilities, the mine has an operating
 Drilling Reliability at Veladero
To the left, Veladero drilling pattern: hole spacing of 7x8 m in waste and 6.5x7 m in ore. To the right, rock sampling: Veladero has a silica-type rock whose hardness
and compression varies throughout the site.
theatre with a surgeon, should any
medical emergency happen whilst the
road is closed.
Because of the remoteness of the
mine, operators at Veladero work a
pattern of 14 days in and 14 days out.
Of the 14 days at the mine, seven are
worked during the day and seven are
worked during the night.
We have special conditions here
that complicate our logistics. Theres
nothing within a 100 km radius around
us, so we expect reliability from our
equipment and suppliers, says Forns .
History
Although mining activities around
the San Juan Province can be traced
as far back as the early 19th Century,
Veladero represents the arrival of
true, large-scale mining to this part
of Argentina and it is Barricks first
operation in the country.
After a programme of regional
exploration in the mid 1990s, it was
not until May 1997, in the middle of
snow storms and cut off roads, that gold
and silver was discovered in an area
124 Blasthole drilling in open pit mining
called Federico. The winter of 1997
was especially bad due to the El Nio
weather phenomenon, making it even
more difficult to access and continue
work in some key areas. After four
years of exploration, in 1998 two very
significant holes were drilled in an area
called Amable; Hole V76 in May and
Hole V90 in October, which revealed
excellent mineralisation and showed
the quality of the project.
Soon after this, MAGSAs then par-
ent company, ARP, sold its shares to
Homestake Mining Company, which in
turn merged with Barrick in 2001. The
environmental impact assessment for
Veladero was approved in November
2003 and that same year construction
started. After an investment of US$540
million in the construction of the mine,
commercial operations finally began in
September 2005 and the first gold bar
was produced in November that year.
Mining & processing
operations
Veladero is an open pit mine extracting
gold and silver from three orebodies:
Filo Federico, Amable and Argenta.
Federico, to the north and Amable, to
the south, are the original open pits.
Extraction at Argenta, located in the
southeast sector of the field, com-
menced in 2010. Exploration has been
carried out at a fourth area, Cuatro
Esquinas, which is located in the centre
and will eventually become a work-
ing pit. Veladero is a low grade mine
producing about 1 gram of gold per
tonne of rock with an ore to waste strip
ratio of 3:1. Metal recovery is achieved
through heap leaching and cyanide
processing methods.
Veladeros gold production in 2011
was 0.96 million ounces of gold at a
total cash cost of US$353 per ounce.
Proven and probable mineral reserves
currently stand at around 11.3 million
ounces of gold.
Rock extraction is car ried out
through drilling & blasting with the
mine currently extracting an average
of 230,000 tonnes/day of rock. Higher
grade ore is crushed to 32 mm size in
a two-stage crushing process and then
transported via overland conveyor and
trucks to the leach pad area. On the

To the left, the PV-271 is drilling 10 5/8 production blast holes at Veladero. Top to the right, Carlos Cavanillas, Drilling & Blasting General Supervisor (left) and
Ramn Arjona, Drilling & Blasting Senior Supervisor. Bottom to the right, Veladero employs standard 15 m high benches.
other hand, very low grade, run-of-
mine ore is hauled directly to the leach
pad area.
All the ore is then stacked in a lined
containment area behind a retention
dam. A cyanide leach solution is app-
lied to the top of the stacked ore and
allowed to percolate through the heap.
As the solution goes through the ore, it
dissolves gold and silver from the rock.
This gold-rich solution is collected at
the base of the leach pad and pumped
to a conventional Merrill-Crowe pro-
cess plant in order to recover the gold
and silver.
Through 2007 and 2008 Barrick off-
ered a US$10 million prize to the sci-
entific community in a bid to improve
silver recovery at Veladero. Recovery
rates for silver are low, less than 7%,
because the metal is bound within
silica, which is difficult to dissolve
using conventional cyanide processing.
As many as 130 proposals were submit-
ted and of these, nine were selected for
testing.
Ever since we started operations,
weve been looking for ways to increase
production, says Forns, explaining
Blasthole Drilling in open pit mining 125
Drilling Reliability at Veladero
that crushing capacity was expanded
from 50,000 to 85,000 tonnes/day in
2009. Heap leaching capacity as well
as transport have also been increased.
Power at the mine is provided
mainly by diesel generators with a total
capacity of 13.5 megawatts. In 2007,
the company installed a wind turbine
which currently produces 2 megawatts
or around 20% of the total electricity
needed to power Veladeros operations.
The use of wind energy provides a
clean source of power for the mine
and also helps us to cut down on fuel
transport, says Forns, explaining that
the wind turbine, which took nearly a
month to assemble, weighs 229 tons,
has a rotor diameter of 80 metres and
is installed on a specially-developed
tower nearly 60 metres high. At 4,110
metres above sea level, this has been
recognized by Guinness World Records
as the highest wind turbine in the
world.
Veladero uses a mine management
system as well as a wireless commu-
nications system for increased data
bandwidth throughout the site and field
communication.
Drilling & blasting
Carlos Cavanillas, Drilling & Blasting
General Supervisor and Ramn Arjona,
Drilling & Blasting Senior Supervisor,
explain the daily work routine for their
area.
We have a daily meeting first thing
in the morning to check what the night
shift is leaving us with; for instance, if
there were any incidents or problems
with the machines, says Cavanillas.
This is followed by a visit to the work-
ing area for a general inspection. We
check the areas that are going to be
blasted that day and determine wheth-
er there will be blasting or not, says
Arjona, explaining that normally, blast-
ing happens twice a day, at 2:00 pm
and then again later on at around 6:00
pm.Veladero uses ANFO for blasting.
The severe weather can interrupt the
operations. Indeed, as Cavanillas points
out, they get an updated weather report
every single day: If theres the possi-
bility of a thunderstorm that day, we
dont blast - it could be catastrophic!
Veladeros current drilling fleet is
composed of 11 diesel rigs, some drilling
 Drilling Reliability at Veladero

pre-split holes and some drilling pro-

duction holes. This includes an Atlas
Copco Pit Viper 271 and a ROC F9
unit. There are also four DM-M2 rigs
amongst other machines.
The ROC F9 rig, which has been
working at the mine about a year longer
than the Pit Viper machine, is currently
working in production, drilling small
4 holes. Its possible that we will use
this machine for pre-splitting in the
near future, says Arjona, explaining
that there is another ROC F9 unit, with
similar configurations working on pre-
split drilling at nearby Pascua Lama.
Weve heard that machine is doing
very well, he says.
The PV-271 rotary drill is also work-
ing in production. Before acquiring it,
Cavanillas wanted to see a similar rig
under working conditions: Ramn
and I went to Chile, where we had the
opportunity to see the PV-351 he says,
referring to the largest model in the Pit
Viper series. Several of these units are
Other Atlas Copco equipment at Veladero includes a ROC F9 crawler drill rig.
working at Codelcos Radomiro Tomic
copper mine, 3,000 metres above sea
level in the Atacama desert of north-
ern Chile. They were impressed by
the performance of the PV-351 and
after discussions, decided that the
smaller PV-271 was the best option for
Veladero.

PV-271 in action
The PV-271, which arrived at Veladero
in May 2010, is currently deployed in
Pit Amable drilling 10 production
blast holes to a depth of 15 metres. The
mine employs standard 15 metre high
bench drilling with a hole spacing of
7 x 8 metres in waste rock and 6.5 x
7 metres in ore.
A sturdy and powerful blasthole
drill rig, the PV-271 features a pull-
down force of up to 311 kN (70,000 lb)
and a 34 tonne (75,000 lb) bit load
capacity for maximum productivity in
hard rock formations. Veladero has a
silica-type rock whose quality varies
throughout the site. We have areas
where the rock is hard, others where it
is quite fragile and others where it is
not only hard but also highly compres-
sive, says Arjona.
Victor Astudillo, the operator of the
Ramn Arjona, Drilling & Blasting Senior Supervisor with the PV-271 drill rig. PV-271, knows this only too well. He

126 Blasthole drilling in open pit mining

 Drilling Reliability at Veladero

explains that depending on the area

where they are working, drilling a pro-
duction blasthole can take anywhere
from 18 minutes to one hour: Most of
the rock is hard so on average, it takes
about 45 minutes to drill a hole.
As all the machines in the Pit Viper
series, the PV-271 uses Atlas Copcos
hydraulic cable feed system, which is
lighter than the traditional chain feed
option. This leads to overall weight
reduction in the tower and feed system
and to smoother drilling, which in
turn extends both bit and feed system
life. Feeding and retracting for pull-
down and pullback is really fast so I
can spend more time drilling, says
Astudillo.
Astudillo, who has been a drilling
operator for four years and has experi-
ence working with the DM series, is
pleased with the ergonomics of the rig:
it is amazing how comfortable it is.
There could be dust and noise outside
but you barely feel it inside here, he
says, adding that he also likes the fact
PV-271 operator Victor Astudillo says that due to the variable quality of the rock, drilling a production
that the drilling and non-drilling con- blasthole can take anywhere from 18 minutes to one hour.
trols are separated: it certainly makes
the machine easier to operate.
Working at high elevations can The PV-271 has given us good levels Communication, Wireless Remote
present a number of problems for any of availability. We can rely on that Tramming, Measure While Drilling and
machine. With every additional metre machine, and for us thats whats Teleremote Operation. Autolevelling
in elevation, air density and pressure important, says Cabanillas. increases quality in set up of the drill.
decrease and traditional electronic According to Forns, when choos- Depending on the ground conditions
components no longer function reli- ing new equipment for the mine they levelling can be done in less than 35
ably. Also, our severe winter can take into account some basic param- seconds with an accuracy in pitch and
affect a machine drastically, says eters, such as the machine being able roll to 0.2 degrees. Autodrilling allows
Arjona, explaining that some areas of to be fitted with specific features for the system to react to the different rock
the machine such as the air and water cold weather or the machines penetra- conditions within one blasthole and
circuits can easily get frozen. So, in tion rate. But in the end, it is the total adjust the drilling as necessary. This
order to work under the weather condi- cost of owning that machine which is feature provides the consistency of
tions at Veladero, the PV-271 had to be going to tip the balance for Veladero: drilling to the correct hole depth, and
equipped with several special features Cost of buying the equipment itself, a consistent water f low to maintain
such as a more powerful engine and cost of operating it and cost per hour. the hole so it does not collapse. GPS
compressor but also with a cold weath- Whichever equipment gives us the Hole Navigation ensures the blast-
er package, which includes additional best results, thats the one well go for hole is positioned where it has been
covering of the machinery housing and in this case it was the Pit Viper designed in the blast pattern and it is
and allows for warm start-up and drill 271. drilled to the correct depth. RRA and
operation in extremely cold ambient Communication connects the drill rig
conditions. Motivated by technology to a standard computer network on a
And how has the PV-271 faired in work site and allows access informa-
this harsh environment? Oh, very The PV-271 is poised to please Vela- tion on the drill rig from any authorised
well indeed and with good reported dero even more once it is fitted with point in a network. Wireless Remote
availability times, too, says Arjona, the Rig Control System (RCS) tech- Tramming gives the operator f lex-
explaining that when comparing nology; this will give the mine a series ibility to tram the machine from the
forecast versus real availability and of highly automated options, includ- bench within a 60-metre distance. Mea-
utilisation in the monthly report, the ing: Autolevelling, Autodrilling, GPS sure While Drilling logs several drill
real figures normally come on top. Hole Navigation, Desktop Viewer and parameters during operation; this data

Blasthole Drilling in open pit mining 127

 Drilling Reliability at Veladero
Atlas Copco and Veladero staff together (from left to right): Miguel Sernaqu, Atlas Copco Drilling Specialist;
Carlos Cavanillas, Drilling & Blasting General Supervisor; Victor Astudillo, Drilling Operator; Ramn Arjona,
Drilling & Blasting Senior Supervisor and ADS Technician Osvaldo Gil from Atlas Copco Argentina.
can be used for prediction of geological
and geochemical variations within drill
patterns on a bench. Teleremote opera-
tion uses the mines wireless network
and allows an operator to utilize the
machine functions mentioned before
from a remote location. Were going
for the full set of RCS functions and are
looking forward to using this technol-
ogy at Veladero, says Cavanillas.
Upgrading the rig entails replacing
the cabin with a new one. During this
time the machine wont be able to oper-
ate, but the changes will be well worth
it, says Atlas Copco Drilling Solutions
Technician Osvaldo Gil, adding that
when the modification is finished, an
Atlas Copco factory specialist will be
there for 10 days to train the operators
and mechanics and to make sure every-
thing works well. Theyre not used to
operating with joy sticks; this will be
128 Blasthole drilling in open pit mining
something new for them, says Arjona,
explaining that they want to use this
opportunity as an incentive for the drill
rig operators: We want them to learn
and then to earn the right to operate
the machine.
This training will be put to another
good use for a second PV-271 now
on order for delivery to the mine.
Effectively, the managers at Veladero
are so pleased with the performance of
the drilling rig that they have decided
to acquire a second unit and this time
it will feature RCS technology from the
start. The idea is that both machines
will have the same configurations,
avoiding the need for different spare
parts and operations, says Gil.
With both machines, the one being
upgraded and the new one, featur-
ing full versions of the RCS system,
Veladero will be able to take its drilling
to the next level. The technology from
Atlas Copco is another factor that keeps
us motivated, says Cavanillas, adding:
Eventually, our idea is to work with
the Pit Viper remotely from a fixed
distant point. We want to be at the fore-
front when it comes to mining technol-
ogy. Using the latest high technology
in drilling automation will certainly
help Veladero achieve this goal. And
if everything continues to go well, our
vision is to eventually replace all our
DM machines with Pit Vipers.
And to ensure that everything will
go well, Atlas Copco has a Technical
Assistance Contract with Veladero,
which was put in place in April 2011.
The contract, which has just been
renewed for another six months, speci-
fies one specialist drilling technician
from Atlas Copco available to Veladero
per shift. Currently that means two
people, each working seven hours
shifts. Were here to help with any
drilling issues that might come up. We
spend time with the rig operators and
the drilling supervisors, giving tech-
nical support to all the Atlas Copco
fleet, not just the PV-271 but also the
ROC F9 and the four DM-M2 units,
says Miguel Sernaqu, one of the Atlas
Copco drilling specialists. Once the
new PV-271 arrives, the plan is to have
two technicians per shift, effectively
four people, available to Veladero.
Servicing Veladero will go even fur-
ther now that Atlas Copco Argentina
has just expanded its operations and
presence in the region with a new
branch and workshop located about 2
km south of Barricks offices in San
Juan. Gil explains that the new branch
offers all types of after-sale services
as well as evaluation, failure analysis,
repair of equipment and major compo-
nents, field equipment set-up and the
stocking of key spare parts. He says:
Were here to see to Veladero and
Barricks needs; thats our priority and
commitment.
Acknowledgements
Articles and photographs by Adriana
Potts. With thanks to Veladero mine
and Atlas Copco Argentina.

Penasquito powers up
Powerful fleet: Five of the seven Atlas Copco Pit Viper 351 blast hole rigs lined up at the Penasquito open pit gold mine.
A perfect match for
large hole drilling.
In just 14 months the site of the
Goldcorp Penasquito mine in the
state of Zacatecas, Mexico, was
transformed from a flat open valley
into a mine producing more than
500,000 tons of rock each day. Its
choice of Pit Viper drills and Seco-
roc drill pipes and tricone bits has
proven to be the perfect fit.
A total community program
Peasquito is Mexicos largest open pit
mine and comprises the Penasco and
Chile Colorado/Azul deposits that con-
tain gold, silver, lead and zinc. At an
elevation of 1 900 m above sea level,
the surface of the site is made up of ap-
proximately 30 meters of alluvium.The
virtually flat topography has helped the
mine carry out its development plan
that includes moving large amounts of
rock. Im used to mining in mountains
so this is easy mining by comparison,
says Mine Manager, Tim Collins.
The company reports that annual
production over the life of the mine
Blasthole Drilling in open pit mining 129
MEXICo, saltillo, ZACATECAS
(estimated to be 22 years) is expected
to ramp up to approximately 500 000
ounces of gold, 30 million ounces of sil-
ver and more than 400 million pounds
of zinc.
The Peasquito project is considered
a total community improvement pro-
gram that includes educating future
generations by building schools. When
looking for potential employees in the
surrounding area, Peasquito found
that most of the local inhabitants had
no mining experience or even a drivers
license. Today, however, 70 percent of
Peasquitos truck drivers are local wo-
men, many of whom had never driven
before, and now work at the mine as
a result of Goldcorps investment. In
addition, operating millions of dollars
of earth moving equipment required an
intensive training program before the
workers entered daily production.
Powerful fleet
From the outset, it was the mine ma-
nagements vision to achieve a high le-
vel of production, but first it was neces-
sary to find the right combination of
equipment and support for the project.
To drill and blast half a million tons of
rock every day, the mine needed a spe-
cial drilling fleet and rig management
program. The mine uses only Atlas
Copco drill rigs which include seven
Pit Viper 351 blast hole drill rigs plus a
DML and an ECM 590 for specialized
tasks.
Production hole size is 311 mm
(12 inches) for the 15 m (49 ft) bench
height. Different types of Atlas Copco
Secoroc epsilon tricone bits are also
used, depending on ground conditions.
The entire drill string, including the
pipe, stabilizers, bushings and subs are
supplied by Atlas Copco Thiessen.
Learning to operate the rig also
required extensive training, but it takes
time to learn the feel of the ground.
To speed up this process, Peasquito
chose rigs with Atlas Copcos Rig
Control System (RCS), which simpli-
fies the drilling functionality for the
operator.
They have it all
These drills have it all, says Mine
Manager Collins. The operator only
needs to move it and level it and the rig
drills its own hole. Collins adds that
he does have four experienced drillers
 Penasquito powers up

who like to drill manually and they can

match the auto-drilling performance.
There are times when the bit can take
more down pressure and less rotation;
a skilled operator can feel that, said
Collins. The Rig Control System (RCS),
integrates common drilling functions
such as collaring a hole with low pres-
sure air and down pressure, applying
just the right amount of water and anti-
jamming, with several high-tech options
such as GPS hole navigation.

Ensures efficiency
RCS ensures efficient drilling, but many
features are also for the safety of the
Drilling and blasting half a million tons of rock every day: The Atlas Copco Pit Viper 351 drill rigs in operation miners and equipment. These include
at Penasquito. The RCS system ensures efficient drilling and the software provides several standard safety jack and tram interlocks which ensure
interlocks. that the rig and tooling are secure before
a rig can move.
The mine has installed a complex
dispatch system that integrates with the
GPS on each haul truck, shovel, drill rig
and every other piece of mining equip-
ment. The entire operation is monitored
from a control room where two dispat-
chers and a maintenance person watch
and direct the activity in the mine.
All data is recorded and is retrievable
by those in the mine who need constant
equipment information. However, the
operation can also be monitored in real
time through a web-browser interface
anywhere in the world.

Technology is the future

Technology is the future of mining,
continues Collins. If youre monito-
ring maintenance and operational data
to this level, decisions are made when
they need to be made. Mining is more
efficient today than it once was tech-
nology has a lot to do with that and
safety can only move forward at the
same time.
When searching for the right equip-
ment, Alan Hernandez, Project Engineer,
Technical Services, and Tim Collins,
spent seven months travelling around
the world trying to decide which pro-
ducts would fit the program. There
were some hard decisions, but for drill
rigs it was always Atlas Copco, said
Hernandez. More time was spent deba-
ting which Atlas Copco drill models
The single pass Pit Viper 351 will drill 50 holes per 12 hour shift, at the 15 m (49 ft) high benches. would best fit the plan.

130 Blasthole drilling in open pit mining


Making the most of bits: Xavier Garcia, Key Account Manager, Atlas Copco, trains operators on the correct use of the eH64OA Secoroc epsilon Tricone bits.
We looked at feasibility studies, cal-
culations, pit design, tonnage every
scenario that would determine what
would work best, says Collins. For
most equipment it was a matter of eli-
mination. The choice consistently came
down to service and support, but with
Atlas Copco there was no debate.
As far as drilling goes, everything
here comes from Atlas Copco, he adds,
complimenting the speed and penetra-
tion rate of the Pit Viper 351. The 351
will drill fifty holes per twelve-hour
shift. The fleet at Peasquito drills an
average of 2,300 to 2,500 holes per-
week. To keep ahead of the crushers,
about 15 million tons of inventory are
kept in the pit. I like to keep at least
a month ahead, says Collins. This
inventory allows time to support the
drills. The maintenance plan includes
having two or three rigs serviced for
preventative maintenance. That takes
care of normal wear and tear. I can say
the Cummins engines in all our drill
rigs are solid, they dont even burn oil.
Blasthole Drilling in open pit mining 131
Close support
In addition to parts and training, Xavier
Garcia, Atlas Copcos Key Account
Manager for Goldcorp, personally han-
dles drilling consumables at the mine.
Twice a month, Xavier spends nearly
a week here analyzing bits. Sometimes
it feels like he practically lives here,
says Collins.
Atlas Copcos Marcus Pantoja and
Octavio Garcia (Service Manager and
Product Specialist) also play a key role,
providing training, equipment start-up,
commissioning and technical support.
To date, the epsilon tricone bit line
has changed from eH53CA to eH61 CA,
eH62OA and eH64OA, to adjust to the
rock formation. We are constantly re-
viewing bit wear and performance.
Well keep testing bits until we settle
on the one that works the best, he says.
A great advantage has been the use of
the TeamAlloy Drill Pipe from Atlas
Copco Thiessen, which seems to last
forever.
Penasquito powers up
Acknowledgements
This article first appeared in Atlas Copco
Mining & Construction magazine No 3
2009. It was written by Scott Ellenbecker
after a visit to the mine in September
2009.
The Peasquito mine will have a long
life. As of December 31, 2008, proven
and probable gold reserves totalled 17.4
million ounces.
Silver reserves totalled 1045.7 million
ounces, while lead and zinc stood at
7.07 million tons and 15.36 million tons
respectively.
Measured and indicated gold resources,
inclusive of proven and probable re-
serves, increased 39 % to 17.8 million
ounces.
Measured and indicated silver resour-
ces increased 55 % to 1.3 billion ounces.
For further information and the latest
updates visit: www.goldcorp.com
 Penasquito powers up

Example of Pit Viper 351 Drill String used at Penasquito

Shock Sub

Drill Pipe Lifting Bail

Top Spindle Sub

TM
TEAMALLOY Drill Pipe

TM
TEAMALLOY Starter Drill Pipe

TM
CENTEROLL Deck Bushing

TM
DURALLOY Bit Sub

TM
EZ-DRILL Roller Stabilizer

Secoroc Tricone Drill Bit

Bit Breaker Basket

Drill string
Production hole size 311 mm 12 1/4 in
Bench heigh 15 m 49 ft
Secoroc epsilon Tricone Rotary drill bits H61CA, eH62OA, eH64OA
The entire drill string from the rotary head to the tricone rotary drill bit is supplied by Atlas Copco
Thiessen and Atlas Copco Secoroc.

132 Blasthole drilling in open pit mining

 Turkey, Usak

Secoroc hammers go for gold

Secoroc COP
Gold hammers
The number of meters drilled is
directly tied to the productivity
level of a mine. The type of rig,
hammers and bits must be able
to handle the geology of the site
while achieving the desired per-
formance levels and do so cost-
effectively.

Powerful drilling,
reliable production
To accomplish this, Tuprag Metal
Mandencilik San. Tic. A. (Tuprag) uses
Secoroc COP Gold DTH hammers on
two Atlas Copco DM45 rigs and a ROC
L6 at the Kisladag gold mine. Designed
for the production drilling market,
Secoroc COP Gold hammers feature a
specially designed piston for efficient
energy transfer; control tube suspension
with steel disc compression rings and
lower buffer rings; steel grade hammer
casing that provides greater impact
strength and excellent wear resistance;
and superb flushing capabilities.
Secoroc COP Gold hammers have
proven to be efficient, reliable and du-
rable with a 10-15 percent longer service
life than equivalent hammers. Further-
more, with the COP Gold E-kit, they can
be rebuilt and restored to their original
performance levels up to three times at
a fraction of the cost of a new hammer.
These factors, along with intensive
training of local operators and main-
tenance personnel, have seen produc-
tivity levels increase beyond expecta-
tions since the mine opened in 2006.

Secoroc hammers on the job

At 157 km, the Kisladag gold mine in
the Usak province of western Turkey is
the largest gold mine in the country. It
is owned by Tuprag Metal Madencilik
San. Tic. A. (Tuprag), a wholly owned Kisladag Mine Manager Ahmet Raci Uslu in front of one of two Atlas Copco DM45 rigs that enables his
subsidiary of Eldorado Gold Corp. team to surpass productivity expectations.

Blasthole Drilling in open pit mining 133

 Secoroc hammers go for gold

Tuprag uses two Atlas Copco DM45

A B C C C
rigs equipped with Secoroc COP 64
Gold DTH hammers for bits with a
QL60 shank. In addition, there is an
10 m

Atlas Copco ROC L6 equipped with a

Secoroc COP 34 DTH hammer for bits
A = 22 m Pre-split holes
B = 11 m Buffer holes
10 m with COP 34 shanks for presplitting, or
C = 11 m Production holes a COP 54 Gold DTH hammer for bits
Pre-split Buffer Production
with a QL 50 shank for production.
holes holes holes The result is reliable performance on
the site that has continuously increased
production from 70,895 ounces in 2006
1m
to 109,177 ounces in just the first six
rm

4.2 m
Be

5.5 m
months of 2009. The grade is 1.41 gram
2.5 m
4.2 m per ton.
5.5 m

4.8 m
Maintaining productivity
5.5 m

Kisladag started commercial produc-

10 m tion in 2006 with a local mine contrac-
tor and has been developed as a low
grade, bulk tonnage open pit operation
using heap leaching for gold recovery.
In May 2008, the mine began the tran-
sition to being a fully owner-operated
The drilling pattern at the Kisladag open pit with 152165 mm production holes, 152 mm buffer holes and pit. The transition, which included
95 mm pre-split holes. The purpose of the pre-split holes and the row of buffer holes is to ensure the technical and practical training of ope-
stability of the final walls of the pit. rators and maintenance crews, was
completed in four months, and the mine
began using its own fleet exclusively in
October 2008.
Kisladag has been using Atlas Copco
rigs with Secoroc hammers and bits
since the transition began. Penetration
rates are good through the volcanic rock
and Ahmet Raci Uslu, mine manager,
says the rigs and rock drilling tools
were selected to maintain the high pro-
ductivity rates required at the mine.
The amount of meters we drill is
really important for us to keep up mine
production, says Uslu. In June 2009
we drilled nearly 48,000 meters and we
aim to maintain this level of production.
High productivity is one of the reasons
we chose Atlas Copco.
The anticipated production capa-
city at Kisladag is 1.73 million tons a
month, but the current rate of mining is
more than two million tons per month.
To achieve this, drilling operations are
run for 20 hours a day; mining ope-
rations are 10 hours per shift and there
are 14 shifts per week.
A ROC L6 equipped with its Secoroc
COP 34 DTH hammer averages 45 m
The ROC L6 with a Secoroc COP 34 DTH hammer drills the pre-split holes. Each hole is 95 mm in diameter per hour drilling pre-split holes. Hole
with an average depth of 45 m. Hole spacing is 1 m. (Inset) the blasting sequence of the pre-split holes. diameters are 95 millimeters and the

134 Blasthole drilling in open pit mining

 Secoroc hammers go for gold

spacing between the holes is 1 meter.

The holes are 22 meters deep and have
an inclination of 65-77 degrees.
For production drilling, the ROC L6
with the Secoroc COP 54 Gold hammer
averages 400 meters per shift. Each
DM45, equipped with a Secoroc COP
64 Gold hammer, averages 31-35 meters
per hour. The hole diameters are 152-165
millimeters and the drilling pattern is
5.5 meters x 5.5 meters with vertical
holes. The production drilling benches
are 10 meters high with 0.5-0.8 meters
of sub-drilling.
The total drilling capacity for all
rigs is 58,000 m/month. This is inclu-
ding 2 x DM45 and one ROC L6. The
availability of the rigs is 92%.
Hole quality is checked by measur-
ing tape before each blast. Kisladag
uses cord, downhole delays and surface
delays for detonators and ANFO and
emulsion ANFO explosives.
While high speed drilling increases
the number of holes completed per day,
air consumption, fuel costs, penetration
rates and bit and hammer life have a
major impact on profitability. The
operating life for the Secoroc DTH
hammers with E-kits is: COP 34-9,900
meters; COP 54 Gold-12,853 meters;
and COP 64 Gold-27,332 meters.
Bahadir Ergener, RDT/GDE product manager, Atlas Copco-Turkey, demonstrates how to use a gauge to
Maximizing, determine when a tungsten carbide bit needs regrinding. Kilada uses a Secoroc Grind Matic BQ2-DTH.

extending bit life
Kisladag uses Secoroc drill bits to
achieve high production rates for
extended intervals. To utilize the full
power of the drill rigs, regular bit
grinding is essential. The bit on the
COP 34 averages 1,540 meters; the bit
on the COP 54 hammer, 2,257 meters;
and the bit on the COP 64 Gold, 3,099
meters.
However, the economics of drill-
ing often comes down to balancing
penetration against bit life. A rule of
thumb is that a 10-percent increase in
penetration rate results in a reduction
of 20 percent in bit life.
To extend the life of its bits and
maximize the number of drilled meters
per bit, Kisladag uses a Secoroc Grind
Matic grinder, and each bit is reground
two or three times. The efficient grind-
ers extend the service life of the bits,
which also results in less wear and tear
on each rigs drillstring. The availability
of consumables and parts, as well as the
durability of the equipment, also played
a role in Ahmet Racis Uslus decision
to use Atlas Copco at Kisladag. We
have our own maintenance shop and
crew. We get good maintenance sup-
port from Atlas Copco Turkey and a
good supply of parts and consumables
that makes life easy for us, he says.
Exceeding productivity
expectations
Since the first year of commercial
production (July 2006), Kisladag has
surpassed productivity expectations.
Initially, plans were to increase produc-
tion in year four, but Tuprag was able
to move forward with expansion in year
two. And the trend continues. Tuprags
parent company, Eldorado Gold, re-
cently completed a review of the
Kisladag mine. The study identified
opportunities to effectively increase
annual production by 30-40 percent,
while decreasing unit operating costs
by approximately 15 percent all of
which is expected to be achieved using
Tuprags existing fleet.
For Ahmet Raci Uslu, the relation-
ship with Atlas Copco and the reliabil-
ity of the equipment will continue to
contribute to the production capability
of Kisladag. And with Secoroc equip-
ment offering the lowest cost per meter
in the industry, taking all costs into
consideration, his fleet will also make
a major contribution to the mines prof-
itability.
Acknowledgements
This article first appeared in Mining
& Construction, No. 3 2009, and was
updated June, 2010.

Blasthole Drilling in open pit mining 135

 Secoroc hammers go for gold

Kisladag to double its gold

Arrival of Pit
Viper 235
In mid 2011 the Kisladag mine
took delivery of a new Pit Viper
235. This is a high pressure unit
used for single pass drilling of
12 m deep blastholes using a
Secoroc DTH hammer. Here is
an update published in Mining &
Construction No 2 2012.

Team of rigs
High on the Anatolian plateau, Can-
adian company Eldorado Gold Corp
has successfully commissioned its
Kisladag gold mine.
Operated through Eldorados subsid-
iary, Tprag Metal Madencilik Sanayi
ve Ticaret, the mine opened in 2006
and is now Turkeys No.1 gold producer
with an annual production of about
285000 troy ounces.
In contrast to the volcanogenic mas-
sive sulphides of the Black Sea region,
the ore at Kisladag is in porphyry-type
mineralization. It grades up to 1 g/t
Good teamwork: The Pit Viper PV-235 above was delivered in mid-2011 and working together with two
gold. with softer, oxidized material at
DM45 rigs, it helped to complete 650 000 drillmeters in 11 months. Insert: Serkan Yksel, Mine Manager
a depth of 30-80 m. at Tuprag, confirms that the mine aims to double production.
Serkan Yksel, Mine Manager at
Tuprag, explains that the company
plans to more than double its ore pro- says operator Yasar Senturk. You can for wall control. The rig drills 20 m
duction by 2014. Since Tprag took also move the rig from setup to setup double bench holes with a diameter of
over mining from a contractor in without lowering the mast which is a 95 mm and 1 m of sub-drilling. The
2008, the operation has relied on two big advantage. That means you can layout involves a spacing of 1m per
Atlas Copco DM45 blasthole drill drill an extra five holes each shift. hole around the entire pit periphery,
rigs for production drilling. Then in Both ore and waste are drilled on requiring very accurate rig set up to
mid-2011, it took delivery of a new Pit a diamond pattern, with a 4.5-5.25 m achieve parallel drilling.
Viper PV-235. Together, the three rigs burden and slightly larger spacing. 152 Another challenge is that the pit
completed 650000 drillmeters in 11 mm holes with a COP 54 Gold hammer slope varies from 65 to 77 degrees,
months. or 165 mm blastholes with the COP 64 depending on the geotechnical sector
Thats over 58800 individual Gold hammer cover the depth of a 10 m from area to area, Yksel explains,
holes, notes Yksel, and during the bench, with typically 800 mm of sub- and we have experimented in the
first four months, the Pit Viper contrib- drilling. past with both single and double plane
uted around 70000 m to that total. We However, the blasthole rigs are not inclined holes.
are using it in the harder rock in the the only Atlas Copco rigs that have
pit so were not really in a position yet helped make Kisladag successful. The Acknowledgements
to make direct comparisons with the mine also runs a ROC L6 (renamed
DM45 rigs. The Pit Viper is powerful FlexiROC D50), equipped with a QLX The article on this page first appeared
and can drill a 12 m hole in one pass, 35 hammer primarily for presplit holes In Mining & Construction, No 2 2012

136 Blasthole drilling in open pit mining

 UKRAINE, KOMSOMOLSK

Advanced iron ore

mining in Ukraine
Profitable pellets
Poltava GOK (PGOK) is one of the
most technically advanced iron
ore mines in Ukraine and argu-
ably one of the most progressive
of its kind in the world. The turn-
ing point in the history of PGOK
came when the new management
made two key decisions: to con-
centrate solely on the production
of pellets, and to invest only in
the most modern mining equip-
ment available. The PGOK fleet
currently includes eight Pit Viper
275 blasthole drills. These are
rotary and DTH rigs covering the
hole diameter range 171-270 mm
(6 "10 58").

Solid position
The open pit iron ore mine near the
town of Komsomolsk in central Ukraine
is one of 10 deposits located on a single
5 km long magnetic anomaly strike.
Owned by Poltava GOK, it dates back
to the former Soviet Union when effi-
ciency was not its first priority.
However, following Ukraines in-
dependence in 1992, and subsequent
privatization, everything changed and
today the ore dressing and processing
facilities are almost unrecognizable.
PGOK, which is owned by Ferrexpo
plc, is a modern, well equipped and
highly developed operation which, with
annual exports of some 10 million ton-
nes of iron ore pellets, ranks among the
worlds top pellet suppliers.
The turning point in the history of
PGOK came when the new manage-
ment made two key decisions: firstly,
to concentrate solely on the production
of pellets, and secondly, to invest only
in the most modern mining equipment
available. And it is the combination
of these two goals that has driven the
mine to success and given it a solid
position among international iron ore The diesel-powered PV-275 is drilling 251 mm holes. In rotary drilling with tricone bits, high pressure air
producers. (24 bar) is used to clean the holes.

Blasthole Drilling in Open Pit Mining 137

 Advanced iron ore mining in Ukraine
The PGOK benches are 10 to 12 m high and the drill pattern is 6 x 6 m in waste and 5.5 x 5.5 m in ore.
Modern drilling
The iron ore at the PGOK deposit is
extracted from medium hard rock and
to drill the required 251 mm blastholes,
the mine specialists chose the Atlas
Copco Pit Viper 275, a top-of-the-line
rotary drill featuring the computerized
Atlas Copco Rig Control System.
Voldymyr Chasnyk, parts and ser-
vice manager at Atlas Copco Ukraine
has this to say: Theres no doubt that
PGOK is one of the most modern enter-
prises in Ukraine. The company is the
industry leader with modern equipment
and has a determination to keep up
with all new technical developments.
PGOK made up its mind to focus
on iron ore pellets in contrast to the
other mines in the country which have
a lot ofdifferent products and they
recognized the superior performance
of the Pit Viper to help them achieve
their goals.
Steady progress
By studying the productivity report,
it is easy to see why the Pit Viper is
the rig of choice here. Since it was first
138 Blasthole Drilling in Open Pit Mining
introduced into the fleet in April 2006,
productivity and output have both
steadily increased whereas the number
of rigs needed in the fleet to achieve
the desired results has successively
declined.
Currently PGOK is operating a
fleet of 23 drill rigs, eight of them Pit
Viper 275. In 2010 there were 19 rigs in
the pit and the total number of meters
drilled was 780 000 (13% of which was
done using three Pit Viper rigs, 17%
with three TEREX rigs and 70 % by
13 SBSh (Russian made) rigs.
For 10 months of drilling in 2011,
the total number of meters drilled was
920 000, of which half was drilled
using the eight Pit Vipers, 8% by
TEREX and 42% using SBSh rigs.
Major shift
PGOK has facilities for crushing, con-
centrating and pelletizing facilities on
site and benefits from its sea port JV
on the Black Sea, at Yuzhnye, near
Odessa, from where it ships pellets to
overseas markets.
Voldymyr Ivanov, First Deputy
Chairman of OJSC (Poltava GOK),
confirms that making the shift from the
traditional fleet to the more modern Pit
Viper has been a major undertaking.
Efficiency is productivity and be-
cause our focus is to be more efficient
we are evaluating every type of equip-
ment. That includes trucks, shovels,
loaders, drills, transport systems
everything. Our fleet plan has been
developed in close cooperation with
Atlas Copco Ukraine. Once our fleet
includes more Pit Viper drills we will
get even more efficiency as mainte-
nance and repairs will be carried out
by the specialized Atlas Copco Ukraine
service company and this will allow for
a considerable increase in equipment
availability and drilling volumes.
Mobility and flexibility
Although the increase in productivity
can, to a certain extent, be attributed to
the advanced functions and efficiency
of the Pit Viper, mobility played a
decisive role in the choice. The mines
previous fleet was electric but the PV
is diesel powered, which meant that the
rigs could move around freely from site
to site without the restraints of power
 Advanced iron ore mining in Ukraine

cables. Ivanov confirms that this

mobility has been one major produc-
tivity driver. Another is the rigs live
tower capability which allows the rig
to be moved with the rotary head at the
top of the tower and rods loaded an
operation that was not possible with the
older fleet. The benches are 10 or 12
m high and the drill pattern is 6 x 6 m
in waste and 5.5 x 5.5 m in ore. In
rotary drilling with tricone bits, high
pressure air (24 bar) is used to clean the
holes. The reason, explains Aleksandr
Protsenko, is that this extends the life
of the consumables. All of the Atlas
Copco equipment is well taken care of
under the terms of a full service agree-
ment.Driller Victor Voznuk, who has
more than three years of experience
operating the PV-275, says he can drill
a 16 m hole in about 15 minutes, which
in these conditions is considered to be
a good performance.
He says he likes the Pit Viper for its
safety features with fewer opportuni-
ties to break things. He adds: The
drills are more comfortable and have a
better way of reporting drilling statis-
tics and tracking productivity.
PGOK exploits the Gorishne Pla-
vninskoye and Lavrikovskoye ore
deposit which is some 8 km long, 2.5 km
wide and 350 m deep, with a gradual
dip ranging from 20 to 37 degrees.

Yeristovsky next in line

Next in line is Yeristovsky GOK
(YGOK) which is already under deve-
lopment. Prestrip operations have
commenced with hard rock mining ex-
pected to start in early 2013. The
deposit has an expected life span of
approximately 32 years under the cur-
rent development plan. It will produce
on average 28 Mt of iron ore and 10
Mt of pellets or concentrate equiva-
lent per year. In total, approximately
1 600 Mt of waste rock is expected to
be removed and 800 Mt of ore to be
produced, giving a favorable strip ratio
of approximately 2:1.
Ferrexpo has engaged international
mining experts to assist in developing
the operation to an international level.
Bob Garrick, an Australian with
many years experience in the mining
industry, says: We have been given
Top picture: The Pit Viper 275 is designed for multi-pass drilling down to 59 m and can be used for angle
drilling with 0 - 30 degrees in 5 degree increments. Above: Driller Victor Voznuk enjojs the comfortable
and ergonomic PV-275 cab.
a blank sheet to design the operation
from the very start, without the con-
straints of having to modify an existing
operation. As a result, we are able to
take advantage of the latest technology
available within the industry world-
wide. We are leading the Ukrainian
mining indust r y with respect to
equipment selection, being the first to
introduce some of the largest trucks,
excavators, rubber tired wheel dozers
and graders. With respect to our selec-
tion for drilling rigs, it was obvious to
us that the Pit Viper options were an
ideal solution.
Garrick adds: We value equipment
reliability, life cycle costing as well
as in-depth preventative maintenance
programs and product support all of
which Atlas Copco provide. Therefore
we are happy with our decision to use
the Pit Viper product.
YGOK intends to demonstrate to the
industry that it is capable of developing
a world class operation. With support
from Atlas Copco and the Pit Viper
drills this aim will soon become a
reality.
Acknowledgements
This article first appeared in Atlas
Copco Mining & Construction magazine
No 1. 2012

Blasthole Drilling in Open Pit Mining 139

 Advanced iron ore mining in Ukraine

140 Blasthole Drilling in Open Pit Mining


Steep wall open pit
mining at Zhelezny
The Zhelezny open pit mine at Kovdor operates Atlas Copco and Russian drill rigs, Russian electric shovels and Belaz, Caterpillar and Komatsu haul trucks. The
in-pit crushing station is on the upper right of the picture.
Super-deep mining
Kovdorsky GOK, one of two mining
companies in the Kola Peninsula
supplying two of Russias major
phosphate fertilizer manufactu-
rers, has decided to utilize super-
deep mining at the Zhelezny open
pit until reserves are exhausted in
2049. The technique relies heavily
on precision drilling with equip-
ment supplied by Atlas Copco.
Treasure Trove
Discovered in 1933, the ore deposit at
Kovdor in Russias Murmansk Oblast
(67 33 N, 30 30E) is unusual, pro-
bably unique. The discrete, deep and
more or less downwardly conical car-
bonatite deposit hosts 45 recorded mi-
nerals and is the type locality for five of
these. It is also one of the Kola Penin-
sulas two major sources of Apatite for
fertilizer production, one of the worlds
Blasthole Drilling in Open Pit Mining 141
Russia, Kovdor, murmansk oblast
few reserves of Baddeleyite (containing
zirconia), and a substantial supplier of
Magnetite.
The mining method developed for
the Zhelezny open pit is a bit special
too. Described as a breakthrough tech-
nique in Russia, super-deep mining re-
quires extraordinary control of drilling
and blasting on near vertical benches.
Kovdorsky GOK, which is part of the
Eurochem fertilizer group, wants to mi-
nimize ore dilution while maintaining
production rates although bench areas
will decrease as the mine deepens. The
rim of the pit is approximately 200
meters (m) above sea level and is 2.3
kilometers (km) in length, 1.7 km wide
and presently 170 m deep. Whereas
mining was scheduled to cease in
2015 Kovdorsky GOK now intends to
mine down to 660 m below sea level,
thereby accessing an additional 330-
400 million tonnes of ore and enabling
Zhelezny to produce 23 million tonnes
per year (Mt/y) until 2032. Output will
then decline until closure around 2049.
Evolution
The mining and processing operations
at Kovdor started in 1959-62, initially
recovering only the magnetite from
6 Mt/y of ore, explained Igor Melik-
Gaikazov and Mikhail B Togunov, re-
spectively Technical Director and Chief
Mining Expert at Kovdorsky GOK.
Super-deep mining is not the opera-
tions first technical breakthrough, they
pointed out. During the 1970s the staff
developed a process for separating the
apatite and baddeleyite as well as the
magnetite, with optimal processing
achieved early in the 1980s. The iron
ore is extracted by magnetic separation,
then the pulp undergoes flotation to
recover the apatite and, finally, gravity
techniques separate the baddeleyite.
In the same period the mineable area
 Steep Wall Open Pit Mining at Zhelezny

2.5 4.0 4.0 5.0 5.0 5.0 (m)

15 m

238 m
B B
C C C

A = Pre-splitting holes 15 m
B = Buffer holes
Sea level C = Production holes
A

A typical drilling pattern for drilling and blasting

the Zhelezny benches.
*The Kovdor property also includes deposits of
apatite-shtaffelite (AShR) and apatite-calcite ores.
During the period 2000 2006 engineers developed
an AShR open pit mining plan with 12 m high
benches. The apatite-calcite part of the deposit
below the AShR is regarded as a long-term strategic
660 m phosphate reserve.
Length 2.3 km

The Zhelezny open pit is 2.3 km long, 1.7 km wide and its current depth is approximately 170 m. The
diagram shows the vertical orebody and the planned angle of the slopes at the projected depth of 900 m
(dotted line). Kordovsky GOK aims to accomplish this with no significant expansion of the pit rim.
was extended by draining part of Lake
Kovdoro and diverting the High Kov-
dora River to access all of the primary
orebody. The pit has since been pro-
gressively deepened, with necessary
changes to the material transportation
systems and equipment fleet. Particu-
larly interesting are the Cyclical Line
Technology (CPT) in-pit crushing and
conveyor systems used to haul ore and
waste.
Privatization in the early 1990s
as Kovdorsky Gorno-obogatitelnyi
Kombinat (Kovdorsky Mining and Pro-
cessing Combine, Kovdorsky GOK)
was followed by a difficult period. But
in 1998 management started exploiting
baddeleyite-apatite-containing waste
from magnetite-only processing stored
in sedimentation ponds*. This enabled
Kovdorsky GOK to compensate reduc-
tions in mine apatite and baddeleyite
output made in response to low iron ore
demand until 2005.
In 2001 EuroChem Mining and
Chemical Company JSC (EuroChem),
reputedly Russias largest integrated
fertilizer producer, acquired the Kov-
dor facilities. A report for Kovdors
40th anniversary in 2002 commented
that 1997-2001 had been a period of
stabilization for the operation and for
Kovdor city.
During 2003 the Kovdorsky team
introduced (and later modified) a
Strategic Development Programme
suited to EuroChems phosphate feed-
stock requirements that covered the
period until 2015. Commenting on pro-
gress in the period 2003 2006, senior
personnel1 pointed out that the mine
succeeded in restoring ore production
to the desired long-term 16 Mt/y target.
The planned apatite concentrate recov-
ery from open pit ore in 2010 would
be about twice the amount achieved in
2001.
Super-deep mine planning
The mining licence for Kovdor allows
mineral extraction from the primary
orebody to a depth of two kilometer
and a major mine redesign to exploit the
lower levels started early this century.
The start of super-deep mining was
preceded by several years of advanced
and extensive studies using some of the
most sophisticated methods of testing,
calculation and data processing in the
industry. In view of general trends and
advances in rock mechanics Kovdorsky
GOK decided to continue development
of the Zhelezny pit to lower levels
rather than switch to underground
mining. To avoid widening the surface
pit rim and creating large volumes of
waste rock the project team focused
on super-deep mining of benches with
vertical or near vertical highwalls.
Initial geomechanical studies ena-
bled expert organizations to produce
parameters for the engineering geolo-
gists and a 3D geological-structural
map of the Kovdor deposit for use in
forecasting potential slope failures.
Five engineering-geological sectors of
the pit were defined and for each one
the bench slope angles, bench heights
and widths of safety berms were cal-
culated.
This information was used to deve-
lop specifications for super-deep ex-
cavation using methods such as pre-
split drilling and blasting. These speci-
fications are used in conjunction with
techniques for the relief of water pres-
sure in the benches; stabilization of
weak rock masses by, for instance, rock
bolting and cement mortar injection;
and thorough slope stability monitor-
ing for which Kovdorsky is using three
methods: visual observation, surveying
with electronic and optical instruments

142 Blasthole Drilling in Open Pit Mining

 Steep Wall Open Pit Mining at Zhelezny

including laser scanning, and seismic

monitoring in high risk areas.
Once the deep mining concept was
approved by EuroChem, the Giproruda
institute started work on the mine
redevelopment plan in 2004 and two
years later completed the project
Reconstruction of the open cut for
restoration of the project capacity of
Kovdorsky GOK by means of the use of
steeper constant open-pit benching and
in-crease of the open pit depth and du-
ration of open-pit mining. Two pit
design versions were used for techno-
economic evaluation. Stage One of for-
ward development will hold open pit
output at 15-16 Mt/y of baddeleyite-
apatite-magnetite ore and 7 Mt/y of
low-iron apatite ore until 2032, there-
after production will decrease gradu-
ally until closure.

Drill and blast design

Blasting at Zhelezny was thoroughly
modernized from the late 1990s to 2005.
The mine introduced non-electric ini-
tiation with Nonel and Primadet sys-
tems and from 2000 progressively
switched to EVV emulsion explosives
VET emulites. Consequently, in
2006 as compared with 2001 (figures
in brackets), 99.1% of blasting was with
EVV, using 21,500 t (9,400 t) of explo-
sive, and yielded 15.25 Mm3 (7.5 Mm3)
of blasted rock; 200t (2,400t) of con-
ventional explosives blasted 0.23 Mm3
(2.59 Mm3) of rock. VET explosive is
mixed by the Russian company Eastern
Mining Services Ltd, a subsidiary of
Maxam, delivered to the holes and
charged using SZM mixing-charging
machines. The new technology signifi-
cantly reduced the number of misfires.
The super-deep mining system re-
quired further improvements to blast-
ing practice. Firstly, it was essential to
reduce fragment size as even sizeable
increases in the amount of explosive
used in the 250 mm production blast
holes did not fragment the rock to di-
mensions sufficiently small to improve
performance of the CPT systems, truck
haulage, or comminution. Secondly,
the drill-blast system used in the zones
near the pit rim must maintain the sta-
bility of the benches and steep highwalls
and not disturb the rock mass outside
Contractor Technobur has four Atlas Copco Drilling Solutions DML rigs working for Kovdorsky GOK. Three are
low pressure (LP) rigs for rotary drilling, and one is a high pressure (HP) rig for DTH drilling or rotary drilling.
the mine walls. Thirdly, because the pro-
portion of wet blast holes is expected to
increase, waterproof explosives would
be required.
Blastability studies led to the defini-
tion of five categories and for each one
the burden, hole distance and height of
explosive charge are calculated in rela-
tion to hole diameters, bench height,
grade of emulsion charge and row posi-
tion in the blasting sequence (see illu-
stration page 110). Typically, the inner
blocks of the bench are drilled with
smaller diameter bits, transitional blocks
are drilled with the smaller holes on the
inner part but with larger holes further
away, and outer production blocks are
entirely drilled with the larger diam-
eter holes. Using emulsion explosives
reduces impact on the environment, es-
pecially the urban area close to the mine
as they emit less gas and dust pollu-
tants and the vibration effects are easier
to control. For routine planning mine
surveyors and drill-blast engineers
use the GIS GEOMIX information
system developed by Kovdorsky and
the VIOGEM FSUE organization and
introduced in 2004. They report that
this has improved blast preparation
and stabilized the quality of ore feed to
the process plant. System development
continues.
Upgrading the drilling fleet
For more than 30 years Zhelezny relied
on Russian-built electric powered ro-
tary drilling rigs to drill 250 mm and
270 mm diameter holes. But, as Mikhail
Togunov pointed out, a fleet able to drill
a wider range of hole diameters with
optimum efficiency would be crucial
for super-deep mining.
Accordingly, in 2004 Kovdorsky
GOK acquired one imported rig for

Blasthole Drilling in Open Pit Mining 143

 Steep Wall Open Pit Mining at Zhelezny
A major player in Kovdovskys Super Deep Mining programme: Atlas Copco s DM45 HP (high pressure) rig
on the pits upper, 12 m high benches.
drilling 171.4 mm diameter holes. Two
Atlas Copco ROC L8 down hole drill-
ing (DTH) rigs were added in 2005 in
order to drill 140 mm pre-split holes
and also 165 mm buffer hole rows
close to the margin of the benches. The
new rigs demonstrated the advantages
of using smaller holes that match the
physico-mechanical properties of the
rock.
These results and the bench configu-
rations required for super-deep mining
persuaded Kovdorsky GOK to use die-
sel-powered as well as electric drilling.
The diesel rigs could drill the required
smaller hole sizes and also work effi-
ciently where long tramming distances
are a disadvantage for rigs with power
144 Blasthole Drilling in Open Pit Mining
Perevozchikov.
cables. Nevertheless, the old electric
rigs achieve high performance indi-
ces and Rig Numbers 15 and 16 have
respectively completed 500 and 600
drill km since they went into operation.
So Kovdorsky GOK has retained five
SBSh electric rotary rigs plus the two
ROC L8 and one other DTH machines.
Management also looked for an exter-
nal drilling partner.
These efforts led to the deployment,
starting in 2007, of a second drilling
fleet comprising Atlas Copco large blas-
thole rigs operated by a Russian con-
tractor, Technobur. This company, ba-
sed in Moscow, was formed in October
2004 by an experienced team speci-
fically to carry out mine drilling. Prior
to the contract at Zhelezny, Technobur
had started work at Olcons Olenogorsk
iron ore mine north of Kovdor and
has a Pit Viper 275 there. The com-
pany also tested a DM 45 against SBSh
rigs at Olenogorsk, finding the diesel
machine was 30% faster. Presently
Technobur operates an Atlas Copco fleet
at Kovdor comprising three DML LP
rigs (1600 and 1200), one Pit Viper 275
LP, one DML HP 1250 and two DM 45
HP machines. This fleet usually does
more than 70% of the meters drilled at
the mine, over 40,000 m of a total of
55,000 m in a month being typical.
All the rigs are set up for multi-pass
drilling. To a depth of 70 m above sea
level benches are 12m high but below
this level they are generally 15 m high
with 3 m sub-drill. Production holes are
normally 14-20 m in depth. Presently
the slope angles range 35-40 from
vertical but the long term aim is to
make them as near vertical as possible.
The rotary rigs use Russian tricone bits
while the down hole production drill-
ing is done with Atlas Copco Secoroc
COP64 hammers and 165 or 200 mm
bits. The DML and DM 45 high pres-
sure rigs can be used either for down
hole drilling or for rotary, in which
case the pressure and engine power
are reduced. They are fitted with incli-
nation angle indicators for use when
tramming. Technobur services the rigs
with help from Atlas Copco, explained
the companys site manager Evgeny
The project has been progressing
according to plan and Kovdorsky GOK
expects to reach its first stage targets
in 2011.
Reference
1. D S Strezhnev, N A Ganza, I V Melik-
Gaikazov, A P Ivakin, N N Melnikov,
N V Cherevko: Kovdorsky Mining-and-
Processing Integrated Works Builds the
Future: Realization of Strategic Program of
Long-term Collaboration. Eurasian Mining
Gornyi Zhurnal 1, 2008.
Acknowledgements
This article first appeared in Atlas
Copco Mining & Construction magazine
No 1 2010. Kyran Casteel of Mineral
Industry Intelligence & Information
visited the mine in 2009.
 MONGOLIA, GOBI DESERT

Mining industrys new

beginnings in Mongolia
Mongolia may
become the new
Saudi Arabia
of Coal
Mongolias newly discovered
metal and energy resources posi-
tion it to become a world mining
leader. The aggressive develop-
ment strategy and rapid growth
of SouthGobi Sands make that
company a trailblazer within
Mongolias coal industry. Part
of the strategy at SGSs Ovoot
Togoi mine has been working
with Atlas Copco to put together
a drill program that will conquer
many of its challenges with its
Pit Viper 275 and DM45 blasthole
rigs.
SouthGobi Sands Ovoot Tolgoi mine has two pits in development: Sunset and Sunrise.

Generally held to be the worlds most

sparsely populated nation, in 2011
Mongolia became the number one
coal importer to one of the worlds
most populous nations, China. To date
China has been able to supply most
of its energy needs itself.However, in
2009 China passed the United States
to become the worlds largest energy
consumer. The International Energy
Agency has forecast that Chinas
overall energy needs will increase 75
percent by the year 2035 and demand
for coal, since China has insufficient
natural gas and oil resources, is rapidly
increasing. In addition to its increasing
consumption of coal, Chinas future
need to import foreign coal will grow
even greater as its own coal production
dwindles. China is believed to have
only about 20 to 30 years worth of its
own mineable coke to support its thriv-
ing steel industry.
Mongolia is positioned better than
any other nation to meet Chinas need.
The countys coking coal resources
hold more than enough coal to meet
Chinas needs, as the Tavan Tolgoi
region of the Gobi Desert in south
central Mongolias holds one of the
worlds largest deposits of high-grade
coking coal. Industry pundits have
suggested Mongolia may be on its way
to becoming the new Saudi Arabia of
Coal, a title generally used in the past
to describe the United States.
While others scurried in response to
Mongolias sudden importance in the
coal industry, Mongolias SouthGobi
Sands (SGS) was already at work at its
Ovoot Tolgoi mine in the Gobi desert
setting high standards for others to
follow. Going into 2012 it owned three
projects already, with exploration
licenses for 12 more, all of them wholly
owned by SGS.
Ovoot Tolgoi
Ovoot Tolgoi was the first of SGSs three
coal projects to go into commercial
production. Mining in the Ovoot Kuhral
Basin, the mine is located only 40 kilo-
meters from the China border, ideally
situated for its primary client.
SouthGobi Sands Ovoot Tolgoi
mine has two pits in development:
Sunset and Sunrise. The older and
larger of the two is the Sunset pit with
Sunrise just taking shape. Licenses
were issued in 2007 when Sunset
produced 1 million tonnes. In 2011
the mine produced 4.5 million tonnes
and confidently set a goal of 8 million
tonnes for the following year.
In December 2011 the mine upgrad-
ed its resource data, having determined
a proven reserve of 62.8 million tonnes
of high-volatile B and A bituminous
coals. According to the ASTM D388
standard, high-volatile B coal yields
7,212 to 7,785 kilocalorie-per-kilogram
(kCal/kg). The heat output of high-
volatile is more than 7,785 kCal/kg.
Another 44 million tonnes of prob-
able resource brings total resources to
106.8 million tonnes. SGS actually

Blasthole Drilling in Open Pit Mining 145

 SOUTH GOBI SANDS
Even though the mine is in the Gobi Desert, the mine had to deal with the challenge of ground water. Ground water often freezes in this climate, so the mine uses
a dewatering unit and switched to a bulk-based explosive program.
produces two other coal products in
addition to hard and semi-soft coking,
or metallurgical, coal. These screened
medium ash and screened high ash/
sulfur coals are upgraded to semi-soft
coking coal through a dry-air separa-
tion and washing.
At Olvoot Tolgoi the company can
remove waste rock and blend different
kinds of coal taken from various seams
with its on-site dry coal-handling facil-
ity. It is capable of processing 9 million
tonnes of coal per year to create higher-
value products.
High production equipment
The mine started out with three Atlas
Copco DM45 blasthole drill rigs for
surface work and, for larger production
holes, uses the Atlas Copco Pit Viper
275 blasthole rigs. To meet its produc-
tion goals the mine added two PV-275
drill rigs to the four it already had.
This plan matches the Ovoot Tolgoi
growth in digging and hauling equip-
ment. The big excavator for the mine is
Liebherrs 996 with its 34-cubic-yard
bucket and the Liebherr 9250 with
17-cubic-yard capacity. The mine uses
146 Blasthole Drilling in Open Pit Mining
the Terrex MT 440PC 240-ton haul
truck. It will be adding a second 996
excavator to its fleet this year and will
increase its truck fleet from 12 to 22.
Unique difficulties in
drilling
Acting Mine Manager John Howlett
said Ovoot Tolgoi is like any mine with
the exception of what he calls some
really crazy seams.
The largest of the seams that run
through both pits is Number 5. It is
about 50 meters thick near the surface,
but dips at a 45-degree angle. There
are multiple seams lying side by side.
Exploration drilling has found seam
Number 5 at a depth of 800 meters.
The Ovoot Tolgoi surface mine
based its plans on a 20-year mine life,
mining to a depth of 300 meters, but
this could increase as coal demands
rise. Future plans tentatively include
going underground.
Ovoot Tolgoi General Manager
Rodney Lacy said to date they have
moved 8 million tonnes of coal to
roughly 35 million total bank cubic
meters (BCM) of overburden. Howlett
said his plan is to keep at least 1,000
holes drilled at all times. A single
excavator can excavate 1,600 BCM an
hour or 28,000 BCM total a shift. SGS
wants to keep 800,000 BCM ready for
the shovels at all times.
Mining coal in Mongolia is a chal-
lenge. With the extreme temperatures
and complex geological formations,
Mongolia challenges even the most
experienced engineers and miners.
Other challenges to the drilling opera-
tions are the sharp folding of the coal
seams and the steeply dipping footwall.
Drilling and blasting practices have
been modified to allow for a stable
final pit wall.
SGS found what Lacy called con-
glomerates at the bottom of the pit.
These areas were tougher to drill and
blast and required patterns to be tight-
ened for better fragmentation. This is
another reason for the transition from
the DM45 to the larger, more powerful
PV-275. The drills greater pull down
force penetrated the conglomerate mass
with ease.
The standard burden and spacing
was 5.4 by 6.2 meters for the DM45
with a 7 -inch hole and 8 by 9 meters
 SOUTH GOBI SANDS

The mine added 200 employees in 2011 with miners being bussed from three local communities up to 130 km away.

for the PV-275 with a 9 7/8 -inch hole. and Noyon soum are 100 kilome- coming from the local communities.
The bench depth was 12 meters with 1 ters and 130 kilometers away from Because of its proximity to the commu-
meter of sub-drill where needed. The Ovoot Tolgoi, respectively. Additional nities, the mine donates 2,000 tonnes of
PV-275 allowed double benching to employees and a few ex-patriots in lead coal annually to them.
help develop the wall in unstable areas. positions were flown in from the coun- Having a fairly new work force also
One unexpected problem they trys capital, Ulaanbaatar, nearly 1,000 required an intensive training program.
encountered was ground water. Even kilometers away. In early 2012 the Lacy thinks the Mongolians are an
though the Gobi Desert shows very company had nearly 600 employees, independent-natured people, requiring
little vegetation and annual precipita- with 75 to 80 percent of the drillers a team approach to training as it relates
tion, the mine has encountered a fair
amount of ground water. Because the
temperature is below freezing, wet
holes freeze over. To remedy the situ-
ation the mine included a dewatering
unit and began a transition from pack-
age explosives to a bulk-based pro-
gram, bringing about significant cost
reductions and greater flexibility.

Developing the mine

The mine has put together an equip-
ment and personnel plan that will
keep it on track. In 2011 alone added
200 employees to the Ovoot Tolgoi
operation. Miners were being bussed
from three of the local communities.
The Gurvantes soum of Umnugobi The largest of the seams that run through both pits is Number 5. It is about 50 meters thick near the surface,
district is the closest to Ovoot Tolgoi, but dips at a 45-degree angle. There are multiple seams lying side by side. Exploration drilling has found
just 30 kilometers away. Sivrie soum seam Number 5 at a depth of 800 meters.

Blasthole Drilling in Open Pit Mining 147

 SOUTH GOBI SANDS

to safety. From the start, each miner has

to learn the basics, from radio instruc-
tion to team work. Communication is a
key part of the training program from
the top down. Lacy said it starts with
a new-hire meeting they have every
Wednesday. Part of that meeting is
devoted to sharing about each others
history and family and offering the
new hire a chance to do the same, said
Lacy. He believed this builds a unity
and camaraderie that promotes safety.

Where does it lead?

SouthGobi Sands is more than a coal
exporter. In addition to the 600 to 700,
100-tonne trucks that roll the 45 kilo-
meters to the China border every day,
the mine is looking to the future.
In the beginning those trucks were
running on a dirt road, and the jour-
ney took nearly three hours. In keep-
ing with its progressive philosophy,
the mine immediately began building
a four-lane road to offer better trans-
port to every mine in the area. That
includes the companys next property,
Soumber Mine, which will open up in
the coming years.
Developing a mine is not enough for
SGS. Management knows Mongolias
future is mining and that, as it builds
Ovoot Tolgoi, it is building the founda-
tion of the industry in Mongolia. The
foundation comes in the form of small
business loans to companies wanting The DM45 is used for drilling 7 inch holes in a 5.4 x 6.2 m drill pattern.
to start up mine service and support
operations as well as from development
of tomorrows miners through techni-
cal school associations and engineering
programs.
The mines engineering team is an
example of the companys success.
Lacy thinks the team is top notch and
is growing their skills. This will not
only support the needs of the mine but
also the development of the country for
years to come.

Acknowledgements
Article and photography by
Scott Ellenbecker

General Manager of Ovoot Tolgoi Operations Rodney Lacy.

148 Blasthole Drilling in Open Pit Mining

 Australia, new south wales & queensland

Coal mining in eastern Australia

Hunter Valley
Shipping 260 million tonnes in
2008, Australia is the worlds larg-
est exporter of black coal. Roughly
one third comes from coalfields in
New South Wales, two thirds from
those in Queensland. Pit Viper
275 rigs are contributing to pro-
duction from the Hunter Valley in
New South Wales and the Bowen
Basin in Queensland.

Multi-seam,
multi-pit mining
Coal production and export is a very
serious business in the Hunter Valley,
New South Wales. Normally one train
passes through Muswellbrook carrying
coals to Newcastle, Australias major coal
shipping port in 2008, every 20 minutes,
said Robert (Rob) Swan. Muswellbrook
(pronounced Musselbrook) lies pretty
central to the main Hunter Valley coal
mines; it is where the Atlas Copco office
and service facilities for the area are lo-
cated and where Rob, who is the Regio-
nal Manager Eastern New South
Wales, is based. It is also quite close to
the Hunter Valley Operations (HVO)
which has proved very convenient for
us, said Dale Radnidge, the HVO Main-
tenance Supervisor, whom we met at
an office complex known as Cheshunt
Bathhouse located in the southern sec-
tion of the HVO.
Located 24 km northwest of Single-
ton, the Hunter Valley Operations, are
100% owned by Coal & Allied Indu-
stries Ltd, which in turn is managed
by Rio Tinto Coal Australia. Rio Tinto
describes the Operations as a multi-
seam, multi-pit open cut mining ope-
ration. HVO comprizes: part of the
Howick mine, now known as the West
Pit, which started operating in 1968; the
Hunter Valley No. 1 mine, where pro-
duction began in 1979, and the Lem-
ington mine, which commenced coal-
ing in 1971. Coal & Allied merged the
Howick and Hunter Valley mines in
2000 to create Hunter Valley Operations
In the Hunter Valley, New South Wales, Coal and Allied Industries mines a multi-seam, multi-pit operation.
and included Lemington when it was
acquired in 2001. The company will
approximately produce between 10.5
and 13.5 Mt/y.
In addition to the Hunter Valley Ope-
rations, the Coal & Allied portfolio in-
cludes the quite new Bengalla strip mine
4 km west of Muswellbrook and the
integrated Mount Thorley Warkworth
open cut mines 15 km southwest of
Singleton.
Purchase factors
Dale Radnidge explained that there had
been various reasons why Coal & Allied
(C&A) wanted to buy the Pit Viper 275.
For one thing, it would be fitted with the
Cummins QSK 19 Tier 2 compliant en-
gine that will meet the relevant Austra-
lian environmental impact regulations
for some time to come. C&A had good
previous experience with the Pit Vipers
predecessor rig, the DM-M2, which
was bought in 1995. This has always
been a very cost effective machine
for the company, with very good life
cycle costs despite the fact that the
rig has had to operate for periods in
ambient temperatures of over 50 C.
Dale had also had positive feedback
from Pit Viper owners concerning the
steps taken by Atlas Copco Drilling
Solutions to improve features that had
been weak points on the older rigs.
At the crunch, Atlas Copco quoted a
competitive purchase price and the com-
ponent life cycle costs were acceptable.
Atlas Copco also offered to pro-
vide a maintenance technician for 12
months: previously an Ingersoll-Rand
Drilling Solutions rig owner himself,
this technician has also helped the Atlas
Copco team at Muswellbrook to iden-
tify maintenance issues.
Regulatory issues
However, life is not too simple for eq-
uipment purchasers in Australia, espe-
cially in New South Wales where the
government guidelines on equipment
specifications, primarily designed for
machinery operating in coal mines,
are the most stringent in Australia. Rio
Tinto Coal Australia management also
has very strict rules covering equipment
specifications and it was necessary to

Blasthole Drilling in Open Pit Mining 149

 Coal mining in eastern Australia
HVO Maintenance Supervisor Dale Radnidge (right) with Atlas Copcos Rob Swan.
have the standard version of the PV-275
modified in a number of respects. Dale
Radnidge, the maintenance electrician
and maintenance fitters at HVO were
involved and so was the units produc-
tion trainer.
The order was placed late in 2007,
not too long after the AIMEX mining
equipment show in Sydney, and Atlas
Copco was able to deliver the PV-275
that had been displayed - in yellow
and gray livery to the Muswellbrook
workshop.
C&A also ordered a new Atlas Copco
DML rig that required rather more
modification than the Pit Viper. Mr
The Coal and Allied Ltd Pit Viper 275 is fitted with a Cummins QSK 19 Tier 2 compliant engine.
150 Blasthole Drilling in Open Pit Mining
Radnidge explained that a major aim of
purchasing these two rigs was to start
to create a unified fleet of different size
drills with a common cabin design so
that each operator can easily switch
from one model to another when neces-
sary. The DML rig has replaced an ex-
isting competitor machine, whilst ano-
ther elderly competitor machine had
been put on stand-by when the PV-275
started work.
Modifications
The HVO maintenance team were able
to inspect the Pit Viper at the Atlas Copco
workshop. They could therefore make
recommendations as to the changes to
be made in addition to those modifica-
tions necessary for regulatory reasons.
These additional alterations were in-
tended to make it easier to maintain
the PV-275.
Meeting NSW electrical equipment
requirements necessitated taking out
the whole electrical system and install-
ing a different one. Some of the hydrau-
lic system components also had to be
changed.
Operation
The mines presently use a walk meter
and laser depth indicator in conjunction
with mine survey data for drill positi-
oning as the hardware needed to use
the GPS system on the PV-275 is not in
place yet. The DML has the Aquila sy-
stem fitted for use with HVOs Modular
Mining Dispatch f leet management
system. Dispatch is also being used to
monitor the availabilities being achieved
by the two new Atlas Copco drilling
rigs. At the time of the visit, the Pit
Viper was being used with five rods
to drill 54 m holes in overburden for
blasting and stripping by either dra-
gline or shovel. However, the drilling
requirements range from 10 60 m
depth although the bulk of the benches
are drilled with 30 40 m vertical
holes. Hole size is 7 in for coal and
partings and 10 in for overburden.
Pre-split holes are drilled at either 10
m or 80 m spacing, in both cases at a
15 angle. Approximately 20 25% of
drilling time is spent on the pre-splits.
All nine drilling rigs working at HVO
use Secoroc tools provided through a
separate supply and service contract
that has been in force for six years.
HVO has two Bucyrus International
draglines (1 x 1370, 1 x 1570), six P&H
electric shovels and a Terex-O&K RH70
hydraulic excavator. As well as the Atlas
Copco drilling rigs there are six older
ones from other manufacturers. Mr
Radnidge explained that this mixed fleet
was built up as a result of the merging
of the mines that are now part of the
Hunter Valley Operations. C&A has
been using the maintenance plan-
ning tools in the SAP software port-
folio since May 2008.

C&A intends to create a fleet of different size drills with a common cab design so that each operator can
switch easily from one model to another.
Summarizing, Dale Radnidge said
that not only was the deal which Atlas
Copco offered sound but the working
relationship that C&A has established
with the Atlas Copco team has been
good too. C&A is comfortable with the
purchase. Indeed, HVO had planned
to buy two more rigs, which had been
shipped to Australia. However, in
the current economic climate this will
not be possible during 2009.
Queensland Drillpro
Services
The vast Bowen Basin coal deposits in
mid-Queensland extend from the area
west of the coastal city of Bowen to
south of the Tropic of Capricorn in an
area which lies west of Gladstone. The
mines are connected by rail lines to
five major ship loading Coal Terminals:
Abbott Point near Bowen, Hay Point and
Dalrymple Bay near Mackay, and the
RG Tanna and Barney Point terminals
Blasthole Drilling in Open Pit Mining 151
Coal mining in eastern Australia
The HVO Pit Viper was being used to drill 54 m
holes in overburden, using five rods.
near Gladstone. The Bowen Basin ac-
counts for roughly half the worlds sea-
borne trade in metallurgical (coking)
coal.
Drillpro Services is a drill services and
drilling contracting company formed
by John Anderson, who had previously
worked in a senior position for a major
Australian equipment dealer handling
machines competing with the Atlas
Copco Drilling Solutions range. Having
started out selling drill rig parts and
doing rig rebuilds, Drillpro bought its
first rig for contract drilling in 2001,
followed by two more each year after
that. For some time the company used
the rigs John Anderson had previously
sold, but later Drillpro experienced
problems with a particular model so
Mr Anderson decided to try the equi-
valent Pit Viper 275. He is now an en-
thusiastic customer and advocate. Cur-
rently the company has two Pit Vipers
working at widely separated mines in Hole sizes are 7 7/8 in for coal and partings, 10 5/8 in
the Bowen basin. The first to be delivered for overburden.
 Coal mining in eastern Australia
Drillpro Services deploys one of the companys two PV-275 rigs at the Wesfarmers Curragh Pty Ltd Curragh
North extension.
is at the Curragh operation between
Blackwater and Emerald, one of several
mines lying close to the Tropic, and the
second about 300 km further north at
the Coppabella mine.
Phil Smith finds the Curragh Pit Viper easy to use.
152 Blasthole Drilling in Open Pit Mining
Curragh North
Operated by Wesfarmers Curragh Pty
Ltd, which is wholly owned by Wes-
farmers Ltd, the Curragh mine was first
developed by an ARCO-led consortium
mainly to supply thermal grade coal to
the Stanwell power station near Rock-
hampton in Queensland. Subsequently
metallurgical coal production has grown
and the company exports this grade
together with surplus thermal coal.
Target export tonnage for the Financial
Year July 2008 June 2009 was 7.0 Mt
while 4.0 Mt would go to Stanwell.
Production from the original Cur-
ragh mine has been supplemented
by the development of the Curragh
North extension. There are three dra-
glines working at Curragh and two at
the extension, where there are also hy-
draulic excavators loading Caterpillar
trucks (793 and 789 models). Both types
of coal are mined from this extension:
one grade is taken to the coal prepara-
tion plant at the original mine by a belt
conveyor, the other is hauled by large
high-sided truck-trailer units. The plant
also washes coal from Yarrabee, some
25 km to the north.
Thiess has the overburden stripping
contract at Curragh North, with Drillpro
doing the drilling and other specialist
firms, including Orica, carrying out the
blasting. The overburden is mainly sand
and gravel. John Anderson explained that
Drillpro Services has worked at Curragh
for 11 years. Under the current three-
year contract the company operates and
maintains two drills that belong to the
mining company as well as the one
PV-275 and one DM-M3 that Drillpro
owns itself. The Pit Viper is working at
the Curragh North extension.
From January 5 to January 18, 2009
Drillpro had drilled 51,000 meters, as
compared to the mines target of 25,000
m/week. This requires a penetration
rate of 850 m per 10 hours drilling per
shift. However, Curragh was looking
to increase the rate to 30,000 m/week.
From early August 2008, when the
PV-275 started work, up until the time
of our visit on January 20, 2009, the rig
had drilled 130,000 meters. The rig was
still using the original drill rods and
had thus far achieved 98% availability,
Mr Anderson said. Both this Pit Viper
and the one at Coppabella drill 270 mm
holes. However, the Curragh machine
has a Cummins QSK engine while the
Coppabella PV-275 has the Cat C27
option.
 Coal mining in eastern Australia

Usually Drillpro uses a DM-M3 for

drilling 25 pre-split holes and 20
bench holes for cast blasting. Some-
times, commented John, Drillpro gets
held up because the pre-split holes are
not blasted soon enough. However, the
area we visited had a soft wall so pre-split
drilling was unnecessary. We watched
Phil Smith operating the PV-275. He
drilled the A/O hole to 51m and the holes
H11 to A11 to between 47 and 50 m.
Phil Smith has 17 years experience
in exploration drilling followed by 3
years of production blasthole work,
including drilling with the DM45 and
the Driltech D75 rigs. He told us that
the PV-275 is better than both of them: it
is easier to use and has more feel for the
drilled rock. The cabins perforated
blinds were very helpful in the bright
Australian sun, eliminating glare but
providing sufficient visibility for Phil
to move the rig from one hole to the
next drilling position. John Anderson
remarked that he would like to have a
window in the cabin roof to provide
a view of the mast, but the design of
the FOPS cab makes this impossible.
Instead there is a camera system which
the operators took some time to get
used to, but now find perfectly satis-
factory.

Modifications
As in New South Wales, though to a
slightly lesser extent, some modifications
are essential to meet the Queensland
government guidelines, explained Don
Emery, who is Atlas Copcos Regional
Manager, Mackay. And although John
Anderson could not have his roof
window, he did get several substantial
modifications that he asked for.
The Curragh Pit Viper was shipped
into Brisbane, trucked to the Mackay
workshops where it was modified,
trammed into the Queensland Mining
Exhibition held from July 24-27, 2008
and then delivered straight to the
mine site. In carrying out the altera-
tions Atlas Copco was considerably
The second Drillpro PV-275 works at the Coppabella & Moorvale JVs Coppabella mine.
assisted by an adjacent firm of boil-
ermakers which could generate the
required drawings and do some of the modifications and additions included: mast; a Hiab crane, with its own power
fabrication. a modified walk-up ladder; one plat- supply mounted under the cabin, to
In addition to rewiring according form in front of the cabin and another help with drill tools handling; addition
to Queensland standards, the main to provide high level access to the of a Chubb fire suppression system on

Blasthole Drilling in Open Pit Mining 153

 Coal mining in eastern Australia

a rail around the engine; two lifting

hooks; and a microwave and fridge.
Several of the standard features were
relocated for greater convenience, such
as the isolators, which were moved to
the back end of the frame to be within
reach from ground level, the Wiggins
fast fill unit and the lube drums. Phil
Smith was particularly enthusiastic
about the Hiab crane which makes his
life a good deal easier, he said.
The Coppabella machine was deliv-
ered with the lift hooks pre-fitted,
an upgraded engine fire suppression
system and greasing access for the
driveline to the pump. In addition, extra
tanks were fitted for dust suppression
so that refilling is required after two
shifts. As well as a Hiab crane and extra
platforms like those on the Curragh Pit
Viper, there is an access to the mast and
the camera on the mast via the top of
the cabin.

Coppabella
The overall operation and the mining
operation at Coppabella are managed by
Macarthur Coal (C & M Management)
Pty Ltd working on behalf of the Cop-
pabella and Moorvale Joint Venture. The
Joint Venture comprizes Macarthur Coal
Ltd (73.3 % stake held via Coppabella
Coal Pty Ltd); CITIC (via CITIC Au-
stralia Coppabella Pty Ltd), Marubeni
Corp. (via Mapella Pty Ltd), and Sojitz
Corp. (via Winview Pty Ltd) each hol-
ding a 7 % interest; JFE Shoji Trade Corp.
(3.7 % held via KC Resources Pty Ltd);
and Nippon Steel Trading Co. Ltd 2.0 %
held via NS Coal Pty Ltd. The coal han-
dling and preparation plant has a capac-
ity in excess of 6 Mt/y raw coal and is
operated by the Sedgman Coppabella
Joint Venture.
The mining lease was granted on
June 1, 1998, overburden removal start-
ed in July 1998 and the first coal was mi-
ned in October 1998. By April 2007
Coppabella had yielded 40 Mt of run
of mine coal. Macarthur Coals attrib-
utable production in 2008 was 2.57Mt.
Proven and probable reserves totalled
67 Mt as at 30 June 2008.
The operation is located adjacent
to the Peak Downs Highway, 140 km
southwest of Mackay between Nebo and
Moranbah. It mainly produces a 9% ash,
Drillpros Pit Viper 275 rig at the Coppabella mine, seen here in the Johnson Pit South, is equipped with the
Caterpillar C27 engine option. The machine drills 20 angled pre-split holes and either 20 or more often
vertical main bench holes.
low volatile PCI grade metallurgical
coal that is railed to the Dalrymple Bay
Coal Terminal near Mackay. But, in
response to market trends, Coppabella
has revised its mine plan in order to
mine thermal coal and reduce PCI
grade output, demand for which has
fallen sharply. This also meant that 140
people were laid off in mid-December
2008.
John Andersons son Matt joined
Drillpro Services in 2003 and now man-
ages four contract sites in the area. Of
these Coppabella, where Neal Torresan
is the companys site supervisor, is the
largest but the other clients are pre-
stigious BHP Billiton Mitsubishi
Alliance (BMA), whose Poitrel mine
is operated by the contractor Leighton;
Vale Australias Broadlea; and Peabodys
Eaglefield, where the main contractor is
Macmahon. Drillpro was also bidding
for work at BMAs South Walker Creek
mine, where Thiess is the mining con-
tractor.
At Coppabella, overburden removal
is primarily by dragline, coal mining by
large excavators loading trucks. Orica
is responsible for blasting the holes
Drillpro drills under the terms of an 18
month contract. There are presently three
producing pits; East, Southern and
Johnson. Drillpro has the PV-275 and
one other rig operating, one spare
machine and one parked unit, all of these
being of other make. (When bidding for
new contracts having idle machines can
help, commented Matt Anderson.)
The Coppabella PV-275 rig drills
20 angle, 18 meter pre-splits and 12-18
meter main bench holes, of which some
are angled at 20 but most are vertical.
The coal is 13-14 m thick in places at
a depth of approximately 37 meters
below surface. Jason Camielleri was
operating the drill during our visit to
the Johnson Pit South.
Routine servicing of the Coppabella
machines Cat C27 engine is done by
Drillpro but any guarantee work is
done by the Caterpillar dealer. At the
time of our visit the machine had done
about 1000 hours.
Acknowledgements
Kyran Casteel, a Contributing Editor for
Coal Age and Engineering & Mining
Journal, visited the New South Wales and
Queensland coalfields in January 2009.

154 Blasthole Drilling in Open Pit Mining

 Australia, brisbane, Queensland

The fuel cost killer of Queensland

New technology
improving drilling
economy
Mining contractor DDQ of Queens-
land, Australia has slashed fuel
costs dramatically since adding
a new Atlas Copco Pit Viper 235
rotary drill rig to its fleet. The se-
cret is the Atlas Copco patent-
pending automatic clutch system.
Also the new breakout system
and the 12.2 m single-pass capac-
ity make the rig a lot quicker and
smoother to operate. DDQ has
been operating at the New Acland
coal mine for about four years and
introduced the PV-235 there in
February 2012.

Drilling contractor
About 75,000 dollars in three months,
1,000 liters every 24 hours, and half a
million dollars per year: these are the
kind of fuel savings now being experi
enced by Australian mining contractor
Deveth Drilling Queensland (DDQ)
after adding a new drill rig to its fleet.
DDQ is benefiting from the first class
economy of Atlas Copcos Pit Viper
235 rotary rig, and is passing its sav
ings on to its client, the New Hope
Corporation and its New Acland coal
mine.
Nigel De Veth, owner and founder of
DDQ, says: In the first three months
alone weve saved the mine 75,000
(AUD) in fuel, and that was through
a trial period, really just phasing the
machine into the work. The potential
savings are over 1,000 liters every 24
hours so youre looking in the vicinity
of half a million dollars a year.
The low fuel consumption was a
decisive factor behind the companys
decision to purchase the PV-235. De
Veth adds: Were now getting about
50 to 55 liters an hour with this rig and
the main contributor to that is the wet
clutch technology on the compressor. The Pit Viper 235 was introduced to the New Acland coal mine in February, 2012.

Blasthole Drilling in Open Pit Mining 155

 The fuel cost killer of Queensland
Nigel De Veth, owner of DDQ, is delighted with the fuel savings and other advantages of the Pit Viper 235.
Push-button economy
The hydraulically operated patent-
pending automatic clutch is an out
standing feature of this hydraulic
tophead drive rig, which can be config
ured to perform a range of rotary and
DTH drilling operations.
With the PV-235 you dont get air
unless you ask for air, so if you want air
for drilling, you press the button and
the clutch engages and the compressor
throws in. So the compressor is only
ever used when you want it, explains
De Veth.
He continues: Atlas Copco has
replaced all the rod greasers and air
greasers, etc, with electric pumps
so they are not reliant on air. Theres
nothing on the machine that relies on
air other than your drill bit.
DDQ has been operating at the New
Acland coal mine for about four years
and introduced the PV-235 there in
February 2012, drilling mainly 229 mm
blastholes to a depth of 50 m.
156 Blasthole Drilling in Open Pit Mining
The best that weve drilled so far is
close to 1,200 meters in 10 hours and I
think theres much better to come yet,
says De Veth. The guys have only just
finished getting used to it and things
are starting to happen. Were probably
looking at 10 meters an hour more with
this machine.
Key to the efficient operation of the
compressor and other functions of the
high-tech rig is the Atlas Copco Rig
Control System (RCS). This system
also facilitates wireless remote tram
ming, auto-levelling, auto-drilling,
remote reporting functions and GPS
navigation.
Other factors underpinning De
Veths confidence in the Pit Viper
includes the single-pass drilling capa
bility. Just the advantage of being able
to drill a 12.2 m clean, single hole with
the lead rod has been very advanta
geous to us with some of the interbur
den shots, he says. The new breakout
system on the machine is unbelievable
it is better than anything weve seen
before. The drill is just a lot quicker
and smoother to operate.
But theres also another important
benefit, De Veth says. The operators
dont get tired. Everything is easy and
accessible from the seat so you come
out of the drill still fresh and alert. And
thats a big thing on the night shift.
Besides the PV-235, the drill fleet
consists of two DM25 rigs and one
DML HP. Two bigger PV-275 units are
on order for delivery in 2013.
Atlas Copco has supplied more than
a dozen Pit Viper rigs to customers
in Queensland, all equipped with the
computerised RCS automation tech-
nology.
Acknowledgements
This article first appeared in Atlas Copco
Mining & Construction No. 2 2012.
 Russia, Kuznetsk Basin, Siberia,

Boosting Siberian energy

Standfirst
Economic growth in southern Si-
beria is increasing year-on-year
and at the Kuznetsk Basin coal
field, new mining enterprises are
appearing and existing operations
are introducing the latest equip-
ment to boost their productivity.

The DML expectance

The Kuznetsk Basin (Kuzbass) is well
known for its huge coal resources, half
of which, some 693 million tons, are
coking coals, the main commercial fuel
for smelting iron. Today, more than 100
underground coal mines and open pits
are in production with, 17 coal clean-
ing plants producing different grades.
Annual production of power station and
coking coals is some 1.5 billion tons.
Drill-and-blast contractor Azot-
Cher nigovets Ltd. offers blasted
material preparation for the open pit
Chernigovsky mine with an annual
production of some 6 Mt.
In our f leet there are only for-
eign rotary blasthole drill rigs, says
Vladimir Bornev, site supervisor.
We drill blocks with five rigs, three
of which are Atlas Copco DML rotary
blasthole rigs.
The plan for 2007 was to achieve
1.1 million drillmeters and by the 11th
month, the company was well on track
to meeting this goal. Comparing the
DML rigs, the most popular in Kuzbass,
with their domestically manufactured
counterparts, Bornev says that the Atlas
Copco rigs are very productive and
maneuverable, with the powerful diesel
engine and compressor productivity
among the main benefits. Local rigs
achieve a maximum of 10,00011,000
drillmeters per month, while the plan
for our DML is 20,00022,000 drill-
meters per month, he says. In fact,
one of our drill rigs has broken all
records at the mine; in August it drilled
30,500 meters. The DML rigs are built
much better, quality-wise, and the
design is more sound and reliable.
The successful Azot-Chernigovets team at the Chernigovsky open pit: (From left) Vladimir Klimov, operator,
Oleg Grebenshikov, operator assistant; Dmitry Kuznetsov, foreman; Vadim Khlebunov, deputy chief
engineer; Vladimir Bornev, drill site supervisor; Victor Yarkov, operator and team leader; with
Yury Dolgov of Atlas Copco.
Victor Yarkov, operator of the record-
breaking DML, says, The cabin is well
insulated, with good visibility and ope-
rating lights. Also, the control levers
are comfortably located. Yarkov has
worked here for almost 20 years and
says good teamwork also contributes
to the successful drilling.
At Chernigovsky, tricone drill bits
are used for the 203 mm and 270 mm
blastholes with 9-meter pipes to depths
of 5-15 meter. The performance of the
rotary head is 100 rpm at 10.575 Nm and
the compressor capacity is 34 m3/min at
758 kPa.
Water in the coal beds is about
50 percent, and in some sectors even
more, says Vadim Khlebunov, deputy
chief engineer of Azot-Chernigovets.
This, combined with fissuring, often
makes drilling and blasting a problem.
However, the rig performance is excel-
lent and if you follow the manufac-
turers recommendations, there will be
no problems at all.
The contractor produces and uses
two types of emulsion explosives for
dry and wet holes. We provide a com-
plete technology process, comments
Khlebunov. We sell fully prepared
cubes of rock mass and run operations
both at Chernigovsky and at a number
of other open pits. The set task per
shift for the DML is 400-500 drill-
meters, so it achieves 800-900 drill-
meters per day over two shifts. Says
Khlebunov, We hold a record of 1,300
drillmeters per day. Our success is
the result of co-ordinated efforts by
all those involved. We want to prove
what the drill rig and the enterprise is
capable of.
Bachatsky open pit
At the Bachatsky open pit, owned by
Kuzbassrazrezugol, the average thick-
ness of the coal seams is 32 meters. Here,
too, the main goal is to increase pro-
ductivity at minimal cost. The rig fleet
has been completely renewed; the pre-
vious 14 electric drill rigs have been
replaced with four diesel and two
electric rigs. Two DM-M2 and two Pit
Viper 271 rigs are in use and the miners
are happy with the equipment.
Alexander Bogatiriov, deputy tech-
nical director, says, Though the rigs
belong to different classes, I think they
are equal in terms of productivity. Ope-
rators hold the same opinion; the
DM-M2 is not second to the Pit Viper.

Blasthole Drilling in Open Pit Mining 157

 Boosting siberian energy

Competition between the rig operators

produces such great results with the
DM-M2 as 30,600 drillmeters per
month and with the PV-271 37,000 drill-
meters per month, which can be com-
pared with a performance of some
8,000 drillmeters per month for the
conventional Russian drill rigs.

Single-pass capability
The first drill rig was commissioned
in 2004 and was the second such drill
rig in Kuzbass. To increase productiv-
ity, the management decided it wanted
single-pass drill rigs and the Pit Viper
proved to be the ideal choice. We have
practically reached the maximum theo-
retical productivity capabilities of the
rigs, says Bogatiriov. As for mainte-
nance, we observe Atlas Copco factory
recommendations. Earlier, the lifetime
of the locally manufactured machines
was five to seven years, but with the new
machines, we expect 10 to 12 years.
Atlas Copcos local distributor, Mi-
ning Solutions, is responsible for staff
training and maintenance of the rigs.
Engineer Vladislav Grebnev, deputy
general director, says, We have had
people on this site from the start, work-
ing hand-in-hand with the customer to
steadily boost the productivity of the
equipment.
The operators traditionally believe
that productivity increases depend so-
lely on torque. Pulldown force was not
taken into account. We worked together
as a team and the rigs started achieving
18,500 meters per month. That was the
start of the productivity increase.
The company provides three types
of service contracts: a complete serv-
ice, including night duty; setting up,
diagnostics, parameter monitoring; and
emergency call-out. Today, 40 units of
Atlas Copco equipment are covered by
the service contracts and practically
all customers extending their contracts
choose the full-service option. Service
contracts are applicable to all rotary drill
rigs including DML, DM45, DM-M2
and Pit Viper 271s in the region.

Acknowledgements
A winters day at the Bachatsky open pit: The Atlas Copco drill rigs DM-M2 and Pit Viper 271 help This article first appeared in Atlas Copco
to produce coal for both the domestic and international markets. Mining & Construction No. 1 2008

158 Blasthole Drilling in Open Pit Mining

 USA, powder river basin, Wyoming

Hidden treasure beneath

America's western prairie
Multi-pass drills
meet demand
Much of the world relies on coal
for electricity generation. This is
especially true in the United
States, where coal is responsible
for over 50 percent of the power
produced. To meet this need, over
1 billion tons of coal is mined on an
annual basis. The proven DM-M3
and now the PV-275 are the drills
of choice in large scale mining ope-
rations in Wyoming. These robust
drills, with their ability to drill large
deep holes at an angle, have be-
come the standard in the Powder
River Basin.

Powder River Basin

Under the rolling grasslands of north-
east Wyoming, massive seams of low-
sulfur, sub-bituminous coal are mined
on a scale unmatched anywhere on earth.
The Powder River Basin (PRB) is home
to 13 major open-pit coal mines, all of
which would be considered large in
their own right. Combined, these mines
tallied 451 million short tons (410 mil-
lion metric tons) of coal production in
2008. Individually, the PRB is home to
the 10 largest coal mines in the United
States, and quite possibly the five larg-
est in the world. Two mines, Peabody
Energys North Antelope/Rochelle
Mine and Arch Coals Black Thunder
Mine, each produced over 88 million
short tons (80 million metric tons) in Massive amounts of overburden - up to 300 ft (91 m) - are removed to reach the seams of coal that can
2008. exceed 80 ft (24 m) thick. Powder River Basin coal is treasured because of its low sulfur content.
The key to the success of these mines
is the thick coal seams, which can ex- high coal production, an enormous primary stripping tool. Draglines are
ceed 80 feet (24 meters) high. While the amount of overburden must be moved. very cost-efficient earthmovers as they
geology may seem very favorable, strip utilize massive buckets (up to 160 cubic
ratios continue to increase as mining Dragline operations yards, or 122 cubic meters), and deposit
progresses. Many of the mines now their material directly without need for
average 3 cubic yards of waste to 1 ton When moving this amount of material, haulage units or conveyors. Unlike a
of coal. This translates to overburden mines turn to the lowest cost equipment shovel or loader, which has a limited
cover in excess of 300 feet (91 meters) available. Many of the PRB mines uti- digging height that dictates the bench
in many areas. Therefore, to meet the lize large walking draglines as their height (usually less than 60 feet, or

Blasthole Drilling in Open Pit Mining 159

 Hidden treasure beneath America's western prairie

Draglines are effective earthmovers, removing overburden and depositing directly into spoil piles as shown here. In the foreground, casted material can be seen
filling the empty pit, while dozers work to build a dragline bench.

18.3 meters), a dragline is capable of

deep digging depths beyond 100 feet
(30.5 meters).
While the dragline is a very effective
earthmover, the overall cost of over-
burden removal can be reduced through
cast blasting. Cast blasting is a method
of drilling and blasting that uses high
explosive energy to throw a sizeable
portion of the bank into the adjacent
empty pit where the coal was previously
removed. This method often results in
casting 30 percent or more of the bank
overburden material to its final resting
place, known as the effective cast or
cast to final.
As dragline operations require a flat
bench, large track dozers with special
wide blades (sometimes referred to as
carrydozers) push the cast material
down and build a bench at a set height
above the coal seam. The dragline will
A dragline digs on the spoil side of the pit. Draglines move in small steps via a cam-type walking mechanism. then uncover the coal seam. This mining

160 Blasthole Drilling in Open Pit Mining

 Hidden treasure beneath America's western prairie

method allows for the excavating of a

large vertical block of material ranging
from 100 feet (30.5 meters) to 200 feet
(61.0 meters) or more in depth, com-
pared to the 50-foot to 60-foot (15.2 to 18.3
meter) vertical benches taken by truck/
shovel methods. A challenge of the drag-
line method is maintaining stability of
the face (known as the highwall) after
excavation, especially when water is
present in the material.
Drilling for cast blasting applications
generally involves deep depths (up to
235 feet or 71.6 meters), large diameters
(up to 12 1/4 inches, or 311 mm) and
angles up to 30 degrees from vertical.
Large diameters result in wider drill
patterns, reducing the number of holes
drilled. Because of the size of the drag- Drilling at an angle then blasting the bank into the adjacent empty pit results in casting 30 percent or more
line buckets, large fragmentation size of the bank overburden material.
from the blast is not a concern. How-
ever, some operations have found that important to remember that the drilling material is so soft that tricone bits are
smaller diameters such as 11 1/4 inches depth increases as the angle increases. rarely used. Instead, aggressive claw-
(286 mm) yield better blasting results For example, if mining a 200-foot type bits are the standard. Contrary to
with the tighter spacing. (61.0 meter) bench, the drilling depth the general belief that soft material calls
Deep blasthole drilling has its chal- at 30 degrees would be 231 feet (70.4 for as high a rotation speed as possible,
lenges. Foremost is the amount of cut- meters). these claw bits rotate at lower RPM (100
tings generated by the large diameter, Some mining regions are fortunate or less), but their design allows them
deep holes. A 12 1/4-inch (311 mm) hole to have soft material, which yields ex- to shear through the material at rates
to 200 feet (61.0 meters), assuming a tremely fast drilling rates and less wear exceeding 1,000 feet/hour (305 meters/
swell factor of 30 percent, would yield on buckets, tires and truck beds. The hour).
7.9 cubic yards (6.0 cubic meters) of PRB is in this class, with much of the To handle the high penetration rates,
cuttings. This is a very large pile that material having a compressive strength large air compressors must be used. This
smaller drills simply cannot contain of less than 5,000 psi (34 MPa). The is especially true in the PRB as these
under their dust hoods. Even though a
small unit might have sufficient pull-
down, rotary torque and air to drill
a hole, it wouldn't be effective due to ex-
cess cuttings falling back down the hole
after the hood area is filled.
Most of the drilling for dragline ope-
rations is done at angles between 20
and 30 degrees. The angle drilling
serves two purposes. First, the angle
can be set to roughly the same angle as
the desired highwall. This is done to
help keep a consistent face-row burden
to improve the effectiveness of the cast
shot. In simple terms, the burden at the
top of the highwall (the crest) should be
similar to the burden at the bottom of
the highwall (the toe). Second, angle
drilling can help shape the direction
of the cast shot. As the blast projects
perpendicularly from the bore hole, an
angled hole gives a vertical component
to the blast, helping lift the mate-
rial and therefore throw it further. It is Drillers on the DM-M3 appreciate the clear view of the breakout wrench and easy access to controls.

Blasthole Drilling in Open Pit Mining 161

 Hidden treasure beneath America's western prairie
Good highwalls are a result of proper drilling and blasting and bench preparation. The dragline seen here is using
the spoil side stripping method as this pit nears completion.
drills often use smaller diameter drill
rods to increase the annular area (the
gap between the wall of the hole and
the drill rod) to allow the larger cuttings
generated by the claw bit to exit the hole
without having to be reground to a
smaller size. High volume compressors
of up to 2,600 cubic feet per minute are
used, and it is important to have suffi-
cient air pressure (100 psi, or 6.8 bar, or
more) available to prevent plugging bits.
Because of the light weight of the over-
burden (approximately 3,000 pounds
per cubic yard, or 1.04 tons per cubic
meter), bailing velocities may dip below
the 5,000 feet per minute (1,524 meters
per minute) recommendation that the
industry would normally prescribe, yet
still effectively clean the hole.
162 Blasthole Drilling in Open Pit Mining
Building drills for the PRB
Atlas Copcos DM-M3 and Pit Viper
275 (PV-275) are ideal for coal mining in
the Powder River Basin and the DM-M3
was, in fact, first designed for mining
the overburden in the PRB. Jon Torpy,
a regional manager for Atlas Copco,
said, The DM-M3 is in a class of its
own with the right balance of air, rotary
head performance, bit load, and depth
capacity. The PV-275 has taken these
strengths and added to them. The DM-M3
was designed to drill the Powder River
overburden so it can drill the deep angle
holes required to reach the coal.
Walt Schroeder is a product support
sales representative for Atlas Copco,
but prior to working for Atlas Copco,
The 235-ft drill depth of the DM-M3 allows the
dragline access to the deep coal in one blast. The
DM-M3 can drill at an angle of 30 degrees, which
maintains the angle of the highwall and helps
shape the direction for the cast shot.
Schroeder was a driller. He has operated
many drills including seven years on a
DM-M3. Schroeder said, I have never
had a bad word to say about the DM-M3
and its always the truth. Ask anyone
who has operated one. There is no other
drill that can mast over to 30 degrees
and drill 240 feet all day, every day
and never even grunt!
Schroeder added, When this rig was
designed there were definitely miners
involved. There isnt a more comfort-
able rig to operate; they got it right when
they engineered this rig. Id say this is
the most ergonomic drill on the planet
and Ive never run a rig that I like more.
Schroeders confidence speaks to
durability, too. Availability is critical
according to Schroeder. There is not
a drill made that has the air, power and
overall drilling performance at this
depth and angle that can match the av-
ailability of the DM-M3. I know guys
you wouldnt let operate your lawnmo-
wer who are drilling with the DM-M3
this rig is tough!
Acknowledgements
Story and pictures by Brian Fox and Scott
Ellenbecker. Portions of this article first
appeared in Mining & Construction USA,
No. 1, 2009.
 USA, gilette, wyoming

Finding a perfect balance

Dry Fork balances
ecology and mining
As one of the newest coal-fired po-
wer plants in the nation, Dry Fork
Station is a testament to how
nature and progress can coexist.
In fact, technological advances in
drilling equipment, coupled with
ecology-conscious coal-mining
management, ensure that a re-
sponsible and mutually beneficial
relationship between all stake-
holders will continue well into
the future.

Award-winning mining
operation
Dry Fork Mine is a surface coal mine
located in the Powder River Basin
approximately seven miles northeast
of Gillette, Wyoming, on Garner Lake
Road. Constructed in 1989, commer-
cial operation began in 1990. Approx-
imately 70 employees work in the mine,
which is well known for its safety and
environmental achievements. In 2009
the mine celebrated having gone nearly
seven consecutive years without a lost
time injury, and it recently received
three prestigious environmental aw-
ards, including the Office of Surface
Mining (OSM) Excellence in Surface
Mining Award; the Wyoming Game,
Fish Industry Reclamation and Wildlife
Stewardship Award; and an Excellence
in Surface Coal Mining from the
Wyoming Department of Land Quality.
Wester n FuelsWyoming, Inc.
(WFW) is owned by a collective of co-
operative power companies. The mine
primarily supplies coal to the utilities
associated with those rural coopera-
tives. Dry Fork is an industry showcase
representing how mining, energy pro-
duction and nature can realize sustain-
able success. Dry Fork balances mining
operations with conservation practices.
The mines 24/7 operation produces
an estimated 5 to 6 million tons of
coal annually, of which 1.5 to 2 million
The mine has won several prestigious environmental awards for achievements. Reclamation at the award
willing property includes returning the land back to its original contour and elevation. Wildlife is abundant
in the area. A herd of dear graze in the distance at the edge of the newly scalped landscape.
tons will be used in the new Dry Fork
Station, a 385 megawatt power plant lo-
cated adjacent to the mine.
The Dry Fork Mine is a truck and
loader operation with Le Tourneau
1850 and 1400 loaders and Cat 793D
240 ton and 789B 190 ton haul trucks.
The drilling is done with a new Atlas
Copco DML blasthole rig with the
new Atlas Copco Secoroc Grizzly Paw
10 inch (270 mm) bit. In the past, the
mine drilled 9 inch (229 mm) holes with
an older rig, but with the new DML
they were able to increase hole size,
which allowed them to expand their
pattern by nearly 30 percent.
As good as new
Every element is part of the mines rec-
lamation plan. Animals, trees, surface
rocks it is all documented in the per-
mitting process. Director of Regulatory
Affairs Beth Goodnough is the keeper
of the permit. Its a constantly evol-
ving permit. Currently its 25 volumes
long and growing.
Goodnough sited specifics to the re-
mediation plan: We make efforts to
replace wildlife microhabitat impacted
by mining by replacing shrubs, build-
ing rock piles, planting trees and bu-
shes, and installing rock and bluff type
ledges in the reclamation. The permit
requires us to restore one shrub per
square meter on 20 percent of the rec-
lamation.
The seed mixes are rather complica-
ted and include the Wyoming big sage-
brush, silver sagebrush and a variety of
native grasses and forbs. The mixes are
tailored to grassland areas, wetlands,
bottomlands, shrub patches and mixed
sagebrush/grassland post mine areas.
To support habitat, rock outcrops are
also replaced where the integrity of the
rock makes it possible. Another recently
constructed feature is a 4 acre alluvial
valley floor that was recreated in a re-
claimed area to look similar to the one
that had been present prior to mining. In
another area, the mine has succeeded
in establishing a wetlands channel and
has three restored wetlands ponds. In

Blasthole Drilling in Open Pit Mining 163

 Finding a Perfect Balance
This DML drill rig uses the new Secoroc Grizzly Paw bit to drill through coal and overburden. The coal is
drilled at a 20 degree angle.
addition to reclamation, all climate and
sub terrestrial elements are examined
and monitored. Wetlands, hydrology,
air quality, climatology, archeology,
wildlife everything is monitored,
documented and reported monthly or
annually. I see different in-spectors
once or twice a month, federal and state,
we have a variety of folks with differ-
ent focuses watching what we do, said
Goodnough.
As for how close reclamation efforts
are to pre-mining conditions, Good-
nough said, Were trying to do in 10
years what it took nature hundreds of
years of evolution to accomplish. In
total the mine manages approximately
10,000 acres (40.5 km2) of land. Of the
mined area, nearly 20 percent of what
has been disturbed has been reclaimed to
what it was, before any mining activity.
Goodnough said the goal is to re-
store disturbed land right behind mined
land. We want a one to one ratio as
we go forward an acre reclaimed for
an acre disturbed. Dry Fork isnt alone
in its efforts to keep the Powder River
Basin sustainable. The region is known
for following thorough reclamation pro-
cesses.
164 Blasthole Drilling in Open Pit Mining
The right machine
The DML is a new drill for Dry Fork,
but drill operator Mark Lindsey said,
It didnt take but a couple weeks to get
comfortable with the controls. I like the
carousel system: its very user friendly.
There are good safety features on this
rig, too, keeping you from screwing up.
Lindsey thinks the drill has lots of
air power and drills fast overall. The
DML is outfitted with a 1900 cfm air
compressor.
As for the technology factor Lindsey
said, I wasnt too sure Id like the drop
GPS, but now Im spoiled because the
depth is always right on the money.
Now I really like it.
Mine Superintendent John Barnes
said, Its an advantage with the lar-
ger diameter hole because we dont
have to shoot daily. He likes that the
driller, Mark Lindsey, can be doing
other things and they can stay ahead.
Each blast usually requires 35 to 40
holes. When overburden is less than
Deeper than 30 feet and they drill on
a 60-feet (18 m) deep, 20-degree angle.
The overburden is generally 60 feet
deep. He said, The Grizzly Paw bit
performs well when drilling through
rock. The drills penetration rate is typi-
cally around 25 to 32 feet per minute
(7 to 10 m/min).
Dry Fork is toward the north end
of the Powder River Basin producing
higher moisture, low sulfur, sub-bitu-
minous coal at 8,000 to 8,200 btu per
pound. The mine has two pits with coal
of different properties, which allows
the mine to mix loads to a power plants
specifications.
Coal depth is a varying factor in the
Powder River Basin coal region. This
makes reclamation a bit more difficult
too. Barnes said, We map everything
to ensure post-mining contours coin-
cide with pre-mining elevations. This
includes setting topsoil aside during
initial excavation so it can be replaced
after reclamation. Basically the reclai-
med land will look just like it does
before, just lower because the coal has
been removed.
The coal in this part of the Powder
River Basin exists in two layers. Barnes
said, The coal deposits came in two
events. The mineable Anderson layer
is on top, which is about 18 feet (5.5 m)
thick and the lower Canyon deposit
is generally 55 feet (16.7 m). A sedi-
mentary stratum about 6 feet (2 m)
thick separates the two coal seams.
When drilling in coal, Lindsey said,
The Grizzly bit drills like a hot knife
in butter and its easy drilling. It wont
plug up either. When drill hole depths
allow, both overburden and coal are
drilled in a staggered pattern at a 20
degree angle.
To be successful here, a mine has to
employ efficient and intelligent people
and equipment. Getting the coal is
just one part of a process that ends in
reclaimed land.
Acknowledgements
This article first appeared in Atlas
Copco Mining & Construction maga-
zine No 3 2010. Story and photos
by Scott Ellenbecker, Ellenbecker
Communications.

Moving mountains
Virginia Drilling now has over 50 Atlas Copco drill rigs in its fleet.
A focus on the
coal industry
In the southern Appalachian range
of West Virginia, Kentucky, and
Virginia, known as the Blue Ridge
Mountains, the seam of coal flows
through the ground at varying
depths, sometimes just at the
base of the mountain. To get the
coal Virginia Drilling Company
works with their coal company
partners to shave off the moun-
tains one 30-ft to 40-ft lift at a
time. Virginia Drillings business
philosophy has developed over
time but has remained simple,
says said founding partner and
company president Verlo Stiltner.
We grow the business by focus-
ing on what you do best and sur-
round yourself with experts.
Blasthole Drilling in Open Pit Mining 165
Virginia drilling
In 1998, partners Verlo Stiltner, David
Hale and Mike Sheets started the
contract drilling company Virginia
Drilling to diversify the existing blast-
ing business, Austin Sales, owned by
Hale and Stiltner.
The company began as a contract
driller on construction applications with
Ingersoll-Rand ECM 490 and ECM
690 crawler rigs. Today the company
has grown to include 28 Atlas Copco
DM45s, nine Atlas Copco DMLs and
seven Atlas Copco crawler drills in
various sizes, including one ECM 490
and one ECM 470 and two ECM 690s
and three ECM 720s.
Virginia Drilling is the largest, if
not the only, contract driller in the world
focused primarily on the coal industry.
Even the smaller construction crawler
USA, Vansant, virginia
drills are dedicated to road, reclama-
tion and underground mine face-ups to
a point that 85 percent to 90 percent of
the work is for the coal mining com-
panies.
Two years ago, the companys co-
founder David Hale passed away, but
the business has continued to grow with
strong leadership and committed em-
ployees. Today the company has 18
drills on order and has a steady business
growth plan slated for years to come.
Getting started
Because of the existing blasting busi-
ness, Virginia Drilling knew everyone
in the area. Founding partner and con-
struction drilling manager Mike Sheets
summed it up, the coal industry in the
region is a real fraternity. Just over a
year after starting the business, which
 Moving Mountains

until that time had focused on construc-

tion projects, Virginia Drilling partners
were approached by a coal company
who knew their blasting expertise and
asked them to drill in the coal field.
The premise was to not waste blast-
ing material on the bench, to work effi-
ciently and maximize outside resources.
The goal was to get costs below indus-
try average and have higher drill uti-
lization.

Partner responsibilities
From the beginning Virginia Drillings
partners accepted that they were not
drill experts. Admittedly, Virginia Drill-
ing Chief Operating Officer Clinton
Evans pointed out they had lots to learn
and wanted to work closely with drill
dealer Brandeis Equipment to develop
a maintenance program.
When choosing a drill it was really
a no-brainer, said Evans. They went
with Atlas Copco because if its prod-
uct reputation, but also they needed a
strong dealer that would support every
aspect of the drill including parts and
support.
According to Brandeis branch ma-
nager, Barry Justice, 40 percent of their
parts inventory is for Atlas Copco Drills.
If the drills dont run, the whole mi-
ning process stops, said Justice.
Brandeis has 19 service trucks in the
field, running its parts department on
a double shift and supplying 24/7 ser-
vice to Virginia Drilling. All that atten-
tion equates to a higher performance
on the drills. The oldest drill in the fleet
is a 1999 DML with 22,000 hours. Typi-
cally on a mine site the cost of drilling
equipment is approximately 5 percent
to 10 percent of the total expenditures.
This is another reason why some mining
companies dont focus on their drilling.
Virginia Drilling knows that the ex-
cavation equipment can catch up to them
but cant pass them.
Atlas Copco regional sales manager
Tom Borer said, Virginia Drilling has
drills with 20,000 hours on them that
run better than drills owned by others
that have 10,000 hours.
There is no big secret here; its all in
the preventative maintenance (PM) pro-
gram. The main pumps, for example,
Two Atlas Copco DML drill rigs prepare for the next shot that will lower the bench to the coal seam. average 7,000 to 8,000 hours for most,

166 Blasthole Drilling in Open Pit Mining


Shouldering the burden for the coal companies. From left: Mike Sheets, Clinton Evans and Verlo Stiltner of Virginia Drilling.
while Virginia Drilling averages 11,000
to 12,000 hours. Its not uncommon for
Virginia Drilling to get 40 percent gre-
ater life out of their drill compo-
nents because of the PM program.
Mike Sheets said, Its all about ta-
king away problems. Brandeis takes
the burden of maintenance away from
Virginia Drilling and Virginia Drilling
takes away the burden of drilling and
blasting from the coal companies.
He emphasized that his customers
focus is to move material. They dont
want to worry about getting the shot
right or all the liability that comes with
explosives.
Sheets said, If everyone focuses on
the part of the business that makes them
money everyone wins, and if were not
drilling holes, were not making money.
To ensure they are drilling holes they
follow the PM program religiously. If a
drill is close to a scheduled PM and a
Brandeis truck is in the area, they will
perform the service rather than let it get
behind. As a contract driller for many
mining operations in the area, Virginia
Blasthole Drilling in Open Pit Mining 167
Drilling takes total responsibility for
the drilling and blasting operation. The
agreement with its customers is a win-
win for everyone.
When this part of the business began
and the deal was laid out for the custo-
mer, he didnt believe it. He told us it
seemed too good to be true, said Sheets.
They proposed a sliding scale based
on 50,000 to 1 million yards of shot
material with discounts built in for vo-
lume. Virginia Drilling guaranteed the
product amount in the customers time-
frame. They absorb most costs related
to putting the product on the ground,
from equipment to human resources to
blasting material.
When we finished making our
proposal the first response was where
do I sign, said Sheets. Today Virginia
Drillings client list is long and growing.
Training equals success
People are a critical part of making this
work. At any one time Virginia Drilling
has seven to eight drill trainees, with
Moving Mountains
that number going as high as ten. The
training program has developed over
time to what it is today, a well executed
system. For the first two weeks they
mostly watch and listen. They learn
how to set up on the bench, put the mast
up and down and terminology. They
learn by watching and listening.
We prefer they dont even come in
with experience, said Evans.
They dont want new employees to
have bad habits and to learn drilling
according to the companys operation.
After they have a couple weeks with
the best drillers they come in for class-
room work. They learn down pressure,
rotation, penetration rates, bit perfor-
mance and compressor and engine ope-
ration, everything they need to know
about the drill and what its responsibil-
ity is for drilling the hole.
Then the trainees go back in the field
with the experienced driller again to
apply the classroom work. Every month
drillers are evaluated to make sure they
are getting optimum production,
maximum penetration and bit life
 Moving Mountains
Blasting off the top benching down to the coal that can be seen at the base of the mountain.
and overall efficiency. But, all the as-
pects of training come right back to
keeping the drill working at its maxi-
mum performance rate.
We expect to get 30,000 hours from
our drills, said Evans.
The drillers have to be doing their
job correctly to ensure that level of
equipment life.
168 Blasthole Drilling in Open Pit Mining
Performance for results
Drill performance also factors into how
Virginia Drilling bids a job. Every-
thing is evaluated when looking at the
cost per foot, said Sheets. Because we
look at all aspects of the drilling and
blasting process, we know how to find
our efficiencies.
One drill site may run into five dif-
ferent layers of sandstone in a mine.
Laminated charts plot out the geology
of the mine. The goal is to get the maxi-
mum penetration in relation to the time
in the hole.
The bit is an integral part of the ope-
ration, said Evans. Bits give you the
data as to how the drill is performing.
Weight and rotation is applied to the bit
according to the situation. In this area a
driller may expect to get a penetration
rate of 6 feet a minute at 165 rpm and
15,000 lbs.
Although bits have an optimum ro-
tation rate its only half the equation.
We are not willing to sacrifice a drill
to drill faster, said Clinton Evans. Vir-
ginia Drilling looks to maximizing the
relationship of down pressure to rota-
tion rpm to ensure the life of the drill.
Using 7 -inch to 9-inch bits on
its DMLs and 6 -inch to 7 -inch
bits on its DM45s, operating between
2,500 to 4,000 hours a year, Virginia
Drilling projects 2 million yards of
rock a month. It is expected that each
drill is responsible for 500,000 yards.
The DMLs are equipped with 6 -inch
x 30-ft pipe, while the DM45s run 5
-inch x 30-ft pipe.
Virginia Drilling can move drills if
needed, and to meet the required ton-
nage they will run three to four drills
per site at one time with a maximum
of five.
Evans prefers the DML because it is
beefier from the frame up, but the per-
formance and hole sizes dictate what
drills will be used. It goes back to
blasting try to make the pattern smal-
ler but get the most value from the caps,
primers and explosives.
Generally, hole spacing is on an 18-ft
x 18-ft pattern. The 7 -inch hole can
support 16-ft to 18-ft spacing, while
the 9-inch hole can do a 19-ft to 21-ft
spacing. Virginia uses a 70/30 ANFO
emulsion blend as an explosive.
Acknowledgements
This article first appeared in Atlas
Copco Mining & Construction maga-
zine No 2 2008. Story and pictures
by Scott Ellenbecker, Ellenbecker
Communications.

Cost busting
Ron Johnson, Atlas Copco Regional Sales Manager for Eastern U.S. coal region, and driller, Kevin Maggard.
Controlling drill
pipe erosion
keeps drill steel
costs down
Sixteen-year veteran driller Kevin
Maggard proudly lis ted sev-
eral reasons he rates his tenure
with James River Coal Service
Company (JRCSC) so highly. At
the top of his list is the way they
keep their equipment up. Their
maintenance program is second
to none, he said. One look inside
Maggards blasthole rig cabin
leaves no doubt that he cares
about his equipment. He keeps it
so clean it looks brand new.
Maggard is also proud of his current
role in the companys field testing of
Atlas Copco Secoroc Teamalloy
drill steel to bring drill steel cost per
hour at JRCSCs Montgomery mine
back down. Regulations two years ago
caused changes in the mines blasting
plan that took its mild steel drill pipe
Blasthole Drilling in Open Pit Mining 169
from 400 hours of life down to just
130. Operations such as this in eastern
Kentucky have limited their blasthole
diameter to 6 inches and brought
their blast pattern in from 18 by 18 to
16 by 16 feet.
Reducing bit size, however, com-
pletely reconfigured a highly produc-
tive drilling formula that had evolved
over years of careful engineering and
practical experience with these drills in
this mines ground conditions. In effect,
maintaining regulatory compliance
doubled and in some instances tripled
the drill steel cost per hour drilled.
So JRCSC has been working with
Atlas Copco to come up with a solu-
tion to get drill steel cost per foot
drilled back down to reasonable levels.
Maggard has been central to the team
effort, which uses his rig and his drill-
ing skills as their test bed.
Because drill pipe can run so long
between changes, JRCSC finds it best
to calculate the drill steel cost per
hour by dividing the total cost of the
drill pipe by the total air compressor
hours logged between installing the
USA, london, kentucky
pipe and removing it. This gives them
a reliable and simple basis on which to
make a comparison.
Less costs more
The cost increase affects JRCSC across
its entire drill fleet, which represents
a variety of manufacturers. When the
large blasthole crawlers were drilling
with 7 -inch rotary bits on 5 -inch
mild steel drill pipe, bailing velocity
(BV) was almost ideal at 6,000 feet per
minute (fpm). Glenn Sharpe, JRCSC
drill mechanic in the Montgomery
mine, said, The drill made little vol-
canoes at the hole made of chips the
size of your fingernail.
Sharpe explained that putting 6 -
inch bits on the same 5 -inch pipe
decreased the annulus so much that
it doubled the BV to 12,000 fpm. The
increased velocity mashed the sand-
stone into grit that scoured the mild
steel drill pipes so aggressively they
lasted only one-third of their normal
life compared to when they were used
to make 7 -inch holes.
 Cost Busting

Above: Driller Kevin Maggard pointed out that by resisting erosion, TEAMALLOY drill steel maintains its stiffness, spinning true with less vibration. This increases bit life
and prevents premature bearing failure. (Top right) Ron Johnson compares bearing play of a bit used before drilling with TEAMALLOY against a new bit to show how
the cost of mild steel was more than just replacing pipe. (Bottom right) Johnson indicates how little the steel has worn after nearly 400 hours of use, maintaining its
relationship to the deck bushing. Mild steel did not often last more than 130 hours in the same conditions.

Their tricone bits also suffered in
these holes, their inserts shearing in
half in the various sandstones of the
Montgomery site.
But the rate at which drill steel wore
down posed a new problem. The gap
that quickly widened between the steel
and the deck bushing gave dust an
escape-way. There was a risk it would
not be captured effectively by the rigs
dust control vacuum. To operate a rig
with uncontrolled dust would put the
mine in jeopardy of violating dust
level limits. So the mine had to switch
drill steel out frequently to keep that
gap tight. The result was that JRCSCs
rigs were now going through drill steel
three times faster than before.
The solutions
Sharpe complimented Maggards skill
as a driller. While Sharpe has seen
some drillers go through a top sub in as
little as six months, he said Maggards
drill string is still topped by the origi-
nal, 6-year-old top sub. It is a certainty
that JRCSC isnt seeing drill steel cost
rise from operator fault or poor drill-
ing technique. Its solely the physics
involved in a change of bit size. Ron
Johnson, Atlas Copcos Regional Sales
Manager for the 11-state eastern U.S.
coal region, performed a complete drill
audit, which included an air compressor
capacity test. This audit showed that
there was much more air than required
for adequate bailing, due to the smaller
annular area.
One solution was to decrease drill
steel diameter, so they replaced the
5 -inch steel with 5-inch. But this
created its own problems. The 5-inch
drill steel was not as rigid. Its flexing
caused drill string vibration and chat-
ter. Inefficient drilling will also tend to
shorten tool life.
Sharpe then addressed the air issue.
Rather than choke the compres-
sor intake to reduce the volume, they
not only regulated it down but vented
excess volume up the mast to decrease
air volume in the hole. As finely tuned
as they could get it, the sandstone still
rapidly eroded their drill steel.
Teamalloy
Thats when Johnson suggested Team-
alloy drill steel. Almost every coal
company in the eastern U.S. would be
keenly interested if Teamalloy were to
work for JRCSC. So far it has. While
mild steel lasted only 130 hours, the
Teamalloy drill steel was indistingui-
shable from new at 300 hours. Ap-
proaching 400 hours, the steel was
starting to show only minimal wear.
The wear was controlled and predict-
able, showing the embedded alloy wear
strips slightly more prominently than
when new. Johnson predicted they
would likely see 500 hours before they
changed it out.
Maggard said that while drilling he
could sense that the Teamalloy pipe
offered greater stabilization and perfect
rotation.
It would seem that JRCSC has found
a successful formula once again. Dust
is down. Drill steel cost per hour is
down. Production is up. And Atlas
Copco Secorocs Teamalloy drill
steel is living up to its billing in their
Montgomery mine, the bet that it will
beat mild steel in cost per hour in any
application, anywhere, every single
time.
Acknowledgements
This article first appeared in Mining
& Construction USA No. 1, 2012,
written and photographed by Joe
Bradfield, senior writer at Ellenbecker
Communications.

170 Blasthole Drilling in Open Pit Mining


Mining in Kazakhstan
The electric-powered DML rig with hydraulic tophead drive.
drilling technology to meet productiv-
Gearing up ity targets and lower their costs.
Two such operations are Bogatyr
for growth Komir and Borly Coal that both operate
The Republic of Kazakhstan, that a mix of Atlas Copco DML and DM45
vast country south of Russia be- blasthole drill rigs. Bogatyr, located
tween the Caspian Sea and China,
in the Ekibastuz coal basin, has total
is on the move. Its infrastructure
is improving and its mining indu- reserves of 4.5 billion tonnes and pro-
stries are being reborn through duces nearly 40 percent of the countrys
new methods and modern equip- coal (46 million tonnes mined in 2008).
ment. It will take time, but the The mine has a fleet of five drill rigs
aim is clear: to become a prime on site, three DMLs and two DM45s.
example of Central Asias grow- Each DML drills around 14,000 meters
ing prosperity. Atlas Copco eq-
uipment and service is playing a
per month, while the DM45 achieves
central part in this modernization. about 20,000 meters per month. Both
types are operating on 25-meter ben-
ches. The DML rigs use 228 mm tri-
cone bits, while the DM45 uses 171 mm
Expansive coal reserves tricone bits. All of the rigs are capa-
ble of producing more drill-meters if
Few countries have such expansive re- required.
serves of coal, oil, uranium, methane With a 7-meter burden and 5-meter
and natural gas as Kazakhstan. And in spacing, each blast consists of 400 holes
this land, characterized by vast open to produce more than 100,000 tonnes
plains, Atlas Copco drill rigs have be- of coal and 60,000 cubic meters of
come the rigs of choice among coal waste per day.
producers. Borly, located in the Karaganda re-
Beneath the surface of the Kazakh gion, produces about 7 tonnes per year
Steppe in the north of the country, there from the Molodezhniy and Kulchek
are massive coal reserves. Here, Atlas mines. It uses both DML and DM45
Copco has been working with a number rigs on 45-meter benches, drilling
of mining companies to upgrade their around 17,000 meters per month per
Blasthole Drilling in Open Pit Mining 171
Kazakhstan
rig, although the rigs have the capacity
to operate at 20,000 to 25,000 meters
per month.
The DML drills a 228 mm hole, while
the DM45 drills a 200 mm hole using
Secoroc EpsilonTM bits lasting 15,000 to
18,000 meters. Borly also has the dis-
tinction of having received the worlds
first electric DML drill rig. Meanwhile,
the recent delivery of the countrys first
Atlas Copco RD20 drill rig for oil and
gas, has paved the way for exploration
of the huge Karaganda methane field.
Rich mineral resources
Kazakhstan also has gold, copper, iron
ore and manganese open pits. Here too,
Atlas Copco drill rigs are well repre-
sented. DM45 and DML blasthole rigs
are used by Kazakhmys Copper Com-
pany and Aktobe Copper Company in
the countrys western copper region.
The multi-pass DM30 for hole diam-
eters of 127 mm to 171 mm, is the rig of
choice for Polymetals Varvarinskoye
Mine, whereas the single-pass Pit Viper
275, for hole diameters up to 270 mm,
is used by Kazzincs VasGold mine.
We have introduced blasthole drill-
ing equipment to Kazakhstan that can
increase productivity and lower oper-
ating costs, explains John Stinson,
Global Business Manager, Atlas Copco,
but it was not a straightforward task.
From the start, Atlas Copco advan-
ced new ideas into Kazakhstan. The
region traditionally used a common
hole diameter, bench height and annual
meterage using electric-powered rotary
drilling methods.
Atlas Copco converted the country
to diesel-powered hydraulic drills, as
well as high-pressure down-the-hole
(DTH) hammer drilling. Today, the
time-tested technology of DTH drilling
has proven itself at Varvarinskoye Gold
as well at the Aktobe Copper Com-
panys 50 Years October copper mine.
This change-over to DTH drilling was
not always successful initially, but with
time and cooperation, they were able to
achieve its full benefit.
 Coal and Gold Mining in Kazakhstan
On site at the Vararvarinskoye Mine, owned by OJSC Polymetal of Russia, where five Atlas Copco DM 30
rigs and one T3W are used for mining gold.
Progress in October
Production at the 50 Years October
deposit, located some 200 km from
Aktobe, started in 2006. During the
initial planning stages, they produced
a 215 mm blasthole in the overburden
through rotary drilling. Once the over-
burden was removed, they studied
DTH drilling for use on harder rock
formations.
Following these studies, the mine
selected eight Atlas Copco rigssix
DMLs and two DM45 high pressure
blasthole rigs for DTH drilling with
Secoroc QL60 and DHD 360 hammers
to drill 171 mm holes on a 12-meter
bench with a 5-meter burden and
6-meter spacing. The central pit has a
14-year life and satellite pits are under
development.
While the owner, Aktobe Copper
Company, was impressed with the pene-
tration rate, overall production levels
had not reached expectations, so the
company turned to Atlas Copco for a
way to increase the rigs productivity.
GRT, a sister company of Atlas Copcos
distributor Ken Group, an experienced
contractor, had been getting good re-
sults with rotary drilling at other cop-
per mines and wanted to duplicate that
success by employing DTH drilling at
the 50 Years October site.
The company operated a DM45HP
rig during a four-month test period. Of
172 Blasthole Drilling in Open Pit Mining
the total meters drilled the rig achieved
60 percent of the total productivity rate
of all three rigs in operation at the site.
According to Alexander Merzlikin,
Deputy General Director, Special Pro-
jects, Ken Group, there were no tech-
nical problems and the drill rigs all
achieved the same penetration rate. Ken
Group/GRT also coordinated all sup-
plies and service to keep the rigs run-
ning at maximum efficiency, including
all lubricants, drilling consumables,
parts, maintenance and repairs.
Merzlikin continues: When you ma-
nage the bench, you need to plan for
up to three months. Our success comes
from teaming experienced operators
with an equivalent service organization
and supply chain. Ken Group/GRT has
a single focus and that is to provide the
maximum meters at the lowest possible
cost.
Moving forward, Ken GroupGRT
will either expand the contract drill-
ing or offer a structured training and
drilling program for Aktobe Coppers
operators.
Developing metals
Varvarinskoye Gold Mine in Varva-
rinka was developed in the 1990s
when European Minerals conducted
exploration, followed by pit work with
overburden removal in 2006. Gold pro-
duction began in December 2007 with
copper-gold concentrate following in
March 2008.
Varvarinskoye is located on the nor-
thwestern plains close to the Russian
border. Recently acquired by OJSC
Polymetal of St. Petersburg, Russia, the
mine is a good example of the equip-
ment used for mining development in
Kazakhstan. To date, the mine has been
moving 3 tonnes per year. It operates
five Atlas Copco DM30s and one T3W
high pressure blasthole drill for DTH
drilling. Three DM30s were acquired
when the mine opened, and two more
were recently purchased, expanding the
fleet to meet ore demands.
The mine will be developed to pro-
duce 4.2 tonnes of ore per year for the
processing facility over the projected
15-year life span of the mine. Each
rig is expected to drill 20 meters per
hour to produce 10,000 drillmeters per
month. The drilling pattern consists
of a 4-meter burden with 3.5 meter
spacing (or 4.5 by 3.7 meter, depend-
ing on the rock) with a bench height
of 5 meters and sub-drilling of up to
one meter. The rigs operate at 24 bar,
each applying 55 bar of pulldown with
70-bar rotation.
The mine uses 152 mm hammers,
with the 165 mm bits averaging 1,000-
1,200 meters per bit and 10,000 meters
on the hammers before they are rebuilt.
Vladymir Sterlyagov, Mine Manager
at Varvarinskoye Gold, is satisfied
with the overall success of the DM30
blasthole rigs. One of these is nearing
12,000 hours. Sterlyagov credits drill
supervisor Pavel Bobylev for keeping
the rigs at a high rate of productivity.
It is Bobylevs working and drilling
knowledge, gained in many different
environments, that has allowed this
team to get the most out of the DM30
and make them successful.
Varvarinskoye has demonstrated the
probability for resources of 3.1 million
ounces of gold and 313 million pounds
of copper.
Acknowledgements
This article first appeared in Atlas Copco
Mining & Construction No. 1, 2010
Story and pictures by Scott Ellenbecker.

Drilling for coal in Vietnam
Within the Vietnamese mountains overlooking Ha Long Bay's karst formations lie the country's largest coal reserve.
Coal mining in
Ha Long Bay
Coal production is a vital part of
the Vietnamese economy, and
the countrys largest field has
turned to modern drilling tech-
nology to optimize productivity
and efficiency. Atlas Copco is wor-
king with many of the regions
companies, providing them drill
rigs of various sizes to meet their
specific excavation needs.
A world wonder
With its thousands of limestone karst
formations that begin in the surroun-
ding mountains and continue to the sea
where they stand out as lush, dome-
shaped islands, Ha Long Bay is rec-
ognized as one of the wonders of the
world. In those mountains that overlook
the bay lies Vietnams largest coal
reserve.
The coal region in Vietnam is cen-
tered in Cam Pha in Quang Ninh pro-
vince, one of the two towns of Ha
Blasthole Drilling in Open Pit Mining 173
Long Bay. Geographically the region
is 130 kilometers long, varying from
10 to 30 kilometers wide, or approxi-
mately 1,300 square kilometers. Reser-
ves here total 2.5 billion tonnes of
sustainable supply. Last year the re-
gions 70 or more enterprises produced
43 million tonnes, representing 90 per-
cent of the coal burned in Vietnam and
100 percent of the countrys exported
coal.
Diverse needs
Atlas Copco supplies the mines of the
region with rigs matched to the size of
their various pits. With a complete pro-
duct line offering a full range of equip-
ment, and with a staff of technicians
there onsite, Atlas Copco meets the spe-
cific needs of each of its customers.
The majority of drilling in the area
is performed by its DML and DM45
blasthole drill rigs. A variety of sur-
face crawlers, including ROC F7, ROC
F6 and ROC L7 CR COPROD drill
rigs, work in smaller operations. The
following is a look at three mines and
VIETNAM, HA LONG BAY
the drilling operations that make them
successful.
Dong Bac
Coal Exploration Enterprise-Dong Bac
Corporation produces 140,000 tonnes
of coal per year running two rigs. The
mine has operated drills from several
manufacturers but found its greatest
success with the Atlas Copco ROC L7
COPROD drill rig because of its availa-
bility. Mr. Vu Van Tan, Chief Operator
at Dong Bac, says, The Atlas Copco
drill rigs have similar penetration rates
with our other rig, but its the uptime of
the ROC L7CR that makes it the mines
most productive rig.
At this mine the ROC L7CR drills
a 165-millimeter (6 inch) hole to
depths of approximately 8 meters (26
feet). The 6-meter (20-foot) deep coal
seam rests at an angle from the surface,
which results in drilling to depths that
end at varying degrees along the coal
seam. Mr. Tan likes the size and mobil-
ity of the ROC L7 and thinks its the
best rig for this size operation.
 Drilling for coal in Vietnam
Ptam Trung Kien, Technical Manager for Nui Beo Coal Company in front of their DM45.
Nui Beo
Nui Beo Coal Company is a much lar-
ger operation working adjacent to the
Dong Bac mine. In 2009 the mine pro-
duced 5.1 million tonnes of coal using
four blasthole drills. Two of those are
Atlas Copco diesel-powered rigs.The
others are Russian-made electric mo-
dels. The mobility and faster pene-
tration of Atlas Copco DM45 and DML
blasthole rigs significantly out-drill the
competitors models.
The two Atlas Copco rigs drill 8,500
meters per month, whereas the other two
rigs drill only 3,000 meters per month.
The mines three shifts produce 22 mil-
lion tonnes of waste annually from a
pit 4 kilometers long by 1.1 kilometers
in width. The projected life extends to
the year 2015, with a new property
already planned and scheduled for
development.
Pham Trung Kien, the electro-mech-
anical department technical Engineer,
oversees the drill fleet for the mine. Of
all these drills, Kien likes the DML the
most. With its Cat engine, he thinks it
offers more power than the DM45, but
both are more productive and efficient
174 Blasthole Drilling in Open Pit Mining
Tay Nam Da Mai prefers the DML drill rig.
than other drills they have operated.
Although he has had no major problems
with his Atlas Copco drills, he likes the
fact that Atlas Copco and Caterpillar
have support people in the area to assist
if he should need them.
The DML and DM45 blasthole rigs
in the area use 230-millimeter (9-inch)
Secoroc tricone bits and 7-meter (23-
foot) rods. At Nui Beo, operations are
currently 100 meters (328 feet) below
sea level on 20-meter (60-foot) benches.
Drilling is done at an angle of 10 to 20
degrees at an incline of 5 to 10 percent.
Tay Nam Da Mai
In comparison, Tay Nam Da Mai Joint
Stock Corporation also operates the
DML, currently drilling at bench
elevations 40 meters (130 feet) above
sea level. The coal seam is about 40
meters below sea level. Benches are 16
meters (52 feet) in depth on a 6 by 5
meter pattern (16 by 20 feet), which is
common in this the area.
Measuring 1.8 kilometers long by
1.5 kilometers wide, this mine produces
1 tonne of coal for every 9 to 10 tonnes
of waste. It yielded one million tonnes
of coal last year and will produce 1.5
million tonnes this year. Here the DML
drills 5,000 to 6,000 meters per month
in the mines harder rock and 8,000 to
9,000 meters per month in the softer
formations, with another 15 years of
life at the current production rate.
Mr. Hoa, Deputy Manager Electro
Mechanical department says, I like
the durability of the Atlas Copco rigs
and their ability to drill more meters.
Because the competitive rigs have less
availability and drilling performance
is less, It takes the (competitive rig) a
year to drill the same meters the DML
will drill in three months.
Because of the variations in pit size
and desired production, the Quang
Ninh province is well served by Atlas
Copcos product line, with the DML as
a leader in the class.
Acknowledgements
This article first appeared in Atlas Copco
Mining & Construction No. 3, 2010.
Story and pictures by Scott Ellenbecker.
 DRILLING METHOD GUIDE

Blasthole Drilling in Open Pit Mining 175

 DRILLING METHOD GUIDE
Drilling method guide
Different applications and rock conditions need different kinds of drilling equipment and performance. This guide is
an attempt to start a discussion around the method and equipment that might provide the ultimate solution for an
application. Below, we compare six different drilling methods on offer from Atlas Copco.
The tophammer method
In percussive tophammer drilling the
impact energy is generated when the
piston is striking the shank adapter.
This energy is transmitted from the
rock drill via the shank adapter, drill
steel and drill bit to the rock, where it
is used for crushing. The entire
system of rock drill, drill steel, drill
bit, rotation, feed force and flushing
must harmonize for maximum
drilling economy. The tophammer
method is primarily used for drilling
in hard rock for hole diameters up to
5 inch (140 mm), and the main
advantage is the high penetration
rate in good solid rock conditions.
Handheld pneumatic rock drills are
used for small hole diameters while
rig mounted hydraulic rock drills are
commonly used for hole diameters
above 15/8 inch (41 mm). Heavy
hydraulic rock drills with an impact
power of up to 40kW are used for
large hole diameters up to 5 inch.
To maintain good drill steel economy
and hole straightness heavy extension
rods or rigid guide tubes with large
outer diamer have to be used.
Hole diameter:
7
8" - 5" (22-140 mm)
Principle: In the
simplest of terms, the
tophammer drilling
method goes back
to manually hitting
the end of a drill
steel with a sledge
hammer. As recoil
makes the rod jump
back it is rotated
to ensure that the
hole is round. In
a similar way the
impact energy of
the rock drill piston
is transmitted to the
drill bit in the form
of shock waves. Drill
cuttings are removed
from the hole bottom
by air or water
flushing.
176 Blasthole Drilling in Open Pit Mining
The COPROD system
The COPROD system combines the
speed of tophammer drilling with the
precision and long service life of the
down-the-hole method. Inside each
rigid, threaded pipe section is an
impact rod. It is furnished with stop
lugs to hold it in place inside the pipe
section. The COPROD sections are
joined together via the drill pipes.
Since the drill pipes transmit rotation
force only, stress to the threads is
minimal and their service life very
long. All negative effects of the
transmission of impact energy
through the threads are eliminated
entirely. The result is high impact
power with minimal wear. Since the
outer pipes are smooth and flush
along the entire length of the drill
string, it is almost impossible for
jamming to occur. Practical
experience with COPROD has been
exceptionally good. The method
gives good overall economy,
particularly in large scale production
drilling and when drilling in fissured
or otherwise demanding rock
conditions.
Hole diameter:
3916" - 6" (90-165 mm)
Principle: The rock
drill is situated on the
feed beam on the rig
and impact energy is
imparted from above.
Threadless impact
rods are stacked
inside the threaded
drill pipes. The
impact rods are used
solely to transmit
impact energy and
feed force, while the
drill pipes transmit
rotation. COPROD
combines the speed
of tophammer
drilling with the
hole straightness of
the down-the-hole
method.
The down-the-hole method
The down-the-hole method is a
reliable way to drill in various
formation from hard to soft,
competent to broken or abrasive to
non abrasive rock. The rock drill
piston strikes the drill bit directly,
while the hammer casing gives
straight and stable guidance of the
drill bit. This results in minimal
deviation and greater hole wall
stability, even in fissured or
otherwise demanding rock. Since the
annulus between the drill pipes and
the hole wall is comparatively small,
a high flushing velocity is main-
tained, which contributes further to
hole quality. Good hole quality
enables the burden and spacing to be
increased, which saves time and
money. Straight holes make charging
easier and enable the amount of
explosive to be reduced. The reliable
DTH method is an easy way to
produce deep, straight holes. From an
environmental point of view, the
noise emissions and vibration from
DTH drilling are comparatively low.
This is of particular advantage when
drilling in densely populated areas.
Hole diameter:
358" - 9" (90-229 mm)
Principle: The
hammer is situated
down the hole in
direct contact with the
drill bit. The hammer
piston strikes the drill
bit resulting in an
efficient transmission
of the impact energy
and insignificant po-
wer losses with the
hole depth. The
method is widely
used for drilling long
holes, not only for
blasting, but also for
water wells, shallow
gas and oil wells,
and for geo-thermal
wells. In mining it is
also developed for
sampling using the
reverse circulation
technique (RC drilling).
 DRILLING METHOD GUIDE

The Reverse circulation method
Dual tube reverse circulation (RC)
drilling is a method used for
collecting rock chips to the surface
for subsequent analysis.The air and
rock chips are then blown past the bit
and up through the centre of the
drillstring. to the surface. Normally
the air exhausts through a centrifugal
classifier so that the rock chips and
dust will be captured in a sampler. A
sample of the rock chips can be
collected in bags. The RC method is
used for mineral exploration as an
alternative to diamond core drilling.
Special RC hammers were developed
to improve the productivity and also
to reduce the degree of sample
contamination. With the RC hammer
the cost of drilling is much less than
diamond drilling and the penetration
rates are an order of magnitude
greater than diamond drills. For this
reason, may drill campaigns start
with reverse circulation drills. When
drilling deep holes, below 200 m
(660 ft) it is common to use a
booster compressor.
Rotary drilling methods
The prime difference from other
drilling methods is the absence of
percussion. Rotary cutting, using
fixed type claw or drag bits, is mainly
used for soft rock which is cut by
shearing. Rotary crushing uses tricone
bits relying on crushing and spalling
the rock. This is accomplished by
transferring downforce, known as
pulldown, to the bit while rotating in
order to drive the teeth (commonly
tungsten carbide type) into the hole
bottom as the three cones rotate
around their respective axis. The softer
the rock the higher the rotation speed.
The drill rigs need to be heavy to
provide sufficient weight on bit.
Generally, drilling below 152 mm
(6 inches) is best accomplished by
percussive drilling unless prevailing
rock conditions are suited for rotary
cutting. Rotary crushing is the prime
choice for large diameter holes, above
254 mm (10 inches) in open pit mining,
overburden stripping at coal mines,
and deep well drilling.
The PARD method
The Percussion Assisted Rotary
Drilling system combines percussive
power and rotational force. The high
frequency impacts provides signi-
ficant increases in the rate of pene-
tration (ROP), when drilling in me-
dium to hard rock. The Secoroc PARD
system consists of a high frequency,
low impact energy DTH hammer and
a specially designed tricone drill bit
that is mounted onto a standard
rotary drill and drill string. The sy-
stem is operating at the conventinal
low pressure used for rotary drilling,
50100 psi (3.57 bar). The PARD
hammer is featuring a leightweight
piston with a short stroke, and a
unique parallell air flow system,
which distributes the air propor-
tionally between the hammer and
the tricone bit.

TONS
TONS

Hole diameter: Hole diameter: Hole diameter:

41516" - 6" (125-165 mm) 434" - 16" (120-406 mm) 978" - 12" (251-311 mm)

Principle: The Principle: Principle: By com-

hammer is situated Rotation is bining a low impact
down the hole in provided by DTH hammer with the
direct contact with a hydraulic or high feed pressure and
the drill bit similar electric motor torque of rotary tricone
to the down-the- driven gearbox, drilling, a higher level
hole method. The called a rotary of energy can be pro-
difference compared head that moves vided for rock drilling,
to DTH drilling is up and down than what a DTH
that the RC-hammer the tower via hammer or rotary
collected the exhaust a feed system, drilling can create
air and the rock chips generating alone. The lightweight
through an inner the pulldown hammer piston strikes
centre tube of the required to give the tricone drill bit
hammer and inside sufficient weight resulting in a trans-
the drill string up to on the bit. mission of the impact
the surface where Flushing of energy to the drillbit.
samples can be drill cuttings The impact energy
collected in bags. between the from the hammer
Flushing of the wall of the hole is supporting the
cuttings is done up and the drill rods spalling and rock
through the chuck is normally made cutting process and
sleeve. with compressed is increasing the
air. penetration rate.

Blasthole Drilling in Open Pit Mining 177

 Specification guide

Specifications guide
From a pure technical point some readers may find the
definitions and units used on the following pages con-
fusing. Several of the terms and units have a history dat-
ing back to the early days when drilling was based more
on practical experience than on advanced engineering.

Feed Force
For many users and equipment manufacturers feed force
is commonly referred to as Weight on bit(WOB), and
expressed in lb (pounds) or kg. Since this term WOB is com-
monly used by many drillers, we decided to include it in the
specifications pages. The Weight on bit is defined as the
downward force on the drill bit, generated by the force from
the pulldown cylinders combined with the force generated
by the weight of the drill string.

From a pure technical point mass and weight are different

properties and a force can not be measured in pounds since
that is a unit for measurement of mass. Since the 18th cen-
tury pound-force (lbf) has been used for low precision meas-
urement of a force. A more precise definition is the newton
(N), the amount of force required to accelerate a mass of one
kilogram at a rate of one meter per second per second.

In the specifications tables you will also find the force gener-
ated by hydraulic cylinders expressed as Hydraulic pulldown
and Hydraulic pullback specified in lbf and kN units.

Conversion table
This unit Times Equals This unit Times Equals This unit Times Equals
Length Ounce (US fluid oz) x 29.57 = ml mph (mile/hour) x 0.45 = m/s
mm (millimeter) x 0.001 (10-3) =m Pint (US liquid) x 0.4732 =l mph (mile/hour) x 1.61 = km/h
cm (centimeter) x 0.01 =m Quart (US liquid) x 0.9463 =l ft/s (foot/second) x 18.29 = m/min
dm (decimeter) x 0.1 =m yd3 (cubic yard) x 0.7646 = m3 ft/min (foot/minute) x 0.3048 = m/min
km (kilometer) x 1 000 (103) =m Force Frequency
in (inch) x 25.4 = mm kN (kilonewton) x 1 000 =N blow/min x 0.017 = Hz
ft (feet) x 0.305 =m kp (kilopond) x 9.81 =N kHz (kiloHertz) x 1 000 = Hz
yd (yard) x 0.914 =m kgf (kilogram force) x 9.81 =N rpm (rev/min) x 0.01667 = r/s
mile x 1609 =m Ibf (pound force) x 4.45 =N degree/second x 0.1667 = r/min
Power Torque (moment of force) Pressure
J/s (joule/second) x1 =W kpm (kilopondmeter) x 9.81 = Nm bar x 100 = kPa
Nm/s (newton meter/second) x1 =W Ibfin (pound-force inch) x 0.11 = Nm bar x 100 000 (105) = Pa
kW (kilowatt) x 1 000 =W Ibfft (pound-force foot) x 1.36 = Nm kp/cm2 x 0.98 = bar
hk (metric horse power) x 735.5 =W Mass (commonly but incorrectly called weight) atm (atmosphere) x 1.01 = bar
hp (horsepower UK, US) x 745.7 =W g (gram) x 0.001 = kg psi (pounds/in2) x 6.895 = kPa
Volume t (tonnes, metric) x 1 000 = kg psi x 0.06895 = bar
l (liter) x 0.001 = m3 grain x 0.0648 =g Area
ml (milliliter) x 0.001 =l oz (ounce) x 28.35 =g mm2 (square mm) x 0.000001 (10-6) = m2
dm (cubic decimeter)
3
x 1.0 =l ozt (troy ounce) x 31.10 =g cm (square cm)
2
x 0.0001 (10-4) = m2
cm (cubic decimeter)
3
x 1.0 = ml lb (pound) x 0.4536 = kg in (square inches)
2
x 645 = mm2
mm (cubic millimeter)
3
x 0.001 = ml ton (long, US) x 1 016 = kg ft (square feet)
2
x 0.0929 = m2
in (cubic inch)
3
x 16.39 = ml ton (UK) x 1 016 = kg yd (square yard)
2
x 0.8361 = m2
ft (cubic feet)
3
x 28.316 =l ton (short) x 907 = kg Acre x 4 047 = m2
Imperial gallon x 4.546 =l Speed (velocity) Square mile x 2.590 = km2
US gallon x 3.785 =l km/h (kilometer/hour) x 0.2777 = m/s ha (hectare) x 10 000 = m2
Ounce (Imp. fluid oz) x 28.41 = ml m/s (meter/sec) x 3.6 = km/h
Equals Divided by This unit Equals Divided by This unit Equals Divided by This unit

178 Blasthole Drilling in Open Pit Mining


Rotary blasthole drills
Atlas Copco offers the most comprehensive line of ro-
tary blasthole drills in the industry. With a multitude of
configurations to choose from, you can find the perfect
solution for your needs. Many models can be configured
for either rotary or DTH drilling, and our blasthole pro-
ducts will drill holes from 4 inches to 16 inches in
diameter.
On the following pages, you will find basic specifications
and brief descriptions of the standard and optional equip-
ment available for each model. The different configura-
tions of drill rigs and drill strings make it possible to find
high-performing solutions for a variety of applications.
Safety and ergonomic design with operator comfort and
well-being in mind, as well as simplicity in maintenance,
have been a focus for many years and are still top
priorities.
When selecting your drill rig, you may have a choice
between high-pressure compressors for DTH drilling or
Blasthole Drilling in Open Pit Mining 179
bLASTHOLE dRILLS
low-pressure units for rotary drilling, and between diesel
or electric power units. Depending on the drilling pattern
and bench height, you can select between drills suitable
for angle drilling or single- and multi-pass drilling.
Some rig models, like the T4BH and the DM series
that use conventional control systems, are well known
throughout the mining community for their rugged and
reliable designs.The newer Pit Viper series, with its more
advanced designs, can be equipped with the RCS com-
puterized network control system which offers possibili-
ties for different levels of drill automation and communi-
cation.
This is only a basic guide. Our product specialists around
the world are prepared to provide you with the informa-
tion you need to select the best drill and drill string
package to suit your specific application.
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DM25-SP Technical data

Drilling Method Rotary or DTH - Single pass

The Atlas Copco DM25-SP is a crawler mounted, self- Hole Diameter 4 in - 7 in 102 mm - 178 mm
propelled, hydraulic rotary table drive, single-pass rotary Hydraulic Pulldown 25,000 lbf 111 kN
drilling rig specifically designed for 4 in. to 6 in. (102
mm to 171 mm) blasthole applications to depths of up to Weight on bit 25,000 lb 11,300 kg
40 ft. (12.2 m) or 50 ft. (15.2 m) of clean hole, depending Hydraulic Pullback 25,000 lbf 111 kN
on tower selection with either rotary or down-the-hole
drilling. Feed pressure generates a pulldown force of up Single pass depth 40 ft or 50 ft 12.2 m or 15.2 m
to 25,000 lbf (111 kN). The optional angle drilling package Maximum hole
allows the tower to be positioned up to a maximum of 40 ft or 50 ft 12.2 m or 15.2 m
depth
15 from the vertical in increments of 5. All controls for
Feed speed 72 ft/min 0.36 m/s
positioning are located at the operators control console
inside the cab. The package includes a drill pipe support. Rotary table, torque 3,500 Ibfft 4.7 kNm
Estimated weight 62,000 lb 28 tonnes
Standard equipment Dimensions tower up (50 ft tower)
Spacious, thermal insulated and sound-attenuated cab
Cab pressurizer/heater Length 30 ft 6 in 9.3 m
Hydraulically retractable dust hood with skirting Height 74 ft 22.6 m
Nine quartz halogen night lighting package
Width 12 ft 8 in 3.9 m
Cooling package rated up to 125F (52C) ambient
temperature Dimensions tower down (50 ft tower)
Heavy duty engine silencer/muffler
Length 72 ft 21.9 m
Separate air intake filters for engine and compressor
Remote hydraulic tower pinning Height 13 ft 4.0 m
Hydraulically powered auxiliary chain wrench Compressor range
(Down-the-hole units only)
Low pressure, Rotary 900 cfm@110 psi 25.4 m3/min@7.6 bar
230 Gallon (870 Liter) fuel tank
Hydraulic spur gear and planetary drive rotary table High pressure, DTH 900 cfm@350 psi 25.4 m3/min@24 bar
with 0 to 170 RPM and a maximum torque of 3,500 lbfft
Engine (Tier III)
Three 48 in. (1,219 mm) stroke leveling jacks with 18 in.
(457 mm) pads Caterpillar C15 425HP / 317 kW@1800RPM (LP 900)
68,000 lb. (30,845 kg) GVW rated excavator-type Cummins QSX15 425HP / 317 kW@1800RPM (LP 900)
undercarriage
19.7 in. (500 mm) wide triple bar grousers Caterpillar C15 525HP / 391 kW@1800RPM (HP 900)
Separate air intake filters for engine and air compressor Cummins QSX15 525HP / 391 kW @1800RPM (HP 900)
Reinforced rectangular steel track frame with
Kelly specifications
oscillation yoke mounting
Full length kelly bar and kelly sub Hole depth* Kelly Suggested bit Thread**
diameter diameters size and
Deck service catwalk with railings
type
Back up alarm
40 ft (12.2 m) 2 7/8" (73 mm) 4" - 5 1/2" 2 3/8" IF
3 3/4" (95 mm) 5 1/2" - 7" 2 7/8" API
4 3/4" (121 mm) 5 7/8" - 7" 3 1/2" API

50 ft (15.2 m) 2 7/8" (73 mm) 4" - 5 1/2" 2 3/8" IF

3 3/4" (95 mm) 5 1/2" - 6 1/4" 2 7/8" API
4 3/4" (121 mm) 5 7/8" - 7" 3 1/2" API
* Clean hole ** All kellys have pin connections on both ends

High pressure DTH drilling

Up to 6" DTH hammer and max. 7" bit diameter

DM25

Visit www.atlascopco.com/blastholedrills for more information

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DM30 Technical data

Drilling Method Rotary or DTH - Multi pass

The Atlas Copco DM30 is a crawler mounted, hydraulic Hole Diameter 5 in - 6 3/4 in 127 mm - 171 mm
tophead drive, muliti-pass rotary drilling rig specifically Hydraulic Pulldown 30,000 lbf 133 kN
designed for production blasthole drilling to depths of
90 ft. (27.4 m) with a 30 ft. (9.1 m) drill pipe change. Weight on bit 30,000 lb 13,600 kg
A four-position drill pipe changer is optionally available Hydraulic Pullback 10,000 lbf 44 kN
to achieve drilling depths of 150 ft. (57.7 m). Nominal
hole size is 5 in. to 6 in. (127 mm to 171 mm). The Single pass depth 26 ft 7.9 m
DM30 generates a bit load force of up to 30,000 lbf Maximum hole depth 150 ft 45 m
(133 kN). The optional angle drilling package allows the
tower to be positioned up to a maxuimum of 20 from Feed speed 100 ft/min 0.5 m/s
the vertical in increments of 5. Designed for quarrying Rotary head, torque 5,400 Ibfft 7.3 kNm
and small mining operations, this versatile drill can be
easily loaded onto a trailer and moved from one Estimated weight 60,000 lb 28 tonnes
location to another. Dimensions tower up
Length 24 ft 4 in 7.4 m
Standard equipment Height 44 ft 4 in 13.5 m
Spacious, thermal insulated and sound-attenuated cab
Cab pressurizer/heater/ventilator Width 11 ft 10 in 3.6 m
Hydraulically raised dust hood with skirting Dimensions tower down
Nine quartz halogen night lighting package
Auxiliary hoist for drill pipe and accessory handling Length 42 ft 2 in 12.9 m
Cooling package rated up to 125F (52C) ambient Height 14 ft 6 in 4.4 m
Heavy-duty engine silencer/muffler
Compressor range
Separate air intake filters for engine and air compressor
Remote hydraulic tower pinning Low pressure, Rotary 900 cfm@110 psi 25.4 m3/min@7.6 bar
Power indexed carousel for two 4, 4 , or 5 in. High pressure, DTH 900 cfm@350 psi 25.4 m3/min@24 bar
OD x 30 ft. drill rods
Engine (Tier III)
Remote hydraulic fork chuck for drill pipe breakout
Hydraulically powered auxiliary chain wrench Caterpillar C15 425HP / 317 kW@1800RPM (LP 900)
250-gallon (946 l) fuel tank Cummins QSX15 425HP / 317 kW@1800RPM (LP 900)
Rotaryhead with single fixed displacement motor with
0 to 100 RPM available, and a maximum torque of Caterpillar C15 525HP / 391 kW@1800RPM (HP 900)
5,400 lbfft Cummins QSX15 525HP / 391 kW@1800RPM (HP 900)
Three 48 in. (1,219 mm) stroke leveling jacks
Drill pipe specification: 30 ft (9.1m)
68,000 lb. (30,845 kg) GVW rated excavator-type
undercarriage Drill pipe diameter Suggested bit Thread
diameters - rotary
19.7 in. (500 mm) wide triple bar grousers
Reinforced rectangular steel track frame with 4" (102 mm) 5" 6" 2 7/8" API
oscillation yoke mounting 4 " (114 mm) 5 7/8" 6 3/4" 3 1/2" API
Deck service catwalk with railings
Back-up alarm 5" (127 mm) 6 3/4" 3 1/2" API or BECO

High pressure DTH drilling

Up to 6" DTH hammer and max. 6 " bit diameter

DM30

Visit www.atlascopco.com/blastholedrills for more information

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DM30 II Technical data

Drilling Method Drilling Method DTH - Multi pass
The Atlas Copco DM30 II is an improved and upgraded Hole Diameter 5 in - 6 3/4 in 127 mm - 171 mm
version of the DM30. It is a crawler mounted, hydraulic
Hydraulic Pulldown 30,000 lbf 133 kN
tophead drive, muliti-pass rotary drilling rig specifically
designed for production blasthole drilling to depths of Drilling Method Rotary - Multi pass
90 ft. (27.4 m) with a 30 ft. (9.1 m) drill pipe change. Hole Diameter 5 in - 7 7/8 in 127 mm - 200 mm
A four-position drill pipe changer is optionally available
to achieve drilling depths of 150 ft. (45.7 m). Nominal Hydraulic Pulldown 30,000 lbf 133 kN
hole size is 5 in. to 7-7/8 in. (127 mm to 200 mm). The Weight on bit 30,000 lb 13,600 kg
DM30 II generates a bit load force of up to 30,000 lbf
(133 kN). The optional angle drilling package allows the Hydraulic Pullback 10,000 lbf 44 kN
tower to be positioned up to a maxuimum of 30 from Single pass depth 26 ft 7.9 m
the vertical in increments of 5. Designed for quarrying
and small mining operations, this versatile drill can be Maximum hole
150 ft 45 m
depth
easily loaded onto a trailer and moved from one
location to another. Feed speed 100 ft/min 0.5 m/s
Rotary head, torque 5,400 Ibfft 7.3 kNm
Major upgrades Estimated weight 70,000 lb 31.5 tonnes
New larger, thermal insulated cabin mounted on the right Dimensions tower up
side of the carrier(seen from the drill end)
Electric over hydraulic control system, similar to what is Length 28 ft 7 in 8.7 m
used on other rigs in the DM-series Height 45 ft 2 in 13.8 m
Optional walk way and enlarged deck area for
improved access to service and maintenance. Width 16 ft 11 in 5.2 m
Improved optional angle drilling package, allows the Dimensions tower down
tower to be positioned up to a maximum of 30 from the
vertical in increments of 5 Length 44 ft 11 in 13.7 m
New long life main frame designed with I-beams, featuring Height 16 ft 8 in 5.1 m
oscillation yoke mounting.
Enlarged hydraulically raised dust hood with skirting Compressor range
provide more space for cuttings. Low pressure Rotary 1050 cfm@110 psi 29.7 m3/min@7.6 bar
New design with hydraulic motor for carousel indexing.
High pressure DTH 900 cfm@350 psi 25.4 m3/min@24 bar
Optional Atlas Copco screw type low and high pressure
compressor, with high air temperature shut down. Engine (Tier III)
New 14 section directional valve system.
Caterpillar C15 475HP / 354 kW@1800RPM (LP 1050)
Standard central lubrication manifold
Caterpillar C15 525HP / 391 kW@1800RPM (HP 900)

Drill Pipe specification: 30 ft (9.1m)

Standard equipment
Drill pipe diameter Suggested bit Thread
Cab pressurizer/heater/ventilator diameters rotary
Eleven quartz halogen night lighting package6
Auxiliary hoist for drill pipe and accessory handling 4 1/2" (114 mm) 5 7/8" 6 3/4" 3 1/2" API
Cooling package rated up to 125F (52C) ambient 5" (127 mm) 6 3/4" 3 1/2" API or BECO
Heavy-duty engine silencer/muffler
5 1/2" (140 mm) 7 7/8" 3 1/2" BECO
Separate air intake filters for engine and air compressor
Remote hydraulic tower pinning High pressure DTH drilling
Hydraulic indexed carousel for two 4, 5 or 5- in. Up to 6" DTH hammer and max. 6 3/4" bit diameter
OD x 30 ft. drill rods
Remote hydraulic fork chuck for drill pipe breakout
Hydraulically powered auxiliary chain wrench
230-gallon (870 l) fuel tank
Rotary head with single fixed or variable displacement
motor with 0 to 160 RPM available, and a maximum torque
of 5,400 lbfft
Three 48 in. (1,219 mm) stroke leveling jacks
77,000 lb. (34,650 kg) GVW rated excavator-type
undercarriage
19.7 in. (500 mm) wide triple bar grousers
Reinforced rectangular steel track frame with oscillation
yoke mounting
Deck service catwalk with railings
Back-up alarm
Visit www.atlascopco.com/blastholedrills for more information

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T4BH Technical data

Drilling Method DTH or Rotary - Multi pass

The Atlas Copco T4BH is synonymous with mobility, Hole Diameter 5 5/8 in - 9 7/8 in 143 mm - 251 mm
power, performance, and productivity. Mounted on a Hydraulic Pulldown 30,000 lbf 133 kN
custom carrier, the T4BH is designed to perform in rough
terrain and has been the leading blasthole drill in its class Weight on bit 30,000 lb 13,600 kg
in the quarry and mining industries for over 35 years. The Hydraulic Pullback 22,000 lbf 97 kN
T4BH is a truck mounted, hydraulic tophead drive, multi-
pass rotary drilling rig specifically designed for production Single pass depth 22 ft 6 in or 27 ft 6 in 6.8 m or 8.4 m
blasthole drilling to depths of 150 ft. (45.7 m) with a 25 ft. Maximum hole depth* 147 ft 6 in or 177 ft 6 in 45 m or 54.1 m
(7.6 m) drill pipe change. An optional 30 ft (9.1m) tower
is also available with the 8 x 4 carrier option. Feed speed 60 ft/min 0.3 m/s
Rotary head, torque 6,000 Ibfft 8.8 kNm
7,165 Ibfft 9.7 kNm
Standard equipment
Spacious, thermal insulated sound-attenuated cab Estimated weight 58,000 lb 26 tonnes
Six quartz halogen night lighting package Dimensions tower up (25 ft tower)
Rectangular dust hood with skirting
Auxiliary hoist for drill pipe and accessory handling Length 28 ft 8 in 8.1 m
Cooling package rated up to 125F (52C) ambient Height 36 ft 6 in 11.1 m
Heavy-duty engine silencer/muffler
Width 8 ft 2.4 m
Separate air intake filters for engine and air compressor
Power indexed carousel for five 4 in OD x 25 ft pipe Dimensions tower down (25 ft tower)
Remote hydraulic fork chuck for drill pipe breakout Length 35 ft 0 in 10.7 m
Hydraulically powered auxiliary chain wrench
Height 13 ft 6 in 4.1 m
225 Gallon (851 Liter) Fuel tank
4SV-2-10 spur gear 2-motor rotary tophead with Compressor range
0 to 160 RPM, and maximum torque 6,500 lbfft
High pressure, DTH 900 cfm@350 psi 25.4 m3/min@24 bar
Three 48 in. (1,219 mm) stroke leveling jacks
Custom designed 3-axle carrier with 380 hp (283 kW) High pressure, DTH 1070 cfm@350 psi 30.3 m3/min@24 bar
diesel engine, 10-speed transmission and 16 in. High pressure, DTH 1250 cfm@350 psi 35.4 m3/min@24 bar
(406 mm) wide flange H-beam frame
Remote tower pinning Engine ( TierII, Tier III)
2 3

Back-up alarm Cummins QSX153 525HP / 391 kW@1800RPM (HP 900)

Cummins QSX15 3
600HP / 447 kW@1800RPM (HP 1070)

Cummins QSK19C2 760HP / 567 kW@1800RPM (HP 1250)

Drill pipe specification: 25 ft (7.6 m)

Drill pipe diameter Suggested bit diameters Thread

4" (102 mm) 5 5/8" 6" 2 7/8" API

4 1/2" (114 mm) 5 7/8" 6 3/4" 3 1/2" API

5" (127 mm) 6 3/4" 7 3/8" 3 1/2" API

or BECO
5 1/2" (140 mm) 6 3/4" 7 7/8" 3 1/2" BECO

6 1/4" (159 mm) 7 7/8" 9" 4" BECO

7" (178 mm) 9"-9 7/8" 4 1/2" BECO

High pressure DTH drilling

Up to 8" DTH hammer and max. 9 7/8" bit diameter
* Maximum hole depth only achieved with certain pipe sizes and
wall thicknesses

T4BH

Visit www.atlascopco.com/blastholedrills for more information

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DM45/DM50 Technical data

Drilling Method Rotary or DTH Multi pass

The Atlas Copco DM45 and DM50 are crawler mounted, Hole Diameter 5 7/8 in - 9 in 149 mm - 229 mm
hydraulic tophead drive, multi-pass rotary drilling rigs Hydraulic Pulldown 45,000 lbf 200 kN
specifically designed for production rotary or DTH
blasthole drilling to depths of 175 ft. (53.3 m) with a 30 ft. Weight on bit 45,000 lb 20,400 kg
(9.1 m) drill pipe change. Hydraulic Pullback 22,000 lbf 98 kN
Single pass depth 27 ft 5 in 8.5 m
Standard equipment Maximum hole depth* 175 ft 53.3 m
Insulated cab with FOPS 80 dB(A)
Cab pressurizer / ventilator / heater Feed speed 146 ft/min 0.7 m/s
Nine quartz halogen night lighting package Rotary head, torque 7,200 Ibfft 9,76 kNm
Dust hood with curtains and hydraulically raising
Estimated weight 77,000 lb - 35 tonnes -
dust flap 95,000 lb 41 tonnes
Auxiliary hoist for drill pipe and accessory handling
Dimensions tower up
Heavy-duty engine silencer/muffler
Separate air intake filters with quick release dust drop Length 31 ft 10 in 9.7 m
covers for engine and air compressor Height 43 ft 7 in 13.3 m
Gear indexing carousel for five 4 in. x 30 ft. pipe
Width 17 ft 2 in 5.23 m
Sliding hydraulic fork wrench for drill pipe breakout
Hydraulically powered auxiliary chain wrench Dimensions tower down
350-gallon (1,324 L) fuel tank Length 43 ft 7 in 13.3 m
4SV-2-10 two motor high speed rotary head with Height 18 ft 5.5 m
spline lubrication, 0 to 160 RPM, and a maximum
torque 7,200 lbfft Compressor range
30 foot drill pipe change Low pressure, Rotary 900 cfm@110 psi 25.4 m3/min@7.5 bar
No-bump rod changer
Low pressure, Rotary 1050 cfm@110 psi 29.7 m3/min@7.5 bar
Ether injection
Jack-up indicator lights Low pressure, Rotary 1200 cfm@110 psi 34.0 m3/min@7.5 bar
Three 48 in. (1,219 mm) stroke leveling jacks High pressure, DTH 900 cfm@350 psi 25.4 m3/min@24 bar
23.6 in. (600 mm) wide triple bar grousers High pressure, DTH 1070 cfm@350 psi 30.3 m3/min@24 bar
Reinforced rectangular steel track frame with
oscillation yoke Engine (Tier III)
Walkways and railings Caterpillar C15 440HP / 328 kW@1800RPM (LP 900)
Remote tower pinning Cummins QSX15 425HP / 317 kW@1800RPM (LP 900)
Back-up alarm
Caterpillar C15 475HP / 354 kW@1800RPM (LP 1050)
Cummins QSX15 475HP / 354 kW@1800RPM (LP 1050)
Caterpillar C15 540HP / 403 kW@1800RPM (LP 1200)
Cummins QSX15 530HP / 395 kW@1800RPM (LP 1200)
Caterpillar C15 540HP / 403 kW@1800RPM (HP 900)
Cummins QSX15 530HP / 395 kW@1800RPM (HP 900)
Caterpillar C18 630HP / 470 kW@1800RPM (HP 1070)
Cummins QSX15 600HP / 447 kW@1800RPM (HP 1070)

Drill pipe specification: 30 ft (9.1 m)

Drill pipe diameter Suggested bit Thread
diameters
4 1/2" (114 mm) 5 7/8" 6 3/4" 3 1/2" API
5" (127 mm) 6 3/4" 7 3/8" 3 1/2" API or BECO
5 1/2" (140 mm) 6 3/4" 7 7/8" 3 1/2" BECO
6 1/4" (159 mm) 7 7/8" 9" 4" BECO
7" (178 mm) 9" 4 1/2" BECO
High pressure DTH drilling (DM45)
Up to 6 1/2" DTH hammer and max. 8" bit diameter
DM45

* Maximum hole depth only achieved with certain pipe sizes and
wall thicknesses

Visit www.atlascopco.com/blastholedrills for more information

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DML-SP Technical data

Drilling Method Rotary or DTH - Single pass
The Atlas Copco DML-SP is a crawler-mounted, hydraulic Hole Diameter 6 in - 9 7/8 in 152 mm - 251 mm
table drive, single-pass rotary drilling rig, specifically
Hydraulic Pulldown 54,000 lbf 240 kN
designed for production blasthole drilling to depths of
up to 60 ft. (18.3 m) in a single pass without a drill pipe Weight on bit 54,000 lb 24,500 kg
change. Nominal hole size range is 6 to 9-7/8 in. (152 to Hydraulic Pullback 54,000 lbf 240 kN
251 mm) for rotary bit applications. The DML-SP has the
option for a 50 ft (15.2 m) clean hole tower or a 60 ft Single pass depth 50 ft or 60 ft 15.2 m or 18.3 m
(18.3 m) clean hole tower. Maximum hole depth 50 ft or 60 ft 15.2 m or 18.3 m
Feed speed 100 ft/min 0.5 m/s
Standard equipment Rotary table, torque 7,500 Ibfft 10.2 kNm
Insulated cab with FOPS
Cab pressurizer/heater Estimated weight 90,000 -100,000 lb 41 - 45 tonnes
Nine-quartz, halogen night lighting package
Dimensions tower up
Rectangular dust hood with skirting and hydraulically
retractable front curtain Length (50 ft tower) 37 ft 6 in 11.4 m
Cooler package rated up to 125F (52C) ambient Length (60 ft tower) 37 ft 6 in 11.4 m
temperature
Heavy duty engine silencer/muffler Height (50 ft tower) 71 ft 7 in 21.8 m
Separate air intake filters with quick release dust drop Height (60 ft tower) 82 ft 7 in 25.2 m
covers for engine and air compressor
Width 13 ft 10 in 4.1 m
Hydraulically powered auxiliary chain wrench
350-gallon (1,324 l) fuel capacity Dimensions tower down
Single motor rotary table with variable hydraulic Length (50 ft tower) 68 ft 20.7 m
motor (0-100 RPM) and a maximum torque of 7,500 lbfft
Length (60 ft tower) 79 ft 24.1 m
Hydrostatic motor feed system
Three 48 in. (121.9 cm) stroke leveling jacks Height (50 ft tower) 19 ft 7 in 6.0 m
31.5 in. (800 mm) wide triple bar grousers Height (60 ft tower) 19 ft 7 in 6.0 m
Reinforced rectangular steel track frame with oscillation
yoke mounting Compressor range
Walkways and deck railings Low pressure rotary 1,200 cfm@110psi / 34.0 m3/min@7.6 bar
Full depth kelly bar
Low pressure rotary 1,600 cfm@110psi / 45.0 m3/min@7.6 bar
Kelly RPM tachometer on console
Remote tower pinning Low pressure rotary 1,900 cfm@110psi / 53.8 m3/min@7.6 bar
Back-up Alarm High pressure, DTH 1,250 cfm@350psi / 35.4 m3/min@24 bar
Ether injection
Engine (2TierII, 3Tier III)
Jack-up indicator lights
Caterpillar C153 525HP / 391 kW@1800RPM (LP 1200)

Cummins QSX15 3
525HP / 391 kW@1800RPM (LP 1200)

Caterpillar C183 630HP / 470 kW@1800RPM (LP 1600)

Cummins QSX153 600HP / 447 kW@1800RPM (LP 1600)

Caterpillar C27 2
800HP / 597 kW@1800RPM (LP 1900)

Cummins QSK19 2
755HP / 563 kW@1800RPM (LP 1900)

Caterpillar C27 2
800HP / 597 kW@1800RPM (HP 1250)

Cummins QSK19C2 760HP / 567 kW@1800RPM (HP 1250)

Kelly specifications
Hole depth* Kelly Suggested bit Thread**
diameter diameters size and type

50 ft. (15.2 m) 4 3/4 in. (121 mm) 6" 6 3/4" 3 1/2 in. Reg.
or
60 ft. (18.3 m) 6 1/4 in. (159 mm) 7 7/8" 9" 4 1/2 in. Reg.
7 in. (178 mm) 9" 9 7/8" 5 1/2 in. Reg.
* Clean hole ** All kellys have pin connections on both ends.

High pressure DTH drilling

Up to 8" DTH hammer and max. 8 7/8" bit diameter

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DML Technical data

Drilling Method Rotary or DTH - Multi pass

The Atlas Copco DML is a crawler mounted, hydraulic Hole Diameter 5 7/8 in - 10 5/8 in 149 mm - 270 mm
tophead drive, multi-pass rotary drilling rig specifically Hydraulic Pulldown 60,000 lbf 267 kN
designed for production blasthole drilling to depths of
Weight on bit 60,000 lb 27,200 kg
175 ft. (53.3 m) with a 30 ft. (9.1 m) drill pipe change. An
optional 35-ft. (10.7 m) steel change is also available to Hydraulic Pullback 22,000 lbf 98 kN
handle single pass drilling requirements. Various carousel Single pass depth 27 ft 5 in or 32 ft 5 in 8.5 m or 10 m
capacities are also available for the 35-ft. (10.7 m) option.
Maximum hole depth* 175 ft or 205 ft 53.3 m or 62.5 m
Feed speed 146 ft/min 0.7 m/s
Standard equipment
Insulated cab with FOPS Rotary head, torque 7,200 Ibfft 9.76 kNm
Cab pressurizer / ventilator / heater Estimated weight 87,000 - 110,000 lb 39.5 - 50 tonnes
Nine quartz halogen night lighting package Dimensions tower up (30 ft tower)
Dust hood with curtains and hydraulically raising dust flap
Length 31 ft 10 in 9.7 m
Auxiliary hoist for drill pipe and accessory handling
Heavy-duty engine silencer/muffler Height 43 ft 8 in 13.3 m
Separate air intake filters with quick release dust drop Width 16 ft 6 in 5m
covers for engine and air compressor Dimensions tower down (30 ft tower)
Gear indexing carousel
Length 43 ft 7 in 13.3 m
Sliding hydraulic fork wrench for drill pipe breakout
Hydraulically powered auxiliary chain wrench Height 17 ft 8 in 5.4 m
350-gallon (1,324 L) fuel tank Compressor range
4SV-2-10 two motor high speed rotary head with spline Low pressure rotary 1,200 cfm@110 psi / 34.0 m3/min@7.6 bar
lubrication, 0 to 160 RPM, and a maximum torque
of 7,200 lbfft Low pressure rotary 1,600 cfm@110 psi / 45.0 m3/min@7.6 bar
30 foot drill pipe change Low pressure rotary 1,900 cfm@110 psi / 53.8 m3/min@7.6 bar
No-bump rod changer High pressure, DTH
1,050 cfm@350 psi / 29.8 m3/min@24 bar
Ether injection (electric motor)
Jack-up indicator lights High pressure, DTH 1,250 cfm@350 psi / 35.4 m3/min@24 bar
Three 48 in. (1,219 mm) stroke leveling jacks High pressure, DTH 1,450 cfm@350 psi / 41 m3/min@24 bar
33.5 in. (850 mm) wide triple bar grousers
Engine (2Tier II, 3Tier III )
Reinforced rectangular steel track frame with oscillation
yoke Caterpillar C153 540HP / 403 kW@1800RPM (LP 1200)
Walkways and railings Cummins QSX153 530HP / 395 kW@1800RPM (LP 1200)
Remote tower pinning
Caterpillar C183 630HP / 470 kW@1800RPM (LP 1600)
Back-up alarm
Cummins QSX15 3
600HP / 447 kW@1800RPM (LP 1600)
Caterpillar C272 800HP / 597 kW@1800RPM (LP 1900)
Cummins QSK192 755HP / 563 kW@1800RPM (LP 1900)
Caterpillar C27 2
800HP / 597 kW@1800RPM (HP 1250)
Cummins QSK19C2 755HP / 563 kW@1800RPM (HP 1250)
Caterpillar C272 800HP / 597 kW@2100RPM (HP 1450)
Weg motor 6808 700HP / 522 kW@50 60Hz
(LP 1200 or HP1050)
Drill pipe specification 30 ft (9.1 m) or 35 ft (10.7 m)
Drill pipe diameter Suggested bit Thread
diameters
4 1/2" (114 mm) 5 7/8" 6 3/4" 3 1/2" API
5" (127 mm) 6 3/4" 7 3/8" 3 1/2" API or BECO
5 1/2" (140 mm) 6 3/4" 7 7/8" 3 1/2" BECO
6 1/4" (159 mm) 7 7/8" 9" 4" BECO
7" (178 mm) 9" 9 7/8" 4 1/2" BECO
7 5/8" (194 mm) 9 7/8" 10 5/8" 5 1/4" BECO
High pressure DTH drilling
Up to 8" DTH hammer and max. 8 7/8" bit diameter
* Maximum hole depth only achieved with certain pipe sizes and
wall thicknesses

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Pit Viper PV-235 Technical data

Drilling Method Rotary or DTH - Multi pass
The Pit Viper series 235 blasthole drills offers several Hole Diameter 6 in - 10 5/8 in 152 mm - 270 mm
advanced options, like the RCS control system, remote Hydraulic Pulldown 60,000 lbf 267 kN
tramming, auto levelling, and GPS navigation. The hy- Weight on bit 65,000 lb 29,500 kg
draulic system has been refined with load sensing and
other features to reduce horsepower demand. There are Hydraulic Pullback 27,000 lbf 120 kN
several engine and compressor combinations available Single pass depth 40, 35 ft 12.2, 10.7 m
for either rotary or high pressure DTH drilling. The
Maximum hole depth* 240, 210 ft 73.2, 64.0 m
PV-235 can be supplied with two towers - to drill 35 ft
(10.7 m) or 40 ft (12.2 m) clean holes up to 10 58" Feed speed 140 - 193 ft/min 0.7 - 1.0 m/s
(270 mm) in diameter. Rotary head, torque 4,900 Ibfft 6.6 kNm
8,200 Ibfft 11.1 kNm

Standard equipment Estimated weight 135,000 lb 61 tonnes

RCS Rig Control System, computerized network Dimensions tower up (40 ft tower)
Spacious thermal insulated cab with FOPS and noise
abated less than 80 dB(A) Length 34 ft 2 in 10.4 m
Cab pressurizer / ventilator / heater Height 62 ft 6 in 19 m
Twelve quartz halogen night lighting package Width 17 ft 4 in 5.3 m
Dust hood with curtains and hydraulically raising
Dimensions tower down (40 ft tower)
dust flap
Auxiliary hoist for drill pipe and accessory handling Length 63 ft 5 in 19.3 m
Heavy duty engine silencer / muffler Height 20 ft 4 in 6.4 m
Separate air intake filters with rubber dust evacuator for
engine and air compressors Compressor range
Gear indexing carousel for 5 in pipe Low pressure rotary 1,600 cfm@110 psi / 45.0 m3/min@7.6 bar
Sliding hydraulic fork wrench for drill pipe breakout Low pressure rotary 1,900 cfm@110 psi / 53.8 m3/min@7.6 bar
Hydraulically powered auxiliary breakout wrench High pressure, DTH 1,250 cfm@350 psi / 35.4 m3/min@24 bar
450 gallon fuel tank (1,700 l)
High pressure, DTH 1,450 cfm@350 psi / 41.0 m3/min@24 bar
4SV-2-10 two speed spur gear rotary head with spline
lubrication, 0-180 RPM, and a maximum torque High pressure, DTH
1,250 cfm@350 psi / 35.4 m3/min@24 bar
of 8,200 lbfft (electric motor)
35 ft drill pipe changer High pressure, DTH 1,300 cfm@435 psi / 37.6 m3/min@30 bar
No-bump rod changer Engine ( Tier III, Tier II)
3 2

Ground level battery and starter lockable master-switches

with jump start receptacle Caterpillar C183 630HP / 470 kW@1800RPM (LP 1600)
Jack-up indicator lights Cummins QSX15 3
600HP / 447 kW@1800RPM (LP 1600)
Four 48 in (1.2 m) stroke leveling jacks Caterpillar C272 800HP / 597 kW@1800RPM
Triple bar grousers 33.5 in (850 mm) wide (LP 1900 or HP 1250)
Reinforced rectangular steel track frame with oscillation Cummins QSK192 755HP / 563 kW@1800RPM (LP 1900 or HP
yoke 1250)
Walkways and railings Caterpillar C272 800HP / 597 kW@2100RPM (HP 1450)
Remote tower pinning
WEG 6808 800HP / 597 kW@50-60 Hz
Back-up alarm
Drill pipe specification: 35 ft (10.7 m) or 40 ft (12.2 m)
Drill pipe diameter Suggested bit Thread
diameters
4 1/2" (114 mm) 6" 6 3/4" 3" BECO
5" (127 mm) 6 3/4" - 7 3/8" 3 1/2" BECO
5 1/2" (140 mm) 6 3/4" - 7 7/8" 3 1/2" BECO
6 1/4" (159 mm) 7 7/8" - 9" 4" BECO
7" (178 mm) 9" 4 1/2" BECO
7 5/8" (194 mm) 9 7/8" 5 1/4" BECO
8" (203 mm) 9 7/8" - 10 5/8" 5 1/4" BECO
High pressure DTH drilling
Up to 8" DTH hammer and max. 8 7/8" bit diameter
PV-235
* Maximum hole depth only achieved with certain pipe sizes and
wall thicknesses

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Pit Viper PV-271 Technical data

Drilling Method Rotary or DTH Single pass

The PV-271 is designed to handle 6-" up to 8- " drill

58 Hole Diameter 6 3/4 in - 10 5/8 in 171 mm - 270 mm
rods. The cable feed system utilizes a dual rod/dual Hydraulic Pulldown 70,000 lbf 311 kN
piston cylinder and offers high feed speeds for increased
productivity. The PV-271 offers a 55 ft single-pass tower Weight on bit 75,000 lb 34,000 kg
with a total depth capacity of 105 ft through a 2-rod Hydraulic Pullback 35,000 lbf 156 kN
carousel with 25 ft rods. It has an option to be delivered
with the RCS Computerized rig control system and a Single pass depth 55 ft* 16.8 m*
new fully integrated cabin, incorporating functions like; Maximum hole depth 105 ft 32 m
remote tramming, auto levelling, auto drilling, and GPS
navigation. Feed speed 127 ft/min 0.6 m/s
Rotary head, torque 8,700 Ibfft 11.8 kNm
Standard equipment Estimated weight 185,000 lb 84 tonnes
Insulated, pressurized, air conditioned cab with tinted Dimensions tower up
glass and suspension operator seat
Caterpillar 345XL undercarriage with hydraulic track Length 41 ft 3 in 12.6 m
tensioners Height 87 ft 26.5 m
Hydraulic cylinders driven cable feed system
Width 18 ft 4 in 5.6 m
Hydraulic motor driven rotary head with spline lubrication,
maximum 8,700 lbfft torque; speed range 0 - 150 rpm Dimensions tower down
Rotary head tachometer on operator console Length 83 ft 7 in 25.5 m
Remote hydraulic tower pinning
Height 22 ft 1 in 6.7 m
Two-rod carousel for 6 " to 8- 58" drill rods
"No-bump" rod changer Compressor range
Hydraulically powered breakout wrench (fork chuck) Low pressure rotary 1,900 cfm@110 psi / 53.8 m3/min@7.6 bar
Hands Free auxiliary hydraulic chain wrench
8,000 lb (3,629 kg) capacity auxiliary hoist Low pressure rotary 2,600 cfm@110 psi / 73.6 m3/min@7.6 bar
Hydraulically retractable dust curtains High pressure, DTH 1,450 cfm@350 psi / 41.1 m3/min@24 bar
Cooling package
Engine (Tier ll)
Separate air intake filters for engine and air compressor
Wide flange structural steel beam frame with oscillation Caterpillar C27 800HP / 597 kW@1800RPM (LP 1900)
yoke mounting Cummins QSK19 755HP / 563 kW@1800RPM (LP 1900)
Hydraulic Test Station
13-light night lighting package-70 watt halogen Caterpillar C32 950HP / 708 kW@1800RPM (LP 2600)
Full deck service catwalks and railings Caterpillar C27 800HP / 597 kW@2100RPM (HP 1450)
Two 48" (1.2 m) and one 60" (1.52 m) stroke leveling jacks
Weg motor 6808 700HP / 521 kW@ 50 or 60Hz
Weg motor 6811 900HP / 671 kW@ 50 or 60Hz

Drill pipe specification: 25 ft (7.6 m)

Drill pipe diameter Suggested bit Thread
diameters
6 1/4" (159 mm) 6 3/4" 9" 4" BECO
7" (178 mm) 9" 9 7/8" 4 1/2" BECO
7 5/8" (194 mm) 9 7/8" 10 5/8" 5 1/4" BECO
8" (203 mm) 9 7/8" 10 5/8" 5 1/4" BECO
8 5/8" (219 mm) 10 5/8" 6" BECO

High pressure DTH drilling

Up to 8" DTH hammer and max. 9 7/8" bit diameter
* There is also a 65 ft (19.8 m) clean hole tower option
(see page 76 - 77)

PV-271

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Pit Viper 271 RCS Technical data

Drilling Method Rotary or DTH Single pass
The PV-271 Rig Control System (RCS) is designed to Hole Diameter 6 3/4 in - 10 5/8 in 171 mm - 270 mm
handle 6-" to 8-58" drill rods. The cable feed system
Hydraulic Pulldown 70,000 lbf 311 kN
utilizes a dual rod/dual piston cylinder and offers high
feed speeds for increased productivity. The PV-271 RCS Weight on bit 75,000 lb 34,000 kg
offers a 55 ft single-pass tower with a total depth capa- Hydraulic Pullback 35,000 lbf 156 kN
city of 105 ft through a 2-rod carousel with 25 ft rods.
This version of the machine comes standard with a new Single pass depth 55 ft* 16.8 m*
cab that fully integrates the RCS with the option to fully Maximum hole depth 105 ft 32 m
incorporate the following functions: wireless remote
tramming, auto leveling, auto drilling, and Feed speed 127 ft/min 0.6 m/s
GPS navigation. Rotary head, torque 8,700 Ibfft 11.8 kNm
Estimated weight 185,000 lb 84 tonnes
Standard equipment Dimensions tower up
Spacious thermal insulated cab with FOPS and noise
abatement to less than 70 dB(A) Length 54 ft 16.4 m
Excavator style chair and controls for increased comfort Height 87 ft 26.5 m
and visibility
Standard Cab pressurizer/ventilator/heater with the option Width 23 ft 8 in 7.2 m
to upgrade the pressurizer Dimensions tower down
Caterpillar 345XL undercarriage with hydraulic track
tensioners Length 86 ft 4 in 26.3 m
Hydraulic cylinders-driven cable feed system Height 23 ft 3 in 7.0 m
Hydraulic motor driven rotary head with spline lubrication,
Compressor range
maximum 8,700 lbf-ft torque; speed range 0 150 rpm
Rotary Head tachometer integrated into the RCS system Low pressure rotary 1,900 cfm@110 psi / 53.8 m3/min@7.6 bar
Remote hydraulic tower pinning Low pressure rotary 2,600 cfm@110 psi / 73.6 m3/min@7.6 bar
Two-rod carousel for 6-" to 8-58" drill rods
High pressure, DTH 1,450 cfm@350 psi / 41.1 m3/min@24 bar
No Bump rod changer
Hydraulically powered breakout wrench (fork chuck) Engine (Tier ll)
Hands-free auxiliary hydraulic chain wrench Caterpillar C27 800HP / 597 kW@1800RPM (LP 1900)
8,000 lb (3,629 kg) capacity auxiliary hoist
Hydraulically retractable dust curtains Cummins QSK19 755HP / 563 kW@1800RPM (LP 1900)
Cooling package Caterpillar C32 950HP / 708 kW@1800RPM (LP 2600)
Separate air intake filters for engine and air compressor
Caterpillar C27 800HP / 597 kW@2100RPM (HP 1450)
Wide flange structural steel beam frame with oscillation
yoke mounting Weg motor 6808 700HP / 521 kW@ 50 or 60Hz
14-light night lighting package 70 watt halogen Weg motor 6811 900HP / 671 kW@ 50 or 60Hz
Full deck service catwalks and railings
Drill pipe specification: 25 ft (7.6 m)
Two 48" (1.2 m) and one 60" (1.52 m) stroke leveling jacks
350 US gallon (1,325 L) fuel tank w/option to upgrade to Drill pipe diameter Suggested bit Thread
larger tanks. diameters
6 1/4" (159 mm) 6 3/4" 9" 4" BECO
7" (178 mm) 9" 9 7/8" 4 1/2" BECO
7 5/8" (194 mm) 9 7/8" 10 5/8" 5 1/4" BECO
8" (203 mm) 9 7/8" 10 5/8" 5 1/4" BECO
8 5/8" (219 mm) 10 5/8" 6" BECO

High pressure DTH drilling

Up to 8" DTH hammer and max. 9 7/8" bit diameter
* There is also a 65 ft (19.8 m) clean hole tower option
(see page 76 - 77)

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Pit Viper PV-275 Technical data

Drilling Method Rotary or DTH Multi pass

The PV-275 is designed to handle 6-" up to 8- " drill

58 Hole Diameter 6 3/4 in - 10 5/8 in 171 mm - 270 mm
rods. The cable feed system utilizes a dual rod/dual Hydraulic Pulldown 70,000 lbf 311 kN
piston cylinder and offers high feed speeds for increased
productivity. The PV-275 offers a multi-pass tower with Weight on bit 75,000 lb 34,000 kg
195-ft depth capacity through a 4-rod carousel with Hydraulic Pullback 35,000 lbf 156 kN
40-ft rods. It has an option to be delivered with the
RCS Computerized rig control system and a new fully Single pass depth 37 ft 11.3 m
integrated cabin, incorporating functions like; remote Maximum hole depth 195 ft 59.4 m
tramming, auto levelling, auto drilling, and GPS
navigation. Feed speed 127 ft/min 0.6 m/s
Rotary head, torque 8,700 Ibfft 11.8 kNm
Standard equipment Estimated weight 185,000 lb 84 tonnes
Insulated, pressurized, air conditioned cab with tinted Dimensions tower up
glass and suspension operator seat
Caterpillar 345SL undercarriage with hydraulic track Length 41 ft 6 in 12.6 m
tensioners Height 67 ft 20.4 m
Hydraulic cylinders driven cable feed system
Width 18 ft 4 in 5.6 m
Hydraulic motor driven rotary head with spline
lubrication, maximum 8,700 lbfft (11,800 Nm) torque; Dimensions tower down
speed range 0 150 rpm Length 63 ft 6 in 19.4 m
Rotary head tachometer on operator console
Remote hydraulic tower pinning Height 22 ft 1 in 6.7 m
Four-rod carousel for 6 " to 8-58" drill rods Compressor range
"No-bump" rod changer
Low pressure rotary 1,900 cfm@110 psi / 53.8 m3/min@7.6 bar
Hydraulically powered breakout wrench (fork chuck)
Hands Free auxiliary hydraulic wrench Low pressure rotary 2,600 cfm@110 psi / 73.6 m3/min@7.6 bar
8,000 lb (3,629 kg) capacity auxiliary hoist High pressure, DTH 1,450 cfm@350 psi / 41.1 m3/min@24 bar
Hydraulically retractable dust curtains
Hydraulic Test Station Engine (Tier ll)
Two 48" (1.2 m) and one 60" (1.52 m) stroke leveling jacks Caterpillar C27 800HP / 597 kW@1800RPM (LP 1900)
Cooling package
Cummins QSK19 755HP / 563 kW@1800RPM (LP 1900)
350 U.S. gallon (1,325 L) fuel tank w/option to upgrade to
larger tanks Caterpillar C32 950HP / 708 kW@1800RPM (LP 2600)
Separate air intake filters for engine and air compressor Caterpillar C27 800HP / 597 kW@2100RPM (HP 1450)
Wide flange structural steel beam frame with oscillation
yoke mounting Weg motor 6808 700HP / 521 kW@ 50 or 60Hz
12-light night lighting package- 70 watt halogen Weg motor 6811 900HP / 671 kW@ 50 or 60Hz
Full deck service catwalks and railings
Drill pipe specification: 40 ft (12.2 m)
Drill pipe diameter Suggested bit Thread
diameters
6 1/4" (159 mm) 6 3/4" 9" 4" BECO
7" (178 mm) 9" 9 7/8" 4 1/2" BECO
7 5/8" (194 mm) 9 7/8" 10 5/8" 5 1/4" BECO
8" (203 mm) 9 7/8" 11" 5 1/4" BECO
8 5/8" (219 mm) 10 5/8" 6" BECO

High pressure DTH drilling

Up to 8" DTH hammer and max. 9 7/8" bit diameter

PV-275

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Pit Viper 275 RCS Technical data

Drilling Method Rotary or DTH Multi pass
The PV-275 Rig Control System (RCS) is designed to Hole Diameter 6 3/4 in - 10 5/8 in 171 mm - 270 mm
handle 6-" up to 8-58"drill rods. The cable feed system
Hydraulic Pulldown 70,000 lbf 311 kN
utilizes a dual rod/dual piston cylinder and offers high
feed speeds for increased productivity. The PV-275 RCS Weight on bit 75,000 lb 34,000 kg
offers a multi-pass tower with a total depth capacity Hydraulic Pullback 35,000 lbf 156 kN
of 195 ft through a 4-rod carousel with 40 ft rods. This
version of the machine comes standard with a new Single pass depth 37 ft 11.3 m
cab that fully integrates the RCS with the option to Maximum hole depth 195 ft 59.4 m
fully incorporate the following functions: wireless
remote tramming, auto leveling, auto drilling, and Feed speed 127 ft/min 0.6 m/s
GPS navigation. Rotary head, torque 8,700 Ibfft 11.8 kNm
Estimated weight 185,000 lb 84 tonnes
Standard equipment Dimensions tower up
Spacious thermal insulated cab with FOPS and noise
abatement to less than 70 dB(A) Length 54 ft 16.4 m
Excavator style chair and controls for increased comfort Height 67 ft 20.4 m
and visibility
Standard Cab pressurizer/ventilator/heater with the option Width 23 ft 3 in 7.0 m
to upgrade the pressurizer Dimensions tower down
Caterpillar 345SL undercarriage with hydraulic track
tensioners Length 67 ft 7 in 20.6 m
Hydraulic cylinders driven cable feed system Height 23 ft 3 in 7.0 m
Hydraulic motor driven rotary head with spline lubrication,
maximum 8,700 lbf-ft torque; speed range 0 150 rpm Compressor range
Rotary Head tachometer integrated into the RCS system Low pressure rotary 1,900 cfm@110 psi / 53.8 m3/min@7.6 bar
Remote hydraulic tower pinning Low pressure rotary 2,600 cfm@110 psi / 73.6 m3/min@7.6 bar
Four-rod carousel for 6-" to 8-58" drill rods
No Bump rod changer High pressure, DTH 1,450 cfm@350 psi / 41.1 m3/min@24 bar
Hydraulically powered breakout wrench (fork chuck) Engine (Tier ll)
Hands-free auxiliary hydraulic chain wrench
Caterpillar C27 800HP / 597 kW@1800RPM (LP 1900)
8,000 lb (3,629 kg) capacity auxiliary hoist
Hydraulically retractable dust curtains Cummins QSK19 755HP / 563 kW@1800RPM (LP 1900)
Cooling package Caterpillar C32 950HP / 708 kW@1800RPM (LP 2600)
Separate air intake filters for engine and air compressor
Wide flange structural steel beam frame with oscillation Caterpillar C27 800HP / 597 kW@2100RPM (HP 1450)
yoke mounting Weg motor 6808 700HP / 521 kW@ 50 or 60Hz
14-light night lighting package 70 watt halogen
Weg motor 6811 900HP / 671 kW@ 50 or 60Hz
Full deck service catwalks and railings
Two 48" (1.2 m) and one 60" (1.52 m) stroke leveling jacks Drill pipe specification: 40 ft (12.2 m)
350 US gallon (1,325 L) fuel tank Drill pipe diameter Suggested bit Thread
diameters

6 1/4" (159 mm) 6 3/4" 9" 4" BECO

7" (178 mm) 9" 9 7/8" 4 1/2" BECO
7 5/8" (194 mm) 9 7/8" 10 5/8" 5 1/4" BECO
8" (203 mm) 9 7/8" 11" 5 1/4" BECO
8 5/8" (219 mm) 10 5/8" 6" BECO

High pressure DTH drilling

Up to 8" DTH hammer and max. 9 7/8" bit diameter

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DM-M3 Technical data

Drilling Method Rotary - Multi pass

The Atlas Copco DM-M3 is a crawler-mounted, hydraulic Hole Diameter 9 7/8 in - 12 1/4 in 251 mm - 311 mm
tophead drive, multi-pass rotary drilling rig specifically Hydraulic Pulldown 90,000 lbf 400 kN
designed for the blasthole drilling of 9-78 in. (251 mm)
to 12- in. (311 mm) diameter holes. The on-board depth Weight on bit 90,000 lb 40,800 kg
capability is up to 240 feet (73 m) when using 8-58 in. Hydraulic Pullback 41,500 lbf 185 kN
diameter (219 mm) drill pipe and a 5-rod carousel.
Standard drill pipe length is 40 feet (12.2 m). Hydraulic Single pass depth 37 ft 11.3 m
pulldown is featuring a patented hydrostatic, closed- Maximum hole depth* 200 - 240 ft 61 - 73.2 m
loop system acting through twin, double-rod hydraulic
cylinders and cable. Feed speed 144 ft/min 0.7 m/s
Rotary head, torque 10,183 Ibfft 13.8 kNm
Standard equipment Estimated weight 230,000 lb 104 tonnes
Insulated, pressurized FOPS cab with heater
Dimensions tower up
Rotary screw 2600 CFM @ 110 psi air
compressor Length 40 ft 5 in 12.3 m
Caterpillar C32 diesel engine (950 HP at 1800 rpm) Height 67 ft 20.4 m
13-light, 70 watt quartz-halogen night lighting system
Cab and ladder access lights plus dust curtain light Width 18 ft 11 in 5.8 m
Cooling package Dimensions tower down
Remote hydraulic tower pinning
Length 66 ft 6 in 20.3 m
Auxiliary hoist of 8,000 lb (3,600 kg) capacity with lifting bail
Hydraulically-actuated, drill pipe carousel internal to tower Height 23 ft 9 in 7.2 m
for 4 drill pipe or 5 for 8- 5/8 in. diameter 40 ft.
Compressor range
Hydraulic sliding fork chuck breakout with auxiliary
hydraulic wrench Low pressure rotary 2600 cfm@110 psi / 73.6 m/min@7.6 Bar
650 U.S. gallon (2,460 L) fuel capacity Engine (Tier ll)
Wide flange structural steel "I" beam main frame with
Caterpillar C32 950HP / 709 kW@1800RPM (LP 2600)
oscillation yoke mounting
Separate three-stage air intake filters for engine and Cummins QST30 950HP / 709 kW@1800RPM (LP 2600)
compressor 6811 900HP / 671 kW@ 50 or 60Hz (LP 2600)
Weg motor
Rotary head tachometer
Three hydraulic leveling jacks and "jacks-up" indicator in cab Drill pipe specification: 40 ft (12.2 m)
Hydraulically actuated rod support arm to align drill pipe Drill pipe diameter Suggested bit Thread
during rod changing operations and when using the angle diameters
drill option
7 5/8" (194 mm) 9 7/8" 10 5/8" 5 1/4" BECO
Full walkways and railings
35.5 in (900 mm) wide, triple bar replaceble grouser pads 8 5/8" (219 mm) 10 5/8" - 11" 6" BECO
Rotary head with spline lubrication 9 1/4" (235 mm) 11" 12 1/4" 6" BECO

10 3/4" (273 mm) 12 1/4" 8" BECO

*Maximum hole depth only achieved with certain pipe sizes and
wall thicknesses.

DM-M3

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Pit Viper 311 Technical data

Drilling Method Rotary or DTH - single pass
The Pit Viper 311 is a crawler-mounted, hydraulic Hole Diameter 9 in - 12 1/4 in 229 - 311 mm
tophead drive, single-pass rotary drilling rig specifically
Hydraulic Pulldown 100,000 lbf 445 kN
designed for the blasthole drilling of 9 in. (229 mm) to
12 1/4 in (311 mm) diameter holes. It has a single-pass Weight on bit 110,000 lb 49,895 kg
depth capability of 65 (20 m) with total depth capability Hydraulic Pullback 50,000 lbf 222 kN
of 135 (41 m). Its hydraulic driven cable feed system is
capable of 110,000 lbf. (490 kN) of bit loading. Due to Single pass depth 65 ft 19.8 m
the light weight of the cable feed system the PV-311 Maximum hole depth* 135 ft 41.1 m
can operate with a live tower. A patented automatic
tensioning system eliminates down time for cable Rotary head, torque 13,800 Ibfft 17.5 kNm
adjustments. It has several advanced options like an Estimated weight 310,000 lb 140 tonnes
auto drilling system, auto levelling, remote tramming,
and GPS navigation. Dimensions tower up
Length 48 ft 14.6 m
Standard equipment Height 100 ft 6 in 30.6 m
RCS rig control system, computerized network
Width 25 ft 4 in 7.7 m
New large insulated cabin with integrated A/C, large
electrical cabinets housing computers, and a training seat. Dimensions tower down
3000 CFM (84.9 m3/min) @ 110 psig (7.6 bar) air compressor
Length 99 ft 30.2 m
Atlas Copco 375 class under carriage with two speed
hydraulic propel and automatic track tensioning. Height 29 ft 8.8 m
Optional: Caterpillar 350 Custom undercarriage with hydraulic Compressor range
propel and automatic hydraulic track tensioning
Low pressure rotary 3000 CFM@110 psi / 84.9 m3/min@7.6 bar
Optional: Fuel saving automatic hydraulic clutch
3800 CFM @110 psi / 107.6 m3/min@7.6 bar
Dual Hydraulic cylinder driven cable feed system
Dual Hydraulic motor driven rotary head with spline Engine (Tier ll)
lubrication Caterpillar C32 1125 HP / 839 kW@1800RPM
Two rod carousel for 7-58" to 10 " diameter x 35' drill pipe
Cummins QSK 38 1260 HP / 940 kW @1800RPM
No-bump rod changer
Hydraulically powered breakout wrench (fork chuck) MTU 16V2000 1205 HP / 899 kW@1800RPM
Hands Free auxiliary hydraulic wrench
Engine (Tier IV)
8,000 lb (3,630 kg) capacity auxiliary hoist
Hydraulically retractable dust curtains Caterpillar C32 1125 HP / 839 kW
Four 72 inch (1.83 m) stroke leveling jacks MTU 16V2000 1300 HP / 969 kW
Cooling package
Drill pipe specification: 35 ft (10.7 m)
700 U.S. gallon (2,649 liter) fuel tank;
1,400 gallon (5,300 liters) optional Drill pipe diameter Suggested bit Thread
Separate air intake filters for engine and air compressor diameters
Wide flange structural steel I-beam frame with oscillation 7 5/8" (194 mm) 9" - 9 7/8" 5 1/4" BECO
yoke mounting
8" (203 mm) 9 7/8" - 10 5/8" 5 " BECO
Full deck service catwalks and railings
Automatic lubrication system 8 5/8" (219 mm) 10 5/8" - 11" 6" BECO
Nordic Night light package 9 1/4" (235 mm) 11" - 12 1/4" 6" BECO
Attention horn, propel alarm
9 3/4" (248 mm) 12 1/4" 7" BECO
Ground level shutdowns
Decking in tower (when horizontal) above rod changer 10 3/4" (273 mm) 12 1/4" 8" BECO
35.5 in (900 mm) wide, triple bar replaceble grouser pads
*Maximum hole depth only achieved with certain pipe sizes and
wall thicknesses.

Visit www.atlascopco.com/blastholedrills for more information

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Pit Viper PV-351 Technical data

Drilling Method Rotary - Single pass
The Pit Viper 351 is a crawler-mounted, hydraulic Hole Diameter 10 5/8 in - 16 in 270 mm - 406 mm
tophead drive, single-pass rotary drilling rig specifically
Hydraulic Pulldown 120,000 lbf 534 kN
designed for the blasthole drilling of 10-58 " to 16 in
diameter holes. It has a single-pass depth capability of Weight on bit 125,000 Ib 56,700 kg
65 (20 m) with total depth capability of 135 (41 m). Its Hydraulic Pullback 60,000 lbf 267 kN
hydraulic driven cable feed system is capable of 125,000
lbf. (511 kN) of bit loading. Due to the light weight of Single pass depth 65 ft 19.8 m
the cable feed system the PV-351 can operate with a Maximum hole depth 135 ft 41.1 m
live tower. A patented automatic tensioning system
is eliminating down time for cable adjustments. It has Feed speed 127 - 158 ft/min 0.6 - 0.8 m/s
several advanced options like an auto drilling system, Rotary head, torque 19,000 Ibfft 25.7 kNm
auto levelling, remote tramming, and GPS navigation.
Estimated weight 385,000 lb - 175 tonnes -
415,000 lb 188 tonnes
Standard equipment Dimensions tower up
RCS rig control system, computerized network
Insulated, air conditioned cab Length 53 ft 10 in 16.4 m
3000 CFM (84.9 m3/min) @ 110 psig (7.6 bar) air compressor Height 103 ft 9 in 31.6 m
Caterpillar 385 Custom undercarriage with hydraulic
Width 26 ft 8 1/2 in 8.1 m
propel and automatic hydraulic track tensioning
Hydraulic cylinder driven cable feed system Dimensions tower down
Hydraulic motor driven rotary head with spline lubrication Length 98 ft 29.9 m
Two rod carousel for 8-5/8" to 13-3/8" diameter x 35 drill pipe
No-bump rod changer Height 27 ft 11 in 8.5 m
Hydraulically powered breakout wrench (fork chuck) Compressor range
Hands Free auxiliary hydraulic wrench
Low pressure rotary 3,000 cfm@110psi / 84.9m3/min@7.6 bar
12,000 lb (5440 kg) capacity auxiliary hoist
Hydraulically retractable dust curtains Low pressure rotary 3,200 cfm@110psi / 90.6m3/min@7.6 bar
(electric motor)
Four 72 inch (1.83 m) stroke leveling jacks
Cooling package Low pressure rotary 3,800 cfm@110psi / 107.6m3/min@7.6 bar
1200 U.S. gallon (4545 L) fuel tank Engine (Tier l)
Separate air intake filters for engine and air compressor
Wide flange structural steel I-beam frame with oscillation Caterpillar 3512 1650HP / 1230 kW@1800RPM (LP 3800)
yoke mounting Cummins QSK45 1500HP / 1119 kW@1800RPM (LP 3000)
Full deck service catwalks and railings
Weg motor 6811 1400HP / 1044kW@ 50 or 60 Hz (LP 3200)
Automatic lubrication system
Nordic Night light package Drill pipe specification: 35 ft (10.7 m)
Attention horn, propel alarm
Drill pipe diameter Suggested bit Thread
Ground level shutdowns diameters
Decking in tower (when horizontal) above rod changer
8 5/8" (219 mm) 10 5/8" - 11" 6" BECO
9 1/4" (235 mm) 11" 12 1/4" 6" BECO
10 3/4" (273 mm) 12 1/4" - 13" 8" BECO
12 3/4" (324 mm) 15" 16" 8" BECO
13 3/8" (340 mm) 16" 10" BECO

Visit www.atlascopco.com/blastholedrills for more information

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Rig Control System (RCS)

The RCS creates an automated platform for the next
generation of technologically advanced machines.
Bulky equipment panels have been replaced by sleek,
ruggedized, and easily accessible left and right operator
panels with push buttons, joysticks and a touch panel
screen. Through these panels, all rig functions can be RCS
controlled. By affixing these control devices to the chair,
the operator will continually remain in full control of the
machine no matter which way the operator turns to
perform their duties.

Providing the backbone for the system is the time proven

yet remarkably agile Controller Area Network-bus (CAN-
bus) standard. All sensors, control devices, and actuators RCS is the common platform shared throughout Atlas Copcos
are cabled into multiple strategically placed Input/Output equipment.
(I/O) Modules.The I/O Modules, left and right operators
panels, (optional) navigation system (GPS or GLONASS),
and (optional) CCI module are connected into the back of
the operators display which houses the central computer.
All cabling is built off the latest CAN-bus Open standard
utilizing molded cables.

RCS is standard on: PV-235, PV-271 RCS, PV-275 RCS,

PV-310 and PV-351

RCS Basic
The RCS design provides many qualities that are advan-
tageous to not only the operator, but also service tech-
nicians, mine planners, and mine management such as:
RCS provides ease of operations even in toughest of
environments.
Flexibility
Modularized system allows for easy add-ons, modifi-
cations, and upgrades equating to minimal downtime A B C
Onscreen calibration and adjustment of system
parameters

Increased Productivity
Computer display of all drilling pressures
On-screen display of powerhead position
Rock formation analysis and data logging
Learning curve dramatically decreased from drill-to-drill
with standardized approach to controls and hardware
Auto-features provide optimal, consistent and predict-
able results

Ease of Maintenance
Each I/O Module and sensor is equipped with LEDs to
denote differing levels of performance. Quick deduction
of variables aids decisive troubleshooting, ultimately
decreasing MTTR
Adjustable automatic identification and display of
system warnings and faults
Diagnostic menus and troubleshooting capabilities
Multiple interchangeable parts meaning less overhead (C) Sensors, control devices, and actuators are all cabled into
five strategically placed (B) I/O Modules which are in turn
and inventory connected into the (A) cab where the main computer is
Display of engine J1939 data housed behind the operators screen.

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Built-in
Clean operating environment (The cab is sealed elimi-
nating hydraulic hoses, bulkhead connections, or leaks
in the cabin)
Reduced noise
Automatic safety interlocks

The RCS has controls, instrumentation buttons, and

graphical user interfaces (GUI) that are common across
other Atlas Copco RCS machines. The GUI provides
multi-language support, built-in diagnostic system,
controlled levels of access and menu based settings. The
screen and joysticks are attached to the operators seat,
so, as the seat swivels the joysticks and screen swivels Leveling screen.
in conjunction with the operator (they are always in an
optimal and ergonomical location).

Add on Features
Auto-Level System
The auto-leveling/de-levling option closes the gap
between an average and expert operator, increasing
the quality of setup. This feature reduces wear and tear
on the machine structure by limiting torsional effect on
the mainframe and tower during leveling. In normal
conditions, this takes less than 35 seconds and is done From the settings screens, varying levels of access privileges
to an accuracy of 0.2 degrees in pitch and roll. allow for quick customized rig functions, creating a fine tuned
comfortable drilling environment.

Auto-Drill System
When activated, this function will detect the rock when
the bit touches the ground and start your air, dust
suppression, rotation and feed to collar the hole. After
the collared distance has been met, this control will
adjust air, dust suppression, rotation and feed to a
drilling setting. This feature will apply optimal pulldown
and rotation to drill as fast as possible without stalling
the rotation or getting stuck. Once the target depth has
been reached, the auto-drill will clean or flush the hole,
shutoff the air and dust suppression, and then return
the bit to a tramming safe position. This feature provides
the consistency of drilling to the correct hole depth,
including water flow to maintain the hole so it does
not collapse. Currently this is available for single pass Drill dashboard - drilling screen.
drilling and multi-pass drilling, although a manual rod
change must be made at this time.

CCI Common Communications Interface

The Common Communications Interface, or CCI, allows
RCS to communicate to other entities and also allows
data transfer to and from the RCS system. In order
for the CCI to wirelessly communicate, the mine must
provide the wireless communications device for their
network. The optional CCI comes complete with the
needed software and Ethernet cable.

GPS navigation screen.

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RRA Rig Remote Access System

The Rig Remote Access (RRA) software, which is
loaded on a mine server, gives a customer the ability
to wirelessly send files to and from the drill rigs in
conjunction with the CCI and the mines wireless
network. Utilizing a type of encoding, similar to a
standard File Transfer Protocol (FTP) server, a number
of working processes in the mine are simplified,
saving valuable man hours. By having a direct link to
the machines, work orders and log files can now be
distributed on demand.

GPS Global Positioning System

GPS hole navigation ensures each blast hole machine
is precisely positioned per the mine engineers design.
GPS antennas are mounted on the tower rest and radio
antennas on the cab to produce an accurate bit position.
Drill plans, designed with the local mine coordinates, are
imported to the RCS in the International Rock Excavation
Data Exchange Standard (IREDES) format, and the bit
position is provided in real time. The bit position is
calculated by taking into consideration the variability of
the bench, providing the operator with correct depth to
drill each hole. While tramming, the operator views a
moving map display with zoom functions as the rig gets
closer to the desired blast hole location. The dominant
system for the precise positioning of a rotary drill on a
blast hole drill plan is with satellite navigation based on
GPS or GLONASS. Accuracies up to 10 cm are possible
to reach, depending on installation and the number of
satellites. After each hole is drilled a new entry is
created on the Quality Log file.

Surface Manager
Surface Manager is a software tool to view and create
customized decision based metrics, graphs, and charts
for a mines Pit Viper fleet. It utilizes the production logs
created by RCS and is transmitted by USB or wirelessly Utilizing the High Precision GPS option, drill operators can
through the RRA server. This reporting tool provides: ensure near perfect and predictable hole positioning.
Drill usage
Consumable metrics
Planned vs Drilled Analysis (with AC HPGPS)
Rock hardness information

Each of the charts and graphs provide highly

configurable options, allowing the user to view the
precise information they require. Additionally, each chart
and graph is exportable to both Excel and PDF, enabling
the user to have a customized drill report. Centralized
management of operator lists and delay codes is also
contained in Surface Manager.

For customers running the RCS GPS system, Surface

Manager provides drill plan management. The system
will take the mines CSV files and convert them into an
IREDES drill plan for the Pit Viper.

Surface Manager is flexible to either run in a centralized

environment (SQL db with multiple client) or as a
standalone client application.

Surface Manager provides new tools to manage your drill fleet.

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Production Logging
The Production Logging option enables the drill to create
and transmit three types of logs (Event, Status and
Measure While Drilling (MWD)). These logs document a
variety of drill parameters and events while the machine
is running. Data is transferred from the RCS, either
through the Common Communications Interface to the
RRA server or by USB memory device connected during
operations. The mine can use the gathered logs for a
variety of reporting to build efficiencies and achieve
greater results in operations the drills are a part of.
Atlas Copcos required format for data interaction is
in the International Rock Excavation Data Exchange
Standard (IREDES) format.

Production Logging Data Includes: Quality Log File includes:

Date and time stamp GPS accuracy and quality (number of satellites available)
Depth tag Average penetration rate
Penetration rate Total drill time
Rotation Speed Torque Hole number
Air Pressure Start hole position
End hole position
Feed force
Drill rig info
Hole information: ID, name, plan ID
Drill Information: Type, serial number, hours, state
Operator log-ins

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Remote Propel System

The remote propel option allows the operator to
wirelessly maneuver the drill using a handheld remote
control within a 60-meter distance on the bench. This
function will allow an operator to safely tram the rig;
avoiding any potentially dangerous blind spots, prevent
any damage next to a high wall or berm, or loading onto
a lowboy. The remote control is equipped with safety
triggers to ensure that the rig will not move unless the
operator has full control to tram the machine. Featured
on the device are an emergency stop button, engine
speed control, dust curtain control, jack control, and
cable reel control (electric units only). The system can
be equipped with additional functions when available.

Teleremote
The teleremote operator panel has the same look, feel,
and buttons as being onboard the drill. The package
includes a four camera system with a one pan/tilt/zoom
camera operated remotely and visible on a 32" screen. Remote propel handheld device.
This compact system can be mounted on a table top or
in a trailer. The teleremote system is to be operated over
the mine network with capacity of 8 Mb/s dedicated per
drill. The remote operator will have full confidence and
awareness of what actions are taking place onboard the
rig as well as in near proximity.

Desktop Viewer
Through a simple software load on a mine networked
computer, the drills current state can be accessed
through our Desktop Viewer. The user will be able to view
all of the RCS screens available to an operator as
if they were in the cab using the touch panel. The drill
will be required to be online via a CCI module.

The teleremote package is small in size, yet large in capability.

Technology...All in a days work

Data Transfer Production Blast Decisions Planning

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Electric power pack

As an alternative to a diesel engine as the main source
of power, several drill models can be configured with
an electric power package, consisting of an electric WEG
motor, starter and transformer. Electric versions are
usually less costly to operate due to fewer lubricants,
having an integrated cooling system, and no diesel fuel
costs. In some cases, the operating cost advantage will
in one year cover the additional investment cost for
ordering an electric version. The service life of an electric
motor is considerably longer than for an equivalent
diesel engine, and has quieter operation.

Weg motor options are available for: DML, DM-M3,

PV-235, PV-271, PV-275, PV-310 and PV-351

Stainless steel battery &

electrical boxes
The Stainless Battery Boxes and/or Stainless Steel
Electrical Boxes is now an available option. The Battery
Box lid flips up, enabling the batteries to be easily pulled
out on a roller tray. The Electrical Boxes
all have a NEMA-4 Rating.

Stainless Steel Battery Boxes available for: PV-271 RCS

and PV-275 RCS

Stainless Steel Electrical Boxes available for: PV-235,

PV-271 RCS, PV-275 RCS, and PV-310

260-amp alternator
This option is an upgrade from the standard option that
comes on the machine to a larger alternator to suit each
mines different requirements.

Available for: PV-235, PV-271 RCS and PV-275 RCS and

PV-310

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Ground level battery isolation

& Jumpstart
This option provides the mine with the ability to isolate
all power on the machine with the turn of a switch. You
can lock each switch in addition to the box to prevent any-
one from accidentally returning power to the machine

This option provides an easy access place to jump start

dead batteries from ground level.

The lockable stainless steel box has a see through door

so that all persons can easily see the power status of the
machine based on the LED lights.

Available for: PV-235, PV-271 RCS, PV-275 RCS and PV-310

Four jack configuration

Stability in the set up of the drill rig is important for
the drilling operations. All drill rigs are provided with
hydraulic leveling jacks, as a basic tripod arrangement
some models have an option of a four jack arrangement
where the two non-drilling end jacks are tied together
acting as one outrigger.

Available for: DML, DM-M3, PV-271, PV-275

Standard equipment for PV-235, PV-310 and PV-351

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Cold weather operation

To secure trouble-free operation and a pleasant
operators working environment, there are several
cold weather options available including: additional
cab heater, hydraulic oil and diesel engine heating,
tank heaters, arctic hoses and cold weather fluids.
A well insulated and heated water injection system is
available.
Gen-sets are available for some models of drill rigs.
Fully utilized these options allow the drill rigs to
operate in arctic conditions.

Angle drilling package

The Atlas Copco advanced angle drilling package
allows the tower to be positioned from the vertical in
increments of 5 degrees. All controls for positioning
are located at the operators control console inside the
cab. This system changes the pivot point on the tower
to drill-deck level and ensures that the hole will always
collar within the dust hood. This design also provides
stability and ensures that a minimum length of the drill
pipe will be unsupported between the centralizer and
the collar. Good stability and guidance of the drill string
during collaring and drilling will reduce hole deviation.
High precision in drilling and blasting will improve
fragmentation and contribute to lowering overall
production costs

Variations of the angle drill package are available on all

other models

Available for: All rigs

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Optional wrap around decking

New decking options offer 360 complete access around
the machine. The combination of the Cab Decking and
the Extended Cooler Access Decking provide complete
access to all components on the machine. The extended
non-cab side decking adds approximately two feet of
walking space, enabling you to access the back of the
coolers.

Available for: PV-235, PV-271 RCS, PV-275 RCS and PV-310

Cooler Access Ladder: only available on PV-271 RCS and

PV-275 RCS

Hammer sub holder

This option will allow for the storage of two spare DTH
hammer units on the rig for easy availability of spare
parts on a mine site. They are located on the drill-end
on the dust collector side. The extended non-cab side
decking must be selected on the PV-270 RCS machines.

Available for: PV-271 RCS, PV-275 RCS and PV-310

Tool holder
An optional tool holder to securely carry brooms and
shovels on the rig is available.

Available for: PV-271 RCS, PV-275 RCS and PV-310

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 DRILL RIG OPTIONS

Cranes
An optional crane located on the drill end of the rig
for loading bits is available. We offer either a HIAB or
Auto Crane brand cranes. The Auto Crane comes with a
remote control.

Available for: PV-235, PV-271 RCS, PV-275 RCS

Lower rod catcher

There is the option for an additional rod catcher located
towards the bottom of the tower.

Available for: PV-271, PV-271 RCS, PV-275, PV-275 RCS,

PV-310 and PV-351

Hydraulic rod catcher

An optional hydraulically operated lower rod catcher is
available for the PV-270 RCS series. When closed, it will
contain the drill rod within the tower and prevent it from
falling out should one ever come loose. It can then be
opened from inside the cab to allow the old drill rod to
come out and a new drill rod to go in when it is time for
drill rod replacement.

Available for: PV-271 RCS and PV-275 RCS

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Auto-level system
For the DM-M3, an AutoLevel system is offered as a way
to achieve reliable and predictable leveling equating
to speed and safety. This option has adapted the same
proven hardware and software from our RCS equipped
drills. Key points on the system:
Safety interlocks: Pitch and Roll limits
Auto-leveling/de-leveling times < 60 seconds
Auto-leveling pitch and roll within 0.2 degrees
View: 6.5 screen in cab for operator awareness,
central computer and maintenance awareness
Control: Toggle switches integrate into existing panel
for ease of turning feature on-and-off

Available for: DM-M3

Under deck misting system

Another option available is the misting system. This
option provides the front of the machine, under the dust
curtain, with a fine spray of mist to assists in suppressing
dust created during tramming and drilling.

Available for: PV-271 RCS, PV-275 RCS and PV-310

Delayed turbo shutdow timer

This option can be installed to help protect the turbo in
the engine. Typically when you turn off the machine there
is still some oil in the turbo that does not have time to
cool off. This option keeps the machine running for about
five minutes after you turn off the key. This allows the
turbo and engine sufficient time to cool off. Once the
five minutes has passed, the machine fully shuts down.

Note when the Emergency Stop is activated this is

by-passed and the machine shuts down immediately.

Available for: PV-271 RCS, PV-275 RCS and PV-310

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Water injection system

The water injection system injects a regulated quantity
of water into the air flow going to the drill pipe. The
water content in the air-flushing suppresses the dust
created by the drilling operation. The water injection
system has a hydraulic motor drive, and is operated
from the cab control system.

There are several sizes of water injection systems

available, and the injection tanks are either mounted
within the frame or on the deck to ensure the drilling
water requirements are met.

Dust collector
Different sized no visible emission dry dust collectors
are available. The design features a pleated paper
element type fan/filter unit. Interval flushing is controlled
by an electronic timer. A vacuum hose allows the fan/
filter unit to draw the dust out of the collection area.
The dust is removed from the air stream as the air flows
through the pleated paper filter elements. Heavy cuttings
are contained around the hole. Operation of the dust
collector is controlled from the cab control system.

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Hydraulic ladder
This Atlas Copco option allows the operator or main-
tenance personnel an easy approach onto the machine.
Instead of having to hoist themselves up a vertical
ladder, this enables hands to be free for other needs,
such as carrying tools. There are integrated safety
interlocks* built into the ladder that will prevent the
drill from moving if the stairs are deployed, as well
as isolation and lockout features.

*Tramming Isolation on RCS Machines only

Available for: PV-235, PV-271 RCS, PV-275 RCS, PV-310

and PV-351

Tower support infill option

The newly designed tower infill is to provide mine
personnel with a dedicated and secure spot to stand
when access to the gear box, the valve bank, and under
the tower support is required. The infill is made of
sturdy slip-resistant decking and also helps with hose
management.

Available for: PV-271 RCS and PV-275 RCS

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Oil centrifuge system option

This option siphons off about 10% of the engine oil
delivered by the engine oil pump before it reaches the
normal engine oil filter. The oil then is returned to the
sump. There is no physical FILTER to change or clean;
maintenance has to remove the lid and the rotor, and
scrape out the dirt that has formed. The results vary
depending on environment and ensuring that regular
samples are taken.

Available for: Depends on engine configurations

Engraved hydraulic schematic

This option provides the machine with an engraved
schematic of the hydraulic system that is then adhered to
the hydraulic tank for easy reference during maintenance
and troubleshooting on the machine

Available for: PV-271 RCS, PV-275 RCS, PV-310 and PV-351

Live sampling
The Live Sampling System has the ability to take samples
for hydraulic oil, engine oil, and compressor oil.
This system continually circulates through this area
so samples are fresh and not stagnant.

Note: Have to select Fast Service Box in order to get

this option

Available for: PV-235, PV-271 RCS, PV-275 RCS and PV-310

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Tower restraint system

The tower restraint system is a dedicated resource
providing a safe means of conducting maintenance in
our towers. A specially designed staircase consists of
individuals steps that are made of sturdy steel grating.
The Stairway also consists of two signed gates at both
the bottom and the top, handrails, and a spacious work
platform. The Tower Fall Restraint system incorporates
a set of cables and harnesses. Once inside the tower
you have access to the cables that are permanently
anchored to the tower cords and include a shuttle on
each side on which to hook the harness. These shuttles
are an integral part of the structure and include a
double-locking mechanism for safety purposes and are
specially designed to withstand the vigors of a mining
environment. They allow the operator full access to the
tower, as well as being able to smoothly move over
transition pieces without the hazardous practice of
having to unhook from the cable, allowing the individual
to keep their hands free for tools and the task at hand.

Available for: PV-235, PV-271, PV-275, PV-310 and PV-351

Additional NDE water tank

An additional 1600 l (422 gal) NDE water tank is now
available for the PV-271 and PV-275 machines. This water
tank mounts onto the newly redesigned tower rest on
the non-drill end of the machine.

Note: Diesel Machines Only

Available for: PV-271 RCS and PV-275 RCS

Blasthole Drilling in Open Pit Mining 225

 DRILL RIG OPTIONS

Mesabi coolers
Mesabi coolers are special cooling fans specifically
designed to handle the cold weather environments.
These arctic coolers are available either from the
factory or as a field retro-fit.

They can operate in temperatures as low as -40F (-40C)

upwards to 125F (52C).

Available for: DM30, DM45, DML, PV-235, PV-271, PV-275,

and PV-310

Mesabi cooler.

Ground level shut down

All rigs are provided with a standard emergency
shutdown button mounted in the cab. As an option, one
or several additional ground level shutdown buttons can
be provided for mounting all over the machine. By pres-
sing the ground level shutdown button, the power to the
engine is then disconnected.

Emergency ladders
In order to better prepare for the event of an emergency,
now offered are either one or two emergency ladders on
the non-drill end of the machine. These ladders flip out
with a quick release and provide a swift means of escape
in the event that they are needed. When theyre not in
use, the ladders fold up onto the rig and re-latch.

Available for: PV-235, PV-271 RCS, PV-275 RCS

and PV-310

226 Blasthole Drilling in Open Pit Mining

 DRILL RIG OPTIONS

Engine roof
The Engine Roof fits over any engine configuration.
It helps protect the machine from a possible fire by
providing a physical barrier between a leaky hose
and a possible ignition source.

Available for: PV-235, PV-310, PV-271 RCS and PV-275 RCS

Extended non-cabside
decking and bit basket
Two integral parts of our 360 deck access are the drill-end
extended decking with a bit basket and the extended
cooler decking.

The drill-end decking extension is an option that in-

cludes a built-in bit basket on the drill-end of the machine.
By adding this decking option, you not only gain complete
access to the machine, but also have a safe, secure, and
dedicated spot to store bits. This option inhibits bits from
being laid unsecured on the deck, opening up a possibility
for them to shift and move during tramming.

By choosing the additional extended cooler decking, you

add approximately 2 feet (61 cm) to the non-cab side of
the machine. This allows uncon-strained access to the back
of the coolers for cleaning, maintenance, or a walkway to
other areas of the machine.

Available for: PV-235, PV-271 RCS and PV-275 RCS

Blasthole Drilling in Open Pit Mining 227

 DRILL RIG OPTIONS

Auto-thread lubrication system

The system includes a cab-activated button that initiates
flow of grease through either pneumatic or electric pump
to a nozzle. The nozzle is located on the drill table, and
sprays the grease at the pipe joint threads. This helps to
extend the life of your pipe threads when changing rods.

Pneumatic only available for: T4BH, DM25 and DM30

Electric only available for: DM45/50, DML, PV-235, PV-271,

PV-271 RCS, PV-275, PV-275 RCS, PV-310 and PV-351

Central lubrication system

The Quicklube lubrication system is designed to
provide a relatively simple and inexpensive method of
centralizing and automating the lubrication of machinery
bearings.

The system dispenses small measured amounts of

lubricant at frequent intervals while the machine is
operating. With a fully automated system, the lubricant
is supplied by an electric pump through one or more
distribution blocks to each point covered by the system.
Even those hard to reach areas are assured of being
properly lubricated and purged of contaminants.

Up to 300 lubrication points can be served, depending on

the length of the hose.
Reliably distributed lubricant in pre-determined
amounts.
Delivers lubricant to the connected lubricant points in
a safe manner.
Each lubrication circuit is equipped with a safety valve
that holds the pressure within permissible values.
If there is a block in a lubrication circuit, lubricant will
leak from the safety valve.
Works through lubrication cycles (interval time,
propagation time and load time).

Can be used in cold weather applications if special low

temperature grease is used.

Option for: T4BH, DM25SP, DM30, DM45/50, DML and PV-235

Standard equipment for: PV-271, PV-271 RCS, PV-275,
PV-275 RCS, PV-310 and PV-351

228 Blasthole Drilling in Open Pit Mining

 DRILL RIG OPTIONS

Remote tramming system

The optional remote tramming system offers the
operator the ability to move the rig from a drive pendant,
which can be worn on the operators shoulders. The
remote tram pendant is connected to the rig by a cord,
and is operated by similar joysticks as those used on the
operators panel in the cab.

Available for: DM45, DML, PV-235, PV-271, PV-271 RCS,

PV-275, PV-275 RCS, DM-M3, PV-310 and PV-351

Note: On RCS rigs this option is wireless, see page 215

Remote control unit with cord connections.

Central hydraulic test station

The central hydraulic test station allows for testing of
component pressures. A standard test fitting gauge can
be used and plugged into the desired port for reading
of the system pressure. The hydraulic test station is
mounted on the deck for easy accessibility.

Available for: T4BH, DM45, DML, PV-235, DM-M3

Standard equipment for PV-271, PV-275 and PV-310

(not required for RCS rigs - electronic sensors are

included in the RCS system)

Fire suppression system

A dry-chemical fire suppression system can be provided
with manual activation points. The system is provided
with canister(s) that are located on the deck of the
machine.

The fire suppression canister contain a dry chemical fire

suppressant which utilizes a nitrogen cartridge for the
pneumatic actuator. Several discharge nozzles located
throughout the machine will spray the suppressant when
the system is activated. This fire extinguisher agents
is rated for extinguishing type A (trash/wood), type B
(liquids) and type C (electrical equipment) fires. The fire
suppression canister can be recharged as needed.

Blasthole Drilling in Open Pit Mining 229

 DRILL RIG OPTIONS

Drain System
The Drain System is a centrally located box on ground
level where the mine can attach a drain hose to any port
and quickly evacuate any and all fluids on the machine.

Available for: PV-235, PV-271 RCS and PV-275 RCS

Standard equipment for: PV-310

Fast Service System

Fast Service system with ground level, quick connect
fittings for quick fill of fuel, hydraulic oil, engine oil, engine
coolant, water (if water injection installed), and bit lube (if
bit lube is installed) is an available option. Each different
fluid port comes with a different sized connection point to
avoid accidental cross contamination of liquids, as well as
a matching set for the mine to use on their refilling hoses.

There is also an additional upgrade to option to the Hydrau-

Flo system which is a safer, cleaner and more reliable
fuel filling valve arrangement which removes the risk of
overfilling, spillage and tank rupture while minimizing
safety and environmental hazards associated with fuel
and water transfer.

Available for: PV-235, PV-271 RCS, PV-275 RCS and PV-351

Standard equipment for: PV-310

Racor fuel filter

The Racor fuel filter is specifically designed to separate
any water that may be in the fuel lines, and a Racor fuel
filter with the heater option, as shown, is available for
some models and engine configurations.

230 Blasthole Drilling in Open Pit Mining

 DRILL RIG OPTIONS

Stereo with CD player

The operators cab can be equipped with a stereo system
with AM/FM radio, CD player, mp3 jack and speakers. The
package also includes a battery equalizer for 24V to 12V
DC conversion.

Available for: DM45, DML, PV-235, PV-271, PV-271 RCS,

PV-275, PV-275 RCS, DM-M3, PV-310 and PV-351

Engine pre-lube system

Special engine pre-lube assembly systems are available
both for Cummins and CAT diesel engines. The engine
pre-lube, lubricates the valve zone prior to engine
startup, giving the benefit of less wear and tear on
the engine over time

Available for: DM45, DML, PV-235, PV-271, PV-271 RCS,

PV-275, PV275 RCS, PV-310, DM-M3 and PV-351
Standard equipment for PV-351 (Cummins)

Towing package
Tow hooks or a tow bar mounted on the non-drill end
of the rig allow for towing.

Available for: DM45, DML, PV-235, PV-271, PV-271 RCS,

PV-275, PV-275 RCS, DM-M3, PV-310 and PV-351

Blasthole Drilling in Open Pit Mining 231

 DRILL RIG OPTIONS

High intensity discharge

lights
The high intensity discharge (HID) night light package con-
sists of upgrading the standard halogen lights to Xenon
24V, 35 Watt lamps. With this upgrade the HID lamps will
be mounted in the standard lamp locations. The HID
lamps have great luminous intensity and a color mimicking
natural daylight. These lamps are designed specifically
for forestry, mining and earth moving applications, and
are designed to have low power consumption. Lights
can be turned on when the engine is on or off.

Available for: DM30, DM45, DML, PV-235, PV-271, PV-271

RCS, PV-275, PV-275 RCS and PV-310

Sodium 240 Volt night light

package
The 240 VAC night light package consists of additional
400 Watt high pressure sodium lights and additional
150 Watt high pressure sodium lights. These lights are
installed in addition to the standard light package on the
rig and require power from an external 240 VAC power
source (like an optional gen-set).

Available for: DM45, DML, PV-271, PV-275 and DM-M3

Standard equipment for PV-351 Electric

LED Lights
The LED night light package consists of upgrading from
the standard halogen lights to LED lights (quantities
vary per machine). With this upgrade the LED lights
will be mounted in standard lamp locations plus a few
additional locations. The LED lights have great luminous
intensity, enough bright color to light up any bench.
LED lights tend to typically consume less power.
Lights can be turned on when the engine is on or off.

Available for: PV-235, PV-271 RCS, PV-275 RCS, PV-310

Tower light marker

There is also an option to place two amber lights on
either side of the top of the tower. The purpose for these
lights are to notify surround machine operators of where
the tower is when it is in the down position.

Available for: PV-271 RCS, PV-275 RCS and PV-310

232 Blasthole Drilling in Open Pit Mining

 DRILL RIG OPTIONS

Buddy seat
If an additional seat is required in the cab, a fold-up
buddy seat can be mounted inside the cabin.

Available for: PV-235, PV-271 RCS, PV-275 RCS and PV-310

(in addition to the standard bench)

Available for: DM45, DML, PV-271 and PV-275

(different version than pictured)

Torque limit control

Rotational torque limit control is standard on high
pressure drill rigs, and is an option available for low
pressure rigs. The torque limit gauge and controller are
mounted in the cab and operate an electrically controlled
remote valve. Torque limit control is used to limit the
rotation pressure within the closed loop rotation circuit.

Available for: DM25, DM30, DM45, DML, PV-235, PV-271

and PV-275

Cab sunshades
Pull down, sunshades located on all windows are
available.

Available for: DM30, DM45, DML, PV-235, PV-271, PV-275,

DM-M3, PV-310 and PV-351

Drill window guard

An optional guard over the cab window closest to the
drill tower is available. The guard will protect against
any objects that could potentially fall from the tower. The
guard will protect the window and absorb the impact of
the fall.

Available for: PV-235, PV-271 RCS, PV-275 RCS and PV-310

Blasthole Drilling in Open Pit Mining 233

 DRILL RIG OPTIONS

EARS
The optional Electronic Air Regulation System (EARS)
is designed to deliver variable air volume control, while
still maintaining constant air pressure. This allows for
savings in power and fuel consumption.

Available for: DM45, DM50 and DML

Standard equipment for: T4BH, PV-271,PV-271 RCS,
PV-275, PV-275 RCS, PV-310 and PV-351

Video camera system

For improved safety and visibility around the drill rig,
an optional video camera system can be installed.
The system consists of three or four rig mounted
video cameras and a LCD display screen mounted
inside the cab.

Each camera has a motorized lens cover for protection,

and contains a heater which automatically turns on when
the temperature falls below 50 F (10C). The cameras
are installed in water resistant housings, complete with
illuminators for low light conditions. The camera image
device is an interline transfer 0 type CDC, with a picture
resolution of 270,000 pixels (horizontal resolution of 380
TV lines and a vertical resolution of 350 TV lines).
The monitor is a 6.8 LCD screen with an auto dimmer.
Screen resolution is 270.000 pixels, and screen controls
include: bright, contrast, color, tint, image selectable,
auto scan time and scale (on/off)

Available for: DM30, DM45/50, DML, PV-235, PV-271,

PV-271 RCS, PV-275, PV-275 RCS, PV-310, PV-351
and DM-M3

Microphone mute
There is the option available on the PV-271 to have a
mic-mute system installed with the stereo. This system
will mute the stereo when the radio mic is cued.

Available for: PV-235, PV-271 RCS, PV-275 RCS, PV-310

and PV-351

234 Blasthole Drilling in Open Pit Mining

 DRILL RIG OPTIONS

Secondary air conditioning unit

The option to have a secondary air conditioning unit
is available. This unit mounts at two positions on the
outside of the cabin and is electrically run-off of 24VDC.
It also consists of three additional vents inside the cab.

Available for: PV-235, PV-271 RCS and PV-275 RCS

Cab map lights

Another option available is for the addition of three
map-reading lights located in the cab. One is located
on the dash by the door going to the powerpack, one is
mounted on the chair, and the third is mounted in
the corner of the windows above the buddy seats.

Available for: PV-235, PV-271 RCS, and PV-275 RCS

Optional bit-viewing hatch

Another option available is a bit-viewing hatch installed
in the decking just outside the cab, which will allow the
operator the ability to view the cuttings coming under
the dust flaps. The hatch can be controlled from inside
the cab.

Available for: PV-271 RCS and PV-275 RCS

Floor window available for: PV-235

Optional XIR glass

XIR Glass is a laminated glass that is stronger than the
standard laminated glass. It uses an infrared heat layer
to reflect heat away. The XIR Glass is also approximately
50% thicker, due to the middle plastic safety layer being
twice as thick than the standard glass, making it signi-
ficantly stronger.

Available for: PV-235, PV-271 RCS, PV-275 RCS, PV-310

and PV-351

Blasthole Drilling in Open Pit Mining 235

 Air compressors and Boosters
Hurricane B4-41/900 booster
A stand-out that meets T4 emission standards
Atlas Copco Hurricane has embraced the challenge of the
new EPA Non-road Regulation Tier 4 emission standards
to create the B4-41/900 booster model with a Cummins
QSB4.5 Tier 4i diesel engine. Based on the B7-41/1000
boosters proven design concept, the B4-41/900 provides
additional flexibility in drilling applications, with models
available for exploration, mining, oil and gas and con-
structionwherever there is a need for a 900 psi
single-stage booster in a more compact package.
The B4-41/900 features a flat base frame and single-point
lifting, with optional bolt-on protection frame. Oversized
forklift pockets and small overall footprint increases
maneuverability.
A pre-cooler bypass system supports cold weather
operation.
Specifications
Booster type
Booster stages
Max suction pressure
Overall dimensions, L x W x H
236 Blasthole Drilling in Open Pit Mining
Standard Features
Automatic load/unload system
Double-acting concentric valves
Watercooled booster and diesel engine
Precooler (a+15F / 8C) & suction scrubber tank
Aftercooler (a+50F / 28C)
Open skid with single point lifting and fork lift slots
Low-pressure switch at booster inlet
Suction, interstage and discharge safety relief valves
Full-function instrument panel monitoring all pres
sures, temperatures and controls with full-protection
shutdown and fault indicators
Other B4-41 options, pressures, and capacities are
available upon request.
Model 276 4 cylinders, reciprocating
1 stage operation
350 psi / 24 bar
98 x 70 x 68 inches / 249 x 178 x 172 cm
 Air compressors and Boosters

M-41/1000 Booster Module

Large power in a small footprint
Built with the same values as the new B7-41 and B4-41 Standard Features
models, the Atlas Copco Hurricane M-41 has a capacity Automatic load/unload system
of 2,440 scfm (69 m3/min.) at maximum 1,000 psi (69 bar) Double-acting concentric valves
discharge, but its small footprint is compatible with Watercooled booster block
installation on water well and reverse circulation drill
Precooler (a+15F / 8C) & suction scrubber tank
rigs, as well as on mobile drill platforms. Its compact size
Aftercooler (a+50F / 28C)
and light weight give customers, even in high pressure
markets, increased flexibility in their applications. Open skid with fork lift slots
Low pressure switch at booster inlet
The M-41 features fork lift pockets in the base frame, a Remote mounted instrument panel monitoring
remote mount control panel, and a digital temperature all pressures, temperatures and controls with full
scanner. protection shutdown and fault indicators

The M-41 offers several options for the units prime Other options, pressures, and capacities are available
mover, including hydraulic or electric motor, PTO/belt upon request.
drive, or diesel engine.

Specifications
Booster type Model 276 4 cylinders, reciprocating

Booster stages 1 stage operation

Max suction pressure 350 psi / 24 bar

Overall dimensions, L x W x H 54 x 57 x 65 inches / 137 x 145 x 165 cm

Blasthole Drilling in Open Pit Mining 237

 Air compressors and Boosters

Atlas Copco
Some nice picture of XRVS 476/1000
Quantum leap ham-
Portable Diesel Oil-flooded Compressor
mers to put here

With normal operating pressure 25 bar (363 psi), this

Atlas Copco rotary screw compressor is designed for
continuous duty in harsh conditions. The ability to vary
pressure outputs from lower to higher makes it ideal for
a wide variety of applications a wide variety of applica-
tions where auxiliary air is needed. Leak-free chassis
and central fluid drain system protect the environment.
Easy access to all service points reduces maintenance
time and operating costs. And Zincor-treated canopies
with powder coat paint finish mean improved resistance
to corrosion for long life and high resell value.

Standard Features
Quiet operation 72 decibels at 7 meters
Tier-III/Stage-III compliant Caterpillar 6 cylinder,
317 kW (426 hp) engines
Fuel consumption 75 l/h at full load.
Guaranteed free air delivery of 975 cfm (460 l/s)
Maximum operating pressure 392 psi (27 bar)
Minimum starting temperature 14 F (-10 C)
Maximum ambient temperature 113 F (45 C)

238 Blasthole Drilling in Open Pit Mining

 drill string

Secoroc rotary drill strings

A complete rotary drilling system
In rotary drilling, the selection of each purpose suited
drill string component is vital to achieve accurate holes
and operational efficiency parameters which affect
operational costs.
When developing a rotary drilling system, most of the
attention is given to the drill rig the capital equipment
that requires significant investment and hence a planned
payback. The second priority in the system tends to be
choice of rotary tricone drill bit. However, to utilize the
full power and capacity of the rig and the bit and at the
same time increase service life and productivity, serious
consideration should also be given to each component
within the drill string.
The optimal drill string includes a shock absorber at the
top, a rotary deck bushing to centralize the drill string
as it passes through the deck of the drill rig, strong and
straight drill pipes and finally a hole stabilizing roller
stabilizer or bit sub-adaptor to optimize the performance.
Giving the necessary attention to every part of the drill
string will lead to the lowest total drill operating costs.
The primary purpose of the drill string is to transmit
the rotational torque and weight from the rotary head
power source to the rock breaking drill bit. As in every
rock drilling method, the power must be transmitted as
efficiently as possible, and return as few vibrations as
possible, as these cause unnecessary wear on the drill
rig and reduces penetration rates.
When selecting components for the drill string, attention
must be given to the different roles of the support tools
in the string.
With the Secoroc rotary drill string the aim is to always:
Absorb damaging vibrations from the bit.
Reduce wear on the drill rigs rotary drive, mast and
power train.
Improve transmission energy from the rotary head to
the drill bit.
Centralize drill string within the hole, ensuring axial
alignment top to bottom.
Longer and more effective bit life.
Compliment performance potential of the drill rig and
drill bit.
Reduce friction as the drill string passes through the
drill rig deck.
Increase penetration rates, lowering total drilling costs.
Achieve blasthole accuracy for improved blasting
efficiency.
Improve the end result the correct fragmentation of
the blasted rock for lower downstream operating costs!
Visit www.atlascopco.com/secoroc and
www.atlascopco.com/blastholedrills
for more information

Secoroc drill strings for the Pit Viper series

Diameter PV-235 PV-271 PV-275 PV-311 PV-351

4 " (114 mm)

5" (127 mm)

5 " (140 mm)

6-" (159 mm)

7" (178 mm)

7 5/8" (194 mm)

8" (203 mm)

8 5/8" (219 mm)

9 " (235 mm)

9 " (248 mm)

10 " (273 mm)

12 " (324 mm)

13 /8" (340 mm)

3

Blasthole Drilling in Open Pit Mining 239

 Rotary drilling TOOLS

Tricone rotary blasthole drilling Introduction

Tricone drilling can move much more material in a given

amount of time than DTH drilling due to the generally
larger diameters used, but Tricone drilling may be a less
ore grade sensitive method due to larger bit diameters
and therefore greater hole burden and spacings used.

Ultimately, the mines production cost is the economic

driver: at the end of the day, which method gives the
lowest COST PER TON of material blasted?

Lets consider this example, for a straight forward rock

removal scenario:
12 1/4 Tricone bit and suitable drill
100 feet (30.5 m) per hour penetration rate
An impressive legacy 50 foot (15.2 m) bench height, plus subdrill
Atlas Copco Secoroc LLC traces its beginnings back to US$300/hour drill operating cost
Howard Hughes, Sr., inventor of the first two-cone rotary 9 DTH and suitable drill
drill bit for rock in 1909. Our purpose is to never be 50 foot (15.2 m) bench height, plus subdrill
satisfied but will continue, with the help of our experi-
125 feet (38.1 m) per hour penetration rate
enced engineers, to anticipate the requirements of the
drilling industry. The words spoken by Mr. Hughes are US$200/hour drill operating cost
valid at Atlas Copco Secoroc LLC today. Howard Hughes,
Sr. left behind an impressive inventors legacy, having Which method has the lowest cost per ton?
held 73 distinct patents. The company continued to be a Using the Hustrulid blasting calculations presented in the
leader in development, with the introduction of the first various Atlas Copco Academy sessions (which calculate
TriconeTM rock bit with inter-fitting teeth in 1933, and the burden, spacing, subdrill, and stemming based on hole
first Tungsten Carbide Insert rockbits in 1951. size, face height, and rock and explosive SG), we see the
following production costs:
Lowering our Customers Total Drilling Cost (TDC)
Atlas Copco Secoroc LLC is dedicated to reducing the 12 " 9"
Tricone & Big drill DTH & Small drill
customers total drilling costs while maintaining the
highest standards of quality. Atlas Copco Secoroc LLC $300 CPH $200
has repeatedly shown customers that a better bit, though 100 ROP 125
more expensive, actually reduces the cost of the drilled
hole. When a mining engineer or a purchasing group 5676.9 Tons per hour produced 3970.2
takes into account the total cost of operating a drill, it is 1 Drill required for tonnage 1.430
easy to see that the best way to cut costs is to drill the
$0.053 Op cost/ton/drill $0.050
hole faster.
$0.053 Actual cost/drilled ton $0.072
Our goal is not to just meet your expectations, but to
exceed them. As part of our commitment to continuous In this example, DTH drilling is almost 50% more costly
improvement, we constantly look for ways to make our than using Tricones. In fact, it takes another 17% in-
products drill faster and more efficiently. crease in Rate of Penetration, to 146 feet/hour, for the
DTH method to equal the Cost per Drilled Ton of the
Tricones or DTH? Tricone method.
How do you decide on which drilling method to use,
Rotary Tricone drilling, or Down The Hole hammer drill- Depending on the commodity mined, the geometry of
ing? Each has several factors in its favor. DTH drilling in the mining benches, the tonnage production rate needed,
hard ground generally has higher penetration rates than etc., it is advised that rotary Tricone drilling always be
Tricone drilling, and exerts less wear and tear on the drill investigated as a more cost effective way to correctly
because heavy pulldown forces are not used with DTH. serve the customer.
But it is much more labor, consumables, and inventory
intensive than tricone drilling. In soft ground, DTH drill-
ing tends to be problematic. DTH loses its penetration
rate advantage at 9 to 10 inch diameter (229 - 254 mm) in
hard rock.

240 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Tricone rotary blasthole drilling Elements of a rock bit

Blasthole Drilling in Open Pit Mining 241

 Rotary drilling TOOLS

Tricone rotary blasthole drilling Bit elements

Cones Carbide Insert Rows

Cones make up the cutting elements of the rock bit and A. Nose
are comprised of the following: B. Inner
C. Next to Gage
1. Tungsten Carbide Inserts - which are pressed into D. Gage
the softer steel material with interference fit to hold
E. Gage Bevel
item in place.

2. Cone Thrust Button - Made of a wear resistant

material used to take axial bearing loads.

3. Outer Cone Shell - Insert lands and cone grooves.

4. Cone Bore - Internal ball and roller bearing races.

242 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Tricone rotary blasthole drilling Bit elements

Lugs
Coupled in threes, by 120 to form the bit body and the
pin connection, the lugs are machined to hold the nozzles
and a journal-bearing surface.

Nozzles
Nozzles are used to create back-pressure in the bit to
force air through the bearing airways and increase
the air-blast force to remove and flush cuttings
from the bottom of the hole. Too large of a nozzle will
cause insufficient volumes of air to be delivered to
the bearings, while too small of a nozzle will increase
the back-pressure above the compressor modulation
setting. When the compressors modulation setting is
reached, it will then reduce its volume output causing
a decrease in (air?) volume going to the bit.

Blasthole Drilling in Open Pit Mining 243

 Rotary drilling TOOLS

Tricone rotary blasthole drilling Tricone bit inserts

Inserts are the actual physical elements that spall and break the rock. Inserts are made from tungsten carbide pow-
der and a cobalt binder material, which is pressed into the designed shape then sintered. Depending on the applica-
tion, the tungsten carbide inserts in a given bit will have a shape and physical properties best suited for the rock
being drilled.

Conical 90 Chisel or trimmer

The conical insert is used primar- The trimmer is used specifi-
ily in medium/medium-hard rock. cally in the MAGNT product
It is designated in the bit nomen- line. It enhances the gage rows
clature with a C. ability to cut the bore hole wall.
The MAGNT feature is used
in soft to medium brittle rock
formations.

Chisel Wedge crested chisel

The chisel insert is used in soft/ Wedge crested chisel inserts
medium-soft rock. It is the stan- are used exclusively on the
dard insert in soft bits (40s & gage rows of very soft to hard
50s) and is designated with an bits (40s through 60s). This
F in the bit nomenclature. shape gives a fracture resistant
insert that is much tougher
than concial or regular chisel
inserts on gage.

Ogive Serrated flat top

The ogive insert is used in areas
where the aggressiveness of the
conical insert is required with
additional toughess. The ogive is
designated as an O in
the bit nomenclature.
Serrated flat top inserts are
used on shirttail lips and along
the lug as armor to protect
against shirttail and lug wear.

Super Scoop Double Angle Conical

The super scoop is used in very Double angle concial inserts
soft rock. With the patented offset with hardmetal retard erosion
tip, digging and gouging help and provides for increased
penetrate in sticky materials. The ROP.
super scoop is designated with
an S in the bit nomenclature.

Round top
The ovoid or round top insert is used in the hardest formations. Its blunt geometry gives
it the most fracture resistant design. The round top is the standard insert in hard bits
(60s 70s & 80s) and is designated with an N in the bit nomenclature.

244 Blasthole Drilling in Open Pit Mining


Tricone rotary blasthole drilling
Atlas Copco Secoroc LLC uses the IADC (International
Association of Drilling Contractors) code along with
the product line and added bit features to help describe
the bit. The IADC code is a three numbered system to
classify the hardness and type for all roller cone rock
bits. ting structures for improved bearing loading, lowered
First digit Identifies the bit type and
major hardness class:
1 Steel Tooth for soft formations
2 Steel Tooth for medium formations
3 Steel Tooth for hard formations
4 Insert for soft formations
5 Insert for soft/medium, formations
6 Insert for medium/hard formations
7 Insert for hard formations
8 Insert for extremely hard formations types in each size from IADC class 4-2 bits up to
Second digit Designates the hardness subclass of
major hardness class. This ranges from 1 to 4, where 1
is classified as the softest subclass and 4 is the hardest
subclass.
Third digit Designates the bits features:
1 Roller bearing
2 Roller bearing air-cooled
3 Roller bearing with gage bevel inserts Insert/Tooth Type:
4 Sealed roller bearing
5 Sealed roller bearing with gage bevel inserts
6 Sealed friction bearing
7 Sealed friction bearing with gage bevel inserts
8 Directional
9 Other
Example: IADC 6-3-2
This is a medium/hard air-cooled roller 2 Tapered Gage Tooth
bearing.
Example: 12 eH63CA
12 Size
eH - Product Line: e = epsilon;
H = harder drilling Product Line and do not have suffixes.
63 First two digits of the IADC code
(rock class "6" subclass "3")
C Insert type (Conical inserts)
A Full armored lug
Blasthole Drilling in Open Pit Mining 245
Rotary drilling TOOLS
Nomenclature
Product lines:
eM epsilon technology evolved from the MAG
product line. Wide variety of drilling applications
using streamlined lugs for greater bailing area and
allowing rapid evacuation of cuttings. Balanced cut
carbide stress and higher capacity bearings for longer
life.
eH epsilon technology evolved from the HD product
line. Wide variety of drilling applications using
streamlined lugs for greater bailing area and allowing
rapid evacuation of cuttings. Balanced cutting struc
tures for improved bearing loading, lowered carbide
stress and higher capacity bearings for longer life.
Om - Omega Sealed Bearing Products
Current sizes are 9 7/8" (251 mm), 10 5/8" (270 mm),
12 " (311 mm) and 13 " (345 mm). Selected bit
IADC class 6-4. Sealed journal bearing or sealed
roller bearing, depending on bit diameter. Bit
cones designed for erosion resistance with high
insert retention aspects, to prevent loss of inserts
in erosive/abrasive conditions. Streamlined epsilon
style lug to maximize cuttings removal from bit and
hole bottom. Proprietary carbide grades to maxi-
mize both insert toughness and resistance to
abrasion.
C Conical
D Double Angle Conical
N Round Top
O Ogive
S Super Scoop
F Chisel
In Steel Tooth (or Mill) Bits: 1 to 5
1 Conventional Gage Tooth
3 T Gage Tooth
4 L Gage Tooth
5 Web Gage Tooth
Ovoids are standard inserts
Lug Features:
A Armor
B Backreaming
ST Shirttail protection in tooth bits
R Regular circulation
Other Features:
H Hard Nose on cones
G Gage bevel on tooth bits
T Tough carbide (breakage resistant)
W Wear resistant carbide
 Rotary drilling TOOLS

Steel tooth bit selection Hard formation bits

Soft formation bits
The Type S, regular circulation steel tooth bit is designed
for optimum performance in formations of low compres-
sive strength, such as soft sand rock, calcite, shale and
clay. These formations quite often contain abrasive ma-
terials such as sharp sand and may be interspersed with
layers of medium and hard formations.
Type H, regular circulation steel tooth rock bits are de-
signed to drill hard formations which contain amounts
of abrasive materials. Formations requiring the use of
this bit type are those having:
1. High compressive strength with low abrasive content
such as dolomite.
2. High compressive strength with high abrasive content
such as dolomite and trap rock.

3. Medium compressive strength with high abrasive

Soft formation bits are designed with long slim, strong
content such as quartz, sandstone and the copper
teeth to permit deep penetration into the formation
ores.
with comparatively light weight. Also, bit geometry is
adjusted to give maximum desirable scraping action on
Compared with the soft and medium formation bits, this
bottom. So specific range of footage or penetration rates
bit has higher capacity bearings and more closely spaced
can be used as a yardstick for determining when to stop
teeth with increased tooth angles to allow the use of
using this type bit, due to wide variation in weight, rotary
heavier weights required to effectively drill hard forma-
speeds and formation variations encountered. However,
tions. The geometry of this bit provides maximum chip-
if excessive tooth breakage occurs, you might safely
ping and crushing action with minimum scraping action.
assume that either the combination of weight and rotary
speed is too great or formation is too hard for this type
The outermost row of teeth on each cone is the driv-
bit.
ing row; that is, this row generates a rock gear pattern
on bottom, which in the case of these strong rocks, is
Normally, these bits are run with relatively light weights,
not easily broken up. Because of this, a webbed gage
ranging from 1,000 pounds to 3,000 pounds per inch of
surface is generally used on heel rows of teeth to keep
bit diameter. Rotary speeds usually range from 120 to
the patterns broken down.
170 revolutions per minute, depending upon the weight
applied to the bit.
Tungsten carbide hardfacing is applied to the webs to
strengthen the gage against abrasive wear.
Medium formation bits
Type H bits are commonly run with weights ranging
from 4,000 to 7,000 pounds per inch of bit diameter with
The Type M and regular circulation steel tooth rack bits
rotary speeds decreasing from 40 to 80 revolutions per
are designed for abrasive and non-abrasive medium for-
minute as weight is increased.
mations. Note that this design differs from the softer
types principally in the progressive strengthening of
the teeth and change in bit geometry to provide more Steel tooth Tricone rock bit type vs. rock hardness
chipping-crushing action. These bits have more closely Rock UCS (PSI) Steeltooth Tricone bit series Rock Type
spaced teeth with a large included angle and more gage
0
surface to resist the wear in harder and more abrasive
formations. They are particularly efficient in formations Unconsolidated Sands
S series
where shales, sandy shales, and limestones alternate. 2,000 Limestone, Siltstone
Weight can be applied very effectively to these bits due
to the more rugged construction of the cutting structure Clay Stone, Mudstone
and bearings. However, excessive rotary speeds should 4,000
be avoided to reduce the shock loads inherent in drill- Marl, Chalky Limestone
M series
ing these harder formations. This is especially important
when formations are broken, causing rough operation. 6,000
You should avoid combinations of weight and rotary Soft Shales
speeds which promote rough running to prevent pre- 8,000
mature failure of bearings and cutting structure. Drilling
weights commonly range from 1,000 to 5,000 pounds Consolidated
Sandstones
per inch of bit diameter, with rotary speeds from 60 to H series
100 revolutions per minute, depending upon the relative 10,000
weight on the bit. Soft Marble, Dolomite
12,000
Tuff, Soft Schist
14,000
Rock UCS hardness (Unconfined Compressive Strength) is only one factor contributing to the drillability of any rock. Other
factors influencing drillability are fracture toughness, shear strength, Youngs modulus of elasticity, Poissons ratio of stress
vs. strain & internal angle of friction. Any particular bit may be used in harder or softer rock than this chart indicates.

246 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Steel tooth bits Bit specifications

S Series
The S series has widely spaced, long tapered teeth with broad, axial crests for
the bottom-hole action necessary to achieve high penetration rates. Inter-fitted
rows of teeth prevent formation packing and facilitate the cleaning action. The
gage bevel is hardfaced for wear resistance. Tungsten carbide hardfacing on the
other critical areas of the S series cutting structure provides superior abrasive
wear resistance and allows the teeth to self-sharpen.

Applications: Softer formations such as clays, shales, soft sandstones, and soft
limestones.

Suggested Operating Parameters:

Weight on Bit 1,000 to 3,000 lbs per square inch of diameter
RPM 70 to 120
IADC range 1-1-2 to 1-4-2

M Series
M series bits are designed with shorter, stronger teeth to withstand the
weight required for these formations. The M series shirttail is overlaid
with tungsten carbide hardfacing for abrasive wear resistance.

Applications: Medium formations, such as limestones, sandstones, and

dolomites.

Suggested Operating Parameters:

Weight on Bit 3,000 to 5,000 lbs per square inch of diameter
RPM 60 to 100
IADC range 2-1-2 to 2-4-2

H Series
H series bits have a heavy gage bevel and short, closely spaced teeth to with-
stand heavier impact loads. Tungsten carbide hardfacing on the shirttail offers
superior wear resistance. The H series has proven successful in drilling opera-
tions in which excessive gage wear must be avoided.

Applications: Hard shale formations, limestones, sandstones, and dolomite

formations.

Suggested Operating Parameters:

Weight on Bit 4,000 to 7,000 lbs per square inch of diameter
RPM 60 to 80
IADC range 3-1-2 to 3-4-2

Blasthole Drilling in Open Pit Mining 247

 Rotary drilling TOOLS

TCI bit selection Bit specifications

Five basic classifications of Atlas Copco Secoroc rock
bits are available for TCI (Tungsten Carbide Insert)
blasthole drill bits. These are divided into the 40, 50, 60, 50 series
70 and 80 series rock bits. The principal design differ- The 50 series bits are
ences are in tailoring the cutting structure of each type to typically character-
most efficiently drill specific formations. For example, 60 ized by more densely
series bits are designed for drilling medium-hard to hard spaced chisel or coni-
formations, the 70 series for hard formations and the 80 cal inserts. This con-
series for the hardest formations. figuration promotes
maximum penetration
rates in soft/medium
The modifications in cutting structure design from series
formations that are
to series are:
fractured or have vary-
ing degrees of hard-
1. The spacing of inserts or teeth is greatest for the
ness.
softer or weaker formations and decreases as the
formation hardness increases.
Applications:
Soft/medium
2. The number of rows and/or the total number of
formations such as
inserts or teeth per bit increases as formation
sandstone, shale, granite
hardness increases.
and some marble.
3. The groove depth and amount of intermesh is
Suggested operating parameters:
decreased as formation hardness increases.
Weight on bit - 3,000 to 6,500 lbs/inch of diameter
Rotations speed - 50 to 150 RPM
4. The insert or tooth projection above the cone
shell is greatest for the softer formations and is
decreased as the formation hardness increases.

Specifications
40 series 60 series
The 40 series bits are The 60 series bits are
typically character- typically character-
ized by large diameter ized by more densely
widely spaced super spaced, shorter pro-
scoop, chisel or conical jecting chisel, concial
inserts. The configura- or ogive inserts.
tion promotes maximum This configuration
penetration rates in promotes maximum
softer formations that penetration rates in
have a tendency to stick medium/hard forma-
and ball up the cutting tions.
structure.
Applications:
Applications: Medium/hard forma-
Soft formations such tions such as hard
as shale, siltstone, soft limestone, hard
limestone and alluvials. shale, basalt and
quartzite.
Suggested operating parameters:
Weight on bit - 1,000 to 5,000 lbs/inch of diameter Suggested operating parameters:
Rotation speed - 50 to 150 RPM Weight on bit - 4,000 to 7,000 lbs/inch of diameter
Rotation Speed - 50 to 120 RPM

248 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

TCI (Tungsten Carbide Insert) bits Bit specifications

70 series 80 series
The 70 series bits The 80 series bits are
are typically charac- typically character-
terized by densely ized by very densely
spaced, shorter spaced, short project-
projecting conical ing ovoid/round top
or ogive inserts with inserts. This con-
a conical or ovoid/ figuration promotes
round top gage insert. maximum penetration
This configuration rates in extremely
promotes maximum hard formations.
penetration rates in
hard formations. Applications:
Extremely hard
Applications: formations such as
Hard formations such chert, hematite ore
as taconite, banded and quartzite.
iron and quartzite.
Suggested operating parameters:
Suggested operating parameters: Weight on bit - 6,000 to 9,000 lbs/inch of diameter
Weight on bit - 4,000 to 8,000 lbs/inch of diameter Rotation speed - 40 to 80 RPM
Rotation speed - 50 to 90 RPM

Technical Data

Pin connection sizes and make-up torques

Bit size range Connection size Torque range
kilogram - pound -
mm inch mm inch
force meter force foot

73 2 7/8 N-Rod* N-Rod* 277-346 2,000-2,500

95-114 3 3/4-4 1/2 60 2 3/8 415-484 3,000-3,500

117-137 4 5/8-5 3/8 73 2 7/8 622-760 4,500-5,500

143-171 5 5/8-6 3/4 89 3 1/2 970-1240 7,000-9,000

194-229 7 5/8-9 114 4 1/2 1660-2210 12,000-16,000
251-349 9 7/8-13 3/4 168 6 5/8 3870-4420 28,000-32,000
381-445 15-17 1/2 194 7 5/8 4700-5530 38,000-40,000
*Non-standard API

Blasthole Drilling in Open Pit Mining 249

 Rotary drilling TOOLS
Tricone rotary blasthole drilling
Sealed bearing tricone bits represent a technological leap
forward over standard air bearing roller cone bits. Very
high precision machining to very close tolerances, inno-
vative seal technology, premium lubricants, and proprie-
tary materials and processes make these bits more expen-
sive to purchase. These same qualities also provide vastly
superior service life and cost savings for the customer.
Air bearing bits have existed for the mining industry since
the mid 1950s, when Hughes Tool Company introduced its
series of RotoBlast air bearing tricone bits. Built with larger
fit tolerances and much rougher surface finishes on all
bearing surfaces, air bearing bits are therefore significantly
less expensive to produce. However, these qualities neces-
sarily give lower service life. Normally between 15% and
30% of the air from the air compressor is diverted into the
bit bearings to keep them cool and clean.
Bearings are still subject to contami-nation, even while
drilling, and therefore may wear rapidly. Sealed bearing
bits on the other hand, are made with very close tole-
rances and extremely smooth bearing contact surfaces.
An outer excluder keeps contamination (cuttings, grit,
and water) out of the bearings under virtually all circumstan-
ces, while an inner seal keeps grease in the bearings to lu-
bricate the bearing elements. The result is a tricone bit with
superior service life without sacrificing productivity (ROP).
250 Blasthole Drilling in Open Pit Mining
Sealed bearing
The Atlas Copco Secoroc Omega sealed
bearing product line:
Exceeds air bearing bit performance by a factor of at
least 2X, in properly applied situations.
Provides a lower Total Drilling Cost where TDC is used
as a value standard.
Provides a lower Cost/Distance where that is the
value standard.
Patents granted on the most recent competitors sealed
bearing bit were very broad and difficult to work around.
Their most important patent was on the excluder, the
outer element that is designed to keep contamination out
of, and away from, the actual grease seal. As a result,
extensive research into excluder design, and extensive
field trials under many different geologic and drilling
conditions, resulted in Secoroc being awarded a patent
for its excluder design.
One result however, of greatly increased bit life, is a
natural tendency for the ROP to fall below acceptable
standards because the bit teeth become increasingly dull
with time. Harder grades of carbide are required to keep
teeth sharp over time, but, harder carbide is more likely to
break if drilling conditions become difficult. Atlas Copco
Secoroc has developed proprietary carbide grades for
tungsten carbide inserts used in Omega bits.
 Rotary drilling TOOLS

Tricone rotary blasthole drilling Sealed bearing

A second problem inherent to operating sealed bearing bits

is cone erosion. The longer a bit runs, the more cone shell
erosion takes place, increasing the likelihood of carbide in-
sert losses. Secorocs bit cones are designed for erosion re-
sistance where abrasive conditions are expected.Insert re-
tention is insured with projection ratios being considered
in all designs.

Product benefits
The Secoroc Omega sealed bearing bit provides better
overall value for customers. Lower TDC, higher ROP, longer
bit life and the ability to use in variable drilling conditions
all contribute to cost savings and profit increases that vary
from mine to mine depending on drill depth and patterns.
Product features provide cutting structure longevity allowing
our customers to significantly reduce bit inventory levels
which also effectively reduces shipping, ordering and
logistics costs.
Customers will experience less drilling down time due
to fewer bit changes as a result of longer bit life.
Customers will achieve a higher rate of penetration
with minimal insert breakage, thereby reducing TDC.
Sealed bearings last longer than air bearings resulting
in more life to the bit and less bit changes.
Sealed bearings are not adversely effected by water
and corrosion like air bearings.
Sealed bearings allow for higher loads of weight and
a higher RPM directly effecting TDC.
Secoroc Omegas streamlined lug design occupies
less volume in the hole. This increases the total area
available at the bit for cuttings to pass through, allow-
ing cuttings to be cleared from the bottom of the hole
more efficiently.
Secoroc Omega is ideal for drilling conditions where
ground water is present in holes or from injected wa-
ter into air streams, which can be acidic and can nega
tively effect bit bearings.

Best Applications
The Secoroc Omega bits have been designed for the most
common drilling applications: copper and coal. 44 type
testing has taken place in Australia coal mines, while 53,
54 and 61 types have been tested in copper mines in
Peru, Chile, and the United States. 13 " Omega bits are
being tested in Canada.
Sealed bearing bit application must, by nature, be
selective.
Sealed bearing bits are not appropriate for all drilling
applications.
Sealed bearing bits are best applied where bearing
failure is the major mode of bit failure.

Secoroc Omega is ideal for drilling conditions where

ground water is present in holes or from injected water
into air streams, which can be acidic and can negatively
effect bit bearings. At mines where carbide insert break-
age, or cone erosion leading to carbide tooth loss, are the
major cause(s) of air bearing bit failures, sealed bearing
bits will be of little value.
*International Association of Drilling Contractors

Blasthole Drilling in Open Pit Mining 251

 Rotary drilling TOOLS
Sealed bearing case study
Newest iteration of bit at 7248 feet with less tooth wear.
US Copper - Largeporphyry deposit drilling
This mine is a large porphyry deposit with extremely
varied ground conditions. The mine groups the rock into
eight main categories with rock sub-types within each
category. What makes the drilling conditions vary so much
is not necessarily the parent rock, but the alteration suites
that were imposed on the parent rock in the pre-mineral,
mineralization and post mineral processes.
The Basin and Range type geology of the area is rather
simple, stacked and layered sediments of the usual
kind, with crustal extension to break things into valley
basins and mountain ranges, but then volcanic activity
introduced hot, molten, igneous material into it, and
varied the geology all together.
This mine is a porphyry deposit that has remained more
or less intact over the eons, without having a lot of the
original deposit eroded away over time. The ore bodies
are mostly quartzite and quartz monzonite formations.
Many areas of this mine contain high percentages of iron
pyrite which has a substantially negative effect on bit life
due to its highly abrasive nature.
Testing of the 12 OM54CA has been occurring at this
property since the conceptual stages of the Secoroc
Omega bits almost a decade ago. Three different bit types
are cur-rently used to drill the varying formations at this
mine. A 53 type bit is used for a majority of the drilling
with 62 type bits being the next most used bit type. A
small percentage of their drilling utilizes 72 type bits, but
that is usually less than 10% of the total drilling.
A 54 type hybrid cutting structure has been developed
over the past 5 years that is successfully drilling different
areas where both 53 and 62 type bits are utilized. This is
very important, because if a 53 type bit is installed and the
drill then moves to an area in which a harder 62 type bit is
needed, the more aggressive bit can be dulled quickly due
to cutting structure damage.
252 Blasthole Drilling in Open Pit Mining
Case study
Previous iteration of bit at 7318 feet. Note the high wear on the
tooth projection.
As is customary in most surface mining environments,
the drills at this property frequently move between
formations, so it was imperative to develop a cutting
structure tough enough to drill a wide range or rock types
without sacrificing speed or Rate of Penetration.
Omega bit testing in late 2009 yielded results in the range
of 2 to 3 times the life of epsilon air bearing direct offsets.
The overall, mine wide result was 2.4 times the average
air bearing bit life with longer runs in the 20,000 to 30,000
foot range. Even though the overall objective for bit life
was achieved, the overall Rate of Penetration, or ROP, was
5% less than the offset bits due to the longer runs.
The major factor in the reduced ROP was wear on the
insert or tooth projection. A follow up iteration was
produced to address this and is currently testing with early
results looking promising. None of the bits in recent tests
have dulled due to bearing failure as the primary dulling
characteristic. The few bearings that have failed are
attributed to bit body wear resulting from cutting structure
damage.
Many times, new bits will start off with a high ROP then
begin dropping off as it progresses through its life. The
goal for this bit is to have an ROP that is more sustainable
over the entire life of the bit. The Secoroc Omega bits can
start with a slightly lower ROP than the more aggressive
53 type bits, but has an overall equivalent or higher ROP
sustained over the entire bit life providing value to the
customer.
A study was done in 2008 to determine the annual cost
savings associated with fewer bit changes. The study
assumed an average bit life for the Omega bit at 2.25 X
the standard bit life. This reduces the overall bit usage by
55.6% saving the customer around $51,000 / year in labor
costs alone, plus eliminates 340 hours of lost production
time per year due to bit changes.
 Rotary drilling TOOLS

Tricone rotary blasthole drilling Case study

Many times, new bits will start off

with a high ROP then begin dropping Cost reduction estimates due to decreased bit changes.
off as it progresses through its life. Bit Reduction Usage /
Condition being Current Mine Usage Secoroc Omega
The goal for this bit is to have an Cost Savings by using
measured / Costs Projections
ROP that is more sustainable over Secoroc Omega
the entire life of the bit. The Secoroc Estimated rotary bit
Omega bits can start with a slightly 270 bits 120 bits 150 bits
usage
lower ROP than the more aggressive
Average estimated
53 type bits, but has an overall 2.25 hours
time for bit change
equivalent or higher ROP sustained
over the entire bit life providing Average number of
value to the customer. employees involved 2-3
in bit change
A study was done in 2008 to Estimated employee
$60
determine the annual cost savings hourly cost
associated with fewer bit changes. Estimated cost
The study assumed an average bit for employees to $337.5
life for the Omega bit at 2.25 X the change a bit
standard bit life. This reduces the
Estimated costs to
overall bit usage by 55.6% saving $91, 125 $40,500 $50,625
change out a bit
the customer around $51,000 / year
Figures used in this chart are preliminary estimates for reduction in cost due to decreased bit changes. Testing was
in labor costs alone, plus eliminates actually conducted at a US mine using estimations only and does not take into account the cost of the bit.
340 hours of lost production time per
year due to bit changes. Testing does not take into account that bits removed for size changes can be used again with better performance, since
sealed bearing bits do not rust, improving overall performance.

Blasthole Drilling in Open Pit Mining 253

 Rotary drilling TOOLS

TCI (Tungsten Carbide Insert) bits Bit selection

Tricone carbide insert rock bit series vs. rock hardness

Rock UCS
Tungsten carbide insert Tricone bit series Rock type
(psi)
0 Claystone, Mudstone
40
series Chalky Limestone
4,000 4-1 Soft Shale
to
4-4 Loose Sandstones
8,000 Limestone, Siltstone
Solid Sandstones
12,000 Medium Shales
50 MAG NT
series series Tuff, Soft Schist
5-1
16,000 Andesite, Rhyolite
to
5-4 Omega Quartzite (Sand, Silt)
20,000 series Limestone, Marble
Monzonite, Granite
24,000 Epsilon Gneiss
series Diorite, Diabase
28,000 Hard Shale, Slate
60
series Limestone, Dolomite
32,000 6-1 Basalt
to
6-4 Tactite, Skarn
36,000 Granodiorite
Taconite
HD NT
40,000 series Quartzite
Syenite
44,000 70 Gabbro
series
7-1
48,000 to Banded Iron Formation
7-4
Taconite
52,000 Chert

56,000 Quartzite

80
60,000 series Amphibolite
8-1
to
64,000 8-4 Hornfels

68,000 Hematite Ore

Lava, Basalt, Biwabic,

Higher
Quartzite
Rock UCS hardness (Unconfined Compressive Strength) is only one factor that contributes to the drillability of any rock. Other factors strongly influencing drillability are: fracture toughness, shear strength,
Youngs modulus of elasticity, Poissons ratio of stress vs. strain, internal angle of friction. Any particular bit may be used in harder or softer rock than this chart indicates.

254 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

When to change a bit Tricone bits

At most mines the decision when to change the bit is

typically left up to the driller, with very little guidance
Analyzing a typical bit run
given. This results in most bits being changed only after Rig cost: $200
they have been completely worn out. We believe that a Bit cost: $3,550
typical operation can save $000s annually by applying
some simple rules. Date Meters Hours ROP TDC/m
9-Oct 727 9 80.8 $7.36
At the end of a Tricone bits life the cutting structure 10-Oct 1,597 20 80.7 $4.70
becomes ineffective either through breakage or wear,
resulting in reduced penetration rate. Using the TDC for- 11-Oct 2,308 29 80.2 $4.03
mula, cost effective bit life can be calculated and 12-Oct 3,106 38 81.6 $3.59
related to penetration rate, giving the drill operator a
13-Oct 3,573 46 77.6 $3.57
guide as to when to change the bit.
14-Oct 4,078 54 76.1 $3.50
15-Oct 4,431 58 76.5 $3.42
16-Oct 4,753 62 76.7 $3.35
17-Oct 5,251 70 75.0 $3.34
18-Oct 5,662 76 74.7 $3.31
19-Oct 6,174 83 74.5 $3.26
20-Oct 6,774 91 74.6 $3.21
21-Oct 7,162 99 72.7 $3.25
22-Oct 7,459 107 69.9 $3.33
23-Oct 7,893 117 67.4 $3.41
24-Oct 8,295 127 65.2 $3.51

Analyzing a typical bit run, as shown in the table above,

the optimum point in time to pull a bit can be identified.
It is seen that had the bit been removed on the 20th of
October, the run would have been $0.30 per meter more
This bit has too many broken teeth to be effective any longer. cost effective than on the 24th October.

Based on 250,000 meters drilled annually, the projected

savings would be $75,000 per annum.

$8.00 - 80.0
TDC
$7.00 Penetration Rate Penetration rate (m/hr)

$6.00 - 75.0

$5.00
- 70.0
$4.00

$3.00
Optimum time to change bit. - 65.0
$2.00 Lowest TDC = $3.21 per meter

$1.00
- 60.0
$
2308

3573

4078

4431

4753

5251

5662

7893

8295
1597

7162
3106

6774

7492
6174
727

Worn teeth cannot penetrate the rock, therefore productivity

Meters Drilled
diminishes.

Blasthole Drilling in Open Pit Mining 255

 Rotary drilling TOOLS

How a rock bit drills Rock failure

Rock cutting, abrasion - vergy small cracks, insert grinds surface. Rock cutting, spalling starts - enough weight applied to hard rock
deeper. Cracks connect. Chips will come free with air blast.

Abrasion Spalling
This is an illustration of the first phase of rock failure, Here, rotation speed (RPM) is still the same but sufficient
called the abrasion phase. This is the result of insuf- weight has been applied to the bit for most effective
ficient weight on the bit. The inserts are contacting the insert penetration into the formation. Note that the shell
rock under very low weight and the resulting action is of the bit is not against the formation.
very similar to placing a knife blade against a grinding
stone. The driller can very easily tell when he is in the
abrasion phase because the cuttings coming out of the
hole will be fine dust.

Rock cutting, deeper abrasion - deeper cracking, but does not

connect. Next cone must crack rock between these teeth.

Rock cutting, deep spalling - cracks connecting at deeper levels.

Cracks connect bertween teeth and between rows.

Fatigue
Here, more weight has been added to the bit with RPM
the same as in the previous illustration. The additional
weight has caused some penetration of the inserts into
the formation, but not actual failure of the rock. This is
called the fatigue phase and again, the driller can easily
recognize this phase by checking the returns. Small chips
and a high percentage of dust will be coming out of the
hole.
In this second illustration, the inserts are loaded under
the proper weight to cause the formation to spall. Chips
are removed by the circulating air, allowing the cutting
structure to advance. Under load condition, the bit
will drill at maximum efficiency. The driller will note a
large amount of chips with very little dust or fines in the
returns.

It should be pointed out that rock failure can be accom-

plished with this type of loading and insert penetration.
However, it may require many impacts on the formation
to cause the rock to fail. The penetration rate will be con-
siderably less than desired.

256 Blasthole Drilling in Open Pit Mining


How a rock bit drills
Rock cutting, overpenetration - cuttings trapped betwween cone
shell and rock. Cannot be blown out by air blast from nozzles.
Excess weight
Once the spalling phase has been achieved, applying ad-
ditional weight to the bit will only be harmful to drilling
efficiency. The additional weight will cause the inserts to
bury themselves in the formation. The result is a de-
crease in penetration rate.
WOB vs ROP
ROP
Weight on Bit (Pulldown)
Maximum cut efficiency
With rotation speed (RPM) fixed, this illustration shows
the effect of weight increases on the rate of penetration.
After the formation has been spalled additional weight
will reduce or not increase the drilling rate.
Blasthole Drilling in Open Pit Mining 257
Rotary drilling TOOLS
Cutting efficiency
RPM vs ROP
ROP
RPM
Maximize ROP
With the bit drilling in the spalling phase, it is possible
to increase the penetration rate by maintaining the
proper weight, while increasing the rotation speed
(RPM). The amount of increase possible in the pene-
tration rate is variable and will be determined by the
experience of the driller, the capabilities of the drill
and the formation characteristics.
Maximum Drilling Efficiency
RPM
ROP
Weight on Bit
Maximum drilling efficiency
The preceding charts illustrate: spalling weight plus
rotation speed equals penetration rate. Therefore, opti-
mum drilling efficiency may be reached as follows:
At a set RPM, determine best weight on bit (WOB) to
produce maximum cut efficiency.
At the WOB that gives maximum cut efficiency,
RPM should be determined to produce best rate
of penetration.
Note: High rotary speeds do not necessarily produce
high penetration rates.
 Rotary drilling TOOLS

Importance of records Tricone bits

Drilling hours Bit selection

Keeping complete and accurate records of blast hole A careful study of bit performance records can be of
bit performance cannot be stressed too much. A care- great help in reducing operation costs through selection
ful study of bit records can be of considerable help in of the most economical bit types and operating condi-
determining the proper bit types and best operating tions. An actual case in which the performance records
conditions to use. The meters drilled by a bit and the and bit selection were given full attention is illustrated in
penetration rate have long been accepted yardsticks the following example:
for evaluating the performance of a rock bit. However,
these are two different units of measure and many er-
roneous conclusions have been drawn from these two
Summary of average performance data
factors alone. It is therefore necessary to combine these Bit type
two units of measure into one, known as Total Drill Cost
Standard product Premium product
per meter or TDC/meter.
Bit cost US $2500 US $2875
The Total Drilling Cost is then, the cost of the bit plus the Meters/bit 5400 5000
cost of operating the drill.
Meters/hour 28 32
The simplistic cost/m would use bit cost/meters drilled, Rig cost/hour 120 120
indeed this makes up one half of the TDC/m equation. Weight 25000 kg 25000 kg
The speed at which the bit drills is included by dividing
the cost of the drill/hour by the penetration rate of the RPM 80-100 80-100
bit. TDC/meter 4.75 4.33

Hence: TDC $/m = Bit cost

+ Rig cost/hour
Bit meters Bit drilling speed
Analysis of the standard product, indicated that gage row
cutting structure was worn, leading to shirttail wear and
It may be seen in the Table below that three bits of type
failure. The premium product, with enhanced tungsten
A were run alternatively with three bits of type B. The
carbide insert features to allow maximum penetration
record indicates that the formation drilled was relatively
rate was tried.
uniform. Type A average 1418 meters in 27.8 hours; type
B averaged 1577 meters in 33 hours. Which bit was most
Using the TDC $/m equation introduced earlier and
economic if bit costs were the same at US $3000 and rig
performance data from above, a breakeven graph can
rate per hour was US $120/hour?
be constructed.
Type A bit TDC $/m = $4.47
Type B bit TDC $/m = $4.57

Now the bits can be compared and Type A is the better

bit with the lower TDC$/m.

Typical bit performance record

Bit Meters Hours Rate Weight Rotary Premium product

type drilled run M/hr in Kg RPM
Soft Med. Hard
A 1907 38.1 50.1 40000 70/90 X
B 1913 39.5 48.4 40000 70/90 X
A 1303 23.9 54.5 40000 70/90 X
B 1485 32.3 46.0 40000 70/90 X
A 1044 21.3 49.0 40000 70/90 X
B 1334 27.3 48.9 40000 70/90 X
Avg. A 1418 27.8 51.1
Avg. B 1577 33.0 47.7

258 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Importance of records Tricone bits

Drilling hours premium bit breakeven

5500
performance
5000
4500 Breakeven Costs Step 1 Premium bit cost = Hours (point A)
Rig cost/hour
4000
Meters drilled

3500 2875
156 hours = 24
3000 120
2500
*Plot to the left of zero on the X axis
3000
1500
1000 Step 2 Premium bit cost = Meters (point B)
605 m step 2 (point B) Standard TDC $/m
500
-25 25 50 75 100 125 150 175 2875
= 605
-24 step 1 (point A) 4.75
Hours

Step 3 Draw a straight line through points A and B

Bit performance above the line will return a profit for

the additional investment in the premium product.

Rotary Tricone Blasthole Drilling

Rock Type All rock types, all rock strengths

Hole Sizes 5 5/8" - 17 1/2" (143 mm - 445 mm)

Hole Depth 10 ft - 250 ft (3.04 M - 76.2 M)

Rate of Penetration, Hole-to-hole Soft (coal overburden): 100 - 300 M/hr Hard (iron ore): 20 - 60 M/hr

Very good in typical 10 - 20 meter benching Suggest using drill string roller stabilizer in long
Straightness of holes
operations holes for casting or deep benching operations

Production Capacity, Typical Tons/

Coal overburden, 7 7/8" (200 mm) bit: 75,000 tons Iron Ore, 12 1/4" (311 mm) bit: 30,000 tons
Shift per drill (10 hrs.)

Low Fuel Consumption, Ltr/Hr 75 - 90 l/hr small to medium drill (0.01 - 0.012 ltr/t) 100 - 120 ltr/hr medium to large drill (0.03 - 0.04 ltr/t)

Economic Drill String Life, M 300,000 meters/pipe, non abrasive rock 40,000 meters/pipe, highly abrasive pipe

Low Drill String Investment Yes, relative to size and hole depth

Suitable for Difficult Drilling Conditions Yes

Suitable for Good Drilling Conditions Yes

Operator Friendly Yes, larger drill cabs, more room, more available amenities

1000 to 4000 CFM, (28.3 - 113.3 cuM/min) depending on drill and bit size. Able to adjust bit air pressure
Flushing Flexibility
with different nozzles. Compatible with high pressure (350 psi/24 bar and higher) air compressors.

Blasthole Drilling in Open Pit Mining 259

 Rotary drilling TOOLS
Air practices
Air is a critical factor in tricone rotary blasthole drilling
performance. Without proper air flow, tricone rotary
blasthole bits cannot be operated efficiently. Bit bearings
are not kept clean and cool. Cuttings are not blown away
from the cutting face of the bit and moved up and out of
the hole. The operating cost of drilling a hole increases.
Key Concepts
Standard Air
Air is a compressible gas. In air compressor design, air
compressor work and air flow calculations, the standard
unit of volume is the cubic foot. The standard tempera-
ture is 70 degrees Fahrenheit, and the standard elevation
is 0 feet, or sea level. Standard atmospheric pressure
at sea level is 14.7 psia. The Standard Cubic Foot (SCF)
of air has a standard mass of 0.07494 pounds. (Stan-
dard density is .07494 lb./cu. ft.) All engineering air flow
calculations are based on the Standard Cubic Foot and
standard conditions: standard air mass, standard air tem-
perature, and standard atmospheric pressure.
Actual Air
Actual air is the free air outside of the drill bit that
does the work in drilling. Compressed air does not move
cuttings away from the cutting face of the bit. Com-
pressed air does not move rock particles up the blasthole
from the bit to the surface. Compressed air must be
released to atmospheric or ambient or actual site
specific conditions before any work can be done.
Actual air is derived from standard air by applying
the Altitude/Temperature factor:
Absolute vs. Gauge Pressure
Pressures are variously reported as psia and psig.
The ending letter, a or g, refers to whether the pres-
sure being discussed is absolute pressure or gauge
pressure.
Absolute pressure is the sum of the local ambient at-
mospheric pressure plus any pressure reading on a pres-
sure gauge. Gauge pressure is the pressure indicated
by a pressure gauge in the air system.
At sea level and 70o F, a Cab gauge pressure of 37 psig is
therefore equivalent to 51.7 psia: 37 psig + 14.7 psi
ambient atmospheric pressure = 51.7 psia. At 5000 feet,
and 70o F the same cab gauge reading would be equiva-
lent to 49.23 psia: 37 psig + 12.23 psia (atmospheric
pressure at 5,000 ft, 70o F) = 49.23 psia. If no a or g
appears after psi, the pressure is taken to mean gauge
pressure.
260 Blasthole Drilling in Open Pit Mining
Introduction
Whenever standard air volumes are calculated, sea
level atmospheric pressure, 14.7 psia, must be added to
gauge pressure.
Gas Law Physics
Boyles Law states that at a constant temperature, the
volume of a gas varies inversely with the absolute pres-
sure: P1 x V1 = P2 x V2
Charles Law states that at a constant pressure, the vol-
ume varies directly with the absolute temperature: V1 x
T2 = V2 x T1
Amontons Law says that at a constant volume, the abso-
lute pressure varies directly with the absolute tempera-
ture: P1 x T2 = P2 x T1
In our work, Boyles, Charles, and Amontons laws all
interact through the Combined Gas Law equation:
P1 x V1 = P2 x V2
T1 T2
Air Density and Atmospheric Pressure
As altitude increases, the ambient (local) atmospheric
pressure decreases. The column of air above that
particular point on the earths surface is not as deep,
therefore it weighs less, and exerts less pressure on that
point. This allows the contents of a SCF to expand
until equilibrium with the new atmospheric pressure is
reached. What starts out as one (1.00) standard cubic
foot of air becomes larger, because the atmospheric
pressure confining it is less.
At sea level, atmospheric pressure is 14.7 psia. At 5000
feet, atmospheric pressure drops to 12.23 psia. This
allows the same weight of air, .07494 lb. (contained in
one cubic foot) to expand into a larger volume. Because
it now has a larger volume, the density is less. At 5000
feet, and 70 Deg. F, one (1) ambient cubic foot of air
weighs .0623 pounds. The original SCF, weighing .07494
pounds has expanded into 1.202 cubic feet: .07494 lb /
.0623 lb = 1.202.
Temperature has the same effect on air as does confining
pressure (altitude). As temperature increases, the density
of air decreases. This can be seen from the gas laws.
Conversely, as altitude decreases, air becomes more
dense. 1.000 SCF becomes 0.89 SCF at -2,000 feet, and
has a density of .0834 pounds per cubic foot.

Air practices
Altitude/Temperature Factor
The A/T factor is used to adjust (derate) air compres-
sor intake ratings in response to changes in local altitude
and ambient temperature; and to expand the calcu-
lated compressed air output to local conditions. The A/T
factor also helps to calculate the % Capacity of the air
compressor during an air compressor volume test; and
using the measured delivered SCFM (which may be quite
different from the specification volume rating) calculates
the Bailing Velocity, Chip Settling Velocity, and the Chip
Exit Velocity.
For example, the A/T factor for 5,000 feet and 70o F is
1.202. (14.7 psia standard atmospheric pressure at
0 feet /12.23 psia ambient atmospheric pressure at
5,000 feet = 1.202.)
Bailing Velocity
The speed of the actual air moving up a blasthole.
A geometrical calculation dependent on bit diameter,
drill pipe diameter, and the volume of air circulated
through the hole. Bailing Velocity must be higher than
Chip Settling Velocity or cuttings will not be transported.
Chip Settling Velocity
The velocity a rock chip falling through air wants to
achieve. Theoretical values are calculated from an
adaptation of Stokes Law. Dependent on cuttings
diameter and rock specific gravity.
Chip Exit Velocity
The speed the cuttings (chips) move up the hole. The
difference between Bailing Velocity and Chip Settling
Velocity: CEV = BV - SV.
Tricone rotary blasthole drill air
requirements
There are two things that clean cuttings from a rotary bl-
asthole and must be combined to make drilling efficient:
air pressure and air volume.
Air pressure determines the force of the jet nozzle air
blast blowing against the bottom of the hole to move
cuttings away from the face of the bit.
Air volume, as bailing velocity, lifts cuttings up out of the
hole once they are moved away from the bit face.
Blasthole Drilling in Open Pit Mining 261
Rotary drilling TOOLS
Air requirements
Two other factors that affect the air requirements are
the moisture content of the rock and cuttings, and the
incidence of fractures and joints. Wet rock, due to ground
water or excessive water injection, will be heavier than
the same rock when dry. Cuttings from wet rock tend
to stick together, making larger particles to be blown
from the hole. Fractured or jointed ground will rob air
from the blasthole, causing the actual bailing velocity to
be lower than the calculated bailing velocity. In both of
these instances, the actual air volume required may be
much higher than what straight theoretical calculations
indicate. Experience is the best guide.
Recommendations:
Bailing Velocity
Bailing Velocity is dependent on three things: ACFM (free
air), hole diameter, and drill pipe outside diameter. The
value normally calculated is a geometric and theoretical
value that assumes a perfectly drilled straight hole with
no air losses out the side of the holes through cracks and
fractures. We must assume this because no one ever
measures a blasthole specifically for its diameter.
Under normal conditions of dry rock, very light water
injection, little or no ground water, and few if any joints
or fractures, minimum bailing velocities of 5,000 to 7,000
feet per minute (FPM) can be used. In situations where
the rock is a denser, heavier material, velocities up to
9,000 FPM could be used with little problem.
In situations where the rock is wet, or dense, or there is
a high penetration rate (above 180 feet per hour), bailing
velocities of 9,000 FPM or more may be needed. Again, it
will depend on individual situations.
The overriding recommendation for bailing air is to have
a minimum of 1,000 feet per minute Chip Exit Velocity
with drill pipe worn to replacement diameter. If this con-
dition is met, bailing performance will be good under all
other conditions.
Annular pressure calculations will not be discussed here.
Once the reader understands the basics of compressed
air use in blasthole drilling, they should pursue an ad-
vanced knowledge of rotary blasthole annular pressures
by obtaining those materials from Secoroc in Grand
Prairie, Texas, USA.
The following discussion of Particle Settling Velocity is
intended to illustrate the problems of varying rock densi-
ties and chip sizes, and how they affect the rate of chip
removal from the drill hole.
 Rotary drilling TOOLS
Air practices
Particle Slip (or Settling) Velocity
Cuttings particles fall through air at velocities dependent
on particle density, particle diameter and shape, and air
density. Large, heavy particles fall faster than small, light
ones. Slip velocity is the speed at which a particle falls
through still air. It is also called settling velocity. Slip
velocities in air may be much higher than one would
expect.
If the bailing velocity in a hole is not greater than the
slip velocity of a given size particle, that particle will not
be carried from the hole. It will be reground until it is of
a small enough size to be carried out by the air stream.
Remember: bigger chips indicate more efficient drilling,
and yield faster penetration rates. The following particle
slip velocity equation is from Walker and Mays, Journal
of Petroleum Technology, July 1975.
Particle Slip Velocity
Vt = {(2G x dp x (DenP - DenF)) / (1.12 x DenF)}.5
Where: be delivered as long as the air compressors are properly
Vt = Terminal Slip Velocity of particle, ft / sec
G = Gravity, 32 ft / sec2
dp = Diameter of Particle, feet
DenP = Density of Particle, lb / cubic foot
DenF = Density of Fluid, lb / cubic foot
Given: Bearing Life
Chip diameter = .125, .25, .50
DenP = 145 lb / ft3 for Sandstone
168 lb / ft3 for Granite
181 lb / ft3 for Dolomite
DenF = .07651 lb / ft3 for air at sea level and 59o F
Terminal Settling Velocity, feet / minute:
Also take into consideration that as altitude increases,
air density decreases; thus, particle slip velocity will
increase. Moving from sea level to 5,000 feet, air density
drops to .0637 lb/cu ft. The settling velocity of a 1/2 inch
chip of granite increases from 4330 ft to 4755 ft. It can
now be seen that chips do not leave the hole at the calcu-
lated bailing velocity, and that loss of air from any part of
the hole can reduce the actual bailing velocity to below
the settling velocity of the chips the bit actually gener-
ates. Recommended bailing velocities of 5,000 FPM are a
minimum recommendation!
Chip
Sandstone Granite Dolomite
Diameter
1/8 2013 2166 2249
1/4 2847 3064 3181
1/2 4031 4339 4503
262 Blasthole Drilling in Open Pit Mining
Particle settling velocity
Bit Pressure Drop
Sufficient air pressure at the bit must be present to
insure that plenty of air is going through the bit bearings.
Bearing air is necessary to: 1) keep the bearings cool,
and 2) keep the bearings clean. Hot and/or dirty bearings
will cause early bit failure.
With air pressure systems whose minimum operating
pressure is greater than 35 psig, Atlas Copco Secoroc
generally recommends bit pressures of 40 psig to 45 psig
minimum. This range has been found to provide enough
pressure in the bearings to keep them clean and cool,
and still direct plenty of air through the nozzles for good
bottom hole cleaning.
The Atlas Copco Drilling Solutions blasthole drill air com-
pressor is normally capable of generating 110 psig at the
receiver tank. Because of the higher level of air pressure
available on these drills for tricone drilling, Secoroc sug-
gests that tricone bit pressures can be in the 60 - 65 psi
range without causing any problems. Full volume will
adjusted, and operating to their specified parameters.
Nozzle Selection
Bearing life can be increased by using smaller nozzles
in the bit. With smaller nozzles, proportionally more air
is forced through the bearing system, providing more
cleaning and cooling. Dulling characteristics of bits
should be determined. If shirttail erosion and expo-
sure or loss of outer bearings is common, increased air
through the bearings will probably help bearing life by
keeping the cone backface and shirttail lip cleaner.
If bit failure is not due to an erosive bearing failure (such
as described above), and the cutting structure is not
highly damaged or eroded, smaller nozzles could again
help by forcing more air through the bearings. In this
instance, however, it is the cooling of the bearings that is
being enhanced. As the bearings rotate under load, heat
is generated. Too much heat build up causes thermal
degradation of the bearing metal. The air in the bearings
still retains some of the heat gained during compres-
sion, and may not provide enough cooling capacity at
low pressures (and flow rates) for the bearings. At higher
pressures, the cooling capacity of the air is increased due
to the increased volume passing through the bearings,
so the bearings stay cooler, prolonging their life.
Bottom Hole Cleaning
Bottom hole cleaning is a function of the force or
power the air blast exerts on the bottom of the hole.
Two things must happen. First, there must be enough
power exerted on the cuttings to dislodge them from
their position on the hole bottom. Cuttings may be
 Rotary drilling TOOLS

Air practices Force exerted by air

laying loose on the bottom, or they might be partially
or completely trapped under a layer of crushed material.
Second, the cuttings must be transported out from under
the bit. The first situation, freeing the cuttings, requires
more power than transporting the cuttings. Once cut-
tings are loose, they are relatively easily transported.
In the Force Exerted By Air Calculation to the right, the
force of air leaving a bit nozzle is calculated. Pressures
and temperatures are actual parameters found on a drill
equipped with a two-stage compressor.
Air volume is converted to weight. Air velocity at nozzle
exit is calculated. Multiplying the air discharge in
pounds per second by the air velocity in feet per sec-
ond gives the quantity pound feet/sec2.This converts
to a measure of force, kg meter / sec2, the Newton.
The calculations are all at Standard Conditions.
In the Force Exerted by Air Calculation, it can be seen
that smaller nozzles will apply more force to the hole
bottom for cleaning. The added benefit is increased air
through the bearings, keeping them cleaner and cooler.
Force Exerted by Air Calculation
Given
1/2 9/16 5/8 Nozzle Diameter
79 psig 57 psig 42 psig Tool Air Pressure
117 F 117 F 117 F Tool Air Temperature
260 CFM 252 CFM 246 CFM dSCFM
the variations of the coefficient of flow for the orifices.
The above flows were calculated with a .80 coefficient of
flow. If the coefficient was .78 for 1/2 and .82 for 5/8, the
flows would be virtually identical. The actual air test was
done with 7/8, 1, and 1 1/8 orifices. With a coefficient of
.78, calculated dSCFMs for the orifices were 796.9, 796.5,
and 797.2 SCFM respectively. No real change from small
to large.
Caution is advised. Although the volumes changed very
little, the amount of force increases with velocity. The
increased scouring action, if carried to an extreme, could
result in increased erosion of the bit. The increased blast
will carry cuttings at a higher velocity, possibly to the
detriment of the bit. This can be especially true if pen-
etration rates are high and cuttings are abrasive.
Keep in mind that 30% to 50% of the air in a bit goes
through the bearings, and is not used to clean the bot-
tom of the hole. Only with adequate pressure in the bit
can you move cuttings out before they can be reground.
Increased force on the bottom of the hole will give better
cleaning. Better cleaning equals higher ROP. Higher ROP
equals a lower Total Drilling Cost.

Calc./Nozzle
(CFM) / 60) x .07494 = lb per second
CFM / 60 / Nozzle area (sq. ft.) = Air velocity, ft/sec
lb/sec x ft/sec = lbft/sec2

Calculate
1/2 9/16 5/8 Nozzle Diameter
Air Weight
.3250 lb/sec .3157 lb/sec .3072 lb/sec
Delivered
3089.5 ft 2470.5 ft 1952.6 ft Air Velocity
Newtons Force/
138 N 107 N 82 N
Nozzle

1 lb ft / sec2 = .1382 kg meter / sec2

1 kg meter / sec2 = 1 Newton

Something is seen in this calculation that runs contrary

to popular wisdom. As nozzle size increased, the volume
and weight of air delivered decreased. This can be attrib-
uted to inaccuracies in air temperature, air pressure, and

Blasthole Drilling in Open Pit Mining 263

 Rotary drilling TOOLS

Air practices Suggested nozzle sizes

Suggested Nozzle ID Sizes for Secoroc Tricone Rotary Blasthole Bits

Nozzle ID Calculations use the following as constants:
Suggested Bit Pressure of 65 psi for Atlas Copco Drills only (pressure at Cab Gauge will be higher).
110 F delivered bit air temperature
70 F air compressor intake temperature

Enter Altitude of Drill Site in Feet: 1000 Meters x 3.28 = Feet A/T Factor: 1.057

Air Compressor Intake Rating - CFM

Bit Diameter 750 900 1050 1200 1400 1900 2600 3800

inches mms inches mms inches mms inches mms inches mms inches mms inches mms inches mms inches mms

5 5/8 143 1/2 12 1/2 13 9/16 14 5/8 16 11/16 17 3/4 20 15/16 23 1 1/8 28

5 7/8 149 7/16 12 1/2 13 9/16 14 5/8 15 11/16 17 3/4 20 15/16 23 1 1/8 28

6 152 7/16 12 1/2 13 9/16 14 5/8 15 5/8 17 3/4 20 15/16 23 1 1/8 28

6 1/4 159 7/16 12 1/2 13 9/16 14 5/8 15 5/8 17 3/4 20 15/16 23 1 1/8 28

6 3/4 171 7/16 11 1/2 13 9/16 14 9/16 15 5/8 16 3/4 19 15/16 23 1 1/8 28

7 3/8 187 7/16 11 1/2 13 9/16 14 9/16 15 5/8 16 3/4 19 7/8 23 1 1/8 28

7 7/8 200 7/16 11 1/2 12 1/2 13 9/16 14 5/8 16 3/4 19 7/8 23 1 1/16 28

8 1/2 216 3/8 9 7/16 10 1/2 12 1/2 13 9/16 15 11/16 18 7/8 22 1 1/16 27

9 229 3/8 9 7/16 10 1/2 12 1/2 13 9/16 15 11/16 18 7/8 22 1 1/16 27

9 7/8 251 1/4 6 5/16 9 3/8 10 7/16 12 1/2 13 11/16 17 13/16 21 1 1/16 26

10 5/8 270 1/8 4 1/4 7 3/8 9 7/16 10 1/2 12 5/8 16 13/16 20 1 26

290 mm 290 X X 1/4 6 5/16 8 3/8 10 7/16 12 5/8 16 13/16 20 1 26

11 279 X X 1/4 6 5/16 8 3/8 10 7/16 12 5/8 16 13/16 20 1 26

12 1/4 311 X X 1/4 6 5/16 8 3/8 10 7/16 12 5/8 16 13/16 20 1 26

13 3/4 349 X X X X 3/16 6 5/16 8 3/8 10 9/16 15 3/4 19 1 25

15 381 X X X X 3/16 4 1/4 7 3/8 10 9/16 14 3/4 19 1 25

16 406 X X X X X X 3/16 5 5/16 8 1/2 13 11/16 18 15/16 24

17 1/2 445 X X X X X X X X 3/16 5 7/16 12 11/16 17 15/16 23

P CO
C O ly
L AS s On
AT ill
Dr

264 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Air practices (other brand drills) Suggested nozzle sizes

Suggested Nozzle ID Sizes for Secoroc Tricone Rotary Blasthole Bits

Nozzle ID Calculations use the following as constants:
Suggested Bit Pressure of 45 psi for other brand drills only (pressure at Cab Gauge will be higher).
110 F delivered bit air temperature
70 F air compressor intake temperature

Enter Altitude of Drill Site in Feet: 1000 Meters x 3.28 = Feet A/T Factor: 1.019

Air Compressor Intake Rating - CFM

Bit Diameter 900 1200 1600 2000 2500 3000 3600 3800

inches mms inches mms inches mms inches mms inches mms inches mms inches mms inches mms inches mms

5 5/8 143 X X X X X X X X X X X X X X X X

5 7/8 149 5/8 16 3/4 18 13/16 21 X X X X X X X X X X

6 152 5/8 16 3/4 18 13/16 21 X X X X X X X X X X

6 1/4 159 5/8 16 11/16 18 13/16 21 X X X X X X X X X X

6 3/4 171 5/8 15 11/16 18 13/16 21 X X X X X X X X X X

7 3/8 187 5/8 15 11/16 18 13/16 21 X X X X X X X X X X

7 7/8 200 9/16 15 11/16 18 13/16 21 X X X X X X X X X X

8 1/2 216 9/16 14 5/8 17 3/4 20 X X X X X X X X X X

9 229 9/16 14 5/8 17 3/4 20 7/8 23 1 26 X X X X X X

9 7/8 251 1/2 12 5/8 15 3/4 19 7/8 22 1 25 X X X X X X

10 5/8 270 7/16 11 9/16 14 11/16 18 13/16 21 15/16 24 X X X X X X

290 mm 290 7/16 10 9/16 14 11/16 18 13/16 21 15/16 24 X X X X X X

11 279 7/16 10 9/16 14 11/16 18 13/16 21 15/16 24 X X X X X X

12 1/4 311 7/16 10 9/16 14 11/16 18 13/16 21 15/16 24 1 1/16 27 1 3/16 30 1 31

13 3/4 349 5/16 9 1/2 13 11/16 17 13/16 20 15/16 23 1 1/16 26 1 3/16 30 1 31

15 381 5/16 8 1/2 12 5/8 16 3/4 20 15/16 23 1 26 1 1/4 29 1 30

16 406 1/4 6 7/16 11 5/8 16 3/4 19 7/8 23 1 26 1 1/4 29 15/16 30

17 1/2 445 1/4 6 3/8 9 9/16 14 11/16 18 7/8 22 1 25 1 28 15/16 29

a nd
br nly
h er s O
Ot rill
D

Blasthole Drilling in Open Pit Mining 265

 Rotary drilling TOOLS

Air requirements and nozzle selection Tricone bits

In rotary blasthole drilling, there is always a concern Air Volume requirements for various hole diameter and drill pipe
with delivery of air in sufficient volume and at the proper combinations - for 5,000 ft. and 7,000 ft. per min. annular velocity
pressure to assure optimum bit performance when drill- D. hole diameter D. pipe O.D. (in) Q. - 5,000 CuFt/ Q. - 7,000 CuFt/
ing with recommended bit weight and RPM. (in) min free air min free air
2 7/8 327 458
Sufficient air volume should be provided to produce an 4 1/2 3 1/2 218 305
annular return velocity of 5,000-7,000 ft./min. for light, 4 116 162
dry materials; and 7,000-9,000 ft./min. for materials that 2 7/8 390 546
are wet and/or heavy, and when drilling at penetration 4 3/4 3 1/2 282 395
rates of 35 m per hour or higher. 4 178 249
2 7/8 491 687
To determine volumetric requirements, the simple Flow 5 1/8 3 1/2 382 535
equation Q = AV may be used. Since friction losses in the 4 280 392
annulus of relatively shallow holes of blasthole drilling 2 7/8 637 892
are negligible, this becomes: 5 5/8 3 /12 530 742
4 426 596
Q= V (D2 - d2) 3 1/2 732 1,025
183.35
6 1/4 4 1/2 513 718
5 382 535
The table on this page shows volumetric requirements
3 1/2 908 1,271
in cubic feet of free air per minute necessary to provide
both 5,000 and 7,000 ft. per min. annular velocity for vari- 4 805 1,127
6 3/4
ous possible combinations of hole size and drill pipe size. 4 1/2 690 966
5 560 784
The equation used is the simple flow equation: Q = AV. 3 1/2 1358 1,900
7 3/8 4 1/2 932 1,305
With all constants combined and area expressed as 5 1/2 658 921
difference between hole and pipe areas, this equation 3 1/2 1358 1,900
becomes: Q = 27.27 (D2- d2). 4 1/2 1138 1,503
5 1/2 867 1,214
7 7/8
Q = cubic feet per minute free air necessary to obtain 6 1/2 625 875
5,000 feet per minutes annular velocity 6 5/8 493 690
7 355 497
d = drill pipe outside diameter, inches 4 1/2 1665 2,331
5 1/2 1383 1,936
D = hole diameter, inches 9 6 5/8 1063 1,488
7 873 1,222
Should Q be desired for some annular return velocity 7 3/4 570 798
V other than 5,000 feet per minute, the result obtained
7 1323 1,852
above or from the table should be multiplied by the fac-
7 3/4 1022 1,431
tor: V/5000. 9 7/8
8 5/8 627 878
9 450 630
Example: A 9 7/8 hole being drilled with 7 3/4 drill pipe
7 1964 2,749
at a desired annular velocity of 5,000 ft. per minute.
7 3/4 1662 2,323
11
8 5/8 1272 1,779
Solution: Q = 27.27 [(9 7/8)2 - (7 3/4)2]
9 1090 1,526
= 27.27 [97.52 - 60.06]
8 5/8 2063 2,888
= 1022 cu. ft. per min. (shown in table)
9 1882 2,635
12 1/4
10 1365 1,911
Had 7,000 ft. per min. velocity been desired:
10 3/4 941 1,317

V7000 10 2429 3,400

Q = (1022) = 1431 cu. ft. per min. 13 3/4
5000 10 3/4 2004 2,806
10 3409 4,772

The above equation may also be rewritten to solve for 10 3/4 2985 4,179
15
annular velocity V when available compressor capac- 12 2209 3,093
ity, hole size and pipe size are known. 13 1527 2,138
10 3743 5,240
17 1/2 14 3007 4,210
183.35Q
V (ft./min.) = 16 1370 1,918
(D2 - d2)

266 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Air requirements and nozzle selection Tricone bits

Nozzle size selection How to remove and install air blast

Nozzles should be selected so that the pressure inside nozzles
the bit is 40-45 psi. The cab operating pressure will be
somewhat higher, depending on the type of drill and Nozzle removal
CFM of air circulated. Typically, on compressors rated
at 65 psi, pressure inside the bit will be 8-15 psi lower 1. Use a screwdriver to pry up the head of the nail
than what the cab gauge shows. On drills with 80-100 psi locking the nozzle into place.
rated compressors, bit pressures can be 25-50 psi lower
than the cab gauge reading. 2. When the nail head is pried up, grab the nail with
pliers and pull the nail completely out of the bit.
The proper procedure for determining the correct nozzle
size is as follows: 3. Remove the nozzle

1. Remove the bit and perform an air test. Record all

pressure readings. Be sure to use at least one orifice
plate in the air test that will give 40-45 psi at the tool. Nozzle installation

2. Determine what the cab pressure is when the tool 4. Put the nozzle into the nozzle boss, with the
pressure is 40-45 psi. beveled edge to the inside, the flat end to the out-
side. Place a nozzle nail into the nozzle hole.
3. Re-install the bit with the original nozzles. Run the air
compressor and record the cab air pressure. 5. With a hammer, pound this nozzle nail down until
the nail head contacts the bit.
4. If you do not get the cab air pressure that you saw
with 40-45 psi tool air pressure during the air test, 6. DO NOT flatten the head of the nozzle nail against
continue to install and check different sets of nozzles the bit.
in the bit until you do get the cab pressure that cor-
responds to 40-45 psi in the tool.

5. Once you get the same cab air pressure with nozzles
that you got during the air test with 40-45 psi tool
pressure, you have found the correct size nozzles to
use in the bit.

The table on the previous page shows approximate bit

air pressure that can be expected with the listed nozzles
and CFM. This can be used as a starting point for deter-
mining correct nozzle size.

Blasthole Drilling in Open Pit Mining 267

 Rotary drilling TOOLS

Air requirements and nozzle selection

Procedure for using pressure drop tables
Air
API Pin course
1. Establish maximum operating pressure and air Bit size range
size size 3
volume delivered for the air compressor being used. each 200 300 400 500 600
Consideration should be given to altitude, volumetric
efficiency, ambient temperature and mechanical con- 10 22 47 62 77
dition of the compressor when establishing these val- 5/16 16 35 47 59
ues if actual volume in not known. NOTE: An air test 2 7/8 3/8
5 to 6 10 25 35 45
is the best way to determine actual delivery of air 3 1/2 1/2
volume and pressure. 9/16 18 26 34
11 18 24
2. From the table, choose the air volume delivered 5/16 42 52 62
column nearest the actual volume established
under item 1. 3/8 33 43 51
6 1/4 to 7
3/8
3 1/2 7/16 27 34 41
3. Proceed down the proper air volume delivered 1/2 23 29 33
column to the bit size range for the bit being
9/16 18 23 29
used.
4. Read the air pressure required for forcing air through 3/8 27 36 45
the bit. The pressure required depends on the size of 7/16 21 28 35
the air blast nozzles.
1/2 21 27

5. Select the smallest nozzle diameter available within 7 7/8 to 9 4 1/2 9/16 20
the given bit size range that can be used without 5/8
exceeding the maximum operating pressure of the 11/16
compressor. Note that 10-50 psi should be reserved
3/4
for a safety buffer and other pressure losses in the
system depending on drill type and manufacturer. 3/8 26 36 46
7/16 19 27 35
Example 1 1/2 21 27
a. Bit size: 7 7/8
b. Air volume delivered: 900 cfm 9/16 20
c. Maximum operating pressure rig: 65 psi 9 7/8 to 11 6 5/8 5/8
From the table, select 7/16 nozzle (49 psi), this allows 11/16
16 psi for safety buffer and system losses.
3/4
Example 2 7/8
a. Bit size: 9 1
b. Air volume delivered: 1200 cfm
7/16 19
c. Maximum operating pressure rig: 50 psi
From the table, select 11/16 nozzle (39 psi) 1/2
9/16
Actual air volumes delivered to the bit is a key factor in 5/8
preventing early bearing failure and providing proper 6 5/8 11/16
cleaning of the tool. Pressure drops listed above are ap- 12 1/4 to 15 to 7
proximate for use as guidelines only. Actual pressures 5/8 3/4
will depend on bit condition, bearing type, and air piping 7/8
conditions.
1

Please contact your Atlas Copco Secoroc representative 1 1/8

for assistance in determining the best nozzle size for 1 1/4
individual bits and mine site condition.

268 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Tricone bits

Nozzle selection
Air pressure drop across Atlas Copco Secoroc blasthole bits with various nozzle size. Air volume delivered - cubic feet per minute

700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2600 2800 3000

71
55 65 75
42 50 58 66 74
31 38 44 58 58 64 71
72 81
61 69 78
48 57 65 73 79
41 48 54 61 67 73 79
34 41 47 51 56 62 67 73 79
55 66 75 83
42 49 55 63 69 75 81
33 39 45 51 59 67 76 84
26 32 37 43 49 55 61 67 73 80
21 26 31 36 41 47 52 57 62 69 73 79
20 25 29 34 39 44 50 55 60 65 71 77
21 25 29 34 37 41 47 51 55 60 65 70 75 79
54 62 70 77
42 50 58 65 72 79
33 39 45 53 60 66 71 77
26 32 38 43 49 54 59 64 68 73 78
19 25 32 36 41 46 49 53 58 62 66 70 74 78
20 24 29 34 39 43 47 51 54 58 62 66 70 74 78
19 22 26 31 36 40 43 47 50 54 57 61 64 68 71 75 79
20 24 26 30 32 35 38 41 44 46 49 52 55 59 63 69 75
19 21 23 25 28 30 33 35 38 40 42 47 52 57
25 30 35 41 46 53 58 63 69 75
18 23 27 33 38 43 47 52 56 60 65 70 75
19 23 27 31 34 38 42 46 50 55 59 63 67 72
19 22 25 27 31 34 38 42 46 49 53 57 61 64 68 72
20 23 26 29 32 35 39 42 45 48 52 55 58 62 66 70
19 22 25 28 31 34 37 40 42 45 48 51 53 57 61 65
17 19 21 23 25 27 28 30 33 35 37 40 42 44 47
17 19 21 23 25 27 29 33 37 41
17 19 21 25 27 29 31
17 19 23 25

Above pressure drops are for bits without anti-backflow valves. For bits with anti-backflow valves, add 3 psi.

Blasthole Drilling in Open Pit Mining 269

 Rotary drilling TOOLS
Rock formation & drillability
General rock characteristics
From the stone age until the present time, man has
worked to improve his ability to drill holes in rock.The
term rock generally refers to all the material that forms
the essential part of the earths solid crust, and includes
loose, incoherent masses as well as the very firm, hard
and solid masses. Most rocks are aggregates of one or
more minerals and are most readily classed according
to their method of origin, as igneous, sedimentary or
metamorphic.
Igneous rocks
Extrusive igneous types: rhyolite, andesite, basalt, dacite,
latite, tuff, agglomerate
Intrusive igneous types: granite, monzonite, granodio-
rite, diorite, gabbro, peridotite, syenite
Igneous rocks form by solidification from a very hot,
molten mass called magma, either on the earths surface
or below it. Igneous rocks (where they have not been
altered after their formation by weathering or other
chemical action) can be very hard and tough and pos-
sess low porosity.
There are two main classes of igneous rocks: extrusive
and intrusive. Extrusive igneous rocks are those
rocks that are expelled onto the surface of the earth by
volcanic activity. Common rocks of this type are basalt,
andesite, rhyolite, and latite. Ash flows from the rock
type called tuff. Agglomerate is a volcanic rock
made up of fragments of other rocks that have been
picked up and transported by molten lava as it flows over
the land surface. Extrusive igneous rocks will generally
have a very fine crystalline structure due to the fact that
they cooled rapidly from the original molten rock.
Intrusive igneous rocks are those rocks that solidify
below the surface of the ground. They will generally
have a coarse crystalline structure. Intrusive rocks that
cooled very slowly will have the largest crystal structure,
while those that cooled more quickly will have a smaller
crystal structure.
Igneous rocks and their drillabilities
Igneous rocks are usually difficult to drill especially
where they are fresh and unaltered by weathering or
alteration. Low drill bit life and low penetration rates are
the general rule (as compared to most common sedi-
mentary rocks). In general, igneous rocks high in quartz
contents, i.e., the granite-diorite group, are very hard,
brittle and abrasive. Those that contain less quartz and
more ferr-magnesium minerals, i.e., gabbro, basalt or
270 Blasthole Drilling in Open Pit Mining
Tricone bits
periodotitie, are less abrasive, but because of the inter-
locking nature of the ferro-magnesium minerals, tend
to be tougher rocks to drill in spite of the fact they are
softer and less abrasive.
If silicified, (silica has been introduced into the rock
through alteration processes) igneous rocks of both ex-
trusive and instrusive types can be very difficult to drill. It
is very common for extrusive igneous rocks (volcanics to
be silicified.
Sedimentary rocks
Types: conglomerate, sandstone, siltsone, claystone,
mudstone, shale, graywacke, limestone, dolomite, coal,
phosphate rock, iron formation
Sedimentary rocks are formed by an accumulation of
sediments in water or air. These sediments may consist
of rock fragments or particles of various size, shape and
chemical composition to form conglomerate, graywacke,
sandstone, siltstone, shale, claystone and mudstone in
order of decreasing grain size and roughly in order of
decreasing rock hardness.
Coal and lignite are formed by the compaction and
decomposition of plants which accumulated in tropical
swamps. Certain limestones and dolomites are formed
from the underwater accumulation of animal remains
such as coral and shellfish.
Sedimentary rocks also form as the product of chemi-
cal action or evaporation. Rocks of this origin include
limestone, dolomite, phosphate rock and a variety of
salts. Chemically deposited limestone and dolomite can
be very tough rocks to drill.
Iron formation is a catch-all term for hard, layered,
tough, brittle, very fine grained iron bearing rocks that
include taconite, banded iron formation and cherty iron
formation. It is of sedimentary origin, occurring through-
out the world, and is the source rock for most of the
words iron ore. Iron formations and their altered or en-
riched equivalents constitute some of the most difficult
of all rocks to drill.
 Rotary drilling TOOLS

Rock formation & drillability Tricone bits

Metamorphic rocks
Types: slate, quartzite, marble, hornfels, schist, gneiss

Metamorphic rocks are formed by the action of heat,

pressure, and chemical action on pre-existing rocks of
any type. Generally, some change in chemical composi-
tion has taken place from the original as a result of the
heat, pressure, and introduced chemical constituents.
Metamorphic rocks can range from very coarse grained
to extremely fine grained, depending on the degree of
metamorphism.

Argillite results from very mild metamorphism of shale,

mudstone or claystone. Slate results from an increased
level of metamorphism on those same rocks. Quartz-
ite can be formed from sandstone, graywacke or ar-
kose. Quartzite is formed when silica is introduced into
sandstone and/or siltstones, and cements the individual
grains together. Marble is derived from limestone or
dolomite, and is a recrystallization of the original struc-
ture. Hornfels is a term applied to fine-grained rocks
formed by intense contact metamorphosis (heat, pres-
sure, introduced chemicals) at the borders of igneous
rock masses. Hornfels are massive rocks unlike schist or
such as those which usually are associated with porphyry
gneiss described below.
copper ore bodies.
Schist is a low grade regional metamorphic rock which
Rock joints occur in virtually every known rock type.
has foliated structure and can be split into thin plates.
Essentially, it is a plane of weakness along which rock
Some of the original structure of the rock may still be
tends to break. It can be seen in most quarries and
present. There can be mineral segregation, where some
mines. Rock can also be fractured in locations adjacent
minerals may occur in bands, where they did not occur
to blasted areas in mines and quarries.
in bands and in the original rock.
Whatever the agency that causes them, fractures in rock
Gneiss is a high grade to very high grade regional
are detrimental to blast hole drilling. They can rob re-
metamorphic rock that is generally coarse-grained and
turn air from the drill hole, thereby reducing ability of the
banded, in which the bands alternate between mafic
return air supply to remove cuttings from the drill hole;
(iron rich) minerals and felsic (non iron) minerals.
secondly, fractured rock may need to be drilled with less
than optimum down pressure and/or rotation speed in
Similar to various igneous rocks in that they are crystal-
order to prevent tooth or insert breakage.
line and have some of the same mineral constituents,
metamorphic rocks are usually difficult to drill. This is
Rock drillability can be considerably affected by the
caused not only by the hardness and character of the
angle at which a drill bit intersects bedding or schistosity
various metamorphic minerals, but by the general inter-
planes. Drilling in directions parallel to bedding/schistos-
locking character of mineral crystals which produces a
ity planes will usually produce a higher drilling rate and
tough rock, difficult to spall.
less bit wear than drilling at an angle to bedding/schis-
tosity.

Rock drilling characteristics - Alteration of rock by surface weathering can be seen in

General
Each of the many types of igneous, sedimentary and
metamorphic rocks has its own particular drilling charac-
teristics produced by its mineral composition and grain
size. Other factors greatly affecting rock drillability are:
rock joints or fractures, bedding or other types of folia-
tion and alteration, which may be simple surface weath-
ering or very complicated chemical alteration processes
most mines and quarries. This process can change a very
hard rock such as a granite into a crumbly sandstone. It
is caused largely by the action of oxygen, carried by sur-
face water or ground water, on the component minerals
of rocks and can extend to depths of 100 m plus.
Alteration associated with metallic ore bodies can also
affect rock drillabilities by changing the mineral composi-
tion of the rock. In general, chemical alteration produces
a rock which is softer than the original rock.

Blasthole Drilling in Open Pit Mining 271

 Rotary drilling TOOLS

Rock mechanics data Tricone bits

Coompressive Poissons Engineering classification
Modulus of rigidity Youngs modulus of elasticity
Specific strength, UCS ration of intact rock
Rock
gravity stress vs. Based on UCS Based Youngs
Psi Mpa strain Psi Mpa Psi GPA
strength compressibility

Amphibolite 3.07 61,335 423 6,641,000 45,800 15,080,000 104.0 A, very high 1 - low

Andesite 2.81 26,535 183 3.944.000 27,200 9,367,000 64.6 B, high 2 - medium

Argillite 2.81 19,720 136 - - 12,194,500 84.1 B, high 1 - low

Basalt 2.94 44,950 310 4,596,500 31,700 11,295,500 77.9 A, very high 2 - medium

Chert, dolomitic 2.67 29,290 202 0.14 3,436,500 23,700 8,149,000 56.2 B, high 2 - medium

Conglomerate 2.67 23,925 165 4,698,000 32,400 11,295,500 77.9 B, high 2 - medium

Diabase 2.94 46,545 321 5,408,500 37,300 13,891,000 95.8 A, very high 1 - low
Diorite 3.01 39,730 274 0.29 6,119,000 42,200 15,515,000 107.0 A, very high 1 - low

Dirorite, augite 2.74 48,285 333 0.25 4,886,500 33,700 12,194,500 84.1 A, very high 1 - low

Dolotmite 2.60 18,995 131 0.18 2,900,000 20,000 6,902,000 47.6 B, high 2 - medium

Gabbro 3.00 44,805 309 0.33 6,394,500 44,100 17,255,000 119.0 A, very high 1 - low

Granite 2.66 37,700 260 0.2 3,422,000 23,600 8,584,000 59.2 A, very high 2 - medium

Granite, aplitic 2.65 51,185 353 0.26 4,756,000 32,800 11,687,000 80.6 A, very high 2 - medium

Granite, gneissic 2.66 30,305 209 0.02 1,299,200 8,960 2,697,000 18.6 B, high 3 - high

Granite, pre-Cambrian 2.80 - - 0.27 7,583,500 52,300 11,904,500 82.1 - 2 - medium

Granodiorite 2.74 36,540 252 0.24 4,060,000 28,000 9,947,000 68.6 A, very high 2 - medium

Greenstone 3.02 39,005 269 6,104,500 42,100 15,225,000 105.0 A, very high 1 - low

Hematite ore 5.07 88,015 607 - - 29,000,000 200.0 A, very high 1 - low

Hornfels 3.19 77,285 533 5,930,500 40,900 13,891,000 95.8 A, very high 1 - low

Limestone 2.68 22,330 154 0.28 3,842,500 26,500 9,874,500 68.1 B, high 2 - medium

Limestone, chalky 1.89 4,205 29 0.02 780,100 5,380 1,609,500 11.1 D, low 3 - high

Limestone, dolomitic 2.78 28,710 198 0.29 5,452,000 37,600 14,094,000 97.2 B, high 1 - low

Marble 2.72 23,925 165 0.3 4,393,500 30,300 11,397,000 78.6 B, high 2 - medium

Marble, taconite 2.71 9,005 62 - - 6,945,500 47.9 C, medium 2 - medium

Marlstone 2.31 21,895 151 0.11 1,609,500 11,100 3,610,500 24.9 B, high 3 - high

Meta-rhyolite 2.84 18,125 125 4,582,000 31,600 11,397,000 78.6 B, high 2 - medium

Monzonite, Quartz 2.68 22,475 155 0.22 - - 10,498,000 72.4 B, high 2 - medium

Phyllite, green 3.24 18,270 126 4,756,000 32,800 11,092,500 76.5 B, high 2 - medium

Quartzite 2.65 54,230 374 0.13 4,466,000 30,800 10,150,000 70.0 A, very high 2 - medium

Quartzite, hematitic 4.07 42,485 293 0.2 5,887,000 40,600 14,195,500 97.9 A, very high 1 - low

Sandstone 2.34 477 3 0.1 - - 57,855 0.4 E, very low 3 - high

Sandstone, argillaceous 2.80 15,225 105 0.05 2,146,000 14,800 4,509,500 31.1 C, medium 3 - high

Sandstone, calcareous 2.60 22,910 158 0.16 3,465,5000 23,900 8,018,500 55.3 B, high 2 - medium

Sandstone, ferriginous 2.60 19,140 132 0.22 2,189,500 15,100 5,553,500 38.3 B, high 3 - high

Sandstone, Navaho, cemented 2.15 12,601 87 -0.09 890,300 6,140 1,508,000 10.4 C, medium 3 - high

Sandstone, Navaho, cemented 2.31 13,094 90 -0.03 1,624,000 11,200 3,146,500 21.7 C, medium 3 - high

Schist, sericite 2.70 23,490 162 3,799,000 26,200 8,700,000 60.0 B, high 2 - medium

Shale 2.81 31,320 216 0.09 3,857,000 26,600 8,439,000 58.2 B, high 2 - medium

Shale, carbonaceous 2.30 16,240 112 0 949,750 6,550 2,015,500 13.9 B, high 3 - high

Shale, siliceous 2.80 33,495 231 0.12 4,422,500 30,500 9,874,500 68.1 A, very high 2 - medium

Siltstone 2.76 37,120 256 3,668,500 25,300 7,714,000 53.2 A, very high 2 - medium

Skarn, garnet-pyroxene 3.28 18,850 130 5,046,000 34,800 12,499,000 86.2 B, high 1 - low

Syenite 2.82 49,935 303 4,103,500 28,300 10,701,000 73.8 A, very high 2 - medium

Syenite, porphytric 2.70 62,930 434 4,393,500 30,300 10,295,000 71.0 A, very high 2 - medium

Tactite, epidote 2.87 38,570 266 0.11 4,016,500 27,700 8,903,000 61.4 A, very high 2 - medium

272 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Guides for best bit performance Tricone bits

I. Exercise care in making-up and breaking-out the B. Hole cleaning is based on feet/minute of up
drill bit to avoid damaging the bit threads and drill hole annular velocity.
steel. Air volume should produce a minimum
A. After the connection is broken, avoid down of 5,000 linear feet per minute annular
pressure on the bit breaker when unscrewing. return velocity for removal of light cuttings
Hoist the drill steel high enough for the bit and 7,000 feet per minute for heavy material.
to drop from the box connection into the bit
breaker. Low up-hole velocity causes cuttings to fall
B. Make sure the deck is clean and the bit breaker back to bottom until they are reground small
is properly mounted in its holder. enough to be carried out of the hole.

C. Clean the threads on the new bit and on the An increase in torque, torque fluctuations,
drill steel, make sure the mating shoulders are either hydraulic pressure or amps, or an
clean and a quality anti-galling lubricant has increase in air pressure, are all indications
been applied. that the hole is not being cleaned.

D. Stab carefully - avoid excessive pressure on C. Some indications that the hole is not being
high angle thread flank. Re-level the machine properly cleaned are:
if the drill stem box doesnt align with bit pin.
E. Always use low torque and slow RPM when Increase in torque indication through higher
making up connection. Mating shoulders hydraulic pressure or higher amp meter
should smoothly make up to 1/8 with low reading.
torque.
Increase in air pressure.
II. When a new bit is installed, drill at reduced weight
for a short break-in period. Use the 1/3 - 2/3 rules: Excess of cuttings in the bottom of the hole
1/3 of normal weight and RPM for 1/3 (more than one foot - after completion of
of the first hole hole and after making a cleaning pass).

2/3 normal weight and RPM for the next 1/3rd Heavy wear and/or damage indications on
of the hole. shirttails.

Normal drilling parameters to finish the hole. D. Some reasons for an increase in air pressure
while drilling:
A. After the break-in period, bit cones should
be checked to be sure that all are about the Fast penetration, not cleaning the holes.
same temperature. One hot cone generally
indicates that the air passage to that particular Foreign material in the bit, coming from
bearing has become obstruction. If one cone inside the air system, or cuttings coming in
is hot the bit should be inspected before any through the air nozzles or shirttails.
damage occurs.
Air passages to the bearings becoming
B. Make sure that all assembly grease is blown plugged with cuttings.
out of all three cutters. When the air is turned
on, air should blow out of the back of each IV. Turn the air on before lowering the bit to collar the
cone. hole. Keep the air on until the bit is finished
drilling and is out of the hole. Always rotate the
III. Provide adequate air to the bit to insure trouble bit when moving in or out of the hole.
free bearing performance and reduced abrasion
wear on cones and shirttails. A. Make sure the cab gage pressure is at its normal
reading and air is circulating through the
A. The compressed air serves two functions: bit before starting to drill. Inadequate air to
Air to the bearings, to cool and clean the the bearings is a principal cause of overheating
assembly. and early bearing failure.
B. Always rotate when coming out of the hole to:
Hole cleaning to remove cuttings from the Help clean cuttings from the hole.
blasthole.
To insure maximum bearing life, a 40 psi mini- Keep cuttings from entering the bearings
mum pressure drop across the bit is desirable. around the back face of the cone.

Blasthole Drilling in Open Pit Mining 273

 Rotary drilling TOOLS

Guides for best bit performance Tricone bits

Eliminate the possibility of clogging and A. If the bit sits idle for any length of time, in
jamming of the roller stabilizer rollers. freezing conditions, and where water
(If used.) injection is used, water can freeze inside the
bearings and air passages. The air temperature
C. Always rotate when going in the hole to: from compressor will normally melt the ice if
enough time is allowed before starting to drill.
Decrease the possibility of damaging the bit
or stabilizer on a ledge or other protrusion in B. The drill steel and bit should be warm before
the hole. the water injection is used. This will prevent
the water from freezing to the cold surfaces.
D. Never use the hydraulic down pressure on the C. A partially dull bit should never be left down
bit to aid in levelling the machine. the hole when repairs require lowering the
head assembly to the deck. This bit should be
V. Maintain as high a pressure drop across the bit substituted by a dull bit to protect the drill
as possible when in wet holes, or when water steel threads.
injection is used.
D. Procedures for cleaning a bit that has been
A. The extra pressure drop helps to keep water taken off the drill and will be reused:
and cuttings from entering the bearings.
Flush the bearings with water making sure
B. When adding extra drill steel in wet holes, the water is going though each bearing.
always make three or four cleaning passes to
get the bottom of the hole as clean as possible. Force air through each bearing.

C. Never remove any device that the Oil bearings and submerge in non-detergent oil.
manufacturer has installed from inside the bit.
IX. Occasionally check the air pressure with the
VI. Regularly inspect the bit and feel the cones bit off to insure that there are no obstructions
to be sure that all are about the same in the hole swivel or steel.
temperature. One hot cone generally indicates
that the passages to that particular bearing have A. A pressure reading with the bit off can be
become obstructed. taken at each bit change and recorded on
the drill report. A change from the prior
A. When making this inspection rotate the cones reading will help determine if a new
and make sure the bearings are clean and not obstruction or new leak has developed.
locked with cuttings.
B. At each bit change any foreign material in the
B. If the cones do not rotate freely, start the dull but should be noted or investigated.
air compressor and blow the cuttings from the
bearings, then repeat the inspection. X. Properly maintain the drill steel and its threaded
connections. A bent steel will often cause early
C. Any time the cones cannot be freed, the bit failure.
should be taken off for inspection and cleaned.
A. A bent drill steel will cause excess loading on
VII. Never allow the bit to drop while on the end one of two cones with resulting bearing
of the drill steel, even for distance of a few failure on those cones.
inches - dropping the bit can cause cracking of
the welds, and/or indentations in the bearing B. Wear patterns on one side of the drill steel and
races. Results will be premature bearing failure. stabilizer are also indications of the problem.

VIII. When a partially dull bit sits idle for a shift or XI. Blasthole bits drill most economically when
longer, rotate the cones by hand to insure that sufficient weight is applied to cause spalling of
they turn freely before drilling. the formation.

274 Blasthole Drilling in Open Pit Mining

 Rotary drilling TOOLS

Guides for best bit performance Tricone bits

A. When spalling occurs the cuttings are large XII. Selecting correct rotary speed is usually a matter
and the penetration rate is improved. of trial and error, depending upon the formation
being drilled.
B. If a sufficient amount of weight is not applied,
the cutting structure will tend to skid along A. Slower RPMs will reduce the penetration rates
the bottom causing early wear, thus reducing and generally increase bit life.
penetration rate and shortening bit life.
B. Faster RPMs increase the penetration rates
C. If too much weight is used for the formation, and if excessive RPMs are used, it tends to
the cutting structure can be buried to full shorten bit life.
depth, trapping cuttings beneath the bit. This
will cause erosion of the cone metal, prevent C. Increased penetration rate is usually the result
the formation from chipping, and reduce the of better spalling of large cuttings.
penetration rate. If cuttings are forced into the
cone, bearings can lock up. Heavy weights will
also reduce hours of bearing life.

Blasthole Drilling in Open Pit Mining 275

 DTH HAMMER SPECIFICATIONS
Industry overview
The quarry and mining operations typically have high
equipment utilization, drilling 60%, even up to 80%, of
the working day. Companies drilling small to medium
blast holes between 85 to 152 mm (3 38" to 6") find that
performance and service life are critical.
For those operations drilling large blast holes (greater
than 152 mm), performance, reliability, fuel efficiency,
servicelife and support are critical. This is often the ideal
application for considering premium DTH (Down-The-
Hole) hammers with faster drill rates resulting in less
time in the hole. This not only reduces labor costs, but
lowers wear and tear on expensive drills. For surface
mining, pre-splitting is often carried out to improve slope
stability. The pre-splitting holes are often 115-140 mm
(4 " - 5 ") and can be made before the drilling of the
production holes.
Selecting the right hammer
The optimum range of hole size for blast hole drilling
with DTH is 90 mm to 254 mm (3 "10"). Smaller blast
holes are generally drilled using tophammer, and larger
holes generally use rotary machines.
In other applications, like foundation drilling, DTH ham-
mers can be used with single bit in hole sizes up to 914
mm (36"). With multiple hammer units CD (Cluster Drills)
drill holes up to 70" or 1778 mm as standard. Larger
cluster drills can be delivered as per customer request.
As a rule of thumb, the smallest hole diameter a DTH
hammer can drill is its nominal size. A 4 inch hammer
276 Blasthole Drilling in Open Pit Mining
will drill a 4 inch (102 mm) hole. The limiting factor is the
outside diameter of the hammer, because, as hole diam-
eter reduces, airflow is restricted. Maximum hole size
for production drilling is the nominal hammer size plus 1
inch, so for a 4 inch hammer the maximum hole size is 5
inch (127-130 mm).
Choosing the right hammer is largely determined by
hole size and type of rock formation. Ideally, the size of
the hammer should match the required hole dimension
as closely as possible, leaving just enough space for cut-
tings to evacuate the hole.
Secoroc hammers are purpose-matched for all rock types
and applications. Where high performance is the main
criterion, Secoroc COP Gold hammers are recommended
in blast hole drilling and Secoroc QLX hammers in deep
hole drilling applications. The QLX hammer has proven
superior performance and adaptability to different air
requirements thanks to the Air Select System.
Where proven technology is required, the Secoroc COP
and QL hammers are known for their reliability and
longevity. They are practically bullet proof, making them
useful for production drilling in quarries, shallow water
well drilling, and underground blasthole drilling.
QM is similar to Standard, but with heavy duty chuck and
wear sleeve, and a back head fitted with tungsten carbide
buttons for wear protection in harsh and abrasive condi-
tions. These also protect the back head from excessive
wear when rotating out of the hole through broken rock.
 DTH HAMMER SPECIFICATIONS

Economy kits A rule of thumb for use of E-kits

In hard and abrasive drilling condition the external parts Rock formation Hammer life Action
of DTH hammer is wearing out before the internal parts
reaches their fatigue limits. In these conditions the E-kit Highly abrasive < 5000 m Use E-kit to rebuild the hammer
1-2 times
can serve as a tool to reduce the total drilling cost. With
the E-kit the hammer can be rebuilt and the internal part Medium abra- 5-10 000 m Consider E-kit to rebuild the
re-used for another run. The cost saving can be substan- sive hammer 1 time
tial as the cost for an E-kit is only 50% of a new hammer. None abrasive >10 000 m Rebuilding not recommended,
An E-kit contains all the needed parts for a rebuild and
risk that internal parts might fail
will ease the logistic constrains as all needed parts can before E-kit worn out
be ordered under one product number.

Breakout bench Reverse circulation

The threaded connections of the driver chuck and back
head may become very tightly tensioned during drill-
ing. It is convenient to break the hammer threads on the
rig, but if the threads cannot be loosened or tend to get
stuck, a breakout bench is the solution.
This handy but powerful breakout bench can easily be
placed in a workshop or container and it breaks DTH
hammers between 3" and 8". Select right breakout bench
depending on voltage and power source.
Atlas Copco Secoroc's reverse circulation hammers are
specifically designed for all kind of exploration drilling
(deep hole and pit grade control applications).
Whether you are exploring potential sites or working an
existing mine, the Secoroc RC hammer will assure of
high performance, exceptional reliability and dependable
support.

Blasthole Drilling in Open Pit Mining 277

 DTH HAMMER SPECIFICATIONS

Technical specifications
Model COP 44 Gold COP 54 Gold COP 54 Gold QM COP 64 Gold COP 64 Gold QM QLX 35
Bit shank style TD 40 QL 50 QL 50 QL 60 QL 60 DHD 3.5
Product code 9704-03-34 9705-05-34 9705-05-36 9706-05-34 9706-05-36 9703-03-68-00
Product number 89001469 89001243 89001255 89000959 89000960 89001572
General specifications English Metric English Metric English Metric English Metric English Metric English Metric
Connection thread API 2 3/8" Reg Pin API 3 1/2" Reg Pin API 3 1/2" Reg Pin API 3 1/2" Reg Pin API 3 1/2" Reg Pin API 2 3/8" Reg Pin
Outside diameter (in/mm) 3.9 100 4.7 120 4.9 126 5.6 142 5.8 146 3.1 79
Length w/o bit shoulder to shoulder (in/mm) 40.8 1 037.5 51.5 1 194.2 51.5 1 194.2 49.5 1 258 49.5 1 258 31.4 799
Weight w/o bit (lb/kg) 89.3 40.5 145.0 65.7 167.0 75.6 211.0 96.0 240.0 109.0 65.0 29.5
Backhead across flats (in/mm) 2.6 65 3.7 95 3.7 95 4 102 4 102 2.5 63.5
Min bit size (in/mm) 4.3 110 5.3 134 5.5 140 6.1 156 6.5 7 3.5 90
Max bit size (in/mm) 5.1 130 6 152 6 152 7 178 7 178 4.1 105
Bore (in/mm) 3.2 82 3.9 100 3.9 100 4.7 120 4.7 120 2.52 64
Piston weight (lb/kg) 17.4 7.9 33.0 15.0 33.0 15.0 45.0 20.5 45.0 20.5 12.0 5.5
Stroke (in/mm) 4.5 115 4.5 115 4.5 115 4.5 115 4.5 115 4 101.6
Max pressure differential (psi/bar) 508 35 435 30 435 30 435 30 435 30 435 30
Make-up torque (ft-lbf/Nm) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 3 000 4 067
Air consumption / Bpm
*Estimated values 400-508 psi (27.6-35 bar)
150 psi / 10.3 bar (scfm / l/s) 215 101 311 147 311 147 334 158 334 158 219 103
150 psi (bpm) 1 540 1 540 1 389 1 389 1 389 1 389 1 303 1 303 1 303 1 303 1 509 1 509
200 psi / 13.8 bar (scfm / l/s) 321 151 425 201 425 201 509 240 509 240 288 136
200 psi (bpm) 1 677 1 677 1 497 1 497 1 497 1 497 1 447 1 447 1 447 1 447 1 699 1 699
250 psi / 17.2 bar (scfm / l/s) 427 201 557 263 557 263 688 325 688 325 348 164
250 psi (bpm) 1 842 1 842 1 614 1 614 1 614 1 614 1 548 1 548 1 548 1 548 1 858 1 858
300 psi / 20.7 bar (scfm / l/s) 533 251 719 339 719 339 862 407 862 407 400 189
300 psi (bpm) 1 973 1 973 1 750 1 750 1 750 1 750 1 691 1 691 1 691 1 691 1 987 1 987
350 psi / 24.1 bar (scfm / l/s) 639 302 891 421 891 421 1 072 506 1 072 506 444 210
350 psi (bpm) 2 095 2 095 1 886 1 886 1 886 1 886 1 817 1 817 1 817 1 817 2 087 2 087
400 psi / 27.6 bar (scfm / l/s)* 745 352 1 009 476 1 009 476 1 326 626 1 326 626 645 275
400 psi (bpm) 2 218 2 218 2 022 2 022 2 022 2 022 1 962 1 962 1 962 1 962 2 293 2 293
435 psi / 30 bar (scfm / l/s)* 819 387 1 081 510 1 081 510 1 504 710 1 504 710 847 340
435 psi (bpm)* 2 303 2 303 2 118 2 118 2 118 2 118 2 063 2 063 2 063 2 063 2 500 2 500
508 psi / 35 bar (scfm / l/s)* 957 452
508 psi (bpm)* 2 462 2 462
Operational specifications
Feed Force (lb / kN) 1 100-3 300 5-15 1 300-4 120 6-19 1 300-4 120 6-19 1 600-4 400 7-20 1 600-4 400 7-20 1 500-2 000 9-7
Rotation (rpm) 25-100 20-70 20-70 15-60 15-60 70-100

278 Blasthole Drilling in Open Pit Mining

 DTH HAMMER SPECIFICATIONS

Some nice picture of

Quantum leap ham-
mers to put here

Technical specifications
Model QLX 50 QLX 55 QLX 60 QLX 65 RC 50
Bit shank style QL 50 QL 50 QL 60 QL 60 RC 50
Product code 9705-05-68-00 9705-05-68-14 9706-05-68-00 9706-05-68-14 9705-52-67-00
Product number 89010092 89010093 52352465 52352473 52292273
General specifications English Metric English Metric English Metric English Metric English Metric
Connection thread API 3 1/2" Reg Pin API 3 1/2" Reg Pin API 3 1/2" Reg Pin API 3 1/2" Reg Pin 4 1/2" Remet BOX
Outside diameter (in/mm) 4.8 121.9 5.08 129.0 5.6 142.2 5.88 149.4 5.13 130
Length w/o bit shoulder to shoulder (in/mm) 41.76 1 060.7 41.76 1 060.7 41.67 1 090.7 41.67 190.7 45.4 1 152
Weight w/o bit (lb/kg) 153.0 69.5 178.0 80.9 205.0 93.2 235.0 106.8 72 158
Backhead across flats (in/mm) 3.7/4 95/102 3.7/4 95/102 4 101.6 4 102.6 4 102
Min bit size (in/mm) 5.25 133 5.5 140 6.13 155.5 6.5 165.1 538 136
Max bit size (in/mm) 6 152 6 152 8.5 215.9 8.5 215.9 6* 165*
Bore (in/mm) 3.95 100.25 3.95 100.25 4.75 120.65 4.75 120.7 4.48 113.7
Piston weight (lb/kg) 33.0 15.0 33.0 15.0 47.0 21.4 47.0 21.4 38 17
Stroke (in/mm) 3.75 95.3 3.75 95.3 3.75 95.3 3.75 95.3 2.5 64
Max pressure differential (psi/bar) 500 34.5 500 34.5 500 34.5 500 34.5 500 35
Make-up torque (ft-lbf/Nm) 5 000 6 770 5 000 6 770 6 000 8 100 6 000 8 100 5 000 6 800
Air consumption / Bpm * For setting casing
*Estimated values 400-508 psi (27.6-35 bar)
150 psi / 10.3 bar (scfm / l/s) 257 121 257 121 360 170 360 170 N/A N/A
150 psi (bpm) 1 426 1 426 1 426 1 426 1 500 1 500 1 500 1 500 N/A N/A
200 psi / 13.8 bar (scfm / l/s) 374 177 374 177 502 237 502 237 466 220
200 psi (bpm) 1 547 1 547 1 547 1 547 1 616 1 616 1 616 1 616 1 744 1 744
250 psi / 17.2 bar (scfm / l/s) 508 240 508 240 655 309 655 309 N/A N/A
250 psi (bpm) 1 668 1 668 1 668 1 668 1 732 1 732 1 732 1 732 N/A N/A
300 psi / 20.7 bar (scfm / l/s) 657 310 657 310 818 386 818 386 648 306
300 psi (bpm) 1 788 1 788 1 788 1 788 1 847 1 847 1 847 1 847 2 026 2 026
350 psi / 24.1 bar (scfm / l/s) 822 388 822 388 993 469 993 469 792 374
350 psi (bpm) 1 909 1 909 1 909 1 909 1 963 1 963 1 963 1 963 2 238 2 238
400 psi / 27.6 bar (scfm / l/s)* 951 449
400 psi (bpm) 2 340 2 340
435 psi / 30 bar (scfm / l/s)*
435 psi (bpm)*
508 psi / 35 bar (scfm / l/s)*
508 psi (bpm)*
Operational specifications
Feed Force (lb / kN) 1 500-2 000 9-7 1 500-2 000 9-7 2 000-3 000 9-13.3 2 000-3 000 9-13.3
Rotation (rpm) 50-80 50-80 30-60 30-60

Blasthole Drilling in Open Pit Mining 279

 secoroc grinding

The right tools to get you back on the cutting edge

Every regrinding operation requires its own special tool. The wrong one can easily damage your bits.
With Secoroc grinding equipment complemented by a global service organization you neednt worry.
Your bits will soon be as good as new.

A machine for every occasion

Button DTH/COPROD Reaming

Grinding machine Integrals
bits bits bits
Secoroc BQ3
Secoroc Jazz
Secoroc Manual B
Secoroc HG
Secoroc BQ3-DTH
Secoroc Manual B-DTH*
Secoroc Swing
Secoroc Senior
Recommended Can be used * Can be used for ODEX pilot bits and reaming bits. A useful tip: use a Secoroc grinding
template, and youll see when its
time for a regrind.

280 Blasthole Drilling in Open Pit Mining


Grinding
Secoroc BQ3
Semi-automatic grinding machine for
button bits.
Electrical specifications Prod No.
400 V 3-phase 50 Hz 87004800
230 V 3-phase 50 Hz 87004801
400 V 3-phase 60 Hz 87004803
230 V 3-phase 60 Hz 87004805
440 V 3-phase 50 Hz 87004806
Grinding capacity
Maximum height of drill bit 200 mm (7 78")
Maximum diameter of drill bit 127 mm (5")
Maximum bit skirt diameter 120 mm (4.75")
Minimum distance
between buttons 3.5 mm (964")
Technical data
Air pressure, max. 7 bar (101.5 psi)
Air pressure, min. 5.5 bar (80 psi)
Air consumption 40 l/min
Capacity of cooling-fluid tank 22 l
Output, spindle motor 1.50 kW
Output, driving plate motor 0.37 kW
Output, coolant pump motor 0.44 kW
Speed, spindle 14 900 r/min
Speed, table (50 Hz) 62 r/min
Speed, table (60 Hz) 74 r/min
Voltage working lighting 24 V
Weight, excluding packaging 222 kg (490 Ib)
Transport dimension L 1 730 x W 1 030 x H 1 160 mm
(68.11" x 40.55" x 43.94")
Accessories included in delivery
Allen key, 4 mm (1 piece)
Centring cup, 11 mm
Centring device (1 piece)
Coolant concentrate, 0.5 l
Extractor
Filter key
Grinding wheel, uncoated for centering
Protective goggles
Operators instructions and spare parts list
Note:
Secoroc BQ3 must be completed with grinding
wheels, centring cups, bitholders (indicate button
size and thread dimension) and indexing templates.
Blasthole Drilling in Open Pit Mining 281
Secoroc BQ3-DTH
Semi-automatic grinding machine for
DTH- and COPROD bits.
Electrical specifications Prod. No.
400 V 3-phase 50 Hz 87004900
230 V 3-phase 50 Hz 87004901
400 V 3-phase 60 Hz 87004903
230 V 3-phase 60 Hz 87004905
440 V 3-phase 50 Hz 87004906
Grinding capacity
Maximum height of drill bit 650 mm (2'1 58")
Maximum diameter of drill bit 178 mm (7")
Minimum distance between buttons 3.5 mm (964")
Technical data
Air pressure, max. 7 bar (101.5 psi)
Air pressure, min. 5.5 bar (80 psi)
Air consumption 40 l/min
Capacity of cooling-fluid tank 22 l
Output, spindle motor 3.00 kW
Output, table drive motor 0.25 kW
Output, coolant pump motor 0.44 kW
Speed, spindle 14 900 r/min
Speed, table (50 Hz) 22 r/min
Speed, table (60 Hz) 26 r/min
Voltage working lighting 24 V
Weight, excluding packaging 345 kg (760 lb)
Transport dimension L 1 200 x W 1 200x H 1 700 mm
(47.24" x 47.24" x 66.93")
Accessories included in delivery
Allen key, 4mm (1 piece)
Coolant concentrate, 0.5 l
Extractor
Protective goggles
Operators instructions and spare parts list
Optional accessories Prod. No.
- Auxiliary set for grinding
threaded bits (excl.
bitholder and templates) 87003939
NOTE:
Secoroc BQ3-DTH must be completed with
grinding wheels, centring cups and bitholders
(indicate button size, bit diameter and type of
hammer).
secoroc grinding
Secoroc Jazz
Rig-mounted, semi-automatic grinding
machine for tapered, threaded, DTH- and
COPROD bits.
Secoroc Jazz, standard Prod. No.
incl. main bit holder for threaded bits 87004100
Secoroc Jazz, DTH Prod. No.
incl. main bit holder for DTH/COPROD bits 87004300
Grinding capacity
Maximum distance between bit holder
and grinding wheel 250 mm (9 78")
Maximum diameter of drill bit 254 mm (10")
Minimum diameter of drill bit 35 mm (1 38")
Minimum distance between buttons 3.5 mm (964")
Technical data
Air pressure, max. 7 bar (101.5 psi)
Air pressure, min. 6 bar (87 psi)
Air consumption 25 l/s
Coolant container 3l
Output, spindle motor 1.00 kW
Speed, spindle 15 000 r/min
Voltage 24 V
Weight, excluding packaging 90 kg (198 lb)
Transport dimension L 800 x W 500 x H 700 mm
(2'7 " x 1'7 58" x 2'3 ")
Accessories included in delivery
Box wrench, 11 mm
Box wrench, 16 mm
Grinding gauge
Protective goggles
Operator's instructions and spare parts list
Optional accessories Prod. No.
- Anti-freeze kit 87004315
- Main bit holder for DTH/ COPROD bits 87004268
- Main bit holder for threaded bits 87004214
- Mounting bracket for Atlas Copco drill rig
- with cabin 87004628
- without cabin 87004456
- 3-leg stand 87004450
- Centring tool 87004465
NOTE:
Secoroc Jazz must be completed with grinding
wheels, centring cups, bitholders and indexing
templates.
 secoroc grinding
Grinding
Secoroc Manual B
Hand-held portable grinding machine
for button bits.
Secoroc Manual B Prod. No.
87001890
Grinding capacity
Maximum diameter of bit skirt 90 mm (3 916")
Threaded bits, maximum diameter 127 mm (5")
Retrac, maximum diameter *127 mm (5")
Tube drilling, maximum diameter *152 mm (6")
* Large clamping device necessary
Technical data
Air pressure, max. 7 bar (101.5 psi)
Air consumption 15 l/s
Coolant container 10 l
Idling speed of hand-held grinder 30 000 r/min
Speed of bit rotation 0-45 r/min
Weight, excluding packaging 55 kg (121.3 Ib)
Weight, including packaging 90 kg (198.4 Ib)
Transport dimension L 1 200 x W 800 x H 850 mm
(3'11 210" x 2'7 510" x 2'9 510")
Accessories included in delivery
Allen key, 4 mm
Centring fingers (4 pcs)
Grinding templates, spherical and ballistic
Hand-held grinder, 30 000 r/min
Open end spanner, 14 mm (2 pcs)
Protective goggles
Operators instructions and spare parts list
Optional accessories Prod. No.
- Vibration absorbing sleeve to fit the
hand-held grinder 87001931
- Set of 5 centring fingers 87001935
NOTE:
Secoroc Manual B must be completed with
grinding wheels and bitholders.
282 Blasthole Drilling in Open Pit Mining
Secoroc Manual B-DTH Secoroc HG
Hand-held portable grinding machine for Hand-held grinding machine for button
DTH- and COPROD bits. bits.
Secoroc Manual B-DTH Prod. No. Secoroc HG Prod. No.
87002300 87002435
Grinding capacity Grinding capacity
Maximum height of drill bit 506 mm (1'7 78") Button size 7-20 mm
Maximum diameter of drill bit 203 mm (8") (932"-2532")
Maximum diameter of bit shank 170 mm (6 ")
Technical data
Technical data Air pressure, max. 7 bar (101.5 psi)
Air pressure, max. 7 bar (101.5 psi) Air consumption, unloaded 50 l/s
Air consumption 15 l/s Air consumption, loaded (at 6 bar, 86 psi) 42 l/s
Coolant container 10 l Hose dimension, air 12.5 mm (")
Idling speed of hand-held grinder 30 000 r/min Hose dimension, water 6.3 mm (")
Speed of bit rotation 0-45 r/min Idling speed 17 000 r/min
Weight, excluding packaging 110 kg (253 lb) Water flushing pressure, max. 4.5 bar (65.3 psi)
Weight, including packaging 148 kg (326 lb) Weight, excluding hoses 2.8 kg (6.2 Ib)
Transport dimension L 1 200 x W 800 x H 940 mm
(3'11 210"x 2'7 510" x 3'1 010") Accessories included in delivery
Adjustable angle connector
Accessories included in delivery Allen key, 2 mm
Allen key, 5 mm Allen key, 3 mm
Allen key, 6 mm Allen key, 5 mm
Centring fingers (4 pcs) Claw coupling (6.3 mm)
Grinding templates, spherical and ballistic Grease gun
Hand-held grinder (spherical, 30 000 r/min) Grinding templates, spherical and ballistic
Open end spanner, 14 mm (2 pcs) Hose (PVC 03)
Protective goggles Hose (PVC 6; L = 0.1 m)
Operators instructions and spare parts list Hose clamp (78.5 mm)
Hose clamp (1113 mm)
Optional accessories Prod. No. Hose clamp (2638 mm)
- Centring fingers (set of 5 pcs), 30 000 r/min 87001935 Nipple
- Clamping device for threaded bits 87002401 Pipe (L = 0.3 m)
Seal kit
NOTE: Seat
Secoroc Manual B-DTH must be completed with Support ring
grinding wheels and bitholders. Operators instructions and spare parts list
Optional accessories Prod. No.
- Lubricator 87002750
- Reconditioning tool for grinding cups 87002810

Grinding
Secoroc Swing
Grinding machine for integrals.
Secoroc Swing Prod. No.
87002482
Technical data
Air pressure, max. 7 bar (101.5 psi)
Air consumption (at 6 bar, 86 psi) 25 l/s
Cutting-edge angle 110
Cutting-edge radius 80 mm (3 532")
Gauge grinding arrangement included
Hose connections:
- Air 12.5 mm (")
- Water 6.3 mm (")
Idling speed 4 080 r/min
Power output 1,10 kW
Size of grinding wheel
- D x T x H 125 x 63 x 32 mm (47/8" x 215/32" x 1")
- DI x TI 80 x 50 mm (3 5/32" x 2")
Spindle diameter 16 mm (5/8")
Weight incl. grinding wheel and
1.5 m water hose 27.5 kg (61 lb)
Accessories included in delivery
Grinding template
Grinding wheel, soft
Pin wrench
Protective goggles
Operators instructions and spare parts list
Optional accessories Prod. No.
- Grinding wheel, hard 87002589
- Grinding wheel, soft 87002811
- Chuck bushing wear gauge
H19 (0,75") 90002667
H22 (0,85") 90002668
H25 (1") 90002669
Blasthole Drilling in Open Pit Mining 283
secoroc grinding
Secoroc Senior
Grinding machine for integrals.
Electrical specifications Prod. No.
220 V 3-phase 50 Hz 87002485
220 V 3-phase 60 Hz 87002493
380 V 3-phase 50 Hz 87135402
380 V 3-phase 60 Hz 87002494
415 V 3-phase 50 HZ 87002488
415 V 3-phase 60 Hz 87002495
440 V 3-phase 60 Hz 87002496
Technical data Secoroc Swing.
Air pressure, max. 7 bar (101.5 psi)
Cutting-edge angle, adjustable 90-130
Grinding wheel
-DxTxH 200 x 102 x 32 mm (7 78" x 4" x 1 )
- DI x TI 150 x 80 mm (5 78" x 3 532")
- Cutting-edge radius, adjustable 80-130 mm (3 532"-5 18")
Idling speed, electric 50 Hz 2 840 r/min
Idling speed, electric 60 Hz 1 690 r/min
Output 3-phase 1.50 kW
Rod hex. max. 25 mm (1")
Weight excluding packaging 105 kg (232 lb)
Weight including packaging 120 kg (265 lb)
Transport dimension L 800 x W 600 x H 650 mm
(2'7 " x 1'11 58" x 2'1 58")
Accessories included in delivery
Grease gun
Grinding template
Grinding wheel, hard
Protective goggles
Socket wrench
Wrench
Operators instructions and spare parts list
Optional accessories Prod. No.
- Grinding wheel, hard 87002591
- Grinding wheel, soft 87002813
- Spacer plate for H19 integral 87000519
- Chuck bushing wear guage
H19 (0.75") 90002667
H22 (0.85") 90002668 Secoroc integral equipment.
H25 (1") 90002669
 secoroc grinding

Profiled diamond grinding wheels for button bits

Secoroc BQ3/BQ3-DTH
Secoroc Jazz/Jazz-DTH
Secoroc Manual B/Manual B-DTH

Grinding wheel for Grinding wheel for Grinding wheel for

spherical buttons ballistic buttons full-ballistic buttons

Dimension, Dimension, Dimension,

Product No. Product code Product No. Product code Product No. Product code
mm mm mm
Spherical 19 87003966 9500-3966 18 87003965 9500-3965
7 87001028 9500-1028 Ballistic 19 87003967 9500-3967
8 87001026 9500-1026 7 87003407 9500-3407 Full-ballistic
9 87001389 9500-1389 8 87003408 9500-3408 7 87004720 9500-4720
10 87001023 9500-1023 9 87003409 9500-3409 8 87004721 9500-4721
11 87003406 9500-3406 10 87003410 9500-3410 9 87004722 9500-4722
12 87001024 9500-1024 11 87003411 9500-3411 10 87004723 9500-4723
13 87001339 9500-1339 12 87003412 9500-3412 10,95 87004724 9500-4724
14 87001025 9500-1025 13 87003413 9500-3413 12,7 87004725 9500-4725
14,5 87004708 9500-4707 14 87003414 9500-3414 14,5 87004726 9500-4726
15 87001384 9500-1384 14,5 87004717 9500-4717 15,83 87004727 9500-4727
16 87001027 9500-1027 15 87003415 9500-3415
18 87003964 9500-3964 16 87003416 9500-3416

Grinding wheels Centering cups*

for steel grinding

Product Product Button Product Button Product

Dimension Product No. Product No.
No. code size code size code
1014 mm 87001530 9500-1530 7,0 mm 87001040 9500-1040 13,0 mm 87001385 9500-1385
Spacer for 10 mm button 87001631 9500-1631 8,0 mm 87000842 9500-0842 14,0 mm 87001043 9500-1043
Spacer for 11 mm button 87001632 9500-1632 9,0 mm 87001047 9500-1047 14,5 mm 87001443 9500-1443
Spacer for 12 mm button 87001633 9500-1633 10,0 mm 87001041 9500-1041 15,0 mm 87001386 9500-1386
Spacer for 13 mm button 87001634 9500-1634 11,0 mm 87000840 9500-0840 16,0 mm 87001387 9500-1387
Spacer for 14 mm button 87001635 9500-1635 12,0 mm 87001042 9500-1042 18,0 mm 87003943 9500-3943
12,7 mm 87000839 9500-0839 19,0 mm 87003944 9500-3944

* NOT needed for Manual B/Manual B-DTH

284 Blasthole Drilling in Open Pit Mining

 secoroc grinding

Bitholders for button bits

Secoroc BQ3/Jazz
Secoroc BQ3-DTH/Jazz-DTH
Secoroc Manual B-DTH Secoroc Manual B/Manual B-DTH

Product Product
Type Product No. Type Product No.
code code
Secoroc BQ3/Jazz Threaded bits* Secoroc Manual B Threaded bits
R25 87003475 9500-3475 R25 87000792 9500-0792
R28 87003476 9500-3476
R28 87000793 9500-0793
SR28 87003960 9500-3960
SR28 87003961 9500-3961
R32 87003477 9500-3477
SR32 87003962 9500-3962 R32 87000794 9500-0794
SR35 87003956 9500-3956 R32 87001848 9500-1848
TC35 87005007 9500-4685 SR32 87003963 9500-3963
R38 87005005 9500-4686 R35 87003360 9500-3360
T38 87005006 9500-4687
SR35 87003957 9500-3957
SR38 87003978 9500-3978
R38/T38 87000795 9500-0795
SR38 retrac, guide 87004081 9500-4081
TC42 87004641 9500-4641 SR38 87003979 9500-3979
T45 87003479 9500-3479 C T45 87000796 9500-0796

A TC45
T51 and retrac
87004569
87003521
9500-4569
9500-3521
T51 87000802 9500-0802
Secoroc Manual B Tapered bits
T60 87004562 9500-4562
7 taper 87001044 9500-1044
Secoroc BQ3/Jazz Tube bits*
12 taper 87001045 9500-1045
ST58 87003522 9500-3522
ST68 87003523 9500-3523 Secoroc Manual B Tube bits
Secoroc BQ3/Jazz Tapered bits* ST58 87001726 9500-1726
7 taper 87003524 9500-3524 ST68 87001573 9500-1573
12 taper 87003525 9500-3525
Secoroc Manual B Reaming bits
Secoroc BQ3/Jazz Reaming bits*
64, 76, 89 mm 87000798 9500-0798
64, 76 and 89 mm 87003526 9500-3526
89,102 and 127 mm 87003527 9500-3527 89, 102, 127 mm 87000799 9500-0799
Secoroc BQ3/Jazz Guide bits*
R32 87003992 9500-3992
SR35 87004056 9500-4056
Secoroc BQ3-DTH/Jazz-DTH/Manual B-DTH
DTH and Coprod bits
COP 32 87002420 9500-2420
COP 34 87003691 9500-3691
DHD 3.5 87004514 9500-4514
DHD 340, TD 35 87002391 9500-2391
DHD 350 87002390 9500-2390
DHD 360 87002389 9500-2389
DHD 380 87004523 9500-4523
TD 40 87004604 9500-4604
Bitholder type A Bitholder type C
QL 40, TD 50 87004515 9500-4515
B QL 50, TD 60 87004033 9500-4033
QL 60, TD 80 87004002 9500-4002
QL 80 87004516 9500-4516
TD 90 87004517 9500-4517
RC 50 87004605 9500-4605
COPROD 76 87004414 9500-4414
COPROD 89 87003155 9500-3155
COPROD 102 87004415 9500-4415
COPROD 127 87002396 9500-2396
* To be able to grind tophammer bits on Secoroc BQ3-DTH, the clamping Bitholder type B
device with Product No. 87003939 / Product code 9500-3939 must be used.

Blasthole Drilling in Open Pit Mining 285

 secoroc grinding

Diamond grinding cups

Secoroc HG

Dimension, mm Product No. Product code

7,0 87002566 9500-2566
For sperical buttons
8,0 87002567 9500-2567
9,0 87002568 9500-2568
10,0 87002569 9500-2569
11,0 87002570 9500-2570
12,0 87002571 9500-2571
13,0 87002572 9500-2572
14,0 87002573 9500-2573
15,0 87002574 9500-2574
16,0 87002575 9500-2575
18,0 87002576 9500-2576
19,0 87004558 9500-4558
20,0 87002577 9500-2577
For ballistic buttons 7,0 87002579 9500-2579
8,0 87002580 9500-2580
9,0 87002581 9500-2581
10,0 87002582 9500-2582
11,0 87002583 9500-2583
12,0 87002584 9500-2584
13,0 87002585 9500-2585
14,0 87002586 9500-2586
15,0 87002587 9500-2587
16,0 87002588 9500-2588
For steel removal around buttons 78 87002700 9500-2700
910 87002701 9500-2701
1112 87002702 9500-2702
1314 87002703 9500-2703
1516 87002704 9500-2704
1718 87002840 9500-2840
1920 87002841 9500-2841

286 Blasthole Drilling in Open Pit Mining

 secoroc grinding

Ceramic grinding wheelss

Cross-type bits, X-type bits and chisel bits

Bit size, Bit Wheel Dimension Dimension Product

Grinding machine Product No.
mm angle angle (DTH), mm (DITI), mm code
35 90 132 300 x 23 x 32 87002594 9555
3841 90 132 300 x 26 x 32 87002595 9556
Grind Matic X 45 90 132 300 x 29 x 32 87002597 9558
Sandvik RG 300 4851 90 132 300 x 32 x 32 87002616 9577
Sandvik RG 320 76 90 132 300 x 52 x 32 87002603 9564
Sandvik RG 340
Sandvik RG 360 76 75 126 300 x 42 x 32 87002608 9569

76 105 139 300 x 58 x 32 87002609 9570

125 x 63 x 32 80 x 50, hard 87002589 9550

125 x 63 x 32 80 x 50, soft 87002811 9500-2811
Secoroc Swing 80 x 50,
Sandvik RG 100 125 x 63 x 32 87004700 9500-4700
hard endurance
80 x 50,
125 x 63 x 32 87004701 9500-4701
soft endurance
200 x 102 x 32 150 x 80, hard 87002591 9552
Secoroc Senior
200 x 102 x 32 150 x 80, soft 87002813 9500-2813
150 x 83 x 32 100 x 64, hard 87002590 9551
Grind Matic Junior
150 x 83 x 32 100 x 64, soft 87002512 9500-2812

Grinding templates

Integral rods and bits

10
r= 80 mm 3,5/32" 10 Skivvinkel
,95 D/3 Wheel
9
110

D
110
1/8"

3/32"
12,7
3 mm

2,4 mm
8

40 30 20 10 0
1 1/2" 1" 3/4" 1/2" 1/4"
Regrind when flat
is 173 of button dia.
5 1/4" 14 5
10
,5 1/4"
10
1/2"
7

1/2"
15 15
3/4" 3/4"
0,5
Min.

For integral rods For button bits For cross-type bits

Grinding template Dimension, mm Product No. Product code

Integral rods 90002610 9101

Button bits, spherical 7 - 14,5 90002944 9104

Button bits, ballistic 7 - 14,5 90503414 9105
Button bits, spherical 10,95 - 19,1 90510753 9129
Button bits, ballistic 10,95 - 19,1 90510758 9130

Cross-type bits 90002611 9102

Blasthole Drilling in Open Pit Mining 287

 DrillCare

Parts and Services

Wherever you are in the world, as an Atlas Copco customer your service experience will always be the same. Its all
about our commitment, our service promise, our capability and our quality. Furthermore, we aim to increase your
productivity. This is the difference that is Atlas Copco Parts and Services. Its not just about our promises, its
about delivery.

Extended warranty
Peace of mind for three years with no small print. Let us protect your investment.
Features Benefits
Three years, unlimited operating hours Focus on your production
Follow Atlas Copco maintenance schedule Preventive maintenance
Atlas Copco genuine parts and selected oils and lubricants Meet warranty conditions
Planned audits Assures rig reliability

Service agreements
Best-in-class maintenance to ensure reliability and highest availability of your drilling equipment.

Features Benefits
Total maintenance Minimize unplanned repairs
Preventive maintenance Lowest operating cost
Fixed-price repair Extended warranty period
Parts-only plans Genuine Atlas Copco parts and selected lubricants

Preventive and corrective maintenance kits

Atlas Copco genuine parts are manufactured to the same exacting quality standards as your drill rig.

Features Benefits
Guaranteed performance Warranted between scheduled services
Quality inspected and tested Ensured reliability and highest availability
Available through our state-of-the-art distribution system Quick, accurate order fulfillment

Atlas Copco Fluids

Atlas Copco Fluids are produced to the exacting specifications required to meet the demands of your
drilling application.
Features Benefits
Designed for the toughest environment Protect your investment
Performance tested Optimize service life
Ensure extended warranty Save money, minimize breakdowns

288 Blasthole Drilling in Open Pit Mining

 DrillCare

Fluid Management
Safer, cleaner reliability.

Features Benefits
Hydraulic hose first aid kit Limit downtime
Hydraulic filter cart Maintain clean, efficient systems
Atlas Copco premium air hose Safety and reliability
International expertise Superior productivity

Hydraulic hose first aid kit

Each kit provides an immediate replacement for every hydraulic hose on your drill rig.

Features Benefits
Drill rig specific hoses and adaptors Fastest possible fix
Complete instructions and accessories First time fix at the jobsite
Environmenatally friendly Spillage control
Wheel or truck mountable Highly mobile

Diesel fuel filter cart

A portable fuel cleaning system designed to protect your investment.

Features Benefits
Controls particulate ingression Maximize usable life of engine components
Prevents water contamination Minimize downtime
Easy spin-on replacement elements Lower maintenance cost

Hydraulic filter cart

A superior contamination control device designed with maximum protection in mind.

Features Benefits
Multi-stage filtration Prevents secondary failures
Highest quality components Safety and reliability
Flexible configurations Matched to your specific needs
Easy spin-on replacement elements Save time, save money

Blasthole Drilling in Open Pit Mining 289

 Service

Our presence marks The Difference

Atlas Copco equipment is built to last. Delivering superior performance in the most efficient and cost effective man-
ner, our equipment is the driving force in your business. At Atlas Copco Service we are committed to delivering
superior service to all customers in the Mining and Rock Excavation industry whenever, wherever.

We act as the most competent speaking-partner regarding the operation of your equipment. We enhance your productivity,
profitability, and peace of mind, ensuring successful and sustainable business relationships. We always put safety and
environmental considerations first in everything we do.

Technical support Safety and

that stands out environment
We know that the moments-of-truth are at delivery, upon The concern for safety and the environment is more
start-up and in operation. prominent today than ever before.

It is here that the difference between those who keep
their promises and those who do not comes to light.
Our dedication to providing the best possible support
comes from recognizing the impact this has on success
or failure. Wherever you are in the world, we strive to
ensure that your service experience will be consistent.
Atlas Copcos concern for safety and the environment are
essential components of our commitment to
sustainable productivity.
Our equipment and genuine parts are designed to
maximize the safety of personnel and mining operations,
and to minimize environmental impact.

290 Blasthole Drilling in Open Pit Mining


Reliability and the highest availability
Service agreements
Atlas Copco provides several types
of service agreements to meet
operational requirements and to
secure your productivity.
Extended warranty Peace of mind,
protecting your investment
Parts-only plan Genuine Atlas
Copco parts and lubricants,
guaranteed performance
Preventive maintenance programs
Lower life cycle cost ensuring
availability
Total maintenance programs
minimize unplanned repairs
Reliability centered maintenance
products Non-intrusive equipment
health check
Blasthole Drilling in Open Pit Mining 291
Service kits
To ensure your equipment
remains fit for purpose, two things
are needed: a good preventive
maintenance schedule and a strict,
genuine parts policy. Atlas Copco
genuine parts help preserve the
superior quality of the products
throughout their entire life-cycle.
Quality tested and inspected to
ensure reliability and highest
availability
All required parts in one kit to
minimize service time
service
Remanufactured Components
When you use Atlas Copco remanu-
actured compo-nents, you can rest
assured that we will have the part you
need in stock when you need it.
Genuine OEM parts Safe, reliable
performance
Superior warranty Peace of mind
Lower operating cost
Components readily available
Sustainable productivity
Recycle Reduce environmental
impact
 Service
Optimization through
tailored technology
solutions
Atlas Copco has been acknowledged as one of the worlds
most innovative companies. Our culture encourages
creativity and passion to deliver energy-efficient and
sustainable products and solutions.
The Atlas Copco technology and energy efficiency
product portfolio offers a wide range of application
conversions, modifications and system and component
upgrades for all equipment ranges.
With a deep understanding of your operations, we
provide tailored solutions that enhance and improve
safety, performance and the environmental impact of
your equipment.
Benefits:
Extended equipment life cycles
Maximized equipment efficiency
Optimized equipment configuration
Guaranteed regulatory compliance
292 Blasthole Drilling in Open Pit Mining
Healthy equiment
through remote
monitoring solutions
Atlas Copco offers an advanced remote monitoring
solution that enables our customers to identify problems
prior to failure.
The Atlas Copco Remote Monitoring system integrates
real-time monitoring, alarms, trends and production
data. This data is filtered, analyzed and transformed into
useful information regarding health and performance of
your equipment based on the original manufacturers
specifications.
Some of the potential gains include:
Shift from emergency to planned maintenance through
early detection of equipment degradation
Reduced maintenance costs through rationalized
scheduled maintenance
Increased production through increased equipment
reliability and performance
 service

Trained people
perform
Atlas Copco provides the very best training as part of
our customer service, and appreciates the difference
between operators who are already experts at handling
our equipment and those who need additional training.

We are more than willing to share the benefits of our

long experience in the market and our complete toolbox
of best practices, to the benefit of all our customers.
Thanks to well-trained staff we are able to offer you
Atlas Copcos premium service support. Our service
technicians go through a rigorous certification process,
ensuring that you always get the best possible technical
support close-by, readily available, whenever needed.

Just what you need,

right when you need it
Atlas Copco aims for a highly efficient supply chain
enabling fast, demand-driven distribution.

Together with our customers and our international

supply chain network we continuously strive to supply
through the most economic and environmentally-
friendly mode of transportation.

Complete, accurate, on-time delivery of your order,

every time, thats our aim. Just what you need, right
when you need it.

Anyplace, Anywhere,
Anytime
Atlas Copco is a world leading supplier in the Mining
and Rock Excavation sector.

The Group delivers sustainable solutions for increased

customer productivity through innovative products and
services. Atlas Copco was founded in 1873. Today it has
a global reach spanning more than 170 countries.

We are committed to sustainable productivity which

means that we do everything we can to ensure reliable,
lasting results with responsible use of resources;
human, natural, and capital.

293
 simulator training

Drill simulator training

Training drill rig operators with the aid of simulators is gaining in popularity, rapidly becoming the method of choice
for mines around the world. Atlas Copco is a forerunner in driving this trend and now offers simulators for most of
its surface and underground equipment, the latest of which is a new simulator for training operators of Pit Viper
blasthole drills.

These modules provide extremely realistic and effective Specification

training for operating such large rigs as the new Pit Viper
Measures
235 in a safe and controlled environment.
Length 5m 197"

The simulator will be used as part of our Master Driller Width 4m 157.5"
program, says Peter Lawrence, Technical Services Man- Height 2.97 m 117"
ager Parts and Services. Weight 2,500 kg 5,500 lbs

The opportunity to learn in a realistic environment will Electrical motion platform

allow operators to thoroughly familiarize themselves
3x3VAC-10% - 3x480VAC+10%, 50 Hz, Fuse 20AT
with these rigs before taking the controls in the real
thing. This means new operators can contribute more 3x3VAC-10% - 3x480VAC+10%, 50 Hz, Fuse 20AT
rapidly to a companys operations.

Computer rack cabin

Simulator training has proven to have a positive im-
pact on performance and reliability as operators learn 110VAC 230VAC, 50-60HZ, Fuse 10AT
to avoid causing unnecessary wear and stress on key
components. In addition, it enables training to take place Humidity in operation
away from the site so that working rigs can continue to
Rel. humidity 85%, no condensation
focus on production.

294 Blasthole Drilling in Open Pit Mining


Glossary of terms
A Bit, Roller Also called a tricone bit. It usually
Actuator A motor or cylinder that is being
put into motion by the flow of a hydraulic
pump.
Adapter-Adaptor (both spellings are
accepted) A device used to connect two
different sizes or types of threads. It is used
to connect rotary head spindles to drill pipe,
drill pipe to stabilizers and stabilizers to drill
bits.
ANFO Ammonium Nitrate Fuel Oil mixture:
explosive most commonly used in blast-
holes.
Angle Drill Drilling a hole at a 0 to 30
degree angle from vertical (in five degree
increments).
Annulus The space between the drill pipe
and the outer diameter of the hole made by
the bit.
Annunciator An electrical signaling device
on a switchboard.
API American Petroleum Institute.
ASME American Society of Mechanical
Engineers.
ASTM American Society of Testing Materials.
Auto Lube System A pump that provides
grease to various components of the drill
through hoses. It can be manual or com-
puter controlled.
B to a hydraulic cylinder, used to turn the
Bank Vertical surface of an elevation; also
called the face.
Beco Thread A coarse type of thread used
on drill pipe.
Bench Work area on the top edge of an
elevation. The work area for blasthole drills.
Bit, Auger A type of bit used to drill soft
formations. It usually has a series of flutes
on the outside.
Bit, Claw A wing-type bit that has multiple
flukes. Sometimes called a drag bit.
Bit Breaker A device installed in the
centralizer table to hold a bit stationary
while the drill pipe is being removed from
the bit by reversing the rotation. Also called
bit basket.
Bit, DHD A solid, one piece bit with shaped
tungsten carbide inserts in the face. Used in
percussion drilling.
Blasthole Drilling in Open Pit Mining 295
has three conical rollers fitted with steel
or tungsten carbide teeth that rip the rock
loose using down pressure.
Bits Tools that pulverize formations so that
material can be removed from the hole, gene-
rally three-blade, three-cone or percussion.
Blasthole A drilled hole used for purposes
of excavation rather than exploration, geo-
logical information or water wells. Holes are
used to load explosives for open pit mining,
and are usually limited to 200 feet.
Blasting The act of igniting explosives in
a borehole to produce broken rock.
Blowdown Term used when releasing
compressed air from the receiver tank on
a compressor when the drill is stopped.
Blowdown Valve The valve that opens
when the drill is stopped and releases all
the air pressure in the receiver tank.
Bore To make a hole in the ground with a
drill.
Borehole The hole made by a bit.
Box End Fitting on the female end of a drill
pipe. See Pin End.
Breakout Refers to the act of loosening
threaded pipe joints, and of unscrewing one
section of pipe from another, while coming
out of the hole.
Breakout Wrench A wrench, connected
upper piece of pipe while the lower pipe
is being held by the fork chuck or sliding
wrench.
Bridge An obstruction in the hole. Usually
caused by a caving formation or something
falling in the hole.
Burden Distance from the blasthole to the
nearest face. Distance measured from the
face to a row of holes. The material to be
displaced.
Buttons Short, rounded teeth of sintered
tungsten carbide inserts which serve as
teeth in drill bits used for drilling very hard
rock.
Butterfly Valve The adjustable inlet valve
of the air compressor.
C Coring The act of procuring a sample of
Cable A strong, heavy steel, wire rope.
Also known as wire rope. Used for pulldown
glossary
and pullback in the tower. Also used in hoi-
sting. May be rotating or rotation resistant.
Cable Reel A device that holds the electri-
cal power cable on electric driven blasthole
drills.
Carousel A rotating device that holds
extra drill pipe. It can be moved under the
rotary head to add and remove drill pipe
from the string, or the rotary head moves
over it.
Carbide, Tungsten W2C. A very hard
compound used in inserts in rock bits.
It has a very high melting point. It is very
strong in one direction but very brittle in
another.
Catwalks Walkways around a working
area of a drill.
Cavitation The pitting of a solid surface
by the formation of low pressure bubbles
formed in the fluid. Air being allowed into
the inlet of pumps.
Centralizer Bushing A circular ring
installed around the drill pipe in the drill
table to keep the pipe aligned properly with
the rotary head. It usually has a replaceable
insert in the center.
Chain Wrench A special wrench, consisting
of a chain section and a metal vee section,
with jaws, that grips the drill pipe and/or the
DHD to tighten or loosen the connections.
Collar the Hole Opening at the top of the
blasthole; the mouth where rock has been
broken by blasting. Usually the first few
feet of the blasthole that are cracked
and broken.
Compressor An asymmetrical rotary screw
driven device for compressing air. May
be single- or two-stage, depending on the
discharge pressure.
Console The panel that contains most of the
drills controls. Also called the operators panel.
Conveyor Equipment used to carry mate-
rial to crushers and screens for reduction
and separation.
Cooler (Hydraulic oil Cooler (HOC),
Compressor Oil Cooler (COC)) All drills
have a cooler or coolers for the hydraulic
fluid and the compressor oil. The engine
radiator is also sometimes referred to as
an engine cooler.
the formation being drilled for geological
information purposes.
 Glossary
Coupling A connector for drill rods, pipe
or casing with identical threads, male or
female, at each end.
Cribbing A set of wooden ties or metal
plates used to add surface area to the jack
pads to prevent the pad from sinking into the
ground. Also called blocking.
Crown Sheaves The upper sheaves in a
tower that supports the cable that connects
to the rotary head.
Crosshead The outer metal can sur-
rounding the leveling jack cylinders. The
crosshead slide is the lower portion that
connects to the bottom of the cylinders and
the crosshead cap is the flanged piece on
top of the crosshead.
Crusher Device used to reduce broken
rock to a smaller fragment size.
Cut (verb) Process of excavating material
to lower the level of part of an elevation.
Cut (noun)
Part of an excavation of a specified depth
and width.
Cuttings Particles of formation obtained
from the hole during drilling operations.
D in the drill table to allow the DHD to start
Decking Process of alternating explosives
with inert material in a blasthole to properly
distribute explosives or reduce vibrations.
Also refers to the metal catwalks around the
outside of the drill.
Delay Interval Elapsed time between deto-
nation of individual blastholes in a multiple
hole blast.
Derrick A tall framework over a drilled
hole used to support drilling equipment.
The part of the drill that contains the feed
system and the rotary head. See Tower
and Mast.
DHD Down Hole Drill. An air driven, piston
powered device for drilling hard rock. It is also
called a hammer.
DHD Bushings The split bushings used to
maintain alignment of the DHD while passing
through the drill table. See Split Bushings.
Differential Pressure The difference in
pressure between the inlet and outlet of a
component, i.e., a cooler.
Dip The angle between a horizontal plane
and the plane of the ore vein, measured at
right angles to the strike.
Diverter Valve A two position, three-way,
valve that allows one hydraulic pump to
perform two separate functions.
296 Blasthole Drilling in Open Pit Mining
Dressing a Bit Sharpening DHD drill bits
with a grinder to shape the carbides.
Drifter An out-of-the-hole drill that rotates
the drill rod and provides a percussive force,
by means of a striking bar, through the rod
to the bit.
Drill A machine for drilling rock or
unconsolidated formations. Also called
a rotary drill. The act of boring a hole
in the ground.
Drill Collar A heavy, thick-walled section
of pipe used to add drilling weight to the bit
and stabilize the drill string.
Drill Rod See Drill Pipe. Hollow, flush-joint-
ed, coupled rods used on small percussion
type rock drills.
Drill Pipe Hollow tubing, specially welded
to tool joints.
Drill/Propel Valve A switch that shifts
the diverter valves to allow pump flow
to go from drill functions to propel
motors.
Drill String The string of pipe, including
subs, stabilizers, collars and bit, extending
from the bit to the rotary head, that carries
the air or mud down to the bit and provides
rotation to the bit.
Driller (Operator) The employee directly in
charge of a drill. Operation of the drill is their
main duty.
Drill Table The area at the bottom of the
tower that contains the centralizer bushing
or master bushing that the drill pipe travels
through.
Dust Collector A vacuum device with a
hose attached to the dust hood that pulls
cuttings away from the hole and deposits
them to the side of the drill.
F Hoist Device used to pick up drill
Face Vertical surface on an elevation. Also
called bank.
Feed Cable Cables, anchored on the
top and the bottom of the tower, that pass
through the traveling sheave block and
connect to the top and bottom of the rotary
head. They are adjusted by tightening the
threaded rods on each end.
Feed Chain Heavy duty chain links con-
nected to the rotary head through upper
and lower sprockets and the traveling
sheave block. They are adjusted similar
to a cable.
Fill Process of moving material into a
depression to raise its level; often follows
the cut process.
Fish An object accidentally lost in the hole.
Fishing Operations on the drill for the
purpose of retrieving the fish from the
hole.
Fishing Magnet Magnet run in the hole
on non-metallic line, to pick up any small
pieces of metal.
Fishing Tools Tools of various kinds run in
the hole to assist in retrieving a fish from the
hole. Overshots fit over the pipe while taps
fit inside the pipe.
Flats Machined areas on the side of drill
pipe or other components where wrenches
can be installed to hold or break the joints.
Some pipe have two flats, others have four
flats.
Floor Level area at the base of a bank or face.
Fork Chuck The handheld or flop-down
wrench used to hold the top of the pipe
on the drill table while adding or removing
other pipe.
H
Hammer A different name for a Down
Hole Drill.
Hammer Bushing Split bushings installed
the hole in a straight line. It is removed once
the DHD is below the table. Also called DHD
bushings.
Haul Distance Distance material has to be
moved, such as from a cut to a fill.
Hauling Equipment Trucks and other con-
veyances for moving material. Also called
haul trucks.
Hazard Any condition of the drilling equip-
ment or the environment that might tend to
cause accidents or fire.
pipe and other heavy objects.
See Winch.
Hoist Plug A lifting device installed in
the box end of a tool. Opposite of lifting
bail.
Hole A bore made by rotating a bit into
the ground.
Hose, Drilling Connects rotary head to top
of hard piping to allow movement of rotary
head. Also called standpipe hose.
Hydraulic Cylinders Double acting
cylinders that are extended and retracted
to perform various functions on a drill.
They are powered by hydraulic fluid
from a pump.

Hydraulic Motors Piston or vane type mo-
tors, driven by hydraulic pumps, that rotate
various devices on a drill.
Hydraulic Pumps Piston, vane and gear
type hydraulic pumps that provide flow for
the various actuators on the drill.
Hydrostatic Head The pressure exerted
by a column of fluid, usually expressed in
pounds per square inch.
I millimeter. About 4/100,000 of an inch.
Inclinometer An instrument for measuring
the angle to the horizontal or vertical of a
drill hole or vein.
I.W.R.C. Abbreviation for Independent
Wire Rope Center. This refers to the type
of construction of wire rope. This wire rope
center is in effect a separate wire rope in
itself that provides a core for the line and
prevents it from crushing or breaking.
Interstage Pressure The air pressure
present between stages of a two-stage
compressor while the compressor is
making air.
J each track of a blasthole track drill with the
J Wrench Specially shaped wrench to fit
the backhead of a DHD. Used to hold a DHD
on the table or to remove the backhead from
the wear sleeve.
K drilling operation with the drill. See Driller.
Kelly Bar A fluted or square drill pipe that
is turned by a rotary table using a set of pins.
L weather, etc.
Leveling Jacks Hydraulic cylinders
mounted in a crosshead that raise and lower
the drill. Also referred to as outriggers or
stabilizers.
Lifting Bail A threaded cap for picking up
pipe, bits, DHDs and stabilizers. It screws on
the pin end. Some bails have a swivel hook
while others have solid tops. Opposite of
hoist plug.
Loaders Large, front end bucket equip-
ment used to pick up material for loading in
various types of hauling equipment.
M Pulldown Force exerted on the drill bit by
Main Frame The welded component of a
track mounted drill. The truck frame on a
wheeled drill.
Main Shaft (axle) The tube connecting the
tracks of a blasthole drill to the main frame.
Makeup The act of tightening threaded
joints. Making a connection.
Blasthole Drilling in Open Pit Mining 297
Making Hole The act of drilling.
Making Up a Joint The act of screwing a
joint of pipe into another joint or section of
pipe.
Manifold A pipe or chamber that has
several openings for hose connections.
Mast A vertical structure. See Derrick.
Micron -:- Mu A unit of length equal to one
millionth of a meter, or one thousandth of a
Mid-Inlet Swivel Device for removing
cuttings from the hole while drilling with
reverse circulation equipment.
Mine Plan Plan for making cuts and
creating elevations, benches for efficient
removal of material. The mine plan con-
siders a variety of factors, including the
type and location of material, the size and
number of shovels, loaders, and hauling
equipment, haul distances, blasthole
patterns, etc.
O of base, engine, compressor, and hydraulic
Oscillation Yoke The beam connecting
main frame that allows the tracks to move
independently up and down.
Open Hole Any uncased portion of a hole.
Operator The person who performs the
Overburden Any unconsolidated material
lying on top of the bedrock or the coal seam.
P
Parasitic Load The load imposed on the
engine by the direct connection of the
compressor and main pump drive during
starting.
Pattern Layout and distances between
blastholes, specifically including burden
and spacing.
Penetration Rate Speed at which a bit
advances while drilling, usually measured
in feet per hour. Instantaneous or drilling
penetration rate is the rate only while drill-
ing. Overall penetration rate is the same as
the production rate (see production rate).
Percussion Drill Drill that chips and pen-
etrates rock with repeated blows.
Pin End Fitting on male end of drill pipe.
See Box End.
Pioneer Work Drilling in rough, broken or
inclined areas. Removing the original layers
of dirt and rock.
glossary
Pipe Dope Special lubricant used to protect
the threads on pipe joints. See Thread Lube.
Pipe Support A device that holds the lower
section of pipe in place while connecting
to the next joint with the rotary head when
angle drilling. Also called rod support.
Pit An excavation in the ground for the
removal of mineral deposits.
PLC Programmable Logic Controller. A de-
vice that monitors many aspects of a drills
operation.
Potable Water Water that is safe to drink.
Powder Factor/Specific Charge Relation-
ship between the weight of explosives in
a blasthole and the volume of materials to
be displaced. It is measured in pounds per
cubic yard or kilograms per cubic meter.
Power Pack Base The welded channel
frame that contains the prime mover, the
compressor and the hydraulic pumps and
gearbox.
Power Pack The complete sub-assembly
drive.
Presplitting Process of drilling a line of
small diameter holes spaced relatively close
together, generally before drilling a produc-
tion blast, and loaded with light explosive
charges to create a clean, unbroken rock
face.
Production Rate Penetration during a
given reporting period. This rate includes
all lost time including maintenance,
breakdowns, long moves, inclement
Propel To cause to move forward or
onward. To drive or tram.
Protectors, Thread Steel or plastic covers
to cover the box and pin ends of drill pipe
when they are not being used.
Pump, Water Injection Pump used to
pump water into the drill air stream to
keep the dust settled and to assist in
flushing the hole.
Pullback The force available to remove
the drill string from the hole.
the thrust of the drill rig and from the weight
of the drill string.
Q
Quick Fill A centralized service station
that connects to various systems on the
drill to allow remote filling of engine oil,
compressor oil and hydraulic oil.
 Glossary
R Sliding Fork A wrench that slides around
Raise A mine opening, like a shaft, driven
upward from the back of a level to a level
above, or to the surface.
Reamer Bit-like tool, generally run directly
above the bit to enlarge and maintain a
straight hole.
Reservoir The tank used for storing the
hydraulic oil used in the hydraulic system.
Reverse Circulation Drilling Using a
double wall pipe to force air/water down the
hole and removing the cuttings between the
two pipes. See Mid-Inlet Swivel.
Rod Changer A device that holds extra drill
rod (pipe). See Carousel.
Rotary Drilling The method of drilling
that depends on the rotation of a column
of pipe to the bottom of which is attached
a bit. Air or fluid is circulated to remove
the cuttings.
Rotary Head A movable gearbox used to
provide rotation to the drill string. It is con-
nected to the feed chains or cables on each
end and to the drill string through the spindle.
S the drill pipe rotation head in the drill tower.
Safety Hook Attached to the end of a hoist
line to secure the hoist plug or lifting bail.
Has a safety latch to prevent the load
from slipping off the hook.
Scales Equipment used to determine the
weight and value of material being trans-
ported from a quarry.
Screens Devices used to separate broken
material into groups of similar size.
Shock Sub A device used to isolate the
shock of drilling from the rotary head. It is
made of hard rubber layers mounted inside
of steel outer rings.
Single Pass Drill Drill rig with a long tower
that permits drilling a blasthole without stop-
ping to add drill pipe (rod). Uses a Kelly in
place of regular pipe. Uses a rotary table to
turn the Kelly instead of a rotary head.
Stemming Material of a specified depth
added on top of a powder column to confine
the blasthole and make the explosion more
efficient.
Strip Mine A large section of land used to
remove coal deposits.
Shot A charge of high explosives depos-
ited in a series of holes to shatter the rock.
Shutdown A term that can mean the end
of the shift or workday or an unplanned
stopping of the drill due to a system failure.
298 Blasthole Drilling in Open Pit Mining
Swivel A coupling on top of the rotary
the flats of the drill pipe to hold the section head to allow the spindle to rotate while the
lower. Controlled by hydraulic cylinder(s). main hose remains stationary.
Used in place of a fork chuck.
Slips Used in the rotary table to hold and
T
Table Drive Drill design that locates the
break out drill pipe. Also used to hold casing
drill pipe rotation mechanism on the drill
in the table.
deck in a stationary position instead of using
the rotary head.
Spacing Distance between blastholes
measured parallel with the face.
Threaded and Coupled Casing (T&C)
Steel casing using a coupling between
Spear Tools of various design that are
each section of pipe. Thread style is right
screwed or wedged inside of bits, pipe, etc.,
hand, fine thread.
that are lodged in the hole. See Fishing
Tools.
Thread Lube A special compound used to
lubricate the threads of drill pipe. See Pipe
Spindle The short section of pipe that
Dope.
rotates within the rotary head, and
protrudes out.
Tongs A type of wrench used to make
up and break out drill pipe using external
Speed Switch An electronic device that
forces, such as hydraulic cylinders or
changes states when the engine reaches
cables.
a certain speed. Used to control dual oil
pressure switches.
Tool Joint A drill pipe coupler consisting
of a pin and box of various designs and
Split Bushings The removable bushings
sizes. Deephole drills normally use API style
that allow the DHD or Stabilizer to pass
threads, while blasthole drills normally use
through the drill table while drilling
Beco style threads.
a straight hole. See DHD Bushings.
Top Head Drill Drill design that locates
Stabilizer, Drill Pipe Heavy -walled pipe
having special spiral or fluted ribs extend-
It moves up and down with the drill string.
ing around the diameter, within 1/8 to 1/4
See Rotary Head.
of hole size. Most stabilizers are fitted just
above the bit, while in-line stabilizers keep
Torque A turning or twisting force.
the hole straight.
A moment caused by force acting on an arm.
A one pound force acting on a one-foot
Standpipe Part of the circulating system.
arm would produce one lb-ft of torque.
The hard and flexible piping from the main
valve to the flexible hosing leading to the
Tower A tall, slender structure used for
rotary head. Water injection, DHD oil and
observation, signaling or pumping. Term
foam are injected into this line.
used to indicate the derrick on a blasthole
drill. See Derrick and Mast.
Static Water Level The distance from the
top of ground down to the standing water
Turning To The Right Slang term for
level.
making a hole.
Strike The bearing of the outcrop of an
Tram A cable car or a four-wheeled open
inclined bed or structure on a level surface.
box in a coal mine. See Propel.
See Dip.
Stuck In The Hole Refers to drill pipe inad- Trammed To move in a tram.
vertently becoming fastened in the hole.
Tramming Process of moving a drill.
Subdrilling Bottom portion of a blasthole See Propelling.
drilled below the floor level to permit
upward displacement of material and Traveling Sheave Block A series of
thereby prevent a toe at the bottom of sheaves, connected to the feed chains or
a face. cables, that are moved up and down the
derrick by the feed cylinders.
Sub A coupling with different type or diam-
eter of threads at either end. The term pin Twist Off To twist a joint of pipe in two by
denotes a male thread, and box, a female excessive torque applied by the rotary head
thread. To connect two components with or rotary table.
different threads. See Adapter.
U
Supercharge Pressure Inlet oil pressure to UL88 The pneumatic valve that controls
the main pump(s) that has been pressurized pressure and volume on a high-pressure
to prevent cavitation. compressor system.

Undercarriage The means of moving a
track type vehicle. It contains the track
frame, rollers, grousers, rock guards, drive
sprocket, propel motors and planetary drive.
Uphole Velocity The speed (in feet per
minute) that the cuttings travel out of the
hole. This is dependent on the bit size, the
compressor size and the pipe size.
W wiping drill pipe clean of cuttings when it is
Washpipe Hard surfaced steel tubes
inserted in swivels to allow rotation of drill
string and prolong life of packing. They are
replaceable in most swivels.
Water injection A method of rotary drilling
where water is dispersed in the air while
drilling.
Blasthole Drilling in Open Pit Mining 299
glossary
Weight On Bit In rotary drilling, a specified
weight is required on the bit for maximum
performance. A gauge on the console is
calibrated to correspond to the drill string
weight.
Winch A stationary hoisting machine
having a drum around which a rope is
wound.
Wiper, Pipe An annular rubber disk for
being withdrawn from the hole.
Wire Rope Rope made of twisted strands
of steel wire. Also called cable.
 Atlas copco
Where to find us
Please contact your local Atlas Copco CustomerCenter.
or visit www.atlascopco.com and select country, or contact:
Atlas Copco Drilling Solutions LLC, Garland, Texas, USA
Telephone: +1 (972) 496 7400
300 Blasthole Drilling in Open Pit Mining
Country City (HQ) Phone no.
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Advantage Pit Viper

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Advantage Pit Viper

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Printed matter no. 58 388 351