underground drilling - tunneling short course

UNDERGROUND DRILLINGKIRBY OWENSACCOUNT / BUSINESS DEVELOPMENT MANAGER TUNNELING USA

Sandvik’s objective is zero harm to our people, the environment we work in, our customers and our suppliers.

SAFETY FIRST

PROTECTIVE EQUIPMENT

ASSEMBLYPOINT

EMERGENCYEXIT

EMERGENCYNUMBER

ALARMFIRST AID KIT

3

COMPLIANCECOMPLIANCEWe’ve always been committed to conducting business with high integrity and in a legal and ethical manner. We embrace our corporate responsibility to combat corruption.

TRENDS IN UNDERGROUNG DRILLING1. Mining and tunneling in more cost effective ways• Minimized waste rock excavation• Strong demand for more precise drilling, charging and blasting to minimize over breaking and vibrations• More challenging underground orebodies (deeper, narrower, hotter, colder, etc.)

2. Focus on product safety and EHS• Aim for a ZERO LTI• Reduce emissions and save energy• Improved ergonomics for all labor

3. Availability of skilled workforce is some geographical areas• Lack of experienced operators• High pressure for increased salary levels

Multiple drilling tasks• Face drilling:

−Full face−Cross cuts

• Long hole drilling:−Probe holes−Grouting holes

• Bench drilling• Bolt hole drilling

UNDERGROUND DRILLING


• Drill & Blast is Economical Rock Excavation Method• Accurate drilling at the bottom of long blasting round• Combined drill hole and blasting design:

− Maximum pull out − No underbreak− Minimum overbreak− No unnecessary damaging of remaining rock− Minimum vibrations

• High quality with maximized productivity without risks

UNDERGROUND DRILLINGVersatile drilling equipment


Versatile drilling equipment• Number of drilling booms from 1 to 3• Power supply options for drilling

− Diesel hydraulic drilling (air mist flushing)− Electric drilling (water flushing or air mist flushing)

• Power supply options for tramming− Diesel engine− Battery tramming (only with electric drilling)

Drilling equipment:• Ergonomic control system with several levels of instrumentation• Drilling angles, predesigned drilling plans on the screen and• Fully automatic drilling operation for the whole face



Automation and instrumentation enables − more flexible drill pattern designs (for example V-cuts)− adjustable drilling pattern and process− No need to paint or mark holes on the wall

Office: Drill plans & analysis Drill rig Drill rig (symbols on the screen)

Boom Closest

hole to

the

boom

Holeend

Holestart

Boom

aligned

Drilledhole

”Drill rig needs to know where it is to drill the holes according to plan”Navigation methods of drilling rig:• Drill bit navigation

− Painted point and reference direction• Tunnel laser navigation

− With or without curve table• Total station navigation

− Curve table needed− Wireless coordinate transfer for Jumbo from totalstation

• New point cloud navigation− Requires onboard 3D scanner


Principle of laser navigation


• Rotation pressure automatically kept on its optimum level during drilling

• Dynamic drilling power adjustment based on rock conditions

• No need for operator to modify any drilling parameters

12

DRILLING CONTROL SYSTEM

13

• The best bit penetration / tool lifetime combination is achieved with modern torque based control system. Optimum drilling power for each rock condition ensures:

• Less deviation in holes – better blasting result

• Better throughput time per face • Excellent hole collaring• Better service life for tools

Torque

Feed Force

Rotation resistance abnormally high

Fast automatic feed reduction by rotation pressure

Anti-jamming function activates due to excessive rotation resistance

UNDERGROUND DRILLINGDRILLING CONTROL SYSTEM

System

Drilling Time

Simplified description

Recovering time

Precorrection

UNDERGROUND DRILLINGDRILLING POWER

• Rock drills− Drilling power from 20 hp to 34 hp (15 kW to

25 kW)− Frequency 50…100 Hz

• Flushing− Water flushing [from 15 up to 30 gallons

minute (60 - 120 lpm )] or− Air: 150 cfm @ 150 psi(4 m3/min @10 bar)

with the air mist • Max. penetration rates

− 6 ftm – 20 ftm (2 in. hole) (2 – 6 m/min, Diam51mm)

− Depends heavily on the rock type14

• Bit design• Efficient flushing and sludge disposal• Different kind of button geometries• Different carbide solutions optimized for

soft and hard rock• Rods

• Round or hexagonal rods are used (size 1,5 inch)

UNDERGROUND DRILLINGRock tools

Automated boom movements and drilling (video)


UNDERGROUND DRILLINGAccurate automatic drilling process requires calibration of boom:• Calibration is always done at factory prior to customer delivery.• Boom bending, roll-over and location compensation models

− increases the calibration and drilling accuracy dramatically.

• Connection / coms with the totalstation by using radio link communication.• Accuracy measurement report is produced after calibration. • Also the site calibration is fast and easy to do by following instructions from the user interface

Drilling plans with office softwareTunnel Line & TheoreticalProfile Design

Drill & Blast Design

Bolting Design

Data Collection Analysis MWD analysis


UNDERGROUND DRILLINGif the face is too big for one drill rig:- one design & two navigations or- one design several drills – combined data

REMOTE MONITORING AND DATA TRANSFER• Remote access to rig via WLAN or Ethernet

connection• Remote status query shows a summary of rig

counters and data available• All necessary data file transfers are possible

(drill plans, tunnel lines and data collection files)

• Jumbo interface displayed on a PC screen via remote monitoring

• Drilling work progression and possible deviations can be followed up


UNDERGROUND DRILLINGEHS

SAFETY CABIN MAKES THE OPERATOR ENVIRONMENT SAFE AND COMFORTABLE• Optimized visibility• reduced noise and dust level inside• more open and spacious operator

environment• maximized safety and operator ergonomics

UNDERGROUND DRILLINGEHS

Tier 4F diesel engine has 90% less emissions compared to tier3

Tier4F emissions limits, g/kW-hr (g/bhp-hr):• NOx (nitrogen dioxide): 0.4 (0.30)• HC 2 (hydrocarbons): 0.19 (0.14)• CO (carbon dioxide): 3.5 (2.6)• Particles: 0.02 (0.015)

SANDVIK UGD TRAINING SIMULATOROPTIMIZING COMPETENCIES

OPERATOR COMPETENCE DEVELOPMENT

24

A skillful, well trained operator

- Recognises his important role in the whole excavation process

- Understands the key features of the total productivity

- Manages challenging rock conditions

- Keeps the machine in good condition and available

- Utilises modern technology efficiently

BENEFITS OF SIMULATOR BASED TRAINING

25

• Safe learning environment

Feature: Training conducted in a classroom environment Zero risk to damage the equipmentZero impact on the environment - operator

• Optimized startup period

Feature: Start training and learning before commissioningHigh utilization from day oneGain in productivity

• Easy logistics to organize training sessions with the simulator

Feature: Portable equipment fitting in a protective caseEasy to setup Multiple operators can participate to a training session

BENEFITS OF SIMULATOR BASED TRAINING

26

• Comprehensive learning

Feature: Preplanned exercisesBriefing and debriefingAssessment and feedback

• Cost effectivess:

Feature: Time saving on rig commissioning No rock tools or fuel consumedLimited training costs

• Training efficency

Feature: Training conducted with real controls and control system with a virtual drill Trainer can define the level of control systemPossibility to repeat training sessions

SANDVIK TRAINING SIMULATORDIMENSIONS

ROADHEADER IN TUNNELINGTODAY’S STATE-OF-THE-ART-ROADHEADER

MECHANICAL TUNNEL EXCAVATION

29

Mechanical Tunnel

Excavation

Part face excavation

Soft (lose) rock

Full face excavation

Hard (stable)

rock

TUNNELING SHORT COURSE 2018CONTENT

30

• Selection criteria for Excavation method

• Parameter on Roadheader Cuttability

• Current Roadheader technology

• Roadheader projects

SELECTION CRITERIA FOR EXCAVATION METHOD

31

ROCK PROJECT ENVIRONMENT

Drill & Blast

ShieldMachines

Hardrock TBM’s

Excavator Attachments

Roadheaders

Compressive Strength

Stab

ility

/ Fra

ctur

ing

Mechanical Excavationwith Breaker / Splitter

SELECTION CRITERIA FOR EXCAVATION METHODEXAMPLES – ROADHEADER SELECTION

32

• Complex geology • Free access to the face• Ability for partial face excavation• Gentle excavation• Not sensitive against squeezing rock• High cutting performance in soft and

medium hard rock (up to 130 m³/NCH)

SELECTION CRITERIA FOR EXCAVATION METHODEXAMPLES – ROADHEADER SELECTION

33

• Flexible system – profile, alignment• Accurate profiling – less over break,

less concrete cost• Low primary investment• Fast mobilization

PARAMETER FOR ROADHEADER CUTTABILITYREPRESENTATIVE ROCK SAMPLING

34

Batching Card for Sample Identification

PARAMETER FOR ROADHEADER CUTTABILITYSPECIMEN CHECK FOR DISCONTINUITIES

35

Ultrasonic P-wave velocity

PARAMETER FOR ROADHEADER CUTTABILITYUNCONFINED COMPRESSIVE STRENGTH TESTING

36

• Determination of: sc, Estat, Esec, e, Wf

• Standard specimen:− D = 50 mm ± 10 %− H = D ± 10 %

• Load:− F = 10 kN/s

H

D

F

PARAMETER FOR ROADHEADER CUTTABILITYBRAZILIAN TENSILE STRENGTH TESTING

37

• Determination of: st

• Standard specimen:− D = 50 mm ± 10 %− H = D/2 ± 10 %

• Load:− F = 10 kN/s

F

H D

PARAMETER FOR ROADHEADER CUTTABILITYCERCHAR ABRASIVITY INDEX (CAI) TESTING

38

• Standard Test Pick Hardness: HRC = 54 - 56• Optional Test Pick Hardness: HRC = 40 - 42• Steel Type: Silver Steel 115CrV3 (DIN)• According to

− 1.2210 Material Number(DIN EN ISO 4597)− 107CrV3 KU in Italy (UNI)− F.5125 (120CrV) in Spain (UNE)− 11ChF in Russia (GOST)− L 2 in USA (AISI)

CAI Testing

CAI Measuring

PARAMETER FOR ROADHEADER CUTTABILITYCERCHAR ABRASIVITY INDEX (CAI) TESTING

39

• 10 mm in 1 second over rough surface

• Load: F = 70 N

• CAI = 10 x d [mm]

.90° d

10 mm

FF

new pick before testing

worn pick after testing

d

Pick wear diameter

PARAMETER FOR ROADHEADER CUTTABILITYHOW TO ASSESS NCR FOR INTACT ROCK

40

• UCS = 100 MPa• UCS:BTS = 8 to15

− → Normal rock

Technical limit defined by machine

Economical limit defined by operation

PARAMETER FOR ROADHEADER CUTTABILITYOPERATING LIMITS DEFINED BY NCR

41

Technical optimum range of operationLimited range

Critical range

PARAMETER FOR ROADHEADER CUTTABILITYHOW TO ASSESS SPC

42

0,001

0,010

0,100

1,000

10,000

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Spec

ific P

ick C

onsu

mptio

n [pi

cks/s

olid

m³]

Uniaxial Compressive Strength [MPa]

Specific Pick Consumption (SPC) for Low Speed Cuttingwith Transverse Cutterhead and 22 mm TC Diameter Picks of High Quality

CAI=0,5CAI=1,0CAI=1,3CAI=1,8CAI=2,3CAI=3,0CAI=4,5

Effective minimum specific pick consumption: 0,005

Uniaxial Compressive Strength measured onH:D=1:1 specimen with 50 mm diameter @ 10

CAI ..... CERCHAR Abrasivity Index measuredon rock surface of natural roughness (e.g.surface of broken Brazilian Tensile Strength testspecimen) using original CERCHAR testing

UCS=100 MPaCAI=1.0

Technical limit defined by machine & toolsEconomical limit defined by operation

PARAMETER FOR ROADHEADER CUTTABILITYOPERATING LIMITS DEFINED BY SPC

43

Technical optimum range of operationLimited rangeCritical range

PARAMETER FOR ROADHEADER CUTTABILITYINFLUENCE ON ROCK MASS PARAMETERS

Sandvik Construction44

PARAMETER FOR ROADHEADER CUTTABILITYPRINCIPLES OF ROCK MASS INFLUENCE

45

Strength

Conditions Orientation

0.5 m

0.3

m 0.3 m

Block size

PARAMETER FOR ROADHEADER CUTTABILITYROCK MASS CUTTABILITY RATING (RMCR) SYSTEM

46

Block size [m3] Rating

> 0,6 20

0,3 - 0,6 16

0,1 - 0,3 10

0,06 - 0,1 8

0,03 - 0,06 5

0,01 - 0,03 3

< 0,01 1

Surface Aperture Wall/Fill Rating Influence on

cuttability

Rating

rough closed hard, dry 30 very favorable -12

slightly

rough

< 1 mm hard, dry 20 favorable -10

slightly

rough

< 1 mm soft, dry 10 fair (and if block

size <0,03m3)

-5

smooth 1 - 5 mm soft, damp 5 unfavorable -3

very

smooth

> 5 mm soft, damp

to wet

0 very unfavorable 0

Rating of joint conditions Rating of orientation of joint

set

100 - 200 2

> 200 1

25 - 50 7

50 - 100 4

1 - 5 15

5 - 25 12

Rating of block size

UCS [MPa] Rating

Rating of uniaxial compressive strength

Evaluation of Rock Mass Influence on NCR(Low cutting speed - 1.4 m/s)

NCReff/NCRtheor = 45,553RMCR-0,9821

R2 = 0,9332

0123456789

10

0 10 20 30 40 50 60

RMCR

NCR e

ff / N

CRth

eor

Erzberg Stillwater PozzanoPremadio Athens BilecaFresnillo Montreal

PARAMETER FOR ROADHEADER CUTTABILITYHOW TO ASSESS NCR FOR ROCK MASS

47

RMCR = 30 =>

increase in NCR ~ 60%

PARAMETER FOR ROADHEADER CUTTABILITYHOW ROCK MASS IMPACT ROADHEADER CUTTABILITY

48

Rock mass favorable for cutting can make an uneconomical or critical operation economical!!!

RMCR = 30

Technical optimum range of operationLimited range

Critical range

PARAMETER FOR ROADHEADER CUTTABILITYROCK MASS CUTABILITY RATING (RMCR) SYSTEM

49

RMRrev Influence on cuttability by roadheaders

40 - 60 no to little influence

25 - 40 moderate influence

15 - 25 considerable influence

10 - 15 high influence

< 10 dominating influence

RMCR

CURRENT ROADHEADER TECHNOLOGYMT720 ROADHEADER WITH ICUTROC TECHNOLOGY

50

• MT720 Tunnel Miner− Heavy-duty Roadheader for tunneling in

“hard rock conditions“− Especially designed for large cross sections

• Key Technical data− Weight: ~135 t− Cutter motor power: 300 kW − Large cutting area: ~61 m²− Fully PLC controlled− ICUTROC technology


51

• Highly efficient stabilized CUTTING SYSTEM

CURRENT ROADHEADER TECHNOLOGYMT720 ROADHEADER

52

• Different cabin designs (FOPS)• Roadheader without cabin• Profile monitoring (optional)• Guidance system (optional)


53

• Keeping records with DATALOGGING SYSTEM

• DRRS – Data Recording & Reporting System

IPC

Control system

Ethernet

EthernetUnderground

Surface

Sandvik supply

Customer supply

ATM 105

Provisions for:

1. Remote Maintenance (not included)2. Data storage (not included)3. Online monitoring (not included)

Benefits

110 – 240 VAC

ROADHEADER PROJECTSROADHEADERS WORKING IN CONSTRUCTION PROJECTS

54

• Project in Sochi for 2014 Olympics

• 2010 until 2012/13

• 2 x ATM75 and 2 x MR360 and 1 x MT360

• 4 x MT520

• 3 x ATM105 and 1 x AHM105 and 2 x MT720

• Projects in Europe• 2015/16 1 x MT720 @ Pforzheim, Germany

• 2013/14 1 x MT720 @ Bormio, Italy

• 2012/13 1 x MT520 @ Polidano, Malta

• 2011/12 1 x MT720 @ Markovec Tunnel

• 1999/2010 7 x MT720 @ Bilbao, Spain

• Projects in North America• 2017/18 2 x MT52 @ Peace River Hydro

• 2013/16 3 x MT720 @ Ottawa Light Rail

• 2008/10 3 x MT720 @ East Side Access

• 2007/08 2 x MT720 @ Devil’s Slide

• 2007/08 1 x MT720 @ Arch

• 2006/07 1 x MT720 @ Wheeler Gulch

• 2005/06 1 x MT720 @ Mining International

• 2004/05 1 x MT720 @ Fox River stone

• 2002/03 2 x MT720 @ Metro Montreal

• Project in Australia• 2009/10 8 x MT720 @ Airport Link Brisbane, Australia

• 2016/18 24 x MT720 & MT520 @ NorthConnex and WestConnex Sydney, Australia

ROADHEADER IN TUNNELINGMARKOVEC TUNNEL, SLOVENIA

55

• Project data− 2,2 km double twin tube road tunnel between Koper

and Izola (Slovenian Coastline)− Residential area at Koper side with overburden of

10-35m− 560m in each tube to be excavated by means of

Road-Header• Geologic data

− Flysch dominated by Marl− Interbeds of Sandstone and Calcarenite (UCS up to

200 MPa)− Area with shallow overburden weak rock predicted− Sandstone layer thickness of 2m

Source: Alpine Bau GmbH, AustriaUNDER CITY ColloquiumApril, 12- 14, 2012Hotel-Congress center Valamar Lacroma Dubrovnik, CroatiaExcavation by means of Road Header at Markovec Road Tunnel

ROADHEADER IN TUNNELINGMARKOVEC TUNNEL, SLOVENIA

56

• Up to 8 m/d

ROADHEADER IN TUNNELINGST. LUCIA TUNNEL BORMIO, ITALY

57

• Project data− About 1km single tube road tunnel− Bypass of Bormio residential area

• Geological data− Quartzitic mica schist− Gneiss− UCS values between 40 – 200MPa − CAI 2,5 – 5


58


59

• ~ 4m/day

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

0

5

10

15

20

25

30

MPA

SOLI

D M

³/CU

TTER

MO

TOR

HO

IOU

RS

Net cutting rate UCS

ROADHEADER IN TUNNELINGMETRO MONTREAL, CANADA

60

• Project data− Metro tunnel− Length: ~1.8 km− Cross section: ~44 m²

• Geologic data− Limestone-shale interbedding, massive

crystalline limestone, diabase dikes− Average UCS: ~90 MPa− Average CAI: ~0.7− Very well bedded rock mass− Average NCR: ~39 solid m³/nch− Average SPC: ~0.1 picks/solid m³


61

Better advance rate than D&B related to single face operation


62

• Visible arguments for Roadheader

ROADHEADER IN TUNNELINGDECLINE FOX RIVER STONE, SOUTH ELGIN

63

• Project data− 2 access ramps with 450m each− 18% decline− Arch profile 6,6m x 5.5m

• Geologic data− Shale at UCS 20-50 MPa

0,000,050,100,150,200,250,300,350,400,450,500,550,600,650,700,750,800,850,900,951,00

05

101520253035404550556065707580859095

100105110115120125130135140145150

12.07

.2005

15.07

.2005

18.07

.2005

21.07

.2005

24.07

.2005

27.07

.2005

30.07

.2005

02.08

.2005

05.08

.2005

08.08

.2005

11.08

.2005

14.08

.2005

17.08

.2005

20.08

.2005

23.08

.2005

26.08

.2005

29.08

.2005

01.09

.2005

04.09

.2005

07.09

.2005

10.09

.2005

13.09

.2005

16.09

.2005

19.09

.2005

22.09

.2005

25.09

.2005

28.09

.2005

01.10

.2005

04.10

.2005

07.10

.2005

10.10

.2005

13.10

.2005

16.10

.2005

19.10

.2005

22.10

.2005

25.10

.2005

28.10

.2005

31.10

.2005

03.11

.2005

06.11

.2005

09.11

.2005

12.11

.2005

15.11

.2005

18.11

.2005

21.11

.2005

24.11

.2005

27.11

.2005

30.11

.2005

03.12

.2005

06.12

.2005

09.12

.2005

12.12

.2005

15.12

.2005

18.12

.2005

21.12

.2005

24.12

.2005

27.12

.2005

30.12

.2005

02.01

.2006

05.01

.2006

08.01

.2006

11.01

.2006

14.01

.2006

17.01

.2006

20.01

.2006

23.01

.2006

26.01

.2006

29.01

.2006

01.02

.2006

04.02

.2006

07.02

.2006

10.02

.2006

13.02

.2006

Spec

ific P

ick C

onsu

mpt

ion

[pick

s/sol

id m

3 ]

Net C

uttin

g Ra

te [s

olid

m3 /h

]

Date

ATM 105/040-IC at Chicago/USA

Daily NCR Cumulative Average NCR Daily SPC Cumulative Average SPC

Average NCR: 50,26 solid m3/h

picks/solid m30,166Average SPC:Net Cutting Rate (NCR) and Specific Pick Consumption (SPC)

ROADHEADER IN TUNNELINGDECLINE FOX RIVER STONE, SOUTH ELGIN

64

ROADHEADER IN TUNNELINGSTATION EXCAVATION, EAST SIDE ACCESS

65

• Project data• Metro station excavation

• Launch chamber for TBM

• Additional auxiliary structures

• Small to large cross sections

• Geologic data• Schist (partly gneissic), pegmatite

• Average UCS: ~80-95 MPa

• Average CAI: ~3.7-3.8

• Massive to significantly fractured

rock mass

ATM105/046 at New York/USA

0

5

10

15

20

25

30

16.1

1.20

09

04.0

2.20

10

25.0

4.20

10

14.0

7.20

10

Date

Net C

uttin

g Ra

te [s

olid

m3 /h

]

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

4,0

4,5

5,0

5,5

6,0

Spec

ific

Pick

Con

sum

ptio

n [p

icks

/sol

id m

3 ]

Daily NCR Cumulative Average NCR Daily SPC Cumulative Average SPC

Average NCR: 17,71 solid m3/h

picks/solid m31,526Average SPC:Net Cutting Rate (NCR) and Specific Pick Consumption (SPC)

ROADHEADER IN TUNNELINGSTATION EXCAVATION, EAST SIDE ACCESS

66

ROADHEADER MT720 ICUTROCLATEST PROJECT EXPERIENCES - CONCLUSIONS

67

• The ICUTROC technology has proven• ... to be an economic alternative for challenging excavation projects• ... the ability to deal with harder & sensitive rock condition forming low risk for the

Contractor/Owner• ... high productivity resulting in low excavation cost

SANDVIK IN TUNNELING

68

UNDERSTANDING UNDERGROUND

underground drilling - tunneling short course

Documents