straight forward drilling€¦ · dth hammer and rotary drilling methods. 2x 128pcs grout holes in...
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LKAB Wassara AB
LKAB Wassara AB - 100 % owned by LKAB
- 50 employees (in two locations in Sweden)
- Distributors in 28 countries
- Strong ambition to grow in coming three years
LKAB - 100% owned by Swedish state
- Sales, BSEK 24 (BEUR 2,8)
- 4 400 employees (20% women)
- World leader in underground mining
- World leader in pellet manufacturer for 50 years
- 90% of the EU’s iron ore production
- Planning to hire 1 250 new employees until 2015
Existing markets
Some European contractors
Skanska PEAB
NCC Trevi
Soletanche Bachy (Vinci) Keller
Zublin / Insond (Strabag) Bilfinger
Rodio Bauer
Porr Hochtief
Lemminkainen Salini
Boart Longyear Marti
Regularly using Wassara
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 3
Rock drilling principles Rotary, Top-Hammer, Down-The-Hole
Ro
tary
Top
-Ham
me
r
Do
wn
-Th
e-H
ole
Wassara the “Hybrid hammer”
Wassara Water Powered DTH hammer
Piston
Valve
Two moving parts
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 5
Unique water-powered DTH hammer
• World patented
• > 20 years in various applications
• > 25 million meters drilled in-house by LKAB
Key Benefits with water powered drilling
The Key Benefits
with Wassara
Safer and benign drilling
Borehole quality and accuracy
High performance
Less environmental
impact
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 6
Penetration rate
TOP Hammer
Reduced penetration rate after ~20 meters
4‐6% of the impact energy is lost at each
joint (exact figure depends on the design,
mass, number and tightness of joints)
DTH
No loss of energy through the drill string
from start to finish of the hole, as with top
hammer.
DTH vs. Top hammer
7
0 25 50 75 100
meter
Penetration rate (ROP)
Top hammer DTH
Ro
tary
Top
-Ham
me
r
Do
wn
-Th
e-H
ole
Ro
tary
Top
-Ham
me
r
Do
wn
-Th
e-H
ole
Higher Performance
Hammer Pressure Flow Frequency
Wassara W100
4’’
180 bar (2600 psi)
3,5-6 l/s (225-350
l/min) 7.5-13 cfm (60-95 USgpm)
3600 blows per minute
(60 Hz)
Air DTH
4’’
30 bar (435 psi)
350-450 l/s (740-950 cfm)
2000-2700 blows per
minute
(35-45 Hz)
Water Hydraulic DTH
1 bar (atm) 2 bar 4bar 30 bar
Water
1L
Water
1L Water
1L Water
1L
Air
1L
Air
1/2L
Air
1/4L
Air
1/30L
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 8
Safer and benign drilling with Wassara
Water DTH
3,5-8 l/s
@ 180 bar
7.5-17 cfm
(55-130 USgpm)
@ 2600 psi
Air DTH
15-20 l/s
@ 30 bar
30-40 cfm
@ 435 psi
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 9
Safer and benign drilling with Wassara
Air DTH
450-650 l/s
@ 1 bar (atm)
750-1400 cfm
@14.5 psi (atm)
Water DTH
3,5-8 l/s
@ 1 bar (atm)
7.5-17 cfm
(55-130 USgpm)
@14.5 psi (atm)
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 10
Minimum disturbance to the formation
Minimal outgoing water velocity -> low pressure!
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 11
Facilitates drilling in water rich formations
Water in the formation does not affect the
Wassara hammer
- Maintained ROP drilling under the ground
water table.
Ex. Air DTH
Ground water
table @ 50m
100
150
200
250
300
350
200m = 20bar 320m = 32bar
Effective Air Pressure = 1bar
21bar
21 Bar
50bar
Effective Air Pressure = 18bar
21bar 21bar
Booster
12
Borehole quality and accuracy Tight Spacing
2-4 mm
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 13
Average deviation Air DTH: 19,2%
Average deviation Wassara DTH: 1,3%
Long straight holes with Wassara
Average deviation for Wassara = 1,05 %
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 14
Energy consumption Reduction of energy consumption with up to 80%
vs
Water Pump Air Compressor
200 bar (2900 psi) 35 bar (510 psi)
490 l/min (129 USgpm) 570 l/s (1207 cfm)
190kW (255 hp) 429kW (575 hp)
Water Pump Air Compressor
Reduction of energy consumption with up to 80%
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 15
- No oil mist in the air
- No dust
Working Environment Mining
AMV drill with Air ITH AMV drill with Wassara
Sound Emission
DTH drilling is much more silent
compared to top-hammer drilling
because the percussion unit follows
the bit down hole.
Water hammer drilling is more silent
compared to air hammer drilling
because the water column will
dampened out the noise from the
hammer.
18
Drilling in existing dams Reinforcement drillings in existing dams for installation of grout
curtains and concrete walls
Old wall New wall
Cavity
Drilling in new dams
A. Inclined drilling downwards for grout injection.
B. Drilling of drainage holes from gallery for pick up
of seepage.
Drilling holes for creation of grout curtains in new dams
A B
Diversion
Upstream face Downstream face
Galleries
for service
and drainage
Better borehole quality with water flush
Wassara drills cleaner and more stable
holes, simplifying geophysical pre-
grouting tests. This gives good
conditions for grouting.
View from the top of the hole at the Urdalur Dam, Spain
Flashlight at 58.5 m depth
Dam rehabilitation
– Urdalur Dam, Spain
Application:
Strengthening/repairing existing drainage/service tunnels by injection of grout
Mission: Very tight
clearance: max borehole
deviation of 0.1% at 58.5 m
(192 ft.) depth.
The distance was only 75 cm
(30”) from the center of the
borehole to the dam wall on
one side and 75 cm (30”) to
the two drainage/service
tunnels on the other side.
Result: Borehole deviation
was confirmed to be less than
0.1%. Drilling completed
within timeframe.
75 cm (30”)
McCook Reservoir Project
Installation of a grout curtain to minimize the flow of water in and out of the reservoir.
U.S. Army Corps of Engineers conducted a test project to compare the water-powered DTH hammer and rotary drilling methods.
2x 128pcs grout holes in two parallel rows was drilled to a depth of 135 meters. The Wassara drilling system was 100% more efficient than the rotary drilling
Borehole accuracy
The allowed borehole deviation was set to 4% at full length. The quality control indicated that Wassara had an average hole deviation of just over 1%.
Chicago Underflow Plan, designed to protect the city from flooding.
Galleries
for
service
and
drainage
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 24
Wolf Creek Dam
Max allowed borehole deviation for the project
was 0.15%. Wassara both met the stringent
requirements and kept the time schedule.
Length: 1280m Depth: 84m
Pilot hole for Cut of wall: Wassara W150 – Ø203mm bit
Grout holes for grout curtain: Wassara W80 – Ø95mm bit
2007-2012
Old wall New wall
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 25
Angostura Dam Water-powered drilling in confined galleries
Max 2% allowed deviation
26 Presenter: John Doe | Company Name
Silvretta Dam – Austria Wassara W50 on a compact drilling rig
Date 2013-11-29 27 Presenter: Peter Johansson | LKAB Wassara
Drilling for consolidation grouting Adana Turkey
Date 2012-08-13 28 Presenter: John Doe | Company Name
Drill time / hole: Wassara: ~20min Rotary drilling: ~1h
Rate of penetration: 1 meter / min
• Silvretta Staumauer, Austria Drilling for grouting 2009
• Tsankov Kamak Hydro Power Dam,
Bulgaria Drilling grout holes for new dam 2004-10
• Niagara Falls, Canada Installation of a grout curtain 2007
• Central Hidroeléctrica Angostura, Chile Drilling grout holes for new dam 2012
• Ohra dam, Germany Drilling grout holes for new dam 2003
• Changuinola I Hydro Power Dam, Panamá Drilling grout holes for new dam 2009-2012
• Urdalur, Spain Strengthening/repairing existing
drainage/service tunnels by injection
of grout 2010
• Bergeforsen, Sweden Sheet pile wall installations 2011-2012
• Seitevare, Sweden Casing advancing for installation of
instrumentation 2008
• Dernier Dam, Turkey Drilling grout holes for new dam 2010-11
• Logam Martin Dam, USA Installation of a grout curtain 2005
• McCook Reservoir Chicago, USA Installation of a grout curtain 2007
• Wolf Creek, USA Installation of concrete walls 2009-2012
• Marchlyn Mawr Dam, Wales Installation of a grout curtain 2008
• Center Hill Dam, USA Installation of concrete walls 2013-
• Reb Bluff Dam, Texas USA Drilling grout holes 2014-
Wassara is recommended by the US Army Corps of Engineers, Vattenfall (Swedish
state dam commissioner), the dam consultants Golder Associates, SWECO, WSP, etc.
Some reference projects
The Jet Grouting Process
Date 2012-08-13 40 Presenter: John Doe | Company Name
www.asconroads.com
1.
Drilling
2.
Injection
of grout
3.
Rotate
& lift
Convential equipment Jet grouting monitor & drag bit
Date 2012-08-13 41 Presenter: John Doe | Company Name
The drilling is normally done with conventional rotary (drag bit) and the operation is
completed in two simple steps.
Problematic formation Boulders, Till, Concrete
Date 2012-08-13 42 Presenter: John Doe | Company Name
Excavation of JG columns
Diameter ~1,8-2,0m
1x Ø5,5mm nozzle @ 450bar
Wassara Jet Grouting Hammer
Date 2012-08-13 47 Presenter: John Doe | Company Name
Diameter ~1,5m
2x Ø4,2mm nozzles @ 450bar
Date 2012-08-13 48 Presenter: John Doe | Company Name
Excavation of JG columns Wassara Jet Grouting Hammer
Brasfond Jobsite Rio de Janeiro
Date 2012-08-13 51 Presenter: John Doe | Company Name
Construction of vertical
shaft for subway station
to the new subway line
20m drilling with roller bit
(conventional system)
~1h -> 1h 20min.
20m drilling with Wassara
jet grouting system:
~20min
20m Jet grouting:
~40-45min
Saturday 25/1 - 2014
kl 13.12 – start drilling
kl 13.31 – finish drilling
kl 13.37 – start jetting
kl 14.23 – finish jetting
Drilling with Roller bit 20m drilling ~ 1 – 1h 20min
Date 2012-08-13 52 Presenter: John Doe | Company Name
Accurate drilling is mine profitability
Straight blast holes
Enables longer blast holes
Reduction of drifts / sublevels
More ore per drilled meter
Optimal Fragmentation
Higher productivity in the crushers
Higher productivity in the process plant
Minimized Dilution
Mine only the ore body, not the waste rock
Increased productivity in the process plant
Maximized Ore recovery
Deviation => poor fragmentation & ore dilution
56 Presenter: Peter Johansson | LKAB Wassara AB
Malmberget Kiruna Logistics
Harbours in
Narvik & Luleå
Main mines in
Kiruna &
Malmberget
New open pit mines in:
Svappavaara
Leveäniemi, Mertainen
Sales 2012: 27 BSEK, Income: 11 BSEK
4100 employees
World leader in underground mining
World-leading in pellet manufacturer
for more than 50 years
Sweden’s largest carrier: >30 Mt hauled by rail
90% of the EU’s iron ore production
Planning to hire >1,250 employees 2013-2015
Investing > 6 Billion SEK/year 2013-2030
2001: 19 Mt 2006: 23 Mt 2012: 27 Mt 2015: 37 Mt
From top-hammer to
Water powered DTH
59
Mine layout
designed after
drilling method
limitations
Mine layout
optimised after
production
15
12,5 12,5
15
m
15
15
12,5 12,5 12,5
Reduction of
sublevels:
Approximately
70 %
Increased volume per
drilled meter:
Approximately 500%
Reduction of sublevels
Result of scaling up
Before
• 12 m distance between levels
• 28m bore hole length
• 1 200 tons per blast
After
• 28 m distance between levels
• 56m bore hole length
• 10 000 tons per blast
Results
• Reduction of sublevels by 70%
• Volume per drilled meter increased by 500%
Etc.
61
12 m
28 m
Long hole drilling at LKAB
62
LKAB drills approximately 1.5 Million meter
blast holes with Wassara every year
Utility holes
63 Presenter: Peter Johansson | LKAB Wassara AB
1136 m 1123 m
1242 m
Length: 141 m
Diameter: 115 mm
Inclination: 61,6 degrees
Length: 133 m
Diameter: 115 mm
Inclination: 62,2 degrees
Deviation 1,5 %
Deviation 1,1 %
Utility holes (for drainage) drilled with the Wassara W100. The demand for minimal
deviation is obvious to be able to reach the desired location at the lower level.
Andina
Pre-conditioning drilling
Long vertical holes with lengths of up to 190 meter and with a diameter of 5 ¾” (146 mm).
Wassara W100 hammer.
The main reasons for choosing Wassara
The Wassara hammers ability to drill long straight holes.
The improved working environment with less dust and no oil mist in the air.
Result
Wassara is seen to have a very large potential since the mine is aiming for even longer pre-conditioning holes.
No need to drill extra bore holes to compensate for the bore hole deviation (top-hammer).
Copper Mine
64 Presenter: Peter Johansson | LKAB Wassara AB
El Teniente
Slot (opening) drilling
Wassara W100 – slot drilling system
Hydrobreaking
Wassara W80 - 100m long, Ø95mm
Utility & dewatering holes
Wassara W150 – 65m long, Ø165mm
Copper Mine
65 Presenter: Peter Johansson | LKAB Wassara AB
Peter Johansson, Area Manager | 2014-04-11 | LKAB WASSARA AB
[email protected] | +46 70 386 90 92
THANK YOU FOR YOUR TIME
68
Top hammer
(28 m)
Wassara DTH-hammer
(55 m)
Controlled directional drilling
with coiled tubing
(~100 m)
”Yesterday” ”Today” ”Future drilling system”
Controlled directional drilling with
coiled tubing technology
Controlled directional drilling with
coiled tubing
Date 2012-08-13 70 Presenter: John Doe | Company Name
Drilling in Sensitive Areas Citybanan, Stockholm Sweden
Installation of 1300pcs micro piles down to
50m depth with Wassara W150
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 72
Costa Concordia
Ten platforms was installed on the seafloor by drilling 12 pieces of 15 meter (50 ft) deep holes and installing anchors that’s grouted firmly in the rock. Wires were then connected to the ship as a counter hold.
Water-powered percussion drilling is the only feasible method for drilling in the highly sensitive Marine National Park environment with its coral reefs.
-No oil for lubrication and no risk of pressurizing the formation!
Anchoring drilling with Wassara W150
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 73
Casing Advancing
High drilling performance
The water lubricates the casing making it possible to drill deeper.
Drills thru any formation
Drills through complex formations, such as
Dense clays Rock Boulders Wooden piles
Unaffected by water in the formation, even at high back pressure.
Foundation and reinforcement work with Wassara
Contractor: Skånsk Energi
Formation: Clay, Sand, Clayish moraine and silty sediment
Hammer: Wassara W100 & 139,7 OD Casing
Casing depth: 126m
Total depth: 320m
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 74
Reconstruction of Slussen (SWE)
The Slussen Project (2013 - 2020)
Installation of >3000pcs - Ø303 RD-micro piles,
~45m deep
-> 3,1 m3 “Drilled volume” / pile
Pre-study drilling methods
Volume cuttings flushed to surface
Air DTH: 6-10 m3 /12m drill pipe => ~30 m3 /pile
The extreme amount of expanding air and high
up hole velocity will flush much more cuttings to
surface than the actual drilled volume.
Wassara DTH:
The low up-hole velocity results in the cuttings
being pressed aside when drilling in overburden
resulting in minimum waste handling.
Comparative study – Air DTH vs Wassara DTH
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 75
Vojmsjön dam rehabilitation project
70 m long drilled steel pile wall with
the Rukki interlock system is being
installed (totally 1 680 m²).
The piles are attached to each other
by interlocking sections, assuring
the wall to be water-tight.
The largest drill depth is 13.5 meter.
Wassara W200
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 76
Geo Energy & Geothermal
• Long Straight Holes
• Drill fewer holes but deeper
• Reduce risk of bore hole colliding.
• Up to 80% reduced fuel consumption compared to air compressor.
• Maintained drilling performance under the ground water table
Drill deep and straight holes with low energy consumption
Ex. Air DTH
Ground water
table @ 50m
100
150
200
250
300
350
200m = 20bar 320m = 32bar
Effective Air Pressure = 1bar
21bar
21 Bar
50bar
Effective Air Pressure = 18bar
21bar 21bar
Booster
Air DTH vs Wassara DTH
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 78
Energy Storage for Malmö KKV
Initially, the geothermal holes were drilled
with air powered DTH hammers.
The very water rich formation resulted in
about 100 m3 of water being pumped up
each hour due to the expanding
compressed air, also resulting high
performance loss.
After 3 weeks of drilling (of tot 10), less
than 10% of the boreholes where done.
By changing to Wassara water-powered
DTH hammers, the delay of the
operation was heavily reduced and the
drilling phase was completed in an
acceptable time frame.
75 boreholes 280m deep in water rich formation.
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 79
Hallandsåsen Horizontal freeze hole drilling
Two 8.7 km long (ID 9m) TBM drilled train tunnels
Project: 1992-2015 Budget: 1,2 BEUR
The 300m long Mölleback zone consisting of
several subsections of clay, silt, fractured rock,
gravel with high water flows, up to 900 l/min.
Stabilizing the rock by freezing.
Casing 160m long horizontal freeze holes with
Wassara W100. 16 freeze holes / tunnel
Drilling of 125m long horizontal grout holes with
Wassara W80 to stabilize the rock before the
actual freeze hole drilling could be carried out
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 81
Citybanan Söderströms railway tunnel
- 6km long railway tunnel
- Project budget:19,4 BSEK (2,3 B€)
- Project start 2009
- Estimated opening of rail track 2017
Anchoring for Söderströms tunnel
Hole accuracy requirements was 1,5%. Measured accuracy resulted in 1,28%
Wassara for core drilling rigs
Diamec 262
Onram 1000
• No heavy investment
• Standard core drilling rig can be used
• Most of the existing equipment can be used
• High penetration rate
~ Five times faster than core drilling
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 83
TBM Probe drilling
Benefits with Wassara
• Straighter holes -> longer holes -> minimize
TBM stoppages
• Maintained drilling speed (ROP) throughout
the hole
• Less noise emission
• Better working environment
Drilling a straight probe hole with Wassara makes it possible to use the probe’s full measuring range
Probe measuring range: ~200m
With top-hammer
With Wassara
Service tunnel for high speed train Turin, Italy – Lyon, France, 55km
Date 2012-08-13 85 Presenter: John Doe | Company Name
Wassara Exploration System
1. Setting casing in difficult ground formations with the
Wassara hammer
2. Pre-collaring to the interesting zone for sampling with the
Wassara hammer
High penetration rate – five times faster than core drilling
Casing advancing
Pre-collaring
Mineral
Wassara
drilling
Core
drilling
Date 2013-11-06 Presenter: Peter Johansson | LKAB Wassara AB 87
Wassara system
• No heavy investment
• Standard core drilling rig can be used
• Most of the existing accessories (water
swivel, rods, water pump etc.) can be
used, especially for setting casing
- Existing equipment can be used
88
Diamec 262 (AC) operation in Peru
• Less dependent on ground
formation
• High penetration rate –
“five times faster than
core drilling”
• Less dependent on the
hole depth* – because you
don’t have to fight the
water table
Water powered drilling
• No stop for core retrieving
• Just add rods and
penetrate until you have
reach the zone of interest
Significant time saving Faster penetration rate
– Key benefits
LF75 (BLY) operation in Mocambique
89
*, compared with air powered hammers
Water powered drilling – The down the hole assembly, N-size
90
1 Drill bit 82 / 81mm 3000121/3000120 5 Weight Rods (4x1,5m) 1500382
2 Wassara W70 hammer (80 mm) 1002760-80 6 Adapter WT70box-NQbox 1001601
3 Guided drill tube, 2*1 m (80 mm) 1500463-80 7 N-size drill tubes -
4 Check Valve 1500043 8 Adapter NQ pin-G 1 1/4’ 1001602
References – Test results from operations in Sweden
91
Date April 2012
Location 800 m underground
Formation Granite, 250MPa
Rig ONRAM 1000 (Sandvik)
Bit wear 82 bit: 1 mm, 81 bit: 1 mm
ROP 0,5 - 0,6 m/min @ 160-170bar
Application underground
Technique Wassara + core drilling
Hole depth 200 m + 200 m
Hole diameter 82 mm + N-size (76 mm)
Time needed 10 + 65 h
Time saving
Application underground
Technique core drilling
Hole depth 400 m
Hole diameter N-size (76 mm)
Time needed 135 h
Scenario 1 Scenario 2
The time needed is reduced with 60 h (45%)
if complement your standard core drilling with
Wassara drilling, and just take samples in a
specific zone of interest.
Saving
– Wassara vs. core drilling
92
Peter Johansson, Area Manager | 2014-04-11 | LKAB WASSARA AB
[email protected] | +46 70 386 90 92
THANK YOU FOR YOUR TIME