Epiroc on Wednesday launched the Explorac RC30 Smart, a reverse circulation drilling rig aimed at improving exploration drilling operations.
The Explorac RC 30 Smart has been designed from the ground up with automation and safety front and centre. It features advanced rod handling which not only enhances safety - it boosts productivity too.
New smart features include mast centralisers with variable grip force and an advanced breakout system.
Mining Magazine sat down with David Benton, Global Product Manager at Epiroc Surface division, to learn more about the development process behind the Explorac RC30 Smart plus its unique qualities and features.
MM: ‘Future-proofing' is a clear objective which we can take home from the messaging around the Explorac RC30 Smart. Could you elaborate on this concept?
DB: Absolutely. Ensuring that the rig can be expanded and upgraded was a vital ingredient in the whole project. Technology is evolving rapidly and equipment can become redundant very quickly. We wanted to build a platform that we could update as needed in the future with hardware and software to keep pace with changing demands. We want to maximise the return on investment for our customers by keeping pace with the technology demand as it changes. It adds value to the rig and ensures that it will remain a valuable asset for many years in our customers' machine parks.
MM: Can you elaborate more about the automation features?
DB: One of the main automation features is the rod handling system. A couple of years ago, a technology roadmap was released by all the major mining houses - this included technology roadmaps for their exploration departments. We've specifically designed and built this machine to meet the requirements of these roadmaps. The first step in this process was rod handling. This task is usually a two-person operation. Under normal circumstances, you have a driller and an offsider, or helper. They had to work together in a synchronized manner. Now, we've taken that process and automated it, with the press of a button, the rig can add and remove rods.
MM: What were the challenges the team faced in developing and applying these smart features?
DB: An exploration rig drills down to a much greater depth than a blast hole machine. Additionally, a blast hole machine has a carousel that's always fixed in the same position. However, with an exploration machine, the drill pad setup is different. The rig needs to be able to work with a support truck as it's not possible to carry the necessary volume of rods on board. This rig has a multi-axis rod handler. It's very dynamic and can pick from many positions. It was a real challenge to create a system that was flexible and yet could be automated.
MM: The software-based safety system is also another first. Could you explain more about it?
DB: It's just that - a software-based control system. In simple terms, we usually have two main layers of machine-based protection. The first layer is traditional guarding, where we put a physical guard in the way. The second layer comprises of interlocks —if you open a guard, it breaks a circuit and shuts down a hydraulic movement for example. For the Explorac RC30 Smart, we have a third layer which protects both operator and machine. This software-based safety system simultaneously monitors all the processes involved in the rod handling sequence. If a parameter is not met within the rod handling sequence at any point in time, it will put the drill into a safe state and then notify the driller. It provides another layer of protection to ensure the machine does what it's supposed to do when it's handling rods. It's all about ensuring as much as possible that everyone comes home safe and sound at the end of each shift.
MM: What are the main benefit of automating the rod handling process?
DB: There are a couple of main benefits. Firstly, you're continually operating within the engineer's design parameters intended for the rig. This can be hard to ensure when manually operating machinery. By utilising automation, it is possible to operate at maximum efficiency while always staying within the design parameters. That should, in turn, create more live efficiency, make planning easier and maximize drilling time.
Secondly — an automated rig is consistent. Customers should start to see longer life expectancy on valuable consumables and wear-parts. This will enable them to plan maintenance schedules better, reduce downtime and minimize costs.
Importantly, these safety systems are constantly working in the background to help prevent accidents and mistakes.
MM: In terms of change management, do the new automation features alter your after-market services for miners? Do all the new systems require a great deal of new operator training for example?
DB: The machine is very intuitive and easy to operate. However, maintenance requirements have changed. As its new technology, Epiroc is very committed to helping drilling contractors work through the change management process. We're bringing automation and technology into a new space, so we want to help our customers make the transition.
MM: We discussed the mast centralisers and the advanced breakout system. These must also help reduce wear on consumables and boost safety?
DB: Yes, there are a couple of elements here. The first one is related to safety. The mast centralisers always maintain two forms of retention on the drill string. So, there is a built-in redundancy. If one system doesn't function, you have another system ready to kick-in and back it up. Secondly, from a consumable management point of view, it also ensures correct thread alignment which reduces wear and tear on the threads. It's a very smooth system.
