Safety system and method for protecting against a hazard of drill rod failure in a drilled rock bore

Abstract

The present invention provides a safety system (1) for protecting against a hazard of a drill rod failure in a drilled rock bore (B) above horizontal, and especially a hazard posed by a broken drill rod section (S) lodged within the bore (B). The safety system (1) comprises: a plug member (2) for insertion into a proximal end region (E) of the bore (B) adjacent a rock-face (F), the plug member (2) being configured to be fixed within the proximal end region (E) of the bore (B); and an impact reduction member (5) for reducing an impact of the broken drill rod section (S) striking the plug member (2) within the proximal end region (E) of the bore (B). The impact reduction member (5) is configured to be located within the proximal end region (E) of the bore (B) and to extend within the bore (B) above the plug member (2).

Claims

1. A safety system for protecting against a hazard of a drill rod failure in a drilled rock bore above horizontal, namely a hazard posed by a broken drill rod section within the bore, comprising: an anchor member configured to be fixed in a proximal end region of the bore, wherein the anchor member is configured to at least partially block or obscure the drilled bore; and an impact reduction member configured to reduce an impact of a falling drill rod section on the anchor member in the proximal end region of the bore, wherein the impact reduction member is configured to be located in the proximal end region of the drilled bore and to extend within the bore above the anchor member to be impacted or struck by the drill rod section falling within the bore.

2. A safety system according to claim 1, wherein the anchor member is configured to fit or plug into the drilled bore and thereby comprises or forms a plug member.

3. A safety system according to claim 1, wherein the anchor member is configured to be driven into the proximal end region of the bore, and wherein the anchor member is configured to be fixed within the bore in a friction fit or interference fit.

4. A safety system according to claim 1, wherein the anchor member comprises an outer diameter larger than an inner diameter of the drilled bore, wherein the anchor member is configured to be driven into the proximal end region of the bore and comprises a slit or gap configured to allow the outer diameter of the anchor member to reduce or to be compressed when the anchor member is driven into the bore.

5. A safety system according to claim 4, wherein the anchor member has a front or leading end region of a reduced diameter which is smaller than an inner diameter of the drilled bore for assisting introduction or insertion of the anchor member into the proximal end region of the bore.

6. A safety system according to claim 1, wherein the impact reduction member comprises a tapered portion configured and arranged to allow movement of the drill rod section relative to the anchor member to effect a gradual or extended transfer of an impact loading imparted from the falling drill rod section to the anchor member.

7. A safety system according to claim 6, wherein the tapered portion is configured to allow movement of the impact reduction member relative to the anchor member to effect the gradual or extended transfer of impact loading from the drill rod section to the anchor member.

8. A safety system according to claim 7, wherein the impact reduction member has an elongate body configured for movement into an interior of the anchor member when impacted or struck by the falling drill rod section, wherein the tapered portion is configured to exert an outward force on the anchor member when the elongate body moves into the anchor member on impact by the drill rod section.

9. A safety system according to claim 6, wherein the tapered portion is configured to allow movement of the drill rod section relative to the impact reduction member to effect the gradual or extended transfer of impact loading from the drill rod section to the anchor member.

10. A safety system according to claim 1, comprising an adapter member configured for connection to a rock drilling apparatus for driving the anchor member and the impact reduction member into the proximal end of the bore together.

11. A safety system according to claim 1, wherein the safety system is configured to be deployed by driving or forcing the anchor member and the impact reduction member into the proximal end region of the bore together.

12. A safety system according to claim 11, wherein the impact reduction member comprises a tapered portion for reducing an impact of the falling drill rod section on the anchor member in the proximal end region of the bore, wherein the tapered portion is configured to allow movement of the falling drill rod section relative to the anchor member to effect a gradual or extended transfer of impact loading from the broken drill rod section to the anchor member.

13. A safety system according to claim 11, wherein the tapered portion, in use, extends within the bore above the anchor member to be impacted or struck directly by the broken drill rod section falling within the bore, and wherein the tapered portion tapers to a tip above the anchor member.

14. A safety system according to claim 1, wherein the impact reduction member comprises an impact dampening material to provide an impact dampening effect to absorb the force or impact of the drill rod section falling within the bore.

15. A safety system for protecting against a hazard of a drill rod failure in a drilled rock bore above horizontal, namely a hazard posed by a broken drill rod section lodged within the bore, the safety system comprising: a plug member for insertion into a proximal end region of the bore, the plug member being configured to be fixed within the proximal end region of the bore to at least partially plug or block the proximal end region of the bore; and an impact reduction member comprising a tapered portion for reducing an impact of the broken drill rod section on the plug member, wherein the impact reduction member is configured to be located within the proximal end region of the bore and to extend within the bore above the plug member to be impacted or struck by the broken drill rod section falling within the bore, wherein the tapered portion is configured to allow movement of the impact reduction member relative to the plug member within the proximal end region of the bore when impacted or struck by the falling drill rod section for effecting a gradual or extended transfer of impact loading imparted from the falling drill rod section to the plug member.

16. A safety system according to claim 15, wherein the plug member is of generally cylindrical shape having an outer diameter, and a leading end region of a reduced diameter for assisting introducing the plug member into the bore, and wherein the plug member has a slit or gap which allows the outer diameter of the generally cylindrical shape to reduce when the plug member is driven into the bore.

17. A safety system according to claim 15 wherein the impact reduction member comprises an elongate body which is configured to be movable relative to the plug member when impacted or struck by the falling drill rod section.

18. A method of protecting against a hazard posed by a drill rod section as a result of drill rod failure in a drilled rock bore extending above horizontal, the method comprising deploying a safety system into the bore in response to drill rod failure, the safety system comprising: an anchor member for insertion into a proximal end region of the bore, the anchor member configured to be fixed within the proximal end region of the bore to at least partially block or obscure the bore; and an impact reduction member for reducing an impact of a falling drill rod section on the anchor member in the proximal end region of the bore, wherein the impact reduction member is configured to be located in the proximal end region of the bore and to extend within the bore above the anchor member to be impacted or struck by the falling drill rod section; wherein the step of deploying the safety system includes fixing the anchor member in the proximal end region of the bore.

19. A method according to claim 18, wherein the step of deploying the safety system comprises driving the anchor member and the impact reduction member into the bore together via a rock drilling apparatus.

20. A method according to claim 18, wherein the step of deploying the safety system comprises fixing the anchor member in the bore in a friction fit or an interference fit.

21. A method according to claim 18, wherein the step of deploying the safety system includes driving the anchor member and impact reduction member into the bore beyond the rock face to be soundly founded in competent rock.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a more complete understanding of the invention and the advantages thereof, exemplary embodiments of the invention are explained in more detail in the following description with reference to the accompanying drawing figures, in which like reference signs designate like parts and in which:

(2) FIG. 1 is a schematic cross-sectional view of an excavated cavity in a mine environment illustrating bores drilled in rock strata extending towards an ore deposit;

(3) FIG. 2 is a schematic cross-sectional side view of a safety system to protect against the hazard of a broken drill rod section in a drilled rock bore according to an embodiment of the invention;

(4) FIG. 3 is a schematic partial perspective view of the safety system of FIG. 2 shown in an installed state in a proximal end region of a bore;

(5) FIG. 4 is a schematic cross-sectional side view of a safety system to protect against the hazard of a broken drill rod section in a drilled rock bore according to another embodiment of the invention; and

(6) FIG. 5 is a flow diagram which schematically represents a method according to an embodiment of the invention.

(7) The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate particular embodiments of the invention and together with the description serve to explain the principles of the invention. Other embodiments of the invention and many of the attendant advantages of the invention will be readily appreciated as they become better understood with reference to the following detailed description.

(8) It will be appreciated that common and/or well understood elements that may be useful or necessary in a commercially feasible embodiment are not necessarily depicted in order to facilitate a more abstracted view of the embodiments. The elements of the drawings are not necessarily illustrated to scale relative to each other. It will also be understood that certain actions and/or steps in an embodiment of a method may be described or depicted in a particular order of occurrences while those skilled in the art will understand that such specificity with respect to sequence is not actually required.

DETAILED DESCRIPTION OF EMBODIMENTS

(9) With reference firstly to FIG. 1 of the drawings, a cross-sectional view of a mine environment is illustrated schematically. An excavated cavity or chamber C of the mine is shown in a cross-section taken normal or transverse to a length of that cavity or chamber C into the page. The cavity C is essentially surrounded by rock strata R and an ore deposit O above the cavity C can also be seen. To access the ore deposit O, the cavity C is excavated into the rock strata R below that body or vein of ore O and then multiple bores B are drilled upwards from the cavity C into the rock strata R towards the ore deposit O above. In this way, explosive charges can be set in the bores B to blast away the intervening rock, which together with the ore deposit O then collapses into the cavity C below for collection and removal for processing.

(10) When drilling the multiple bores B upwards into the rock strata R towards the ore body O, the individual bores drilled are often tens of metres long (e.g. in the range of 20 to 60 metres) and the drill rods (not shown) which extend over that length may have a diameter of about 80 millimetres. As the composition and properties of the rock strata R typically varies through its depth, and in any case in comparison to the composition and properties of the ore deposit O, the drill rods are subjected to varying and unpredictable loading during the drilling of each bore B. Failure or breakage of a drill rod is not uncommon when multiple bores B are being drilled to lay the explosive charges above the cavity C. Thus, a section S of drill rod, which may, for example, be 20 or 30 metres long with a mass in the range of 100 kg to 500 kg, may be left in the bore B extending above the cavity C presenting a major hazard to personnel and/or equipment in the cavity C, as this massive broken drill rod section S could unexpectedly fall out of the bore B.

(11) With reference now to FIGS. 2 and 3 of the drawings, a safety system 1 according to a preferred embodiment for protecting against just such a hazard posed by the broken drill rod section S in the drilled bore B is shown schematically. The safety system 1 comprises an anchor member 2, which is configured to be inserted and fixed in a proximal end region E of the bore B adjacent or close to a rock-face F of the cavity C at which the drilling takes place. The anchor member 2 is provided in the form of a plug member which is configured to be driven into and fixed within the proximal end region E of the drilled bore B in a friction fit or interference fit. In this regard, the plug member 2 comprises a split tube 3 formed from a round steel tube or pipe having an outer diameter Do sized larger than an inner diameter Di of the bore B. For example, if the bore B has an inner diameter Di of 89 mm, the split tube 3 may have an outer diameter Do of about 100 mm and a wall thickness t of about 6 mm to 9 mm, e.g. about 8 mm in this case. Furthermore, the split tube 3 has a longitudinally extending slit or gap G formed or cut in the wall (as seen in FIG. 3) which allows the outer diameter Do of the split tube 3 (i.e. plug member 2) to be compressed or to reduce when the plug member 2 is driven into the drilled bore B of smaller diameter Di. A front or leading end region 4 of the split tube 3 also has a reduced diameter Dr that is smaller than an inner diameter Di of the drilled bore B to assist the initial introduction or insertion of the plug member 2 into the proximal end region E of the bore B. In this way, the plug member 2 comprised of the split tube 3 can be fixed in the proximal end region E of the bore B adjacent the rock-face F in a friction fit, in a manner similar to that known for a “split-set” type of rock anchor. As with the other dimensions of the split tube 3, the length Ls of the split tube 3 may be selected as appropriate to the rock-strata R, but it is preferably in the range of about 400 mm to 800 mm; e.g. 600 mm in this case.

(12) The safety system 1 further comprises an impact reduction member 5 for reducing an impact of the broken drill rod section S in the event that it falls and strikes the anchor member or plug member 2 in the proximal end region E of the bore B. The impact reduction member 5 is also arranged in the proximal end region E of the bore B and extends within the bore B above the anchor or plug member 2. In this embodiment, the impact reduction member 5 comprises an elongate body 6 which is arranged centrally of the plug member 2 and which is configured and arranged to be impacted or struck directly by the broken drill rod section S, in the event that the broken drill rod section S falls within the bore B. The elongate body 6 may be formed of steel (e.g. mild steel) and may be machined from bar stock with a round cross-section. A portion 7 of the elongate body 6 within the split tube 3 preferably has a substantially constant diameter Dc and a portion 8 of the elongate body 6 extending above the split tube 3 is tapered, i.e. an outer surface 9 of the elongate body 6 in the tapered portion 8 tapers outwardly at an angle α of about 1° to 3°, e.g. about 1° in this case. The length Lt of the tapered portion 8 may be selected as appropriate to the safety system, but this length is preferably in the range of about 200 mm to 400 mm; e.g. 290 mm in this case, with the tapered portion 8 tapering from a maximum diameter of about 80 mm at its distal end to a diameter of about 70 mm at the constant diameter portion 7 within the split tube 3.

(13) In this embodiment, the impact reduction member 5 is configured for movement relative to the plug member 2 upon impact by the falling broken drill rod section S. That is, the body 6 of the impact reduction member 5 is configured for movement into an interior of the plug member 2 if impacted or struck by the drill rod section S. In this way, the outer surface 9 of the tapered portion 8 of the body 6 contacts and bears against an inner surface of the split tube 3. As an initial impact by the broken drill rod section S drives the elongate body 6 downwards into the split tube 3, the slight taper of the tapered portion 8 exerts an outward force on the split tube 3 and thus enhances or increases engagement between the bore B and the tube 3. The tapered portion 8 thereby acts to effect a gradual or extended transfer of impact loading from the broken drill rod section S to the plug member 2. In particular, by extending the stopping distance for the falling drill rod section S (i.e. the distance travelled by the drill rod section S after initial impact) via the tapered portion 8, the impact force is reduced significantly, such that the friction fit or interference fit of the anchor member or plug member 2 within the bore B can readily withstand the impact loading. In this way, the safety system 1 of this embodiment can effectively and reliably protect workers and/or equipment in the cavity C from the hazard of broken drill rod sections S falling from a bore B drilled above horizontal.

(14) To facilitate deployment of the safety system 1 described above, the safety system 1 may include an adapter member 10 configured to cooperate with a rock drilling apparatus (not shown) for introducing the plug member 2 and the impact reduction member 5, into the proximal end E of the bore B. The adapter member 10 may, for example, be configured to be received in a drill rod carousel of the rock drilling apparatus. This enables the safety system 1 to be placed in and held by the drill rod carousel and then introduced or inserted (e.g. hydraulically driven or forced) into the proximal end region E of the bore B by the rock drilling apparatus. To this end, the adapter 10 may include a head 11 configured for connection with the rock drilling apparatus. Furthermore, the adapter member 10 may be connected to, and preferably integrally formed with, the body 6 of the impact reduction member 5. The adapter member 10 further includes a collar 12 which sits within and engages a corresponding groove or slot 13 in the adapter member 10. The split tube 3 of the plug member 2 seats against the collar 12, such that the collar 12 imparts an axial force to the plug member 2 to drive the plug member 2 (together with impact reduction member 5) into the proximal end E of the drilled bore B in a friction fit. As is apparent from FIG. 2, the collar 12 preferably has an outer diameter slightly less than the inner diameter Di of the bore B and a rear or trailing end region 14 of the split tube 3 which abuts and seats against the collar 12 is also swaged inwards to a reduced diameter Dr, i.e. like the front or leading end region 4. This configuration enables the anchor member 2 and the impact reduction member 5 of the safety system 1 to be driven into the drilled bore B beyond the rock face F. This may be particularly useful where the rock at the rock face F is friable or crumbing, because it enables the safety system 1 to be driven deeper into the bore B beyond the rock face F where it can be soundly founded in competent rock.

(15) With reference now to drawing FIG. 4, another embodiment of a safety system 1 is shown and like parts are designated with like or corresponding reference signs compared with the embodiment of FIGS. 2 and 3. In this embodiment, the safety system 1 again includes a plug type anchor member 2 comprising a split tube 3 having longitudinally extending slit or gap (not shown) and a front or leading end region 4 of reduced diameter Dr to assist driven or forced insertion into a proximal end region E of a bore B in an interference fit or a friction fit. The safety system 1 furthermore again includes an impact reduction member 5 comprising an elongate body 6 arranged within the plug member 2. The body 6 may again be formed of steel (e.g. mild steel) and may be machined from bar stock with a round cross-section. A portion 7 of the body 6 within the split tube 3 may have a substantially constant diameter Dc and a portion 8 of impact reduction member 5 which extends above the split tube 3 is tapered; that is, a surface 9 of the tapered portion 8 tapers at an angle α of about 3° to 8°, e.g. about 5° in this case, such that the tapered portion 8 forms an elongate wedge that tapers along its length Lt towards an inner periphery of the bore B.

(16) The impact reduction member 5 is again configured and arranged to be impacted or struck directly by the broken drill rod section S, in the event that the broken drill rod section S falls within the bore B. Specifically, in this embodiment, the wedge surface 9 of the tapered portion 8 is configured and arranged to be impacted or struck directly by the broken drill rod section S. In this embodiment, however, the impact reduction member 5 is not configured for any significant movement relative to the plug member 2 upon impact by the falling broken drill rod section S. Rather, as the falling broken drill rod section S initially impacts or contacts the surface 9 of the tapered portion 8, the drill rod section S is gradually deflected towards and into contact with the opposite inner wall of the bore B. This contact generates friction which acts to brake the falling object and dissipate the impact. Again, therefore, the tapered portion 8 acts to cause gradual or extended transfer of impact loading from the drill rod section S to the anchor member 2. In particular, by extending the stopping distance for the falling drill rod section S (i.e. the distance travelled by the drill rod section S after initial impact) via the tapered portion 8, the impact force is again reduced significantly, such that the friction fit or interference fit of the anchor member 2 within the bore B can readily withstand the impact loading. The safety system 1 of this embodiment may thus also effectively and reliably protect workers and/or equipment in the cavity C from the hazard of a broken drill rod section S. As before, the safety system 1 of FIG. 4 includes an adapter member 10 configured to cooperate with a rock drilling apparatus (not shown) for deploying the plug-like anchor member 2 and the impact reduction member 5 into the proximal end E of the bore B.

(17) Finally, referring to FIG. 5 of the drawings, a flow diagram is shown that illustrates schematically the steps in a method of protecting against a hazard resulting from drill rod failure, particularly the hazard posed by a broken drill rod section S falling out of an upwardly drilled rock bore B, according to the embodiments of the invention described above with respect to FIGS. 1 to 4. In this regard, the first box i of FIG. 5 represents the step of providing a safety system 1 according to any one of the embodiments of the invention described above. The second box ii then represents the step of fixing an anchor member 2 of the safety system 1 within the proximal end region E of the bore B to at least partially plug or block the proximal end region E of the bore B adjacent or near an outer rock-face F. The third box iii represents the step of arranging an impact reduction member 5 within the proximal end region E of the bore B above the anchor member 2. In this regard, it will be appreciated by persons skilled in the art that steps represented by boxes ii and iii in FIG. 5 may occur simultaneously or in reverse order. The final box iv in FIG. 5 of the drawings represents the step of reducing an impact of a drill rod section S striking the plug member 2 within the proximal end E of the drilled bore B via the impact reduction member 5.

(18) Although specific embodiments of the invention are illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations exist. It should be appreciated that the exemplary embodiment or exemplary embodiments are examples only and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.

(19) It will also be appreciated that in this document the terms “comprise”, “comprising”, “include”, “including”, “contain”, “containing”, “have”, “having”, and any variations thereof, are intended to be understood in an inclusive (i.e. non-exclusive) sense, such that the process, method, device, apparatus or system described herein is not limited to those features or steps or elements or parts recited but may include other features or steps or elements or parts not expressly listed or inherent to such process, method, device, apparatus or system. Furthermore, the terms “a” and “an” used herein are intended to be understood as meaning one or more unless explicitly stated otherwise. Moreover, the terms “first”, “second”, “third”, etc. are used merely as labels, and are not intended to impose numerical requirements on or to establish a certain ranking of importance of their objects unless otherwise indicated by the context of the disclosure.

LIST OF REFERENCE SIGNS

(20) 1 safety system 2 anchor member or plug member 3 split tube 4 front or leading end region of split tube 5 impact reduction member 6 elongate body 7 constant diameter portion of elongate body 8 tapered portion 9 outer surface of tapered portion 10 adapter member 11 head of adapter member 12 collar 13 groove or slot 14 rear or trailing end region of split tube C cavity or chamber R rock strata O ore deposit or ore body F rock-face B bore S broken drill rod section E proximal end region of bore t wall thickness of split tube G longitudinal slit or gap Di inner diameter of bore Do outer diameter of split tube Dr reduced diameter of leading and/or trailing end region of split tube Ls length of split tube Lt length of tapered portion α taper angle