Atlas Copco Rock Drilling Tools

SECOROC Down-the-hole equipment

CONTENTS

Secoroc DTH equipment . . . . . . . . . . . . . . . . . 3 A product of ingenious engineering . . . . . . . 4 Operating economy . . . . . . . . . . . . . . . . . . . . 6 Selecting the right hammer . . . . . . . . . . . . . . 8 Premium bits . . . . . . . . . . . . . . . . . . . . . . . . . 10 Grinding equipment . . . . . . . . . . . . . . . . . . . 12 Secoroc drill tubes . . . . . . . . . . . . . . . . . . . . 13 COP Backhammers . . . . . . . . . . . . . . . . . . . . 14

Secoroc DTH equipment for the lowest cost per foot drilled
Tradition and expertise To say that Secoroc knows a thing or two about rock drilling is an understatement. Our earliest experience of mining and steel production dates all the way back to the 15th Century. In the intervening 600 years we like to think weve acquired a measure of expertise. Not only in rock drilling but also in serving you the customer, whether your business is mining, quarrying, construction or water well drilling. And now, with the advent of a new century, were in a stronger position than ever to support the operations of DTH drillers across the globe. The recent amalgamation of Secoroc and Atlas Copco Rock Tools under the Secoroc brand has further strengthened both our expertise and our product range. An example of this is the COP family of DTH hammers (Secorocs and Atlas Copcos combined DTH hammer technology now bears the COP name). Recently launched, the first product of this union is the Secoroc COP 64.2, a second generation 6" hammer and yet another leap in hammer design. Innovation and range The unbeatable productivity of Secorocs COP DTH hammers is all down to innovation. Several ingenious design features, such as our patented air cushion, combine to utilize the air for superior penetration and low air/fuel consumption. These hammers are complemented by a full range of Premium DTH bits with a unique head design for even greater efficiency. But productivity isnt just gauged by the number of feet you drill in a day. Its also measured by how long your equipment lasts. Which is why were consistently innovative in this area, too. Take our COP backhammer, for example. Equipped with one, DTH drillers can now extract expensive equipment that would otherwise be lost. Whats more, youll find our range of Grind Matic grinding equipment will help you greatly increase the service life of your bits. And our cold drawn DTH tubes complete the picture, ensuring a trouble-free drilling cycle. Taken together, these products and services add up to the lowest cost per foot drilled. And thats ultimately what Secoroc is all about.

A product of ingenious engineering

The secret is in the hammer design Ingenuity often reveals itself in simplicity. The same can be said for Secorocs patented COP DTH hammers. The hammer has a straight air-flow which acts directly on the surface of the piston without any retarding channels in the piston or outer tube. Weve also fitted a new type of choking system, a new suspension, a self-centering air distributor and piston, providing precise tolerances and less air consumption. Secoroc downthe-hole hammers are easy to start, even at great drilling depths with significant water back pressures. When its time to lift the hammer from the bottom of the hole, you obtain a powerful flushing effect, as theres almost nothing to impede the air rushing through the hammer. The hole is cleaned more efficiently and the drill string discharges its air, allowing for the rapid addition of new drill tubes. Additional flushing a help not a hindrance Because compressed air is costly, low air consumption is a key sales argument. Traditionally, air for both additional flushing and drilling is directed through the hammer and the bit, causing back pressure and drilling resistance. The Secoroc design is somewhat smarter and avoids these problems. The air to the hammer is regulated in such a way that the additional flushing air is only released through the back of the top sub, and the entire system is able to maintain maximum penetration. As an added bonus, the service lives of the chuck and sleeve Conventional Secorocs flushing integrated are increased.
through a choke plug

Cushion and accelerator in one When moving to its upper position, the piston comes up against a compressed air cushion. The damping action of this cushion stops the piston from coming into direct contact with the upper part of the hammer. This prevents any devastating recoils from being transmitted into the drill string. Furthermore, this compression action reverses Compressed and accelerates the piston on its downward air cushion journey, adding even greater power to the down-stroke.

Integrated flush adapter gives extra flushing when needed. New compression ring.

New simple and functionally reliable check valve. Flexible control tube suspension with new buffer ring.

Reinforced robust cylinder, heat-treated for maximum impact resistance and durability.

top sub flushing

New control tube.

High strength, impactresistant steel piston, specially designed for optimum transmission of impact energy to the bit.

Bits of different designs adapted for optimum penetration in all types of rock formation.

COP 64.2 another leap in hammer design Building on the reputation of its predecessor, the brand new COP 64.2 delivers performance no competing solution can match. Traditionally, our hammers have always offered outstanding air efficiency and penetration rates. But now, thanks to new internal hammer components, were providing unparalleled reliability, too. Weve not only improved check valve design and reinforced the control tube, but also added completely new buffer and compression rings. The result is easily the markets most dependable DTH hammer.

Reliable foot valve design.

Operating economy the lowest cost per foot drilled

Increase your penetration by 10% Lower your hammer costs by 30% If you drill quickly, with low air consumption and high penetration, you can drill a fair number of holes in a day. But in your quest for profitability always bear in mind that the cost of the hammer or bit is not the most crucial factor. In fact, to see the big productivity picture you must look carefully at how quickly the hammer penetrates rock and how much fuel is used to produce the air. In other words, the cost per foot drilled. Secorocs DTH hammers offer the lowest cost per foot in the industry.
Cost of hammer Lifespan (ft) + Cost of bit Lifespan (ft) + Rig running cost/hour Penetration rate (ft/h)

Secoroc Economy Kit

= Cost /feet

A Secoroc hammer is not a thirsty worker Following political and environmental trends, gas prices are rising. Which is why its of vital importance that your drilling equipment is fuel-efficient. Thanks to the smart design of our hammers, you wont have to run your compressor nearly as much as with competing solutions. Rebuild your hammer with our Economy Kit Traditionally, a DTH hammer has to be replaced when the hammer is worn out externally or the penetration rate has dropped by 20% or more. Not so with Secoroc. When the time comes, our Economy Kit consisting of top sub, cylinder and chuck readily replaces worn components. That way you can rebuild your hammer at least once with no drop in performance before investing in a new one. Complete service on-site takes just 10 minutes Regular service intervals are a must to ensure the high availability, low fuel consumption and continued performance of your hammer. To that end weve developed a combined field service/breakout bench, the perfect inexpensive tool for hammer service. You can now break and service the hammer in the same vice. The hammers themselves are designed for quick and

easy field service: no special tools are required once the top sub and chuck threads have been loosened. The bench can handle hammer sizes from 3" up to 8". A patented design with proven results Its one thing saying youre the best, its quite another proving it. So we proved it. We went head to head and bit to bit with some of our leading global competitors in a productivity test. All the drilling was done in the same rock (Swedish granite, compressive strength 220 Mpa, silica content 28%) and with the same bit design. To obtain a fair productivity gauge, we measured the volume of rock removed per litre of air consumed. The Secoroc COP DTH hammers outperformed all their competitors. We call this the Performance Factor.

Sustained hammer efficiency

Penetration rate 100% 100% 95% 80% 0% Feet drilled 80% 0% Feet drilled
Loss approx. 20% Exterior worn out Exterior worn out

Penetration rate

Rebuild

Rebuild

Economical drilling Uneconomical drilling

Secoroc COP hammer Competitors

Fuel saved with COP 44 hammer after 20 000 ft of drilling

500 450 400 350 300 250 Gallons of fuel saved

Fuel saved with COP 54 hammer after 20 000 ft of drilling

350 300 250 200 150 COP 44 vs Comp. A Comp. B Comp. C Comp. D Comp. E Gallons of fuel saved 100 50 0 COP 54 vs Comp. A Comp. B Comp. C

200 150 100 50 0

Fuel saved with COP 64 hammer after 20 000 ft of drilling

900 800 700 600 500 400 Gallons of fuel saved 300 200 100 0 COP 64 vs Comp. A Comp. B Comp. C Comp. D Comp. E

Fuel saved with 84 L hammer after 20 000 ft of drilling

1600 1400 1200 1000 800 Gallons of fuel saved 600 400 200 0 COP 84L vs Comp. A COP 84 Comp. B Comp. C

Selecting the right hammer

Type COP 34 COP 44 COP 54 COP 64 COP 84

Std M

Q QHD QM Q2 Q2HD L

Standard design Customise the hammer Equipped with a regulator in the top sub for the release of extra flushing air, the hammer can be customised to suit your compressor capacity. Moreover, this design allows you to adjust the air volume going into the hole, while evacuating large water and cutting volumes is no longer a problem. The system also maintains cutting velocity when drilling over-sized holes. Releasing air from the top sub is effective when youre drilling RC, using a collector sub behind the hammer. The choking air blows the cuttings directly into the collector sub. Typical applications are water well drilling and exploration/RC drilling. M-design (Mission bit shank style) Same as Standard hammers but for use with Mission style bits. Typical applications are water well drilling and exploration/RC drilling. Q-design (Quarry) Less parts, lower costs The no-flushing option in the top sub means less hammer parts and a lower price. Whats more, fewer parts further minimise the risk of hammer failure. This design can be used down to a depth of 100 metres (330 ft) with a standard bit size for the hammer. Also for use in underground mining, production drilling in quarries as well as shallow water well drilling.

QHD (Quarry Heavy Duty) Increased service life Just like Q, but with the added bonuses of a heavy duty chuck, wear sleeve and top sub. The top sub is also equipped with tungsten carbide buttons for wear protection, increasing the service life of the external parts in particularly harsh and abrasive conditions. Furthermore, the top sub wear protectors are built to withstand collapsing hole walls. The buttons protect the top sub from excessive wear when rotating out of the hole through the broken rock. For areas of application, see Q-design. Q2 (Quarry Two start) Much the same as Q, but with a two-start thread on the chuck in order to minimise the risk of it unscrewing in the hole. A word of warning. When using this design, the drill rig must be equipped with a hydraulic breakout wrench to be able to break out the chuck. Applications are the same as for Q, and where unscrewing the chuck is a problem. Q2HD (Quarry Two start Heavy Duty) Equipped with the same features as QHD, but with two-start thread on the chuck to minimise the risk of it unscrewing in the hole. Exercise caution when using this version. The drill rig must be equipped with a hydraulic breakout wrench for breaking out the chuck. Areas of application are the same as for QHD, and when unscrewing the chuck poses problems. L (Low volume) Cutting costs Lower air consumption is not the only thing that sets it apart from the Standard design. This ones cheaper too. Applied to water well drilling with standard hole depths of down to 200 metres (660 ft), standard compressor volumes can be used to keep down costs.

Hammer Length excl. thread, mm (in) External diameter, mm (in) External diameter HD, mm (in) Hammer weight, kg (lbs) Hammer weight HD, kg (lbs) Recommended bit size, mm (in) Rec. bit size HD hammer, mm (in) Bit shank Piston diameter, mm (in) Piston weight, kg (lbs) Top sub thread Wrench flat, mm (in)

COP 34 954 (37.5) 83,5 (3.3) 27 (60) 92-105 (3.6-4.1) Secoroc 3.5"/COP 34 68 (2.7) 4,8 (10.7) 23/8" API Reg 65 (2.6)

COP 44 958 (37) 98 (3.9) 38 (84) 110-125 (4.3-4.9) IR 340 78 (3.1) 7,1 (16) 23/8" API Reg 65 (2.6)

COP 54 1069 (42.1) 120 (4.7) 126 (4.9) 57 (126) 67 (148) 134-152 (5.3-6.0) 140-152 (5.5-6.0) IR 350 100 (3.9) 12,5 (28) 23/8" API Reg 31/2" API Reg 65 (2.6) 23/8" 95 (3.7) 31/2" 102 (4.0) 31/2" HD

COP 64 1213 (47.8) 142 (5.6) 146 mm (5.8) 95 (209) 109 (240) 156-178 (6.1-7.0) 165-178 (6.5-7.0) IR 360 alt. Mission SD6/53-15 120 (4.7) 20,5 (45) 31/2" API Reg 102 (4.0)

COP 84L 1230 (48.4) 160 (6.3) 139 (306) 191-219 (7.5-8.6) Mission SD8/63-15 120 (4.7) 20,5 (45) 41/2" API Reg 120 (4.7)

COP 84 1323 (52.1) 178 (7) 158 (348) 203-254 (8.0-10.0) IR 380 153 (6.0) 37,3 (82) 41/2" API Reg 140 (5.5)

Feed force, kN (normal) lbs (normal) Working pressure, bar (psi) Rotation speed, r/min

3-12 (6) 700-2500 (1300) 6-25 (87-360) 30-90

5-15 (10) 6-25 (87-360) 25-80

6-17 (12) 6-25 (87-360) 20-70

7-20 (14) 1600-4400 (3100) 6-25 (87-360) 15-60

7-20 (14) 1600-4400 (3100) 6-25 (87-360) 10-40

10-30 (22) 2200-6600 (4800) 6-20 (87-290) 10-35

1100-3300 (2200) 1300-3700 (2600)

COP 34

COP 44

COP 54

Drill bit = 100 mm bar Working pressure

Drill bit = 115 mm bar Working pressure

Drill bit = 140 mm bar Working pressure

COP 64

COP 84L

COP 84

Drill bit = 165 mm bar Working pressure

Drill bit = 203 mm bar Working pressure

Drill bit = 203 mm bar Working pressure

Penetration rate, mm/min

Air consumption, l/s

Premium bits the light headed approach to bit design

Chunking is common with DTH bits, and is largely brought about by fatigue. With our new range of Premium bits, weve paid particular attention to this problem. After 1,000,000 feet of test drilling in the harshest conditions imaginable, were happy to report a 20% increase in bit life. Thats not just a 20% increase on our old bits, but all other DTH bits on the market. A product of listening and learning The bit head on our Premium bits is noticeably smaller. Weve gone down in size to make the bits lighter, which means you need less power to extract maximum performance from your hammer. Moreover, the head has been adapted to hammer size, successfully reducing cylinder abrasion and increasing the service life of the hammer. The steel quality has also been upgraded. In-house production gives us full control We manufacture our tungsten carbide buttons in-house, right from milling the raw tungsten carbide powder and cobalt, to pressing, sintering and grinding the buttons to a finish. Recently, we also fine-tuned our manufacturing process and certified our plant in accordance with ISO 9002. As a result, you can be absolutely sure that theres a commitment to quality throughout the entire process, right from taking delivery of the raw materials to shipping the finished bits.
Convex/Ballistic front design Convex front with large cutting grooves and ballistic gauge and centre buttons. For soft to medium hard nonabrasive 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 efficient cuttings removal. Concave front design normal Concave front with spherical buttons. Perfect choice for medium hard to hard less abrasive fractured formations. Gives good control over the hole deviation. Concave front design HD Concave front with spherical buttons, with larger gauge buttons. Ideal for medium hard to hard, abrasive and fractured formations. Concave DGR front design normal Concave front with double rows of spherical gauge buttons. Only available for 8" bits and larger. The reinforced gauge gives superior protection in medium hard to hard, abrasive and fractured formations.

Soft rock

Medium hard rock (220 MPa/32000psi)

Hard rock

FLAT FRONT HD

SPEEDBIT

CONVEX/BALLISTIC

CONCAVE NORMAL

CONCAVE HD CONCAVE DGR

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Hammer size 3.5" 4" 5" 6" 8" 10-12"

Flat front design HD

SpeedBit

Convex/Ballistic front design

Concave front design HD Standard

Concave DGR front design

Standard dimensions

For restricted use only

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Grinding equipment for sharp-minded drillers

Grinding the buttons to bite To extract full power from your hammer and squeeze the maximum number of metres out of each drill bit, regular grinding is essential. A drill bit with worn buttons soon loses its capacity to crush rock efficiently. Once the buttons are worn to a third of their diameter, button wear accelerates dramatically and the penetration rate suffers accordingly. Not to mention the risk of button damage. The best way to grind your drill bits is to use Secorocs Grind Matic grinding machines. Grind Matic is a range of efficient, ergonomically designed grinding machines for fixed installations, field operations and manual grinding. They ensure quick and accurate grinding of all buttons, including ballistic buttons. Remember to grind your drill bits in good time. That way youll optimize bit life and productivity. Button wear vs penetration rate
Penetration rate 100%

75%

Soft rock

50%

Hard rock 1/3 flat 1/2 flat 2/3 flat

25%

Wear flat

Secoroc Grind Matic BQ2-DTH

Secoroc Grind Matic Manual B-DTH

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Secorocs drill tubes dont go down the hole without them

Durable, accurate, manageable the hallmarks of a Secoroc tube Tubes play a significant role in all DTH drilling, regardless of application, rock type, hole depth or drill rig. But their importance is often underestimated. The key features of a high quality DTH tube are durability, accuracy and manageability. These are also the features youll find in any Secoroc tube. Our tubes are made from cold drawn tubing, providing a superior surface finish and tolerance compared to conventional tubes made from hot rolled tubing. This superior surface finish drastically reduces the risk of scaling from the tubes entering the hammer, the cause of so many premature hammer failures. The threads and the joint between the tube and the end pieces are traditionally the tubes weakest points. Our joints are friction-welded to achieve maximum strength in the tool joint, and the threads of the end pieces are heattreated for optimum durability and strength of the thread profile. Heat treatment of the threads ensures not only long life in the threads, but also makes thread joining and breaking quick and simple, thus reducing drilling cycle time. Depending on the application, different API threads are available. For applications where foam injection is used we recommend the IF thread. Naturally, we also offer a wide range of subs and crossover subs to meet an array of demands. These are made of the same high quality steel and heat-treated in the same way as our tube end pieces. Types of subs and crossover subs

ROC design

Sub type box x box

Sub type box x pin

Sub type pin x pin

Drill tube OD 70 mm OD 76 mm OD 76 mm OD 89 mm OD 89 mm OD 102 mm OD 114 mm OD 114 mm OD 114 mm Quality API grade N-80 Lower yield limit Tensile strength Elongation A5 Core hardness Surface hardness

RD 50 Wall 3.6 mm Wall 3.6 mm Wall 5.6 mm Wall 3.7 mm Wall 5.7 mm Wall 5.7 mm Wall 4.3 mm Wall 5.7 mm Wall 7.9 mm Standard tubes min 550 min 650 18 190-230 End pieces and adapters min 550 min 700 21 210-250 58-62

23/8" API Reg

23/8" API IF

27/8" API Reg

27/8" API IF

31/2" API Reg

Thread RD 50 23/8" API Reg 23/8" API IF 27/8" API Reg 27/8" API IF 31/2" API Reg 41/2" API Reg

Description The classic DTH thread in 70 mm drill pipes Conical thread for all-purpose application, both percussion and rotary drilling Conical thread for maximum internal passage Conical thread for normal and heavy duty rotary drilling Conical thread with large internal passage diameter but suitable for relatively low torque Conical all-purpose thread for percussion and rotary drilling with maximum torque Conical all-purpose thread for percussion and rotary drilling with maximum torque

N/mm2 N/mm2 min % HB HRC

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COP Backhammers the art of saving time and equipment

COP Backhammer Rock drilling can be a demanding business, particularly if the rock is unyielding. One mistake and youre stuck in the hole, looking grimly at serious downtime. Then its too late to wish you had a COP Backhammer. And to think, the cost of one is just a fraction of the cost of being without! COP Backhammers can be fitted in a suitable tube joint between the drill support and the rotation head. It provides an effective combination of backward hammering and vibrations. To further increase efficiency, simply drill a hole in the choke plug to maintain flushing. If conditions are particularly demanding, two backhammers can be fitted one after the other. The COP Backhammers are tough and reliable and come in just three parts with a plastic cover. Maintenance consists only of keeping it clean and protecting the connections when the unit is not in use. The plastic cover functions as a muffler as well as diverting the discharged air.

Cover

Piston

Anvil

Choke plug Spindle

COP Backhammer Standard thread 31/2 API Reg Hammer size, in Working pressure, max bar (psi) Installed length, mm (in) Diameter, mm (in) Weight, kg (lb) Air consumption at 6 bar (87 psi) Chokeplug without hole, l/s (cfm) Chokeplug with hole 6 mm, l/s (cfm)

COP BH 140

COP BH 160

COP BH 190

3-5 8 (116) 415 (163/8) 180 (71/16) 31 (68)

5-6 8 (116) 445 (171/2) 200 (77/8) 44 (97)

8 - 12 8 (116) 445 (171/2) 225 (87/8) 63 (139)

42 (89) 80 (170)

58 (123) 90 (191)

67 (142) 105 (223)

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Atlas Copco Secoroc AB A Company within the Atlas Copco Group Phone: +46 223 461 00 Fax: +46 223 461 01 www.atlascopco.com
THP Communication

9851 2140 01

Subjected to alterations without prior notice. Atlas Copco Secoroc AB. All rights reserved. 2002.02