The Changing Face of Surveying within the Mining Industry

www.bentley.com

The Changing Face of Surveying within the

Mining IndustryA Bentley White Paper

Dave Body Solution Executive,

Mining

Published: July 2014

The Changing Face of Surveying within the Mining Industry 2

Contents

Abstract 3

Introduction 4

Digital Data – Big Data 4

Mine Surveying – Overview 6

Mine Surveying – Regulatory Requirements 7

Mine Surveying – Technology 7

UAV and ALS Convergence 10

Mobile Laser Scanning 11

Conclusions and Recommendations 12


Abstract

The mining industry typically operates in a cyclic fashion with periods of strong growth followed by inevitable downturns. The industry is currently in the throes of a downturn with many owner-operators now looking inwardly in an attempt to identify opportunities to improve productivity, while reducing costs. For many, as they attempt to drive productivity enhancements, their attention has turned towards innovation. One such innovation gaining industry wide acceptance is the adoption and manipulation of digital data. Digital data comes from a wide array of sensors and sources and as this data becomes readily available to the broader enterprise, the mining industry is beginning to acknowledge its importance and where it can be leveraged throughout the enterprise to improve productivity.

This ability to successfully leverage digital data across an enterprise – often described as “information mobility” – provides a key to unlock value across the entire mine lifecycle. As the mining industry transitions into this era of digital data and information mobility, there is growing recognition of the scale of digital data created and the need to better manage, maintain, and disseminate this information across the entire enterprise to ensure the right information reaches the right people at the right time.

Of particular importance within a mine environment is spatially located digital data. During the operational phase of a mine the process of design, develop, and extract becomes an integrated and continuous loop. This continual cycle becomes the focal point of a mine’s operation, with particular emphasis directed towards the results achieved throughout the extract phase. In order to test the execution, effectiveness, and accuracy of mine planning methods, it is necessary to measure production against this plan. This tests both the accuracy of the geological and evaluation models on which the targets are based and the efficiency of the ore and metal recovery departments. Key to this is the accurate positioning of the excavations mined and the geological and evaluation features encountered. Unless this is achieved, it is impossible to gauge the progress made with any accuracy.

Enter the surveyor and the new technology now at their disposal.

Today’s technology is changing the face of surveying. Yes, the goal of any survey is still categorized into two specific areas: collecting spatial data and positioning spatial data. However, new technology and the era of “big data” are challenging traditional surveying methods and workflows. Laser scanners and unmanned aerial vehicles (UAVs) that create this data, along with software solutions that maintain, display, analyze, and manage the voluminous amounts of spatially located digital data are now required.

As spatially located digital data provides another level of visibility to an enterprise, it is set to become a highly sought-after type of data for a wide variety of users within an enterprise. The ability to efficiently manage, maintain, and disseminate this spatial data to the right people at the right time will be critical to the success of an enterprise.

Enter Bentley Systems and solutions that support today’s requirements and tomorrows needs.

This ability to successfully leverage digital data across

an enterprise – often described as “information mobility” – provides a key to unlock value across the

entire mine lifecycle.


Introduction

The mining industry typically operates in a cyclic fashion with periods of strong growth followed by inevitable downturns. The industry is currently in the throes of a downturn. However, many experts within the industry are signalling this downturn as something more than an inevitable cyclic movement and are now describing this as a “seismic or paradigm shift.”

As owner-operators continue to slash billions of dollars of spending, shed jobs, divest underperforming mines, cut back on capital projects, and attempt to reign in wages, many have begun to focus on long-term optimization of operating costs and capital allocation as sustainable measures for their business. As noted by BHP Billiton’s chief financial officer, “That was the easy bit [slashing billion’s dollars of spending]. When you talk about costs there are two elements. One is how you tighten your belt and make the easy changes. The second is productivity, getting more out of your existing people, your equipment and your infrastructure. Productivity will deliver more benefits over time, but takes a little more time to be done.”

Digital Data – Big Data

In an attempt to drive productivity enhancements, the mining industry’s attention has turned towards innovation. As noted by Accenture’s mining program and project manager “the mining industry is currently in a phase where innovation is quickly turning tip-of-the-spear technologies into disruptive new capabilities that present opportunities for strong differentiation and massive leaps in efficiency.”

Innovation comes in many forms. One such innovation embraced by industry is the adoption of digital data, including data-enabled equipment, operating/safety/ environmental sensors, and the growing acceptance of the use of laser scanning or point-cloud data. Digital data will increasingly be used to support real-time tracking, surveillance, traffic management, environmental monitoring, various automated routines (e.g., driverless trucks), improved maintenance and asset management, and production monitoring and reporting.

As data from these various sources becomes readily available to the broader enterprise, the mining industry needs to better leverage this digital data to target specific productivity challenges. This ability to successfully leverage digital data across an enterprise is often described as “information mobility.” Information mobility is a key to unlocking

1Clara Ferreira-Marques, “After cost cuts, miners need to do more with less, BHP says,” Reuters, August 21, 2013, http://www.reuters.com/article/2013/08/21/mining-costs-idUSL6N0GM1IX20130821.

2Cole Latimer, “A revolution revolt? The next stages of mining automation,” Australian Mining, January 30, 2014, http://www.miningaustralia.com.au/features/a-revolution-revolt-the-next-stages-of-mining-auto.


value across the entire lifecycle and without it, data languishes in “islands” where it becomes stale and obsolete.

As the mining industry transitions into this era of digital data and information mobility, there is growing recognition of the scale of digital data being created and the need to better manage, maintain, and disseminate this information across the entire enterprise to ensure the right information reaches the right people at the right time. For example, Rio Tinto’s Pilbara iron ore mining, transport, and shipping activities are already generating 2.4 terabytes of data per minute. The terminology that has gained mindshare is “big data.” Big data is the raw material that can be “mined” for insights, and to which algorithms and expert systems can be applied to produce predictive analytics. On many remote sites, big data may prove challenging with reliable and capable communications a major consideration. The idea that big data equals the “cloud” may not always be applicable and will need careful consideration.

•Anglo American is one of the world’s largest mining companies, and operates in Africa, Asia, Australia, and North and South America. Their future mining vision anticipates fully automated and remote operations. To achieve this ambitious vision, especially as data volumes increase, Anglo American intends to exploit the full richness of spatial 3D information.

Historically, spatial data has been captured and stored as “islands” of data. Throughout Anglo American, numerous business operations (i.e., iron ore and manganese, platinum, copper, diamonds, etc.) and departments (i.e., survey, geology, environmental, exploration, land management, engineering, Mineral Resource Management [MRM], planning, head office, etc.) produce and consume spatial data.

In many instances, spatial data is relevant to many departments. However, this same data was not often shared between departments, frequently leading to the existence of duplicated data and large stores of unmanaged data that could not be efficiently utilized for effective decision making. Additionally, relevant data was not integrated, thus a holistic view of the data was not utilized to make informed decisions. From a number of departments within different operations, Anglo American identified numerous critical data sources, including:

» High resolution geospatial point-cloud data scans (autonomous mining machines, survey total stations, laser scanners, etc.)

» Spatially referenced photographic and video data (aerial photography, autonomous vehicles, regular photos, and video, etc.)

» Geological models

» Geometallurgical exploration data


» Geographic information systems (survey, topographical, satellite, etc.)

» Mine planning information (designs, schedules, etc.)

» Engineering/CAD models

» Spatially referenced documents (tenements, leases, etc.)

» Automated services (real time data import from weather stations, air/dust monitoring stations, conveyor belt sensors, location tracking, etc.)

» Production systems data (Modular, Jigsaw, drill holes, slope monitoring, Acquire, etc.)

In Anglo American’s vision, typical consumers of spatial data include:

» Automated machines (mapping, navigation, positioning, etc.)

» Survey (mapping, volumes, etc.)

» Engineering (design, planning, civil works, services, performance management, etc.)

» Mining (design, planning, optimization, performance management, etc.)

» Exploration (targeting, planning, resource characterization, etc.)

» Geosciences (resource characterization, reserve estimation, etc.)

Business applications used in organizations today cannot afford to exist in isolation. Anglo American users expect instant access to all business functions, regardless of in which system the functionality may reside. To overcome this enterprise-wide disconnect, Anglo American implemented the Geospatial Integration Project (GIP), designed to build an integrated GIS platform based on a common architecture that can effectively provide a single management system for geospatial data, workflows, and reports.

To assist Anglo American in bringing this vision to fruition and the GIP to reality, they turned to Bentley Systems and its mature geospatial solution, including Bentley Map, ProjectWise Geospatial Server, and Bentley Geo Web Publisher. By linking, combining, and providing access to related geospatial datasets, consumers of spatial data can now exploit multiple, diverse datasets in a common geospatially referenced framework. To date, the volume of data managed under the GIP frameworks exceeds 15 terabytes. Additionally, time improvements of up to 4000 percent have been identified throughout a number of processes and workflows, ensuring the ROI associated with Anglo American vision is significant.

Mine Surveying – Overview

Like all other major projects, a mining operation needs to design and develop the necessary infrastructure prior to its operation. However, unlike many other infrastructure projects (i.e., bridges, highways, buildings, etc.), once a mine site becomes operational the process of design, develop, and extract becomes an integrated and continuous loop, with this cycle remaining for the life of mine (LOM),

“To overcome this enterprise-wide disconnect,

Anglo American implemented the Geospatial

Integration Project (GIP), designed to build an

integrated GIS platform based on a common

architecture that can effectively provide a single

management system for geospatial data, workflows,

and reports.”


which is often measured in years, if not decades. This continual cycle becomes the focal point of a mine’s operation, with particular emphasis directed towards the results achieved throughout the extract phase.

In order to test the execution, effectiveness, and accuracy of mine planning methods it is necessary to measure production against this plan. This tests both the accuracy of the geological and evaluation models on which the targets are based and the efficiency of the ore and metal recovery departments. Key to this is the accurate positioning of the excavations mined

and the geological and evaluation features encountered. Unless this is achieved, it is impossible to gauge the progress made with any accuracy. Additionally, there can be no improvement in the base data used for evaluating the next planning cycle.

Timing is a fundamental part of the control issues on a mine. Operations are in effect, continuous, so snap-shots have to be taken to measure planned production against actual outputs. Monitoring the actual extraction volumes versus production target rates has traditionally been measured by surveyors at month’s end. However, there is a growing desire by industry to measure the volume of extracted material at much shorter intervals, allowing management to better monitor and define the progress of the mine’s production rate. The ability to accurately monitor this phase is therefore seen as mission critical; and therefore the role of mine surveying is central to the success of this cyclic phase.

Mine Surveying – Regulatory Requirements

Throughout the globe, a mine’s operation is typically governed by a significant number of stringent and rigorous regulatory requirements. These regulatory requirements vary from region to region with many requirements directly impacting a raft of mine surveying practices, processes, and workflows. In many instances it is imperative the mining operation maintain and manage the mine’s survey data, including legacy survey data, in a secure environment throughout the life of the mine. Traditionally this information has been maintained in hard-copy formats; however, as the industry transitions to digital, mechanisms and solutions that manage and maintain this mixed information environment will need to be established. Solutions and systems offering opportunities of secure data management capabilities, including an ability to store all survey data (i.e., raw observations/measurements, calculated information), survey control, survey notes, survey reports, plans of surveys, mine accurate plans, and more will be required.

Image courtesy of Trimble


Mine Surveying – Technology

Due to the advancement of survey equipment technology, traditional and historical surveying workflows are continuously being challenged. However, unlike other surveying disciplines (e.g., engineering or cadastral/land surveying), some aspects of mine surveying deal with unique circumstances. This is especially evident for underground operations, where surveying methods and techniques need to overcome the challenges of this environment. For this reason, traditional and

historical survey workflows (i.e., tape and offset surveys) are still evident within industry today, however, there is an industry desire and need to promote innovative techniques to survey the underground environment.

Over the past 50 years the survey industry has undergone massive changes due to technology advancements, including the introduction of electronic distance meters (EDMs), total stations, global navigation satellite systems (GNSS), and robotic total stations. Today, point-cloud creation technologies are challenging those traditional mine surveying workflows, with surveyors’ now looking at solutions capable of quickly producing accurate point-cloud data of the mine’s “in-progress” state. Technologies such as unmanned aerial vehicles (UAV) combined with photogrammetric processes are now used to create point-cloud data quickly, effectively, and safely.

•Slovakia’s largest mining company recently adopted a UAV-based survey to determine the effects of land subsidence due to its underground coal operations at Bane Novaky. Over a 12-month period, a number of surveys were conducted over the 300 hectares area (a 1500-meter-by-2000-meter area). Due to significant advantages, including logistics and ROI benefits, UAV-based surveys coupled with digital terrain model (DTM) capabilities found within Bentley’s PowerCivil for Czech Republic V8i were adopted.

The survey was conducted to validate theoretical calculations, performed during the design phase, of possible land subsidence within the immediate area of the underground operations. The results of the UAV survey coupled with a series of mine plans were used to evaluate damages on agriculture production caused by the subsidence (i.e., subsidence was in excess of 4 meters in certain areas, therefore creating a new lake and large areas of unsuitable/boggy land). Confirmation of theoretical calculations versus actuals was established with only very small discrepancies identified over the entire area. The UAV survey provided imagery required for photogrammetry workflows culminating in the creation of a point cloud with over 750,000 points and an orthophoto map mosaic of the area in question. Bentley’s PowerCivil for Czech Republic V8i was used to create the DTM and perform the various analysis routines, including isopach models, terrain profiling, and cross sectional plan production and reporting.

The use of UAV and the subsequent point-cloud generated data, culminating in a series of DTMs, contributed to an estimated saving of approximately GBP 30,000,

“Today, point-cloud creation technologies are

challenging those traditional mine surveying workflows,

with surveyors’ now looking at solutions capable

of quickly producing accurate point-cloud data of

the mine’s “in progress” state”.

Image courtesy of Hornonitrianske Bane Preievidza


including a dramatic savings in survey and processing time usually associated with more traditional survey approaches.

In many regions, laser scanning workfl ows have been slow to make an impression within the mining industry. However, the past few years has seen a very different trend with terrestrial laser scanning (TLS), airborne laser scanning (ALS), and mobile laser scanning (MLS) systems becoming ever

present within the industry. The increase use of this technology can be traced back to a combination of factors, including reduced size and costs of units, coupled with better performing and durable hardware suitable for the mining environment. In addition, software vendors are now catching up with the hardware, providing innovative solutions capable of effi ciently working with, managing, and maintaining voluminous amounts of point-cloud data.

Today laser scanners are used on a broad range of survey related workfl ows, including end-of-month reconciliation surveys, overburden and/or stockpile volume surveys, mine subsidence surveys, general 3D topographical surveys (surface and underground), and many other surveys where cost-effective data collection is required.

•At South Africa’s Mponeng mine, owned and operated by AngloGold Ashanti and regarded as the world’s deepest underground gold mine, a decision to perform a laser scan survey provided some signifi cant cost savings to the operation. The purpose of this survey was to determine the exact location of rock surfaces and associated infrastructure within the haulage line located at level 116. The laser scan, resultant point-cloud data and 3D model were used to determine the viability of transporting a new transformer to its substation location, some 640 meters along the haulage line.

Equipment delivered to site that doesn’t fi t, as it traverses through the mine, can be both costly and frustrating, hence, operational and maintenance access studies are generally considered business critical. Given that time and accuracy are always central considerations for these types of maneuvers, laser scanning is fast becoming the preferred survey method. This project included a total of 28 laser scan setups, capturing over 220 million points along the 640 meters of haulage line.


Image courtesy of Hornonitrianske Bane Preievidza


Using a number of Bentley solutions, including Bentley Pointools, MicroStation, Bentley Descartes, and Bentley Rail Track, a 3D information model of the rock surfaces and associated infrastructure (pipes, structures, etc.) was developed. Additionally, the 3D design of rail track used to transport the transformer into place was also created. To compliment the rail track, a 3D model of the rail dolly was developed, with the minimum cross section footprint of the required transformer added to the dolly. Leveraging this information, an animation of the movement along the rail alignment was performed, resulting in a 3D model showing the minimum envelope required to move the transformer.

Both Bentley Pointools and Bentley Navigator were then used to determine where clashes occurred along the haulage line, with either the rock surface or with “soft” infrastructure assets (i.e., temporary services/utilities) or “hard” infrastructure assets ( i.e., permanent services/utilities). Each identified clash was reviewed in detail to determine what corrective action should be applied prior to the delivery of the transformer.

The scanning of the haulage line and the subsequent analysis prior to transporting the transformer to the substation location resulted in the identification of a number of key clashes. The resultant review of the accurate and detailed 3D models provided decision makers with information that allowed them to make well-informed decisions, resulting in significant cost savings for the mine.

As industry continues its pursuit in increasing productivity and efficiencies there are a number of more recent innovative survey approaches coming to the fore.

UAV and ALS convergence

With the introduction of lightweight laser scanners to the market, the combined benefits of UAVs and laser scanning offers surveyors another option to create point clouds. These combined technologies provide a relatively low cost, safe, quick, and accurate option to map a mine’s in-progress state leveraging the point-cloud data to create 3D information models (i.e., DTM). A leading manufacturer of UAVs, Microdrones GmbH, recently announced an all-in-one solution for the mining industry: “The laser Microdrone is a complex, highly integrated system with various sensors. We see this as a complete game changing solution for the market with extremely affordable value.”

Riegl, another leading laser scanner manufacturer also recently released a purpose-built lightweight scanner (Riegl VUX-1), specifically targeting the UAV market (UAS/UAV/RPAS, gyrocopter, and ultra-light aircraft).

Mobile Laser Scanning

Within a mining environment various laser scanning techniques have been used to collect and map a mine’s in-progress state. More recently, advanced mobile laser scanning (MLS) techniques have been adopted for underground mining environments. Leveraging a


simultaneous localization and mapping (SLAM) technique that consists of a spinning 2D LiDAR unit and an industrial-grade mounted inertial measurement unit (IMU), the acquired scan data is processed through a series of steps to produce a dense and accurate geo-referenced 3D point cloud that can be collected quickly and efficiently, without disrupting mining operations. An extension of this SLAM technique has recently been successfully completed in South Africa using a handheld version of the vehicle-mounted SLAM technology.

•South Africa’s Mponeng mine, the world’s deepest and most substantial gold mine, owned and operated by AngloGold Ashanti, recently completed a pilot using a lightweight handheld laser scanner mounted on a simple spring mechanism that continuously scans as the operator walks through the environment. As the scanner loosely oscillates about the spring, it produces a rotation that converts 2D laser measurements into 3D fields of view. The technology, developed by Australia’s Commonwealth Scientific and Industrial Research Organisation, (CSIRO) is called Zebedee/ZEB1.

The Zebedee/ZEB1 was piloted in an “up dip stope panel” with the resulting 3D model conforming to existing plans of the mine workings. According to Michael Harcombe, senior mine surveyor, AngloGold Ashanti, “The results of the ZEB1 test were much better than we could possibly have expected. The model generated from the ZEB1 scanning was placed in the mine’s plans for a comparison with the current excavation and found to conform to the outline of the workings. We were hoping to compare the results with our existing laser scanning set up however the test area was simply too small for traditional laser scanners, another significant advantage for the ZEB1.”

These industry technology advances have seen the exponential increase of spatially defined digital data throughout the enterprise. However, regardless of the survey technology adopted, mine surveying still remains the technique and science of accurately determining the 3D spatial location of points and or features on or below the Earth’s surface. As with all other surveying disciplines, the goal of any survey can be categorized into two specific areas:

» Collecting spatial data

» Positioning spatial data

In addition, mine surveying personnel are also called upon to:

» Analyze and validate spatial data

» Manage and maintain spatial data

3“Laser microdrones take mining to a new level,” UAVRobotics.com, November 30, 2013,http://www.uavrobotics.com.au/cms/laser-microdrone-takes-mining-to-a-new-level/.

4ZEB1 Laser Scanner Put Through its Paces at World’s Deepest Gold Mine,” Mining.com, January 2, 2014, http://www.mining.com/web/zeb1-laser-scanner-put-through-its-paces-at-worlds-deepest-gold-mine/.



•Drawing on over 30 years of software development experience and industry knowledge, Bentley Systems, in development partnership with mining majors such as Anglo American Platinum, AngloGold Ashanti, Lonmin Platinum, and Royal Bafokeng Platinum Mines, is set to launch Bentley OpenMine Survey – a new and comprehensive surface and underground survey application for the mining industry. Acknowledging the need to support today’s requirements with tomorrow’s needs ensures the soon-to-be-released Bentley OpenMine Survey solution addresses the digital data and big data conumdrums, while addressing current survey workflows.

Built from the ground up with the advantage of leveraging established core platform software and technologies such as MicroStation, Bentley Map, OpenRoads, Bentley Geo Web Publisher, and Bentley Geospatial Server ensures that Bentley OpenMine Survey will provide the most proven and stable platform available to the industry today. Additionally, this solution directly addresses the survey/GIS chasm, ensuring all data generated throughout the survey process is automatically incorporated within the broader geospatial requirements and workflows.

Suitable for both surface and underground operations, Bentley OpenMine Survey includes functionality to address key survey workflows such as:

» Actuals/operational surveys

» Check/QA/QC surveys

» Control surveys

» Setout surveys

» Topographical surveys

The important aspect of survey data management forms a central and key component, including provisions for:

» Comprehensive auditing capabilities

» Maintenance of the parent-child relationship

» Fusion of survey and spatial data

» Reporting and dissemenination of survey data

» Maintenance of spatial data

» Management and storage of survey data

Conclusions and Recommendations

As the mining industry begins the transition to a productivity-centric approach, digital data is set to become pervasive and extremely influential throughout an enterprise. Spatially located digital data provides another level of visibility to an enterprise, and to this end, will be highly sought after by a wide variety of users within an enterprise. The ability to efficiently manage, maintain, and disseminate this spatial data to the right people at the right time will be critical to the success of an enterprise.

“Acknowledging the need to support today’s

requirements with tomorrow’s needs ensures

the soon-to-be-released Bentley OpenMine Survey

solution addresses the digital data and big data conum-drums, while addressing

current survey workflows.”

13

© 2014 Bentley Systems Incorporated. Bentley, the ‘B’ logo , Bentley Map, ProjectWise Geospatial Server, Bentley Geo Web Publisher, PowerCivil, Bentley Poin-tools, MicroStation, Bentley Descartes, Bentley Rail Track, Bentley Navigator, and Bentley Geospatial Server are either registered or unregistered trademarks or service marks of Bentley Systems, Incorporated, or one of its direct or indirect wholly-owned subsidiaries. Other brands and product names are trademarks of their respective owners. 6971 07/14

The Changing Face of Surveying within the Mining Industry

Spatially located digital data enters an enterprise from a number of sources, however, much of this data is managed or captured by surveyors as they go about their daily routines. This is especially true throughout the operational phase where continuous monitoring of the mine’s in-progress state is maintained.

While every mining operation and every challenge is unique, the industry can draw on the collective wisdom and experience of those owner-operators and software vendors delivering solutions for today’s requirements and tomorrow’s needs. Therefore, a number of recommendations tendered include:

1. Review your organization’s vision. Determine whether your current systems are capable of supporting and delivering on this vision. Specifically, review the impact an exponential increase in digital data (i.e., big data) may have to your systems and whether these systems can efficiently and effectively manage, maintain, and disseminate this data.

2. Think information mobility. Data and information are key enablers in support of productivity and optimization. Having access to the right information, in the right format, at the right time, provides the fundamentals for informed decision making. Unlocking this data and information from silos is critical for both today’s and tomorrow’s mining operation.

3. Consider spatial enablement. Typically, spatially located digital data is considered a totally separate application to be handled exclusively by a GIS. However, and as shown, spatially located digital data will be created by many and various sources. The use of an industry-standard database, such as Oracle Spatial or SQL Server Spatial, is recommended. This spatial ability is further enhanced by enabling data editing to be performed in any Open Geospatial Consortium (OGC) standards-based GIS that supports viewing and editing directly in the Oracle Spatial or SQL Server Spatial database. This means that your enterprise offers a truly open, spatially enabled capability that can be used with any open GIS technology.

4. Review your survey solution. Obviously, an organization’s survey solution needs to support today’s requirements; additionally, the survey solution needs to prepare for tomorrow’s needs. As the mine surveyor transitions to digital data (and big data) they will need a survey solution that supports both traditional and future workflows from a wide variety of survey sensors (and manufacturers). For a surveyor, the distinction between field and office is set to blur. As mobile computing processing power continues to improve and communications to and from field also improves, the industry is set to see many more surveys completed at the “point of work”. Therefore, ensure your survey solution has the capabilities to support these transitional workflows and requirements. Importantly, ensure your solution seamlessly supports the enterprise-wide vision, requiring that all data generated throughout the survey process is automatically incorporated within the broader geospatial requirements and workflows.

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The Changing Face of Surveying within the Mining Industry