Post on 22-Jul-2020
transcript
A
SUPER MAXBIT / SUPER MAXBIT G-MODEL
OPERATION MANUAL
RT14A
SUPER MAXBIT and SUPER MAXBIT G-MODELdevices stabilize boreholes in unconsolidated overburden formations.
This is an advanced technology compared to the other eccentric drilling methods. It consists of two to three wings connected to a Down the Hole Hammer. The bit heads are extendable/retractable when the drill string rotates in the forward/reverse direction. Drilling and casing are possible simultaneously with the use of a casing shoe or casing driver ( shoeless ).
The SUPER MAXBIT has a following advantages:●Higher-speedcasingadvancement●Straightboreholedrilling.●Uniformrotationwhiledrillingofboulders,
sand and gravel.●Reliabilityofextendingandretractingproven
by customer experiences.·Highlyefficientbitfor· Foundation / Construction · Water Well / Environmental testing · Geothermal
TheSUPERMAXBITG-MODELhasafollowingadvantages:●Economicalcostperdrilledfoot●Designforthickercasingpipes ( shoed or shoeless )●Fasterpenetration●Stableopeningandclosingmechanism●Straightandsmootherboreholedrilling●Highefficientbitfor
· Foundation construction · Water well· Environmental testing · Geothermal· Geological survey
-TABLE OF CONTENTS-
OPERATIONA. Drilling / Casing Advancement Procedures A-1.Beforestartingtodrill A-2.Casingshoeattachment(Weldingprocedure) A-3.Assemblingandsettingupthedrillstrings A-4.SettingUptheDrillRigtoDrill A-5.InstallingCasing A-6.Collaring/Drillingapilothole A-7.Checkingthecasingpipealignment A-8.RotationspeedofBit A-9.ContinueddrillingorDrillingOperation A-10.Reopeningbitwingsorrestartdrilling A-11.Jointingthedrillstringsandthecasingpipes A-12.CasingWeldingprocedure A-13.Termination/Endofdrilling A-14.Pullingcasingpipesout A-15.WaterinjectionB. Drillingindifficultformations B-1.Clayformations B-2.Fracturedzone–Brokenrockformations B-3.Sandformations B-4.Self-SustainingHole/Solidrockformation
MAINTENANCE C. ComponentsD. Exchange of components D-1.Bitwings D-2.Device D-3.PinE. Reassembling bit wings on the device E-1.Takeoffthepinsets E-2.Pulloutthebitwings E-3.Re-assemblingprocedureF. Build-upweldingrepairofthedeviceshoulder
TROUBLE SHOOTING
111456899101214141619192020202022
23252526262727303032
33
1
A. Drilling / Casing Advancement Procedures
A-1. Before starting to drillKnowingtheformationyouaredrillinginhelps,butisn’talwaysknownbeforeyoustartdrilling.Casing advancement is done with a top head rotary drive drill rig. You need to decide if you will advance the casing by the use of an internal drive shoe welded to the bottom of the casing ( shoed application ). This drive shoe welded to the bottom of the casing will pull the casing through the formation while being drilled. NOTE: smaller hole through the drive shoe. Theuseofacasinghammer /casingdriver,usesanexteriordriveshoe likeacable toolstyle drive shoe welded to the bottom of the casing ( shoeless application ). Both of these applicationswillalsoworkonatophammerdrills advancingcasing in theground.Casingsizeandwallthicknessisveryimportanttobeknown.Thishelpstodecidetherightdeviceanddrive shoe to match the casing being used. Also helps for the selection of bit heads to cut a large enough diameter borehole to advance the casing.
A-2. Casing shoe attachment ( Welding procedure )1.Bevel theendof thecasing toanangleofabout60degrees (θ inFigure1shouldbe
30degrees ).Besure thatall surfaces tobeweldedarecleanand free fromanydirt,contaminationincludingmoisture.Pre-heattheendofthecasingshoeto100degrees ( Celsius ).
2.Insertthecasingshoeinsidethecasingpipe.Besurethecasingshoeisinthecenterofthecasing pipe.
3.Temporarytack-weldthecasingtocentralize.Tackweldingshouldbedonediagonally.4.Weldingonthecircumference.Normally(3)passesisrecommended.Takesufficienttime
to weld the casing using the correct welding rod.5.Afterwelding,useagrinder tosmooth theweld.Thiswillhelpwhile installingcasingnot
to drag drill cuttings into the borehole on the outside of the casing causing drag during installation.
6.Recommendation: Plugweldsordiamondsarecut in thecasingand thenwelded tostrengthenthecasingtothedriveshoe.PleasereferTable1forplugsizeandthenumberofplugs.
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
2
1. Cleaning atall surfaces
2 .
3 .
Tack welding should be done diagonally
1 st
2 nd
3 rd 4 th
4.
5.
6 .
Plug welding
Figure1: Weldig procedure
Table1: Plug size and the number of plugs
Casing size (inch) Plug size Number4”–6” 20–30mm 3-48”–12” 30mm 6andup14”–20” 30–35mm 8andup
Super Maxbit Super Maxbit G-Model Operation Manual
3
NOTE: The casing shoe must be correctly welded to the casing in order to carry out a successful casing drilling operation. If the casing shoe is not welded correctly to the casing,possibleprematurefailurescouldhappen.Thecasingshoecouldseparatefromthecasing,possibleboreholedeviationordamagetotheshoulderofdevice.
Figure2: Alignment for the casing pipes and casing shoe
✔Good
×Bad
Gap between casing and the casing shoe Tilting connection
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
4
NOTE: Checking to see if bit heads are open TheSMBorSMB-Gdevicenowrotatingorturningclockwisewillopenthebitheadstothedrillposition.Tocheckthebitheadstoseeiftheyareopenorinthedrillposition,stoprotationandslightlypickuponthedrillstring,withthebitheadsopenthetoolswillstopmovingupwardbecausethebitheadsarehittingthebottomofthedriveshoe.DONOTPULLEXCESSIVLY,youcoulddamagebitheadsorbreaktheretainingpins.(Werecommendthatpickuporliftthecasingdrillstringseparately,ifthebitwingscloseorareinretractposition,thereispossibilitythatcasingpipewillfall.)
A-3. Assembling and setting up the drill stringsAfterthecasingshoeisattachedtothecasingpipe,theassembledSUPER MAXBIT ( SMB ) or SUPER MAXBIT G-MODEL ( SMB-G ) is attached to the down the hole hammer. The bit shouldbeexaminedduringassemblytobesurethatallpartsareinproperworkingorderandcomplete. The hammer is threaded on to the drill string. An optional guide sleeve or stabilizer is recommended on the top of the hammer.
Before inserting the dri l l string into the casing inspect the tools, device and bit heads to be free to open and close with ease to a full open position before drilling. When inserting thedrillstring into thecasingpipe, theSMBorSMB-Gwingswillbe in theclosed position. InserttheSMBorSMB-Ganddrillstringintothecasingpipeuntilthebitwingshaveclearedthe drive lip and casing shoe. The device now should be in contact with the drive shoulder and the drive shoe.
Super Maxbit Super Maxbit G-Model Operation Manual
5
A-4. Setting Up the Drill Rig to DrillIt is important for drilling to set up the drill rig so it is level and stable. This also helps in leveling thedrillstringtodrillstraight.Usuallya levelingapparatus isused.Inmostcases,vertical totheground,unlesshorizontallydrilling.
Figure3: Setting up the Drill Rig to Drill
✔Good ×Bad
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
6
✔Good ×Bad
Figure4: Installing Casing
✔Good ×Bad
A-5. Installing CasingWith thecasingshoeordriveshoeweldedonthe1st lengthofcasing, the2ndcasingandeachcasing lengthafter thatshouldbealigned / leveledandweldedkeepingstraight.Themisalignmentofthecasingpipe/crookedpipeweldsmaycausedrag/highfrictiononcasinginstallation.
Figure4: Installing Casing
Super Maxbit Super Maxbit G-Model Operation Manual
7
NOTE: Themisalignmentof thecasingpipescause1.Possibilityofbreakingof theweldedjoints.2.Prematurewearof thedeviceshoulder.3.Themisalignmentorweldingslag occurring may cause friction on the drill string and or prevent the drill string from retracting after drilling. Also possible mushrooming.
Figure5: The mushrooming caused by the misalignment of the casing pipes
×Bad
Misalignment drilling
Burr
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
8
NOTE: Beforeyoustartdrillingtheairpressureshouldbesetbetween125to185PSI(8to12bar)(dependingonthehammersize).Toomuchairpressure/volumeatfirstwillcause cuttings to come up around the outside of the casing instead of the inside of the casingpipe.Inthiscase,cuttingsinsideofthecasingcannotcomeupandmaycauseblockage.AlsohighPSIcouldcauseprematurewareandpossiblefailureofthedevice.
Figure6: Too much air pressure when start drilling / collaring
A-6. Collaring/Drilling a pilot holeMostwaterwelldrillerswilldrillapilothole tostartdrillingoperation, thiswillhelphold thecasing pipe and stabilize the bit in place. Beforeyoustartdrilling,airpressureshouldbe(dependingonthedeviceandhammerbeingused)setforoperationsbetween125to185PSI(8to12bar).CheckthatBitwingsareintheopenposition.Beforestartingtodrill,applyair,startrotationand(injectwater/foam/orfluids)thenlower/feed tools to start drilling. It is good practice to run a stabilizer or centralizer over the UR and hammer.
×Bad ×Bad
✔Good
Super Maxbit Super Maxbit G-Model Operation Manual
9
A-7. Checking the casing pipe alignmentWhenthecasingpipeisdriven,periodicallychecktheangleofcasingpipe.Ifthecasingpipeisnotparallelorstraightwiththemast,thiswillcausedragonthecasingbeinginstalledandpossibly require the extraction of the casing pipe and starting the hole again.
A-8. Rotation speed of BitAlwaysdrillconsideringgroundformationsencounteredas theyaredrilled,hard formations–slowerrotationspeed,softer formationsrotationspeed isa little faster toachievesmoothdrilling and not binding. Refertothefollowingfigurefornormalrotationspeeds.Select the range of uniform rotation during drilling. The normal rotation speed range from 10 to 80 rpm, all depending on the device size and formation being drilled. Higherrotationspeedswillwearthebitprematurelyandpossiblebitbreaking.
Figure7: Checking the casing pipe alignment
Figure8: Rotation speed of Bit
✔Good ×Bad
100
80
60
40
20
04 8 12 16 20 24 28 32
Rotation Speed
Rot
atio
n S
peed
(rpm
)
Nominal Size (in.)
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
10
A-9. Continued drilling or Drilling OperationWhiledrillingtheholeshouldbeflushedoutfrequentlytopreventblockageandhelpremovecuttings. Under most drilling conditions, the most common operating pressure is 185 PSI ( 12.8 bar ). YouneedtoconsidertheoperatingpressurerequiredtooperatetheDTHhammer,airpressurelossgoingthroughthehammer,waterandoilinjection.
Do not reverse rotation while advancing/drilling for any reason. Theunscrewingofdrill tools, retractionof thebitwingsorheads. If thebitheadsarenotcheckedtobeopenordrillposition,thebitheadswilldrillasmallerborehole,causingproblemsto advance the casing. ( see P.13 )
Drillingindifficultformationbeloworsee P.20.
-Clayformation-Whendrillinginclayformations,injectmorefluids,helpscleantheborehole.Taketimetodrilland flush theborehole.Lower thebitacouple inchesata timeallowingair toblowoffandclean the bore hole until threw this clay formation.
-Sandformation-Whenencounteringsand, there ismore flushing thanactualdrilling.Thismaycause thebitwingsnot tobeable tocontact theboreholebottom.Try tokeepthecasingfromfallingonorbeatingagainst thebackofbitheadwingswhichcouldcauseapossible failure. Whiledrillingthroughsandformations,thepenetrationrateandspeedarerelativelyhigherthanother formations. Change the rotation speed higher or lower in accordance with drilling speed.
-Hardrockformation-Drillingwillbeslower,adjustyourairpressureandrotationspeed, ifbindingoccurs,adjustholdback,rotationandslowlylowerdrillstringtoachievesmoothdrillingandproceed.
NOTE: High PSI will cause premature wear and possible failure.
Super Maxbit Super Maxbit G-Model Operation Manual
11
-Bitwingslockingup/Encounteringboulders-Whenyou feel theSMBorSMB-Gbit heads /wingsbindup, or lockup, youmaybeencounteringcobblesor largeboulders.Try to freebystopping the forward rotation, turnslightlybackwards,thenraisingthebitoffthebottomoftheholeslightly,flushingoutthehole,thenstartrotationagainslowly.Thelowerfeed/percussionwillbreakorpushtherockaside.Ifyoucontinuetodrillwithoutfreeingthebitandflushingthehole,damagetothebitmayoccurifbinding.
Figure9: Encountering Boulders
NOTE: Whiledrilling,ifyounoticeanycasesbelow,stopdrillingandflushtheholeclean.1.Drillpipesarejumping(Drillingboulders)slowrotationandfeed.2.Thehammeringsoundsuddenlystopsorismuffled.(Theholeisfillingwithcuttings
orbound).Rotation isstopped.Casingpipe issuddenlydrivendownmorethan4inch(10cm)withoutdownpressure.(Drillinginsand,clayorvoids.Afterbreakingthrough boulders. )
BoulderLowPercussion
LowPercussion
LowPercussion
1.
3.
2.
3.
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
12
Figure10: Reopening bit wings or restart drilling
A-10. Reopening bit wings or restart drillingStartrotation,Opentheairvalveandfluidinjection1.Afterflushingtheholecleanlowerthebittothebottomoftheboreholetoproceeddrilling.
( Do not reverse rotation )2.AdjustFeed(Downpressure)andproceeddrilling
NOTE: rotation is necessary when reopening Bit wings.
①Forward Rotation
②Open the air valve
③Feed
④Start Percussion
Continue Rotation
1.
2. 3.
Super Maxbit Super Maxbit G-Model Operation Manual
13
NOTE: Itisveryimportantthatthebitheadsare“FULLYOPEN”beforeadvancingthecasing.Ifthebitheads/wingsdon’tfullyopen,thebitheadswilldrillasmallerborehole.Thismaycausethecasingpipetobecomestuckinthesmallerhole.Thiscanalsoresultinthebreakingofbitheads/failureofwelds,prematuredevicewear.
1.Raisethedrillstringandcasingslightlytilldeviceturnsfreely.2.Opentheairvalve,startforwardrotation3.Thenadjustholdbackandlower/feedtoolstoreopenbitwingsandstartdrilling.
Figure11: Drilling with the Bit Wings open insufficiently
1.
3.
2.
Feed
LowPercussion
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
14
A-11. Jointing the drill strings and the casing pipesUsuallydonebeforestartingtodrill,installdrillrodintocasingUseaspecialliftingslingforthedrillpipeandcasing,normallycalledacasingelevator/clamshellorcasingsling(picksupdrillrodandcasingatthesametime).Insertthethreadofdrillpipeatthetopofthemastfirst.After tightening, installotherend intodrillpipealready installed in thegroundand tighten.Lowerhangingcasingdown tocasingalready installed, levelandweld.Afterwelding iscomplete, lowerdiverter /casinghammeronto thetopof thecasing.Startaircompressor, (fluid injection,)rotationthencheckbitheadstoseeif theyare intheopendrillposition(byslightlypickingupdrillstringsandcheckingifthebackofbitheadwingshitthecasing),lowercasing / drill string and proceed to drill.
It is very important for a smoother drilling operations to set the drill rig stable and level. Also casing and drill rod are in alignment.
A-12. Casing Welding procedure1.Bevelbothendsofthecasingtobeweldedatananglearound60degrees(θinFigure12
shouldbe30degrees).Ensurethatallsurfacestobeweldedareperfectlycleanandfreefrom any contamination including moisture.
2.Useacasingalignmentclamp / tool, to lineupcasing.Tackweldingshouldbedonediagonally. Remove the alignment clamp.
3.Weld per A-2 Casing welding instructions ( see P.1 ) -Takesufficienttimetoweldnottocauseaweldcrack,duetosuddenheatingorcooling.
4.Afterwelding,iftheweldandweldingslagprotrudesontheoutsideofthecasing joint(exceeds1.5mm=1/16ofaninch)grinddownwithanelectricgrinder.Thiswillreducethefriction with the material in the holes wall.
NOTE: Themisalignmentforthecasingpipescausewearonthedevicedriveshoulder,dragonthecasingfromrubbingboreholewallandpossiblecasingbreakingataweldedjoint.
NOTE: The casing pipes must be correctly welded each other to carry out successful casingdrilling.Ifthecasingpipesisnotweldedaccuratelyeachother,misalignmentwillresult.Thismaycauses,1.Holedeviation,2.Damagetothecasing,and3.Damagetothe shoulder of device.
Super Maxbit Super Maxbit G-Model Operation Manual
15
Figure12: Casings Welding procedure
Should be beveled
Cleaning at all surfaces
Tack welding should be done diagonally
1.
2.
3. 4.
1st
2nd
3rd 4th
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
16
Whenweldingcasing,theinsidehshouldnotexceed0.5mm ( =1/64 inch ) ofmaterial (weld) because the clearancebetween the bit and the casing pipe (D-d)/2rangesfrom0.85to1.15mm(=1/32to3/64 inch).Theweldthickness insidethe casing may prevent the device from retracting after drilling.
h: Height of inside weld d: The device diameter D: The inside diameter of the casing pipe
A-13. Termination/ End of drillingAfteryouhavedrilledtorequireddepth, theSMBorSMB-Gcanberetractedbackupinsidethe casing / drill pipe.1.Afterdrillingtoacompletiondepth,flushoutandcleanthebottomofthehole.Normallywith
slowrotationandair. Inwaterwelldrilling,stoprotationorslowrotation insidethecasingpipewithairblowing(takesufficienttime).Thegroundwaterwillbeclearanddeveloped.
2.Besuretoleaveroomunderthecasingorthatlastcasingtubeshouldnotbeburiedtotally.Needtoreserve20 to30cm(7 to10 inch)ofmachine feed forpercussion inorder toretract the bit wings.
NOTE: Whenthedrillstringscannotbepulledoutbecauseoftheweldinside,pullupthe drill strings slowly with forward slow rotation carefully. Donothurrytopullup,becausetheweldorburrinsideofthecasingcanbegroundoffbythedeviceshoulder.Thisisn’tafastprocess,maytaketimetoachieve.
Figure13: Inside welding
Inside weld
h
d
D
Super Maxbit Super Maxbit G-Model Operation Manual
17
Figure14: Reserving machine feed for retraction the Bit wings
RECOMMENDATION: Normally turningcounterclockwise(backwards)with thebitheads/wingsonthebottomofthehole.Orpickupdrilltoolstillthebacksideofthebitheadstouchthebottomofthecasing,turnbackwards,1-3revolutionsusuallyallowsbitheads to close and then retract.
NOTE: 1.Whenthebitwingsareclosedorretracted,cautionthattoomanyturnsbackwards
mayloosenthehammerordrillstrings.Ifthebitwingsdonotretract,thefirsttimetryagain.Useforwardrotation,stopthenusesuggestions1-2again.
2.Insandformations,becarefulofexcessiveflushingafterstoppingfeed.Awashingand flushing occurs. This may cause the bit wings not to be able to contact the boreholebottom.Retractionisdifficultwhenthishappens.
20~30 cm
✔Good ×Bad
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
18
NOTE: Important Device Information – Extended time in water or drill cuttingsTheSMBorSMB-Gdeviceshouldnotbeleftforalongperiodoftimeinmuddy/drillingwater after drilling completion. The clay and mud can solidify preventing the bit heads fromopening/retractingproperly.Inthiscase,thedrillstringsandtheSMBorSMB-Gshould be raised for one drill rod length.
Figure15: Important point for when the Bits be left for a long period
Underground water
✔Good
Super Maxbit Super Maxbit G-Model Operation Manual
19
A-14. Pulling casing pipes outWhenpulling casing pipe, use elevators on thecasing. Use of the device / bit heads is NOTrecommended. Friction on the casing pipe can be too hightomovecasingpipes.Thereisariskthatthebitwingswillbreakat theretainingpinorpinbreakagedue to pulling load is on the pin.
A-15. Water injectionWater injectionwillhelpflushoutcuttings.Allowsthehammerandthedeviceorbitwingstoruncooler.Improvetheenvironment/dustaroundtheworksite.
Figure16: Pulling casing pipes out
Figure17: Typical Rig Setup
Air Compressor
Lubricator
Rotary Head
Guide Shell, Mast
Dust Collector(Diverter)
Drill RodCasing
Air Hammer
Super Max BitSuper Max Bit-G
Casing Shoe
×Bad
Air Compressor
Lubricator
Rotary Head
Guide Shell, Mast
Dust Collector(Diverter)
Drill RodCasing
Air Hammer
Super Max BitSuper Max Bit-G
Casing Shoe
×Bad
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
20
B. Drilling in difficult formations
B-1. Clay formationsIt is easy to notice drilling through clay formations because the hammering sound becomes difficulttohear.
1.Periodically,youshouldstopdrillingandflushtheholeclean. Inclayformations, frequenthole cleaning is necessary.
2.Claywilldrillfaster,bewareofdrillingtoofast.Airpressurewillincrease,useplentyofwaterwhendrilling.Waterinsidethecasingpipeshelpscuttingflushthecuttingsout.
3.Ifcasingisn’tmovingdownward,stoptoinspectandfigureoutwhy,continualdrivingwithoutmovementwillcauseafailureorcasingbreaking.
B-2. Fractured zone – Broken rock formationsWhiledrillingthroughafracturedzone,drillstringsmayrotateirregularly.
1.Thebitshouldbeoperatedwithlowerfeedpressure.Ifthebitisoperatedatnormalspeedsandpressures, therotationanddownpressurewillbetoogreatandthebitwingscannotrotate and will possibly be damaged.
2.When irregular rotation isobserved, thebitshouldbepulledupa little tomakedrillingsmoother and be sure that the hole is cleaning adequately. Drill with less or lower feed pressure until drilling conditions change.
3.Whenthebitcannotrotateatall,pullupthecasingpipealittleuntilrotationispossible.
B-3. Sand formationsWhenencounteringsandformations,thepenetrationrateandspeedarerelativelyhigherthanother formations. Becarefulwhentoomanycuttingsareflushedoutrelativetothedrilleddepth.Heavingsandsand cleaning sand / material too far ahead of the casing must be cautioned. A washing and flushingoccurs.Thismaycausethebitwingsnot tobeabletocontact theboreholebottom.Thereisariskthatthebitwingswillbreakattheretainingpinorpinbreakage,becauseallloadof bit wings is on the pin. Feedandairpressuremustbecarefullywatchedtokeepthebitwingsatholebottom.
Super Maxbit Super Maxbit G-Model Operation Manual
21
Figure18: Encountering Sand formation
Sand formation
Pin
Stress
1. 2.
3. 4.
Feed
Sand formation
Sand formation
×Bad ✔Good
Super Maxbit Super Maxbit G-Model Operation Manual
OPERATION
22
Figure19: Self-Sustaining Hole / Solid rock formation
B-4. Self-Sustaining Hole / Solid rock formationInsomedrillingconditions,frictiononthecasingpipeisminimaltohelpkeepthecasingshoeoffbacksideof thebitwings.Theloadof thecasingpipesmaybeonthebitwingsandtheretainingpin.Thereisariskthatthebitwingswillbreakattheretainingpin.Usecasingholdbackorcasingblocksonthecasingtokeepthecasingweightoffthebackofthebitheads.
Low friction on the pipes
×Bad
Super Maxbit Super Maxbit G-Model Operation Manual
23
Device
Bit wings
Casing shoe
Pin sets
Device
Bit wings
Casing shoe
Pin sets
C. Components
Bit wings Device Pinsets(Pin,Plasticseal,RetainerringCasingshoesee P.28 ) Casing shoe
SUPER MAXBIT ( SMB )
Figure20: SMB Components
Super Maxbit Super Maxbit G-Model Operation Manual
MAINTENANCE
24
Figure21: SMB-G Components
SUPER MAXBIT G-MODEL ( SMB-G )
Device
Bit wings
Casing shoe
Pin sets
Device
Bit wings
Casing shoe
Pin sets
Super Maxbit Super Maxbit G-Model Operation Manual
25
D. Exchange of components
D-1. Bit wings1.When theweardetectionmarkonawingdisappears.SMB-Gdoesn’thave thewear
detectionmark.Pleasecheckexcessivewearongaugecarbidesorbrokencarbidesorwearon the upper side of bit head next to the casing.
2.Whenthecarbidewearisexcessive.(Check1/3<W/D<1/2)
3.Whenwingbodywearsandcarbidespopout.
Figure23: The carbide wear
Figure22: The wear detection mark on a wing
Super Maxbit Super Maxbit G-Model Operation Manual
MAINTENANCE
26
D-2. DeviceWhentheweardetectionmarksonthedeviceenddisappear.
D-3. PinWhen the wear attains the following value. Please exchange the pin if you observe excessive wear. Recommendationtoinspecttheretainingpinsandretainingclipsevery500foot(150m).
Figure24: The wear detection mark on the device end
Table2: The pin wear
0.5-1.0 0.5-1.0Amount of Wear (mm)
Geometry
Amount of Wear (mm)Amount of Wear (mm)
Two Wing Type Three Wing Type
Super Maxbit Super Maxbit G-Model Operation Manual
27
①Pull off by using a snap ring pliers
②Push
②Push off
① ② ③
E. Reassembling bit wings on the device
E-1. Disassemble - Take off the pin sets1. CCR ( C-Clip Retainer ) pin sets
Figure25: Take off the CCR pin sets
NOTE: Wehaveaspecialtoolsforpullingoffpinsfor3wingstype.
Figure26: Retracting pins with special tools
Super Maxbit Super Maxbit G-Model Operation Manual
MAINTENANCE
28
①Pull off by using a snap ring pliers
②Push off
②Push
①Pull off the stopper by using a screw driver
Washer Stopper
②Slide and pull off the washer
③Push
2. SCR ( Seeger-Clip Retainer ) pin sets
3. NPR ( New Pin Retainer ) pin sets
Figure27: Take off the SCR pin sets
Figure28: Take off the NPR pin sets
Super Maxbit Super Maxbit G-Model Operation Manual
29
PushPush
Push off Spring pin and Pin
4. SPR ( Spring Pin Retainer ) pin sets
5. CSR ( Coil Spring Retainer ) pin sets
Figure29: Take off the SPR pin sets
Figure30: Take off the CSR pin sets
Super Maxbit Super Maxbit G-Model Operation Manual
MAINTENANCE
30
Mud or sand should be removed
Push Push
Insert the pin and spacer
E-2. Pull out the bit wingsClean the holes of the device. Mud or sand should be removed.
When the wear attains the following value. Please exchange the pin if you observe excessive wear. Recommendationtoinspecttheretainingpinsandretainingclipsevery500foot(150m).
E-3. Re-assembling procedureSPR ( Spring Pin Retainer ) pin sets
Figure31: Clean the holes of the device
NOTE: IfafterpushingtheSPRpinout,oneendoftheSpringpindrivenmaydeformorspread.Ifyoutakethepincompletelyout,changeendsandreinstall.
Figure32: Re-assembling for the SPR pin sets
Super Maxbit Super Maxbit G-Model Operation Manual
31
Push
✔Good×Bad
CSR ( Coil Spring Retainer ) pin sets
Figure33: Re-assembling for the CSR pin sets
NOTE: WheninstallingtheCSRpinin,theSpringpinmustbesetinthecenterofthePin.
Figure34: Important point for Re-assembling for the CSR pin sets
Super Maxbit Super Maxbit G-Model Operation Manual
MAINTENANCE
32
F. Build-up welding repair of the device shoulder
In thecaseofwearingof thedeviceshoulder,build-upweldingrepair isneeded.Carefullyfollowtheproceduretoperformthebuild-upweldingrepairortaketoaweldingshopthatcandothisforyou.Otherwiseheattreatmentissueswillcauseweldingcracks.
1.Pre-heatthebasematerialto200to300degreeCelsius.2.Weldthemateriallayeronthesurfaceofthebasematerial.3.Graduallycoolthedevice.Neverrapidlycoolit.4.Applyafinishingprocess.Theangleofthedeviceshouldershouldbe30degree.
NOTE: Productrepairedwiththebuild-upweldingcannotbeguaranteed.
Figure35: Build-up welding repair of the device shoulder (cross-section)
Device shoulder– Base material
Finishing process
30 degree
Super Maxbit Super Maxbit G-Model Operation Manual
33
Reason Solution
Less hammering.
Airpressureistoolowtowork.( The hole is too deep that causes shortage of air pressure )
Compressor should be replaced with a larger one or installadditionalaircompressorandairreceivertank.
Justdrillingthroughclayformation. The frequent hole cleaning is necessary. ( see P.20 )
Drive sub is loosened Besuretotightenalldrilltoolsandjointswheninstalling.Rotateinforwarddirection,pulldrillstringandretighten.
Cuttings,Sandorclayinfiltratingintothehammer. Checkforbrokenorweakcheckvalespringinhammerbackhead.
Cutting are remaining between driver and bit Useplentyofwatertohelpflushthecuttings
Cuttingarestickinginbitblowhole. Flush frequently.
The bit does not rotate at all. Rotation fluctuation or jamming.
Drilling through fractured zone. The bit should be operated with lower feed pressure. ( see P.20 )
Hit a scrap iron or steel in the bore hole. Becautious,drillingscrapironorsteelwilldamageanybit. Try to remove steel with magnet.
Thebottomoftheholeisfilledwithcuttings. Usewater injection,alsoaddingdrillingfoamcanhelpflushout.
Stickingthroughcavezone. Becautious,drill slowlywith light feeduntil drillingsmooth out.
Hit a boulder. Drill slowly to try to cut a straight hole threw the boulder. Otherwiseraisethedrillstringupslightlytogetboulderin front of the bit to break it up or straight hole isachieved to continue drilling.
Too many cuttings are flushed out relative to the drilled depth.
Drilling through soft sand zone. Be careful not to pull to many cuttings out in front of the bit. Try stopping drilling earlier than normal.
Super Maxbit Super Maxbit G-Model Operation Manual
TROUBLE SHOOTING
34
Reason Solution
Cuttings are not flushed out of the hole well.
Air compressor air volume. Compressor should be replaced with a bigger one or installadditionalcompressorsandairreceivertank.
JustdrillingsthroughClay formation. The frequent hole cleaning is necessary. ( see P.20 )
Cuttings are staying inside the casing pipe. Besurebitisn’tplugged.Useplentyofwaterforflushingwhile drilling
Drillingthroughcrackformation,Formationairloss Use water and drilling foam until circulation resumes.
Casing pipes are not driven down.
Breakageoftheweldjoint.
Usethreepasseswhileweldingeachjoint.CheckthecasingpipeisverticalandstraightCheck that eachweld is smooth so thatweld sizedoesn’tcausefrictionbetweenthecasingpipeandborehole wall is minimum.
ThreadedcasingJoints. Neverusethreadedjointcasingpipeinwithcausedragand failure
Breakage of the pin.
Hammering while the bit is not on the bottom of the hole. Keep the bit wings on the bottom of the hole.
Hammering in sand formation. Feed and air pressure must be carefully watched to keepthefaceatthebitwing.(see P.20 )
The bit wings does not open.
The bit wings are not on the bottom of the hole. Keep the bit wings on the bottom of the borehole
Clay or mud has intruded into the hole of the device. Clean the holes of the device. Flush with water / drilling fluids
StickyClaysIfstickyclay isencountered, take time todrill, flush,drill,flushwithlotsofwatertokeepthebitheadsopen.Leavebits headsunder casing in drillmodewhenadding a new rod / casing.
Super Maxbit Super Maxbit G-Model Operation Manual
35
Reason Solution
Sudden drop of drilling speed.
Reachingthehardrockformations. SlowdownandoperatetheSMB/SMB-GdevicelikeaDTH bit. Change to the single DTH drilling.
Thebitwingsdon’topenfully.Pull up both the drill strings and the casing pipes to a position where the bit wings can open fully. Aslightamountofpercussionandrotationwillmakethebit wings open fully.
Premature wear of the device shoulder.
Insufficienthardnessofthecasingshoe.The use of other manufactures / untreated drive shoes not to Mitsubishi specifications will case premature mushroomeffectofdriveshoes,wearonthedriveliponthe SMB device and void warranties.
Rotation speed is too high. See rotation chart ( see P.9 )
Premature breakage of the bit wings shaft.
Prematurewearorbreakingbitheads. Rotationspeeds,Check theweardetectionmarksonthedevice,toomuchdownpressure.
The bit wings does not close.
The bit wings is not on the bottom of the hole. See Termination of drilling ( see P.16 )
Cuttingsarestickingaroundthebitwingssomuch. Flushing out cuttings with AIR and Water
The drill strings cannot be pulled out.
The thicknessof theweld insideof thecasingpipesexceeds limitation.
Pullupthedrillstringsslowlywithforwardslowrotation,carefully. Donothurrytopullup,becausetheweldorburrinsideofthecasingcanbegroundoffbythedeviceshoulder.Thisisn’tafastprocess,maytaketimetoachieve.(see P.16 )
There is a dent on the outside or inside of the casing pipe which happened during drilling.
Checkcasingbefore installing. Inwaterwelldrilling,sometimesrocks/ largegravelcanroll into thecasingwallduringdrillinganddrivingcausesadent,socarefulcasing inspection before drilling installations and operations are necessary.
Super Maxbit Super Maxbit G-Model Operation Manual
TROUBLE SHOOTING
36Super Maxbit Super Maxbit G-Model Operation Manual
MITSUBISHI MATERIALS CORPORATIONOVERSEAS OPERATIONS CENTERKFC bldg., 7F, 1-6-1, Yokoami, Sumida-ku, Tokyo 130-0015, JapanTEL +81-3-5819-8723 FAX +81-3-5819-5259E-Mail: rocktool@mmc.co.jp
JAPAN / ROCK TOOLS
Subsidiaries of MITSUBISHI MATERIALS CORPORATION
http://mrt.mitsubishicarbide.com
MMC HARTMETALL GMBH (Germany)
MITSUBISHI MATERIALS TRADING CORPORATION PERTH BRANCH (Australia)
MITSUBISHI MATERIALS TRADING CORPORATIONSINGAPORE BRANCH (Singapore)
MITSUBISHI MATERIALS CORPORATION OVERSEAS OPERATIONS CENTER(Japan)
MMC METAL DE MEXICO, S.A. DE C.V.(Mexico)
MMC METAL DO BRASIL LTDA.(Brazil)
MITSUBISHI MATERIALS U.S.A.CORPORATION (U.S.A.)
MITSUBISHI MATERIALS (Shanghai) CORPORATION (China)
MITSUBISHI MATERIALS TRADING CORPORATIONSEOUL BRANCH (South Korea)
Australia
South Korea
Singapore
China
U.S.A.
Germany
Brazil
Mexico
MITSUBISHI MATERIALS U.S.A. CORPORATION105 Corporate Center Dr. Suite A, Mooresville, NC 28117, U.S.ATEL +1-980-312-3150 FAX +1-704-746-9595E-Mail: mmusclt@mmus.com
MMC HARTMETALL GMBHComeniusstr. 2,40670 Meerbusch, GermanyTEL +49-2159-9189-32 FAX +49-2159-9189-30079E-Mail: rocktools@mmchg.de
MMC METAL DO BRASIL LTDA.Rua Cincinato Braga, 340 13°- andar.Bela Vista-CEP 01333-010 São Paulo-SP., BRASILTEL +55-11-3262-5095 FAX +55-11-3285-4906E-Mail: mmbr@mmbr.com.br
MMC METAL DE MEXICO S.A. DE C.V.Av. La Canada No.16 Parque Industrial Bernardo QuintanaEl marques, Queretaro.TEL +52-442-221-6136 +52-442-221-6137FAX +52-442-221-6134E-Mail: gonzalez@mmcmex.com
U.S.A.
Germany
Brazil
Mexico
Australia
South Korea
Singapore
China
MITSUBISHI MATERIALS TRADING CORPORATIONPERTH BRANCHLevel1, 468 Belmont Avenue, Kewdale, WA 6105 AustraliaTEL +61-8-6258-7200 FAX +61-8-6258-5614E-Mail: info@mmtau.com
MITSUBISHI MATERIALS TRADING CORPORATIONSEOUL BRANCH#1812, Samsung Cheil Bldg, 309, Teheran-Ro, Gangnam-Gu, Seoul, 06151, KoreaTEL +82-2-3474-2331 FAX +82-2-572-2834
MITSUBISHI MATERIALS TRADING CORPORATIONSINGAPORE BRANCH10 Anson Road, #32-09 International Plaza, 079903 Singapore TEL +65-6221-7233 FAX +65-6325-4220
MITSUBISHI MATERIALS (Shanghai) CORPORATIONRoom 3911, UNITED PLAZA 1468, Nanjing Road West, Shanghai, 200040 ChinaTEL +86-21-6235-0745 FAX +86-21-6235-0741
2019.5.E(5A)