SUPER MAXBIT / SUPER MAXBIT G-MODEL OPERATION MANUAL · When inserting the drill string into the...

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

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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


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


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.


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


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


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


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


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.)


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.


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.


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.


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


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.


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


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


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


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


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


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.


21

Figure18: Encountering Sand formation

Sand formation

Pin

Stress

1. 2.

3. 4.

Feed

Sand formation

Sand formation

×Bad ✔Good


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


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


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


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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


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


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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


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


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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


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


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


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


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.


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.


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.


TROUBLE SHOOTING

36Super Maxbit Super Maxbit G-Model Operation Manual

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2019.5.E(5A)

SUPER MAXBIT / SUPER MAXBIT G-MODEL OPERATION MANUAL · When inserting the drill string into the...

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