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ULTRA MAXBITOPERATION MANUAL
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ULTRA MAXBIT CASING ADVANCEMENT SYSTEM
High speed and straight drilling In a wide range of ground conditions
●ULTRA MAXBIT (UMB) is used for simultaneous drilling and casing in unstable ground formations.
●UMB isalsoapplicable forwide rangeofground conditions such as sand, gravel and boulders and rock.
●Easylockingsystem.
●Thedualbit systemalsoallowsvertical,horizontal, and even inclined drilling.
●Fasterpenetration ratesdue to largebitsurface area contacting formation.
●Variouscasingsystems/modelsareavailableforanyapplications.
-TABLE OF CONTENTS-
A. Technological Features
B. Models and UsageB-1.ULTRAMAXBITCASINGSYSTEMandMODELSB-2.Application
C. Operation C-1.Casingshoeattachment(Weldingprocedure)C-2.RingBitattachment–ThreadconnectiontypeC-3.DrillOperationC-4.UnlockandRelockProcedure
D. Maintenance D-1.CheckingwearatPilotBitD-2.CheckingwearatPilotBitshoulderD-3.Build-upWelding
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4
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9
9121314
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171819
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Figure 1 : Easy lock system
Easy and Speedy lock system
UMBEASYLOCKSYSTEMstructure isconsistsofmalekeyon thepilotbit andfemalekeyontheringbit.
•Easyunlockand re-lock systemwhenflushing to remove cuttings.
•Cuttingscannotstayinfemalekey.
1.Drivethepilotbitthroughthecasingpipe
2.Rotatetolockedpositionwiththeringbit.
3.READYTODRILL
4.Finishdrillingby rotating thepilotbit inoppositedirectionandpullingitout
Unlock and relock procedure see P.14.
1 2 3 4
Female key
Male key
ULTRA MAXBIT OPERATION MANUAL
Technological Features
2
The dual bit system / Various casing systems and models
Thedualbit systemalsoallowsvertical,horizontal, and even inclined drilling.UMB isalsoapplicable forwide rangeofground conditions such as sand, gravel and boulders and rock.
Variouscasingsystems/modelsareavailableforanyapplications.
SeeP.4ModelsandUsage
ULTRA MAXBIT OPERATION MANUAL
3
Dimension explanation
Whenselecting typesofULTRA MAXBIT (UMB),make sure that the type of thesystem (equal to the minimum innerdiameterofaringbit)andcasingpipesize(outer diameter and maximum thickness) areappropriatetoyourconstructionplan.
Foot valve
ShankHammer type
Ultra Max BitPilot bit
Ring bit
Casing shoe
Outer diameter
Inner diameter
MinimumInner diameter
ULTRA MAXBIT OPERATION MANUAL
Technological Features
4
VariousULTRAMAXBITcasingsystems/modelsareavailableforanyapplications.Selectthemostappropriatesystems.IntheTable1,youcanseetherangeofcasingsizesofuseforeachcasingsystems/models.
Standard DTH System
Top Hammer System
Model connection Suitablefor CasingType Application
Single Pass Model
Thread •Softground•Shallowhole Permanent Pilling
construction
Normal Model
Thread •Heavyduty•Deephole Permanent
•Pilling construction• Water well/Geothermal
Multi Use Model
Thegroovemakesthecasingpipepulledeasily.Casingpipeandringsetscanbeusedrepeatedly.
InterLinked Re-Using Retrievable/Temporary
Anchoring, foundation
Model connection Suitablefor CasingType Application
Top Hammer Model
Thread Smallholetunneling Permanent Pilling
construction
B-1. ULTRA MAXBIT CASING SYSTEM and MODELS
ULTRA MAXBIT OPERATION MANUAL
Models and Usage
5
Standardsystem Big Bore system
ex)CasingpipeOuterDiameter:65/8”(168.3mm)InnerDiameter:6.18”(157.3mm)
BigBoresystemhaslargerinnerdiameter.WecandrillthroughwithlargerdiameterDTHsinglebit.
Big Bore DTH SystemModel connection Suitablefor CasingType Application
Big Bore Model
InterLinked Larger BoreDrilling Permanent Water well
/Geothermal
Casing outer diameter
Table 1 : The range of casing sizes of use for each casing systems/models
[In.] 0 3 4 ½ 5 ½ 14 18 40
[mm] 0 76.3 114.3 139.7 355.6 457.2 1,016
3 ½ “89.1mm
Standard – Single Pass (shallow, soft)
Standard – Multi Use (Re-using)
Standard – Normal (deep, heavy duty)
Big Bore
Top Hammer
ULTRA MAXBIT OPERATION MANUAL
Models and Usage
6
Standard system Big Bore system
ULTRA MAXBIT VENTURI MODEL
TheVENTURIMODELhasa followingadvantagesandbestsolutionfordrilling insensitiveground:-Theflushingairdoesnothitdirectlytothebottomoftheborehole.-Minimal air leakage into the formation will not enlarge the borehole.-Thereverseflushingcausesavacuumeffecttoremovethecuttings.-TheefficientflushingandfacegroovedesignedbyCAEsimulationandanalysis.-StandardsystemandBigBoresystemareavailable.
Air Flushing Slimulation
ULTRA MAXBIT OPERATION MANUAL
7
Figure 3 : Forepoling
B-2. Application
Permanent casing - Tunneling / ForepolingForepoling,alsoknownas tubeumbrella,isanapplicationusedtostrengthentunnelroofinbrokenrockconditions.TopHammermodelsareused in theseapplicationswithrelativelyshorthole requirementand thecasing is left in the ground.
Permanent casing drill through- Water well / GeothermalCasing drilling is used inmakingwaterand thermal wells in broken overburden conditions. Thecasingpipe is left in thegroundasaprotectionpipeofthewaterorthermalwell.After drilling through the overburden to the solid bedrock then drilling is continued with singleDownTheHolebit.STEP1:DrillingtobedrockSTEP2:PullingoutpilotbitSTEP3:Re-drillingbedrockbysingleDTHbit
Permanent casing - Pilling and Underpinning/Foundation/Horizontal drillingSoftergroundconditions require that thefoundations of any type of constructionmustbestabilized.Drillingsystemconsistofcasingpipesdrilledthroughtheoverburdento the solid bedrock and filled with concrete.Horizontal drilling is used to lead water, sewage,orcablepipesunderroads,riversandbuildings.There isnoneed tomakeextensive surface cuttings that block the roadsorruinthelandscape.STEP1:DrillingtobedrockSTEP2:PullingoutpilotbitSTEP3:Cementing
RecommendationSoftground/Shallowhole→SinglepassHeavyDuty/Deephole→Normal
Figure 2 : Permanent casing
ULTRA MAXBIT OPERATION MANUAL
Models and Usage
8
RecommendationSoftground/Shallowhole→SinglepassHeavyDuty/Deephole→NormalForlargeboredrillingbedrock→BigBore
Retrievable/Temporary casing - Anchoring, FoundationInsomeoverburdendrillingapplicationsthecasing has to be removed from the ground. Multi-UseModel isperfect forRetrievable/Temporarycasing.ThegroovedesignofMulti-Usemodelmakespulling thecasingpipeeasy.Casingpipeandringsetscanbeusedrepeatedly.
STEP1:DrillingtobedrockSTEP2:PullingoutpilotbitSTEP3:SetupstructuralobjectSTEP4:Pullingoutcasing
Figure 4 : Permanent casing drill through
Figure 5 : Retrievable casing
1 2 3 4
ULTRA MAXBIT OPERATION MANUAL
9
Figure 6 : Welding procedure
C-1. Casing shoe attachment (Welding procedure)
Standard DTH / Top hammer system1. Bevel the end of the casing to an angle of
about30degrees. Be sure that all surfaces to be welded
are c lean and f ree f rom any d i r t ,contamination including moisture.
Pre-heat theendof thecasingshoe to100 degrees (Celsius), 212 degrees(Fahrenheit).
2.Insert thecasingshoe inside thecasingpipe.Besure thecasingshoe is in thecenterofthecasingpipe.
3.Temporary tack-weld the casing tocentralize.Tackweldingshouldbedonediagonally.
4.Whenwelding on the circumference,normallythreepassesarerecommended.Takesufficient time toweld thecasingusing the correct welding rod.
5. After welding, use a grinder to smooth theweld.Thiswillhelpwhile installingcasing so not to drag drill cuttings into the borehole on the outside of the casing and causing drag when installing.
6.Recommendation:Plugweldsordiamondscut in the casing to strengthen the weld fromcasing todriveshoe.Please referfollowing table for plug size and thenumberofplugs.
1
2
3
4
5
6
Cleaning at all surfaces
30°
Casing
Casing Shoe
1st
2nd
3rd 4th
Tack welding should be done diagonally
Plug welding
ULTRA MAXBIT OPERATION MANUAL
Operation
10
Figure 8 : Fillet welding
Figure 7 : Big Bore ring sets attachment and welding
Big-Bore DTH system1. Be sure that all surfaces to be welded
are c lean and f ree f rom any d i r t ,contamination including moisture.
Pre-heat theendof thecasingshoe to100 degrees (Celsius), 212 degrees(Fahrenheit).
2.Put the ringsets (thecasingshoeandthe ring bit) to the casing. Be sure the casing shoe is in the center of the casing pipeandthereisnogapbetweentheringbit and casing shoe to make the ring bit rotatesmoothly.See Figure7.
3.Temporary tack-weld the casing tocentralize.Tackweldingshouldbedonediagonally.
4.Whenwelding on the circumference,normallythreepassesarerecommended.Takesufficient time toweld thecasingusingthecorrectweldingrod.Thewidth(W)of thefilletweldshouldbeduplicateof the height (H) of the fillet weld (W = 2H). See Figure8.
Be sure that the ring bit can rotate smoothly(rotatebyhands)afterwelding.See Figure7.
5. After welding, use a grinder to smooth theweld.Thiswillhelpwhileinstallingthecasing to not drag drill cuttings into the borehole on the outside of the casing and causing drag when installing.
6.Recommendation:Plugweldsordiamondscut in the casing to strengthen the weld fromcasing todriveshoe.Please referfollowing table for plug size and thenumberofplugs.
✔Good
×Bad
Ring Bit
Casing
Casing Shoe
Check that the ring bit can rotate smoothly
No Gap
The ring bit cannot rotate
Gap
W = H x 2 W : Width
H : Height
ULTRA MAXBIT OPERATION MANUAL
11
NOTE: Thecasingshoemustbecorrectlywelded to thecasing inorder to carryoutasuccessfulcasingdrillingoperation. If thecasingshoe isnotweldedcorrectly to thecasing,possibleprematurefailurescouldhappen.Casingshoecouldseparatefromthecasing,causingholedeviationordamagetotheshoulderofthepilotbit.
Figure 9 : Alignment for the first casing pipe and casing shoe
✔Good ×Bad ×Bad
Gap between casing and the casing shoe
Tilting connection
ULTRA MAXBIT OPERATION MANUAL
Operation
12
NOTE: 1.Donotapplyagreasewhenfitting
thethread.Sandorgravelmaybecaughtbythegrease.
2.Check thenominal typeofbothRing bi t and casing shoe.Aproductwithadifferentnominaltypecannotbeused.
Figure 10 : Thread connection
C-2. Ring Bit attachment -Thread connection type
Attachment of the ring bit is completedonlybyfittingthethreadtothecasingshoewhichispre-weldedtothefirstcasingpipe.Interlinked type(MultiUseModelandBig-BoreModel)isassembledinthefactoryandcannot be disassembled.
-DTHspecification-MostoftheDTHHammerrotateclockwise. The ringbit andcasingshoeare fitwithLeft-hand Thread.
-TopHammerspecification-M o s t o f t h e To p H amme r r o t a t ecounterclockwise.Theringbitandcasingshoe are fit with Right-hand Thread.
ULTRA MAXBIT OPERATION MANUAL
13
Figure 11: Rotation speed of Bit
C-3. Drill Operation
Compressor pressureNormaloperatingpressureisfrom10.5barto13.8bar(150psito200psi).Consider thedepthofundergroundwaterwhendrillingthroughthelayer.Incaseof30m(90ft.)depth,add3.1bar(45psi)totheairpressure.Donotsetover21bar(300psi).NOTE: In loose formationsuchassand,compressorcanbesetto7bar(100psi).
FlushingFor proper hole cleaning, verify that anadequate up-hole air velocity can beobtained.Anannularvelocityof3000feet-per-minute(1000meter-per-minute)ormoreisrequired.Usethis formulatocheckwhatthevelocitywillbe:
Q–SupplyAirvolumeD–Insidediameterofcasingpiped–Outsidediameterofthedrilltube
Pull down forceThemoderatepulldownforceonpilot is9kg/mm(500lbs./inch)
Rotation speedAlwaysdrillconsideringground formationsencountered as they are dri l led, hardformations–slower rotationspeed,softerformationsrotationspeedisalittlefastertoachieve smooth drilling and not binding.Refer to the following figure for normalrotationspeeds.Select therangeofuniformrotationduringdrilling.The normal rotation speed range from 10 to 80 rpm, all depending on the device size and formation being drilled.Higher rotation speedswillwear thebitprematurelyandcausebitfailure.
100
80
60
40
20
04 8 12 16 20 24 28 32
Rotation Speed
Rot
atio
n Sp
eed
(rpm
)
Nominal Size (in.)
Velocity (ft/min) =
Velocity (m/min) =
(183.4) × Q (Ft3/min)(D2(inch)- d2(inch))
(1273500) × Q (m3/min)(D2 (mm)- d2(mm))
ULTRA MAXBIT OPERATION MANUAL
Operation
14
C-4. Unlock and Relock Procedure
TheULTRAMAXBITenables thepilotbitandringbit tobeeasilyunlocked(separated)andrelocked(reconnect)evenduringdrilling.Thismechanismfacilitatesa flushingactionandenhancesefficiencyofthesubsequentdrilling.Followtheprocedurebelowtounlockorrelockthepilotbitandringbit.
Unlock procedure1.Afteryouhavedrilled torequireddepth.
Flushtheholewhilelightlymovingthebitupanddownwiththebitlocked.
2.Keepthepilotbitatholebottom.3.Rotate (a few revolutions) slowly to
unlockedpositionwiththeringbit.4.Raisethepilotbit.5.Performtheflushingactionwhilerotating
thepilotbitinoppositedirection.
Figure 12 : Unlock procedure
NOTE: Whenpullingcasingpipe,useelevatorson the casing. See P.8 Temporary casing applications UseofthepilotbitortheringbitisNOTrecommended. There is a r isk that the male keybreakagedue topulling load ison themalekey.
Figure 13 : DO NOT USE the pilot bit when pulling casing pipe
1
4 5
2 3 Rotate a few revolutions
×Bad
ULTRA MAXBIT OPERATION MANUAL
15
Relock procedure1. STOP AIR SUPPLY.2.Lower thebitslowlybyrotating thepilot
bitslowly.3.Keepthepilotbitatholebottom.Rotate(a
fewrevolutions)slowlytolockedpositionwith the ring bit.
4.Slowly raise thepilotbit toconfirm thatthepilotbitandtheringbitarelocked.
5.Supplyairandrestartdrilling.
NOTE: If the air supply is not stopped, thepistonofDTHhammerwillcontinue tooperateandpercussionwilloccur.Thismaycause:
A.Themalekeyofthepilotbitpercussiontheringbitandpushitforward.
B.Themalekeycanbedamaged.
Ensure that theair supply is stoppedbefore lowering the bit. See Figure15.
Figure 15 : Relock with Air supply
Figure 14 : Relock procedure
1
3 4 5
2Stop Air Supply
Percussion
×Bad
A.
B.
With Air Supply
Push the Ring bit forward
Percussion
Damage
ULTRA MAXBIT OPERATION MANUAL
Operation
16
Figure 16 : Failure to relock
Figure 17 : How to deal with when failure to relock caused.
When the ring bit goes forward to the casing pipe, failure to relockcanbecaused(Themalekeymaybestuckorthepilotbitcannotrotate as show in Figure16)
Carefully followtheprocedurebelowwhenfailure to relock is caused. See Figure17.
1.Lowerthebitbyrotatingslowlytolockedposition.
2.Stoprotation.3.Supplyasmallvolumeair/lowpercussion
tomovethepilotbittothelockedposition.4.Keepthepilotbitatholebottom.Rotate
(a fewrevolutions)slowly to the lockedpositionwiththeringbit.
5.Slowly raise thepilotbit toconfirm thatthepilotbitandtheringbitarelocked.
6.Supplyairandrestartdrilling.
1
3
4
2 Stop rotation
Low percussion Low percussion
×Bad
ULTRA MAXBIT OPERATION MANUAL
17
Figure 18 : Checking wear at Pilot bit
D-1. Checking wear at Pilot Bit
A: Carbide buttons and base material1. If thewearwidthat thetipend ishalfof
thechipdiameteror less,regrind thetipend.
2.Ifthebasematerialaroundthetipiswornandinapyorrhea-likecondition, thentipretentiondecreasesandpopoutswilloccur.
B: Pilot bit shoulders - give blows/percussions to the ring bit and the casing shoe1.Use the template to check thewear.
15mm of wear width on the part totransmit thepercussionenergy indicatesit has reached the end of its lifetime.
2.Drillingconditionsand improperuseofthesystemmaycauseabnormalwearofthepilotbitshoulder.
3.Removetheburronthepilotbitshoulderwith a grinder.
C: Male key- give rotation energy to the ring bit1.Wearofhalf thesplinewidth indicates it
has reached the end of its lifetime.2. Improper lockingmaycauseabnormal
wearonthemalekeyormaketheringbitlifeshorter.Seelockingprocedurepage**
Thepilotbitgivespercussion/rotation/feedenergytotheringandpercussionenergytothe ground.Wear on the face of the bit causes the male key towear, andeventually thepilot bitreaches the end.Continuouslyusing thebitwhich reachestheendmaycausedrillingtrouble.Conducting a periodic wear check isrecommended.
A: Carbide buttons/Base materials
B: Pilot bit shoulder
C: Male key
Striking faces
Contact faces
ULTRA MAXBIT OPERATION MANUAL
Maintenance
18
Figure 19 : Check the wear at pilot bit shoulder.
Figure 20: Check the wear width
D-2. Checking wear at Pilot bit shoulder
Youcanusethecheckingtemplatetocheckthewearatpilotbitshoulder.Whenthewearwidthattains15mmitmayshow wear limit.Pleasestopusingthepilotbitandfollowthebuild-uprepairprocedure.
Figure 21 : Build-up welding repair of the pilot bit shoulder (cross-section)
D-3. Build-up Welding
In the case of wearing on the pilot bitshoulder,build-upweldingrepairisneeded.Carefullyfollowtheproceduretoperformthebuild-upweldingrepairortaketoaweldingshop that cando this for you.Otherwiseheat treatment issues will cause welding cracks.
1.Pre-heat the basematerial to 200 to300degreeCelsius,392 to572degreeFahrenheit.
2.Weldthemateriallayeronthesurfaceofthe base material.
3.Graduallycoolthepilotbit.Neverrapidlycool it.
4.Applya finishingprocess.Theangleofthedeviceshouldershouldbe30degree.
NOTE: Product repairedwith thebuild-upwelding cannot be guaranteed.
Before Use
Later Stage of Wear
Before Use
Male keyPilot Bit Shoulder
Wear Check Template
10mm
15mmWear Limit
30 degree
Finishing process
Pilot bit shoulder – Base material
ULTRA MAXBIT OPERATION MANUAL
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