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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

1

4

47

9

9121314

17

171819

1

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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