DTH Introduction & Hammers 20041

DTHDTH

Hammer Hammer

DrillingDrilling

IntroductionIntroduction

A type of DTH hammer was patented in the US

by Royal Lee of Lee Engineering Research Company,

Milwaukee, Wisconsin.

DTH Hammer History

1928

DTH Hammer History

1954

Andre Stenuik in Belgium applied for a patent in London.

This DTH hammer is considered to be the fore-father

for the modern DTH hammer.

DTH Hammer History

1960

Several different DTH Hammer designs were

launched during this period by companies such as

Mission, Halco, Ingersoll Rand,

Atlas Copco, and Bohler & Co.

The basic design of DTH hammers has not changed much.

But operating air pressures have more than doubled…

150 psi (10 bar) to 350 psi (24 bar).

DTH Hammer History

1970

DTH Hammer History

1990

In addition to the air pressures more than doubling

so to has the number of DTH hammer manufacturers.

To stay ahead of the pack, Mission launches the

XL generation of hammers.

Mirror Impact TechnologyDeveloped by Rainer Beccu PhD.

at SRT Houston Facility

In 2000 Driltech Mission introduced the

DTH Hammer History

1999

DTH Hammer History

2003

500 psi air compressors are now entering the market

and one of our challenges is to develop tools to

withstand these pressures.

Drilling Methods and Applications

130 ft.40 M

12,000 ft.4,000 M

32000 ft.10,000 M

1 2 3 4 5 6 8 12 15 17.5 24 33 43

HOLE DIAMETER IN INCHES

Hard Rock

Hard Rock

Hard Rock

Soft Rock

Soft Rock

Soft Rock

DTH Hammer Drilling

Rotary Drilling

Top Hammer Drilling

Surface Mining

Construction

Mineral Exploration

Oil & Gas

Underground Mining

Waterwell

25 51 76 102 127 152 203 304 381 444 610 8381092

DTH and Top Hammer

Uniform penetration rate

Can drill to greater depths

Generally straighter holes

Safer in broken ground

Lower noise level

Longer drill string life

DTH

Top Hammer

20 kW

18.4

16.9

15.6

14.4

20 kW

20

20

20

20

8% loss / coupling

DTH and Rotary Drilling

• Faster drilling in hard rock

• Lower capital cost

• Capable of large diameters

• Minimum hole deviation

• Lighter drill pipe

• Lighter rig

• Less torque and pulldown

DTH

ff

PSIPSI

RotaryFFPSIPSI

Pressure – Penetration Rate

15 m /hr50 ft /hr

30 m /hr100 ft /hr

45 m /hr150 ft /hr

150 PSI 250 PSI 350 PSI

Each time the Mission 6 piston hits the bit, it is the same as being dropped 16 feet.

16 Ft. (4.9m)

40 lb. (18kg)

876 ft.lbs. (1187Nm)

Load On Bit At Impact

Piston traveling at ……..38 ft/sec (11.5 m/sec)

Blow Energy……………..876 ft.lb. (1187 Joules)(Nm)

Time of Impact is approximately only …..

0.0002 SecondsWhich is approximately the time it takes the shock wave to go to the top of the piston and back.Decelerating the piston so fast results in huge impact loads on top of the bit.

What is Important in the Drilling System

What is important in the drilling system Compressor

Air Delivery Volume CFM Maximum Operating PressureGenerally the compressor

should be sized for economical operation when drilling a particular hole size.

A larger compressor will only give better performance if the hammer can use this air efficiently

What is Important in the Drilling System Hammer

Air Consumption Maximum Operating Pressure Generally the hammer should

be selected so that all the air from the compressor is used while still maintaining the highest air pressure possible.

This will use the capacity of the compressor to it’s maximum

What is Important in the Drilling System Rig

Rod Length Control of Weight on Bit Rotary Speed

Drill Rigs can be very sophisticated but their efficiency can be greatly affected by hammer and bit selection

Their biggest contribution to productivity comes from other areas such as rod handling, set up time and ease of operation.

What Features Most AffectHammer Performance

1. Suitable compressor (flow give pressure)

2. Piston diameter

3. Piston impact energy and frequency

4. Piston & Bit energy transfer

5. Correct diameter of drill pipe

Comparing Hammers

ProductivityPenetration rateReliability

Hammer life

Hammer cost per meter

Total Drilling Cost per meter

DT

H C

ost Calculator.xls

Matching Titon & Mission

Drilling Parameters1. Rock Type

2. Feed Pressure

3. Rotation Speed

4. Flushing

5. Air pressure

Characteristics of the rock to be drilled

namely :-

- DRI – Drilling Rate Index

- Compressive strength

- Silica Content

- Competency – solid, broken, faulted

Rock Type

Drilling Rate Index

Most accurate means of comparing rock drillability

for percussive drilling.

Considers brittleness of rock.

More accurate than using crushing strength (UCS).

High DRI = Easy to drill Low DRI = Hard to drill

Rock is the leading cause of Hammer & Bit problems

Rock Type

ANORTHOSITE GRANITE GNEISS

AMPHIBOLITE

MICA GNEISS

QUARTZITE LIMESTONE MARBLE

DIABASE PHYLLITE

SANDSTONE PEGMATITE

DIORITE

GABRO SLATE SHALE

MONTSONITE

GREYWACKE NORITE

GNEISS GRANITE MICA SCHIST

GNEISS

TACONITE GRANITE

Drilling Rate Index

10 20 30 40 50 60 70 80 90

Location Alachua Tamrock testmine, Finland

Rock Type Texas PinkGranite

MyllypuroGranodiorite

Drilling Rate Index 49 43Cerchar Abrasivity Index, CAI 6.0 6.0Vickers Hardness Number,VHNR

821 820

Density (g/cm3) 2.59 2.65Brittleness Value, S 20 53 41Sievers J value, SJ 6.2 12.0

For example a Mission6 hammer tested in Alachua at 350psi (24bar) anda 6-1/2” (165mm) bit would drill at 192 ft/hr (58.5m/hr). In the Tamrock TestMine we could expect a penetration rate of:-192 ft/hr * (49/43) .8 = 175 ft/hr58.5 m/hr * (49/43) .8 = 53.3 m/hr

For further reference to these numbers see pages 10-17 of Tamrock’sUnderground drilling handbook.

Drilling Rate Index

Penetration Rate vs. Bit Diameter

Rate of Penetration "A" = ROP "B" x

Dia. "B”

( )Dia. “B”

= 126.8 feet/hr.

( )

3

3

Penetration rates for different bit diameters may be calculated using the following formula.

Assume:

Dia. “B” = 6.5”Dia. “A” = 6.125”

ROP “A” = 116 x 6.66.125

Bit Dia vs ROP Calculator.xls

-Compressive Strength 12,000 – 60,000 psiUsually called “hardness”

-Tensile Strength indicates brittlenessNot normally considered except where rock is reluctant to break apart such

as a recrystallyzed shale

-Silica Content – 0% - 100%A higher silica content the faster the carbide and steel wear

-Competency – solid, broken, faultedBroken & Faulted tends to ‘lead’ the drill string and cause “I’m Stuck” and

“The bit just shanked”

Rock Type

COMPRESSIVE STRENGTHSof

COMMON ROCK TYPESDiorite

Gabbro

Gniess

Granite

Limestone

Marble

Quartzite

Sandstone

Slate

Shale

Taconite

psi '000 10 20 30 40 50 60

mPa 69 138 207 276 345 414

Diorite

Gabbro

Gniess

Granite

Limestone

Marble

Quartzite

Sandstone

Slate

Shale

Taconite

% Silica 10 20 30 40 50 60 70 80 90 100

AVERAGE SILICA CONTENTSof

COMMON ROCK TYPES

GOLDEN RULE OF THUMB

HARDER ROCK requires more impact

energy and higher torque

SOFTER ROCK requires higher feed rates

and better flushing

MORE ABRASIVE ROCK requires

more consumables $$

FeedPressure

Feed Pressure

Keeping the bit closed against the driver sub to transfer most energy

Influenced by - Operating Air pressure

-Rock type

Also known as Hold Down or Pull Down

Feed PressureInsufficient Weight on Bit

Unable to Hold Constant Air PressureRattling or Erratic DrillingDrop in Rate of PenetrationDamage to Bit and Hammer

Excessive weight on bit:Does Not Increase Penetration RateAccelerates Bit WearRaises Rotation Motor LoadCan cause deviation in hole

Weight on Bit needs to be monitored and adjusted by the Driller

RotationSpeed

The distance the buttons on the bit are moved

between each blow of the piston. The optimum

distance generates the biggest chips or cuttings

and gives the most efficient drilling.

Affected by :-

-Rock Type

-Air Pressure (piston blow energy)

-Bit Design (face shape & button size)

Rotation Speed

Rotation Speed

Approximate Blows per Minute

at Maximum Operation Conditions

Pressure Blows Per

Hammer (PSIG) Minute

M30 300 2375

M40B 350 2000

M50/55 350 1920

SD-6 350 1520

M60/M65 350 1890

SD-8 350 1589

SD-10 250 1335

SD-12 250 1501

Rotation Formula:

RPM = PM x f

D x 3.1416 (

PM = Peripheral Movement (mm)F = Piston FrequencyD = Bit Diameter (mm)

PM must vary according to the formation being drilled and design of bit.The harder and more mineralized the rock, the smaller the value of PM.Example:

165 mm (6-1/2”) bitM65 @ 350 psi - 1890 BPM35000 psi (250MPa) Granite - PM = 8 mm

RPM = 29 RPM ORRotation Calculator.xls

Rotation Speed

Adjust rotation speed so

the RIG doesn’t shake, rattle and roll,

the cuttings are as big as possible

and

rotation is not jerky

Flushing

Getting cuttings out of the hole…..

Affected by

-Annulus size

-Bit design

-Hole depth

-Water in the hole

Flushing

Recommended minimum

up-hole velocity

is

5,000-7,000 ft/minute

(25-35 m/s)

Flushing

Where AA is the annular area = .785 x (Dh2 – Dp2)

Annular velocity should be 5,000 Ft/Min or more.

Excessive annular velocity accelerates wear. To calculate annular velocity, use this formula:

Annular Velocity = SCFM x 144 (Ft/Min)AA

Dh = Hole Diameter (inches)Dp = Drill Pipe Diameter (inches)

Velocity Calculator.xls

Make sure that you’ve got

cuttings coming out of the hole

while you’re drilling.

Otherwise…..

Flushing

YOUR STUCK !!

Just like a gardener,you planted your hammer and bit!

Water InjectionAdvantages Reduce Dust Reduce Operating Temperature Stabilize Hole Wall Better Control Cuttings Removal

Disadvantages May Increase Need for Oil Injection Can Cause Corrosion May Cause Solid Contamination

FoamAdvantages

Improves flushing Dissipates water (aerates) Stabilizes hole Reduces annular velocity requirements

Disadvantages

Cannot use oil injection – kill foam Will Cause Corrosion – dissolves oil Solid Contamination Added Maintenance – strip hammer after use

November2003

April2001

May2003

Feb2000

June2004

Mission Hammer Introduction Schedule

New Shank New Shank

XL32 - December ‘98RC5 - December ‘00XL5.5 - December ‘02SD4 - December ‘02XL4 - December ‘02XL3 - March ’04XL5 - September ‘04SD5 - December ‘04XL6 - June ‘04XL8 - June ‘04SD6 - December ‘05SD8 - December ‘05SD10 - December ‘05SD12 - December ‘05XL12 - June ‘05

Obsolescence Schedule

HAMMERS OBSOLESCENCE SCHEDULE TO DECEMBER 2005

Item Jun '03 Sep '03 Dec '03 Mar '04 Jun '04 Sep '04 Dec '04 Mar '05 Jun '05 Sep '05 Dec '05XL3 Hammers Discontinued - upgrade to M30

Parts Parts built to customer order only DiscontinuedBits Bits remain available for customers using other hammers with IR3.5 Shank

Guide Devices Guide devices remain available for customers using other hammers with IR3.5 ShankSD4 Hammers Discontinued - upgrade to M40B

Parts Discontinued - upgrade to M40BBits Bits remain available for customers using other hammers with SD4 Shank

Guide Devices Guide devices remain available for customers using other hammers with SD4 ShankXL4 Hammers Discontinued - upgrade to M40B

Parts Discontinued - upgrade to M40BBits Discontinued - upgrade to M40B

Guide Devices Discontinued - upgrade to M40BSD5 Hammers Discontinued - upgrade to M50/M55

Parts

Bits Bits remain available for customers using other hammers with SD5 ShankGuide Devices Guide devices remain available for customers using other hammers with SD5 Shank

XL5 Hammers Discontinued - upgrade to M50/M55Parts Parts built to customer order only

Bits Bits built to customer order onlyGuide Devices Bits built to customer order only

XL5.5 Hammers Discontinued - upgrade to M50/M55Parts Discontinued - upgrade to M50/M55

Bits Discontinued - upgrade to M50/M55Guide Devices Discontinued - upgrade to M50/M55

SD6 Hammers Current Product - Only model available is 32-SD6/4Parts Current Product

Bits Current ProductGuide Devices Current Product

XL6 Hammers Only model available in 32-XL6HD/4C/BC Discontinued - upgrade to M60/M65Parts

Bits

Guide Devices

Parts

Bits Current ProductGuide Devices

Parts

Bits Current ProductGuide Devices

Parts Current ProductBits Current Product

Guide Devices

Parts

Bits Bits remain available for customers using other hammers with SD8 ShankGuide Devices


Guide Devices


Guide Devices

Parts

Bits


Parts

Bits Bits remain available for customers using other hammers with IR3.5 ShankGuide Devices

Parts Discontinued - upgrade to M40BBits Bits remain available for customers using other hammers with SD4 Shank

Guide Devices

Parts Discontinued - upgrade to M40BBits Discontinued - upgrade to M40B

Guide Devices

Parts

Bits Bits remain available for customers using other hammers with SD5 ShankGuide Devices

Parts

Bits

Guide Devices

Parts Discontinued - upgrade to M50/M55Bits Discontinued - upgrade to M50/M55

Guide Devices


Guide Devices Current ProductXL6 Hammers Only model available in 32-XL6HD/4C/BC Discontinued - upgrade to M60/M65

Parts Parts built to customer order only DiscontinuedBits Bits built to customer order only Discontinued

Guide Devices Bits built to customer order only DiscontinuedMission6 Hammers Discontinued - order new M60/M65 Hammer or upgrade with rebuild kit

Parts Rebuild kit only DiscontinuedBits Current Product

Guide Devices Current ProductMission6W Hammers Discontinued - order new M60/M60W Hammer or upgrade with rebuild kit

Parts Rebuild kit only DiscontinuedBits Current Product

Guide Devices Current ProductSD8 Hammers Current Product


Guide Devices Current ProductXL8 Hammers Discontinued - upgrade to M85

Parts Parts built to customer order only DiscontinuedBits Bits remain available for customers using other hammers with SD8 Shank

Guide Devices Guide devices remain available for customers using other hammers with SD8 ShankSD10 Hammers Current Product


Guide Devices Current ProductSD12 Hammers Current Product


Guide Devices Current ProductXL12 Hammers Current Product Discontinued - Replace with SD12

Parts Current Product Parts built to customer order onlyBits Current Product Bits (IR112) built to customer order only


Item Jun '03 Sep '03 Dec '03 Mar '04 Jun '04 Sep '04 Dec '04 Mar '05 Jun '05 Sep '05 Dec '05

What is

Mirror

Impact

Technology?

20 kg

20 kg

It is the optimumTransfer of Energy

“Too little” energyis not

productive

“Too much”energy

is wasted

“Just right” energyis optimum results

Imagine two balls on a snooker table

Heavy HeavyLight Light

Both balls continue Bounce back

Stop Continue

1.Top Sub

2. Piston Case

3. Feed Tube Assembly

4. Piston

5. Guide Sleeve

6. Bit Retainer

7. Driver Sub

8. Button Bit

Simple Design

1.

2.

3.

4.

5.6.

7.8.

Check valve

M65 Features & Benefits

Thicker Piston CaseM6 new diameter 5.75”M65 new diameter 5.9”

Results inLonger Wear Life

Longer Driver SubM6 = 1.5”

M65 = 2.5”Results in

Longer Wear Life

Plazma Nitride SurfaceResults in

Stronger Piston

Longer Top Sub andSmaller Wrench Flats

Results inLonger Wear Life

Choke in the Feed TubeSuits wider range of

compressor sizes

Hammer32-M65/04C

32 = Hammer

M30 = Mission30M40B = Mission40BM50 = Mission50M55 = Mission55M60 = Mission60M60W = Mission60WM65 = Mission65M80 = Mission80M85 = Mission85

Top Sub Configuration16 = 2-7/8 API04 = 3-1/2 API Reg55 = 3-1/2 Beco77 = Cubex Number 2419 = 4-1/2 API17 = Blank

C = Retrac Buttons

Hammer Part Numbers

Top Sub33-48001/16A

33 = Top Sub

48 = Mission40B Series58 = Mission 50 Series68 = Mission 60 Series88 = Mission 80 Series 001= Standard Duty

002= Heavy Duty

A = Assemblywith O-RingThread Type

16 = 2-7/8 API04 = 3-1/2 API55 = 3-1/2 Beco19 = 4-1/2 API77 = Cubex #2417 = Blank

Hammer Part Numbers

Piston Case35-48001A

35 = Piston Case

48 = Mission40B Series58 = Mission 50 Series68 = Mission 60 Series88 = Mission 80 Series

001= Standard Duty002= Heavy Duty

A = Assembly with Piston Retaining Ring

Hammer Part Numbers

Driver Sub34-48001A

34 = Driver Sub


001= Standard Duty002= Heavy Duty

A = Assembly with O-ringNew Mission Hammers being designed

without o-ring!

Hammer Part Numbers

Piston36-48081

36 = Piston


Heat Treatment Method041= Salt Bath Nitride081= Plazma Nitride

Hammer Part Numbers

Feed Tube37-48001A

37 = Feed Tube


001= Blast Hole301= Water Well

A = Assembly with Retaining Pin

Hammer Part Numbers

EZ Help Part Number Guide

32- Hammers

33- Top Subs

34- Driver Subs

35- Piston Cases

36- Pistons

37- Feed Tubes

38- Various minor parts

39- Check Valve Guides

42- Bits

47- Foot Valve

56- Tuning Ring

80- Guide Devices

81- Pilot Bits

82- Reamers

84- Casing Shoes

DTH Introduction & Hammers 20041

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