Hyper 66DH/DHD360
Contents
1. oscillates at 930 bpm at 150 psi 10bar It is therefore extremely important that an adequate supply of the correct type of rock drill oil is constantly fed to the hammer whilst it is operating Failure to do so will quickly lead to excessive component wear and if the oil supply is cut off for any reason the piston will quickly seize inside the wearsleeve resulting in irrepairable damage to both components An air line lubrication system should be installed preferably on the drill rig The lubricator reservoir should be of sufficient capacity to supply the required volume of rock drill oil for a full shift It is equally important that the lubricator system must be adjustable and have a visual check to ensure the lubricator does not run out of oil As a good general guide all Bulroc hammers require a third of a pint of oil per 100 cfm of air through the hammer 0 07 litre per meter cubed Eg Hyper 66DH operating at 150 psi 296 1 pint per hour 10 3 bar 8 4 M 0 56 litre per hour The amount of lubrication oil should be increased by 50 when drilling with water or foam When new drill pipes are added to the drill string it is recommended that a half pint quarter of a litre of rock drill oil is poured into the pipe to provide a good internal coating and helps prevent the hammer from running dry at any time The grade of rock drill oil will be determined by the ambient temperature at the drilling site Ifthe ambient tempera2. 0 CFM 25 Gu Minimin 900 800 20 Cu Mtr min 600 CFM 15 Cu Mtr min i oolid Choke Plug fitted as Son Cid standard i 10 Cu Mtrimin 300 5 Cu Miimi 200 CFM EO e Ze ER S 8 2 E 2 10 BAR 15 20 BAR 25 BAR Additional Flushing A solid choke is fitted at the end of the control tube In certain drilling conditions extra flushing air may be required to overcome increased back pressure and to maintain sufficient up hole velocity to ensure efficient hole cleaning In such conditions the solid choke plug can be replaced with an open hole choke of a particular size or can be removed completely to give the maximum amount of additional live flushing air depending on the operating pressure The top two tables show the extra flushing air that can be passed through each choke at different pressures The bottom two tables show the total air required for the Hyper 66DH hammer with different chokes and at different operating pressures Extra flushing air for a choke in cubic feet per min Extra flushing air for a choke in cubic metres per min 430 ps os 75 os 1206 1438 162 1 2026 Total air requirements for a choke in cubic feet per min lg Total air requirements for a choke in cubic metres per min STRIPPING THE HAMMER 6 After extensive drilling the chuck and the back head might become too difficult to loosen on a Hammer Bench Splitter or the drill rig In such conditio
3. HYPER 66DH MAINTENANCE OPERATING AND SERVICE MANUAL DHD360 Geothermal Water Well CONTENTS Introduction Components Parts List Specification Air Consumption Stripping the Hyper 66DH Checking for wear amp damage Rebuilding the hammer APPENDICES Clamp Positions INTRODUCTION 1 The Bulroc Hyper 66DH is a strong robust valveless DTH hammer of a simple and straightforward design to provide maximum performance with a minimum of maintenance The Hyper 66DH is specifically designed to operate efficiently at air pressures between 10bar 150psi and 30 bar 430psi and to operate efficiently at depths overcoming high heads of water The combined control tube diverter and check valve minimises the number of component parts reducing the overall length of the hammer for ease of handling The Hyper 66DH is supplied as standard with a check valve arrangement that is designed to help maintain pressure inside the hammer when the air is turned off for rod changing and so prevent contaminated water from entering the hammer The standard backhead connection on the Hyper 66DH is 322 API reg pin The Hyper 66DH hammer is designed to give optimum performance with minimum air consumption and is fitted as standard with a Solid Air Choke However for particularly deep holes or excessively high inflows of water a selection of chokes are supplied with each hammer The Choke Plug can be completely removed if necessary givin
4. Piston 10 with Rock Drill oil and slide it into the Backhead 1 end of the Wearsleeve Ensure the Piston striking face enters first 5 Slide the Control Tube into the Wearsleeve 6 Insert the Spring 4 into the Check Valve 3 and then slide the assembly into the Control Tube 7 Cover the threads of the backhead with a copper based grease and insert it into the backhead end of the wearsleeve 15 by hand tightening 8 Should the backhead be removed the wearsleeve should not be inverted past the horizontal position unless it is necessary to remove the piston Note Ensure both the backhead and chuck are fully torqued up prior to commencing drilling 11 BUTTON BIT FOOT VALVE Foot Valve Diameter 38 1 mm 1 500 Protrusion Height 49 27 mm 1 940 The Bulroc Hyper 66 DHD 360 hammer is designed to be used with foot valves The correct foot valve must be fitted otherwise the performance of the hammer will be seriously affected Using a foot valve which is larger in diameter than the specified will result in the rapid failure of the foot valve Using a foot valve which is smaller in diameter than the size specified will greatly reduce the performance of the hammer The protrusion height is also important and to ensure the correct height and prevent damage when replacing the foot valve it is recommended the correct insertion tool is used Bulroc Part Ref BBFVITO93 LUBRICATION 12 The Hyper 66DH piston
5. aned inspected and re oiled prior to use to be sure of smooth drilling 14 TROUBLESHOOTING PROBLEM PROBABLE CAUSE REMEDY INOPERATIVE DRILL Insufficient air pressure Check compressor discharge and increase to operational value SLOW PENETRATION Insufficient air pressure Increase discharge pressure Dull drill bit Re grind or change bit Worn drill parts Replace worn parts Too much or too little lubrication Check oil level and if necessary adjust lube needle value Dirt in drill Strip and clean LOW RETURN AIR VELOCITY Insufficient hole flushing air passing Drill or increase hole size through the through hammer piston SPASMODIC OPERATION Oo eee A CHUCK RELEASE WASHERS UW 22 u D 2222222 CHUCK RELEASE WASHERS HAMMER MODEL HYPER 66DH 0 310 7 87mm 0 330 8 38mm Chuck Release Washers are fitted to the Bulroc Range of Hyper Hammers to assist the removal of the Chuck from the Wearsleeve after drilling The Chuck Release Washer is manufactured from a composite material that reduces the friction between the lock up faces on the Chuck and Wearsleeve making it easier to overcome the tensional loading applied to these parts during the drilling process Due to the forces applied to the Chuck Release Washer you may find that its thickness W is reduced during the drilling cycle and it is therefore recommended that a new Washer be fitted each time the Chuck is removed It is possible thaton some of the lar
6. g a through hole size of 1 4 6 3mm 0 Geothermal Water Well ALWAYS THINK SAFETY FIRST This manual is published by and copyright O of Bulroc UK Ltd All Rights Reserved Always operate your Bulroc drilling equipment according to the instructions contained within this operating manual Further copies of this manual can be downloaded from the Bulroc website www bulroc com For urgent support or sales enquiries call Bulroc on 44 0 1246 544700 or Skype BULROCUKSALES E amp 2 COMPONENTS Backhead Breakout Washer Backhead Compression A Di Wearsleeve Check Valve Spring Control Tube iston Retaining Ring Bush O Rings Bit Retaining O Ring Bit Retaining Ring Breakout Washer PARTS LIST Ref Description Part Number Qty 6 ChokeSet amp allankey CT HSHOGDH1Q D 8 Buh 5 D 9 Bush O Ring HSH66DH87 Piston HSH66DH03 Piston Retaining Ring HSH6132 Bit Retaining Ring HSH66DH37093 Chuck HSH66DH35093 Breakout Washer HSH66DH26 Wearsleeve HSH66DH0093 Bit Retaining O Ring HSH66DH37A093 QUICK ORDER CODES Complete Hammer eremo SPECIFICATIONS 4 Hammer Diameter 5 5 141 Weight less bit Length less bit Outside dia Piston weight Stroke Overall length 40 90 1039mm 1303 219 Ibs AIR CONSUMPTION 11000 A 100
7. ger Hammers in the Bulroc range when driling with large diameter Button Bits or Overburden Systems certain conditions can generate higher torques than normally expected resulting in difficulties when trying to remove the Chuck from the Wearsleeve Should this occur then the removal of the Chuck can be achieved by cutting away the Chuck Release Washer We do however stress at this point that cutting away the Chuck Release Washer is a final option and should not be done until allother options have proved unsuccessful If the cutting away of the Chuck Release Washer is necessary for the removal of the Chuck then it must be done with extreme care to avoid damage to either the Chuck or the Wearsleeve The composition of the Chuck Release Washer allows for itto be cut with either a hacksaw or a small hand grinder equipped with a slitting wheel The hacksaw method is much safer and less likely to damage the Chuck or Wearsleeve but obviously much slower than the hand grinder with a slitting wheel To remove the Chuck Release Washer a cutmust be made in the centre of the washer all the way around it s circumference and completely through the Washer thus transforming the single washer into two thinner washers that will then spin freely Great care must be taken especially if the Washer is cut with a slitting wheel to ensure that the cut only penetrates the Washer and does not pass through into the body of the Chuck The size shown as D in the above table s
8. hould be your MAXIMUM depth of cut and itis recommended that either the saw blade orthe slitting wheel are marked in some way so as to indicate when they have achieved this depth B CLAMP POSITIONS CLAMP POSITIONS HAMMER MODEL X DISTANCE FROM WEARSLEEVE END FACE HYPER 66DH 9 000 229mm Always clamp away from threads to avoid damage There are many different Splitting Machines available for unscrewing the threaded connections on a Bulroc Hyper Hammer some are attachments to the Drill Rig others are independent hydraulic units or purpose made Bench arrangements Regardless of which machine is chosen they all require some method of securing the Wearsleeve whilst applying a torque to either the Chuck or Backhead The most common machines use either Clamps or Chains around the O D of the Wearsleeve and the positioning of these is very important if they are placed too close to the joint being Split they will in effect increase the frictional forces on the threaded connection making it impossible to unscrew the component from the Wearsleeve The above table shows the correct position for the clamping mechanism to ensure no additional load will be applied to the threaded connection thus making the joint easier to split Due to the high torque loads applied to a Hammer during its drilling cycle equally high loads are required to Split the Chuck and Backhead away from the Wearsleeve and because of this the clamping ar
9. nless there is damage to the piston retaining ring there should be no need to remove it However if this should need replacing dropping an inverted piston down the upright wearsleeve from the backhead end should remove it Piston retaining ring 8 CHECKING FOR WEAR amp DAMAGE Premature wear to internal parts is a result of either 1 Insufficient or incorrect lubrication 2 The ingress of debris into the hammer 3 Incorrect service and storage The maximum wear allowance shown in this section are a guide as to when to replace parts In certain conditions parts may need to be replaced before they reach the sizes shown Piston Footvalve bore diameter Body Diameter Control tube bore diameter Max Footvalve bore 1 525 38 3mm Max Control tube bore 1 610 40 89mm Min Body diameter 4 577 116 26 There are two main areas to examine a used piston 1 Check the body diameter for signs of pickup and burning both are signs of poor lubrication Using a micrometer measure the diameter and refer to the quoted minimum size above Any light Pick up marks can be removed using emery cloth however if there are signs of overheating and cracking the piston should be replaced and the lubrication system examined 2 Secondly using a micrometer measure the diameter of the bore at both ends of the piston and refer to the maximum quoted sizes 3 Examine the striking face Some degree of distortion i
10. ns the breakout washer can be ground or drilled which will relieve the pressure and enable the chuck to be removed NB On no account should the wearsleeve be impacted by a hammer Splitting should never be assisted by the use of localised heat ie Blow torch Breakout washer Any signs of hammer indentations or applied heat will void the warranty Assuming now both the backhead and chuck threads have been loosened either on the drill rig or a Hammer Splitter the stripping operation is as follows 1 Remove the chuck assembly 2 Removing the O ring from the bit retaining ring Breakout washer will allow the bit to be removed Alternatively pulling the two pieces apart will allow the O ring to stretch enough to fit over the end of the bit shank Bit retaining ring Ring 3 The bit can now be removed from the chuck quite easily STRIPPING THE HAMMER T 4 With the hammer laid horizontal unscrew the backhead and remove it from the wearsleeve o The control tube assembly now be removed from the backhead 6 The checkvalve spring can now be removed should it be necessary although generally this will not be needed 7 The guide bush can be removed by tilting the wearsleeve downwards and shaking If this proved difficult the guide bush can be pushed out 8 Tilting the hammer upside will allow the piston to be removed taking care to catch the piston as it falls out 9 U
11. rangement around the Wearsleeve must generate enough friction to prevent it from spinning during the process However great care must be taken to make sure the clamps or chains are not over tightened as this can cause deformation to the Wearsleeve that can result in both Wearsleeve failure and Piston seizure once the Hammer is returned to service To help increase the Wearsleeve s resistance to deformation it is recommended that the Hammer Piston is first slid to the end of the Hammer being split before clamps of chains are attached By doing this the Piston O D will limit the amount of deformation in the Wearsleeve bore if too much clamping pressure is applied NOTE The use of Chain type Hydraulic Breakers can leave deep intrusions in the O D of the Wearsleeve which may result in stress concentrations that could lead to premature failure of the Wearsleeve INIA A Your Bulroc Hyper 66DH Hammer has been proudly manufactured in Great Britain Turnoaks Business Park Burley Close Chesterfield Derbyshire S40 2UB Tel 44 0 1246 544700 Fax 44 0 1246 544701 E mail info bulroc com website bulroc com HYPER 66DH360 16 10 13
12. s acceptable proving there are no signs of cracking If distortion has affected the chamfer and possibly distorted the footvalve bore diameter this needs to be reformed on a lathe and footvalve bore re ground to its original diameter Burrs and dents can be removed with an emery stone CHECKING FOR WEAR amp DAMAGE Maintaining the piston face Fig 1 New Piston Face Fig 2 Worn Piston Face During the working life of the hammer the Striking Face RADIUS A on the Piston may become dented or deformed see fig 2 To prevent this face from cracking or chipping the Piston should be returned to a lathe where the strking face can be re machined flat and then have the outer radius and inner chamfer reformed see fig 3 CHAMFER B Care should be taken to remove the minimum amout of material during this re machining process and at no point should more than 2mm be removed from the face Pistons with wear patterns or indentations deeper than 2mm should be replaced The table below contains useful machine information for reforming the piston face MACHINE DETAIL HAMMER RADIUS CHAMFER HYPER 66DH 0 250 0 125 45 Fig 3 Area to be machinec 9 CHECKING FOR WEAR amp DAMAGE Control Tube Note Control Tube minimum diameter 1 595 40 51mm Diameter Examine the control tube diameter using a micrometer Check the diameter has not worn under the specified minimum If there are
13. signs of pickup they should be removed by using emery cloth Wearsleeve Using either a micrometer vernier measure the outer diameter of the Wearsleeve If it is below the minimum it must be replaced The wear rate of the Wearsleeve can be slowed by replacing the Chuck before the wear area reaches the Wearsleeve The bore of the Wearsleeve should be periodically checked for any signs of Pick up If a piston has broken within the wearsleeve it is imperative that the bore is honed to remove any burrs or pick up Diameter Failure to do so will result in pick up on the replaced piston and will lead to early o failure of this component Note Wearsleeve minimum diameter 5 25 133 35mm REBUILDING THE HAMMER 10 1 Ensure all the maintenance work outlined in the previous section has been completed 2 Stand the wearsleeve 15 on the floor with the Chuck end upwards Insert the piston retaining ring 11 into the bore and hammer the ring down until it springs into the groove in the Wearsleeve 3 Clamp the wearsleeve horizontally in a vice taking care not to over tighten the jaws First fit the bit bush 8 with new rings then push into the wearsleeve Assemble the chuck 13 breakout washer 14 and bit retaining rings 12 ensure to fit a new O ring around the button bit Cover the threads with a copper based grease Hand tighten the chuck assembly into the wearsleeve 4 Coat the
14. ture is between and 25 degrees centigrade then a 30 grade oil should be used Ifthe ambient temperature is greater than 250 degrees centigrade then use a 50 grade oil Bulroc supply their own recommended rock drill oil See below for all the recommended brands of oils MAKE TYPE 30 GRADE TYPE 50 GRADE BULROC T220 T320 BP ENERGOL RD E 100 ENERGOL RD E 300 CHEVRON ARIES 100 ARIES 320 SHELL TORCULA 100 TORCULA 320 ESSO EXXON AROX EP100 AROX EP320 13 STORAGE PROCEDURES We recommend following the points listed below when removing a Down the Hole hammer from service This will ensure trouble free operation once the hammer starts work again The hammer should be stripped and cleaned and freed of as much water moisture as possible Bulroc 320 orsimilar rock drill oil should be poured into the backhead allowing all parts to be coated throughout the hammer The check valve should be depressed to help the ingress of oil Amount required of a pint or 0 43 litre Both ends of the hammer should then be covered to prevent the ingress of dirt etc It should be laid horizontally in a dry environment ready for use next time If this procedure is followed then apart from protecting the hammer from corrosion it will protect the parts from premature wear and of course reduce down time and eventual repair costs However we strongly recommend that the hammer especially if stored for any long period of time should be stripped cle
Download Pdf Manuals
Related Search