A fluid pressure driven, high frequency percussion hammer for drilling in hard formations is presented. The hammer piston (20) of the percussion hammer has a relatively large and longitudinally extending bore (41) that provides minimal flow resistance for a drilling fluid flowing through the bore (41) during the return stroke of the hammer piston (20). The bore (41) is closeable in the upstream direction by a valve plug (23) that follows the hammer piston (20) during the stroke. The valve plug (23) is controlled by a relatively long and slender valve stem (49) that is mechanically able to stop the valve plug (23) by approximately 75% of the full stroke length of the hammer piston (20) and separates the plug (23) from a seat ring (40). Thus the bore (41) opens up such that the bore fluid can flow there trough, and the inherent tension spring properties of the valve stem (49) returns the valve plug (23) so rapid that it will be good through flow during return of the hammer piston (20).
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1. A fluid pressure driven high frequency percussion hammer for drilling in hard formations, the percussion hammer comprising:
a housing which in one end thereof is provided with a drill bit designed to act directly on the hard formation;
a hammer piston moveably received in said housing and that acts on the drill bit, the hammer piston having formed therein a longitudinally extending bore having a predetermined flow capacity, the longitudinally extending bore being closeable in an upstream direction by a valve plug that partly follows the hammer piston during its stroke;
a valve stem operatively coupled to the valve plug and slideably received in a valve stem sleeve, said valve stem comprising:
a stop plate disposed at an upstream end of the valve stem, the stop plate engaging the valve stem sleeve to: 1) stop the valve plug at a predetermined percentage of a full stroke length of the hammer piston thereby opening the bore; and 2) elastically strain the valve stem such that said elastically strained valve stem is recoiled back to an uppermost position of the valve stem in the valve stem sleeve by non-helical tension spring properties of the valve stem; and
wherein said hammer piston is mechanically compressed when striking the drill bit so that said mechanically compressed hammer piston is recoiled back towards the uppermost position of the hammer piston in the housing due to pressure tension properties of the hammer piston.
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The present invention relates to a fluid pressure driven, high frequency percussion hammer for drilling in hard formations, which percussion hammer comprises a housing, which in one end thereof is provided with a drill bit designed to act directly on the hard formation, which percussion hammer further comprises a hammer piston moveably received in said housing and acts on the drill bit, which hammer piston has a longitudinally extending bore having predetermined flow capacity, and the bore being closeable in the upstream direction by a valve plug that partly follows the hammer piston during its stroke.
Hydraulically driven percussion hammers for drilling in rock have been in commercial use for more that 30 years. These are used with jointable drill rods where the drilling depth is restricted by the fact that the percussion energy fades through the joints, in addition to the fact that the weight of the drill rod becomes too heavy such that little energy finally reaches the drill bit.
Downhole hammer drills, i.e. hammer drills installed right above the drill bit, is much more effective and are used in large extent for drilling of wells down to 2-300 meter depth. These are driven by compressed air and have pressures up to approximately 22 bars, which then restricting the drilling depth to approximately 20 meters if water ingress into the well exists. High pressure water driven hammer drills have been commercial available more than 10 years now, but these are limited in dimension, which means up to about 130 mm hole diameter. In addition, they are known to have limited life time and are sensitive for impurities in the water. They are used in large extent in the mining industries since they are drilling very efficiently and drill very straight bores. They are used in a limited extent for vertical well drilling down to 1000-1500 meters depth, and then without any directional control.
It is desired to manufacture downhole drill fluid driven hammer drills which can be used together with directional control equipment, which have high efficiency, can be used with water as drill fluid and can also be used with water based drill fluid having additives, and having economical lifetime. It is expected great usage both for deepwater drilling for geothermic energy and for hard accessible oil and gas resources.
In percussion drilling, drill bits are used having inserted hard metal lugs, so called “indenters”. These are made of tungsten carbide and are typically from 8 to 14 mm in diameter and have spherical or conical end. Ideally viewed, each indenter should strike with optimal percussion energy related to the hardness and the compressive strength of the rock, such that a small crater or pit is made in the rock. The drill bit is rotated such that next blow, ideally viewed, forms a new crater having connection to the previous one. The drilling diameter and the geometry determine the number of indenters.
Optimal percussion energy is determined by the compressive strength of the rock, it can be drilled in rock having compressive strength over 300 MPa. The supply of percussion energy beyond the optimal amount, is lost energy since it is not used to destroy the rock, only propagates as waves of energy. Too little percussion energy does not make craters at all. When percussion energy per indenter is known and the number of indenters is determined, then the optimal percussion energy for the drill bit is given. The pull, or drilling rate, (ROP—rate of penetration) can then be increased by just increasing the percussion frequency.
The amount of drilling fluid pumped is determined by minimum necessary return rate (annular velocity) within the annulus between the drill string and the well bore wall. This should at least be over 1 m/s, preferably 2 m/s, such that the drilled out material, the cuttings, will be transported to the surface. The harder and brittle the rock is, and the higher percussion frequency one is able to provide, the finer the cuttings become, and the slower return rate or speed can be accepted. Hard rock and high frequency will produce cuttings that appear as dust or fine sand.
The hydraulic effect applied to the hammer drill is determined by the pressure drop multiplied with pumped quantity per time unit.
The percussion energy per blow multiplied with the frequency provides the effect. If we look into an imaginary example where drilling into granite having 260 MPa compressive strength and drilling diameter of 190 mm is performed, water is pumped by 750 l/min (12.5 liters/second) from the surface. It is calculated that approximately 900 J is optimal percussion energy.
With reference to known data for corresponding drilling, but with smaller diameters, a drilling rate (ROP) of 22 m/h (meters per hour) with a percussion frequency of 60 Hz, can be expected. It is here assumed to increase the percussion frequency to 95 Hz, consequently ROP then become 35 m/h. Required net effect on the drill bit then becomes: 0.9 kJ×95=86 kW. We assume the present hammer construction to have a mechanical-hydraulic efficiency of 0.89, which then provides 7.7 MPa required pressure drop over the hammer.
This hammer drill will then drill 60% quicker and by 60% less energy consumption than known available water propelled hammer drills.
This is achieved by a percussion hammer of the introductory said kind, which hammer is distinguished in that the valve plug is controlled by an associated valve stem slideably received in a valve stem sleeve, said valve stem comprises stopping means able to stop the valve plug by a predetermined percentage of the full stroke length of the hammer piston and separates the valve plug from a seat seal on the hammer piston, said bore thus being opened and allows the bore fluid to flow through the bore.
Preferably the stopping means comprises a stop plate at the upstream end of the valve stem, and a cooperating internal stop surface in the valve stem sleeve.
In one embodiment the predetermined percentage of the full stroke length of the hammer piston can be in the order of magnitude 75%.
Conveniently, it is the inherent tension spring properties of the valve stem that returns the valve plug, which valve stem being long and slender.
Preferably, the percussion hammer can further be provided with an inlet valve assembly, which is not opening for operation of the hammer piston until the pressure is build up to approximately 95% of full working pressure, which inlet valve assembly being adapted to close off a main barrel, and a side barrel within the hammer housing can pressurize an annulus between the hammer piston and the housing elevating the hammer piston to seal against the valve plug.
Conveniently, the hammer piston and the valve assembly can be returned by recoil, where both the hammer piston and the valve assembly are provided with hydraulic dampening controlling the retardation of the return stroke until stop.
Conveniently, the hydraulic dampening takes place with an annular piston which is forced into a corresponding annular cylinder with controllable clearances, and thus restricts or chokes the evacuation of the trapped fluid.
Further, an opening can be arranged in the top of the valve stem sleeve, into which opening the stop plate of the valve stem is able to enter, and the radial portions of the stop plate can seal against the internal side of the opening with relatively narrow radial clearance.
Further, an annular backup valve can be arranged in a ring groove underneath the opening, which backup valve being able to open and replenish fluid through bores in the valve stem sleeve.
The percussion hammer housing can be divided into an inlet valve housing, a valve housing and a hammer housing.
The hammer drill construction according to the present invention is of the type labeled “Direct Acting Hammer”, i.e. that the hammer piston has a closing valve thereon, which valve in closed position enables the pressure to propel the piston forward, and in open position enables the hammer piston to be subjected to recoil. The previous variant of a hydraulic hammer has a valve system that by means of pressure propels the hammer piston both ways. This provides poor efficiency, but more precise control of the piston.
The key to good efficiency and high percussion frequency, is in the valve construction. The valve needs to operate with high frequency and have well through flow characteristics in open position.
With great advantage, the hammer drill construction can also be used as surface mounted hydraulically driven hammer for drilling with drill rods, but it is the use as a downhole hammer drill that will be described in detail here.
Other and further objects, features and advantages will appear from the following description of preferred embodiments of the invention, which is given for the purpose of description, and given in context with the appended drawings where:
The detailed section in
The detailed sections in
The arrangement shown in detailed section in
The first pilot chamber above the pilot piston 32 is drained and the inlet valve 18 opens up. At the same time the opening 45 is closed such that drainage through the bore 44 is shut off so that pressure is not lost through this bore in operating mode. The pressure in the chamber above the hammer piston 20 and the closed valve plug 23 results in start of the working cycle with instant full effect. The arrangement with a backup valve 47 and a nozzle 48 is provided to obtain a reduced drainage time of the second pilot chamber 46 for thereby achieve relatively slow closure of the inlet valve 18. This to obtain that the inlet valve 18 remains fully open and is not to make disturbances during a working mode since the pressure then fluctuates with the percussion frequency.
A moveable valve stem 49 having a stop plate 50 now lands on the abutment surface of a stationary valve stem sleeve 51 in the housing 9 and stops the valve stem 49 from further motion, as shown in enlarged detailed view A in
The kinetic energy of the valve plugs 23 momentum will by the abrupt stop thereof marginally elongate the relatively long and slender valve stem 49, and thereby transform to a relatively large spring force that very quick accelerates the valve in return. The marginal elongation of the valve stem 49, here as an example calculated to be about 0.8 mm, needs to be lower than the utilization rate of the material, which material in this case is high tensile spring steel. The mass of the valve plug 23 should be as small as possible, here as an example made of aluminum, combined with the length, the diameter and the properties of the material of the valve stem 49, determines the natural frequency of the valve assembly.
For practical usages, this should be minimum 8-10 times the frequency it is to be used for. The natural frequency is determined by the formulas:
The mass and the spring constant have most significance. The natural frequency for the shown construction is about 1100-1200 Hz and therefore usable for a working frequency over 100 Hz.
The shown construction has in this example a recoil velocity that is 93% of the impact or strike velocity.
The kinetic energy of the hammer pistons 20 momentum is partly transformed into a spring force in the hammer piston 20, since the piston is somewhat compressed during the impact. When the energy wave from the impact has migrated through the hammer piston 20 to the opposite end and back, the hammer piston 20 accelerates in return. The return velocity here at the start is calculated to be about 3.2 m/s, about 53% of the strike or impact velocity, this because a portion of the energy has been used for mass displacement of the drill bit 11, while the rest has been used to depress the indenters into the rock.
The detailed view D in
The backup valve 58 of the type “annular backup valve”, which in this embodiment is an annular leaf spring, is chosen since this has little mass and relatively large spring force and accordingly is able to work with high frequency.
The detailed view B in
The gap between the valve seat 40 and the valve plug 23 needs not to be closed completely in order that the pressure to build up and a new cycle starts.
Calculations show that with an opening of 0.5 mm the pressure drop is approximately the same as the working pressure. This results in that the surface pressure on the contact surface between the valve plug 23 and the seat 40 becomes small and the components can experience long life time.
The vertical axis for curve A shows the velocity in m/s, stroke direction against the drill bit 11 as + upwards and − downwards, here the return velocity.
The vertical axis for the curve B shows distance in mm from the start position. The curve section 61 shows the acceleration phase, where the point 62 is the moment when the valve is stopped and the return thereof is initiated. The point 63 is the impact of the hammer piston 20 against the drill bit 11.
The curve section 64 is the displacement of the drill bit 11 by progress into the rock, 65 is the acceleration of the recoil, 66 is the return velocity without dampening and 67 is the return velocity with dampening. The curve section 68 is the recoil acceleration for the valve, 69 is the return velocity for the valve without dampening and 70 is the slow down dampening phase for the return of the valve.
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