Air Drilling Manual

Air Drilling Techniques

Introduction

Underbalanced Drilling (UBD) is a technique in which oil, gas or geothermal wells are
drilled using pressures lower than the reservoir pressure. The result is an increase in
rate of penetration (ROP), reduced formation damage and reduced drilling costs. Air
drilling provides an efficient system in terms of operations costs and environmental
safety benefits.

“Air Drilling” refers to the use of air in the circulating system. The purpose for using an
air drilling method is to drill low-pressure formations. During the last 20 years, air-
drilling techniques have been applied worldwide, successfully drilling for energy.

The five general classifications of air drilling techniques are as follows:

1. “Dust” Drilling
2. “Mist” Drilling
3. “Foam” Drilling
4. “Aerated Fluid” Drilling
5. “Nitrogen” Drilling

Advantages

Air drilling techniques offer the following advantages, when compared to the use of
conventional mud systems.

• Faster Rates of Penetration. (Especially in harder formations)

• Improved Bit performance. (More footage per bit)
• Detection of low-pressure zones.
• Effective pressure control through loss circulation zones.
• Lower mud material costs.
• Fast return of uncontaminated cuttings for geological evaluation.
• Minimized formation damage.
• Improvements in Deviation Control. (Due to less weight on bit).
• Operating conditions are cleaner.
• Overall costs for drilling operations are lower.

Disadvantages

• Formation pressure control is minimal and, therefore, drilling is limited to

geological regions where reservoir pore pressures are low.
• Drilling is limited to geological regions where the rock formations are mature
and competent because there is little or no fluid pressure to support the borehole
wall and prevent sloughing.
• There is limited ability to cope with significant volumes of water entering the
annulus from water producing formations.

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• The bit gage can be appreciably reduced during drilling (with exception when
using Diamond Enhanced Inserts- D.E.I.)
• The drill pipe can experience rather high wear due to sand blasting
characteristics of annular stream flow.
• There is little or no drill string cushion effect, which results from fluid in the
borehole during drill string handling mishaps.
• There is danger of downhole fire.

This increase in R.O.P. may be 2-5 times the drilling rate of a conventional mud drilled
hole. This can reduce the number of days required to complete a well, and reduce
drilling costs.

Rate of Penetration – (R.O.P.)

The downhole circulating density of an air drilling system is low, compared to a typical
mud system. The decreased circulating fluid pressure exerted on the wellbore increases
the relief of the vertical and axial stresses residual in the formations. This results in a
“reverse pressure” gradient that increases the drill ability of the rock.

As the down hole circulating fluid pressure is lowered below the formation pressure, the
rock tends to “explode” at the bit tooth. This result in faster penetration rates provided
there is sufficient circulating fluid volume to clear the hole of cuttings.

Bit Performance

An air drilling system provides sufficient fluid turbulence to ensure proper cleaning of
the cutting structure. Abrasive cuttings are carried away from the bit and into the
annulus, faster than a conventional mud system. This lessens the regrinding of drilled
cuttings, increasing the removal efficiency of the solids control equipment, and
improving bit performance. (R.O.P.)

Elevated formation temperatures are common when drilling a geothermal well. One of
the main factors affecting the performance of a bit is bearing life. As high formation
temperatures are encountered, bearing life can be decreased. An air drilling system
supplies the bit with a cool stream of air that flows around the bearings, reducing the
bearing temperature and increasing bit performance.

Decreasing the bearing temperature and reducing the regrinding of drilled cuttings,
increases the footage that can be drilled for a given bit. This can result in fewer bits
required to complete a well, reducing well costs.

Drilling through Loss Zones

Once “loss” or production zones are encountered, drilling may continue through and
beyond these low-pressure formations. The operator may increase production from each
well, by drilling deeper and encountering new production zones.

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The existing air circulating system may or may not have to be changed to maintain full
circulation. A properly engineered air drilling system will permit a rapid conversion
from one technique to another, without any excessive delay.

Minimize Formation Damage

The use of air drilling techniques can minimize formation damage and enhance
production from low-pressure wells, when compared to a conventional mud drilled
well. If the circulating fluid pressure is less than the formation pressure, there is little
chance that circulating fluids and cuttings will invade and damage producing zones.

Some geothermal operators have indicated that wells completed with conventional
drilling fluid systems have less geothermal production, when compared to wells dried
with air drilling systems in the same area. These operators feel that low bottom hole
circulating pressures decrease invasion and “Baking off in the high temperature
fractures of drilling fluid and cuttings.

“DUST” Drilling

Compressed air is injected into the standpipe and circulated through the drill string in
much the same way as conventional mud. The “Dust” technique is used when drilling
dry formations, or where any water influx is slight enough to be absorbed by the air
stream. The name “Dust” was chosen because cuttings return to the surface as a cloud of
dust.

The drilling fluid is used to cool the drill string and bit. The temperature of the air
injected into the hole should be slightly higher than the temperature at ambient
conditions. As the air travels down the drill string the air is heated to the temperature of
the surrounding formation.

When the air passes through the jet nozzles, the air expands and the velocity increases to
supersonic flow. This expansion occurs because of the large pressure drop between the
bottom hole and the above bit pressures. This causes the temperature to decrease and
cool the bit and the bit bearings. As the air travels up the annulus, the air is then
reheated to the temperature of the surrounding formation.

If lubrication is desired of the drill string and bit, a lubricant must be added to the air
stream. There are several products that perform this function. The application of a
lubricant decreases torque and increases bit life. If soap is used, there will be an increase
in the carrying capacity of the circulating fluid.

“Dust” drilling is the ultimate progression from a high to a low density drilling fluid.
Bottom hole pressures slightly exceed the value of the air column pressure head plus the
weight of the entrained cuttings. This allows for maximum relief of the vertical and axial
stresses residual in the formations. This procedure offers the fastest drilling rates and
best economy.

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Hole Cleaning

The lifting power of an air drilling system is proportional to the circulating density, and
to the square of the velocity. The density, and thus the suspension properties, of an air
stream is much lower than a conventional mud system. Therefore, the annular velocity
is the primary factor in transporting the cuttings to the surface.

Air volumes that generate annular velocities of 3,000 ft/min. are normally adequate to
“Dust” drill. However, when penetration rates exceed 60-ft/hr. or when cuttings are
large or wet, higher annular velocities may be required to effectively clean the hole.

“MIST” Drilling

This technique is used where the amount of water-influx is high enough to prevent
“Dust” drilling, but not enough to cause hole-cleaning problems. The name “Mist” was
chosen because a pretreated drilling fluid is injected with the air, and the combination
returns to the surface as a mist. A small quantity of water containing a foaming agent
(soap) is injected into the “air” stream at the surface, with the water mist being carried in
the air in what is a continuous air system.

This technique offers increased drilling rates and economy over that of a conventional
mud drilled hole. The lower bottom hole circulating pressure exerted on the well bore
allows for greater relief of the vertical and axial stresses residual in the formations. Like
dry air drilling, this system relies on the annular velocity of the air for cuttings transport
out of the hole. Air mist drilling is used when the amount of water influx is high enough
to preclude air dust drilling, but not so high as to cause hole cleaning problems.

Essentially, the equipment for a successful “dust” and “mist” drilling applications is the
same. The principle difference being an increase in the air volume requirements 30%,
and the injection of a pretreated drilling mud.

Hole Cleaning

Switching to a “mist” drilling technique requires an increase of at least 30% in the air
volume. The additional volume is needed to overcome higher frictional losses caused by
wet cuttings adhering to the drillstring and hole, higher slip velocities of larger wet
cuttings, and transportation of the heavier wet air column. The mud is injected with the
air stream to disperse the cuttings and inhibit them from adhering to the drillstring and
hole.

Although injection pressure of 100 to 200 p.s.i.g. are normally enough for “dust”
drilling, pressures exceeding 350 p.s.i.g. can be encountered while “mist” drilling.
Pressures of 1250 p.s.i.g. may be requires when large amounts of fluids are present in the
annulus. The rate of fluid intrusion will dictate the amount of air and fluid that must be
injected to efficiently clean the hole. Formation fluid entries of up to 150 bbl/hr
(100gpm) have been successfully “mist” drilled.

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The addition of a foaming agent reduces the interfacial tension of the water and cuttings
in the hole and allows small water/cutting droplets to be dispersed as a fine mist in the
returning air stream. This allows the cuttings and water to be removed from the hole
without formation of mud rings and bit balling.

Proper amounts of water and soap must be added to achieve a nominally continuous
flow of foam and cuttings and adequate separation of the cuttings. Obtaining the proper
combination of water and soap is a trial and error process. Good starting points are:

1. 1.5 – 2.0 bph water/per inch of hole diameter (8.75” bit = 14 – 18 bph /water)
2. 2 – 3 GPH soap – fresh water
3. 2 – 4 GPH soap – Brine Water

The above totals are based on experience with the air hammer and may need to be
adjusted according to hole conditions and bit selection.

The requirements are a function of the type and volume of influx water. Many produced
brines are effective defoamers, requiring use of additional soap. Produced oil requires a
special type of soap.

To determine the proper amount of water and soap to be injected, several “rules of
thumb” are helpful:

1. Air volumes for mist must increase by 30% as compared to dust drilling.
2. Pressures generally run at 300 - 600 psi for mist.
3. Insufficient air/soap leads to hole surging.

Corrosion Control

The fluid properties required for “Mist” drilling are lower than a conventional mud
system. Chemical treatment is needed to minimize corrosion caused by the additional
fluid and air.

Basic corrosion control is provided by maintaining the pH of the mud system above
10.5, and treating any hardness or carbonates with the appropriate chemical. Hydrogen
sulfide and carbonate scale are treated in much the same way as in a conventional mud
system,

To reduce carbonate corrosion, lime is used to treat out the carbonates, and some excess
is maintained to buffer against this type of corrosion.

Oxygen corrosion is the most difficult to combat in an air drilling system, because of the
air supplies large quantities of oxygen to the wet circulating system. There are several
types of chemicals that can be used to minimize this type of corrosion.

Scale is a common problem with some type of fluids. Using an alkaline fluid, and
treating the carbonates and hardness with the appropriate chemicals will greatly reduce

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the tendency of scale to occur. If the fluid circulating system is correctly pretreated,
corrosion can be maintained at an acceptable level.

Stiff Foam Drilling

The removal of drilled cuttings from low-pressure formations is a serious problem,

particularly when permeability is high and the rocks are unconsolidated. When
conventional methods are used, solids can be forced back into the formation. Since the
reservoir pressure is extremely low, these contaminants stay in place and restrict
permeability with a subsequent reduction in productivity.

A low density circulating fluid minimizes contamination of the producing zoned by

mud materials and cuttings. Decrease circulating pressures allow the drilling of severe
loss zones with minimum fluid loss. A proven method for lowering the hydrostatic head
is to use the “stiff foam” drilling technique.

The “stiff foam” technique is a stable air in mud emulsion. Stiff foam is a mixture of
water, foamer, appropriate mud additives, and compressed air. The foam is generated at
the surface and injected in the drillstring as the circulating fluid. This technique can be
used when “dust” or “mist” drilling techniques would not be practical because of
economic, mechanical, or other reasons.

When to use Stiff Foam Drilling

1. To drill severe loss circulation zoned, particularly those with wet or weeping
formations.
2. To drill water sensitive shales which tend to slough when mist drilled.
3. To drill unconsolidated formations or producing zones.
4. To cope with situations where not enough air is available for large diameter
holes, remoteness of location, or economics.

Advantages

1. Low hydrostatic pressure is exerted against the wellbore which limits the
invasion of drilling fluids and cuttings thereby minimizing formation damage.
2. Full circulation can be obtained in holes where it has been impossible to maintain
returns with conventional fluids.
3. Analyzing the foam returns at the blooie line can readily identify oil and water
zones.
4. Lower annular velocities by approximately 100 to 300 ft/min. permit the drilling
of unconsolidated formations without the problems associated with hole
washout.
5. Lower fluid volumes enhance the ability to drill in gauge, large diameter holes.

The mud products are used to provide hole stability, carrying capacity, foaming
characteristics, and corrosion control. They also decrease the tendency of the air to

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“break out” of the foam in the annulus. The air is used to reduce the down hole
circulating pressure.

Properly mixed foam weighs 2 to 4 lbs/cu. ft. When the foam is compressed down hole
it exerts minimum hydrostatic pressure with little or no fluid loss to the formation. Foam
has excellent carrying capacity for cuttings, about 7 – 8 times that of water.

The foam mixture cannot be recirculated. It must be transferred to a sump, dispersed

into liquid form, and then hauled off to a dumpsite. Environmental concerns may result
when large amounts of foam are present in the surface sumps.

“Stiff Foam” drilling does not work well when large formation flows are encountered.
As the formation fluid enters the wellbore the foam strength is reduced, decreasing the
ability of the circulating system to clean the hole of cuttings. To combat this problem an
increase in the circulating rate and material concentration is required to strengthen the
foam, which increases the drilling costs.

There are many types of foaming products on the market that will perform well in fresh
water, slat, water, oil, and gas producing zones. It is better to purchase a quality foamer
rather than a bargain foamer. When drilling problems are encountered the additional
cost of the quality foamer will be offset by better performance down hole.

Cuttings removal is strictly dependent on the stability of the foam. If the foam returns
and cuttings are watched constantly, they give adequate warning of impending trouble.
When the foam is muddy, or when carvings begin to appear it is apparent that the hole
is enlarging. As the hole enlarges the annular velocity drops and the foam ceases to lift
the cuttings efficiently.

As long as an adequate air volume and foam mix is available to lift drill solids and fluid
entries, hole integrity is the only limiting factor in successful foam drilling of low-
pressure reservoirs.

Stiff Foam Mix for Air Drilling With Hammer

Initial pre-mix

1. 3 sacks of Soda Ash

2. 1 sack of Caustic
3. 4 sacks of KCL
4. 10 gallons of 105 Polymer – (screened)
5. 1-2 sacks of Pac R for maintaining 37-40 viscosity

Secondary mixture:

1. 2 sacks of Soda Ash

2. 1 sack of Caustic
3. 2 sacks of KCL

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4. 5 gallons of 105 Polymer – (screened)

5. 1-2 sacks of Pac R for 37-40 viscosity

Nitrogen Drilling

Because nitrogen is inert and inflammable, it is the preferred gas for underbalanced
drilling. Nitrogen can be supplied for oil field use by three different methods: cryogenic
liquid separation, pressure swing absorption, and hollow fiber membranes. The
selection of nitrogen supply from one of these methods depends on the cost of delivered
nitrogen, the required flow rates and pressure, the required nitrogen purity, and the
reliability of the equipment for nitrogen generation.

Total underbalanced drilling system costs are also a primary consideration. Until mid
1994, nitrogen for underbalanced drilling in western Canada was supplied from
cryogenic plants not central to the major drilling areas and was subject to seasonal
demand pressures. Thus, the cost of cryogenic nitrogen was higher and a major
component of total well costs.

In 1994, the first hollow fiber membrane units were shipped to Canada and placed in
service to supply gaseous nitrogen for underbalanced drilling. More than 120 wells have
been drilled in Canada using nitrogen supplied from these hollow fiber membrane units.

The projected amount of required nitrogen may be estimated through the use of
advanced computer simulation models that analyze multiphase flow of the combined
drilling fluid, injection gas, produced formation fluids, and hole cuttings through the
drillstring, bottom hole assembly, and surface production equipment.

Although this type of simulation modeling is extremely complex and subject to many
uncertainties, it has proven effective on numerous jobs when applied by experienced
drilling engineers. Critical data for this type of modeling include bottom hole pressure,
flow rates, and temperatures.

Nitrogen Supply

Nitrogen for oil field operations can be supplied on site in liquid form or can be
produced on site by extracting nitrogen from compressed air.

Cryogenic nitrogen is obtained when air is super cooled to a point where the density
differences between nitrogen and oxygen allow for high purity separation. Generally,
liquid nitrogen is obtained from this process, and the liquid nitrogen is stored and
transported to the well site for gasification and injection.

Pressure swing absorption (PSA) equipment can generate gaseous nitrogen from
compressed air. PSA units usually have two or more tanks containing a loose or
granulated carbon material that absorbs oxygen. Compressed air is pumped into the
tank, the oxygen absorbs onto the carbon material, and nitrogen flows through to the
outlet. When the carbon material in the tank approaches an oxygen saturation point,

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oxygen sensors on the outlet detect the increasing oxygen content in the nitrogen, and
then valves open and close to redirect the compressed air flow to a second tank.

The tank containing the oxygen-saturated carbon material is then depressurized to

release the oxygen, and the cyclic process continues. PSA units can provide nitrogen at
purities up to 99%. Because of the cost, bulkiness, weight, and mechanical complexity of
these units, however, they are not widely used in the oil field, particularly at the high
nitrogen flow rates required for drilling.

Hollow fiber membrane nitrogen-generated systems also produce gaseous nitrogen

from a supply of compressed air. They use special polymers configured into very small
diameter fibers that are bundled together in tubes called modules.

Compressed air flows down the inside of each hollow fiber. Oxygen and water vapor
molecules diffuse through the walls of the fibers at a much faster rate than the nitrogen,
thus providing separation to produce nitrogen at the outlet. The oxygen and water
vapor are vented to the atmosphere.

Multiple modules can be manifold together to achieve the desired nitrogen flow rates.
These units have few moving parts; can be configured onto smaller skids, and have a
large range of nitrogen production rates.

The selection of nitrogen supply for underbalanced drilling is usually based on both cost
and technical, specifications (amount of nitrogen needed, required flow rates and
pressures, and nitrogen purity) of the drilling operation.

Nitrogen supply costs can vary substantially and depend on factors such as distance
from supply points, trucking costs, job duration, and total quantity required, and purity.
Oxygen corrosion can be a concern if membrane-generated nitrogen is used to drill wells
in conjunction with water containing chlorides or if significant amounts of water
containing chlorides are produced during the operation.

Oxygen corrosion is the only significant corrosion concern with membrane-generated

nitrogen. Oxygen corrosion can occur in the presence of water containing significant
amounts of chlorides and pH levels lass than 7. In these conditions, only a few parts per
million oxygen can cause corrosion.

There have been instances of oxygen corrosion with membrane-generated nitrogen, and
these have occurred when good practices were not followed.

Nitrogen production units

Membranes used in nitrogen production units (NPU’s) are made of a special polymer
extruded into very small diameter hollow fiber has a circular cross section and uniform
wall thickness and is so small that several may fit through the eye of a needle. The small
fiber size provides a huge surface area to separate large quantities of nitrogen.

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Compressed air is directed to the NPU equipment, where it is first filtered to remove
particulates and entrained water and oil droplets down to about 0.1µ diameters. The
clean compressed air, at 120-350 psig, enters the inlet of the membrane module and
travels down the fiber tubes.

Oxygen and water vapor molecules permeate the wall of the fiber membrane and are
vented to atmosphere. The product nitrogen remains inside the fiber and is collected at
the outlet connection, where it is metered. Permeation of the oxygen and water vapor
through the membrane wall is governed by Fick and Henry’s laws and is not a matter of
molecule size, per se.

The hollow fiber membranes can produce nitrogen purities up to 99.9%. The total flow
rate of nitrogen product from the membrane is inversely proportional to the purity. For
most drilling applications, in which 92-95% nitrogen purity is sufficient, the membrane
efficiency is generally 50-67%, depending upon the particular NPU equipment used.
Membranes have intrinsic performance characteristics that are a function of temperature
and pressure, and thus different membranes may have optimum operating pressures
and temperatures at selected purities.

Equipment Configuration

The NPU receives compressed air from one or more primary compressors at pressures
ranging from 100 to 350 psig. The product nitrogen is pumped, with about a 20-40 psig
pressure drop, to the suction of a booster compressor where its pressure is increased to
that required for injection into the drillstring.

NPU’s have three major components: an air filtration system, an array of air separation
modules, and a control panel.

The air filtration system usually consists of a scrubber, coalescing filler, and a particulate
filter. Some NPU’s also include an activated carbon bed filter and possibly a refrigerated
air dryer. The activated carbon bed filter removes aerosol-sized and smaller oil droplets
down to a concentration of a few parts per billion. The refrigerated air dryer reduces the
relative humidity into the carbon bed to improve oil droplet filtration.

The arrays of hollow fiber modules are manifold together to accept the clean
compressed air feed and to collect and deliver the nitrogen product. The oxygen and
water vapor permeate stream is also collected from each membrane module and piped
at near atmospheric pressure to the outside of the NPU skid, where it can quickly and
harmlessly dissipate into the atmosphere.

The control panel on the NPU allows monitoring and control of the operation. Control
panel design and function vary greatly depending on the manufacturer. Some panels
measure flow rates, temperatures, purity, and pressure drops across the NPU precisely,
yet others only provide simple output of flow rate and nitrogen purity.

Nitrogen purity is controlled by varying the back pressure on the membrane modules.

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Nitrogen purity

To date, for nearly all horizontal underbalanced drilling operations using nitrogen, the
nitrogen purity requirement has been based on the concern of hydrocarbon combustion
or flame propagation as the hydrocarbons produced from the formation came into
contact and mix with the drilling fluids.

The nitrogen purity required to prevent combustion is a function of pressure,

temperature, and composition of hydrocarbons encountered. Previous work by the U.S.
Bureau of Mines and others has indicated that methane may combust in oxygen
concentrations as low as 12-14%, but this lower explosive limit of oxygen content
decreases to 8% or less as pressure and temperature increase. Subsequent studies by
Canadians Operators and one Canadian University have indicated that the minimum
amount of oxygen required to initiate and propagate a flame may be as low as 6% in the
presence of hydrogen sulfide and under high temperature, high pressure conditions.

Other drilling applications

In addition to its use in horizontal underbalanced drilling, nitrogen is often used to drill
oil and gas wells under other conditions. The most common practice is to drill with
straight dry nitrogen instead of compressed air or misted compressed air.

Although leasing NPU equipment increases the total drilling costs slightly, drilling with
straight dry nitrogen can reduce total well costs by eliminating concerns about
downhole fires or explosions, increasing penetration rated, improving bit life, reducing
the number of drilling trips, reducing or eliminating corrosion, and improving safety.

The use of NPU generated nitrogen in some traditional air drilling areas (West Texas,
eastern Oklahoma, and the San Juan basin, for example) has become commonplace and
often the method of choice both to cut costs and improve drilling operations.

Nitrified mud drilling is also becoming popular, particularly in areas where water based
muds cannot be used, rates of penetration with liquid muds are slow, there are lost
circulation zones, aeration of mud may cause excessive corrosion, or drilling mud
invasion and permeability damage are concerns, In these applications, nitrogen is
injected into the drilling fluid at rates as low as 300 scfm or as high as 3,000 scfm,
depending on operating conditions. This technique has been applied successfully in East
Texas, eastern Oklahoma, the Texas panhandle, the Permian basin; the Over thrust belt,
and the San Juan basin.

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LAYOUT # 1

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LAYOUT # 2

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AIR VOLUMES FOR PERCUSSION DRILLING

Air Compressors

There is two basic types of compressor equipment used in air drilling, the screw and
piston type air compressors.

During air drilling operations the compressor uses local atmospheric air. The
compressor unit intakes a specific volumetric rate of atmospheric air, compresses the
volume to the required pressure level (or it pressure capability limit) and injects this air
into the standpipe manifolds. A booster may be required to increase the pressure of the
airflow from the compressors.

The piston type compressor is the general type used for air drilling operations. This type
of compressor has the important characteristics of responding to pressure variations
without appreciably altering the volumetric flow rate from the machine. Increased
pressure requirements are met with increased power to produce a higher pressure at the
exit.

In air drilling the volumetric flow rate is very important to hole cleaning and the field
equipment must have the capability of producing a relative constant volumetric flow
rate under a variety of pressure conditions. There have been many disputes in the past
regarding the manner in which the volumetric output of a compressor unit is reported.

Photo of a Clark CFB 4

Product Description

• 4 Stage Design
• High Volume, High Pressure

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• Dust, Mist, Foam and Aerated Mud Drilling

• Trailer Mounted
• Sufficient annular velocities for hole cleaning

Product Specifications

Compressor 4 – Stage Reciprocating

Driver Caterpillar D398TA V-12, Turbocharged Diesel
Engine
Driver Rating Rated 750 HP @ 900 RPM
Volume Output 1250 SCFM @ 1150 PSIG discharge w/ booster;
1200 SCFM @ 2100 PSIG discharge w/ booster
Cylinders Cylinder 1: 21” bore
Cylinder 2: 13 ½” bore
Cylinder 3: 8 ¼” bore
Cylinder 4: 4 ¾” bore
Compressor Dimensions / 39’ L x 13’11” H / Weight = 84,000 lbs.
Weight
Booster Dimensions / Weight 39’ L x 10’W x 13’11” H / Weight = 84,000 lbs.±

Photo of a GHH 246 - G

Product Description

• Screw / Booster Design

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• Twin Screw, Oil-Flooded Compressor

• Two Stage Booster
• Trailer Mounted
• Air, Mist, Foam and Aerated-Mud Drilling
• Ideally suited for Geothermal applications

Product Specifications

Screw CF246G Single – Stage

Booster Cylinder 1: 6” bore
Cylinder 2: 3.625” bore
Driver Caterpillar 3412 E-TA V-12, twin turbo-discharged
diesel engine
Driver Rating Rated 750 HP @ 1800 RPM
Volume Output 1250 SCFM @ 1700 PSIG
1450 SCFM @ 600 PSIG
Dimensions / Weight 33’ L x 8 ½” W x 13’3” H – 46,000 lbs.±

Free Air (acfm)

Free air is the actual amount of air delivered by the compressor unit without correction
for temperature, pressure, and humidity (acfm). A value reported in free air (acfm) must
be accompanied with the pressure, temperature, and humidity for that reading to give
any significance to the value.

Standard Air (scfm)

Standard air (scfm) is the amount delivered by the compressor adjusted for pressure,
temperature, and humidity variations for standard conditions. Correcting free air to
Standard air allows the use of a set of standard conditions as the reference point for
comparison between various locations. If a value is reported in comparison between
various locations. If a value is reported in Standard air (scfm) the pressure, temperature,
and humidity are known and does not have to be provided when reporting the flow
rate.

The compressor unit compresses its rated intake volumetric flow rate at the intake
pressure and temperature conditions to some higher pressure and temperature. This
results in a smaller airflow rate at the exit of the unit.

Particle Dynamics

A particle falling under the influence of gravity will accelerate until the drag force on the
particle just balances the gravitational force. The particle will continue to fall at a
constant rate known as the “terminal velocity”.

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The terminal velocity of a typical cutting in air will be very high compared to the
terminal velocity of the same cutting in mud.

The velocity of the air must exceed the terminal velocity of the cutting to move upward
in the annulus. To use air as the circulating fluid requires a high annular velocity to
successfully clear the hole of cuttings.

As cuttings are generated at the bit, they will rise rapidly past the drill collars. Once the
cuttings clear the top of the collars and enter the annulus between the drill pipes and the
well bore, the fluid velocity decreases considerably because the cross sectional area
increases. Due to this reduction in fluid velocity, the point of most difficult lift is located
at the top of the drill collars.

Particles that are larger than the critical diameter capable of being lifted by the
circulating fluid will tend to accumulate in this section. They will fall back and be re-
ground between the drill pipe and the well bore, drill collars, and the well bore, the bit,
or by collisions with other particles. This process will continue until the larger particles
are broken into a size such that their terminal velocity is less than the fluid velocity
above the collars.

When air drilling has failed, very often the reason has been an insufficient air volume, or
velocity, to clean the hole at the fast drilling rates. As the well deepens, more air is
necessary to maintain the velocity needed to bring the cuttings to the surface. The
increase in the air requirements stem from higher friction losses due to the lengthening
fluid column, and density increases due to the consequently lower bottom hole
velocities. If no additional compressor capacity is immediately available, air
requirements may be reduced by decreasing the area of the annulus by either decreasing
the hole size or increasing the drill pipe diameter. A smaller annulus imparts higher
velocities for a given injection rate.

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MINIMUM ANNULAR VELOCITY IN FEET PER MINUTE

528 (√DC)
D = Density of material in pounds per cubic foot
C = Chip diameter in inches
528 = constant (increases 5% compounded by 1000’)
528 (/165x .5) (165 average rock density x .5 – ½” diameter of rock)
528 (/ 82.5)
528 x 9.08
4,794 Feet Per Minute at 1000’

TO INCREASE CONSTANT BY 5% PER 1000’

2000’ – 528.0000 X 1.05 = 554.4

3000’ - 554.4000 X 1.05 = 582.12
4000’ – 582.1200 X 1.05 = 611.226
5000’ – 611.2260 X 1.05 = 641.7873
6000’ – 641.7873 X 1.05 = 673.8766
7000’ – 673.8766 X 1.05 = 707.570
8000’ – 707.5700 X 1.05 = 742.94
9000’ – 742.9400 X 1.05 = 780.087
10000’ – 780.0870 X 1.05 = 819.091

CUBIC FEET PER MINUTE - MINIMUM REQUIREMENTS

CFM = AV (H² - D²)

183.3
CFM = Cubic Feet per Minute
AV = Annular Velocity
H = Hole Diameter
D = Drill Pipe Diameter
183.3 = Constant
CFM = 4794 (8.75² - 4.5²)
183.3
CFM = 4794 (76.56 – 20.25)
183.3
CFM = 4794 X 56.31
183.3
CFM = 269,950
183.3
CFM = 1,473

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DETERMINE BAILING VELOCITY AND SCFM REQUIREMENTS

Let’s determine the recommended bailing velocity of a 7 7/8” hole dusting with
4 ½” drill pipe at 6000’ when drilling sand. (Sand weight is 165 lbs/ft³)

First we use a simplified formula to get an estimate>

V = 528 D¹⁄² C¹⁄² (U.S. Units)

Where V = Bailing Velocity in Feet per minute
D = Rock Density in pounds per cubic feet (see appendix)
C = Diameter of Rock cuttings in inches

We assume a large chip size of ½”, so that we are assured of cleaning small ones
from hole.

V = 528 ⁰⁃⁵C⁰⁃⁵
V = 528 (165) ⁰⁃⁵ (0.5) ⁰⁃⁵
V = 4795 FT/MIN (1000’ Depth.) = 6119 ft/min (6000’ Depth)

A good usable rule of thumb is to add 5% compounded per 1000’ to compensate

for depth and compressibility changes.

Now that we have the recommended bailing velocity the following formula will
be used to determine the CFM required.

CFM = V (D ²н-DDP²)
183.3

Where: V = Bailing Velocity In ft/min

Dн = Diameter Hole in Inches
DDP = Diameter Drill Pipe in Inches
183.3 = Constant Conversion Factor (U.S. Units)
CFM = Standard Cubic Feet Per Minute

CFM = V (D ²н-DDP²) = 6119 (7.875² - 4.5²) = 6119(62.01 – 20.25) = 1394 cfm

183.3 183.3 183.3

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 Air Drilling Manual

Recommended Air Requirements for Dust Drilling SCFM

Hole Size Drill Pipe Depth/Feet

1000 2000 4000 6000 8000 10000 12000
SCFM
16”–17 ½” 4½ 7481 7854 8658 9544 10520 11599 12786
14 ¾ - 15 4½ 5356 5624 6201 6837 7537 8310 9162
12 ¼” 4½ 3395 3565 3929 4332 4775 5264 5803
11” 4½ 2635 2766 3049 3362 3706 4086 4504
9⅞ 4½ 2021 2121 2339 2578 2842 3133 3454
8 ½-8 ¾ 4½ 1473 1546 1704 1879 2071 2283 2517
7⅞ 4½ 1092 1147 1264 1393 1536 1693 1867
6¾ 3½ 871 914 1008 1111 1225 1351 1489

* Recommended additional 30% for mist drilling and directional wells.

Air Volume (SCFM) Correction Factor For Altitude And Ambient Temperature

ALTITUDE IN FEET
Temperature ˚F 0 1000 2000 3000 4000 5000
-40 .805 .835 .866 .898 .932 .968
-30 .824 .855 .886 .920 .954 .991
-20 .844 .875 .907 .941 .976 1.014
-10 .863 .895 .928 .962 .999 1.037
0 .882 .915 .948 .984 1.021 1.060
10 .901 .935 .969 1.005 1.043 1.083
20 .920 .954 .990 1.026 1.065 1.106
30 .939 .974 1.010 1.048 1.087 1.129
40 .959 .994 1.031 1.069 1.110 1.152
50 .978 1.014 1.051 1.091 1.132 1.175
60 .997 1.034 1.072 1.112 1.154 1.198
70 1.016 1.054 1.093 1.133 1.176 1.221
80 1.035 1.074 1.113 1.155 1.198 1.244
90 1.055 10.94 1.0134 1.176 1.221 1.267
100 1.074 1.114 1.154 1.198 1.243 1.290
110 1.093 1.133 1.175 1.219 1.265 1.313
120 1.112 1.153 1.196 1.240 1.287 1.336

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 Air Drilling Manual

AIR HAMMER DESCRITION

The hammer selection can be the most complicated option to consider since there are
many designs and the details of each hammer’s operational characteristics (i.e. piston
weight, frequency, actual stroke length, etc.). These tools are chosen according to area,
bit size design and well design. With different types of tools, we can match the one that
best fits your needs.

Hammer Configuration

• Choke size should be determined to operate 350 psi differential across

the hammer

• Hammer with heavy piston has been found to be faster in misting

and/or hard rock applications

• Hammer with lighter piston but higher frequency has been found to
be faster in medium to soft rock while dusting

Conventional Air Hammer Design

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Air Hammer Comparison Chart

Air Hammer Comparison

Hole Tool Tool API Piston Piston Air Req. BPM @
Size Series O.D. Conn. Weight Stroke (CFM) @ 350 psi
Range 350 psi
3 5/8” – Dominator 3.12” 2 3/8” 11 lbs. 4.00” 450 2200
3 7/8” 350¹ Reg. Pin
4 1/4” – Dominator 3.75” 2 3/8” 18 lbs. 4.00” 620 2000+
4 7/8” 400¹ Reg. Pin
6” – 6 Dominator 5.625” 3 1/2” 57 lbs. 4.00” 990 2040
3/4” 600¹ Reg. Pin
7 7/8” Dominator 6.75” 4 1/2” 87 lbs. 5.13” 1165 1479
750¹ Reg. Pin
7 7/8” - FAM-Us 7.125” 4 1/2” 94 lbs. 5.00” 985 1580
9 1/2” 8² Reg. Pin
8 1/4” – Dominator 7.125” 4 1/2”112 lbs. 3.35” 985 1579
9 1/2’ 880¹ Reg. Pin
9 3/4” – Dominator 9.06” 6 5/8”167 lbs. 5.50” 2000 1450
11” 1000¹ Reg. Pin
12 1/4” Mach 132¹ 10.750” 6 5/8”314 lbs. 5.90” 2500 1277
– 17 Reg. Pin
1/2”
17 1/2” SW 15³ 14.750” 8 5/8” 385 lbs. 4.00” 2100 1200 @
– 26” Reg. Pin 250 psi
Information above is based on hammer manufacturers charts.

¹ – Hammer manufactured by Halco America

² – Hammer manufactured by Puma Tools in Chile
³ – Hammer manufactured by Drillmaster International

Check Valve

The check valve assembly consists of an aluminum check valve with a spring. The check
valve head is fitted with a permanently molded rubber which seats the check valve in
the internal bore of the backhead, virtually eliminating potential air leakage.

Rubber coated spring-loaded stem, which stops flow back through the hammer when air
supply has been stopped.

Piston

The only moving part of the hammer, the piston travels at very high frequency and
transfers energy to the bit and formation. Usually the heavier part of the hammer, the
piston may travel at 800 to 1700 beats per minute. The piston, which has a large contact

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area with the cylinder to minimize wear on the piston & cylinder bore, directs the
airflow thereby eliminating the need for an internal cylinder.

Bit Retaining Rings

Two semi circle devices which are captured between the driver sub and the top bit
bearing to keep the bit engaged in the hammer and provide the freedom for the bit to
travel from off bottom to on bottom position.

Driver Sub – (Chuck)

Internally splined drive collar attached to hammer that aligns with splined section of bit
to transit rotational force from hammer and drill string to the bit. Polymer pins between
bit and driver sub splines eliminate metal-to-metal contact and help prevents galling on
the 12” and 18” series bits.

Description of Air Hammer Operations

Air hammer operation begins with the hammer bit off bottom. Bypassing air through
the timing ports and through the piston and bit.

As the hammer is lowered to bottom, the bit slides up in the hammer and moves piston
up. The lower chamber air ports in the piston align with the feed tube windows and the
lower chamber is charged (pressurized) starting the piston in the upward stroke. The
piston lifts off the blowtube (standard hammer) or seal area (FAM-Us) allowing the
lower chamber to exhaust through the bit. The feedtube windows misalign with the
lower chamber ports at this time.

Bottom Chamber exhausting Bottom Chamber exhausting

Conventional Air Hammers FAM-Us Series Hammers

While traveling upwards, the top chamber is charged when the feedtube windows align
with the upper ports in the piston. When the pressure in the top chamber exceeds the
upward force of the piston, the lower chamber is exhausted, thus the piston stops and

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begins its downward travel. The piston travels downward with great velocity until
impacting the bit strike face and sending the energy through the hammer bit and into
the formation.

As soon as the piston impacts the strike face area of the bit, it quickly rebounds and the
cycle is repeated until the bit is picked up off-bottom or is not properly in the on bottom
position (drilled off and not keeping proper weight on bit).

Off Bottom On Bottom

Air Flows Freely Bit Set on Bottom

through the bit allowing pressure
in lower chamber

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On Bottom On Bottom

As piston moves upward Pressure in upper

the lower chamber is exhausted chamber forces piston down

On Bottom

Piston strikes bit and cycles starts again

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Best Drilling Practices

Along with the improved hammer and bit design, field operations have made
improvements which can be documented as “Best Drilling Practices” for percussion
applications.

It has been noted in field operations that in hard formations, a hammer with a heavy
piston and/or long stroke will usually out penetrate a hammer with a light piston
and/or short stroke, especially in “misting” applications. However, it is difficult to see a
major difference in the rate of penetration in softer formations and/or when “dusting”.
It is also worth noting that the bit life is often extended with the lighter piston and/or
short stroke hammers in soft formations. Thus, for example in Terrell County, where
most of the applications have medium formation strengths and can be dusted, a hammer
with a higher frequency but moderate impact strength (average piston weight; average
stroke) delivers the optimum rate of penetration and bit life combination.

Air Volume

• Minimum A.V. of 3000 ft/min. (Angel’s curves)

• Optimum A.V. of 5000+ ft/min. (Field experience)

• 30% additional air volume suggested for misting and/or directional

applications

Air Volume suggested for drilling and cleaning these straight air circulation holes is
suggested to be enough to deliver an annular velocity of 5000 feet/min. It is also
suggested that an additional 30% air volume should be used when misting or drilling a
directional hole.

The FAM-Us series hammers have a “by-pass” choke for allowing additional air to be
circulated, (for hole cleaning) without running the hammer over its optimum operating
parameters. The Halco series hammers do not have the “by-pass” choke system.

Bypass Volumes for Hammer Chokes

PSI 1/8” Choke 3/16” Choke 1/4” Choke 5/16” Choke 3/8” Choke
200 psi 34 76 136 212 306
250 psi 42 94 168 262 377
300 psi 50 112 199 311 449
350 psi 58 130 231 361 520

The optimum differential pressure ranges from 350 to 380 psi while “dust” drilling,
therefore the choke size will be installed to allow the hammer to operate in this range. It
is important to have the means to calculate accurate air flow so that the proper choke is
installed.

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Air Hammer Operation

Air Hammers are primarily used to improve penetration rate and control deviation in
medium to hard formations.

Bit weight, torque loads and rotation speed can be reduced when compared to
conventional rotary drilling. Air Hammer Bits require only 200 to 500 pounds of down
pressure per inch of bit diameter. (ex.: 7 7/8” = 2000 – 4000 lbs.). In highly deviated
areas, a lighter bit weight may be required than the rule of thumb method. The light bit
weight required by the air hammer eliminates the need for additional drill collars.
Excessive weight on bit will accelerate bit wear.

WOB & RPM

• WOB should be minimized but must maintain a “closed” hammer

• Typically 500 lbs or less per inch of bit diameter is found to be sufficient.

• RPM should depend upon formation, hole size and frequency of the hammer

• RPM with high frequency hammer in soft formation would utilize higher RPM
(i.e. 40 – 60 RPM for 8 3/4” hole size in shale)

• RPM for hard abrasive formations in large hole sizes, (12 1/4” – 17 1/2”) should
be as low as possible. (i.e. 10 – 20 RPM)

The short rapid blow of the downhole air hammer provides for good penetration rates
while drilling straight holes. When increasing the blows per minute, (BPM), an
accompanying increase in the rpm may be required. When drilling in softer formations,
the rpm’s may have to be increased.

Torque loads and rotation speeds are much in air hammers than rotary bits. A rotary
speed of 30 to 45 rpm’s will allow the inserts to penetrate new formation after each blow.
The piston drives its energy through the bit and into the formation. After fracturing
occurs, the inserts are rotated to a new position. Bit rotation should also be as slow as
possible to maintain a smooth operation with as little torque as possible.

Drilling speed and the ability to clean the wellbore are proportional to the amount of air
pressure and volume used. Air hammers require no more air volume but higher
pressures than rotary drilling. Different rock types and conditions will dramatically
affect penetration rates.

Hammer Bit Application Procedures – Rig Site

1. Examine hammer to make sure no foreign material has entered the tool.
2. Torque ALL connections to proper requirements. Do not attempt to tighten all
connections at the same time.

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Recommended Torque for Air Hammers

Hammer Series Pin Connection Backhead to Chuck to
(ft./lbs.) Wearsleeve Wearsleeve
(ft./lbs.) (ft./lbs.)
Dominator 400 6,800 2,600 2,600
Dominator 600 9,600 7,900 7,900
Dominator 750 19,000 16,700 16,700
Dominator 880 19,000 19,400 19,400
FAM-Us 8 19,600 19,400 19,400
Dominator 1000 47,000 42,000 42,000
Mach 132 47,000 46,000 46,000

It should be emphasized that the torque values shown in the table are minimum
requirements. The normal torque range is from the tabulated figure of 10% higher.

3. Test fire the air hammer on the rig floor before tripping in the hole. Place the
hammer and bit on a block of wood and turn the air on slowly until the air
hammer “fires”.
4. While TIH, pour one quart of rock drill oil for every ten stands of drill pipe. Use
the recommended rock drill oil for the air hammer.
5. Be cautious when approaching bottom. Establish the off bottom pressure before
beginning drilling operations. Be sure that the rock drill oil and/or mist is on the
recommended settings. Always make sure you’re off bottom pressure is normal
and that you have circulation before going to bottom with the air hammer.
6. Engage the rotary table before approaching bottom. Allowing the air hammer to
fire before starting rotation may cause premature insert/bit body breakage.
7. Set Rotary Torque at 22% of capacity (reviewed by rig)
8. Engage the hammer slowly. Do Not Attempt to put the required WOB all at
once.
9. RPM’s and WOB should be adjusted to allow the bit to run smoothly. In most
cases, RPM will be as slow as possible to maintain consistent torque reading.
10. After drilling Kelly down, always leave at least 12 inches on the Kelly, the rotary
table should remain turning, the brake handle locked and the bit allowed to drill
off. After the bit drills off and the hammer quits firing, raise Kelly about 2’ to 3’
off bottom and blow hole clean before making a connection. If mist drilling,
allow hole to unload before making a connection.
11. Do not break the air until Kelly bushings clear the floor. Never break the air
close to bottom as this may allow cuttings into the hammer, causing the hammer
to plug and resulting in a trip to replace the hammer.
12. Always keep a watch on the air pressure and monitor the air chart at all times. If
you have any pressure increases, pick up off bottom and monitor the pressure.
Make notes showing the reason for the increase. The pressure must return to the
normal off bottom pressure before resuming drilling.
13. The on bottom pressure, when the air hammer is closed, should be 80# to 100#
higher than the off bottom pressure. This is based on “Dust” drilling
applications. Mist drilling will carry a higher differential. This on bottom
pressure should remain steady while the bit is on bottom drilling.

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14. Do Not keep trying to get the hammer to drill. If the bit is broken, (shanked),
this will only tend to drive the bit head deeper into the formation. This will also
lead to additional failures.
15. The following may result from a “shanked” hammer bit:
• ROP – rate will slow or cease
• Pressure may fluctuate dependent upon where the bit is “shanked”.
• Hammer operations will be erratic
16. If any of these occur, pick up off bottom, compare the off bottom pressures to
previous pressures.
17. Blow hole clean
18. Turn off air supply and set hammer on bottom where you will put several turns
in the drill string “before” TOH. This procedure is to insure that the drill string
and air hammer connections are tight before TOH. Note the wraps in and what
you got back. Quick Rule of Thumb: “6 in and 6 out”

Note: If drilling out float equipment, drill out cement and float equipment using a
mist drilling system. You will drill 5’ to 10’ of new formation, you will pick up off
bottom and blow hole dry. Dry up hole and continue “dust” drilling until hole
conditions require changes to be made to the air drilling system.

Automatic Drillers

• Make sure automatic driller is serviced periodically or between wells.

• The use of an automatic driller and appropriate braking system will keep a
consistent low WOB and more uniform RPM’s.
• Keeping a consistent WOB and RPM is “KEY” to minimizing the downhole
operating parameters which are typically significantly greater that the
surface.

• Only qualified personnel should attempt to operate automatic driller while

using the air hammer.

LUBRICATION

It is recommended that drill rigs used for downhole drilling be equipped with automatic
oilers. The use of a positive displacement pump for injecting oil into the air stream is
preferred to the aspirator type of pump.

The rate of lubrication is a function of air hammer consumption, which is dependent on

the operating pressure and the choke size being used. Recommended minimum oil
requirements can be calculated for a specific application using the rule of thumb.

Rate of Lubrication = 0.2 quarts per hour per 100 SCFM

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Over the past years, the need for environmentally safe oils has been increasingly
apparent due to governmental regulations and increasing environmental awareness. For
environmentally sensitive applications where the use of petroleum hydrocarbon oils is
prohibited, a number of rock drill oil

Suppliers are offering synthetic oils specially formulated for these applications. As with
the standard rock drill oils, the viscosity grade of sympathetic oils must be proper for
the climatic and operating conditions at the drill site and is, therefore, dependent upon
the ambient temperature, air delivery temperature and the operating pressure. For any
environmentally sensitive drilling application, the selection of the lubricant must be
coordinated with the supplier of the lubricant and the regulating agency at the drill site.

Prior to start up of drilling, the following lubrication practices are recommended:

1. Coat inside diameters of hammer and drill pipe with rock drill oil.
2. Make sure that all threads, stress relief grooves and make up faces are coated
with thread lubricant.
3. Check the oil level in the lubricator and make sure that it is filled with the
recommended grade of rock drill oil for the specific application and location.
4. Determine the hammer air consumption based on pressure and choke size.
Calculate or look up the lubrication rate for the hammer in the table in the
Operating and Maintenance Manual. Remember to use the next higher grade of
rock drill oil when drilling with water injection.
5. Adjust the lubricator setting to the proper lubrication rate.
6. To insure that the lubricator is working, the main air valve should be partially
open for a couple of minutes with the rotary headset for a low RPM. After
turning the main air valve off, the air hole in the face of the bit should be checked
for evidence of a thin film of oil.

When drilling, it is recommended that the level of oil in the lubricator be monitored
on a regular basis. Drilling with the lubricator empty is extremely hazardous. It is
also recommended that air be blown through the inside of the drill pipe to remove
debris when adding a new section of drill pipe and that a quart of oil be poured
down each section of pipe.

Most manufacturers of air hammers recommend the use of rock drill oils for
lubrication. These oils are specially formulated to provide operating characteristics
such as:

1. High film strength

2. Extreme pressure characteristics
3. Resistance to shock loading
4. Resistance to corrosion
5. Emulsibility

These are all useful in promotion trouble free operation of the air hammer.

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Hammer Energy

Piston size determines the area that the air can act on to provide the force that causes
the piston to accelerate and strike the bit. This energy is transferred to the bit in the
form of an impact wave and travels through the bit to the formation through the
inserts. This energy wave crushes the formation directly under the insert and
resultant stresses cause cracks and secondary fractures in the formation.

The following simplified formula can be used to understand this relationship of

piston size, PSI and stroke to blow energy:

Blow Energy = PSI x Piston Area x Stroke

(Ft./lbs.) 24

It is evident that while stroke and PSI increases are linear the area is a squared
function of the diameter thus a small increase in diameter will make a much larger
increase in blow energy.

Since R.O.P. is related to the energy, (work), put into the formation the following
simplified formula can be used to understand the horsepower input:

H.P.= Blow Energy x Beats Per Minute

33,000

From this relationship it is easy to understand that piston beats per minute, (B.P.M.),
and blow energy per stroke determine the H.P. is reached. The optimum horsepower
is limited depending on hole cleaning capabilities and downhole equipment design
limitations. Excessive blow energy can cause piston breakage, (cracking), bit failures,
and premature insert damage.

The hammer size should be selected as close to the size of the hole drilled as possible
and leave adequate area for the cuttings to pass. This will not only insure a large
robust shank on the bit but will provide a hammer with the largest piston for
efficient rock destruction.

The manner in which a formation fractures and its resistance to fracturing,

(compressive strength), can effect R.O.P. greatly. Any friable rock can usually be
drilled with a hammer bit and the R.O.P. will vary with the compressive strength
and with the porosity of the formation. Unconsolidated formations such as clay and
gravel should not be drilled using a hammer and a better choice would be roller cone
rock bits.

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BHA and STABILIZER SELECTION FOR PERCUSSION DRILLING

In General, percussion bottom hole assemblies are pendulum for straight holes and
packed for directional holes. In most straight hole application, hammer operators, (rig
site supervisors provided by the hammer company), will suggest a slick assembly,
(pendulum), because it maintains a straight hole with minimum drag, (minimum drag
reduces the chance of the hammer not closing completely). However, in some instances
a pendulum assembly with the # 1 stabilizer sixty feet from the hammer bit and the # 2
stabilizer ninety feet from the hammer bit will be utilized to maximize the pendulum
effect. (NOTE: 1/16” to 1/8” undergage stabilizers are recommended to minimize drag
when used with the air hammer)

The packed hole assembly for percussion drilling is assembled in three ways for mild,
medium and severe cases of crooked hole problems. The most common BHA would be
the mild, (for directional holes), with the hammer bit, air hammer, 1/16” undergage
near bit stabilizer, full drill collar, and finally another 1/16” undergage string stabilizer.
Other directional BHA’s may include stabilizing the hammer either on the driver sub,
retainer or the hammer housing.

In place of the stabilizers, roller reamers are advised when drilling with an air hammer.

When planning on a bottom hole assembly for use with the air hammer, consult your
hammer company or bit company to determine which bottom hole assembly is better
suited for the hammer bit.

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HAMMER BIT DESCRIPTION

Blow Tube

Delrin tube which is pressed into the upper bore of the bit. This tube mates in the
bottom ID of the piston, seals the lower chamber and starts the piston in an upward
direction after it strikes the bit. The blow tube also exhausts the lower chamber after the
piston clears it to start the next cycle.

Bit Strike Face

Uppermost surface of bit that is perpendicular to shank which when contacted by the
piston in its downward thrusts allows energy to be transferred from piston through bit
and ultimately to the formation.

Upper Bearing Surface

Area supported by the upper bearing which helps align the bit and keep the bit as close
to parallel with the hammer as possible.

Bit Retaining Area

The upper area of bit with the smallest outside diameter which allows the bit to be
captured by the bit retaining rings and also allow the bit to travel in and out of the
operating positions.

Drive Splines

Externally splined section of bit that mates with the internally splined section of the
hammer to transfer rotational force from drill string through hammer to the bit.

Lower Bearing Surface

Area of the shank closest to the bit head that helps support the bit in the driver sub
when on bottom.

Dual sleeve retention system

A dual sleeve retainer that features a “positive lock” system. The inner halves fit over
the drive sub and retention ring on the bit. The outer sleeve then slides down over the
inner sleeves protecting them from the cuttings. This is a patent pending system.

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 Air Drilling Manual

Marquis Hammer Bits

Double Sleeve Bit Retentions System (Patent Pending)

Large Solid Retaining Shoulder Drive Sub lower onto bit Outer Sleeve slid down
and inner sleeves placed on bit to protect the inner sleeves

Head Section

Bottom area of hammer which contains the inserts that transmit energy from the
hammer to the formation. Contained in the head are the exhaust ports which allow air
from hammer to travel through bit and help carry cuttings up the annulus and to the
surface.

US SYNTHETIC

U S Synthetic is the leading manufacturer of polycrystalline diamond inserts used in oil

and gas drilling
• Proprietary interface technology
– Enhances diamond/carbide attachment strength
– FEA improved designs favorably manage residual stresses inherent to
diamond inserts for longer life
• Application-specific percussion insert properties:
– Highly impact resistant
– Resistant to wear (long life)
• ISO 9001 certified quality program
– Delivers defect free products

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 Air Drilling Manual

– In-house testing necessary to develop impact resistant diamond inserts.

U S Synthetic facilities allow testing of multiple designs quickly to improve product

“G” Feature

Diamond enhanced inserts are placed on the O.D. side of the hammer bit to stabilize and
to prevent drilling an undergage hole. These inserts are set at 90 degrees to the
longitudinal axis of the bit and project out to just smaller than gage diameter.

It is desirable to always have the “G” feature undersize to the diameter of the gage
cutters. This feature is designed to become effective when the gage wears or breaks
and eliminate costly reaming of hole prior to running another bit.

BIT SIZES ‘G’ TOLERANCE API BIT GAUGE

6’ – 13 ¾” Nominal Minus 1/32” +1/32” minus 0

14” – 17 ½” Nominal Minus 1/16” +1/16” minus 0
17 5/8”- 26” Nominal Minus 3/32” +3/32” minus 0

Hammer Bit Design

Blow Tube

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39