DTH Hammer Fluid Flow Control System for Pressure Regulation
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Solution Overview
Problem
Current down the hole (DTH) hammers, particularly reverse circulation (RC) hammers, are designed to be inefficient to prevent mechanical failures due to excessive fluid pressure and flow rate, leading to increased operational costs and energy requirements when drilling deep holes, as they incorporate built-in inefficiencies to protect components from excessive airpower.
Innovation Solution
A DTH hammer with a fluid flow control system that adjusts the annulus radial width to vary fluid pressure and flow, allowing for efficient operation by matching compressor output with the mechanical limits of the device and environmental conditions, using a ring and flow control body to define the flow path annulus and move between choke positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current RC hammer design incorporates built-in inefficiencies to protect components from excessive airpower, then reliability is improved, but energy efficiency deteriorates and compressor power requirements increase
Solution Approach 1:
The patent applies dynamics by making the flow restriction adjustable rather than fixed. The movable flow control element (216) allows the annulus width (Aw) to be varied, enabling the system to adapt between protected operation mode (smaller Aw for short holes) and efficient operation mode (larger Aw for deep holes), resolving the contradiction between reliability and energy efficiency
Solution Approach 2:
The patent changes the parameter of flow restriction from a fixed design value to a variable parameter. By moving the flow control element to different positions, the annulus radial width Aw can be adjusted, allowing optimization of both component protection and energy efficiency under different operating conditions
2Use of energy by moving object
If flow restriction is reduced to improve energy efficiency, then compressor power requirements decrease, but component protection is compromised leading to potential material and lubrication failures
Solution Approach 1:
The system dynamically adjusts the flow restriction level based on operational needs. The movable flow control element enables real-time modification of the annulus width, allowing operators to balance between energy efficiency and component protection rather than being constrained by a fixed design
3Productivity
If larger compressors are used to compensate for in-line losses in deep hole drilling, then productivity is improved, but operational costs increase
Solution Approach 1:
The patent changes the flow restriction parameter to be variable, allowing optimization for deep hole drilling without requiring oversized compressors. By adjusting the annulus width Aw to a larger value, sufficient pressure differential can be achieved at the piston while using appropriately sized compressors, reducing operational costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables increased fluid flow efficiency and pressure regulation, allowing the DTH hammer to operate effectively across varying drilling conditions without the need for excessive compressor power, reducing operational costs and extending component lifespan.
Implementation Method 1
a fluid flow control system arranged to facilitate control of fluid available to drive the piston; the fluid flow control system comprising a ring having an inner diameter which forms an outer radius Ro of a flow path annulus through which a fluid from an upstream fluid supply flows to drive the piston
Implementation Method 2
The working fluid is pressurised and delivered at a pressure and rate dependent on many factors including the capacity of the driving compressor/pumping system
Data Source
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AI summary
A down the hole hammer (10) incorporates: an inner tube assembly (100); a fluid flow control system (200); a bit retaining system (400); a porting sleeve (600); and a piston (700). Each of the: inner tube assembly (100); fluid flow control system (200); bit retaining system (400); porting sleeve (600); and piston (700) in their own right provide benefit to the overall operation and/or reliability of the hammer (10).