Flushing head / rotary distributor / rotary union for well drilling rigs are flushing heads that enable a well drilling rig to supply water from the pump to the drilling tool. The flushing head is a rotating element that feeds water without losses into the drill pipe. Flushing heads can be made of steel or stainless steel.
1. Flushing head / rotary distributor / rotary union for well drilling rigs
2. The construction of a well drilling rig with a rotary distributor / flushing head for wet drilling
3. The rotary union or the flushing head for the well drilling rig or the gear motor and the corresponding shaft connections
4. Build flushing head for wells yourself or buy it as a kit
5. The construction of the rotary distributor / flushing head for your well drilling rig or gear motor made of stainless steel
6. The exact arrangement of the individual parts within the flushing head with the stuffing box packings and the ball bearings
7. The shaft ends of the rotary distributor / flushing head
8. The flushing head seals as stuffing box packings and the safety overflow
9. Changing the stuffing box bands on the rotary distributor / flushing head
10. The house-height advantage of a stuffing box packing over a mechanical seal in a flushing head for a well drilling rig
11. The material of the entire rotary union or flushing head
12. The attachment of the thread adapter (screw connection) for the flush pipe linkage to the rotary distributor / flush head
13. The production of the individual parts of the rotary distributor / flushing head with a CNC lathe
14. Further websites on the subject of rotary distributor / flushing head for well drilling equipment
Today it is impossible to imagine well drilling equipment without rotary unions or flushing heads, because what was not so important a few years ago has become an increasingly important commodity in recent years. We speak of water. But what does a flushing head for a well have to do with water? This question can be answered relatively easily. In today's society we consider water to be a "normal good" which is available in abundance and always available. Unfortunately this is not always the case! Water has become much more expensive in recent years and will continue to rise steadily but gradually in the future. Unfortunately, this cannot be prevented, because the water shortage in Europe and especially in Germany will continue to increase, as we can already see. Because the last summers are getting hotter and hotter and the water is getting scarcer.
Due to the rising temperatures, it is only natural that the rainy seasons are getting less and less and we still want to have our water balance secured. To reach this state, however, a small effort is required to get to the water in the ground, as a direct source of drinking water. For this purpose, well drilling equipment is an important asset, which is also recognized by homeowners and the idea of drilling a well matures itself. Now, of course, you can say to yourself, ok, I have the possibility to borrow a well drilling machine with a rotary distributor flushing head and use it to drill a well in my garden. This idea is very good, but if you now start looking to rent such a water rotary distributor flushing head as a well drill, you will soon realize that this can and partly is an almost hopeless undertaking. Because such professional well drilling equipment can hardly be found at the rental locations. And when you have found a drilling rig you will find that it is only intended for dry drilling and usually only allows a maximum depth of 5-7 meters. In order to penetrate to greater depths, it is indispensable to use water flushing methods equipped with a rotary distributor flushing head to penetrate to very great depths.
Water must be constantly pressed through a pipe to flush out the layers of earth around the drill. For this purpose a rotating element with a rotary union or flushing head or a rotary distributor for water must be connected. If you want to use these great depths, you can also get a quote from a professional well drill master, who can quickly take a drilling price of 2000-2500 Euro for a depth of 14-16 meters, if the well installation is already included. But who can afford such high prices, if it is only to supply his garden with free water and if possible also to connect his house to the well. This idea is even more tempting, because then the costs for water will be reduced to almost zero. Imagine supplying your washbasin, toilet and bathtub with filtered well water from great depths. You save extreme costs for life, which you would otherwise have to pay. Now, in order to penetrate to such great depths of water, where the water does not dry up and is also very clear and clean, you should always drill to a depth of over 13 metres to 20 or 25 metres. However, we do not want to quantify the costs for this, especially if you have to consider that a guarantee from the well drilling master about the success of the well drilling is excluded in the offer. If no water is found, one can decide to invert the costs of 1500 Euro or more to make a second drilling and then to play the lottery in the hope of success. For this reason, more and more people are deciding to save these costs and build themselves a simple wet well drilling machine, which is not very expensive and you can drill your own wells for very little money anytime and as often as you want, until you succeed. Many garden owners or land owners then pool some money and build a flushing head well drill for wet flushing in a joint project. So everybody can use the device as often as he wants and as long as it takes. Without time limit!
The construction of a well drilling rig with a rotary distributor / flushing head for wet drilling
Once the decision to build a well drilling rig has been made, you can start building your own independent well drilling rig. It is practically not very complicated. Such a device for drilling wells consists essentially of a support sub-frame, a mast, which allows the guide carriage to run on rollers. The frame that supports the construction can be placed on two wheels for easy transport, making it very easy to get to the well drilling site. The guide carriage that can be moved up and down the mast is only equipped with a gear motor. To enable the up and down movement, a cable pull, which is electrically driven, is usually attached to the carrier frame. This can then move the carriage up and down. In order to bring the entire carrier frame with the mast naturally into line on the borehole, it is always advisable to use at least three supports from a large trailer, which can be set to the desired position by means of a crank handle. The whole construction is already aligned. However, a flushing head or a rotary distributor / rotary union for water distribution must be attached to the gear motor as the almost most complicated part. This flushing head must be flanged directly to the gearbox output shaft and can be provided with a water connection. Due to the intelligent design, the shaft can rotate and still the water can be transported into the drilling spindle without any loss. This is the only way that water can be continuously pressed into the flushing head via a pump while the drill bit and drill pipe are rotating and then be further discharged into the rotating drill pipe. Now you can penetrate the ground almost indefinitely deep via the flushing method and drill until you have clear and clean water and do not have to worry that the water will dry up once. If this should happen later, simply take your well drilling machine with the rotary union / rotary distributor / flushing head and drill another new hole without additional costs!
The rotary union or the flushing head for the well drilling rig or the gear motor and the corresponding shaft connections
Some time ago we decided to develop a flushing head for well drilling equipment, so that you only have to flange it to your motor shaft or gear output shaft and you can start drilling with your well drilling equipment. Since this is a complex part of a well drilling rig and most people do not have the possibility to produce such a flushing head at an affordable price, we have taken over this part for you and would like to supply you with inexpensive, new flushing heads and offer them for sale in our online shop as a finished assembly or to build it yourself. Since all gear motors always have a different shaft diameter and a different thread attachment to screw the drill pipe to the flushing head, we have decided to leave all options free for you. The motor shaft side of the rotary union or the flushing head is equipped with a 20 mm bore, so that you either have to drill the bores yourself to adapt the shaft of the flushing head to your gear motor, or weld the shaft end directly to an existing shaft hub, which is located on the gear shaft. A keyway is not required in this case, because we have provided the flange side for your gear motor with two screws which engage directly into the keyway, thus ensuring the necessary power transmission to the flushing head shaft. The same applies of course to the side of the flushing head shaft to which the drill pipe must be connected. Here we have prepared an attached shaft outlet which has a bore for the water supply with a diameter of 22 mm. An enormous amount of flushing water can be pressed through this drilling channel and directly transferred to the drill rods. You have the possibility to weld your threaded connection to this shaft end, so that the rotary union or flushing head can be used and installed for any diameter and any variation. Likewise, we also offer you the suitable screw connections for the drill pipe, so that you can also build the drill pipe yourself. But more about this later.
Build flushing head for wells yourself or buy it as a kit
In order to save costs, future well owners have many possibilities to drill or build their own well. The definitely most complex part is always the rotary distributor or the rotary distributor flushing head (rotary union) of the well drilling equipment. All other parts, such as the gear motor and the steel parts as well as the gear carriage, which holds the gear, can also be produced well by yourself. But with the flushing head it is somewhat different. On our website we offer a finished flush head to install it on the motor. But if you want to build your own rotary distributor flushing head for the well drilling machine, you will soon realize how much it can cost. Because first of all the technical drawings have to be made and for that you need some knowledge. But that is the even easier part. The second step is to find a company that can also set up individual parts on the lathe and manufacture them for you at a reasonable price. Let's face it, most turning shops will probably not even answer such inquiries or offer extremely high prices or costs, so that the project "build your own flushing head" is quickly off the table. So we would like to supply you in the near future with either a complete flushing head for your well drilling equipment via our online shop or as a kit. So you can buy the individual parts from us as a kit and assemble your (rotary union) flushing head yourself. These basic parts include the continuous shaft and the fixed drum. Furthermore there are the two bearing flanges or pressure flanges on both sides and the pipe double nipple as well as the single screws. Please have a look around our website now to buy either a completely assembled rotary distributor flush head made of stainless steel with bearings and stuffing box seals from us, so that you can build your own flush head.
The construction of the rotary distributor / flushing head for your well drilling rig or gear motor made of stainless steel
The design of the flushing head is such that the main shaft is a shaft with a diameter of 45 mm. This shaft has an internal bore on the gearbox flange side, which can be easily bored out as required. This diameter is 20 mm. The opposite end has a through-hole up to the middle of the shaft, through which the flushing water can flow freely and in large quantities. At the level of the water inlet via the double nipple of the fixed drum, there are cross holes which can guide the water via the drum into the shaft. The drum is also provided with a connection in a 3/4 inch pipe thread and screwed to a pipe nipple. You can simply connect the water supply to this pipe nipple and install a ball valve if required. The drum from the rotary distributor is installed later and can be easily held or fixed around the pipe nipple with a pipe clamp. Thus the flushing head has a secure and firm fit. The drum is supported by two thin ring bearings which are naturally closed on both sides by a protection. In front of the ball bearings there are three rows of cords of a stuffing box packing on each side, which completely secure the shaft against water leakage. We have deliberately chosen a cord seal as stuffing box packing because these are the best and cheapest seals when it comes to sealing contaminated water. These seals are pressed together in three packages by the flange, where the ball bearings are located, and the pressure screws, so that a long sealing surface on the shaft can be created. Only this long sealing surface to the shaft ensures long sealing times with rotating shaft and stationary housing. Since cord seals are coastal, this type of packing is the best and most cost effective way to keep shafts permanently sealed from dirty water. If the square cord seals give way once, the flange can easily be adjusted and everything is tight again! When the square sealing cords to the shaft are worn out, the seals can be removed and turned through 90 degrees and then re-inserted as stuffing box packings into the (rotary union) rotary distributor flushing head. The whole process can be repeated 4 times with these seals.
The exact arrangement of the individual parts within the flushing head with the stuffing box packings and the ball bearings
In this article we would like to explain the exact design of the flushing head for a well drilling rig in more detail. The shaft and the drum are used as the main unit. Here the drum is equipped with the 3/4 inch double nipple with the locking nut and holds everything together well. On each side of the drum there is a pressure flange, which contains the shaft bearing on one side and the function of compressing the stuffing seal on the other. Inside the drum, marked in blue, are the three stuffing box cords which are then pressed together with the flange against the drum stop, thus allowing sealing. The pressure can be easily regulated via the flanges. The studs, three on each flange, have the task of creating the correct counterpressure when tightening the flanges and the seal in the correct position, so that the tightening screws are under pressure and nothing can come loose. The second is to use jacking screws when the bearings need to be pushed off the shaft for maintenance or stuffing box packing replacement.
The shaft ends of the rotary distributor / flushing head
The gear shaft side is provided with a bore and can be easily attached to the existing motor shaft flange by welding or can be brought to the correct dimension by drilling. The opposite side has a recess in which our threaded pipe connections for the flush drill pipe fit and can be fixed by a weld seam. However, you can also drill the hole and integrate and weld or otherwise fasten your threaded distributors for the existing flush pipe rods. We have also integrated a spanner flat for counterholding on the shaft, with which a counterholding can be held when opening the flush pipe rods with a 41 mm spanner.
Attention: The ball bearings, as shown in the picture, are not open at delivery, but are supplied as double-sided closed bearings. We have only removed the bearing covers from the drawing for a better understanding to be able to see how the bearings fit in the flanges.
The flushing head seals as stuffing box packings and the safety overflow
In the following picture we would like to show you how the flushing head is constructed so that the stuffing box packings seal the entire unit. Of course, with long use and very stony water or polluted water, the whole shaft will be flushed around the area. The stuffing box or square cord will cleanly seal the shaft over an area of 24 mm mm on each side of the shaft sealing area. Only this type of sealing guarantees a long service life. If after some time the sealing effect should diminish slightly and water should get through the shaft and the flange tensioning part in the direction of the ball bearing, the water can easily escape to the outside at the two boreholes which are located opposite each other and the user of the flushing head will immediately see the water leakage. Now, simply by adjusting the pressure flange part, the triple packing of the stuffing box can be further compressed and the shaft seal is restored.
Changing the stuffing box bands on the rotary distributor / flushing head
After a certain amount of wear and after retightening the packing of the flushing head several times, the stuffing boxes or the packing cord are worn out on the shaft area and their contact surfaces. To disassemble the entire flushing head, we have attached three jacking screws each, which can now be screwed in to pull the flange with the bearing cleanly under the shafts. Practical like a puller without hits. This guarantees the protection of the entire shaft of the flushing head. Now the stuffing bands can also be removed and the three layers of the square cable are turned num by 90 degrees. This can be done with all stuffing box bands and the bands can be put back into the drum. The worn surfaces of the square cable are now in the direction of tension and the shaft contact can be sealed again. This wear procedure on the flushing head can be repeated 4 times. Only then must new square packing tapes be inserted. A cheaper way of sealing with manual adjustment is only possible with this head and saves a lot of costs.
The house-height advantage of a stuffing box packing over a mechanical seal in a flushing head for a well drilling rig
When designing the (rotary union) rotary distributor flushing head, we deliberately decided to use stuffing box packing. There are several reasons for this, whereby the square cord, i.e. the stuffing box, was the winner. On the one hand, a mechanical seal has an extremely high purchase price in relation to the degree of utilisation when used in a flushing head, where the seals are constantly flushed with fine sand. Of course, a mechanical seal adjusts itself automatically, but due to this constant pressure of the spring pieces on the mechanical seal and the counterpart, the wear is also correspondingly higher. The most important point, however, is that the area of the rings rubbing against each other is very small in order to achieve a sealing effect. This means that the sealing effect can only be achieved with this narrow ring surface, hence the increased pressure of the spring pieces to make the surfaces tight. The pure contact surface is only a few mm wide and as soon as the edges are worn down by the rinsing water and the sand mixture, the wear starts even stronger and the ring wears out faster. A stuffing box packing on the other hand has three layers in our flushing head design. This square cord has a diameter of 8x8 mm. Three layers give a theoretical sealing surface of 24 mm. These 24 mm now seal the drum against the shaft. Now you can imagine how long it will take until a leak will occur with such a large sealing surface? And when the time comes, the pressure can be gently adjusted by readjusting the flanges so that the seal is restored. Furthermore, if the sealing surface is worn, which only starts on one side of the four sides, the stuffing box band can be reused simply by turning it through 90 degrees! So you can use the whole thing four times. Only then is the square sealing cord worn out. Furthermore, the sealing cord costs only a fraction of what a mechanical seal costs as a wearing part. Even the replacement of bearings or the sealing tapes is no problem with our flushing head and can be changed by anyone. And all this without further great costs. So all these are only advantages that have already been successfully used in the past.
The material of the entire rotary union or flushing head
Normally such a rotary distributor flushing head (rotary union) is always made of mild steel, which has a certain strength. This "normal" mild steel has of course also the disadvantage that it comes into contact with a lot of water and then after a long period of use it automatically starts to rust, i.e. corrode. This cannot be avoided with this material. For this reason, we have decided to manufacture the entire flushing head for your well drilling equipment from V2A stainless steel. This means that corrosion build-up can be almost completely avoided and the ball bearings are not affected if the bearing fits are used once and the ball bearings have to be replaced. Also all screws are made of stainless steel, so that also here no corrosion can start.
The attachment of the thread adapter (screw connection) for the flush pipe linkage to the rotary distributor / flush head
We do not only supply you with the flushing head for your well drilling rig, but also with the matching threaded adapters for the drill pipe. So you can see on the picture how our suitable thread adapter fits to the shaft of the flushing head and can be connected to the shaft by a weld seam. It does not matter whether you want to weld a thread adapter as a "male" on the shaft end or whether you want to weld the thread adapter as a "female". Both possibilities are free to your choice.
The production of the individual parts of the rotary distributor / flushing head with a CNC lathe
The production of the individual elements, which later form a flushing head, must first of all be cut to size as raw material blanks on a machine saw. Once this stage has been completed, the CNC lathe is set up and set up so that the machine is loaded with the CNC program and understands exactly how the production process is to be carried out. Once the program is loaded and the raw material is clamped and aligned in the head, the entire part should be roughed in this clamping in order to create the approximate contours that will later serve the shaft. In this process, all steps must be carried out precisely so that the dimensional accuracy is accurate. The most expensive is to work in the fits for the ball bearings for the drum and the shaft in order to place the ball bearings and the seals on them without play. The shaft must also have two surfaces turned on, which on the one hand serve as a sealing surface for the lip seals and on the other hand as ball bearing seats. The two shaft end holes must also be drilled and the cross holes for the water supply. The same is done with the flanges, which can be found on both sides of the (rotary union) flushing head and which exert pressure on the seals.
During the production of the drum housing for the rotary distributor or the (rotary feedthrough) flushing head, similar measures as mentioned above are necessary to start production on the CNC lathe. The raw material has to be precisely aligned in the chuck of the lathe and then the heels on both sides for the bearings and the seals have to be turned in. These surfaces are also mating surfaces and make the turned parts so expensive and complex because mating surfaces always have to be checked by multiple checks using limit plug gauges. In order to give you an insight into how such a CNC lathe works, we would like to show you this video, which does not show the production of a flushing head, but shows exemplary other processes for turned parts during the production on a CNC lathe.
Further websites on the subject of rotary distributor / flushing head for well drilling equipment