200 Ton Dq30-Bq Top Drive for 3000m Land Oil Drilling Rigs

Product Description

Product Description

 The top drive system is a drilling technology that uses a suspended motor (typically electric or hydraulic) to provide the torque needed to rotate the drill string. This system replaces the traditional rotary table and kelly drive methods, offering advantages like increased drilling efficiency, reduced manual labor, and improved safety

1. 1. Typical Parameter

Items	Data	(British System)
Nominal drilling depth (114mm drill pipe)	3000m
Rated Load capacity	1800 KN	200 ton
Working height (96" elevator link)	5205mm	18.24 ft
Rated continuous output torque	27.5 KN.m	20283 lb.ft
Max. Torque of breakout	41 KN.m	30240 lb.ft
Static maximum brake torque	27.5 KN.m	20.283lb.ft
Speed range of main shaft (stepless adjustable)	0~200 r/min
Drill pipe range of back-up tong clamping	85-187mm
Max bore hole of back up tong	200 mm	7.87 in
Mud circulation	64 mm	2.5 in
Rated pressure of the mud circulation	35/52 MPa	5000/7500 Psi
Rotation angle of rotating head	0-360°
Speed of rotating head	2~5r/min
Max.tilt angle of elevator link	Forward 30°, backward 55°
IBOP(double ball valves )	Φ187  6-5/8 REG  70MPa
Saver Sub ( standard )	Φ187  6-5/8 REG  NC50
Working Pressure of hydraulic system	0~14Mpa	0~2280 Psi
Voltage of EX solenoid valves	24 VDC
Rated Power of Main motor	290KW	388.9HP
Rated Speed of Main motor	1200 r/min
Rated Torque of Main motor	2308 N·m	1702.29 lb.ft
Rated Voltage of Main motor	600 VAC
Rated frequency of Main motor	61 Hz
Rated current of Main motor	365 A
Max. speed of Main motor	2400 r/min
Electricity of VFD room	600 VAC/50Hz
Suitable ambient temperature	-45ºC~55ºC
Altitude	≤1,200 m	≤3,937ft
Distance between center of main shaft and center of guide rail	532.5mm	1.747ft
Incoming wire voltage of VFD room	575~625 VAC
Incoming wire frequency of VFD room	47~53 Hz

1. 1. Outline dimension and weight

Items	Data
Dimension of Main Body	4740mm*970mm*1267.5mm
Weight of Main body	8t
Weight of Main body (include transportation frame and one section of guide rail)	10 t
Length of guide rail ( standard 5 sections)	3900mm+4000mm*4+4868mm=24768mm
Weight of guide rail	5t
Weight of VFD room	9.2t
Dimension of VFD Room	5050mm*2300mm*2580mm
Dimension of driller console	870 mm×350 mm×300 mm
Weight of driller console	30kg

 

 

Mechanical system 

The mechanical system is composed of main motor system, air cooling system, brake system, gear box, wash pipe assembly, rotating head mechanism, tilt mechanism, back-up tong mechanism, internal blowout prevention mechanism (IBOP), guide rail and carriage mechanism, container, etc. 
The top drive is powered by an AC frequency conversion asynchronous motor to realize AC frequency conversion drive.

1. 1. 1. Main Motor and Air Cooling System

The main motor is a single top drive special AC frequency conversion asynchronous motor with a power of 290KW. The main technical parameters include:
Rated Voltage 600VAC
Rated Frequency 61Hz
Rated Current 365A
The main motor is equipped with a heater and an explosion-proof wind pressure switch
The main motor adopts forced air-cooling mode.
The air-cooling motor : voltage 380VAC / 50Hz, power 4kW, insulation grade F, protection grade IP55, explosion proof  level ExdIICT4, wind capacity not less than 70 m3/min, air pressure 203mm water column.

1. 1. 1. Break System

The top drive main motor is equipped with a set of special hydraulic disc brake device, which can assist the drill string orientation in the directional inclined drilling operation.
The disc brake device is installed at the upper extension end of the motor shaft, using a pair of Swedish DELLNER cylinders connected by a special hard pipeline, durable. When the speed of the main motor is reduced to 3rpm, the friction forces on the brake disc through the brake cylinder can realize the braking function of the main motor.

1. 1. 1. Gear Box

In order to increase the output torque of the top drive motor, reduce the motor volume and improve the motor performance, one set of gear box is configured.
The gear box adopts involute hard tooth surface gear with secondary bevel gear to realize stable transmission, transmission ratio is 11.91:1. The lubrication in the box adopts the combination form of splash lubrication and forced lubrication by the oil pump circulation.

1. 1. 1. Gooseneck Assembly

The gooseneck is specially designed for well logging. During drilling, corrosion resistant liner and nuts are used to block the upper high-pressure mud pipeline to avoid mud overflow.
One end of the gooseneck is connected with the wash pipe assembly. The wash pipe assembly adopts the super high pressure structure, which is an important part of sealing the high pressure mud and adopts self-sealing and rapid disassembly structure. When the wash pipe and the packing are damaged by wearing and need to be replaced, merely open the cover of upper and lower packing to taker off the whole device without removing the gooseneck and the mud hose. It is easy to stop drilling to replace at any time during the drilling process.
The another end of the gooseneck is connected with the mud hose, and the connection is a 4-inch female union, and the thread type is Fig1003.
A mud prevention device is installed at the connection between the main shaft and the wash pipe to meet the requirements of site operation

1. 1. 1. Rotating Head

One set of rotating head system is configured, which can rotate independently of the main shaft, and the elevator links are suspended on the link adaptor.
Adopt worm gear transmission structure, drive smoothly.
The rotating head can rotate both clockwise and counterclockwise in 360°and can drive the elevator link and elevator to rotate together, so as to grasp the single pipe in the mouse hole and the triple stem on the monkey board.
The rotating head relies on a set of hydraulic motor system to drive the rotation, using the Danfoss cycloid motor, the speed range is 2 ~ 5 r/min.

1. 1. 1. Tilt System

The tilt cylinder can drive the elevator link to swing to realize the tilt forward and tilt backward . The forward tilt function allows the elevator to extend to the mouse hole and the monkey board.  During drilling, the backward tilt function is used to realize the lower end surface of the back up tong close to the drilling platform, so that the drilling tool can be fully utilized.
The tilt range is related to the length of the elevator link, with an forward angle of 30 and a backward tilt angle of 55 (adjustable).
Note: If you need to configure other length links, please communicate with the sales men in advance.
The hydraulic system setting includes the "middle" of the tilt mechanism, under which the elevator link can be automatically returned, that is, the free swing state, to avoid the pressure in the tilt cylinder to cause the impact on the hydraulic system.
 

1. 1. 1.  Counterbalance System

Suspension bail counterbalance system is an important part of the top drive system. The bail is connected with the gear box through the pin shaft, and the upper part is hung on the hook or the traveling block. The main function is to balance the weight of the body.  VSP top drive adopts double hydraulic cylinder with internal force balance mode, which can be directly hang with hook or traveling block, no need to add other devices, which makes the system more safe and reliable during operation.

1. 1. 1. Back Up Tong Assembly

Equipped with one set of L-type back up tong assy, using the motor and the  cylinder to clamp, release, makeup and breakout. it can connect and remove the saver sub without disassembly of tong body , facilitate drilling operation. A whole set of pipe handling device is formed with the tilt mechanism and rotating head , which improves the working efficiency of makeup & breakout operation and drilling tool layout operation, and greatly reduces the labor intensity and danger level of the staff.
Applied drill pipe range:85-187mm

1. 1. 1. Internal Blow Out Preventer (IBOP)

It is integrated structure with manual and remote control double ball valve , the main technical parameters are as follows:
Working Pressure 70MPa
Thread Type 6-5/8"API REG  × 6-5/8"API REG
O.D.        Φ187mm
I.D.               3"
The actuator of remote control IBOP consists of a pair of hydraulic cylinders, IBOP sliding sleeve, gear, etc. The connection type between the cylinder and the sliding sleeve is the roller touching to ensure that the axial relative movement of the sleeve simultaneously with the rotation of the main shaft , also the drive wrench can realize the opening and closing of the manual IBOP.
This function can quickly close the IBOP once well kick or blow-out to achieve well control safety.
The IBOP sliding sleeve is driven in the form of gear rack with cam gear to improve reliability.

1. 1. 1. Guide Rail and Carriage

A folding guide rail assembly is configured, including multi sections guide rails, connections, crown block support, adjustment beam assembly and installation accessories.
Adopting the folding type design, the site installation is fast and convenient.
The friction type of the carriage and the guide rail is a pulley structure.
The pulley adopts double side cam follower structure to make each roller evenly stressed and prolong the life .

1. 1. 1. Container

For easy transportation, two containers (open top) are equipped , one places the top drive body, the another places the guide rail and cable assy,

Electrical Control System

The top drive electrical control system contains main control system, electrical control room, driller's console, power cable, auxiliary and composite control cable, power supply cable, driller's console cable, grounding cable, etc.
The top drive equipped an AC asynchronous induction motor to provide drilling power and adopt AC frequency conversion drive mode.

1. 1. 1.  Main Control System 

One set of electrical control system is equipped , using ABB ACS880 AC frequency conversion speed regulating device, programmable logic controller (PLC), auxiliary control unit, etc., the system has perfect self-diagnosis function, protection function and anti-harmonic interference function, to realize all electrical control functions in the operation of the top drive .
The Simatic S7-1500 series PlC of Siemens is adopted which controlled by ProfiBus-DP bus, to carry out the system operating parameter setting and hardware and software status detection;
The main control system and driller console are controlled by ProfiBus bus, with strong anti-interference ability, accurate and reliable control, and convenient for on-site use, installation, debugging and maintenance.
The auxiliary control unit shares the cabinet with the PLC and adopts the Siemens electric  components.
A set of IPC system is configured to display the top drive operation parameters, system setting, alarm record, action screen, data curve, maintenance information and network topology functions.
The main control cabinet reserves two analog output interfaces of 4 ~ 20 mA or 0~10V for torque and speed logging signals respectively.
The reserved networking interface can be optional facilitate the field connection of the wireless network or mobile network and realize the top drive remote data transmission.

1. 1. 1. Electrical Control Room (VFD Room)

The cabinets of the electric drive and control system are concentrated in the electrical control room, with firm and reliable installation and convenient maintenance.
The VFD room is equipped with air conditioning equipment, and the temperature in the room shall be 25ºC -30ºC.
The interior decoration material of the control room is plastic spray steel plate, and the wall have the interface ports with the external cables.
The electric control room is equipped with external 380V emergency power interface, which can realize the makeup, breakout and low speed operation in special situation (the power supply is no less than 200KW).

1. 1. 1. Driller Console 

One set of driller console can be installed and fixed inside the driller house for the operation and control of the top drive.
The driller console is a sealing structure with stainless steel shell, which adopts positive pressure explosion-proof design. The explosion-proof device includes pressure release valve, air and water separator, joints, interface, filters, etc. When the air pressure in the box is abnormal, the sound and light alarms as well as the corresponding indicator light on the panel of console .
It has the functions of torque limit, elevator link tilt, back up tong operation, brake operation, IBOP operation, emergency stop, drilling operation and other functions, including the necessary operation indicators and instruments.
Configure the switches, indicators, installing fittings, connectors etc which required by operation of the top drive.
The console panel is equipped with a 9-inch LCD screen, which can display the working state, fault and other states of top drive.

1. 1. 1. Power Service Loop

One set of power service loop (standard) is equipped to supply power to main motor
One set of terminal rack is equipped on derrick to fix the power loop
The cable of loop is in accordance with ZR specifications for domestic offshore drilling.
Power Cable Lenth: 70m;
with explosion-proof connectors, level Exd IIC T5

1. 1. 1. Auxiliary and Control Service Loop

One set of auxiliary and control service Loop is equipped,  the Length is match with power service loop.
The length 70m;
with explosion-proof connectors, level Exd IIC T5

1. 1. 1. Power Supply Cable

Equipped with a set of power supply cable, connect the generator and electrical control room, the length of 35m, voltage 0.6 / 1KV, using the standard wire lug connection.

1. 1. 1. Control Cable of Driller Console

One set of control cable is configured to realize the power supply and communication  between the driller console and the CPU, the length is 70 m

1. 1. 1. Grounding Cable

One set of grounding cable assembly is configured, using domestic made cable, including 1.5 m galvanized grounding rod (2 pcs), the length is 5 m (2 pcs).

Hydraulic Control System

The hydraulic system is integrated in the top drive body, which is composed of hydraulic source, hydraulic main control valve set, hydraulic actuator, hydraulic auxiliary parts and hydraulic oil radiator.

1. 1. 1. Hydraulic Source

The hydraulic pump of hydraulic source is the inclined axial plunger variable pump, used for hydrostatic transmission in open circuit, the flow is proportional to the drive speed and displacement, by adjusting the inclined plate Angle, the flow can be stepless adjustment, the two oil outlets on shell have excellent oil sucking characteristics, low noise, and long service life, the drive shaft can withstand axial and radial load.
The electrical circuit system of hydraulic source adopts explosion-proof design, and the electrical control box and motor all adopt explosion-proof components.
The main technical parameters of the hydraulic system include:
Rated working pressure of system :      14 MPa
Rated flow rate of the hydraulic pump:    16 mL/r
 

1. 1. 1. Hydraulic Valve Manifold

One set of hydraulic manifold is equipped, the plug valves adopt the WANDFLUH hydraulic components , and the solenoid valves also adopt the products of WANDFLUH Company.
:The hydraulic control valves adopt the form of plug-in type, and the solenoid reversing valves are all explosion-proof products. Its specific composition is as follows:
First line: the counterbalance system controls the oil circuit. It is composed of pressure relief overflow valve, hydraulic control check valve, throttle valve and accumulator. The main function of the counterbalance system is to balance the weight of the body to protect the threads from wearing when the joints makeup and breakout. The function of the pressure relief overflow valve is to adjust the working pressure of the balance cylinder to meet the weight of the body; the accumulator acts as buffer, shock absorption and pressure protection. The balance cylinder is equipped with safety overflow valve with pressure set of 17MPa to prevent impact load to protect the hydraulic cylinder.
Second line: the main motor brake oil circuit.,consists of EX solenoid reversing valves.
Third line: the oil circuit of motor on rotating head. It is composed of explosion-proof solenoid reversing valve and pressure regulating valve. The damping hole of solenoid valve is made of hard alloy material to improve the service life.
Fourth line: the Oil circuit of remote control internal blowout preventer (IBOP) consists of explosion-proof solenoid reversing valves.
Fifth line: the back-up tong control oil circuit. oil circuit.explosion-proof solenoid reversing valves, equipped with pressure sensor.
Sixth line: the Tilt system oil circuit. It is composed of explosion-proof solenoid reversing valve and throttle check valve and other units. The solenoid valve plays the reversing role, and the throttle check valve makes the elevator link stop in any position for a long time, which can be set to the swing state when the elevator link is in the middle position.
The above oil circuits are all set with pressure detection points to monitor the working pressure of each oil circuit. At the same time, the air in each oil circuit and oil cylinder can be discharged through the pressure measurement point to make the system work smoothly.

1. 1. 1.  Hydraulic Actuator 

The hydraulic actuator consists of the following parts
Counterbalance Cylinder(2 ea),Break Cylinder(2 ea),Drive Motor of rotating head (1 ea),IBOP actuator Cylinder(2 ea),Back-up Tong Cylinder(1 ea),Tilt Cylinder(2ea).

1. 1. 1. Hydraulic Auxiliary Components 

Hydraulic auxiliary components consists of accumulators, filters and oil tank, etc.
Accumulators are divided into brake accumulator and balance accumulator.
Filters are divided into oil filter, high pressure filter, oil return filter and air filter.
Install a upper mounted oil tank to store the hydraulic oil required for the work of the hydraulic system and dissipate the heat of the system.

1. 1. 1. Radiator 

The radiator is located at the air inlet of the cooling blower. The main motor is used to cool the hydraulic oil by force to effectively ensure the service life and stability of the hydraulic system.