Qd40-B Top Drive System (TDS) 300ton for 4000m Drill Rig with 470kw Variable Frequency AC Motor

• Customization: Available
• After-sales Service: 3 Year
• Warranty: 2 Year
• Model NO.: DQ40-B
• Certification: CE, RoHS, ISO 9001:2000, ISO 9001:2008, API
• Power Source: Electric
• Operation Pressure: Atmospheric Pressure
• Applicable Medium: Mud, Water, Natural Gas, Crude Oil
• Structure: Vertical
• Material: Alloy
• Document 1: Inspection Report
• Document 2: Quality Certificate
• Crew Training: Provide for Free
• Debugging: Provide at Site
• Installation: Guidance Support
• Spare Parts: in Supply
• After Service: Dedicated Team
• Painting: as Client′s Request
• Transport Package: Container
• Specification: 300 ton load
• Trademark: VSP
• Origin: China
• HS Code: 8431431000
• Production Capacity: 120 Sets/Yesr
• Package Size: 600.00cm * 220.00cm * 220.00cm
• Package Gross Weight: 15000.000kg

Product Description

Brief Description:

The The top drive system is a cutting-edge drilling technology that harnesses a suspended motor, which can be either electric or hydraulic, to deliver the essential torque required for the rotation of the drill string. This innovative system supersedes the traditional rotary table and kelly drive methods, offering a plethora of benefits such as heightened drilling efficiency, minimized manual labor, and enhanced safety measures.

DQ40B-VSP Top Drive Features
1. Folding Guide Rails: Experience an installation process that's not only safe but also fast and hassle-free, ensuring the top drive is set up efficiently.
2. Boasts a 360° swivel head rotation function, allowing for unmatched flexibility and adaptability during drilling operations.
3. The pulley incorporates a double-wheel structure to prevent singular stress on the roller, thereby significantly extending the roller's service life.
4. IBOP Rack and Pinion Drive Mechanism: Guarantees precise and accurate switching of the Internal Blow Off Preventer, ensuring operational reliability.
5. Inclined Hanging Backup Tong: Simplify the replacement process of tong teeth and their seats, making it faster and more convenient.
6. Hydraulic Radiator: Enhances the longevity of the hydraulic system, ensuring sustained, reliable performance.
7. An internal counterbalance system is adopted, providing safe and stable jumps. It eliminates the need for additional components when hanging the large hook or traveling carriage, allowing for direct suspension.
8. The compact cross-sectional size of the top drive is optimally designed for better compatibility with derricks.

1. 1. Typical Parameter

Items	Data	(British System)
Nominal drilling depth (114mm drill pipe)	4000m
Rated Load capacity	2660 KN	300 ton
Working height (96" elevator link)	5770mm	18.93 ft
Rated continuous output torque	50 KN.m	36878 lb.ft
Max. Torque of breakout	75 KN.m	55317 lb.ft
Static maximum brake torque	50 KN.m	36878 lb.ft
Speed range of main shaft (stepless adjustable)	0~180 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	525 mm	1.722 ft
Incoming wire voltage of VFD room	575~625 VAC
Incoming wire frequency of VFD room	600 VAC/50 Hz

1. 1. Outline Dimension and Weight

Items	Data
Dimension of Main Body	5600mm*1255mm*1153mm
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	9 t
Weight of VFD room	11 t
Dimension of VFD Room	6058mm*2438mm*2951mm
Dimension of driller console	800 mm×350 mm×300 mm
Weight of driller console	30kg

1. 1. Drilling Parameters

Items	Specification
Transmission ratio	13.37:1   two-stage transmission
Lubrication method	Splash lubrication, forced lubrication, immersion lubrication
Back tong diameter	Φ200mm
Back tong clamping range	86~ 187mm
Elevator link	2740mm, 250ton Other models optional

MMechanical System

The mechanical system is an ensemble of the main motor system, an air cooling system, a brake system, a gear box, a wash pipe assembly, a rotating head mechanism, a tilt mechanism, a backup tong mechanism, an internal blowout prevention mechanism (IBOP), a guide rail, and carriage mechanism, along with a container, showcasing a comprehensive and integrated design.
The top drive is energized by an AC frequency conversion asynchronous motor, enabling an advanced AC frequency conversion drive that maximizes efficiency.

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

The main motor is a specialized single top drive AC frequency conversion asynchronous motor, boasting a power of 290KW. Its main technical parameters include:
Rated Voltage 600VAC
Rated Frequency 61Hz
Rated Current 365A
The main motor is adeptly equipped with a heater and an explosion-proof wind pressure switch, ensuring safe and optimal operation.
The main motor employs a forced air-cooling mode, optimizing performance while maintaining temperature stability.
The air-cooling motor operates at a voltage of 380VAC / 50Hz, with a power of 4kW, featuring an insulation grade F, protection grade IP55, and is explosion-proof. The motor's level of ExdIICT4 ensures a wind capacity not less than 70 m3/min, with air pressure measured at 203mm water column.

1. 1. 1. Brake System

The top drive main motor is outfitted with a specialized hydraulic disc brake device, facilitating precise drill string orientation during directional inclined drilling operations.
The disc brake device is strategically installed at the upper extension end of the motor shaft, utilizing a pair of Swedish DELLNER cylinders connected by a robust hard pipeline. When the main motor's speed declines to 3rpm, the brake cylinder's friction forces on the brake disc effectuate the braking function of the main motor.

1. 1. 1. Gear Box

To amplify the output torque of the top drive motor, reduce motor volume, and enhance performance, a strategically configured gear box is integrated.
The gear box is a masterpiece of engineering, boasting an involute hard tooth surface gear that seamlessly integrates with secondary bevel gear technology to deliver a flawless transmission experience. With an impressive transmission ratio of 11.91:1, it ensures optimal performance. The lubrication system ingeniously combines splash lubrication and an oil pump circulation for forced lubrication, guaranteeing longevity and efficiency.

1. 1. 1. Gooseneck Assembly

The innovative gooseneck is meticulously crafted to cater specifically to well logging applications. During drilling operations, it employs corrosion-resistant liners and nuts to effectively seal the upper high-pressure mud pipeline, preventing unwanted mud overflow with ease.
One end of the gooseneck seamlessly connects with the sophisticated wash pipe assembly. This assembly is designed to withstand super high pressures, playing a crucial role in sealing high-pressure mud. Featuring a self-sealing, rapid disassembly structure, it allows for quick and easy replacement when the wash pipe and packing succumb to wear. Simply open the upper and lower packing covers to effortlessly remove the entire device without the need to dismantle the gooseneck or the mud hose. This makes it remarkably simple to halt drilling and perform replacements at any time throughout the drilling process.
The opposite end of the gooseneck connects seamlessly with the mud hose, featuring a robust 4-inch female union with a Fig1003 thread type for reliable and secure attachment.
A meticulously designed mud prevention device is strategically installed at the junction of the main shaft and the wash pipe, ensuring compliance with operational site requirements.

1. 1. 1. Rotating Head

The system includes a single rotating head configuration, capable of independent rotation from the main shaft. The elevator links elegantly suspend from the link adaptor, enhancing operational efficiency.
Employing a worm gear transmission structure, this system ensures smooth, consistent driving performance.
The rotating head is engineered to execute full 360° rotations both clockwise and counterclockwise, synchronously rotating the elevator link and the elevator to skillfully grasp single pipes in the mouse hole and triple stems on the monkey board with precision.
Harnessing the power of a hydraulic motor system, the rotating head utilizes the renowned Danfoss cycloid motor to achieve a speed range of 2 to 5 r/min, offering superior control and functionality.

1. 1. 1. Tilt System

The tilt cylinder is designed to dynamically drive the elevator link, enabling forward and backward tilt movements. The forward tilt function allows the elevator to adeptly extend to both the mouse hole and monkey board. During drilling, the backward tilt ensures the lower end of the back up tong is closely aligned with the drilling platform, maximizing the utility of the drilling tool.
The tilt range intricately correlates with the length of the elevator link, offering a forward tilt angle of 30 degrees and a backward tilt angle of 55 degrees, both of which are adjustable.
Note: For specific link length configurations, please engage with our sales team for prior arrangements.
The hydraulic system is equipped with a 'middle' setting within the tilt mechanism, facilitating automatic return of the elevator link to a free swing state. This feature is instrumental in mitigating system impact caused by pressure buildup in the tilt cylinder.

1. 1. 1. Counterbalance System

The suspension bail counterbalance system plays a pivotal role in the top drive system. It connects to the gear box via a pin shaft, with its upper section suspended from the hook or traveling block. Its primary function is to balance the system's weight. The VSP top drive's adoption of a double hydraulic cylinder with internal force balance mode eliminates the need for additional devices, enhancing safety and reliability during operations.

1. 1. 1. Back Up Tong Assembly

The system is equipped with an L-type back up tong assembly, driven by the motor and designed for smooth and efficient operation. The cylinder mechanism is ingeniously designed to simplify operations, allowing for seamless clamping, releasing, makeup, and breakout actions. It effortlessly connects and detaches the saver sub, ensuring efficient operation. Our innovative design eliminates the need to disassemble the tong body, streamlining the drilling process. By integrating the tilt mechanism with a rotating head, it forms a comprehensive pipe handling device. This significantly enhances the efficiency of makeup and breakout operations, as well as drilling tool layout operations, while dramatically reducing staff labor intensity and safety risks.
This advanced system is compatible with a broad range of drill pipes, specifically designed for diameters between 85mm to 187mm, providing versatility and adaptability in various drilling scenarios.

1. 1. 1. The robust Internal Blow Out Preventer (IBOP) system is engineered to offer exceptional control and safety during drilling operations.

It features a seamlessly integrated design, combining both manual and remote operation capabilities, with a precision-engineered double ball valve. The main technical specifications include:
An impressive Working Pressure capacity of 70MPa, ensuring durability and reliability.
Thread Type is precisely engineered for 6-5/8" API REG × 6-5/8" API REG, ensuring compatibility with industry standards.
The outer diameter (O.D.) is a robust Φ187mm, providing structural integrity.
The inner diameter (I.D.) is 3", designed for optimal performance.
The remote control IBOP actuator is composed of a meticulously designed pair of hydraulic cylinders, IBOP sliding sleeve, and gear mechanism. The cylinder connection to the sliding sleeve employs a roller-touching method, ensuring synchronized axial movement of the sleeve with the rotating main shaft, while the drive wrench facilitates the seamless opening and closing of the manual IBOP. This feature ensures rapid IBOP closure,
quickly acting to secure the IBOP in the event of a well kick or blow-out, enhancing well control and safety measures.
The IBOP sliding sleeve is operated via a gear rack with cam gear, enhancing system reliability and precision.

1. 1. 1. Guide Rail and Carriage system

incorporates a folding guide rail assembly with multiple sections, convenient connections, crown block support, an adjustable beam assembly, and comprehensive installation accessories. Its foldable design ensures quick and efficient site installation.
Utilizing a folding type design, it allows for fast and convenient on-site installation, maximizing operational efficiency.
The carriage utilizes a friction type pulley structure on the guide rail,
with double side cam follower pulleys ensuring even roller stress distribution, significantly extending operational lifespan.

1. 1. 1. Container system

is optimized for easy transportation with two open-top containers. One is designated for the top drive body, while the other accommodates the guide rail and cable assembly,

Electrical Control System

boasts an advanced setup, including a main control system, electrical control room, driller's console, as well as power, auxiliary, and composite control cables, along with grounding cables, driller's console cable, ensuring comprehensive and reliable connectivity.
The top drive is powered by an AC asynchronous induction motor, delivering exceptional drilling power through an AC frequency conversion drive mode.

1. 1. 1. The Main Control System

features an integrated electrical control system with ABB ACS880 AC frequency conversion speed regulation, a programmable logic controller (PLC), and auxiliary control unit. It includes robust self-diagnosis, protection, and anti-harmonic interference functions, ensuring flawless electrical control throughout top drive operations.
With the adoption of the Siemens Simatic S7-1500 series PLC, controlled via ProfiBus-DP bus, the system ensures precise operating parameter settings and thorough hardware and software status monitoring.
The main control system and driller console are expertly managed through state-of-the-art ProfiBus bus technology. This ensures superior anti-interference capabilities, offering precision and reliability in control. Enjoy seamless on-site operation with easy installation, straightforward debugging, and hassle-free maintenance.
Our auxiliary control unit is ingeniously integrated within the same cabinet as the PLC, leveraging top-tier Siemens electric components for unparalleled performance.
An advanced IPC system is meticulously configured to bring to life a comprehensive overview of the top drive's operation. It showcases vital parameters, system settings, alarm records, action screens, data curves, essential maintenance insights, and pioneering network topology functions.
The main control cabinet thoughtfully includes two analog output interfaces - 4 ~ 20 mA or 0~10V - tailored for precise torque and speed logging signals.
With a reserved networking interface, optional field connections to wireless or mobile networks become effortlessly possible, facilitating seamless remote data transmission of the top drive.

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

Designed for excellence, the cabinets housing the electric drive and control system are consolidated in the robust electrical control room, assuring sturdy installation and straightforward maintenance.
Our VFD room is equipped with efficient air conditioning, maintaining an optimal room temperature between 25ºC and 30ºC for peak performance.
The interior decoration material of the control room is crafted from premium plastic spray steel plates, featuring interface ports for effortless external cable connections.
The electric control room is equipped with a 380V external emergency power interface, enabling crucial operations such as makeup, breakout, and low-speed functionality in special scenarios (power supply not less than 200KW).

1. 1. 1. Driller Console

A sophisticated driller console is meticulously installed within the driller house, dedicated to the operation and control of the top drive.
Constructed with a resilient stainless steel shell, the driller console boasts a sealing structure and a positive pressure explosion-proof design. The explosion-proof system incorporates essential elements such as pressure release valve, air and water separator, joints, interfaces, filters, and more. Experience peace of mind with sound and light alarms when air pressure anomalies occur in the box, as well as the corresponding indicator lights prominently displayed on the console panel.
It has a comprehensive suite of functionalities including torque limit, elevator link tilt, backup tong operation, brake operation, IBOP operation, emergency stop, drilling operation, and more. It also features necessary operation indicators and instruments for impeccable control.
Configure with precision: switches, indicators, installation fittings, connectors, and more, essential for the operation of the top drive.
The console panel boasts a sleek 9-inch LCD screen, displaying real-time insights into the working state, fault conditions, and other critical states of the top drive.

1. 1. 1. Power Service Loop

A robust power service loop is included as standard to deliver power efficiently to the main motor.
A terminal rack is strategically installed on the derrick, providing secure support for the power loop.
The cable loop adheres strictly to ZR specifications, ensuring compliance for domestic offshore drilling operations.
Power Cable Length: 70m;
equipped with explosion-proof connectors, rated at level Exd IIC T5.

1. 1. 1. Auxiliary and Control Service Loop

A dedicated auxiliary and control service loop comes equipped, perfectly matching the length of the power service loop.
The loop extends to a length of 70m;
with explosion-proof connectors, certified at level Exd IIC T5.

1. 1. 1. Power Supply Cable

Outfitted with a reliable set of power supply cables, connecting the generator to the electrical control room, extending to a length of 35m, with a voltage capacity of 0.6 / 1KV, utilizing industry-standard wire lug connections.

1. 1. 1. Control Cable of Driller Console

A meticulously designed control cable set connects the driller console seamlessly with the CPU, ensuring robust power supply and flawless communication over a generous span of 70 meters.

1. 1. 1. Grounding Cable

An expertly assembled grounding cable set is provided, featuring top-quality domestic-made cables and includes two 1.5-meter galvanized grounding rods. Each cable generously extends to 5 meters for optimal grounding efficiency.

Hydraulic Control System

Ingeniously integrated within the top drive body, the hydraulic system is a powerhouse comprising a hydraulic source, precision-engineered hydraulic main control valve set, reliable hydraulic actuator, essential hydraulic auxiliary components, and a high-performance hydraulic oil radiator.

1. 1. 1. Hydraulic Source

The hydraulic source features an advanced inclined axial plunger variable pump, perfect for open circuit hydrostatic transmission. This pump offers a flow rate that varies proportionally with drive speed and displacement, allowing for stepless adjustment through precision plate angle tweaks. Its dual oil outlets boast superior oil suction capabilities, maintaining low noise and ensuring an extended service life. Its design ensures superb oil suction performance, minimal noise, and long-lasting durability. The rugged drive shaft is engineered to withstand both axial and radial loads, ensuring robustness and reliability.
The electrical circuit system is meticulously crafted with explosion-proof technology, utilizing explosion-proof components for both the control box and motor to ensure safety and reliability.
Key technical specifications of the hydraulic system include:
System's rated working pressure: 14 MPa
Hydraulic pump's rated flow rate: 16 mL/r

1. 1. 1. Hydraulic Valve Manifold

Featuring a state-of-the-art hydraulic manifold, equipped with WANDFLUH's superior plug valves, complemented by solenoid valves which also adhere to WANDFLUH's high standards. These valves exemplify WANDFLUH Company's exceptional quality and reliability.
The hydraulic control valves are designed in a plug-in format, while the solenoid reversing valves are crafted with explosion-proof integrity. Its intricate composition includes:
First line: A sophisticated counterbalance system governs the oil circuit, incorporating a pressure relief overflow valve, hydraulic control check valve, throttle valve, and accumulator. This system's primary role is to balance the body's weight, safeguarding threads during joint makeup and breakout. The pressure relief overflow valve finely tunes the balance cylinder's pressure to align with body weight, while the accumulator provides buffering, shock absorption, and pressure protection. Additionally, a safety overflow valve set to 17MPa prevents impact loads, ensuring the hydraulic cylinder's protection.
Second line: The main motor brake oil circuit, skillfully integrated with EX solenoid reversing valves for precise control.
Third line: The rotating head motor oil circuit, featuring explosion-proof solenoid reversing valves and a pressure regulating valve. The solenoid valve's damping hole, crafted from durable hard alloy, significantly enhances its service life.
Fourth line: The remote control internal blowout preventer (IBOP) oil circuit, equipped with reliable explosion-proof solenoid reversing valves.
Fifth line: The back-up tong control oil circuit, meticulously designed with explosion-proof solenoid reversing valves and an integrated pressure sensor for optimal performance.
Sixth line: The Tilt system oil circuit, expertly composed of explosion-proof solenoid reversing valves, throttle check valves, and complementary units. The solenoid valve facilitates reversing, while the throttle check valve ensures the elevator link remains securely in any desired position. The link can adapt to a swing state when positioned centrally.
To ensure seamless operation, all oil circuits are equipped with pressure detection points for real-time monitoring of working pressure. Additionally, these points facilitate the expulsion of air from each oil circuit and cylinder, paving the way for a flawlessly efficient system.

1. 1. 1. Hydraulic Actuator

The heart of our hydraulic actuator comprises several key components meticulously designed for optimal performance.
This robust assembly features: 2 Counterbalance Cylinders, 2 Brake Cylinders, a Drive Motor for the rotating head, 2 IBOP Actuator Cylinders, 1 Back-up Tong Cylinder, and 2 Tilt Cylinders, each engineered for precise functionality.

1. 1. 1. Hydraulic Auxiliary Components

Our hydraulic auxiliary components are an ensemble of accumulators, filters, and an oil tank, among others, each playing a crucial role in sustaining system operations.
Accumulators Our range of accumulators includes brake accumulators and balance accumulators, each crafted for specific operational needs.
Our filtering system encompasses oil filters, high-pressure filters, oil return filters, and air filters, all diligently ensuring purity and performance.
An upper-mounted oil tank is strategically installed to store essential hydraulic oil, while also serving as a heat dissipation hub, maintaining the system's exceptional efficiency.

1. 1. 1. Radiator

Expertly positioned at the air inlet of the cooling blower, the radiator is crucial in forcefully cooling hydraulic oil using the main motor, thus safeguarding the system's longevity and reliability.