Brief Description:
The The cutting-edge top drive system is a revolutionary drilling technology, ingeniously utilizing a suspended motor-either electric or hydraulic-to deliver the essential torque required for drill string rotation. This system elegantly replaces the conventional rotary table and kelly drive methods, offering significant benefits such as enhanced drilling efficiency, reduced manual labor, and augmented safety.
DQ40B-VSP Top Drive Features
1. Folding Guide Rails: Experience safe, swift, and efficient top drive installation.
2. Equipped with a 360° swivel head, offering unparalleled rotation capabilities.
3. The pulley features a robust double-wheel design to prevent single-point stress on the roller, thereby prolonging its service life.
4. IBOP Rack and Pinion Drive Mechanism: Guarantees meticulous and precise IBOP (Internal Blow Off Preventer) switching.
5. Inclined Hanging Backup Tong: Swift and effortless replacement of tong teeth and seats.
6. Hydraulic Radiator: Extends the hydraulic system's longevity, ensuring consistent performance.
7. Adopted Internal Counterbalance: Ensures stable and secure jumps, eliminating the need for extra components to hang the large hook or traveling carriage-it can be hung directly.
8. Compact Cross-Sectional Size: Ideally suited for modern derricks, maximizing space efficiency.
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- Typical Parameters
| 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° |
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| 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 |
470KW |
630HP |
| 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 |
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- Outline Dimensions 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 |
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- 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 |
Mechanical SystemMechanical System
The mechanical system comprises a robust ensemble including the main motor system, air cooling system, brake system, gearbox, wash pipe assembly, rotating head mechanism, tilt mechanism, backup tong mechanism, internal blowout prevention mechanism (IBOP), guide rail and carriage mechanism, and container, among others.
The top drive is powered by an AC frequency conversion asynchronous motor, expertly facilitating AC frequency conversion drive.
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- 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. The main technical parameters include:
Rated Voltage 600 VAC
Rated Frequency 61 Hz
Rated Current 365 A
The main motor comes with an installed heater and an explosion-proof wind pressure switch for optimal safety.
The main motor employs a forced air-cooling mode to maintain performance.
The air-cooling motor specifications: voltage 380 VAC / 50 Hz, power 4 kW, insulation grade F, protection grade IP55, explosion-proof level ExdIICT4. Wind capacity is no less than 70 m3/min, with air pressure at a 203 mm water column.
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- Brake System
The top drive main motor is outfitted with a specialized hydraulic disc brake device, designed to assist with drill string orientation during directional inclined drilling operations.
The disc brake device, strategically installed at the upper extension end of the motor shaft, uses a pair of premium Swedish DELLNER cylinders connected through a specially designed hard pipeline, ensuring durability. As the main motor speed decreases to 3 rpm, the brake disc's friction forces, activated through the brake cylinder, effectively deliver the braking function for the main motor.
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- Gear Box
To amplify the top drive motor's output torque, reduce the motor's volume, and enhance its performance, a sophisticated gearbox is installed.
The gear box features an innovatively designed involute hard tooth surface gear combined with a secondary bevel gear. This engineering marvel ensures a stable and reliable transmission with an impressive ratio of 11.91:1. The lubrication system is a sophisticated blend of splash lubrication and forced lubrication, efficiently circulated by an oil pump, guaranteeing optimal performance and longevity.
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- Gooseneck Assembly
Our expertly crafted gooseneck is specifically tailored for well logging. During drilling operations, it utilizes corrosion-resistant liners and nuts to effectively block the upper high-pressure mud pipeline, skillfully preventing any mud overflow and ensuring seamless drilling performance.
One end of the gooseneck seamlessly connects with the wash pipe assembly. This assembly is engineered with a robust super high-pressure structure, playing a crucial role in sealing the high-pressure mud. It boasts a self-sealing and rapid disassembly design, allowing for effortless maintenance. Should the wash pipe or packing sustain wear and need replacement, simply open the covers of the upper and lower packing to effortlessly remove the entire device without the need to detach the gooseneck and the mud hose. This design facilitates easy halting of the drilling process for replacement at any desired moment during drilling operations, ensuring minimal disruption.
The opposite end of the gooseneck connects seamlessly with the mud hose. This connection features a 4-inch female union, with the thread type specified as Fig1003, ensuring a secure and reliable fit.
A sophisticated mud prevention device is installed at the junction of the main shaft and the wash pipe, meticulously designed to meet the rigorous requirements of site operations and prevent any unwanted spillages.
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- Rotating Head
The system includes an advanced rotating head configuration, which operates independently of the main shaft while the elevator links are expertly suspended on the link adaptor, ensuring smooth and efficient operation.
This design incorporates a worm gear transmission structure that guarantees smooth and reliable drive mechanics.
The rotating head possesses the capability to rotate both clockwise and counterclockwise through a full 360°, managing to drive the elevator link and elevator in unison. This allows for skillful grasping of the single pipe in the mouse hole and the triple stem located on the monkey board, ensuring precision handling and enhanced operational efficiency.
The rotation is powered by a state-of-the-art hydraulic motor system, utilizing a premium Danfoss cycloid motor with a reliable speed range of 2 to 5 r/min, providing consistent and effective rotation.
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- Tilt System
The tilt cylinder is engineered to drive the elevator link, enabling a smooth transition between forward and backward tilt. The forward tilt function elegantly extends the elevator to the mouse hole and monkey board, facilitating seamless operations. During drilling, the backward tilt function is ingeniously designed to bring the lower end of the back-up tong close to the drilling platform, maximizing the utilization of the drilling tools with unmatched precision.
The tilt range is adeptly related to the elevator link's length, with a forward angle of 30° and an adjustable backward tilt angle of 55°, offering adaptability in varying drilling conditions.
Note: Should there be a requirement for configuring links of other lengths, advanced communication with our sales team is highly recommended.
The hydraulic system includes a strategic 'middle' setting within the tilt mechanism, allowing the elevator link to automatically return to a free swing state, effectively avoiding any hydraulic system impact due to excess pressure in the tilt cylinder.
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- Counterbalance System
The suspension bail counterbalance system is a pivotal part of our top drive system. The bail is ingeniously connected to the gearbox via a pin shaft, with the upper area securely suspended on the hook or traveling block. This system primarily balances the weight of the body. The VSP top drive is equipped with a dual hydraulic cylinder featuring an internal force balance mode, allowing direct suspension with the hook or traveling block, eliminating the need for additional devices. This results in superior safety and reliability during operations.
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- Back Up Tong Assembly
Our assembly includes a precision-engineered L-type back up tong assy, meticulously powered by a state-of-the-art motor and the Built with precision, the cylinder efficiently clamps, releases, makes up, and breaks out components, seamlessly connecting and removing the saver sub. Experience uninterrupted drilling operations with our innovative design that eliminates the need for tong body disassembly. The integrated pipe handling device, complemented by a tilt mechanism and rotating head, significantly enhances the efficiency of makeup and breakout operations. It optimizes drilling tool layout, markedly reducing both labor intensity and potential hazards for your team.
Compatible with drill pipe ranging from 85mm to 187mm.
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- Featuring an Internal Blow Out Preventer (IBOP) for enhanced safety.
This solution is engineered as an integrated structure, featuring both manual and remote control capabilities with a dual ball valve system. Key technical specifications include:
Designed for a Working Pressure of 70MPa, ensuring reliable performance.
Thread Type Specification 6-5/8" API REG × 6-5/8" API REG for robust connections.
External Diameter (O.D.) Φ187mm, engineered for optimal performance.
Internal Diameter (I.D.) 3", tailored for maximum efficiency.
Our remote control IBOP actuator incorporates dual hydraulic cylinders, an IBOP sliding sleeve, gears, and more. The cylinder and sliding sleeve connection uses roller contact, ensuring synchronized axial movement with the main shaft's rotation. The manual IBOP's opening and closing are effortlessly realized by the drive wrench. This capability swiftly seals the IBOP
to ensure well control safety in the event of a well kick or blow-out, upholding the integrity and safety of your operations. Reliability is enhanced by driving the IBOP sliding sleeve using a gear rack with cam gear.
Innovative Guide Rail and Carriage System
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- The assembly features a folding guide rail design with multi-section rails, robust connections, crown block support, and an adjustable beam assembly,
alongside essential installation accessories. Quick and convenient site installation is facilitated by the folding design.
The carriage and guide rail utilize a friction-type pulley structure, ensuring smooth operation.
The double side cam follower structure in the pulleys ensures even stress distribution across each roller, enhancing the lifespan.
Transportable Container Solution
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- For streamlined logistics, we provide two open-top containers: one for the top drive body, and another for the guide rail and cable assembly,
ensuring secure and efficient transport.
Advanced Electrical Control System
Our top drive electrical control system boasts a comprehensive main control system, housed in an electrical control room, and includes the driller's console. It is equipped with power, auxiliary, and composite control cables, along with power supply and grounding cables, ensuring seamless connectivity and reliable operation.
Equipped with an AC asynchronous induction motor, the top drive delivers consistent drilling power, leveraging AC frequency conversion for precise drive control.
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- Innovative Main Control System
The system integrates an ABB ACS880 AC frequency conversion speed regulating device, PLC, and auxiliary control unit, offering comprehensive self-diagnosis, protection, and anti-harmonic interference functions to optimize the top drive's electrical controls.
Harnessing the power of Siemens Simatic S7-1500 series PLC, managed by ProfiBus-DP bus, the system allows for detailed operating parameter settings and thorough hardware and software status monitoring.
The main control system and driller console are powered by a robust ProfiBus bus, showcasing exceptional anti-interference capabilities. This ensures precise and reliable operations, making on-site use, installation, debugging, and maintenance seamless and efficient.
The auxiliary control unit, sharing the cabinet with the PLC, integrates superior Siemens electric components, offering unparalleled reliability and performance.
Equipped with an advanced IPC system, it delivers a comprehensive display of top drive operation parameters, system settings, alarm records, action screens, data curves, maintenance information, and network topology functions, ensuring an all-in-one operational overview.
The main control cabinet is meticulously designed with two reserved analog output interfaces, offering 4~20 mA or 0~10V for torque and speed logging signals respectively, ensuring high precision and versatility.
A reserved networking interface offers optional support for seamless field connectivity via wireless or mobile networks, enabling efficient top drive remote data transmission.
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- Electrical Control Room (VFD Room)
In the dedicated electrical control room, the electric drive and control system cabinets are sturdily installed, ensuring reliability and convenient maintenance access.
The VFD room is equipped with state-of-the-art air conditioning systems, maintaining an optimal temperature range of 25ºC - 30ºC for enhanced equipment performance.
The interior decoration material of the control room is crafted from high-quality plastic spray steel plate, featuring wall ports for seamless external cable integration.
The electric control room comes with an external 380V emergency power interface, enabling makeup, breakout, and low-speed operations under special conditions, with a power supply threshold of no less than 200KW.
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- Driller Console
A driller console is securely installed within the driller house, providing intuitive operation and control of the top drive with ease.
The driller console boasts a robust sealing structure with a stainless steel shell, utilizing a positive pressure explosion-proof design, including pressure release valve, air and water separators, joints, interfaces, filters, etc., all complemented by sound and light alarms in case of abnormal air pressure, with indicators prominently displayed on the console panel. It has
capabilities such as torque limit, elevator link tilt, backup tong operation, brake operation, IBOP operation, emergency stop, drilling operation, and more, complete with essential indicators and instruments for streamlined operations. 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.
Outfitted with switches, indicators, and all necessary fittings and connectors for optimal top drive operation efficiency.
The console panel features a vibrant 9-inch LCD screen, offering clear displays of the top drive's working state, faults, and various operational states, ensuring operators are always informed.
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- Power Service Loop
A standard power service loop is installed to ensure a consistent power supply to the main motor,
with a terminal rack fitted onto the derrick for power loop stabilization.
The loop cable meets ZR specifications, making it ideal for domestic offshore drilling operations.
Power Cable Length: 70m;
featuring explosion-proof connectors, achieving level Exd IIC T5 certification for safety and reliability.
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- Auxiliary and Control Service Loop
It includes an auxiliary and control service loop, length-matched with the power service loop for consistent connectivity.
The length 70m;
equipped with explosion-proof connectors, adhering to level Exd IIC T5 standards, ensuring safety and durability.
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- Power Supply Cable
A power supply cable is included, linking the generator to the electrical control room with a 35m stretch, supporting voltage ranges of 0.6/1KV, connected via standard wire lugs for secure and efficient power transfer.
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- Control Cable of Driller Console
For seamless communication and efficient power supply between the driller console and the CPU, our superior control cable set, measuring 70 meters, is expertly configured to deliver unmatched performance.
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- Grounding Cable
Our reliable grounding cable assembly, crafted with high-quality domestic cable, includes two sturdy 1.5-meter galvanized grounding rods. This set ensures robust grounding with a length of 5 meters each (2 units).
Hydraulic Control System
Expertly engineered within the top drive body, our advanced hydraulic control system features a comprehensive integration of hydraulic source, sophisticated hydraulic main control valve set, efficient hydraulic actuator, essential hydraulic auxiliary components, and a state-of-the-art hydraulic oil radiator.
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- Hydraulic Source
The hydraulic source boasts an inclined axial plunger variable pump, specifically designed for hydrostatic transmission in an open circuit. With precise proportional flow adjustment relative to drive speed and displacement, stepless flow adjustments are possible by adeptly modifying the inclined plate angle. Dual oil outlets ensure resilience and functionality. These outlets shine with superior oil suction capabilities, minimal noise, and an impressive lifespan. Engineered for durability, the drive shaft is robust enough to handle both axial and radial loads.
Prioritizing safety and reliability, the hydraulic source's electrical circuit system employs an explosion-proof design, ensuring the motor and electrical control box are fortified with explosion-proof components.
Unveiling the primary technical specifications of our hydraulic system:
System's Rated Working Pressure: 14 MPa
Hydraulic Pump's Rated Flow Rate: 16 mL/r
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- Hydraulic Valve Manifold
Our hydraulic manifold set is equipped with premium plug valves utilizing renowned WANDFLUH hydraulic components, ensuring unmatched performance. Incorporating solenoid valves from the esteemed WANDFLUH Company, we guarantee reliability and excellence.
Featuring plug-in type hydraulic control valves, paired with explosion-proof solenoid reversing valves, the system's precise composition includes:
1. Counterbalance System Oil Circuit: This line features pressure relief overflow valves, hydraulic control check valves, throttle valves, and accumulators, designed to stabilize body weight and safeguard thread integrity during joint actions. The pressure relief overflow valve ensures optimal working pressure, while the accumulator enhances buffering, shock absorption, and pressure protection. With a safety overflow valve set at 17MPa, the balance cylinder is secured against impact loads.
2. Main Motor Brake Oil Circuit: Comprising advanced EX solenoid reversing valves for superior braking control.
3. Rotating Head Motor Oil Circuit: Featuring explosion-proof solenoid reversing valves and pressure regulating valves, with solenoid valve damping holes of hard alloy material for prolonged durability.
4. Remote Control IBOP Oil Circuit: Equipped with explosion-proof solenoid reversing valves for enhanced blowout prevention.
5. Back-up Tong Control Oil Circuit: Includes explosion-proof solenoid reversing valves and an integrated pressure sensor for effective control.
6. Tilt System Oil Circuit: Comprising explosion-proof solenoid reversing valves and throttle check valves, this circuit ensures precise positioning and stability, with the ability to maintain elevator link positions reliably.
In the high-performance QD40-B Top Drive, each oil circuit is intricately designed with pressure detection points, ensuring precise monitoring of working pressures throughout the system. These intuitive points not only monitor but also facilitate the effortless discharge of air from oil circuits and cylinders. This meticulous design guarantees the fluid operation of the system, enhancing efficiency and reliability.
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- Hydraulic Actuator
The meticulous design of the hydraulic actuator is composed of several critical parts, each engineered for optimal performance.
It includes: two Counterbalance Cylinders, two Brake Cylinders, one Drive Motor for the rotating head, two IBOP actuator Cylinders, one Back-up Tong Cylinder, and two Tilt Cylinders. Each component plays a vital role in ensuring seamless operation.
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- Hydraulic Auxiliary Components
The hydraulic auxiliary components are comprehensive in design, comprising essential elements like accumulators, filters, and a robust oil tank, among others, all crafted to enhance system functionality.
Accumulators are expertly segmented into two categories: brake accumulators and balance accumulators, each tailored for specific system needs.
The filters are strategically categorized into oil filters, high-pressure filters, oil return filters, and air filters, ensuring the purity and efficiency of the hydraulic system.
A strategically installed upper-mounted oil tank serves a dual purpose: it stores the hydraulic oil essential for the system's operation and aids in dissipating heat, maintaining optimal system temperatures.
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- Radiator
Positioned at the air inlet of the cooling blower, the radiator works in tandem with the main motor to powerfully cool the hydraulic oil. This process is crucial for maximizing the service life and stability of the entire hydraulic system, making it a cornerstone of the QD40-B's robust design.
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