Brief Description:
The top drive system is an advanced drilling technology that revolutionizes conventional drilling methods. By using a suspended motor, either electric or hydraulic, it delivers the essential torque needed to efficiently rotate the drill string. This cutting-edge technology replaces the old-school rotary table and kelly drive methods, boasting remarkable advantages such as significantly enhanced drilling efficiency, minimized manual labor, and vastly improved safety measures.
DQ40B-VSP Top Drive Features:
1. Folding Guide Rails: Experience a safe, swift, and hassle-free top drive installation that sets a new standard in operational convenience.
2. 360° Swivel Head Rotation: Ensures dynamic and flexible operational capabilities, enhancing overall performance.
3. Double-Wheel Pulley Structure: Designed to distribute force evenly, this innovative structure prolongs the roller's service life, ensuring longevity and durability.
4. IBOP Rack and Pinion Drive Mechanism: Guarantees precise and accurate IBOP (Internal Blow Off Preventer) switching, enhancing operational control.
5. Inclined Hanging Backup Tong: Streamlines the process of replacing tong teeth and seats, making it faster and more efficient.
6. Hydraulic Radiator: Engineered to extend the hydraulic system's lifespan, ensuring sustained performance and reliability.
7. Internal Counterbalance: Provides a safe and stable jump mechanism, eliminating the need for additional components to suspend the big hook or traveling carriage, allowing for direct suspension.
8. Compact Cross-Sectional Design: Optimized for compatibility with derrick structures, enhancing adaptability and integration.
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- 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° |
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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 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 |
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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 System
The mechanical system is meticulously composed of a robust array of components, including a main motor system, air cooling system, brake system, gear box, wash pipe assembly, rotating head mechanism, tilt mechanism, backup tong mechanism, IBOP, guide rail and carriage mechanism, and a durable container, all working harmoniously.
The top drive is expertly powered by an AC frequency conversion asynchronous motor, enabling a sophisticated AC frequency conversion drive.
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- Main Motor and Air Cooling System
The main motor is an exclusive single top drive AC frequency conversion asynchronous motor, boasting a power of 290KW. Key technical parameters include:
Rated Voltage 600VAC
Rated Frequency 61Hz
Rated Current 365A
The main motor is equipped with an advanced heater and an explosion-proof wind pressure switch, ensuring safety and reliability.
The main motor utilizes a forced air-cooling design to maintain optimal performance under demanding conditions.
The air-cooling motor features: voltage 380VAC / 50Hz, power 4kW, insulation grade F, protection grade IP55, and is explosion-proof. Level ExdIICT4, with a wind capacity not less than 70 m3/min, and an air pressure of 203mm water column, ensuring efficient cooling.
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- Brake System
The top drive's dedicated hydraulic disc brake system is engineered to assist in orienting the drill string during directional inclined drilling operations, enhancing precision.
The disc brake system features Swedish DELLNER cylinders linked by a specialized hard pipeline for durability. When motor speed drops to 3rpm, the brake cylinder's friction on the disc accomplishes the essential braking function.
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- Gear Box
To amplify the top drive motor's output torque while reducing motor volume and enhancing overall performance, a state-of-the-art gear box is configured.
Our state-of-the-art gear box showcases involute hard tooth surface gears combined with secondary bevel gears, ensuring a seamless and stable transmission experience. With an impressive transmission ratio of 11.91:1, this system guarantees optimal performance. The lubrication method features a sophisticated integration of splash lubrication alongside a robust forced lubrication system facilitated by an oil pump circulation, ensuring longevity and reliability.
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- Gooseneck Assembly
Ingeniously crafted, the gooseneck assembly is tailored specifically for well logging applications. During the drilling process, its corrosion-resistant liner and robust nuts effectively seal the upper high-pressure mud pipeline, preventing any unwanted mud overflow, thereby enhancing operational safety and efficiency.
One end of the gooseneck seamlessly integrates with the wash pipe assembly. This assembly, designed to withstand super high pressure, plays a crucial role in sealing the high-pressure mud. It features an innovative self-sealing mechanism and a rapid disassembly structure, allowing for quick and easy maintenance. When wear and tear necessitate replacement of the wash pipe or packing, you simply need to open the upper and lower packing covers to effortlessly remove the entire device without detaching the gooseneck, or disconnecting the mud hose. This design facilitates easy interruption of drilling, ensuring you can conveniently replace components at any given moment during the drilling operation.
On the other end, the gooseneck connects flawlessly to the mud hose through a reliable 4-inch female union, utilizing the Fig1003 thread type, ensuring a secure and dependable connection.
A strategically placed mud prevention device is installed at the junction of the main shaft and the wash pipe, effectively meeting the rigorous demands of site operations.
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- Rotating Head
Our rotating head system is meticulously designed to rotate independently from the main shaft, with elevator links gracefully suspended on the link adaptor, allowing for a smooth and efficient operation.
The system employs a worm gear transmission structure, which guarantees smooth and reliable driving.
The ability of the rotating head to rotate both clockwise and counterclockwise a full 360° allows it to synchronize with the elevator link and elevator, enabling precise handling of a single pipe in the mouse hole, or the triple stem on the monkey board, showcasing its versatility.
Driven by a powerful set of hydraulic motors utilizing the Danfoss cycloid motor, the rotating head offers a speed range of 2 to 5 rotations per minute, ensuring flexibility and control.
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- Tilt System
Our advanced tilt cylinder is designed to drive the elevator link into a seamless swing motion, enabling both forward and backward tilting. The forward tilt function allows the elevator to extend efficiently to the mouse hole and the monkey board, simplifying operations. During drilling, the backward tilt function aligns the lower end of the back up tong closely with the drilling platform, maximizing the utilization of the drilling tool.
The tilt system's range varies with the length of the elevator link, offering a forward tilt angle of 30 degrees and an adjustable backward tilt angle of 55 degrees, ensuring adaptability.
Note: Should you require configuration of links with alternative lengths, please initiate communication with our sales team ahead of time.
Our hydraulic system incorporates a 'middle' setting within the tilt mechanism, which enables the elevator link to automatically revert to a free swing state, mitigating any pressure impact on the hydraulic system by relaxing the tilt cylinder.
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- Counterbalance System
The suspension bail counterbalance system is a pivotal component of the top drive system. The bail is securely attached to the gearbox via the pin shaft, with the upper part suspended from the hook or traveling block. Its primary function is to effectively balance the weight of the apparatus. The VSP top drive employs a dual hydraulic cylinder with an internal force balance mode, allowing direct suspension with the hook or traveling block, eliminating the need for additional apparatus, thereby enhancing safety and reliability during operations.
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- Back Up Tong Assembly
Equipped with a robust L-type back up tong, assembly, powered by a motor, ensuring efficient operation and Experience the seamless efficiency of our cylinder system, designed to effortlessly clamp, release, make-up, and break-out with precision. It enables simplified connection and removal of the saver sub, ensuring smooth operations. Enjoy uninterrupted drilling operations with a non-disassembly tong body. Our integrated pipe handling device, complete with a tilt mechanism and rotating head, significantly enhances the efficiency of make-up and break-out operations as well as the layout of drilling tools. This innovation substantially decreases labor intensity and elevates staff safety, minimizing danger.
Our solution accommodates a broad range of drill pipes, specifically from 85mm to 187mm, ensuring versatility and adaptability in diverse drilling scenarios.
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- Featuring an Internal Blow Out Preventer (IBOP), designed for optimal safety and performance.
Our product showcases an integrated design, featuring both manual and remote control mechanisms, and includes a sophisticated double ball valve. Key technical specifications include:
Working Pressure Rated at an impressive 70MPa
Thread Type 6-5/8"API REG × 6-5/8"API REG, ensuring reliable and robust connections.
O.D. Φ187mm, providing optimal dimensions for superior performance.
I.D. 3", designed for efficient and effective operation.
Our remote control IBOP actuator is engineered with precision, comprising hydraulic cylinders, an IBOP sliding sleeve, and gears, ensuring seamless operation. The connection type between the cylinder and the sliding sleeve utilizes roller interaction, guaranteeing simultaneous axial movement with main shaft rotation. In addition, the drive wrench offers effortless manual IBOP opening and closing.
This capability ensures rapid IBOP closure, essential in scenarios like well kicks or blow-outs, ensuring maximum well control safety.
Our IBOP sliding sleeve utilizes a gear rack with cam gear, enhancing reliability and trust in operation.
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- Guide Rail and Carriage
Configured with innovation, our folding guide rail assembly includes multiple sections, connections, crown block support, and adjustable beam assembly along with installation accessories, ensuring comprehensive support and flexibility.
The folding design enables fast and convenient site installation, optimizing time and resources.
Our carriage and guide rail friction type features a pulley structure,
with a double-side cam follower to ensure even roller stress distribution, prolonging service life.
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- Container
For optimal transportation, two open-top containers are provided, one housing the top drive body, the other for the guide rail and cable assembly,
Electrical Control System
Our top drive electrical control system integrates a main control system, an advanced electrical control room, and a driller's console, supported by power cables, auxiliary and composite control cables, power supply cables, and a driller's console cable, grounding cable, etc., ensuring comprehensive and efficient control.
Equipped with an AC asynchronous induction motor, our top drive delivers powerful drilling performance, utilizing advanced AC frequency conversion drive technology.
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- Main Control System
Includes a robust electrical control system featuring an ABB ACS880 AC frequency conversion speed regulating device, a PLC, and auxiliary control unit, offering comprehensive self-diagnosis, protection, and anti-harmonic interference capabilities for seamless top drive operation.
Employing the Siemens Simatic S7-1500 series PLC, managed by a ProfiBus-DP bus, our system facilitates precise operating parameter settings and thorough hardware/software status detection.
The main control system and driller console are interconnected via a ProfiBus bus, providing strong anti-interference capabilities, precise and reliable control, and facilitating easy 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.
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- 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).
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- 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.
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- 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
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- 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
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- 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.
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- 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
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- Grounding Cable
Our meticulously crafted grounding cable assembly is a testament to robust engineering, featuring a set of high-quality, domestically-made cables. It includes a pair of 1.5 m galvanized grounding rods, each spanning an impressive 5 meters, ensuring optimal conductivity and safety.
Hydraulic Control System
The Hydraulic Control System is ingeniously integrated into the top drive body. It comprises a sophisticated hydraulic source, a comprehensive main control valve set, efficient hydraulic actuators, auxiliary parts, and a state-of-the-art hydraulic oil radiator.
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- Hydraulic Source
Our hydraulic source boasts an inclined axial plunger variable pump, renowned for hydrostatic transmission in an open circuit. The flow adapts seamlessly to drive speed and displacement, allowing infinite adjustment by altering the inclined plate angle. Features dual oil outlets on the shell, delivering unparalleled oil suction capabilities, reduced noise levels, and an impressive lifespan, with a drive shaft designed to endure both axial and radial loads with ease.
The electrical circuit system of the hydraulic source is crafted with an explosion-proof design, utilizing explosion-proof components for both the control box and motor, ensuring utmost safety in hazardous environments.
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
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- Hydraulic Valve Manifold
Equipped with a sophisticated hydraulic manifold, the system incorporates WANDFLUH hydraulic components for the plug valves, while the solenoid valves also feature premium products from the esteemed WANDFLUH Company, ensuring reliability and excellence.
The hydraulic control valves feature a plug-in type design, with all solenoid reversing valves employing explosion-proof technology. The intricate components include:
First line: The counterbalance system, a master of oil circuit control. Comprised of a pressure relief overflow valve, hydraulic control check valve, throttle valve, and accumulator, it skillfully balances body weight, protecting threads during makeups and breakouts. The pressure relief overflow valve fine-tunes the balance cylinder's working pressure, while the accumulator provides buffering, shock absorption, and pressure protection. Equipped with a safety overflow valve set at 17MPa, the balance cylinder safeguards against impact loads, ensuring the hydraulic cylinder's longevity.
Second line: The main motor brake oil circuit is expertly constructed with EX solenoid reversing valves, ensuring precise and efficient operation.
Third line: The rotating head's oil circuit features an explosion-proof solenoid reversing valve and a pressure regulating valve. The solenoid valve's damping hole, crafted from hard alloy material, enhances durability and service life.
Fourth line: The remote control internal blowout preventer's (IBOP) oil circuit is fortified with explosion-proof solenoid reversing valves, ensuring unwavering safety and control.
Fifth line: The back-up tong control oil circuit, with explosion-proof solenoid reversing valves, is equipped with a pressure sensor for added precision.
Sixth line: The Tilt system oil circuit integrates an explosion-proof solenoid reversing valve, throttle check valve, and additional components. This system allows the elevator link to halt in any position indefinitely and can easily transition into a swing state when centered.
Each oil circuit is meticulously equipped with pressure detection points, allowing for real-time monitoring of working pressures. Additionally, these points facilitate the expulsion of air from each oil circuit and cylinder, promoting smooth system operation.
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- Hydraulic Actuator
The hydraulic actuator is an assembly of meticulously engineered parts, each contributing to a powerful and efficient performance.
Experience unparalleled efficiency with our QD40-B Top Drive's sophisticated hydraulic components which include: Dual Counterbalance Cylinders, Dual Break Cylinders, a robust Rotating Head Drive Motor, Dual IBOP Actuator Cylinders, a single Back-up Tong Cylinder, and Dual Tilt Cylinders. Each component is meticulously designed to ensure superior performance.
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- State-of-the-Art Hydraulic Auxiliary Components
Our advanced hydraulic auxiliary components feature an integrated system of accumulators, precision-engineered filters, and a sizable oil tank. These elements work in harmony to optimize performance and reliability.
High-Performance Accumulators Our accumulators are expertly categorized into brake accumulators and balance accumulators, each serving a critical role in maintaining system equilibrium and operational precision.
Our comprehensive filter system is meticulously categorized into oil filters, high-pressure filters, oil return filters, and air filters, ensuring the utmost purity and protection of the hydraulic system.
The strategically positioned upper-mounted oil tank is designed to efficiently store the required hydraulic oil while dissipating system heat, thereby enhancing operational longevity and efficiency.
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- Innovative Radiator System
Our radiator is precisely located at the air inlet of the cooling blower, utilizing the main motor for forced cooling of the hydraulic oil. This ensures the hydraulic system's longevity and stability, maintaining peak performance under demanding conditions.
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