Manufacturer of Top Drive System (TDS) with Load Capacity Max. 300 Ton for 4000m Well Drilling

• Customization: Available
• After-sales Service: 3 Year
• Warranty: 2 Year
• 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 embodies cutting-edge drilling technology by utilizing a suspended motor, either electric or hydraulic, to generate the essential torque for rotating the drill string. This modern approach supersedes traditional rotary table and kelly drive methods, bringing forth significant advantages, such as heightened drilling efficiency, diminished manual labor, and enhanced safety measures.

DQ40B-VSP Top Drive Features
1. Folding Guide Rails: Enjoy the safety, speed, and ease of a seamless top drive installation.
2. Advanced 360° Swivel Head Rotation: Empowering unparalleled maneuverability and precision.
3. Robust Double-Wheel Pulley Structure: Designed to evenly distribute force, this feature prolongs the roller's operational lifespan.
4. IBOP Rack and Pinion Drive: Guarantees precise and seamless IBOP (Internal Blow Off Preventer) transitions.
5. Inclined Hanging Backup Tong: Experience quicker and more straightforward tong teeth and seat replacements.
6. Efficient Hydraulic Radiator: Enhances the hydraulic system's longevity and performance.
7. Internal Counterbalance System: Ensures safe and stable operation, allowing direct attachment of the big hook or traveling carriage without additional components.
8. Compact Cross-Sectional Design: Optimized for integration with der rick systems, offering superior versatility.

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	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

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

Mechanical System

The mechanical system is an intricately engineered assembly comprising 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.
Leveraging an AC frequency conversion asynchronous motor, the top drive is powered to achieve dynamic AC frequency conversion drive.

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

At the heart of the system lies a dedicated single top drive AC frequency conversion asynchronous motor, boasting a robust power capacity of 290KW. The main technical parameters include:
Rated Voltage 600VAC
Rated Frequency 61Hz
Rated Current 365A
Equipped with a heater and an explosion-proof wind pressure switch, the main motor exemplifies safety and reliability.
The main motor's performance is further enhanced through a forced air-cooling mode.
The air-cooling motor boasts specifications of voltage 380VAC / 50Hz, power 4kW, with insulation grade F, and protection grade IP55, ensuring explosion-proof safety. With a classification of level ExdIICT4, the air-cooling system delivers a wind capacity of no less than 70 m3/min, sustaining an air pressure of 203mm water column.

1. 1. 1. Brake System

The top drive's main motor is fortified with a specialized hydraulic disc brake device, facilitating precise drill string orientation during directional inclined drilling operations.
Positioned strategically at the upper extension end of the motor shaft, the disc brake device incorporates a pair of robust Swedish DELLNER cylinders, linked by a specially hardened pipeline for long-lasting durability. When the main motor's speed descends to 3 rpm, the brake cylinder exerts frictional forces on the brake disc, effectively executing the main motor's braking function.

1. 1. 1. Gearbox

To augment the output torque of the top drive motor, reduce motor dimensions, and enhance overall motor performance, a state-of-the-art gearbox is incorporated.
The gear box of the QD40-B Top Drive features an advanced involute hard tooth surface gear, paired with a sophisticated secondary bevel gear, ensuring ultra-smooth and stable transmission. With an impressive transmission ratio of 11.91:1, the lubrication system is optimized through a dual-method approach; it combines splash lubrication with a forced lubrication system powered by an oil pump circulation to maintain peak performance.

1. 1. 1. Gooseneck Assembly

Innovatively engineered, the gooseneck is designed specifically for well logging. Utilizing corrosion-resistant liners and nuts, it effectively blocks the upper high-pressure mud pipeline during drilling, preventing any mud overflow for seamless operations.
One end of the gooseneck connects seamlessly with the wash pipe assembly. The assembly features a super high-pressure structure, crucial for sealing high-pressure mud. It integrates a self-sealing and rapid disassembly structure, enabling easy replacement when wear occurs. To replace the wash pipe or packing, simply open the covers of the upper and lower packing to remove the entire device without the need to detach the gooseneck, or the mud hose, allowing for a swift stop in drilling to facilitate quick replacement, at any point during the drilling process with minimal downtime.
The other end of the gooseneck is adeptly connected to the mud hose with a secure 4-inch female union, complemented by the robust Fig1003 thread type for reliable performance.
To ensure operational safety, a mud prevention device is strategically installed at the link between the main shaft and the wash pipe, meeting rigorous site operation standards.

1. 1. 1. Rotating Head

The rotating head system, a marvel of engineering, is configured to rotate independently from the main shaft. It allows elevator links to be suspended securely on the link adaptor, enhancing flexibility and control.
The system employs a worm gear transmission structure, ensuring seamless and smooth operation throughout.
The rotating head is engineered for versatility, capable of rotating both clockwise and counterclockwise in a full 360°. It can synchronize the rotation of the elevator link and elevator, enabling effortless grasping of a single pipe in the mouse hole or the triple stem on the monkey board, enhancing operational versatility.
Driven by a sophisticated hydraulic motor system, the rotating head utilizes a high-performance Dan foss cycloid motor, offering a speed range from 2 to 5 r/min for precise control.

1. 1. 1. Tilt System

The tilt system's cylinder efficiently maneuvers the elevator link to swing, facilitating both forward and backward inclines. This dual tilt capability allows the elevator to reach the mouse hole and monkey board with ease. During drilling, the backward tilt brings the lower end of the back up tong closer to the drilling platform, maximizing the utility of the drilling tool.
With an adjustable forward tilt angle of 30° and a backward tilt of 55°, the tilt range adapts to the length of the elevator link for optimal performance.
Note: For specific configurations with different length links, kindly consult our sales team in advance for tailored solutions.
The hydraulic system is equipped with a 'middle' setting within the tilt mechanism, allowing the elevator link to automatically revert to a free swing state. This prevents excessive pressure in the tilt cylinder, averting potential impact on the hydraulic system.

1. 1. 1. Counterbalance System

The counterbalance system, integral to the top drive, features a sophisticated suspension bail design. Connected to the gear box via a pin shaft, it hangs securely from the hook or traveling block. Its primary role is to counteract the body's weight. The VSP top drive utilizes dual hydraulic cylinders with an internal force balance mode, allowing direct suspension from hooks or traveling blocks, omitting the need for additional apparatus. This design enhances safety and reliability during operational tasks.

1. 1. 1. Back Up Tong Assembly

Outfitted with an L-type back up tong assembly, it employs a powerful motor system for optimized performance and, The innovative cylinder mechanism efficiently clamps, releases, and facilitates makeup and breakout operations. It seamlessly connects and disengages the saver sub, enhancing operational fluidity. Engineered to operate without the need for disassembling the tong body, this advanced system streamlines drilling operations. A sophisticated integration with a tilt mechanism and rotating head forms a comprehensive pipe handling device, significantly boosting the efficiency of makeup and breakout processes. Additionally, it enhances the layout operations of drilling tools while drastically minimizing labor intensity and potential hazards for the workforce.
Suitable for a wide range of drill pipe sizes, specifically from 85 to 187mm.

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

This system showcases an ingeniously integrated architecture, featuring both manual and remote control capabilities with a robust double ball valve. Discover the paramount technical parameters below:
Operational Pressure Rated at an impressive 70MPa
Thread Specification Compatible with 6-5/8" API REG × 6-5/8" API REG standards
Outer Diameter Measuring at Φ187mm
Inner Diameter 3" measurement
The remote control IBOP actuator is composed of dual hydraulic cylinders, an IBOP sliding sleeve, and a precision gear system. The connection mechanism between the cylinder and the sliding sleeve employs roller contact to guarantee synchronized axial movement of the sleeve in conjunction with the main shaft's rotation. Additionally, the drive wrench efficiently controls the opening and closing operations of the manual IBOP.
This feature ensures rapid IBOP closure in the event of a sudden well kick or blow-out scenario, thereby maintaining exemplary well control safety standards.
The IBOP sliding sleeve's operation is enhanced by a gear rack with cam gear configuration, ensuring superior reliability.

1. 1. 1. Guide Rail and Carriage System

This comprehensive folding guide rail assembly incorporates multiple sections of guide rails, secure connection points, crown block support, and an adjustable beam assembly accompanied by necessary installation accessories.
Featuring a folding design, the application ensures swift and hassle-free on-site installation.
The carriage and guide rail boast a friction-based pulley structure.
The pulley utilizes a double side cam follower design, distributing stress evenly across each roller, thus extending its operational lifespan.

1. 1. 1. Container Solutions

For seamless transportation, two open-top containers are configured. One securely houses the top drive body, while the other accommodates the guide rail and cable assembly,

Electrical Control System Overview

The advanced top drive electrical control system integrates a main control system, a dedicated electrical control room, and a sophisticated driller's console, alongside power cables, auxiliary and composite control cables, power supply cables, driller's console cables, grounding cables, and more.
The system is equipped with a high-performance AC asynchronous induction motor, which provides the necessary drilling power while utilizing an AC frequency conversion drive method.

1. 1. 1. Main Control System Excellence

Equipped with a state-of-the-art electrical control system, which includes an ABB ACS880 AC frequency conversion speed regulating device, a programmable logic controller (PLC), and an auxiliary control unit. The system is endowed with comprehensive self-diagnosis, protective measures, and anti-harmonic interference capabilities to ensure flawless electrical control operations throughout top drive utilization.
The utilization of Siemens' Simatic S7-1500 series PLC, managed through the ProfiBus-DP bus, ensures meticulous system operating parameter configurations and comprehensive hardware/software status diagnostics;
With control over both the main system and driller console via the ProfiBus bus, users benefit from robust anti-interference properties, precise and dependable control, and ease of use, installation, debugging, and maintenance on-site.
Immerse yourself in the realm of precision with our auxiliary control unit, meticulously engineered to share the cabinet with a state-of-the-art PLC, featuring premium Siemens electric components that promise unparalleled efficiency.
Experience seamless operation with our sophisticated IPC system, expertly configured to present a comprehensive view of top drive parameters. Effortlessly access system settings, alarm records, action screens, dynamic data curves, maintenance details, and an advanced network topology interface.
Our main control cabinet is smartly designed with two reserved analog output interfaces of 4 ~ 20 mA or 0~10V, ensuring precise logging of torque and speed signals with unmatched reliability.
With our innovative reserved networking interface, you have the flexibility to easily connect to a wireless or mobile network, enabling efficient remote data transmission for the top drive.

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

In our electrical control room, the electric drive and control system cabinets are strategically concentrated for firm, reliable installation, ensuring convenient maintenance for optimized performance.
Equipped with cutting-edge air conditioning, our VFD room maintains a stable, comfortable temperature range of 25ºC -30ºC, ensuring optimal equipment performance.
The interior decor of our control room boasts high-quality plastic spray steel plates, with walls that seamlessly integrate interface ports for external cables, combining functionality with aesthetic elegance.
Incorporating an external 380V emergency power interface, our electric control room excels in versatility, supporting makeup, breakout, and low-speed operations under special conditions with a robust power supply of no less than 200KW.

1. 1. 1. Driller Console

Our driller console offers seamless integration within the driller house, serving as a vital hub for the comprehensive operation and control of the top drive.
Crafted with a rugged stainless steel shell, our driller console features a sealed structure with a positive pressure explosion-proof design, incorporating advanced safety mechanisms including pressure release valve, air and water separator, joints, interfaces, and high-performance filters. The system is equipped with sound and light alarms to promptly alert operators of abnormal air pressure, complemented by corresponding indicator lights elegantly displayed on the console panel.
This console embodies a suite of essential functions such as torque limit, elevator link tilt, back-up tong operation, brake operation, IBOP operation, and emergency stop. It supports seamless drilling operations, providing all necessary operation indicators and instruments.
Expertly configure switches, indicators, fittings, and connectors as required for the flawless operation of the top drive, establishing an environment of precision and ease.
Our console panel features an intuitive 9-inch LCD screen, clearly displaying operational status, fault notifications, and other essential states of the top drive, ensuring operators remain informed and in control.

1. 1. 1. Power Service Loop

Our power service loop is meticulously designed to provide dependable power to the main motor,
with a robust terminal rack installed on the derri ck for secure power loop fixation,
ensuring the cable of the loop meets stringent ZR specifications, tailored for domestic offshore drilling applications.
Boasting a generous length of 70m, our power cable is equipped
with explosion-proof connectors rated at level Exd IIC T5, offering maximum safety and reliability.

1. 1. 1. Auxiliary and Control Service Loop

A meticulously crafted auxiliary and control service loop complements the power service loop, matching its length perfectly to ensure seamless integration.
Extending 70m in length,
this loop is fortified with explosion-proof connectors at level Exd IIC T5, enhancing safety and operational efficiency.

1. 1. 1. Power Supply Cable

Our power supply cable is expertly engineered to connect the generator and the electrical control room with a reliable length of 35m and a voltage of 0.6 / 1KV, utilizing standard wire lug connections for optimal performance.

1. 1. 1. Control Cable of Driller Console

Our control cable is precisely configured to facilitate seamless power supply and communication between the driller console and the CPU, with a substantial length of 70m to ensure uncompromised connectivity.

1. 1. 1. Grounding Cable

Included is a comprehensive grounding cable assembly, featuring high-quality, domestically manufactured cables. This set comprises two pieces of a 1.5-meter galvanized grounding rod and two segments of cable stretching a generous 5 meters each, ensuring reliable connectivity.

Hydraulic Control System

Elegantly integrated within the robust top drive body is the advanced hydraulic system. This intricate system is composed of several vital components: a potent hydraulic source, a sophisticated main control valve set, dynamic hydraulic actuators, essential auxiliary parts, and an efficient hydraulic oil radiator, all working together seamlessly for optimal performance.

1. 1. 1. Hydraulic Source

The hydraulic source boasts an inclined axial plunger variable pump, expertly designed for hydrostatic transmission in open circuits. It offers a flow rate that gracefully adjusts in direct proportion to drive speed and displacement. By finely tuning the angle of the inclined plate, you can achieve a stepless flow adjustment, with its dual oil outlets on the shell providing exceptional oil suction capabilities, whisper-quiet operation, and remarkable longevity, with the drive shaft engineered to endure both axial and radial loads.
Emphasizing safety and reliability, the hydraulic source's electrical circuit system incorporates an explosion-proof design. Both the electrical control box and the integral motor are constructed with 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

Equipped with a state-of-the-art hydraulic manifold, this set features plug valves made of top-tier WANDFLUH hydraulic components. The solenoid valves are also premium products from WANDFLUH Company.
The hydraulic control valves follow the plug-in type design, while the solenoid reversing valves are crafted as explosion-proof products. The specific structure includes:
First line: The counterbalance system expertly manages the oil circuit. It integrates a pressure relief overflow valve, hydraulic control check valve, throttle valve, and accumulator. Its primary role is to balance the body's weight, safeguarding the threads against wear during joint makeup and breakdown. The pressure relief overflow valve fine-tunes the balance cylinder's working pressure, aligning with the body's weight. The accumulator functions as a buffer for shock absorption and pressure protection. The balance cylinder includes a safety overflow valve set to 17MPa to shield the hydraulic cylinder from impact loads.
Second line: The main motor brake oil circuit comprises EX solenoid reversing valves.
Third line: The rotating head motor's oil circuit consists of explosion-proof solenoid reversing and pressure regulating valves. The solenoid valve's damping hole is fashioned from hard alloy, enhancing its longevity and reliability.
Fourth line: The oil circuit for the remote control internal blowout preventer (IBOP) is composed of explosion-proof solenoid reversing valves.
Fifth line: The back-up tong control oil circuit features explosion-proof solenoid reversing valves, complete with a precise pressure sensor.
Sixth line: The tilt system oil circuit combines explosion-proof solenoid reversing valves with a throttle check valve and complementary units. The solenoid valve facilitates reversing, while the throttle check valve allows the elevator link to remain stationary at any given position for extended periods, with an option to set it to the swing state when centrally positioned.
All aforementioned oil circuits are equipped with pressure detection points, meticulously monitoring each oil circuit's working pressure. Additionally, air trapped in both the oil circuit and cylinder can be efficiently released via these measurement points, ensuring flawless system operation.

1. 1. 1. Hydraulic Actuator

The hydraulic actuator is composed of the following precision-engineered parts
Counterbalance Cylinder (2 ea), Brake Cylinder (2 ea), Drive Motor of Rotating Head (1 ea), IBOP Actuator Cylinder (2 ea), Back-up Tong Cylinder (1 ea), Tilt Cylinder (2 ea).

1. 1. 1. Hydraulic Auxiliary Components

Our comprehensive range of hydraulic auxiliary components includes essential elements for optimal system performance such as accumulators, filters, and oil tanks, among others.
Accumulators These are expertly categorized into brake accumulators and balance accumulators, ensuring precise control and stability across operations.
Our filter lineup is meticulously divided into oil filters, high-pressure filters, oil return filters, and air filters, each designed for peak filtration efficiency.
An upper-mounted oil tank is strategically installed to house the hydraulic oil necessary for system operations while also serving to effectively dissipate heat, guaranteeing optimal functionality.

1. 1. 1. Radiator

Positioned at the air inlet of the cooling blower, the radiator plays a crucial role in forcefully cooling the hydraulic oil using the main motor, thereby significantly enhancing the longevity and stability of the entire hydraulic system.