Dq50 Bq 350 Ton 800kw Top Drive System for 5000m Oil Well Drilling Rig

Introducing the VSP newly designed DQ50-BQ, an upgraded marvel in the top drive system. Enhanced across numerous components from its traditional predecessors, this system boasts a remarkable competitive edge. Its notably more compact size belies its substantial torque and operational efficiency, setting a new standard in top drive performance.

Mechanical SystemMechanical System

The mechanical system of our top drive is a sophisticated assembly comprising a main motor system, air cooling system, brake system, gearbox, wash pipe assembly, rotating head mechanism, tilt mechanism, back-up tong mechanism, internal blowout prevention mechanism (IBOP), guide rail and carriage mechanism, as well as a container. Each component is meticulously engineered for optimal functionality and reliability.
The top drive harnesses the power of an AC frequency conversion asynchronous motor, enabling a state-of-the-art AC frequency conversion drive for seamless operation.

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

The main motor is a powerhouse-a single top drive special AC frequency conversion asynchronous motor delivering a robust power output of 290KW. The main technical parameters are as follows:
Rated Voltage 600VAC
Rated Frequency 61Hz
Rated Current 365A
This exceptional main motor is equipped with a heater and a crucial explosion-proof wind pressure switch for heightened safety and performance.
The main motor employs a forced air-cooling mode, ensuring optimal temperature control and consistent operation.
The air-cooling motor features specifications of 380VAC / 50Hz, with 4kW of power, insulation grade F, protection grade IP55, and is explosion-proof, safeguarding against potential hazards. The specifications extend to level ExdIICT4 with a wind capacity no less than 70 m3/min and an air pressure of 203mm water column, highlighting its robust design.

1. 1. 1. Brake System

The top drive main motor is complemented by a specialized hydraulic disc brake device, essential for aiding the drill string orientation during directional inclined drilling operations.
The disc brake device is ingeniously installed at the motor shaft’s upper extension end, utilizing a pair of Swedish DELLNER cylinders connected via a specialized hard pipeline. This configuration is highly durable. As the main motor’s speed diminishes to 3rpm, the braking function activates through friction forces on the brake disc via the brake cylinder, ensuring controlled deceleration.

1. 1. 1. Gear Box

To amplify the output torque of the top drive motor and enhance performance while minimizing volume, a sophisticated gearbox is integrated.
Our gearbox showcases involute hard tooth surface gears with a secondary bevel gear, achieving ultra-stable transmission. The transmission ratio is a precise 11.91:1. We utilize a hybrid lubrication technique, combining splash lubrication and forced lubrication through oil pump circulation, for optimal gear performance.

1. 1. 1. Gooseneck Assembly

The gooseneck is crafted with precision, particularly for well logging applications. It features corrosion-resistant liners and nuts to effectively block the upper high-pressure mud pipeline, preventing potential mud overflow during drilling sessions.
One end of this expertly designed gooseneck connects with the wash pipe assembly, which features a super high-pressure structure vital for sealing high-pressure mud. It boasts a self-sealing and rapid disassembly structure. When wear necessitates replacement of the wash pipe and packing, simply open the upper and lower packing covers to remove the entire device without disturbing the gooseneck and the mud hose. This design facilitates a seamless stop in drilling processes for component replacements, ensuring minimal downtime and maximum efficiency during operations. at any time during the drilling process, allowing for swift and easy maintenance.
At the heart of the Efficient 350 Ton Top Drive, a robust 4-inch female connection seamlessly integrates the gooseneck with the mud hose. This union boasts a Fig1003 thread type, ensuring secure and efficient connectivity.
Enhancing safety and functionality, a sophisticated mud prevention device is skillfully installed at the juncture between the main shaft and wash pipe, fulfilling operational site demands with aplomb.

1. 1. 1. Rotating Head

Our state-of-the-art rotating head system is designed to operate independently of the main shaft, with the elevator links gracefully suspended from the link adaptor. This ensures a seamless, reliable operation, enhancing versatility and control.
Utilizing an advanced worm gear transmission structure, the rotation is executed with unparalleled smoothness and stability.
The rotating head is engineered to effortlessly rotate a full 360° in both directions, harmoniously working in tandem with the elevator link and elevator to expertly handle both single pipes and triple stems in various positions. This extraordinary capability ensures maximum efficiency on both the mouse hole and monkey board.
Driven by a cutting-edge Danfoss cycloid motor, the hydraulic motor system empowers the rotating head, offering a versatile speed range between 2 to 5 r/min, perfect for precise and responsive operations.

1. 1. 1. Tilt System

The innovative tilt cylinder propels the elevator link with precision, enabling it to elegantly swing forward and backward. This dynamic forward tilt reaches out to both the mouse hole and monkey board, optimizing operational reach. In drilling scenarios, the backward tilt feature ensures the lower surface of the backup tong aligns closely with the drilling platform, maximizing the usage of drilling tools.
Tailored for flexibility, the tilt range is influenced by the elevator link’s length, offering an adjustable forward angle of 30 degrees and a backward tilt angle of 55 degrees.
Note: For customized length links, proactive communication with our sales team is encouraged to ensure optimal configurations.
Our hydraulic system boasts a unique ‘middle’ setting for the tilt mechanism, allowing the elevator link to automatically return to a free swing state, mitigating pressure-induced impacts on the hydraulic system.

1. 1. 1. Counterbalance System

Central to the top drive system, our suspension bail counterbalance mechanism is ingeniously connected via a pin shaft to the gearbox and anchored on the hook or traveling block. Featuring a double hydraulic cylinder with an internal force balance mode, this system ensures seamless, device-free operation, enhancing safety and reliability.

1. 1. 1. Back Up Tong Assembly

Our L-type backup tong assembly, a marvel of engineering, includes a motor and cylinder for swift clamping, releasing, makeup, and breakout processes. It is adept at connecting and removing the saver sub without necessitating the disassembly of the tong body, streamlining drilling operations significantly. Together with the tilt mechanism and rotating head, it forms a comprehensive pipe handling device that elevates the makeup & breakout operation efficiency, optimizes drilling tool layout, and substantially reduces staff labor intensity and hazard levels.
Designed to handle an extensive drill pipe range of 85-187mm, our system is both versatile and capable.

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

The IBOP is a sophisticated integrated structure featuring both manual and remote-control capabilities, with technical specifications that include a dual ball valve setup for maximum control and safety.
Working Pressure Our system thrives under an impressive 70MPa working pressure, showcasing its robust engineering.
Thread Type Engineered for seamless integration, the thread type is 6-5/8″API REG × 6-5/8″API REG, ensuring compatibility and reliability.
O.D. With an outer diameter of Φ187mm, our system is crafted for precision and durability.
I.D. 3
The actuator of the remote control IBOP is exquisitely engineered with a sophisticated pair of hydraulic cylinders, an IBOP sliding sleeve, a gear assembly, and more. The connection type between the cylinder and the sliding sleeve features a roller interface, ensuring seamless axial movement of the sleeve in perfect harmony with the spindle’s rotation, while also allowing the drive wrench to competently manage the opening and closing of the manual IBOP.
This remarkable feature facilitates the swift closure of the IBOP in the event of a well kick or blow-out, thereby securing well control safety.
The IBOP sliding sleeve employs a gear rack configuration with cam gear for enhanced reliability.

1. 1. 1. Guide Rail and Carriage

The intelligent design features a folding guide rail assembly with multi-sectional guide rails, secure connections, crown block support, an adjustment beam assembly, and installation accessories for seamless integration.
With its innovative folding design, on-site installation becomes a swift and straightforward process.
The carriage and guide rail utilize a friction type pulley structure.
This pulley system, with a double side cam follower structure, ensures even roller stress distribution, significantly extending the lifespan.

1. 1. 1. Container

For effortless transportation, two open-top containers are provided; one houses the top drive body, while the other accommodates the guide rail and cable assembly.

Electrical Control System

The state-of-the-art top drive electrical control system includes a main control system, an electrical control room, a driller’s console, power cables, auxiliary and composite control cables, power supply cables, and driller’s console cable, grounding cables, among other essential components.
The top drive is powered by an AC asynchronous induction motor, adopting an AC frequency conversion drive mode for optimal drilling power.

1. 1. 1. Main Control System

A sophisticated electrical control system is equipped, featuring the ABB ACS880 AC frequency conversion speed regulating device, a programmable logic controller (PLC), an auxiliary control unit, etc. It boasts comprehensive self-diagnosis, protection, and anti-harmonic interference functions, ensuring all electrical control functions are seamlessly executed during top drive operations.
The system employs the Simatic S7-1500 series PLC by Siemens, controlled using the ProfiBus-DP bus, to facilitate system parameter settings and thorough hardware and software status checks.
With the main control system and driller console both managed via ProfiBus bus, the setup provides robust anti-interference capabilities, precise and dependable control, and straightforward on-site usage, installation, debugging, and upkeep.
The auxiliary control unit shares the cabinet with the PLC and utilizes Siemens electric components.
Equipped with an IPC system, it displays top drive operation parameters, system settings, alarm records, action screens, data curves, maintenance info, and network topology functions.
The primary control cabinet includes two reserved analog output interfaces (4~20 mA or 0~10V) specifically for torque and speed logging signals.
Additionally, a reserved networking interface can optionally facilitate field connections to wireless or mobile networks, enabling remote top drive data transmission.

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

Consolidating the electric drive and control system cabinets within the electrical control room ensures secure, reliable installation and effortless maintenance.
The VFD room features air conditioning equipment, maintaining a comfortable temperature range of 25ºC – 30ºC.
The interior decoration material is meticulously chosen to complement the high-functionality environment. The control room boasts a robust plastic spray steel plate construction, featuring interface ports seamlessly integrated with external cables, ensuring streamlined functionality and connectivity.
Equipped with a versatile 380V emergency power interface, the electric control room is designed to support makeup, breakout, and low-speed operations in special circumstances, provided the power supply is no less than 200KW.

1. 1. 1. Driller Console

A singular driller console can be precisely installed and securely fixed inside the driller house, providing comprehensive operation and control of the top drive.
The driller console features a sealing structure encased in a stainless steel shell, employing an advanced positive pressure explosion-proof design. This includes a sophisticated explosion-proof device with pressure release capabilities. valve, air and water separators, joints, advanced interface connections, and filters. In the event of abnormal air pressure within the box, both audible and visual alarms, along with corresponding indicator lights on the console panel, are activated.
It offers a suite of functionalities including torque limit, elevator link tilt, backup tong operation, brake operation, IBOP operation, emergency stop, drilling operation, as well as essential operation indicators and instruments.
The console is equipped with switches, indicators, mounting fittings, and connectors necessary for seamless top drive operation.
Featuring a 9-inch LCD screen on the console panel, it provides real-time display of working status, fault detection, and other operational statuses of the top drive.

1. 1. 1. Power Service Loop

A standard set of power service loop is meticulously equipped to ensure power delivery to the main motor,
while a terminal rack is strategically installed on the derrick to firmly secure the power loop.
The loop cable complies with ZR specifications, tailored specifically for domestic offshore drilling operations.
Power Cable Length: 70m;
featuring explosion-proof connectors, rated at level Exd IIC T5, ensuring comprehensive safety.

1. 1. 1. Auxiliary and Control Service Loop

Equipped with an auxiliary and control service loop, its length is harmonized to match the power service loop,
with a length of 70m,
also featuring explosion-proof connectors rated at level Exd IIC T5 for uncompromised safety.

1. 1. 1. Power Supply Cable

A set of power supply cables is included, bridging the generator and electrical control room, with a length of 35m, voltage rated at 0.6 / 1KV, utilizing standard wire lug connections for reliable performance.

1. 1. 1. Control Cable of Driller Console

One comprehensive control cable set is configured, facilitating power supply and communication between the driller console and the CPU, with a considerable length of 70m for enhanced connectivity.

1. 1. 1. Grounding Cable

A robust grounding cable assembly is included, utilizing domestically produced cables, complete with two 1.5 m galvanized grounding rods, each accompanied by a 5 m cable length for superior grounding capabilities.