Compact Drawworks System With Modular Motor And Gearbox Assembly
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Solution Overview
Problem
Existing drawworks systems in drilling and production operations are often large and complex, leading to maintenance and repair challenges that result in increased downtime and inefficient drilling operations.
Innovation Solution
A compact drawworks system incorporating multiple motors, a gearbox, a brake, and a drum configuration that allows for efficient lifting of loads using both motors or a single motor in case of failure, with a control system for managing gear ratios and braking, enabling reduced downtime and efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a compact drawworks system is designed, then maintenance and repair become easier, but the system must still provide sufficient lifting capacity and operational reliability
Solution Approach 1:
The drawworks system is divided into modular components including a drum assembly, motor assembly, and gearbox assembly that can be independently maintained and repaired. The drum is mounted on a drum shaft that rotates within a drum housing, while the motor assembly with transmissions can be independently serviced, allowing easier maintenance without compromising overall system reliability
Solution Approach 2:
The system incorporates a brake assembly that can hold the drum shaft stationary, providing a safety mechanism that prevents unintended movement during maintenance. The control system is configured to prevent operation when only one motor assembly is functioning, ensuring reliable operation while allowing safe maintenance of individual components
2Loss of time
If the drawworks system continues operation with a single motor, then downtime is reduced, but the risk of further motor failure increases
Solution Approach 1:
The control system dynamically adjusts operational parameters based on the number of functioning motor assemblies. When one motor assembly fails, the control system reconfigures to allow operation with the remaining motor at reduced capacity, minimizing downtime while monitoring system stability. The brake assembly can be engaged to safely stop operation if further failure risk is detected
Solution Approach 2:
The control system continuously monitors the operational status of both motor assemblies and automatically reconfigures operation when a failure is detected. The system provides feedback regarding the number of functioning motors and adjusts operational parameters accordingly, allowing continued operation with one motor while alerting operators to the reduced reliability state
3Power
If a multi-motor configuration is used, then lifting capacity is increased, but system complexity increases
Solution Approach 1:
Both motor assemblies are configured with identical transmissions and gear ratios, allowing either motor to independently drive the drum shaft and provide full lifting capacity when needed. The motor assemblies can operate independently or in parallel, providing universal functionality that increases lifting capacity while maintaining manageable complexity through standardized components
Solution Approach 2:
The two motor assemblies are merged into a single integrated system that shares a common drum shaft, gearbox assembly, and control system. This combining approach allows the system to achieve increased lifting capacity through parallel motor operation while avoiding the complexity of completely separate drive systems, as both motors contribute to the same mechanical output
Data Source
AI summary
A drawworks system for a mineral extraction system includes a drum mounted on a drum shaft and configured to support a cable. The system also includes a gearbox assembly having a gearbox housing, a gearbox supported by the gearbox housing and having a gearbox input shaft and a gearbox output shaft, wherein the gearbox input shaft is configured to be coupled to at least one motor and the gearbox output shaft is coupled to the drum shaft to drive rotation of the drum shaft and the drum, and a brake supported by the gearbox housing and coupled to the drum shaft to block rotation of the drum shaft and the drum, wherein the gearbox and the brake are positioned on one side of the drum along an axial axis of the drawworks system.