Electric Top Drive Actuation via Rotary Motor
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Solution Overview
Problem
Hydraulic systems used in subterranean operations often result in messes due to leaks, equipment replacement, or repair, highlighting the need for improved rig systems.
Innovation Solution
The development of an electrically operated top drive system that minimizes hydraulic components by using electric actuators and a generator to power components below the handler motor, enabling efficient subterranean operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic systems are used to operate components in the top drive, then reliable actuation and control are achieved, but hydraulic leaks cause mess and operational disruptions
Solution Approach 1:
The patent replaces the hydraulic actuation system with an electric motor system. The electric motor directly drives the rotary portion and associated components, eliminating hydraulic fluid and potential leaks while maintaining reliable actuation and control of the top drive components.
Solution Approach 2:
The patent eliminates the need for hydraulic systems by using an electric motor with direct mechanical coupling. This substitution removes the hydraulic fluid medium entirely, preventing leaks and the associated mess and operational disruptions while maintaining system reliability.
2Force
If hydraulic components are used for actuation, then sufficient force and control are provided, but equipment replacement and repair create mess and downtime
Solution Approach 1:
The patent substitutes hydraulic actuators with an electric motor system that provides equivalent or superior force and control. Electric motors are inherently more reliable and easier to maintain, with fewer moving parts and no hydraulic seals that can fail, thereby reducing downtime and simplifying repairs.
Solution Approach 2:
The electric motor system eliminates the complex hydraulic infrastructure including hoses, seals, and fluid reservoirs that require maintenance and replacement. This simplification reduces the frequency and complexity of repairs while maintaining adequate actuation force for all top drive operations.
3Object-generated harmful factors
If electric actuators are used to power components below the handler motor, then hydraulic leaks are eliminated, but providing sufficient power to rotating components becomes challenging
Solution Approach 1:
The patent merges the electric motor with the rotary portion assembly, with the motor mounted on the main body and directly coupled to the rotary components. This integration allows efficient power transmission to rotating components such as the backup wrench and lower well control valve without requiring complex wiring through rotating joints, thereby eliminating leaks while maintaining adequate power delivery.
Data Source
AI summary
A top drive that can include a main body portion having a quill that is rotatable relative to the main body portion, a rotary portion that rotates relative to the main body portion and relative to the quill, and a component coupled to the rotary portion, wherein the component rotates with the rotary portion, and wherein the component is electrically actuated.