Wellbore Top Drive Floating Quill for Independent Load Support
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Solution Overview
Problem
Downtime due to top drive device failures is a significant issue in wellbore drilling operations, particularly in offshore drilling, despite existing maintenance efforts, leading to costly interruptions.
Innovation Solution
A top drive system with a floating quill system, thrust bearing, and multiple load paths to support vertical loads during drilling and tripping, bypassing the transmission and motors, and incorporating a slewable leg structure for elevator bails to manage loads efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a top drive device is used to drive the drilling tubulars string, then rotary torque can be imparted to the string, but the device is prone to failures causing downtime
Solution Approach 1:
The top drive device is divided into separate functional modules: a first load path for rotary torque transmission (motors → transmission → quill → drill string) and a second load path for vertical load support (thrust bearing → outer main shaft → inner main shaft → drill string). This segmentation allows the vertical load path to be independent of the rotary drive components, so failures in motors or transmission do not affect vertical load capacity, thereby maintaining reliability and reducing downtime.
Solution Approach 2:
The inner main shaft acts as an intermediary component that receives vertical loads from the outer main shaft and transmits them to the drill string, while also serving as a rotational element driven by the quill. This intermediary structure enables the system to decouple vertical load bearing from rotary drive functions, allowing the top drive to maintain operational reliability even when motor or transmission components fail.
2Ease of operation
If the top drive device is suspended from the frame structure, then it can be easily positioned, but it cannot independently support vertical loads during drilling
Solution Approach 1:
The load support function is segmented from the positioning function. The frame structure with suspension cables handles positioning and general support, while the dedicated vertical load path (thrust bearing → outer main shaft → inner main shaft) handles vertical drilling loads. This segmentation allows the top drive to be easily positioned during operations while independently capable of supporting vertical loads without relying on the suspension system.
Solution Approach 2:
The thrust bearing serves as an intermediary element between the suspended top drive assembly and the vertical load path. It transfers vertical loads from the quill assembly through the outer and inner main shafts to the drill string, enabling the suspended top drive to independently support vertical loads during drilling operations while maintaining its positioned state.
3Device complexity
If a fixed quill system is used, then the structure is simple, but it cannot accommodate controlled vertical motion during make up and breaking of connections
Solution Approach 1:
The quill system is transformed from a fixed structure to a dynamic one with controlled vertical motion capability. The floating quill assembly can move vertically relative to the transmission housing through controlled displacement, allowing the system to accommodate make up and breaking of threaded connections. This dynamic capability is achieved through actuators that control the vertical position of the quill, enabling adaptability without excessive structural complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces downtime by effectively managing vertical loads during drilling and tripping operations, enhancing operational efficiency and reducing equipment failure risks.
Implementation Method 1
a thrust bearing configured to support the load of a drilling tubulars string
Implementation Method 2
one or more floating quill shaft vertical displacement actuators configured to cause controlled vertical motion of the floating quill shaft
Implementation Method 3
an elevator bails carrier that is configured to carry elevator bails
Data Source
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AI summary
A top drive system for wellbore related activities involving a drilling tubulars string. The system comprises a frame structure and a top drive device with one or more top drive motors, a transmission housing, a floating quill system with a hollow vertical floating quill shaft. The top drive device has a thrust bearing housing arranged below the transmission housing and suspended via said first and second vertical frame members from the top frame member. A hollow vertical outer main shaft is suspended from the thrust bearing housing and a hollow vertical inner main shaft is arranged vertically mobile within the outer main shaft. The inner main shaft is connected to the floating quill shaft and has a lower connector end that is configured to be connected to a drilling tubulars string via a threaded connection, so as to allow for transmission of the rotary torque from the one or more top drive motors via the transmission, the floating quill shaft, the inner main shaft, to the threadedly connected drilling tubular string.