An Electric Drive for a Drilling Rig Top Drive System
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lectric Drive for a Drilling Rig Top Drive System E. V. Belousova, * and M. A. Grigoreva a
South Ural State University (National Research University), Chelyabinsk, 454080 Russia *e-mail: [email protected] Received May 14, 2020; revised May 31, 2020; accepted June 1, 2020
Abstract—The operation of a drilling rig top drive system (TDS) in drilling practice at a great depth or during the construction of a drill pipe stand in the case of failure of one of two motors is considered. In the existing kinematic scheme of most domestic and foreign TDSs, the two motors are mechanically rigidly connected to the drive shaft through a gear reduction unit. It is proposed to replace the gearbox with rigid mechanical connections with a double planetary gear reducer and, thereby, ensure the operation of the electric drive with two independent mechanical channels. Such a kinematic scheme with independent mechanical channels makes it possible to provide the drilling rig operation at great depths in the case of failure of one of the drives and when constructing pipes when disassembling the drilling string. Due to a wider range of torque control for each of the two channels, in the case of failure of one of the drives, the proposed scheme implements the indicated operating modes at a reduced speed, avoiding expensive downtime. The static mechanical characteristics of the TDS for the existing and proposed systems are presented. The calculation of the mechanical converter providing the required gear ratios for each of the mechanical channels is performed. The operation of the control system and power distribution unit of two drives is considered. Keywords: drilling rig, top drive system, differential electric drive, planetary gear reducer DOI: 10.3103/S1068371220070032
The use of top drive systems (TDSs) is most appropriate when drilling controlled directional and horizontal wells, as well as deep and superdeep wells, and drilling in complex subsurface conditions. Top drive systems have brought drilling technology to a whole new level due to the reduction in the number of human-operated process steps when adding a drill pipe length using thurible stands. In this case, a kelly joint that mechanically connects the swivel and the rotary table is not needed. The use of TDSs also minimizes the possibility of emergency drill pipe sticking. In recent years, TDSs have become more widespread in drilling rigs on the strength of all these reasons. The vast majority of newly commissioned drilling rigs are equipped with TDSs [1]. The use of TDSs allows 5-, or even 10-km, extended reach drilling, covering thereby an area of deposits up to 320 km2. Increasing the drilling depth for access to mineral deposits up to 8–12000 m increases the load on the drilling rig. The mass of the drill string in this case can reach 500 t. Modern top drives can reach power up to 1900 kW. The range of torque at the spudding is hundreds of Nm for a string of several pipe stands to a maximum torque of 50.3 kN m (for example, SVP–320). A TDS should provide a sh
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