Top drive systems for wellbore and drilling operations

A gear system has a gear housing and a lower planetary carrier disposed in the gear housing, the lower planetary carrier being adapted to rotate relative to the gear housing. A top drive system is operatively coupled to the gear system, the top drive system having a top drive shaft that is adapted to be driven by the gear system. A single bearing that is adapted to facilitate rotation of the lower planetary carrier is positioned between the gear housing and the lower planetary carrier. A motor apparatus is operatively coupled to and adapted to drive the gear system by rotating the lower planetary carrier relative to the gear housing, wherein a rotational axis of the single bearing is adapted to move in a lateral translational direction with respect to the gear housing while the motor apparatus is rotating the lower planetary carrier.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to top drive systems; parts thereof; and methods of their use.

2. Description of Related Art

The prior art discloses a variety of top drive systems; for example, and not by way of limitation, the following U.S. patent application and U.S. patents present exemplary top drive systems and components thereof: U.S. Pat. Nos. 4,458,768; 4,589,503; 4,753,300; 4,800,968; 4,807,890; 4,813,493; 4,872,577; 4,878,546; 4,984,641; 5,433,279; 6,007,105; 6,276,450; 6,536,520; 6,679,333; 6,705,405; 6,913,096; 6,923,254; 7,186,686; and 7,270,189 all incorporated fully herein for all purposes.

Certain typical prior top drive drilling systems have a derrick supporting a top drive which rotates tubulars, e.g., drill pipe. The top drive is supported from a traveling block beneath a crown block. A drawworks on a rig floor raises and lowers the top drive. The top drive moves on a guide track.

Certain prior systems include a top drive with a gear system with a lower or second stage planetary carrier which rotates with respect to multiple (e.g. two) vertically spaced-apart bearings which are secured in place and which do not float radially (or axially).

BRIEF SUMMARY OF THE INVENTION

The following presents a simplified summary of the present disclosure in order to provide a basic understanding of some aspects of the invention. This summary is not an exhaustive overview of the disclosure, nor is it intended to identify key or critical elements of the subject matter disclosed here. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.

The present disclosure is generally directed to certain illustrative aspects of a top drive system that may be used during wellbore operations. In one exemplary embodiment, a system is disclosed that includes a gear system having a gear housing and a lower planetary carrier disposed in the gear housing, the lower planetary carrier being adapted to rotate relative to the gear housing. The illustrative system also includes, among other things, a top drive system that is operatively coupled to the gear system, the top drive system having a top drive shaft that is adapted to be driven by the gear system. Additionally, a single bearing is positioned between the gear housing and the lower planetary carrier, the single bearing being adapted to facilitate a rotation of the lower planetary carrier relative to the gear housing. Furthermore, a motor apparatus is operatively coupled to the gear system, the motor apparatus being adapted to drive the gear system by rotating the lower planetary carrier relative to the gear housing, wherein a rotational axis of the single bearing is adapted to move in a lateral translational direction with respect to the gear housing while the motor apparatus is rotating the lower planetary carrier and while the gear system is driving the top drive shaft.

In another embodiment of the present disclosure, a system is disclosed that includes a gear system having a gear housing and a lower planetary carrier disposed in the gear housing, the lower planetary carrier being adapted to rotate relative to said gear housing. The system further includes, among other things, a single bearing positioned between the gear housing and the lower planetary carrier, the single bearing being adapted to facilitate a rotation of the lower planetary carrier relative to the gear housing, and a bearing cartridge that is adapted to maintain the single bearing in position between the gear housing and said lower planetary carrier. The bearing cartridge includes an outer part that is releasably secured to the gear housing and a radially movable inner part that is encompassed by the outer part, wherein the single bearing abuts the radially movable inner part. Furthermore, the system also includes a motor operatively coupled to the gear system, the motor being adapted to rotate the lower planetary carrier relative to the gear housing, wherein a rotational axis of the single bearing and a centerline axis of the radially movable inner part are adapted to move in respective lateral translational directions during the rotation of the lower planetary carrier relative to the gear housing.

DETAILED DESCRIPTION

FIGS. 1A-1Dillustrate a top drive system10according to the present invention which has a plurality of components including: a gooseneck11, a bonnet12, brakes13, a motor14, a gear system15, a drive shaft16, a bearing system17, a swivel body18, a pipe handler lock assembly19, a link support22, a swivel ring23and a load (or landing) collar29. The components can be collectively suspended in a typical derrick from a typical traveling block for up and down movement in the derrick.

During certain operations, the motor14within a housing14arotates the drive shaft16which, in turn, rotates a drill string and a drill bit to produce an earth bore. Fluid pumped into the top drive system through the gooseneck11passes through the drive shaft16, a drill string, and a drill bit and enters the bottom of an earth bore.

In certain aspects, the motor housing14a(e.g. made of sheet metal or aluminum) includes a series of tie rods14bwhich are secured to a top member14cand a bottom member14dto strengthen the housing14a. In certain particular aspects the housing14ais made of metal such as aluminum or steel. In one particular aspect the motor14is a motor as disclosed in U.S. Pat. No. 7,188,686. In another particular aspect the motor14(as may be any motor herein) is a salient pole permanent magnet motor.

The gear system15is located above a bearing retainer21which serves to maintain the drive shaft16in place (radially and axially) e.g. during drilling, and houses an upper race of a thrust bearing system16b. As shown inFIG. 1D, the bearing retainer is a separate item secured to and below the housing of the gear system15. As discussed in detail below, in one embodiment of the present invention, a bearing retainer is made integral with the gear system housing. A load flange16aof the drive shaft16moves on bearings16c.

An encoder/resolver24(seeFIG. 1D) measures the position and speed of the motor14and provides a signal indicative of the position of the drive shaft16. With certain salient pole motors, the encoder/resolver24can be deleted since motor controls for salient pole permanent magnet motors indicate the position of the rotor of the motor and, therefore, the position of the drive shaft16(e.g., the position of the drive shaft during tubular connection make-up and break-out and during drilling). Certain typical salient pole motors (with embedded tangential or radial rotor magnets) have relatively higher inductance than non-salient motors and provide smoother starting from a standstill.

The top drive system10has a motor control system20(shown schematically,FIG. 1A) which, in certain aspects, includes an output reactor20a(also called an “inductor”) which insures efficient operation by increasing the inductance applied to the motor. This inductor is used with certain low inductance motors. In other aspects, by using a relatively high inductance motor, e.g. a relatively high inductance salient pole motor, the inductor20ais eliminated since the high inductance motor applies a sufficient amount of inductance.

FIG. 2A-2Dshows a top drive system30according to the present invention which, in some aspects, is like the system10,FIG. 1A(and like numerals indicate like parts). A motor14m(like any of the motors14) is above a gear system25(instead of the gear system15) has a housing14h.

Parts of the housing14hincluding sides14s, top14t, and bottom14vfollowing assembly are not connected together by tie rods (as are housing parts in the top drive ofFIG. 1A). In one aspect the housing14his made of steel and is sufficiently strong so that a portion of it is threaded to threadedly connect the bonnet12thereto. A steel housing motor can be relatively larger than a motor with a weaker (e.g. aluminum) housing. This novel elimination of tie rods allows a motor of a greater diameter (larger size) to be used in a similar space. This relatively larger diameter means that the motor provides relatively greater horsepower with greater efficiency.

A lower portion48of a gear housing46serves as a bearing retainer to retain bearing44.FIGS. 2A-2Dare exploded views or views that show parts not assembled together.

When assembled, the bearing44is within a bearing retainer48. The bearing retainer, a lower portion48of the housing46is releasably secured to the housing46, e.g. with bolts.

FIG. 3shows a top drive system50(partially exploded view) according to the present invention. A motor60has a brake system54and an output shaft56. The output shaft56is connected to a gear system100. The gear system100driven by the motor60, drives a main drive shaft70. Bearings58(thrust bearings) are retained in place by a bearing retainer80which is bolted to or integral with the gear system100. An attachment frame90(a “swivel body”) provides for the connection of a torque track for conducting torque from the system to the torque track. The swivel body90is, typically, suspended from a block in the derrick by bails.

FIGS. 4A-4Dshow the gear system100of the top drive system50. A housing102has a motor mounting surface104on which the motor is positioned. A part107is releasably secured to the housing with bolts107b. Gear reducer system110within the housing102includes a gear reducer111and a bearing116. The gear reducer system110includes a first stage carrier112; a second stage sun pinion113; a second stage carrier114; and a bearing cartridge115. The cartridge115with the bearing117is held in place by bolts115x. Removing the bolts107band the bolts115xpermits removal of the cartridge115for bearing replacement, in one aspect, with a single bearing117.

There are three first stage planetary gears127(seeFIG. 4C). The gear system100has a bottom surface130(seeFIG. 4D). A temperature gauge134can be inserted in a tapped thread portion132. A tip of the gauge sits in the oil flow path and dynamically measures the temperature of the oil flow.

A lower portion120of part107of the housing102serves as a bearing retainer to retain in place the bearing44(seeFIG. 4E). An inline flow meter121which measures oil flow to the housing has an oil inlet port122. Magnetic plugs123are positioned in holes124to attract and hold metal shavings and debris. An air breather125is in communication with the interior of the housing120.

As shown inFIGS. 4B and 4E, the cartridge115has a part115bwhich is adjacent a part115a. The part115aincludes an upper part115gand a side115f. The part115bis encompassed within structure of the part115a(upper part115gand side115f) and a top surface107aof the part107. The part115arests on a top surface107bof the part107and against a side107cof the part107. In one aspect, the top surface107ais lower than top surface107b.

Due to the tolerances between the part115band the part115asome slight movement is possible of the part115bwith respect to the part115a. An interface between the parts115band115ais sealed by one or more seals—two o-ring seals115care shown in corresponding recesses115din the part115b. These seals are sized, configured, and positioned to accommodate the movement of the part115bwith respect to the part115a.

The bearing117is held in place by a holder114cbolted to the second stage carrier114by bolts114band rests partially on a ledge115eof the part115band under a shoulder114dof the carrier114. The bearing117can move radially (and/or axially) the extent that the part115bcan move radially (and/or axially), thus permitting the bearing117when it is movable radially to “float” horizontally. This inhibits interference in the horizontal plane between the bearing117and the bearing44(which can cause excessive bearing wear and premature failure). The bearing117does not float so much that the second stage carrier114moves too far axially, i.e., so far that splines on the periphery of the second stage carrier114would not properly mesh with corresponding splines on the main shaft of the motor.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a motor apparatus; a main shaft extending from the main body, the main shaft having a top end and a bottom end, the main shaft having a main shaft flow bore therethrough from top to bottom through which drilling fluid is flowable; a quill connected to and around the main shaft; and, in one aspect, the quill is part of a gearbox of a gear system; a gear system interconnected with the quill, the gear system driven by the motor apparatus so that driving the gear system drives the quill and thereby drives the main shaft, the main shaft passing through the gear system; upper components connected to the main body above the top end of the main shaft.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including a motor and gearing system including a motor housing, a motor within the motor housing, and the motor housing comprising a top and a bottom and a plurality of rods interconnected between the top and bottom to connect the top and the bottom together.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a top drive shaft; a motor apparatus; a motor shaft extending from the motor; a gear system driven by the motor shaft, the gear system driven by the motor apparatus so that driving the gear system drives the top drive shaft, the gear system including a lower planetary carrier; the gear system including gear apparatus enclosed within a gear housing; a single bearing adjacent and in contact with the lower planetary carrier; a bearing cartridge connected to the gear housing; and the bearing cartridge abutting the single bearing and in contact with and holding the single bearing in position with respect to the lower planetary carrier. Such a system may have one or some, in any possible combination, of the following: the bearing cartridge including an outer part secured to the gear housing, and an inner part within the outer part, the inner part movable radially with respect to the outer part; the single bearing abuts the inner part and the inner part is movable radially with the single bearing; the single bearing maintains the lower planetary carrier in radial position; a shaft bearing around the top drive shaft, and a bearing retainer portion on a lower part of the gear housing for retaining the shaft bearing; wherein the inner part and the single bearing are movable to inhibit interference in the horizontal plane of the single bearing with the shaft bearing; wherein the motor apparatus is a salient pole permanent magnet motor apparatus; at least one seal on the inner part, the at least one seal projecting from the inner part and abutting the outer part, and the at least one seal accommodates movement of the inner part with respect to the outer part; there are two spaced-apart seal recesses on the inner part, and the at least one seal is two seals, one seal in each seal recess; wherein the bearing cartridge is releasably secured to a first part of the gear housing; and/or wherein the first part is releasably secured to the gear housing.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a top drive system for wellbore operations, the top drive system including: a main body; a top drive shaft; a motor apparatus; a motor shaft extending from the motor; a gear system driven by the motor shaft, the gear system driven by the motor apparatus so that driving the gear system drives the top drive shaft, the gear system including a lower planetary carrier; the gear system including gear apparatus enclosed within a gear housing; a single bearing adjacent and in contact with the lower planetary carrier; a bearing cartridge connected to the gear housing; the bearing cartridge abutting the single bearing and in contact with and holding the single bearing in position with respect to the lower planetary carrier; the bearing cartridge including an outer part secured to the gear housing; an inner part within the outer part, the inner part movable radially with respect to the outer part; the single bearing abuts the inner part and the inner part is movable radially with the single bearing; wherein the single bearing maintains the lower planetary carrier in radial position; a shaft bearing around the top drive shaft; a bearing retainer portion on a lower part of the gear housing for retaining the shaft bearing; and wherein the inner part and the single bearing are movable to inhibit interference in the horizontal plane of the single bearing with the shaft bearing.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for facilitating rotation of a lower planetary carrier of a gear system of a top drive system, the top drive system having a motor and gearing system including a motor housing, a motor within the motor housing, and the motor housing being a top and a bottom and a plurality of rods interconnected between the top and bottom to connect the top and the bottom together, the method including: rotating the lower planetary carrier with respect to the single bearing, and holding the single bearing in position with the bearing cartridge. Such a method may have one or some, in any possible combination, of the following: the bearing cartridge including an outer part secured to the gear housing, and an inner part within the outer part, the inner part movable radially with respect to the outer part, wherein the single bearing abuts the inner part and the inner part is movable radially with the single bearing, the method further including allowing the single bearing to move radially to an extent of possible radial movement of the inner part; wherein the single bearing maintains the lower planetary carrier in radial position, the method further including maintaining the lower planetary carrier in position with the single bearing; the top drive system having a shaft bearing around the top drive shaft, and a bearing retainer portion on a lower part of the gear housing for retaining the shaft bearing, the method further including retaining the shaft bearing in position with the bearing retainer portion; wherein the inner part and the single bearing are movable to inhibit interference in the horizontal plane of the single bearing with the shaft bearing, the method further including inhibiting interference in the horizontal plane between the single bearing and the shaft bearing; and/or the top drive system having at least one seal on the inner part, the at least one seal projecting from the inner part and abutting the outer part, the at least one seal accommodates movement of the inner part with respect to the outer part, the method further including with the at least one seal accommodating movement of the inner part with respect to the outer part.

The present invention, therefore, provides in some, but not in necessarily all, embodiments a method for inhibiting interference in the horizontal plane between a single bearing in a gear housing adjacent a lower planetary carrier of a gear system of a top drive system and a shaft bearing around a top drive shaft of the top drive system, the top drive system having a main body, a top drive shaft, a motor apparatus, a motor shaft extending from the motor, a gear system driven by the motor shaft, the gear system driven by the motor apparatus so that driving the gear system drives the top drive shaft, the gear system including a lower planetary carrier, the gear system including gear apparatus enclosed within a gear housing, a single bearing adjacent and in contact with the lower planetary carrier, a bearing cartridge connected to the gear housing, and the bearing cartridge abutting the single bearing and in contact with and holding the single bearing in position with respect to the lower planetary carrier, the method including allowing the single bearing to move radially with respect to the gear housing in a controlled manner.

In conclusion, therefore, it is seen that the present invention and the embodiments disclosed herein and those covered by the appended claims are well adapted to carry out the objectives and obtain the ends set forth. Certain changes can be made in the subject matter without departing from the spirit and the scope of this invention. It is realized that changes are possible within the scope of this invention and it is further intended that each element or step recited in any of the following claims is to be understood as referring to the step literally and/or to all equivalent elements or steps. The following claims are intended to cover the invention as broadly as legally possible in whatever form it may be utilized. The invention claimed herein is new and novel in accordance with 35 U.S.C. 102 and satisfies the conditions for patentability in section.102. The invention claimed herein is not obvious in accordance with 35 U.S.C. 103 and satisfies its conditions for patentability. This specification is in accordance with the requirements of 35 U.S.C. 112. The inventors may rely on the Doctrine of Equivalents to determine and assess the scope of their invention and of the claims that follow as they may pertain to apparatus not materially departing from, but outside of, the literal scope of the invention as set forth in the following claims. All patents and applications identified herein are incorporated fully herein for all purposes.