Modular top drive.

(54) Title: MODULAR SUPERIOR CONTROL. (54) Title: MODULAR TOP DRIVE.

(57) Summary

The present invention relates to an upper control system characterized in that it comprises: an upper control comprising a plurality of motor modules and one or more upper control modules adapted to be on or off a critical path; a plurality of circulators adapted to provide cooling to at least the plurality of motor modules; and a common conduit coupled to communicate to each of the plurality of circulators and at least each of the plurality of motor modules, wherein the common conduit extends through a top drive support structure and is operable to allow continuous cooling from at least one circulator that does not fail when one of the plurality of circulators fails.

(57) Abstract

A top drive system with a plurality of top drive modules, which are configured to be quickly exchanged. The top drive modules may inelude any or all of the following: a main body module, a gearbox module, a drive motor module, a pipe handler module, an upper fluid module, a lower well control valve module, a block interface module, a retract system interface frame module, a cooling system module, a work platform guard module, and a quill saver sub module. Alternatively, the top drive may comprise a first top drive and a second, top drive which are configured to be quickly exchanged.

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PATENT TITLE NO. 342255 _SE_ semrARiA or * economy

Institute

Mexican Property

Industrial i

Owner (s): CANRIG DRILLING TECHNOLOGY, LTD.

Address: 14703 FM 1488, Magnolia, Texas, 77354, USA

Denomination: MODULAR UPPER CONTROL.

Classification: IC.8: E21B19 / 00

Inventor (s): BEAT KUTTEL; RANDALL S. PYRCH; FAISAL J. YOUSEF; ALAN S.

RICHARDSON; GREG KOSTIUK

Number:

MX / 'a. J11 / 014049

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23 of l of prest

REQUEST

Presentation date of December 2006

I of Patent Number: 298100

PRIORITY

Date: Number:

December 2005 60 / 752,116 »ncia: Veinte ños ia de Vene lient

I patent of reference if it comes from the erections.

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Law of the taxation of the census of 2026, 1st, 2nd section V. 6 'section III, and 59 of the Industrial Property Law.

This patent has a validity of twenty years, Arrogables, rntemedona and will be subject to the payment of so much to keep agents the

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and III ropiedac | iien subscribes the present Industrial piety (Daily i / 01/2004, 16/06/2005, 2 ia), 4 "and 12 ° 1/07/2002, 15/07/2004, 2Í title tflee with fundamdHto, in Ib tfisoueste by the articles 6 ° fractions III and 7 ° bis 2 of i Oficial dela Federación fD.O »ifl7 / Q6 / 1991. Reformed on 02/06/1994, 10/25/1996. 12/26/1997, 1/2006, e / 05 / 2009,06 / 01/2010, - * / 06/2010 2006 / 20-0? Λ0'.2Ο12 and 3 * 04/2012) articles 1,: I Regulations of the Mengano Institute of. Proceded Industrial (DOF 12/14/1999, io a), 16 frac

7/2004 yjf / 09/2007); articles 1 ', 3', 4 °, 5 'fraction ViflOSO fractions I and III and 30 of the Estati

Law of the (7/05/1999, section V formed the Organic 107); 1, 3 and 5 Clause a) of the Agreement that delegates powers to the Deputy Directors General, Coordinator, Divisional Directors, Holders of the Regional Offices, Divisional Deputy Directors, Departmental Coordinators and other subordinates of the Mexican Institute of Industrial Property. (DOF 12/15/1999, amended on 02/04/2000, 07/29/2004, 08/04/2004 and 09/13/2007).

Issue Date: September 21, 2016

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MODULAR UPPER CONTROL

M / l α) 2.0 i 'lo

IMPI

MEXICAN INSTITUTE OE INDUSTRIAL PROPERTY

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CROSS REFERENCE

This application claims priority under 35 USC § 119 for the US provisional patent application with serial number 60 / 752,116, filed on December 20, 2005, titled "Superior Command", the content of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

Increasedly, drilling contractors are using upper drives instead of drive shafts or stem bushings. A top knob is a drilling tool that hangs from the traveling pulley and has one or more motors to start a drive shaft to which the crew members attach the drill string. Because the top drive motor can rotate the drill string, no drive shank or shank bushing is required. The upper control also incorporates a turning capacity and a torque wrench.

In addition, the upper control has elevators on the chains. The benefits of top drives may include the ability to work in 27.43 meter increments more than in 9.14 meter increments to which a stem bushing is generally limited. I mean, a tube joint is

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MEXICAN INSTITUTE OF PROPERTY

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generally 9.14 meters long. Therefore, a higher mana allows an operator to work with 3 pipe joints by incrementing a given operation. For example, top controls allow operators to assemble three-joint (27.43 meter) pipe bases off the critical 5 path to save time. Similarly, on some occasions, such as, for example, applications involving highly deviated or horizontal well holes, it may be desirable to remove the tube from a well hole by a procedure known as reaming. A superior knob allows operators to ream tube 10 from a well hole in bases of three tube joints, which may be intact.

On a drilling rig, the critical path includes all the tasks and equipment required to continue drilling without interruption. When a task or equipment on the critical path is delayed, the entire drilling operation is delayed. Therefore, because mechanical devices require a certain amount of repair and / or maintenance, many drilling rig critical path components are kept in redundant quantities to decrease machine downtime caused by inevitable repair and maintenance. .

Conventionally, the upper controls have been an exception to this redundancy principle. Because the upper controls are generally on the critical path, the upper controls create the potential for point failure - that is, if the upper control drops, the operation of

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MEXICAN INSTITUTE 1 total perforation stops, leaving the platformforfiehwx ^ íwple

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until the upper control can be brought back online. Diagnosis generally occurs on the critical path before any repairs are made, causing an additional delay in operation before the repair even begins. Similarly, maintenance operations can be on the critical path creating a period of machine downtime.

BRIEF DESCRIPTION OF THE INVENTION

This invention relates to the field of drilling for oil or gas wells and more particularly a method and apparatus for drilling a well and handling the tubes.

In accordance with an aspect of the invention, an upper control system is provided, comprising: a first upper control; and a second upper knob where the first and second upper knobs are configured to interchange quickly.

Another aspect of the invention provides a superior control system comprising: a plurality of modules wherein the modules are configured to be quickly interchanged.

Still another aspect of the invention provides a method of increasing drilling efficiency comprising: providing a first top command module on a critical path; provide a second module

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MEXICAN INSTITUTE OF INDUSTRIAL PROPERTY

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top command out of critical path, replace first top command module with second top command module such that second top command module is on critical path and first top command module is out of critical path .

BRIEF DESCRIPTION OF THE FIGURES

This invention can be better understood when reading the following description of non-limiting modalities with respect to the attached drawings where the similar parts of each of the figures are identified by the same reference number and which are briefly described as follows:

Figure 1 is a perspective view of an embodiment of the upper control system having the following upper control modules: one main body, one gear box, two transmission engine modules, one pipe manipulator, one upper fluid module, one lower well control valve, one block interface, two work platform protection modules, two cooling system modules, a shaft guard submodule and a retraction system interface frame module.

Figure 2 is a schematic view of an embodiment of the upper control system of Figure 1.

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INSTITUTO WLXICANQ DI LA FKOH WA O

Figure 3 is a partial perspective view merit ^ Bbttadá * ^ one embodiment of a bearing lubrication system "" Figure 4 is a partially cutaway perspective view in one embodiment of the gearbox lubrication system.

DETAILED DESCRIPTION OF THE INVENTION

This invention relates to the field of drilling for oil or gas wells and more particularly a method and apparatus for drilling a well and handling pipes. Referring now to Figure 1, in accordance with an embodiment of the invention, a top command system 1000 is provided with a number of top command modules. Referring now to Figure 2, in a particular embodiment, the top command modules may include one or any number of the following: one main body module 1100, one gear box module 1200, two transmission engine modules 1300, one pipe manipulator module 1400, one upper fluid module 1500, one lower well control valve module 1600, one module Block interface modules 1700, two work platform protection modules 1800, two cooling system modules 1900, a shaft protection submodule 2000, and a retraction system interface frame module 2100. Each of these modules can have components and features as listed below.

IMPI ^

MEXICAN INSTITUTE OF PROPERTY

When it is necessary to carry out the maintenanceffléfW erT — σπ particular component of a modular superior control system * of this invention, for example the superior control system 1000, due to failure or routine maintenance, a superior control module containing this component can be quickly replaced with a corresponding top control module that is already in proper operation. This allows operations to continue without major interruption. As operations continue, maintenance and / or repair can be performed on the component outside the critical path, so that the removed top command module can be used when the need arises. Alternatively, the entire upper command module can be shipped off-site for repair or the upper command module can be discarded.

Another aspect of a modular superior command of this Invention is the ability to dual activities simultaneously. By way of example, and not by limitation, replacement of a transmission motor in a conventional top drive is a lengthy procedure due to the serial nature of the replacement steps. That is, the electrician may need to disconnect the electrical connections from the transmission motor before the mechanic can remove the transmission motor. This allows the mechanic to align and install the replacement drive motor. The electrician can then make the electrical connections to the new transmission motor. Instead, a modular top knob of this Invention can be assembled in

Mexicano Mexican institute 'í • E PROPERTY I

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in such a way that the electrical connections are physically located as far away from the mechanical connections as possible, so that it is electrically operated and the mechanic can carry out their tasks in parallel, that is to say at the same time or almost at the same time, thus reducing the period of inactivity of the machine.

Interchangeable top drive modules may also be desired for reasons beyond maintenance or repair. For example, different top drive modules can be used for different drilling and / or forming configurations. In certain drilling applications, different drilling speeds may be required. Instead of using a variable or multi-speed gearbox, different speeds can be provided to interchange gearbox modules with different speed gear arrangements that are simpler and more reliable. Similarly, the different tubular diameters can be accommodated by swapping the lower well control valve modules. Similarly, different transmission engine modules may be better for different applications such as core extraction, drilling, and reconditioning. Other advantages of different modular configurations will be apparent with the benefit of this disclosure to a person skilled in the art.

Depending on the specific 1000 top command system and the specific conditions, any number of

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MEXICAN INSTITUTE Itt LA FMOttEPAD superior command. For example, a single higher modulus '^' can be used. In this example, the superior command module supérióf'pUéffé ihóldir he complete superior command system 1000, and can be interchanged with another complete superior command system module 1000. This configuration does not require diagnosis to determine which component is problematic until the 1000 top controller is offline. Similarly, a short module replacement time simplifies the procedure for making the repair or replacement decision such that the module can be quickly replaced and the diagnostics conducted on the replaced module are beyond criticism. If the full 1000 top drive system is replaced it is not practical, or otherwise unwanted, and multiple top drive models can be used. The components of the 1000 top command system can be grouped into modules in any number of ways and the configuration of the Individual modules should not be limited by the specific modalities mentioned below.

The top drive modules of a modular top drive system of this invention can be coupled in accordance with a variety of techniques • while the techniques allow for the quick changeability of the modules in a top modular drive. Additionally, it is desired that the connections allow the exchange of a superior command module with a similar superior command module. In addition, it may be desired for connection mechanisms to allow the vertical ascent and descent of the upper control modules while connecting and disconnecting to a

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ΙΝ / Πτυτο MEXICANO modular upper control system. The connection techniques include, but are not limited to, a multiple-netration system, drives, bolts, inserts and pins, dovetail slide, eccentric locking devices, keyway, pilot rings and clamps, splined connections, shear rings, guide pins, torque stop mechanisms, O-ring seals, flanges, pins and grooves and any combination thereof. Additionally, one skilled in the art will, with the benefit of the disclosure, know other techniques for coupling the modules of a modular top command system.

In an exemplary embodiment, shown in FIG. 2, a top drive system 100 may have a main body module 1100, a gear box module 1200, two transmission engine modules 1300, a pipe manipulator module 1400, a upper fluid module 1500, one lower well control valve module 1600, one module

Block Interface 1700, Two Work Platform Protection Modules 1800, Two Cooling System Modules 1900, a Shaft Protection Submodule 2000, and a Retraction System Interface Frame Module 2100.

The main body module 1100 can serve as a base, and other top control modules or components can be attached to the main body module 1100, either directly or indirectly using one or more connection techniques described above. The main body module 1100 can have any or all of the following: a top mounted mounting housing for a 1700 block interface module;

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MEXICAN INSTITUTE • the main bearings age died; a hollow spindle, which may be £ §tffládb connection to gearbox module 1200, a floating shaft ', the shaft may have a free float path of 20.32 centimeters and a male spline connection; a top bearing carrier with motor mounts; a 5 retraction system interface frame with blowers for motor cooling; and a self-oiling system. Some modalities may have a modular self-contained bubbling lubrication system. Similarly, some embodiments, eg, the top drive system 1000, may have a retraction system interface frame that is modular. The main body module 1100 may additionally or alternatively include any other components that could generally remain intact when another top command module is changed.

Gearbox module 1200 can be quickly attached to or detached from main body module 1100 using one or more of the connection techniques described above. For example, the connection can be via a spline and pins that act as a gravity hold as well as a torque containment mechanism. This allows the 1200 gearbox module to be completely removed and replaced with another 1200 gearbox module, 20 allowing the repair of any component therein outside the critical path. The 1200 gearbox module can have any or all of the following: a single speed gearbox, which can have a reduction ratio between approximately 6,890 to 1 and

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MEXICAN INSTITUTE

9,000 to 1; input shafts for one or more of the trailers; one or more couplings with a protootor y-cte-trancmition axis; inspection windows; one or more torque wrenches and quick-lock assemblies for easy removal and installation; a splined turning gear to transmit a torque to the spindle; and a self-contained gearbox lubrication system. The self-contained gearbox lubrication system may include the following: a dry sump; a suction strainer, one or more screw pumps, and one or more electric motors; one or more filters with visual indicators and remote sensors; a multiple distribution; a remote sensor to detect oil pressure; and an oil cooler in pipes with an electric fan. In some embodiments, the 1200 gearbox module can include a multi-speed gearbox. In other embodiments, a plurality of single-speed gearboxes, which can be easily interchanged, may be more preferable than a multi-speed gearbox for reasons of reliability. The gearbox module 1200 may additionally or alternatively include any other component that could generally be associated with the components of the gear system.

Transmission engine module 1300 can be quickly attached to or detached from main body module 1100 using one or more connection techniques described above. This allows the 1300 transmission engine module to be completely removed and replaced with

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another 1300 transmission engine module. This allows the component of the 130U transmission engine module Tüéiá dé la'rüíá critica. The 1300 transmission motor module may include one or more motors, such as AC electric motors, GE model GEB-20, 1150 HP; a 5 motor module frame to allow quick installation and removal of the complete 1300 transmission motor module, a coupling for the 1200 gear box module for quick alignment or isolation in case of failure; a brake system; a programmable logic controller (“PLC”) junction box or a simple electrical junction box for control and sensors; and a protective and lifting assembly. The brake system may include the following: five (5) disc brake calipers; hydraulic controls; and a self purge system. In some embodiments, it may be desired to locate the electrical connections of the drive motor module separate from the mechanical connections to enable dual activities during replacement, maintenance, and / or repair. Transmission engine module 1300 may additionally or alternatively include any other components that could typically be associated with components of the engine system.

The pipe manipulator module 1400 can be quickly attached to or detached from the main body module 1100 using one or more of the connection techniques described above. For example, the connection may be made by means of a slide module using cut-off rings as the main connection method together with guide pins

IMPI

MEXICAN INSTITUTE OF THE EHOMBDAO

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which act as a locator guide and as urí * Tffi? tüdo th? torque containment. This allows the 1400 Pipe Handle Module to be completely removed and replaced with another 1400 Pipe Handler Module. This allows repair of all 5 components to occur outside the critical path. The pipe manipulator module 1400 can include any or all of the following: a mounting plate; multiple turns for air and hydraulic communication; an elevator chain bracket; an integrated chain counterweight system; a chain tilt assembly; a backwash; a management framework for movement when removed; and a self-oiling system. The mounting plate may include the following: hydraulic valve assemblies mounted directly to a carrier plate to eliminate hose and leakage points; a redundant manipulator to rotate the modules; a redundant manipulator to close the modules; Boxes of 15 dual PLC splice with quick connection; and a folded guard which can be folded like a work platform. Some modalities, for example the Top Drive System 1000, may have one or more folded guards that are modular, for example, the Work Platform Guards 1800. Multiple rotation may include the following: 20 twenty (20) conduits with ports test and radial bearings for centralization. The chain tilt assembly can have bidirectional hydraulic activation and float capabilities. Recoil wrench can have quick change capability with controlled vertical placement

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INSTITUTO MEXICANO of the driller and includes the following: an adapter h ^ rwfóox'cd&gt; r¿wSf&gt;^:capacity above 27.94 centimeters in diameter and 102,720 Νητ; controlled vertical collation of the driller; removable die holders; and a guide for plumbing pipe. The pipe manipulator module 1400 may additionally or alternatively include any other component that might be generally associated with the components of the pipe manipulator system.

Upper fluid module 1500 can be quickly attached to or detached from main body module 1100 using one or more of the connection techniques described above. For example, the cap may be bolted or secured to the main body module by means of a spline and an O-ring seal connection. Alternatively, an O-ring clamp or flange and seal may be used. This allows the upper fluid module 1500 to be completely removed and replaced with another upper fluid module 1500. This allows component repair to happen outside of the critical path. The 1500 upper fluid module can include a wear pipe assembly with 7500 PSI WP, a 10.16 centimeter hole, a top seal that includes a cleaner, remover, labyrinth seal, and lubrication oil seals to the exclusion of powder; and a 7500 PSI WP top access powder line, a 10.16-centimeter hole. The upper fluid module 1500 may additionally or alternatively include any of the components that

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fluid. —- The lower well control valve module 1600 can be quickly attached to or detached from the main body module 1100 using one or more of the connection techniques described above. For example, the connection can be made by means of a cut-ring connection of a shaft protection submodule 2000. This allows the Bottom Well Control Valve Module 1600 to be completely removed and replaced with another Bottom Well Control Valve Module 1600. This allows for repair of components out of the critical path. Bottom well control valve module 1600 can include knurled shaft guard submodule, for example, shaft guard submodule 2000, body can be knurled for quick removal, allowing multi-axis connections to match string of pipe given. Additionally, a knurled shaft guard submodule, for example a shaft guard submodule 2000 can accommodate future or unscheduled pipe string connections. The protective submodule may have a remote lower well control valve operated; a hydraulic valve actuator; two manual bottom well control valves and connection clamps. The examples and properties of axle guard submodules can be further described in US application Serial No. 11 / 405,940 which is incorporated herein by reference. The lower well control valve module 1600 may additionally or alternatively include

IMPI,,. INSTITUTO MEXICANO any component that can be associated generates ^^ t ^ components of the lower well control system.

Block interface module 1700 can be quickly attached to or detached from main body module 1100 using one or more of the connection techniques described above. For example, the connection can be made using a latch or slot connection or a spacer ring connection. This allows for repair or inspection of components in the load path outside the critical path. The 1700 block interface module can include four top strings; two attached to the release adapters; a block adapter; and four load cell pins. Block interface module 1700 may additionally or alternatively include any component that could generally be associated with the components of the block system. Block interface module 1700 can be exchanged for another block interface module for example when platforms are changed.

Cooling system module 1900 can quickly be attached to or detached from one or more main body modules 1100, drive motor module 1300, and retraction system interface frame module 2100 using one or more of the connection techniques previously described. This allows the 1900 cooling system module to be completely removed and replaced with another 1900 cooling system module. This allows for repair of components out of the critical path. In some modalities, the

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1WTTTU7 OM 7X ¡c * .r¡ &lt;7 cooling system 1900 can be hinged%^l'$ &amp; í © &amp;^!HE connected to a part of the modular top drive system, eg the 2100 retraction system interface frame module, such that the cooling system module 1900 can be rotated outside, for example, the transmission engine module 1600 to provide improved access to it. The cooling system module 1900 can have one or more circulators, for example a blower and / or a pump and one or more ducts. In some embodiments, one or more circulators and one or more conduits may be modular. The 1900 10 cooling system module generally uses air to cool. However, any refrigerant can be used. The cooling system module 1900 may additionally or alternatively include any component that could generally be associated with the cooling system component.

The retraction system interface frame module 2100 can be particularly useful when exchanging a complete top drive system 1000. The retraction system interface frame module 2100 can have a pin configuration that can be between a plurality of guide platforms and / or retraction systems so that the 2100 interface frame module can be interchanged between cranes. The 2100 Retraction System Interface Frame Module may contain a self-lubricating system. The 2100 retraction system interface frame module may additionally and alternatively include other components such as junction boxes, circuitry

IMPI

MEXICAN INSTITUTE

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refrigeration, PLC, lubrication systems, filters for system ^ iWil'ubriea ^ fer and the like, to allow dual activities when 00'roomplaaon loo modules of a modular top command system of this invention. The retraction system interface frame module 2100 may additionally or alternatively include any of the components that could generally be associated with the retraction system interface frame system components.

In accordance with other embodiments of the invention, a modular top drive system of this invention may be an interchangeable top drive system comprising dual top drive systems such as, for example, top drive system 1000. This assists operators to troubleshoot and / or configure the upper controller offline while the other upper controller is operating. Operators can change a complete upper control. Each of the upper controls can have permanently installed service circuits. Each upper knob can be configured for different perforations and / or recovery configurations.

Another embodiment of the invention relates to different configurations of a modular top control system. For example, in addition to the exemplary embodiment of the 1000 top drive system, another embodiment can be formed from the following top drive modules: dual-coupled main drive motors, quick-change IBOP (LWCW), pipe 1400, module

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MEXICAN INSTITUTE 1200 gearbox, a lubrication system, and a lfavef ^ e "p®trd ^" In addition, using the principles of muüolar construction dyuir sisÍeri ia above command, a person skilled in the art will know the numerous Additional modular constructions of the top drive systems, comprising virtually any number of top drive modules, which can fit numerous perforations, coatings and any other tubular handling applications.

Some modes of the 1000 top drive system have an engine cooling system. In some embodiments, the cooling system may have modular components, for example, 1900 cooling system module. The system may be a cooling system for one or more main drive engines. It may also have ducts integrated with the upper handle support structure, which may include modular or non-modular frames and / or protective structures such that the ducts are hollow beam interiors of the support structure. One or more circulators may be connected to one or more motors through multiple systems and / or duct systems so that any one or more circulators can cool any and / or all motors. The cooling system can circulate air or other refrigerant. This creates redundancy in the system.

Modes such as, for example, the upper drive system 1000 may also have separate lubrication systems for the gearbox and bearings. This prevents any traces of wear

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INSTITUTO M £ XICAN &lt;OCLA nOMKOAU INDUSTRIAL

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the gearbox from interacting with it and potentially damaging the bearings. In the bearing lubrication system, there may be no circulation and filtration force, and circulation can be achieved through natural convection and gravity. Figure 3 shows an exemplary embodiment of such a 2200 bearing lubrication system. Bearing lubrication system 2200 may include a sump 2210 connected to riser 2220, which connects to reservoir 2230. Lubricant flows between riser 2220 and bearings 2240.

In the gearbox lubrication system, the waste components of the gears that contaminate the lubricant generally require forced circulation and filtration. Figure 4 shows an example of such a 2300 gearbox lubrication system. The 2300 gearbox lubrication system may have a 2310 oil sump, a 2320 oil passage, one or more circulators (not shown), and one or more filters (not shown), which serve to lubricate a surface of contact between an input pinion 2330 and a turning gear 2340. When a plurality of circulators and / or filters are used, they may be configured to create redundancy in the system.

In modalities with an interchangeable wear tube, the wear tube can be quickly changed to minimize machine downtime. The change can be done remotely with an automatic quick change capability.

Interchangeability of various top control modules_

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MEXICAN INSTITUTE OF LA PRONEOAD

INDUSTRIAL

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may allow for repairs, maintenance, inspection, and / or reconfiguration of performance performed off the critical path. This can reduce machine downtime for a modular top drive system which corresponds to reduced machine downtime for the entire platform. Some or all of the top control modules may be symmetrical allowing installation in more than one location on the top control.

Therefore, this invention is well suited to achieve the aforementioned purposes and advantages, as well as those inherent therein. The particular embodiments described above are only illustrative, as the invention can be modified and practiced in different but equivalent ways, which are apparent to those skilled in the art that have the benefit of the teachings thereof. For example, this invention can be used to operate a drill pipe as well as casing or other pipes. Furthermore, there are no limitations provided for the construction or design details shown herein other than those described in the following claims. Therefore, it is evident that the particular illustrative embodiments described above can be altered or modified and such variations are considered within the scope and spirit of this invention. Also, the terms in the claims have the full and ordinary meaning unless the patent owner explicitly and clearly defines otherwise.