Post on 27-Mar-2021
Bentec GmbH Drilling & Oilfield Systems Deilmannstraße 1, D- 48455 Bad Bentheim Germany
Page 1 of 33
Technical Bulletin Top Drive TD-500-HT Top Drive TD-350-HT
-
TD-500-HT
DE P01
Technische Information
Technical Bulletin Top Drive Index
Page 2 of 33
1 Introduction............................................................. 4 1.1 Overview ........................................................................... 5
2 Technical Data ......................................................... 6 2.1 Dimension drawing ........................................................... 6 2.2 General.............................................................................. 7 2.3 Performance Data ............................................................. 7 2.3.1 Torque Speed Diagram...................................................... 8 2.4 Connection values ............................................................. 9 2.5 Operation conditions ......................................................... 9
3 Setup and Function ................................................... 10 3.1 Module description.......................................................... 10 3.1.1 Drilling Unit ..................................................................... 11 3.1.2 Pipehandler ..................................................................... 16 3.1.3 Carriage Package............................................................. 20 3.1.4 Torque Beam Assembly................................................... 20 3.1.5 Hoisting equipment ......................................................... 21 3.1.6 Tool Kit............................................................................ 21 3.2 Top Drive Control ............................................................ 22 3.2.1 Service Loop ................................................................... 22 3.3 Drillers Control ................................................................ 23 3.4 VFD Power control System.............................................. 23 3.4.1 VFD – Power Supply ....................................................... 24 3.4.2 VFD – Power Stack & VFD Controls ................................ 24 3.4.3 VFD – Motor Control center (MCC) ................................. 24 3.4.4 VFD – Braking Chopper Module & Resistor..................... 24 3.4.5 VFD – Transformer.......................................................... 25 3.4.6 VFD – UPS System.......................................................... 25 3.4.7 VFD – ESD System.......................................................... 25 3.4.8 VFD – Air Conditioning Unit............................................. 25 3.5 Incoming Power Cable .................................................... 25
4 Transport............................................................... 26
5 Recommended Option - Rig survey ................................ 27
6 Recommended Option - Implementation Kit...................... 27
7 Option - Training...................................................... 28 7.1 Training Course – Operation............................................ 28 7.2 Training Course – Hydraulics .......................................... 28 7.3 Training Course – Electrics.............................................. 28 7.4 Training Course – Mechanics .......................................... 29
Technical Bulletin Top Drive Index
Page 3 of 33
8 Option - Yearly Maintenance Service.............................. 29
9 Option - Recommended Spare Parts for one year ............... 29
10 Option - Lubricants for one year.................................... 29
11 Option - Service Loop Container.................................... 30
12 Option – Saver Sub Set .............................................. 30
13 Option – Tool Joint Adapter Kit ..................................... 30
14 Option – Wireline Adapter........................................... 30
15 Option – Top Drive Control Driller’s Chair implementation .... 30
16 Option – Color Camera system ..................................... 31
17 Option – Top Drive Genset (Independent Power source)........ 32
18 Option – Offshore Certification ..................................... 32
19 Contact ................................................................. 33
Technical Bulletin Top Drive
Introduction
Page 4 of 33
Pos: 1.1.1 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/Technical Bulletin/1000 1. Einführung @ 4\mod_1279695641388_581.doc @ 38564
1 Introduction Pos: 1.1.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4001 4.0.0 Einführung @ 4\mod_1279025442084_581.doc @ 37340
The Bentec Top Drive is designed as transportable as well as permanent installed unit for deep drilling rigs with different mast types. The System is powered by an AC motor. The Top Drive is controlled by a separate control panel.
The standard Top Drive version includes the following items:
Hanger assembly with integrated Counterbalance cylinders
Standard washpipe
Link-tilt-system with position monitoring designed for high impacts
Remote-controlled and manual IBOP
Backup Clamp to make up and break the Top Drive drill pipe connection
Guide rail system inducing the torque within the mast.
Electrical service loop
Onboard hydraulic unit.
The blower rate for the motor cooling is variable and depends on the motor temperature.
The drives of the system have been carefully chosen to meet current noise protection regulations.
Technical Bulletin Top Drive
Introduction
Page 5 of 33
Pos: 1.1.3.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/4. Aufbau und Funktion/4100 4.1. Übersicht @ 4\mod_1278926224268_581.doc @ 36606
1.1 Overview Pos: 1.1.3.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4100 4.1.0 Übersicht _Bild @ 4\mod_1279025653859_581.doc @ 37360
Right Side
Left side
Rear
Front
Abb. 1 Pos: 1.2 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
Technical Bulletin Top Drive
Technical Data
Page 6 of 33
Pos: 1.3.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/3. Technische Daten/3000 3. Technische Daten @ 4\mod_1278919879993_581.doc @ 36436
2 Technical Data Pos: 1.3.2.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/3. Technische Daten/3100 3.1. Maßblatt @ 4\mod_1278920457472_581.doc @ 36449
2.1 Dimension drawing Pos: 1.3.2.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3100 3.1.0 Maßblatt @ 4\mod_1279023392166_0.doc @ 37256
764
16001708
660
535
843 865
Abb. 2
Technical Bulletin Top Drive
Technical Data
Page 7 of 33
Pos: 1.3.3.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/3. Technische Daten/3200 3.2. Allgemeine Angaben @ 4\mod_1278920832597_581.doc @ 36466
2.2 General Pos: 1.3.3.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3200 3.2.0 Allgemeine Angaben @ 4\mod_1279023470335_581.doc @ 37261
Description Value Dimension
Weight 16200 kg
Length 6730 mm
Width 1780 mm
Height 1540 mm Pos: 1.3.4.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/3. Technische Daten/3500 3.5. Leistungswerte @ 4\mod_1278924144825_581.doc @ 36536
2.3 Performance Data Pos: 1.3.4.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3500 3.5.0 Leistungswerte Tabelle @ 4\mod_1279024204468_581.doc @ 37296
Description Value Dimension
API Load Capacity (350t Top Drive) 350
3125
ton
kN
API Load Capacity (500t Top Drive) 500
4480
ton
kN
Pressure Rating 500
7500
bar
PSI
Power Rating 758
1030
kW
HP
Drill Speed 0 to 115/230 1 min-1
Drilling Torque 63.000
46.500
Nm
ft lbs
Make up / Break out Torque 100.000
73.760
Nm
Ft lbs
Static Break Torque 105.000
77.440
Nm
ft lbs
Link Tilt Lifting Capacity 2500 kg
5500 lbs
@1,4 m
@4 ½ “
Gear box Ratio 1. Gear 14:1
Technical Bulletin Top Drive
Technical Data
Page 8 of 33
Pos: 1.3.4.3 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/3510 3.5.1. Drehmoment Geschwindigkeitskurve @ 4\mod_1279024483787_581.doc @ 37310
2.3.1 Torque Speed Diagram Pos: 1.3.4.4 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3510 3.5.1.0 Drehmoment Geschwindigkeits kurve @ 4\mod_1279024399758_581.doc @ 37306
Abb. 3 Pos: 1.3.5.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/3. Technische Daten/3300 3.3. Anschlusswerte @ 4\mod_1278922039727_581.doc @ 36480
Technical Bulletin Top Drive
Technical Data
Page 9 of 33
2.4 Connection values Pos: 1.3.5.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3301 3.3.0 Hauptantrieb-elektrisch @ 4\mod_1279023631471_581.doc @ 37266
Main drive electric
Description Value Dimension
Voltage D 575 V AC
Current load (max.) 880 A
Power input (max.) 750 kW Pos: 1.3.5.3 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3302 3.3.0 Motorlüfter-elektrisch @ 4\mod_1279023682516_581.doc @ 37271
Main drive cooling electric
Description Value Dimension
Voltage D 400 / S690 V AC
Current load (max.) 14,3 / 8,3 A
Power input (max.) 7,5 kW Pos: 1.3.5.4 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3303 3.3.0 Antrieb Hydraulikaggregat-elektrisch @ 4\mod_1279023752545_581.doc @ 37276
Hydraulic Power Unit
electric
Description Value Dimension
Voltage D 400 / S690 V AC
Current load (max.) 14,3 / 8,3 A
Power input (max.) 7,5 kW Pos: 1.3.5.5 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3304 3.3.0 Antrieb Getriebeschmierung-elektrisch @ 4\mod_1279023839105_581.doc @ 37281
Gearbox Lubrication
electric
Description Value Dimension
Voltage D 400 / S690 V AC
Current load (max.) 14,3 / 8,3 A
Power input (max.) 7,5 kW Pos: 1.3.6.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/3. Technische Daten/3400 3.4. Betriebsbedingungen_Titel @ 4\mod_1278923125180_581.doc @ 36504
2.5 Operation conditions Pos: 1.3.6.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/3400 3.4.0 Umgebung Temperatur @ 4\mod_1279024098112_581.doc @ 37291
Environment
Description Value Dimension
Temperature range -45...+ 55 °C Pos: 1.4 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
Technical Bulletin Top Drive
Setup and Function
Page 10 of 33
Pos: 1.5.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/4. Aufbau und Funktion/4000 4. Aufbau und Funktion @ 4\mod_1278925574849_581.doc @ 36582
3 Setup and Function Pos: 1.5.2 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/4. Aufbau und Funktion/4200 4.2. Baugruppenbeschreibung @ 4\mod_1278926559989_581.doc @ 36620
3.1 Module description Pos: 1.5.3 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4200 4.2.0 Baugruppenbeschreibung_Bild @ 4\mod_1279025724825_581.doc @ 37370
The Machine is divided in subassemblies as follows:
Drilling Unit
Pipehandler
Elevator/Links
Carriage Package
Service Loop
Guide Rails
Abb. 4 Pos: 1.5.4 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
Technical Bulletin Top Drive
Setup and Function
Page 11 of 33
Pos: 1.5.5 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4210 4.2.1.0 Drilling unit @ 4\mod_1279025726107_581.doc @ 37375
3.1.1 Drilling Unit
The Drilling Unit consists of the following subassembly groups:
Hydraulic Unit
Mud Supply
Hanger Assembly
Protection Frame
Drive
Abb. 5
Technical Bulletin Top Drive
Setup and Function
Page 12 of 33
Pos: 1.5.6 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4211 4.2.1.1 Aufhängung @ 4\mod_1279026404233_581.doc @ 37395
3.1.1.1 Hanger Assembly
1
2
3
Abb. 6
The Hanger Assembly consists of:
Yoke (1)
Two upper links (2)
Counterbalance system (3). The counterbalance system (3) is integrated within the Upper Links and consists of:
– two Hydraulic cylinders – two hydraulic accumulators
The cylinders are assembled between Yoke (1) and Upper Links (2). The Counterbalance System can compensate a maximum distance of 200 mm. When starting the operation the counterbalance system is charged by the hydraulic system. During operation the hydraulic system refills the counterbalance system to the adjusted pressure.
Pos: 1.5.7 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4212 4.2.1.2 Antrieb @ 4\mod_1279026462857_581.doc @ 37399
3.1.1.2 Drive
Drive
The drive system contains of the following components:
1 Engine Cooling System 2 Brake 3 AC motor 4 Gearbox 5 Mainshaft
2
3
4
5
1
Abb. 7
Technical Bulletin Top Drive
Setup and Function
Page 13 of 33
Pos: 1.5.8 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42121 4.2.1.2.0 Motorkühlung @ 4\mod_1279026560245_581.doc @ 37403
1
2
3
4
5
Abb. 8
Motor Cooling System A frequency controlled motor (2) drives the engine fan (1). The fan speed depends on the motor temperature which is determined by sensors. (COD) Cooling on Demand. Cooling air is conducted via a noise reduced suction hood (3) through a blower channel (4) into the ac motor of the Top Drive and transmission oil cooler. (5).
Pos: 1.5.9 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42122 4.2.1.2.0 Drehstrommotor @ 4\mod_1279026663023_581.doc @ 37407
Abb. 9
AC Motor The rated power of the motor is 758 KW / 1030HP. It is controlled by a frequency drive and temperature monitored. The maximum operating temperature is controlled by sensors in the motor.
Pos: 1.5.10 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42123 4.2.1.2.0 Drehgeber Haltebremse @ 4\mod_1279026733959_581.doc @ 37411
21
Abb. 10
Rotary encoder(1) The rotary encoder is assembled to the holing brake and - via shaft extension - directly connected to the engine shaft
Brake (2) The disc brake is hydraulic closed and spring force opened. It can absorb a torque of 105.000 Nm.
Technical Bulletin Top Drive
Setup and Function
Page 14 of 33
Pos: 1.5.11 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42124 4.2.1.2.0 Getriebe @ 4\mod_1279026804645_581.doc @ 37415
12
3
Abb. 11
Gearbox The two-stage gearbox is helical cut with a total transmission ratio of 14:1. The speed of the engine is reduced twice before it is transferred to the bullgear (1) of the gearbox. The bullgear is located on the thrust bearing. The mainsahft is concentrically located in the bullgear and connected to it via multiple splining. The gearbox is lubricated with combined splash/pressure lubrication (3). If the gear oil has reached its maximum temperature it is piped via a bypass through an oilcooler. The oilcooler is included in the ventilation system of the motor.
Pos: 1.5.12 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42125 4.2.1.2.0 Mainshaft @ 4\mod_1279026871377_581.doc @ 37419
1
3
2
4
5
Abb. 12
Mainshaft The mainshaft (4) – powered by the bullgear - is located in the gearbox together with the thrust bearing (2). It is conducted via lower bearing (3). In order to execute drilling fluid a washpipe (1) is connected. At the bottom of the mainshaft there is an API pin as connection to the drill string. The drill string is powered by the mainshaft. The mainshaft holds the load collar (5) which bears the link adapter the drill pipe during elevator operation.
Pos: 1.5.13 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4213 4.2.1.3 Spülungszufuhr @ 4\mod_1279027224570_581.doc @ 37423
3.1.1.3 Mud Supply
12
34
Abb. 13
The mud feeding comprises a 3“ washpipe and a goose neck with 2“ Fig 1502 input for wireline operation as well as a 4” Fig 1002 mud hose connection. The mud feeding disposes of a pressure rating of 7500 PSI.
Pos: 1.5.14 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4214 4.2.1.4 Integriete Hydraulikeinheit @ 4\mod_1279027344582_581.doc @ 37427
Technical Bulletin Top Drive
Setup and Function
Page 15 of 33
Pos: 1.27 /Bentec Produkte/Top Drive /TD-500-HT/4. Aufbau und Funktion/421 4.2.1.4 Baugruppe Hydraulikeinheit @ 1\mod_1259752821452_581.doc @ 24520
3.1.1.4 Onboard Hydraulic Unit
1
3
45
2
Abb. 14
The hydraulic unit disposes of
Speed controlled internal gear pump(1)
Valve block for the hydraulic unit (2)
Valve block for the pipehandler (3).
Main valve block (4)
Valves are operated by robust 24 volt coil. A low-noise pump is integrated in the stainless steel system tank (5).
Pos: 1.5.15 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4215 4.2.1.5 Schutzrahmen @ 4\mod_1279027429641_581.doc @ 37431
3.1.1.5 Protection Frame
Abb. 15
The protection frame is fixed at the front of the Top Drive. A service platform(1) can be swung out for installation and repair work
Pos: 1.5.16 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
Technical Bulletin Top Drive
Setup and Function
Page 16 of 33
Pos: 1.5.17 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4220 4.2.2.0 Pipehandler @ 4\mod_1279028087730_581.doc @ 37435
3.1.2 Pipehandler
The Pipehandler consists of the following sub assembly groups:
IBOP / Saversub
Link tilt
Linkadapter housingSupport
Rotary Actuator / Arresting Device
Hydraulic Swivel
Back Up Clamp
Abb. 16 Pos: 1.5.18 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
Technical Bulletin Top Drive
Setup and Function
Page 17 of 33
Pos: 1.5.19 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4221 4.2.2.1. Drehantrieb @ 4\mod_1279028184883_581.doc @ 37439
3.1.2.1 Rotary Actuator
1
23
Abb. 17
Hydraulic Rotary Actuator The pipehandler is infinitely rotatable by 360 °. The main gear wheel (3) is run by the pinion. The pinion is moved by a hydraulic drive.
Pos: 1.5.20 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4222 4.2.2.2. Feststeller @ 4\mod_1279028265677_581.doc @ 37443
3.1.2.2 Arresting device
1
23
Abb. 18
Arresting Device The gear segment (2) is moved by a hydraulic cylinder (1). It grabs at the main gear wheel(3) and arrests the pipehandler in intervals of 3°.
Pos: 1.5.21 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4223 4.2.2.3 Drehdurchführung @ 4\mod_1279028306863_581.doc @ 37447
3.1.2.3 Hydraulic Swivel
Abb. 19
Hydraulic swivel Hydraulic lines of the consumer of the Pipehandler are transferred through the hydraulic swivel. Free channels are available, enabling the connection of additional consumers.
Pos: 1.5.22 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4224 4.2.2.4. Linkadapterhousing @ 4\mod_1279028366362_581.doc @ 37451
3.1.2.4 Linkadapterhousing
Abb. 20
Linkadapterhousing The linkadapter (2) positioned in the linkadapterhousing (1). The link adapter is supported by the Liftingspring (3). While drilling the liftingspring raises the linkadapter thus enabling free rotation of the mainshaft. The load collar (4) holds the linkadapter during elevator operation. The load collar transfers the load into mainshaft. The load collar consists of two half-shells with grooves that grap into the mainshaft. A housing keeps the shells together..
Technical Bulletin Top Drive
Setup and Function
Page 18 of 33
Pos: 1.5.23 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4225 4.2.2.5 Linktilt @ 4\mod_1279028676383_581.doc @ 37455
3.1.2.5 Linktilt
Abb. 21
Linktilt Two hydraulic cylinders (2) move Links and Elevator. Hereby the elevator can be placed in any position necessary for picking the pipes. The system can lift a maximum of 2,5 t at a distance of 1,4 m to centre well.
Pos: 1.5.24 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42251 4.2.2.5.0 Linktilt Reichweite Tabelle @ 4\mod_1279028770661_581.doc @ 37459
The Link tilt system is able to move Links with in the following Limits
Link Typ L f b
[mm] [``] [mm] [``] [mm] [``]
108`` 2743 108 1473 58 2013 79
120`` 3048 120 1637 64 2237 88
132`` 3353 132 1081 71 2460 97
144`` 3658 144 1964 77 2684 106
168`` 4267 168 2292 90 3131 123
180`` 4572 180 2455 97 3355 132 Pos: 1.5.25 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42252 4.2.2.5.0 Linktilt Reichweite Abb @ 4\mod_1279028858033_581.doc @ 37463
L
Abb. 22
Technical Bulletin Top Drive
Setup and Function
Page 19 of 33
Pos: 1.5.26 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4226 4.2.2.6 Linktilt Überwachung @ 4\mod_1279028969186_581.doc @ 37467
3.1.2.6 Pipe handler Monitoring
1
2
3
Abb. 23
Pipe handler Monitoring The position of the elevator is determined at all times. A hydraulic cylinder (3) communicates via hydraulic swivel (2) with a measuring cylinder (1) transferring the elevator position to a connected Drawworks Anti Collision System. Depending on the Anti Collision System a number of different link positions can be teached in, to be approached during drilling operation.
Pos: 1.5.27 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4227 4.2.2.7 Haltezange @ 4\mod_1279029119916_581.doc @ 37471
3.1.2.7 Back up Clamp
1
2
Abb. 24
The purpose of the backup Clamp(2) is making up and breaking drill pipe connections between Top Drive (Saversub) and drill string. The back up clamp is connected to the Linkadapterhousing via torque beam.(1)
Pos: 1.5.28 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/42271 4.2.2.7.0 Backeneinsätze @ 4\mod_1279029214834_581.doc @ 37475
1
2
Abb. 25
The Jaw Assemblies(1) are moved by a hydraulic cylinder(2). Using different kinds of jaw assemblies allows making up and breaking of drill pipe with various OD`s. The Top Drive is equipped with one Jaw size. Additional Sizes for other Tool Joint OD’s are available as the option “Tool Joint Adapter Kit”
Jaw size Tool Joint OD
I 4“ – 5“
II 5 ¼“ – 6 ¼“
III 6 ¼“ – 7 ½“
IV 7 ½“ – 8 ½“
Technical Bulletin Top Drive
Setup and Function
Page 20 of 33
Pos: 1.5.29 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4228 4.2.2.8. IBOP Saver Sub @ 4\mod_1279029762582_581.doc @ 37491 Pos: 1.39 /Bentec Produkte/Top Drive /TD-500-HT/4. Aufbau und Funktion/422 4.2.2.7 Baugruppe IBOP,Saversub, Load Collar @ 1\mod_1260947387369_581.doc @ 24940
3.1.2.8 IBOP/ Saversub
1234
Abb. 26
The IBOP (2) is connected to the mainshaft via API pin
Internal
Blow
Out
Preventer
The saver sub (4) is screwed between IBOP (2) and pipe. Dielocks (1,3) prevent the threaded joints from over torque from the mainshaft to the IBOP and accordingly from the IBOP to the saver sub.
Pos: 1.5.30 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4230 4.2.3. Führungswagen @ 4\mod_1279029308425_581.doc @ 37479
3.1.3 Carriage Package
Abb. 27
The Top drive is guided by a carriage package. It transfers the torque from the top drive into the Guide rails.
The Carriage Package consists of a frame(1) with slide shoes(2), it transfers the Torque it to the Mast structure. The glide shoes are equipped with vibration dampers (3). Adjustment to centre well is performed by adjusting devices(4)
Pos: 1.5.31 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4240 4.2.4. Führungsschiene @ 4\mod_1279029433655_581.doc @ 37483
3.1.4 Torque Beam Assembly
Abb. 28
The Torque beam assembly absorbs the torque of the guide dolly and transfer it to the mast structure. The Torque beam assembly is segmented into 4 sections and delivered within a transport frame. The Transport frame allows easy and safe handling during transport and Rig up.
Technical Bulletin Top Drive
Setup and Function
Page 21 of 33
Pos: 1.5.32 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4250 4.2.5. Hoisting equipment @ 4\mod_1279029563808_581.doc @ 37487
3.1.5 Hoisting equipment
Abb. 29
The Top Drive can be equipped with the following Links(1) and elevators(2)
Load Size
350 ton 2 ¾” x 120” (recommended)
350 ton 2 ¾” x 132”
500 ton 3 ½” x 120” (recommended)
500 ton 3 ½” x 144”
Other elevator link sizes are available on request.
Elevator links for Casing running Tools are available on request.
Manual Elevators are available in the following sizes:
350 ton
500 ton
A Bushing set of the for the following Drillpipe sizes will be attached:
3 ½” , 4 ½” , 5” , 5 ½” , 6 5/8”
Bushings for other Drillpipe sizes are available on request.
Hydraulic elevators are available on request. Hydraulic connections for a hydraulic elevator are already available.
Pos: 1.5.33 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
3.1.6 Tool Kit
The top drive will be delivered with
IBOP Hex wrench
IBOP repair tools
Manual oil pump
Technical Bulletin Top Drive
Setup and Function
Page 22 of 33
Pos: 1.5.34 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4260 4.2.6. Topdrive Control - Konsole @ 4\mod_1279721650920_581.doc @ 38630
3.2 Top Drive Control
The Top Drive Control System consist of the following parts
Service Loop
Drillers Control
Terminalbox
Drillers Control CableDrillfloor
Drillers Control CableGround Level
Supply Cable
Incoming Power Cable
VFD Power Control System
Abb. 30 Pos: 1.5.35 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
3.2.1 Service Loop
Abb. 31
The Top drive has a Power Loop (1) that supplies electrical power to the motor and a Control Loop (2). The control Loop holds all control lines and the electrical power supply for the auxiliary drives.
The Loop Length is based on the existing rig specifications.
The Length of the Supply Cable is determined by customer or recommended by Bentec.
The Length of the Incoming Power Cable is determined by customer or recommended by Bentec.
Technical Bulletin Top Drive
Setup and Function
Page 23 of 33
Pos: 1.5.36 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4261 4.2.6.1. Service Loop @ 4\mod_1279030085626_581.doc @ 37499 Pos: 1.5.37 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4262 4.2.6.2 VFD Power Control System @ 4\mod_1279030274654_581.doc @ 37503 Pos: 1.5.38 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4263 4.2.6.3. Driller Control Konsole @ 4\mod_1279703324803_581.doc @ 38600
3.3 Drillers Control
The Top Drive is controlled by the Panel shown below. This panel is used as a standalone unit installed within the doghouse.
An implementation within the Drillers Chair is available on request.
Abb. 32 Pos: 1.5.39 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
3.4 VFD Power control System
Abb. 33
The VFD Power Control contains all control devices and frequency converters that are needed to operate the Top drive.
Container Dimensions: Width: 3m / Length: 3,4m / Height: 3m
ISO Container with Lifting Edges & Pad eyes for rigging
Sun shed roof, entrance door and removable front
Heat insulation
Environmental temperature -45°C to +55°C
2 Air conditions 15kW each
1 heating unit 2kW
Incoming switchboard 600V/60Hz or 690V/50Hz 3Phase
1000A draw out circuit breaker
Plug panel 400mm² power pins 6 each
Power choke and rectifier
Air cooled VFD Inverter 1600A for main motor
MCC for all auxiliary drives with VFD’s for support drives
Chopper unit 200kW intermittent
Default incoming power cable
Technical Bulletin Top Drive
Setup and Function
Page 24 of 33
3.4.1 VFD – Power Supply
The Power Supply consists of an AC Bus (600/690V) to feed the transformer, the MCC Consumers a Diode Bridge with choke and fuses and the incoming circuit breaker (which feeds the DC Bus). The DC Bus feeds the VFD-Unit for the TD Main Motor.
Technical Data: Supply Voltage: 600/690V DC Current: 1700A Diode Bridge B6U
The plug panel for Power Supply is installed outside of the container. For each Phase there are two (2) Power Pins available. (3x2 Power Pins)
3.4.2 VFD – Power Stack & VFD Controls
The BENTEC VFD Units are designed not only to meet but exceed the customer requirements. The fool-proof design allows an easy & safe operation for the staff, field-bus connected PLC's are used to offer a comfortable maintenance, even via Internet (Option). Technical Data: Supply Voltage: 820…950 V DC Output Voltage: 575 V AC Output Current: 1600A Programmable Logic Controller: MODICON Schneider Cooling System: Air Cooled
Alarms are displayed in clear languages including histogram and display of actual system data for maintenance and troubleshooting purpose in one central Display.
All controls for the Top Drive like Link tilt, etc. are included in the VFD System.
The plug panel for the connection of the Top Drive is installed outside of the container.
3.4.3 VFD – Motor Control center (MCC)
The MCC is equipped with starters and feeders to the requirements of the Bentec Top Drive. Each starter will be complete with a magnetic only breaker, a contactor and an ambient compensated overload element (heater). All Status and Alarm messages will be indicated on a separate Human machine interface.
3.4.4 VFD – Braking Chopper Module & Resistor
The braking chopper module is installed to feed the braking resistor for regenerative braking.
Technical Data:
Chopper Module 200kW intermittent
Braking resistor 50kW continuous
Technical Bulletin Top Drive
Setup and Function
Page 25 of 33
3.4.5 VFD – Transformer
One transformer fed by AC Supply panel to fed 460/400/230V consumers of the MCC and small power distribution.
Technical Data: Rated power: 50kVA Primary voltage: 600/690V Secondary voltage: 400/460V
3.4.6 VFD – UPS System
One battery buffered UPS system to feed all control systems with uninterruptable stable power supply to allow for safe operation.
Technical Data: Input 400VAC, 50/60Hz Output: 24-28V DC / 40A Buffer battery capacity: 24V50Ah
3.4.7 VFD – ESD System
This safety system is split in two parts as follows:
Emergency Shut Down:
Single systems VFD, MCC, TD Control will be shut down in a controlled safe way
Blackout:
All systems will be shut down in a safe way and all power will be shut off.
3.4.8 VFD – Air Conditioning Unit
Two air conditioners are installed inside of the container to monitor and control the temperature inside of the container at a level of 25°C. The air is also used to cool all controls as well as the air cooled VFD.
3.5 Incoming Power Cable
Cables for connection of the VFD container with the Existing SCR unit. Other lengths are available on request. The Cables are pluggable on both sides. Customer supply power 690V/50Hz or 600V/60Hz – 760kW
Technical Bulletin Top Drive
Transport
Page 26 of 33
Pos: 1.5.40 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-Module/4300 4.3. Tool Kit @ 4\mod_1279030454400_581.doc @ 37511
Pos: 1.6 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805 Pos: 1.7.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/5. Transport und Zwischenlagerung/5000 5.Transport @ 4\mod_1278928593693_581.doc @ 36659
4 Transport Pos: 1.7.2 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/5001 5.0.0. Tarnsportmaße-Dubble Rail-Rahmen @ 4\mod_1279095056207_581.doc @ 37578
Transport Data
Description Value Dimension
Length 7400 mm
Width 2880 mm
Height 2880 mm
Weight 20.000 kg
Pos: 1.7.3 /Betriebsanleitungen-Mechanisch/Bentec Produkte/Top Drive/TD-500-HT/5002 5.0.0 Transortmaße-Dartsellung Double Rail Rahmen @ 4\mod_1279095056488_0.doc @ 37583
2880
7400
Abb. 34 Pos: 1.8 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
Technical Bulletin Top Drive
Recommended Option - Rig survey
Page 27 of 33
Pos: 1.9.1 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/Technical Bulletin/Z000 Z. Schulung @ 4\mod_1279691844542_581.doc @ 38541
5 Recommended Option - Rig survey For a turnkey Top Drive implementation Bentec recommends a rig survey in advance to fit the Top Drive system in an optimal way into the existing rig. The Rig survey takes two days and will be performed by two Bentec engineers. The Following Points will be surveyed.
Survey Contents:
Measurements at Mast
Measurements on Drill floor
Measurements on fingerboard Level
Measurements for Tieback kit
Check of Mast for Service Loop implementation
Check of Mast for possible collisions with the Top Drive
Check of Doghouse for control implementation
Check of Power supply Pos: 1.10 /Standardmodule /nL.......... Seitenumbruch .......... @ 0\mod_1226928886124_0.doc @ 805
6 Recommended Option - Implementation Kit An Implementation kit can be offered after a rig survey to provide a turnkey implementation for the Bentec Top Drive. The Implementation kit includes the following parts. Size and design of these parts are depends on the results of the rig survey.
Implementation kit Contents:
Hang off Links for Crown Block Section
Intermediate Tiebacks
Lower Tieback
Misc. Beams for implementation
The Implementation of Bentec Top Drives may influence the statics of the Mast. Bentec will submit static relevant data’s within a confirmation drawing after purchase order. The client is responsible for the verification of the Mast statics.
To implement the Top Drive in an efficient way Bentec need the following technical Drawings (CAD-File or scanned file):
Mast / Derrick – detailed Drawings
A-Frame (if available)
Drillfloor Layout
Fingerboard
Crown Block
Rig Layout
Standpipe Information
Drillpipe sizes which should be use on the Rig
Elevator Links & Elevator Information
Travelling Block Information
Technical Bulletin Top Drive
Option - Training
Page 28 of 33
7 Option - Training The following Training courses are available in advance or onsite.
Pos: 1.9.2 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/Technical Bulletin/Z100 Z.1. Bedienerschulung beim Hersteller @ 4\mod_1279691999830_581.doc @ 38545
7.1 Training Course – Operation
This training course includes the complete operation of the Top Drive System. This course contains one theoretical part and one practical part.
Training Contents:
Top Drive commissioning & decommissioning
Top Drive operational functions
Detailed training of the mechanical systems
Detailed training of the electrical systems
System safety
Participants:
This Course is provided for: Driller, Toolpusher, Repair- and Maintenance
Crews or people who are directly responsible for the Top Drive Pos: 1.9.3 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/Technical Bulletin/Z200 Z.2. Bedienerschulung An der Bohranlage @ 4\mod_1279692449776_581.doc @ 38549
7.2 Training Course – Hydraulics
This training course includes a deep training of the hydraulic system and their parts of the Top Drive.
Training Contents:
Hydraulic plans
Hydraulic pressure unit (HPU)
Operation of all hydraulic circuits.
Maintenance of the hydraulic system
Installation of the hydraulic pump
Installation of control elements
Participants:
This Course is provided for: Repair- and Maintenance Crews or people who are
directly or indirectly responsible for the hydraulic functions of the Top Drive.
7.3 Training Course – Electrics
This training course includes a deep training of the electric system and their parts of the Top Drive.
Training Contents:
Electrical plans
Power Supply
AC-Motors – VFD-Technology / PLC Controls
Maintenance of the Electrical System
Safe operation at the electrical systems
Participants:
This Course is provided for: Electric Crews or people who are directly or indirectly responsible for the electrical functions of the Top Drive.
Technical Bulletin Top Drive
Option - Yearly Maintenance Service
Page 29 of 33
7.4 Training Course – Mechanics
This training course includes a deep training of the mechanic system and their parts of the Top Drive.
Training Contents:
Mechanical plans
Load Path
Main Assemblies
Sub Assemblies
Lubrication & hydraulic System
Recommended Maintenance
Safe operation at the mechanical systems
Participants:
This Course is provided for: mechanic & maintenance Crews or people who are
directly or indirectly responsible for the mechanical functions of the Top Drive.
8 Option - Yearly Maintenance Service The Yearly Maintenance service will be done by Bentec onsite. Within the yearly Maintenance Service Our Top Drive Maintenance Specialists will be check all the Top Drive Parts, systems and functions. The following points are all points that have to be done according to the technical documentation. If there are some parts or systems need to be repaired or replaced Bentec will charge the costs separately
Maintenance Service Contents:
Maintenance of all Motors
Maintenance of the gearbox
Maintenance of the complete hydraulic system
Maintenance of the complete mechanical system
Maintenance of the complete electrical system
Function Test
9 Option - Recommended Spare Parts for one year The recommenced spare part package contains wear parts and spare parts that needed during normal operation for one year. The Spare Part kit guarantees a safe uptime of the Top Drive due to spare parts availability at the rig or base.
10 Option - Lubricants for one year Lubricants for the Top Drive are
Summer Lubricants
Hydraulic Oil: Shell Omala HD 150
Gear Oil: Shell Tellus 32
Winter Lubricants (recommended for Temperatures <0°C)
Hydraulic Oil: Shell Tivela 150
Gear Oil: Shell Tellus 32 Arctic
Technical Bulletin Top Drive
Option - Service Loop Container
Page 30 of 33
11 Option - Service Loop Container The Service Loop Container is an open Top 20 ft open top container. The Service Loop and Service Loop saddle can be stored within this container during rig move. The Service loop will be stored within this container in optimal environments and avoid any damages during transport and storage.
12 Option – Saver Sub Set The Top Drive is equipped with a one Saver Sub Set + one Saver sub for spare. The Thread Connection to the Drillpipe is NC50. Additional Saver subs and thread Connections are available on Request. The Following sizes are available. Saver subs quality control is according to API 7-1
NC 38
NC 40
NC 46
NC 50
5 ½” FH
6 5/8” FH
Special threads are available on request.
13 Option – Tool Joint Adapter Kit To clamp different Tool Joint sizes an Adapter Kit is available. The Adapter Kit consist a Jaw Assembly and a stabbing guide which fits to the Tool Joint Range.
The Following Tool Joint OD’s are possible:
4”-5”
5 ¼” – 6 ¼”
6 ¼” – 7 ¾”
7 ½” – 8 ½”
14 Option – Wireline Adapter The Wireline adapter allows using Wireline Tools with the Bentec Top Drive. The Wireline Adapter will be mounted below the Pipehandler Main Frame.
15 Option – Top Drive Control Driller’s Chair implementation The Top Drive controls can be implemented into an existing Driller’s Chair. The Implementation work onsite will be executed by a Bentec Service engineer. Technical Information’s about the Drillers chair are necessary in advance
Technical Bulletin Top Drive
Option – Color Camera system
Page 31 of 33
16 Option – Color Camera system A Color Camera system is a fixed or pan- and tiltable Color Camera. This Camera can be installed at any position on the rig to monitor hazardous areas like finger board level, drillfloor level, and crown block level. The preferred position of the camera needs to be determined by the customer. The Monitor the Camera is mounted in the Driller’s Cabin. The Number of Camera’s and Cable Lengths has to be determined by the customer. The printed boards for the controls are mounted in a separate Ex’d’ box. Cablings from the camera to the Ex’d’ box is directly connected without plugs. ATEX certified plugs are available on request.
Specifications Camera
EX de housing with temperature controlled space heater
Stainless steel weather protection hood
Size: 120 x 120 x 400 mm / 5kg
Automated brightness control
Motor operated zoom & Autofocus
Excellent clear picture even bad light conditions
Specifications Monitor & Control
Housing IP65, made in stainless steel with installation holder
Size: ca. 450 x 350 x 280 mm / 10kg
12'' (1024x768) TFT Color Screen Panel - IP65
Light intensity 1.300 candelas
Galvanic separation of video signal
50m multicore control cable halogen free for connect each camera
Camera selection switch
Zoom in/out / pan left & right / tilt up & down
Switches military standard
Specifications Pan/Tilt Unit
Pan angle: 356° Tilt Angle 176° & end stop limits
Size: 165 x 286 x 228 mm / 18kg / max. load 35 kg / Ex 'd' housing
Power Supply
230V AC 50/60Hz
Technical Bulletin Top Drive
Option – Top Drive Genset (Independent Power source)
Page 32 of 33
17 Option – Top Drive Genset (Independent Power source) The Top Drive can be equipped with a Genset Module to operate the Top Drive an independent unit.
18 Option – Offshore Certification For Offshore applications the Top Drive system will be certified by a third-party organisation. This Certificate is formally known as a Case-by-Case approval.
Supported Certification Organisations
DNV – Det Norske Veritas
ABS – American Bureau of Shipping
Lloyds British
The Certification includes design verification and product verification. Furthermore all load-path included parts will be Type approved. Interface related points between the existing rig system and the Top Drive System need to be clarified during an interface clarification meeting between Bentec and client.
Technical Bulletin Top Drive
Contact
Page 33 of 33
Pos: 1.11 /Betriebsanleitungen-Mechanisch/Bedienungsanleitungen-Alle/13. Adressen/16. Adressen @ 4\mod_1279544177034_581.doc @ 38495
19 Contact
Germany
Headquarters Production Service Sales
Bentec GmbH Drilling & Oilfield Systems Deilmannstraße 1 48455 Bad Bentheim Postfach 1253 • 48443 Bad Bentheim
Phone: +49-5922/72-80 Fax: +49-5922/72-457
E-Mail: info@bentec.de Web: www.bentec.com
Russia
Bentec GmbH Drilling & Oilfield Systems Respubliki –str. 252, bild.1 office 1-06 625014 Tyumen
Phone: +73452261479
E-Mail: info@bentec.de
Bentec GmbH Drilling & Oilfield Systems Russia Representation Office 1. Kasatschij per. 7, room 13 109017 Moscow
Phone: +7 495 234 42 38 or 39 Fax: +7 495 234 42 40
E-Mail: bentec@yandex.ru
Turkmenistan
Bentec GmbH Drilling & Oilfield Systems Turkmenistan Representation Office Azadi Street 95 / 2011 744000 Ashgabat
Phone: +99 312 395 561 Fax: +99 312 352 169
E-Mail: bentec.ashgabat@mail.ru.de
Kazakhstan Bentec GmbH Drilling & Oilfield
Systems Kazakhstan Branch Kabanbai Street 172 RK 480012 Almaty
Phone: +7 32 92 571 321 Fax: +7 3292 571 321
E-Mail: benteckz@gmx.de
Oman IDTEC
International Drilling Technology Co.LLC P.O.Box 1278 PC 133 Al Khuwair
Phone: +968-2459-0103 Fax: +968-2459-0163
E-Mail: mick@idtecoman.com
===== Ende der Stückliste =====