U.S. patent application number 12/005032 was filed with the patent office on 2009-06-25 for top drive systems for wellbore & drilling operations.
Invention is credited to Arthur William Braman, JR., Bastiaan De Jong.
Application Number | 20090159271 12/005032 |
Document ID | / |
Family ID | 40787220 |
Filed Date | 2009-06-25 |
United States Patent
Application |
20090159271 |
Kind Code |
A1 |
De Jong; Bastiaan ; et
al. |
June 25, 2009 |
Top drive systems for wellbore & drilling operations
Abstract
A top drive system for wellbore operations, the top drive system
in certain aspects including a main body, a motor (in certain
aspects a salient pole motor), a motor apparatus, a motor shaft
extending from the motor, a gear system driven by the motor shaft
and interconnected with a drive shaft, the gear system driven by
the motor apparatus so that driving the gear system drives the
drive shaft, the gear system having a housing and a bearing
retainer integral with the housing. This abstract is provided to
comply with the rules requiring an abstract which will allow a
searcher or other reader to quickly ascertain the subject matter of
the technical disclosure and is submitted with the understanding
that it will not be used to interpret or limit the scope or meaning
of the claims, 37 C.F.R. 1.72(b).
Inventors: |
De Jong; Bastiaan; (Rancho
Santa Margarita, CA) ; Braman, JR.; Arthur William;
(Cypress, CA) |
Correspondence
Address: |
Guy L. McClung, III
#114, 5315B FM 1960 Road West
Houston
TX
77069-4410
US
|
Family ID: |
40787220 |
Appl. No.: |
12/005032 |
Filed: |
December 21, 2007 |
Current U.S.
Class: |
166/244.1 ;
166/77.1 |
Current CPC
Class: |
E21B 3/02 20130101; F16H
1/28 20130101 |
Class at
Publication: |
166/244.1 ;
166/77.1 |
International
Class: |
E21B 19/22 20060101
E21B019/22 |
Claims
1. A top drive system for wellbore operations, the top drive system
comprising 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.
2. A top drive system for wellbore operations, the top drive system
comprising 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.
3. The top drive system of claim 2 further comprising 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.
4. The top drive system of claim 3 wherein the single bearing abuts
the inner part and the inner part is movable radially with the
single bearing.
5. The top drive system of claim 4 wherein the single bearing
maintains the lower planetary carrier in radial position.
6. The top drive system of claim 2 further comprising 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.
7. The top drive system of claim 6 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.
8. The top drive system of claim 2 wherein the motor apparatus is a
salient pole permanent magnet motor apparatus.
9. The top drive system of claim 3 further comprising 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.
10. The top drive system of claim 9 wherein 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.
11. The top drive system of claim 2 wherein the bearing cartridge
is releasably secured to a first part of the gear housing.
12. The top drive system of claim 11 wherein the first part is
releasably secured to the gear housing.
13. A top drive system for wellbore operations, the top drive
system comprising 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.
14. A method for facilitating rotation of a lower planetary carrier
of a gear system of a top drive system, the top drive system
comprising 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
method comprising rotating the lower planetary carrier with respect
to the single bearing, and holding the single bearing in position
with the bearing cartridge.
15. The top drive method of claim 14 wherein the top drive system
includes the bearing cartridge with 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 comprising
allowing the single bearing to move radially to an extent of
possible radial movement of the inner part.
16. The method of claim 14 wherein the single bearing maintains the
lower planetary carrier in radial position, the method further
comprising maintaining the lower planetary carrier in position with
the single bearing.
17. The method of claim 14 wherein the top drive system includes 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 comprising retaining the shaft bearing
in position with the bearing retainer portion.
18. The method of claim 14 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
comprising inhibiting interference in the horizontal plane between
the single bearing and the shaft bearing.
19. The method of claim 15 wherein the top drive system includes 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 comprising with the at least one
seal accommodating movement of the inner part with respect to the
outer part.
20. 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 comprising 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 comprising
allowing the single bearing to move radially with respect to the
gear housing in a controlled manner.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention is directed to top drive systems; parts
thereof; and methods of their use.
[0003] 2. Description of Related Art
[0004] 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--these
patents all incorporated fully herein for all purposes.
[0005] Certain typical prior art 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.
[0006] Certain prior art 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
[0007] The present invention, in certain aspects, provides a top
drive system for wellbore operations, the top drive system
including: a main body; a motor apparatus (e.g. one motor, two or
more spaced-apart motors; a plurality of motors, two, three, four
or more stacked one on the other and providing power in series; or
a plurality of motors providing power in parallel; and, e.g., to
drive a single gear of a top drive gear system); a drive shaft; a
gear system interconnected with the motor for driving the drive
shaft; the gear system having a housing which in one aspect has an
integral bearing retainer for retaining in position bearings below
the gear system.
[0008] In one aspect, the present invention discloses a top drive
system with a motor having a housing that includes top and bottom
parts connected together by tie rods.
[0009] Accordingly, the present invention includes features and
advantages which are believed to enable it to advance top drive and
top drive motor and gear apparatus technology. Characteristics and
advantages of the present invention described above and additional
features and benefits will be readily apparent to those skilled in
the art upon consideration of the following detailed description of
preferred embodiments and referring to the accompanying
drawings.
[0010] Certain embodiments of this invention are not limited to any
particular individual feature disclosed here, but include
combinations of them distinguished from the prior art in their
structures, functions, and/or results achieved. Features of the
invention have been broadly described so that the detailed
descriptions that follow may be better understood, and in order
that the contributions of this invention to the arts may be better
appreciated. There are, of course, additional aspects of the
invention described below and which may be included in the subject
matter of the claims to this invention. Those skilled in the art
who have the benefit of this invention, its teachings, and
suggestions will appreciate that the conceptions of this disclosure
may be used as a creative basis for designing other structures,
methods and systems for carrying out and practicing the present
invention. The claims of this invention are to be read to include
any legally equivalent devices or methods which do not depart from
the spirit and scope of the present invention.
[0011] What follows are some of, but not all, the objects of this
invention. In addition to the specific objects stated below for at
least certain preferred embodiments of the invention, there are
other objects and purposes which will be readily apparent to one of
skill in this art who has the benefit of this invention's teachings
and disclosures. It is, therefore, an object of at least certain
preferred embodiments of the present invention to provide:
[0012] New, useful, unique, efficient, non-obvious top drive
systems, components and parts thereof, and methods of their use;
and
[0013] Such systems with a gear system with a removable bearing
cartridge;
[0014] Such systems with a movable bearing holder permitting radial
movement of a bearing adjacent a planetary carrier, and, in one
aspect, such systems with a single bearing adjacent a planetary
carrier;
[0015] Such systems with a movable gear system bearing movable
radially which does not interfere in a horizontal plane with a
system shaft bearing; and
[0016] Such a system with a lower part of a gear housing for
retaining a system shaft bearing.
[0017] The present invention recognizes and addresses the problems
and needs in this area and provides a solution to those problems
and a satisfactory meeting of those needs in its various possible
embodiments and equivalents thereof. To one of skill in this art
who has the benefits of this invention's realizations, teachings,
disclosures, and suggestions, various purposes and advantages will
be appreciated from the following description of preferred
embodiments, given for the purpose of disclosure, when taken in
conjunction with the accompanying drawings. The detail in these
descriptions is not intended to thwart this patent's object to
claim this invention no matter how others may later attempt to
disguise it by variations in form or additions of further
improvements.
[0018] The Abstract that is part hereof is to enable the U.S.
Patent and Trademark Office and the public generally, and
scientists, engineers, researchers, and practitioners in the art
who are not familiar with patent terms or legal terms of
phraseology to determine quickly from a cursory inspection or
review the nature and general area of the disclosure of this
invention. The Abstract is neither intended to define the
invention, which is done by the claims, nor is it intended to be
limiting of the scope of the invention in any way.
[0019] It will be understood that the various embodiments of the
present invention may include one, some, or all of the disclosed,
described, and/or enumerated improvements and/or technical
advantages and/or elements in claims to this invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0020] A more particular description of embodiments of the
invention briefly summarized above may be had by references to the
embodiments which are shown in the drawings which form a part of
this specification. These drawings illustrate certain preferred
embodiments and are not to be used to improperly limit the scope of
the invention which may have other equally effective or equivalent
embodiments.
[0021] FIG. 1A is a back view of a top drive system according to
the present invention.
[0022] FIG. 1B is a side view of the top drive system of FIG.
1A.
[0023] FIG. 1C is a front view of the top drive system of FIG.
1A.
[0024] FIG. 1D is a cross-section view along line 1D-1D of FIG.
1C.
[0025] FIG. 2A is a perspective view of a top drive system
according to the present invention with a motor/gear apparatus
according to the present invention.
[0026] FIG. 2B is a partially exploded view of the top drive system
and motor/gear apparatus shown in FIG. 2A.
[0027] FIG. 2C is a cross-section view of the system of FIG.
2A.
[0028] FIG. 2D is a side view of the system of FIG. 2A.
[0029] FIG. 2E is a front view of the system of FIG. 2A.
[0030] FIG. 3 is a rear view of a top drive system of according to
the present invention.
[0031] FIG. 4A is a perspective view of a gear apparatus for a top
drive system according to the present invention.
[0032] FIG. 4B is a side view partially in cross-section of the
apparatus of FIG. 4A (along line 4B-4B of FIG. 4C).
[0033] FIG. 4C is a top of the apparatus of FIG. 4A.
[0034] FIG. 4D is a bottom view of the apparatus of FIG. 4A with
part in cross-section (along line 4D-4D of FIG. 4B).
[0035] FIG. 4E is an enlargement of part of the apparatus of FIG.
4B.
[0036] Presently preferred embodiments of the invention are shown
in the above-identified figures and described in detail below.
Various aspects and embodiments of the invention are described
below are some are set out in the dependent claims. Any combination
of aspects and/or features described below or shown in the
dependent claims can be used except where such aspects and/or
features are mutually exclusive. It should be understood that the
appended drawings and description herein are of preferred
embodiments and are not intended to limit the invention or the
appended claims. On the contrary, the intention is to cover all
modifications, equivalents and alternatives falling within the
spirit and scope of the invention as defined by the appended
claims. In showing and describing the preferred embodiments, like
or identical reference numerals are used to identify common or
similar elements. The figures are not necessarily to scale and
certain features and certain views of the figures may be shown
exaggerated in scale or in schematic in the interest of clarity and
conciseness.
[0037] As used herein and throughout all the various portions (and
headings) of this patent, the terms "invention", "present
invention" and variations thereof mean one or more embodiment, and
are not intended to mean the claimed invention of any particular
appended claim(s) or all of the appended claims. Accordingly, the
subject or topic of each such reference is not automatically or
necessarily part of, or required by, any particular claim(s) merely
because of such reference.
DETAILED DESCRIPTION OF THE INVENTION
[0038] FIGS. 1A-1D illustrate a top drive system 10 according to
the present invention which has a plurality of components
including: a gooseneck 11, a bonnet 12, brakes 13, a motor 14, a
gear system 15, a drive shaft 16, a bearing system 17, a swivel
body 18, a pipe handler lock assembly 19, a link support 22, a
swivel ring 23 and a load (or landing) collar 29. The components
can be collectively suspended in a typical derrick from a typical
traveling block for up and down movement in the derrick.
[0039] During certain operations, the motor 14 within a housing 14a
rotates the drive shaft which, in turn, rotates a drillstring and a
drill bit to produce an earth bore. Fluid pumped into the top drive
system through the gooseneck 11 passes through the drive shaft 16,
a drillstring, and a drill bit and enters the bottom of an earth
bore.
[0040] In certain aspects, the motor housing 14a (e.g. made of
sheet metal or aluminum) includes a series of tie rods 14b which
are secured to a top member 14c and a bottom member 14d to
strengthen the housing 14a. In certain particular aspects the
housing 14a is made of metal such as aluminum or steel. In one
particular aspect the motor 14 is a motor as disclosed in U.S. Pat.
No. 7,188,686. In another particular aspect the motor 14 (as may be
any motor herein) is a salient pole permanent magnet motor.
[0041] The gear system 15 is located above a bearing retainer 21
which serves to maintain the drive shaft 16 in place (radially and
axially) e.g. during drilling, and houses an upper race of a thrust
bearing system 16b. As shown in FIG. 1D, the bearing retainer is a
separate item secured to and below the housing of the gear system
15. 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 flange 16a of the drive shaft 16 moves on bearings
16c.
[0042] An encoder/resolver 24 (see FIG. 1D) measures the position
and speed of the motor 14 and provides a signal indicative of the
position of the drive shaft 16. With certain salient pole motors,
the encoder/resolver 24 can 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 shaft
16 (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.
[0043] The top drive system 10 has a motor control system 20 (shown
schematically, FIG. 1A) which, in certain aspects, includes an
output reactor 20a (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 inductor 20a is
eliminated since the high inductance motor applies a sufficient
amount of inductance.
[0044] FIG. 2A-2D shows a top drive system 30 according to the
present invention which, in some aspects, is like the system 10,
FIG. 1A (and like numerals indicate like parts). A motor 14m (like
any of the motors 14) is above a gear system 25 (instead of the
gear system 15) has a housing 14h.
[0045] Parts of the housing 14h including sides 14s, top 14t, and
bottom 14v following assembly are not connected together by tie
rods (as are housing parts in the top drive of FIG. 1A). In one
aspect the housing 14h is made of steel and is sufficiently strong
so that a portion of it is threaded to threadedly connect the
bonnet 12 thereto. 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.
[0046] A lower portion 48 of a gear housing 46 serves as a bearing
retainer to retain bearing 44. FIGS. 2A-2D are exploded views or
views that show parts not assembled together. When assembled, the
bearing 44 is within a bearing retainer 48. The bearing retainer, a
lower portion 48 of the housing 46 is releasably secured to the
housing 46, e.g. with bolts.
[0047] FIG. 3 shows a top drive system 50 (partially exploded view)
according to the present invention. A motor 60 has a brake system
54 and an output shaft 56. The output shaft 56 is connected to a
gear system 100. The gear system 100 driven by the motor 60, drives
a main drive shaft 70. Bearings 58 (thrust bearings) are retained
in place by a bearing retainer 80 which is bolted to or integral
with the gear system 100. An attachment frame 90 (a "swivel body")
provides for the connection of a torque track for conducting torque
from the system to the torque track. The swivel body 90 is,
typically, suspended from a block in the derrick by bails.
[0048] FIGS. 4A-4D show the gear system 100 of the top drive system
50. A housing 102 has a motor mounting surface 104 on which the
motor is positioned. A part 107 is releasably secured to the
housing with bolts 107b. Gear reducer system 110 within the housing
102 includes a gear reducer 111 and a bearing 116. The gear reducer
system 110 includes a first stage carrier 112; a second stage sun
pinion 113; a second stage carrier 114; and a bearing cartridge
115. The cartridge 115 with the bearing 117 is held in place by
bolts 115b. Removing the bolts 107b and the bolts 115b permits
removal of the cartridge 115 for bearing replacement, in one
aspect, with a single bearing 117.
[0049] There are three first stage planetary gears (not shown). The
gear box has a bottom surface 130 (see FIG. 4D). A temperature
gauge 134 can be inserted in a tapped thread portion 132. A tip of
the gauge sits in the oil flow path and dynamically measures the
temperature of the oil flow.
[0050] A lower portion 120 part 107 of the of the housing 102
serves as a bearing retainer to retain in place the bearing 44. An
inline flow meter 121 which measures oil flow to the housing has an
oil inlet port 122. Magnetic plugs 123 are positioned in holes 124
to attract and hold metal shavings and debris. An air breather 125
is in communication with the interior of the housing 120.
[0051] As shown in FIGS. 4B and 4E, the cartridge 115 has a part
115b which is adjacent a part 115a. The part 115a includes an upper
part 115g and a side 115f. The part 115b is encompassed within
structure of the part 115b (upper part 115g and side 115f) and a
top surface 107a of the part 107. The part 115a rests on a top
surface 107b of the part 107 and against a side 107c of the part
107. In one aspect, the top surface 107a is lower than top surface
107b.
[0052] Due to the tolerances between the part 115b and the part
115a some slight movement is possible of the part 115b with respect
to the part 115a. An interface between the parts 115b and 115a is
sealed by one or more seals--two o-ring seals 115c are shown in
corresponding recesses 115d in the part 115b. These seals are
sized, configured, and positioned to accommodate the movement of
the part 115b with respect to the part 115a.
[0053] The bearing 117 is held in place by a holder 114c bolted to
the second stage carrier 114 and rests partially on a ledge 115e of
the part 115b and under a shoulder 114d of the carrier 114. The
bearing 117 can move radially (and/or axially) the extent that the
part 115b can move radially (and/or axially), thus permitting the
bearing 117 when it is movable radially to "float" horizontally.
This inhibits interference in the horizontal plane between the
bearing 117 and the bearing 44 (which can cause excessive bearing
wear and premature failure). The bearing 117 does not float so much
that the second state carrier moves too far axially, i.e., so far
that splines 114s on the second stage carrier 114 would not
properly mesh with corresponding splines on the main shaft of the
motor.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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. .sctn. 102 and satisfies the
conditions for patentability in .sctn. 102. The invention claimed
herein is not obvious in accordance with 35 U.S.C. .sctn. 103 and
satisfies the conditions for patentability in .sctn. 103. This
specification is in accordance with the requirements of 35 U.S.C.
.sctn. 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.
What follows are some of the claims for some of the embodiments and
aspects of the present invention, but these claims are not
necessarily meant to be a complete listing of nor exhaustive of
every possible aspect and embodiment of the invention. In the
claims, means-plus-function clauses are intended to cover the
structures described herein as performing the recited function and
not only structural equivalents, but also equivalent structures.
Thus, although a nail and a screw may not be structural equivalents
in that a nail employs a cylindrical surface to secure wooden parts
together, whereas a screw employs a helical surface, in the
environment of fastening wooden parts, a nail and a screw may be
equivalent structures. It is the express intention of the applicant
not to invoke 35 U.S.C. .sctn. 112, paragraph 6 for any limitations
of any of the claims herein, except for those in which the claim
expressly uses the words `means for` together with an associated
function.
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