Top drive washpipe system

Abstract

A top drive system for wellbore operations, the top drive system, in at least certain aspects, including a motor, a main shaft driven by the motor, the main shaft having a top end and a bottom end, a speed reduction system interconnected with the main shaft, a washpipe shaft interconnected with the speed reduction system for driving the washpipe shaft at a speed of rotation less than a speed of rotation of the main shaft. 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.P.R. 1.72(b).

1 . A top drive system for wellbore operations, the top drive system comprising
 a main shaft with a main shaft channel therethrough,   drive apparatus for rotating the main shaft at a main shaft speed,   a speed reducer apparatus connected to the main shaft,   a washpipe shaft connected to the speed reducer apparatus so that the washpipe shaft is rotatable by the speed reducer apparatus at a washpipe shaft speed less than the main shaft speed,   the washpipe shaft having a top end and a bottom end, and a washpipe shaft channel therethrough,   a washpipe having a washpipe channel therethrough, the washpipe shaft channel in fluid communication with the washpipe channel,   the washpipe shaft channel in fluid communication with the main shaft channel,   a first seal holder connected to the washpipe and holding first seal assemblies for sealing against the top end of the washpipe shaft, and   a second seal holder connected to the main shaft and holding second seal assemblies for sealing against the second end of the washpipe.   
   
   
       2 . The top drive system of  claim 1  wherein the speed reducer apparatus reduces the washpipe shaft speed to at least 25% less than the main shaft speed. 
   
   
       3 . The top drive system of  claim 1  wherein the speed reducer apparatus reduces the washpipe shaft speed to about 50% of the main shaft speed. 
   
   
       4 . The top drive system of  claim 1  wherein
 the speed reducer apparatus is a gear system including first gear apparatus connected to the main shaft and second gear apparatus connected to the washpipe shaft,   the first gear apparatus for driving the second gear apparatus.   
   
   
       5 . The top drive system of  claim 4  wherein
 the first gear apparatus includes a first gear,   the second gear apparatus includes a plurality of second gears, and   the first gear drives the plurality of second gears to rotate the washpipe shaft.   
   
   
       6 . The top drive system of  claim 1  further comprising
 the speed reducer apparatus having a ring housing, and   a torque arrester connected to the ring housing and to the washpipe.   
   
   
       7 . The top drive system of  claim 6  wherein the torque arrester is connected to the first seal holder which is connected to the washpipe. 
   
   
       8 . The top drive system of  claim 1  wherein the drive apparatus includes a top drive motor and a top drive gear system driven by the top drive motor. 
   
   
       9 . A top drive system for wellbore operations, the top drive system comprising
 a main shaft with a main shaft channel therethrough,   drive apparatus for rotating the main shaft at a main shaft speed,   a speed reducer apparatus connected to the main shaft,   a washpipe shaft connected to the speed reducer apparatus so that the washpipe shaft is rotatable by the speed reducer apparatus at a washpipe shaft speed less than the main shaft speed,   the washpipe shaft having a top end and a bottom end, and a washpipe shaft channel therethrough,   a washpipe having a washpipe channel therethrough, the washpipe shaft channel in fluid communication with the washpipe channel,   the washpipe shaft channel in fluid communication with the main shaft channel,   a first seal holder connected to the washpipe and holding first seal assemblies for sealing against the top end of the washpipe shaft,   a second seal holder connected to the main shaft and holding second seal assemblies for sealing against the second end of the washpipe,   the speed reducer apparatus reduces the washpipe shaft speed to about 50% of the main shaft speed,   the speed reducer apparatus is a gear system including first gear apparatus connected to the main shaft and second gear apparatus connected to the washpipe shaft,   the first gear apparatus for driving the second gear apparatus, and   the drive apparatus includes a top drive motor and a top drive gear system driven by the top drive motor.   
   
   
       10 . A method for dynamically sealing a drive shaft of a top drive system, the top drive system suitable for wellbore operations, the method comprising
 rotating a washpipe shaft of a top drive system,   sealing against a top end and a bottom end of the washpipe shaft, the washpipe shaft comprising part of the top drive system, the top drive system comprising a main shaft a with a main shaft channel therethrough, drive apparatus for rotating the main shaft at a main shaft speed, a speed reducer apparatus connected to the main shaft, a washpipe shaft connected to the speed reducer apparatus so that the washpipe shaft is rotatable by the speed reducer apparatus at a washpipe shaft speed less than the main shaft speed, the washpipe shaft having a top end and a bottom end, and a washpipe shaft channel therethrough, a washpipe having a washpipe channel therethrough, the washpipe shaft channel in fluid communication with the washpipe channel, the washpipe shaft channel in fluid communication with the main shaft channel, a first seal holder connected to the washpipe and holding first seal assemblies for dynamically sealing against the top end of the washpipe shaft, a second seal holder connected to the main shaft and holding second seal assemblies for dynamically sealing against the second end of the washpipe, and   rotating the washpipe shaft at a speed less than the speed of the main shaft.   
   
   
       11 . The method of  claim 10  wherein the washpipe shaft speed is at least 25% less than the main shaft speed. 
   
   
       12 . The method of  claim 10  wherein the washpipe shaft speed is about 50% of the main shaft speed. 
   
   
       13 . The method of  claim 10  wherein the speed reducer apparatus is a gear system including first gear apparatus connected to the main shaft and second gear apparatus connected to the washpipe shaft, and the first gear apparatus for driving the second gear apparatus, the method further comprising
 driving the second gear apparatus with the first gear apparatus.   
   
   
       14 . The method of  claim 5  wherein the first gear apparatus includes a first gear, the second gear apparatus includes a plurality of second gears, and the first gear is for driving the plurality of second gears to rotate the washpipe shaft, the method further comprising
 driving the plurality of second gears with the first gear to rotate the washpipe apparatus.   
   
   
       15 . The method of  claim 10  wherein the speed reducer apparatus has a ring housing, and a torque arrester connected to the ring housing and to the washpipe. 
   
   
       16 . The method of  claim 10  wherein the drive apparatus includes a top drive motor and a top drive gear system driven by the top drive motor, the method further comprising
 driving the top drive gear system with the top drive motor, and   driving the main shaft with the top drive gear system.   
   
   
       17 . A top drive shaft system comprising
 a main shaft with a main shaft channel therethrough,   drive apparatus for rotating the main shaft at a main shaft speed,   a speed reducer apparatus connected to the main shaft,   a washpipe shaft connected to the speed reducer so that the washpipe shaft is rotatable by the speed reducer apparatus at a washpipe shaft speed less than the main shaft speed,   the washpipe shaft having a top end and a bottom end, and a washpipe shaft channel therethrough,   a washpipe having a washpipe channel therethrough, the washpipe shaft channel in fluid communication with the washpipe channel, and   the washpipe shaft channel in fluid communication with the main shaft channel.   
   
   
       18 . The top drive system of  claim 17  further comprising
 a first seal holder connected to the washpipe and holding first seal assemblies for sealing against the top end of the washpipe shaft, and   a second seal holder connected to the main shaft and holding second seal assemblies for sealing against the second end of the washpipe.   
   
   
       19 . The top drive system of  claim 17  wherein the speed reducer apparatus reduces the washpipe shaft speed to at least 25% less than the main shaft speed. 
   
   
       20 . The top drive system of  claim 17  wherein the speed reducer apparatus reduces the washpipe shaft speed to about 50% of the main shaft speed. 
   
   
       21 . The top drive system of  claim 17  further comprising
 the speed reducer apparatus having a ring housing, and   a torque arrester connected to the ring housing and to the washpipe.   
   
   
       22 . A drive shaft system comprising
 a main shaft with a main shaft channel therethrough,   drive apparatus for rotating the main shaft at a main shaft speed,   a speed reducer apparatus connected to the main shaft,   a secondary shaft connected to the speed reducer apparatus so that the secondary shaft is rotatable by the speed reducer apparatus at a secondary shaft speed less than the main shaft speed,   the secondary shaft having a top end and a bottom end, and a secondary shaft channel therethrough,   a pipe having a pipe channel therethrough, the secondary shaft channel in fluid communication with the pipe channel,   the secondary shaft channel in fluid communication with the main shaft channel,   first sealing apparatus for sealingly contacting the secondary shaft for sealing a main-shaft secondary-shaft interface, and   second sealing apparatus for sealingly contacting a secondary-shaft-pipe interface.