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).

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.