Integrated casing drive

An integrated casing drive system comprising:

• a top drive having a rotary drive portion and a top drive frame,
• a stator mounted to said top drive frame and a rotor rotationally mounted to the stator,
• a pipe handler having a gripper wherein said pipe handler is mounted to said rotor,
• at least one lock including a casing drive selectively actuable to lock said rotary drive portion to said pipe handler,
• whereby, in a casing-drive mode, a tubular such as a casing tubular, held in the gripper is rotated by rotation of said rotary drive portion of said drive system and wherein said at least one lock is selectively actuable to lock said rotor to said stator or to said top drive frame when in said normal operating mode, and wherein said at least one lock is selectively actuable to lock said rotor to said rotary drive portion when in said casing-drive mode.

A top drive having an integrated casing drive, the top drive comprising:

• a top drive frame,
• a selectively driven drive system, supported by said top drive frame, having a rotationally driven rotary drive portion including a drill string engagement piece,
• a rotor rotationally mounted in cooperation with, for selective rotation when in a normal operating mode relative to, said top drive frame and said rotary drive portion, a pipe handler and corresponding gripper mounted on said rotor,
• a mode-shift mechanism cooperating with said drive system and said rotor, wherein said mode-shift mechanism selectively switches between said normal operating mode and a casing-drive mode wherein, in said casing drive mode, said rotor is fixed by said mode-shifting mechanism so as to be substantially in a fixed rotational position relative to, for rotation with, said rotary drive portion of said drive system,
• whereby, in said casing-drive mode, a tubular such as a casing tubular, held in the gripper is rotated by rotation of said rotary drive portion of said drive system,
• wherein said mode shift mechanism includes a selectively engageable casing drive lock engageable between said rotor and a spindle, shaft, quill, drive sprocket or bull gear of said rotary drive portion so as to lock rotation of said rotor relative to said rotary drive portion when said mode shift mechanism is in said casing-drive mode;
• and
• wherein said casing drive lock includes a shear beam load cell as a locking member thereof.

A top drive comprising:

• a frame,
• a rotary drive portion supported by the frame and rotatable relative to the frame about an axis, the rotary drive portion threaded to engage a drill string;
• a main drive coupled to drive rotation of the rotary drive portion;
• a rotor coupled to the frame for rotation about the axis;
• a pipe handler comprising a gripper suspended from the rotor;
• a locking member carried by the rotor, the locking member selectively operable to:
• couple the rotor to the rotary drive portion or another member driven by the main drive such that the main drive is coupled to drive the rotor and pipe handler to rotate about the axis;
• or
• uncouple the rotor from the rotary drive portion or the other member such that the main drive can be operated to turn the rotary drive portion while the rotor and pipe handler do not rotate about the axis;
• wherein the locking member comprises a shear beam load cell.

A top drive comprising:

• a frame,
• a rotary drive portion supported by the frame and rotatable relative to the frame about an axis, the rotary drive portion comprising a main shaft and a main sprocket or bull gear attached to the main shaft;
• a main drive comprising one or more drive motors operable to drive the rotary drive portion by way of the main sprocket or bull gear;
• a rotor coupled to the frame for rotation about the axis;
• a gripper supported by the rotor;
• a locking mechanism carried by the rotor, the locking mechanism selectively operable to:
• couple the rotor to the main sprocket or bull gear such that the main motor is coupled to drive the rotor and gripper to rotate about the axis or
• uncouple the rotor from the main sprocket or bull gear such that the main motor can be operated to turn the rotary drive portion while the rotor and gripper do not rotate about the axis;
• and
• a pipe handler rotate motor separate from the main drive, the pipe handler rotate motor coupled to drive rotation of the rotor by a mechanism that permits the pipe handler rotate motor to be decoupled from the rotor when the locking mechanism is operated to couple the rotor to the main sprocket or bull gear;
• wherein the locking mechanism comprises pins engageable between the main sprocket or bull gear and the rotor.

A top drive comprising:

• a frame,
• a rotary drive portion supported by the frame and rotatable relative to the frame about an axis, the rotary drive portion comprising a main shaft and a main sprocket or bull gear attached to the main shaft;
• a main drive comprising one or more drive motors operable to drive the rotary drive portion by way of the main sprocket or bull gear;
• a rotor coupled to the frame for rotation about the axis;
• a gripper supported by the rotor;
• a locking mechanism carried by the rotor, the locking mechanism selectively operable to:
• couple the rotor to the main sprocket or bull gear such that the main motor is coupled to drive the rotor and gripper to rotate about the axis or
• uncouple the rotor from the main sprocket or bull gear such that the main motor can be operated to turn the rotary drive portion while the rotor and gripper do not rotate about the axis;
• and
• a pipe handler rotate motor separate from the main drive, the pipe handler rotate motor coupled to drive rotation of the rotor, and a brake operable to brake the pipe handler rotate motor;
• wherein the locking mechanism comprises pins engageable between the main sprocket or bull gear and the rotor.

A top drive comprising:

• a frame,
• a rotary drive portion supported by the frame and rotatable relative to the frame about an axis, the rotary drive portion comprising a main shaft and a main sprocket or bull gear attached to the main shaft;
• a main drive comprising one or more drive motors operable to drive the rotary drive portion by way of the main sprocket or bull gear;
• a rotor coupled to the frame for rotation about the axis;
• a gripper supported by the rotor;
• a locking mechanism carried by the rotor, the locking mechanism selectively operable to:
• couple the rotor to the main sprocket or bull gear such that the main motor is coupled to drive the rotor and gripper to rotate about the axis or
• uncouple the rotor from the main sprocket or bull gear such that the main motor can be operated to turn the rotary drive portion while the rotor and gripper do not rotate about the axis;
• and
• a pipe handler rotate motor separate from the main drive, the pipe handler rotate motor coupled to drive rotation of the rotor relative to the top drive frame, wherein the pipe handler rotate motor is connected to freewheel when the locking mechanism is operated to couple the rotor to the main sprocket or bull gear and the main sprocket or bull gear is rotated;
• wherein the locking mechanism comprises pins engageable between the main sprocket or bull gear and the rotor.