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Manual No.

165-55850-2

INSTRUCTION, OPERATION AND


SERVICE MANUAL
FOR
MODEL 2025A BRAKE CONTROL
WITH BATTERY BACK-UP

EQUIPMENT FURNISHED
BY

National Oilwell
500 INDUSTRIAL BLVD.
SUGAR LAND TEXAS 77478-2898
TELEPHONE: (281) 240-6111
FAX: (281) 240-0426

05/01
Rev. B
TABLE OF CONTENTS

Paragraph Page
SECTION 1
INTRODUCTION AND DESCRIPTION

1.1 SCOPE OF MANUAL 1-1


1.2 GENERAL DESCRIPTION 1-1

SECTION 2
DESCRIPTION OF OPERATION

2.1 THEORY OF OPERATION 2-1


2.2 DRILL FLOOR COMPONENTS 2-1
2.2.1 Driller's Control (Drawing 55858) 2-1
2.2.2 Rig Floor Selector Switch (Drawing 55860) 2-2
2.3 SAFE AREA COMPONENTS 2-3
2.3.1 SCR Power Converter Model 2025A
(Drawing 55850-2) 2-3
2.3.2 Auxiliary Printed Circuit Board 2-6
2.3.3 System Block Diagram 2-10
2.3.4 Intrinsic Safety 2-12

SECTION 3
SPECIFICATIONS
3.1 GENERAL 3-1
3.2 INPUT POWER REQUIREMENTS 3-1
3.2.1 Brake Power Controller Input AC 3-1
3.3 INPUT SIGNAL REQUIREMENTS 3-1
3.4 BRAKE CONTROLLER OUTPUT POWER 3-1

SECTION 4
INSTALLATION
4.1 GENERAL 4-1
4.2 HAZARDOUS AREA COMPONENTS 4-1
4.2.1 Driller's Control (Drawing #55858) 4-1
4.2.2 Rig Floor Selector Switch (Drawing #55860) 4-2

i
TABLE OF CONTENTS (Cont'd) Page
Paragraph

4.3 SAFE AREA COMPONENTS 4-2


4.3.1 General 4-2
4.3.2 Power Transformers 4-3
4.4 INITIAL SYSTEM POWER-UP 4-3
4.4.1 Test Equipment Required 4-3
4.4.2 Functional Test 4-3
4.5 HAZARDOUS AREA CONSIDERATIONS AND APPROVALS 4-7
4.5.1 General 4-7
4.5.2 Driller’s Control (Drawing #55858) 4-8
4.5.3 Rig Floor Selector Switch (Drawing #55860) 4-8
4.6 APPROVALS 4-8

SECTION 5
OPERATING INSTRUCTIONS

5.1 SCR POWER CONVERTER 5-1

SECTION 6
MAINTENANCE
6.1 BRAKE AND CONTROL 6-1

SECTION 7
PARTS AND SERVICE
7.1 GENERAL 7-1
7.2 PARTS AND SERVICE 7-1
7.3 RECOMMENDED SPARE PARTS 7-2
7.3.1 SCR Assembly – 25KW Model 55858 7-2
7.3.2 Miscellaneous 7-3

SECTION 8
DRAWINGS

ii
SECTION 1
INTRODUCTION AND DESCRIPTION

1.1 SCOPE OF MANUAL


This manual provides information pertaining to the
installation, operation and maintenance of the following
component parts of the Baylor Brake Control System:

• SCR Power Controller


• Intrinsic Safety Barrier
• Hazardous Area Components

The manual is divided into sections giving a narrative


description of the theory of operation, function of
controls, operating instructions, maintenance and service.
Also recommended spare parts and supplies are listed along
with schematics, block diagrams, and major assembly
drawings.

Operators are requested to read and thoroughly familiarize


themselves with this manual before attempting to operate the
equipment.

1.2 GENERAL DESCRIPTION


The Eddy Current Brake Control System (referred to in the
balance of this Manual as CONTROL SYSTEM), provides a
variable DC voltage and current input to an Eddy Current
Brake. Braking control is accomplished through the movement
of a single driller’s control handle. The movement of this
control handle increases or decreases the level of the
direct current excitation voltage input to the field coils
of the Eddy Current Brake. The system is designed to
operate any of the several BAYLOR Eddy Current Brakes, as
well as other systems having like voltage and current
requirements.

1-1
SECTION 2
DESCRIPTION OF OPERATION

2.1 THEORY OF OPERATION


The Baylor Brake Control System consist of a power conversion
circuit and a circuit that processes, shapes and compares the
driller’s control handle position input and the resulting
current supplied to the Brake. Since the handle position is
a function of the amount of braking effort the driller
desires, and the output current determines the amount of
Braking effort the Brake will supply, (within it’s rated
torque capability), the circuit continuously checks for any
discrepancies in the Brake Control System.

Due to the inductive nature of the eddy current brake, the


rise time of brake current as a result of an instantaneous
change in driller’s input, may vary from approximately 3
seconds to 6 seconds. This variance in output current rise
time is a function of the position of the Brake Control power
selector switch. In the “DRILL” position, approximately one
half of the maximum current is supplied by the Power
Controller. In the “TRIP” position maximum current is
supplied by the Power Controller. The electronic circuit
automatically modifies scale factors internally to match
system operation when the power selector switch is in the
“DRILL” position. The circuitry provides an adjustable
window comparator for determination of proper brake
controller operation.

2.2 DRILL FLOOR COMPONENTS


2.2.1 Driller's Control (Drawing 55858)
The Driller’s Control has been designed to give a maximum of
trouble free operation in the rugged drill floor
environment. It consists of a spring loaded handle which
rotates a cam. These are the only moving parts in the
Driller’s Control assembly. A sensor (P/N 6575-95-0011) is

2-1
2.2.1 Driller's Control (Cont’d)
positioned in the lower section of the assembly in such a
manner that the cam surface is approximately .020” from the
top surface of the sensors. As the cam is rotated, an
increasing air gap is created between the cam and the sensor
top. The sensor is able to measure this air gap change and
convert it into an electrical analog. The electrical analog
is a linear DC voltage that is directly proportional to the
handle movement of the Driller’s Control and thus the amount
of braking effort the Driller requires.

The sensor electrical signal is connected to the Brake


Control through zener type barriers to establish intrinsic
safety. In the Brake Control, the signal is connected to an
amplifier circuit on the Firing Circuit Board P/N 55854 and
produces two outputs. One of the amplified output signals is
used as a "BRAKING LEVEL REQUESTED" reference. The other
amplifier output signal becomes the input to the Firing
Circuit of the SCR Power Controller.

2.2.2 Rig Floor Selector Switch (Drawing 55860)


The Selector Switch divides the maximum braking capability
into tow ranges; “DRILL” and “TRIP”.

NOTE!

“TRIP” position provides more braking than


“DRILL” position.

2-2
2.3 SAFE AREA COMPONENTS
2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2)
The SCR Power Converter is a three-phase, full wave silicon
controlled rectifier bridge. It requires a nominal 240 volt
three-phase 60 Hz input from the secondary of a delta
connected transformer source. The transformer primary
voltage must be specified at the time of purchase to match
the rig power source. The power converter is an SCR Bridge
that requires properly timed gating or firing pulses. The
firing pulses are generated in a firing circuit (P/N 55854).

The Firing Circuit is connected to the SCR Power Controller


through multi-conductor plugs and a terminal strip. These
are listed as follows:
J1 - AC Current Input
J2 - DC Voltage Sensing
J3 - AC Voltage Sensing
J4 - External Metering and Reset
J5 - Activation of Throttle (2 Sets of Dry Contact)
J6 - Firing Ckt. PCB Alarms (2 Sets of Dry Contact)
J101 - SCR Firing for A Phase SCR Module
J201 - SCR Firing for B Phase SCR Module
J301 - SCR Firing for C Phase SCR Module
J-10 - Auxiliary Board Interconnection
FTB1-1 - Common
FTB1-2 - 33% Power Selection - N/A
FTB1-3 - 67% Power Selection - N/A
FTB1-4 - Driller's Control Signal Input
FTB1-5 - Drill/Trip Power Selection (+15V drill, OV- trip)
FTB1-6 - Open
FTB1-7 - -15 Vdc
FTB1-8 - +15 Vdc
FTB1-9 - Open
FTB1-10 - +15 Vdc

2-3
2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2) (Cont’d)
The Firing Circuit Board will come to the customer already
set-up and adjusted. A minor trim adjustment may be needed
to match the Driller's Control output with the Firing
Circuit Board. To make this trim adjustment, place the
Driller's Control Handle in the "OFF" or minimum output
position. Adjust the "ZERO" potentiometer until the Yellow
and Green L.E.D.’s associated with the Driller’s Control
input just light up. TP1 with respect to TP22 (COM) should
be 0.5 Vdc +/- 0.5 Vdc. Then with the Driller’s Control in
the “FULL ON” or maximum output position, adjust the “GAIN”
potentiometer until its associated L.E.D.’s just light up.
TP1 with respect to TP22 (COM) should be –8.00 Vdc +/- 0.5
Vdc. This will complete the trim adjustment.

The Model 2025A SCR Power Converter operates in a “CURRENT


REGULATED” mode. The Driller's Control actually commands an
output current rather than an output voltage, as in earlier
SCR Controls. The current regulated mode forces the current
to its commanded set point and then the voltage will maintain
the commanded brake current.

The Current Regulation mode of operation will, if unchecked,


force current through a Hot Brake, making it get even hotter
and thus accelerate the breakdown of coil insulation. This
is checked by a Brake Coil Kw limiting circuit (See schematic
Dwg. #56041 for proper setting). This circuit works to
insure that the brake never dissipates more energy than it's
coils can handle. This may result in the brake current being
less than the full rated current. Also, operating at maximum
rated Coil Kw for extended periods of time can cause
excessive heating if the Brake Rotor is turning less than 2
or 3 RPM’s. This happens when the Driller’s Control handle
is moved to “FULL ON” and left there for prolonged periods of
time to assist in drilling. There is additional circuitry

2-4
2.3.1 SCR Power Converter Model 2025 (Drawing 55850-2) (Cont’d)
which allows the Brake Control to operate in the “DRILL
ASSIST” mode. After approximately two minutes at full
current command, the maximum allowed power to the brake
coils will be slowly reduced from 100% to 50% over a period
of approximately 10 minutes. Note that 50% power to the
Brake still results in approximately 85% of full braking.

Full Current command is restored by simply returning the


Driller's Control handle to the "OFF" position and then back
"ON".

If a Brake Coil does fail and must be removed from the


circuit until time permits a repair or replacement, Switch S2
(Applies to only Brakes that have all of the coils connected
parallel, see Schematic Drawing 56041) allows for removal of
one or two coils. The remaining coils will be properly
current limited and controlled. The Brake should be
overhauled as soon as possible if a coil has failed.
OFF ON
4 Coils (Normal)S2-1 [ X ] [ ]
Operational S2-2 [ X ] [ ]

3 Coils Only S2-1 [ X ] [ ]


Operational S2-2 [ ] [ X ]

2 Coils Only S2-1 [ ] [ X ]


Operational S2-2 [ ] [ X ]

NOTE!

“OFF” is toggle to the left.

2-5
2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2)(Cont’d)
In summary, under normal conditions, the Control System would
respond as follows:
1. Driller's Control handle "FULL ON"
2. Input to the Firing Circuit PC Board Terminal FTB-1-1 to
FTB-1-4 should be approximately 0.5 Vdc at "FULL ON".
3. Gate pulses for power SCRs expanded fully into firing
zone giving maximum output.

The circuit approaches linearity, and linear output readings


can be expected. (i.e. Driller's Control 50% "ON" and gate
pulses expanded halfway into the firing zone giving 50%
output.)

2.3.2 Auxiliary Printed Circuit Board


The Auxiliary Printed Circuit Board attached to the door of
the cabinet, provides two functions. It provides circuits to
monitor and alarm under certain conditions and L.E.D.'s
arranged in a mimic panel to show the status of various parts
of the Brake Controller. (Reference Figure 2-1). The
monitored conditions are as follows:

The indicating L.E.D.'s will be Green in the Normal or


Non-Alarm Condition and will be Red in the Alarm Condition
except as noted.

1. “PHASE ROTATION”
The 240V, 3 Phase AC has the proper phase rotation
(ABC).

2. “DRILL/TRIP” Power Select Switch


The Drill Floor Power Selector Switch is in a reduced
range position. (L.E.D. is Yellow when in the “DRILL”
position.)

2-6
2.3.2 Auxiliary Printed Circuit Board (Cont’d)
3. “DRILL ASSIST”
L.E.D. indicates the SCR Bridge has “TIMED OUT” and gone
into the Drill Assist mode of operation. (L.E.D. is
Yellow when activated.)

4. “STANDBY CP” Normal


The 120V Single Phase AC Power provides backup power to
the monitor circuits but cannot provide DC power to the
Brake.

5. “MAIN CP” Normal


The 240V, 3 Phase AC power is available. This power
must be present in order for the SCR Bridge to provide
DC power to the Brake.

6. “POWER QUALITY”
The Input AC Power is satisfactory.

7. “THROTTLE SIGNAL MISMATCH”


The commanded current is below the acceptable window of
acceptability. This will turn the SCR to full “ON” and
provide contact closure to activate any backup brake
supply.

8. “OVERCURRENT”
L.E.D. indicates current to the Brake is under or over
the set limit.

9. “OVER KILOWATT”
L.E.D. indicates the Kilowatt output to the Brake is
under or over the set limit.

10. “SCR FAILURE”


The six (6) SCR’s in the Bridge are each monitored for
proper gating control.

2-7
2.3.2 Auxiliary Printed Circuit Board (Cont’d)
11. “DC CABLE GROUNDED”
L.E.D. indicates a ground condition on the (+) DC Power
conductor.
L.E.D. indicates a ground condition on the (-) DC Power
Conductor.

12. “AC PHASE GROUND”


One of the 3 phases of the AC input power is grounded.

13. “OPEN COIL FUSE”


L.E.D. indicates one or more of the fuses in F-1, F-2,
F-3 and F-4 has blown or is open.

14. “BATTERY BACKUP” (Optional)


Battery Backup is in use.

15. “BAR GRAPH DISPLAY”


Display of relative magnitude of commanded braking
current.

16. “BAR GRAPH DISPLAY”


Display of relative magnitude of commanded braking
current.

2-8
Figure 2-1 System Status and Mimic Display Panel

2-9
2.3.3 System Block Diagram
The System overall block diagram is shown in Figure 2-2. The
control signal paths are marked by arrows showing also the
direction of information flow.

The Driller's Control command signal is the input to the


firing board on TB1-4 with respect to TB1-1 (Common). This
will be a negative DC voltage. The signal is then scaled to
be +.0 Vdc to -7.5 Vdc representing a 0 to 80 Amps DC current
command with a 10% deadband at the start. With Switch S1 in
the "REVERSE" position, the voltage changes from Driller's
Control "OFF" to "FULL ON", even though the Driller’s Control
commanded voltage will be declining from its maximum to its
minimum. The current command is then processed through the
command reduction circuitry, where the signal is reduced to
50% of its input value, if the Drill Floor Power Selector is
in the "DRILL” position. This "CURRENT COMMAND" is the input
to the current regulating loop.

The current feedback is sensed from the AC current


transformers. The AC current signals are then rectified and
summed to create an analog signal that represents the DC
current flowing to the Brake. This signal is scaled 1 volt
for 10 Amps of DC current and is the feedback for the current
regulating loop.

The output of the loop is called the “CONTROL VOLTAGE” and


ranges from about –4 Vdc to about +7 Vdc. This produces an
output from the SCR Bridge that ranges from –240 Vdc to +310
Volts. This range allows the current excitation to the brake
to be changed as rapidly as possible to follow the current
command from the Driller’s Control.

2-10
2-11
2.3.4 Intrinsic Safety
The Zener type barriers used with the Brake Control are
energy limiting devices to limit the available energy to a
level that cannot ignite the hazardous atmospheres likely to
be present at the device being protected. Therefore the
circuits on the drill floor are classified as intrinsically
safe.

Device spacing is used to ensure that protected wiring is


segregated from non-protected wiring and from protected
wiring of different potential.

The panel layout and wiring is designed to comply with the


recommended practices set forth in the ISA RP 12.6
publication.

The assembly is designed to act as an interface between safe


area equipment and the equipment located in hazardous
locations.

2-12
SECTION 3
SPECIFICATIONS

3.1 GENERAL
The BAYLOR Brake Control is designed to meet the special
requirements of an offshore drilling rig service. The
material and workmanship will satisfy the service demands of
normal drilling operations. The System is rated for 50ºC
maximum ambient temperature. All drill floor control
circuits are designed to satisfy the requirements of
intrinsically safe classification as set forth in ISA-RP 12.6
and NEPA 493.

3.2 INPUT POWER REQUIREMENTS

3.2.1 Brake Power Controller Input AC


Input AC Power required: (Reference TABLE 3-1 Page 3-2.)
Note: See ABS Table 4/5.2 for proper cable sizing.

3.3 INPUT SIGNAL REQUIREMENTS


There are no external input signals required that are not
generated by Sensors and Transducers supplied with the Brake
Control.

3.4 BRAKE CONTROLLER OUTPUT POWER


DC voltage to the Brake is adjustable to match Brake
nameplate requirements. (Reference TABLE 3-2 Page 3-3.)

3-1
3-2
BRAKE COILS CURRENT COIL
BRAKE
DC PER PER CONNECTIONS
MODEL
VOLTS BRAKE COIL PARALLEL SER/PAR SERIES
15050 325 4 30.2 #
9650 310 4 19.9 #
7838 250 4 18.5 #
8350 258 4 20.2 #
7040 250 4 19.5 #
6032 250 4 20.8 #
5250 310 4 24.6 #
5032 250 4 23.3 #
3550 254 4 24.6 #
19RD130 310 2 22.7 #
9RD130 155 1 22.7 #
7RD150 90 2 20.7 #

3-3
SECTION 4
INSTALLATION

4.1 GENERAL
The Baylor Model 2025A Brake Control System has 2 components
mounted in the hazardous area and a Power Controller cabinet
mounted in the safe area.

All initial installation and startup should be performed by a


qualified technician.

All components mounted in the hazardous area are either


designed for use in such areas or protected by devices that
render them intrinsically safe.

CAUTION!

Interconnecting cables must be of size and type


to comply with standards and practices in effect.
Total cable inductance and capacitance must not
exceed values published by certifying groups for
intrinsic safety at voltages used.

4.2 HAZARDOUS AREA COMPONENTS

4.2.1 Driller's Control (Drawing #55858)


Install the Driller's Control so a downward movement of the
handle advances the control toward the “FULL ON” position.
The return spring will bring the handle back to the “OFF”
position when the driller releases the handle. This
arrangement seems most natural to drillers since it gives the
Control System the same direction and sense as the drawworks
mechanical friction brake lever.

4-1
4.2.2 Rig Floor Selector Switch (Drawing #55860)
The Rig Floor Selector Switch is designed to be mounted in
sight of and easily accessible by the Driller.

The enclosure is water-tight, and the device inside is


rendered intrinsically safe by means of a zener barrier in
the circuit. The zener barrier is located in the Brake
Control #55850-2 cabinet.

CAUTION!

Use caution while working on the Intrinsically


Safe Circuits since shorting the cables may
destroy the Zener Barriers and render the System
inoperative.

4.3 SAFE AREA COMPONENTS

4.3.1 General
The Brake Controller Cabinet should be mounted in a space for
ease of maintenance and economy of cable runs.

The Controller can be mounted in any convenient non-hazardous


location. Usual practice is to mount the Controller System
at the nearest convenient safe location to the drill floor,
since this minimizes cable inductance and capacitance
considerations in the intrinsically safe wiring, and may
allow shorter runs for less cable expense.

NOTE!

After completion of initial installation of the


System, Proceed to Section 6 of this manual and
make measurements required to establish a record
for this Brake and Monitor System.

4-2
4.3.2 Power Transformers
The Power Transformers provided are to be wired in a 3 phase
delta-delta bank to feed the SCR Brake Power Controller. Mount
the transformers in any convenient location using the mounting
hardware on the transformer. Once the installation is
accomplished, frequent access to the transformers should not be
required.

4.4 INITIAL SYSTEM POWER-UP


After all system components are properly installed and all
cables are connected using wiring information supplied in
this manual, proceed as follows to confirm that all
components and circuits are within acceptable tolerances.
These tests are intended as a basis for acceptance in terms
of operational performance as measured at selected test
points.

4.4.1 Test Equipment Required


1. Digital Multimeter with: 0-300 Volt, 0-20 Volt and 0-1
Amp range
2. Ammeter: 0-100 Amp range
3. Ohmmeter or continuity meter
4. Oscilloscope
5. Two (2) Decade Resistance boxes

4.4.2 Functional Test


Functionally test the system by proceeding through the
following steps:
Step 1 - Verify that all connectors are plugged into the Firing
Circuit PC Board and that all input wiring is connected
to FTB1 and to the terminals located on the right side
panel.
Step 2 - Verify and/or set the circuit board switches as
follows:
S1 - Normal
*S2-1 (Upper) - To the Left (OFF)
*S2-2 (Lower) - To the Left (OFF)
S3 - Volts

4-3
4.4.2 Functional Test (Cont’d)

Note: *Switch S2 is provided so that in the event of one or


two coils failing and needing to be disconnected from
the Brake Control, the Brake Control does not try to
apply full excitation to the remaining coils. Switch
the bottom half of S2 to the “ON” position. The power
applied to the Brake Coils should be reduced to
approximately 3/4 of full power. This position must be
used if one coil is disconnected. Switch the top half
of S2 to the “ON” position (leaving the lower half
“ON”) and the power applied to the Brake Coils should
be reduced to approximately 1/2 of full power. This
position must be used if two coils are disconnected.
This also allows the testing of the Control Circuit at
reduced power levels.

Step 3 - Insure that the Circuit Board fuse F-1 is a 1/2 Amp
Slo-Blo type fuse. (Part #6525-25-0211).

WARNING!

THE FUSE CLIP WILL BE AT SUPPLY VOLTAGE WHENEVER


THE MAIN ISOLATOR CIRCUIT BREAKER IS TURNED “ON”.
TURN “OFF” ALL POWER BEFORE INSERTING OR
REMOVING.

Step 4 - Turn on the main circuit breaker that supplies 240


Volts 3 Phase AC to the SCR Brake Control. Measure the
power supply output at TP6 (Test Point 6) with respect
to common TP22. The voltage to common TP22. The
voltage should be +15.00 +.15 Volts dc.
Record reading TP6 _________ Vdc

4-4
4.4.2 Functional Test (Cont’d)
Step 5 - Driller’s Control Test
Place the Power Selector Switch on the “TRIP” or “MAX”
position. Confirm that the Driller’s Control is
working by measuring a varying voltage at FTB1-4 with
respect to FTB1-1. This voltage should vary from “OFF”
equal to –11 + .5 Vdc to -.5 + .2 Vdc at full “ON” with
switch S1 in the “REVERSE” position. To optimize the
control move the Driller’s Control to “OFF” and adjust
R5 until the associated Green and Yellow L.E.D.’s both
just toggle off and on. Next move the Driller’s
Control to full “ON” and adjust R6 until the associated
Green and Yellow L.E.D.’s both just toggle off and on.
There is some interaction between these adjustments so
the above may need to be repeated several times.

Record: Control “OFF” ___________ Vdc

Control Full “ON” ___________ Vdc

Step 6 - Change Switch S3 on the Firing Circuit Board to


“CURRENT”. Slowly increase the Driller’s Control while
measuring the DC output voltage at the input to the
Eddy Current Brake. At maximum Driller’s Control
movement, the meter indication should be 250 + 5 volts
DC. Connect the oscilloscope at the same place and
view the rectified wave shapes of the DC output as the
Driller’s Control is slowly increased. The
oscilloscope trace should be uniform and its level of
magnitude should change smoothly as the voltage
increases. Measure the voltage at TP24 with respect to
TP22. It should be proportional to the DC output
voltage in the ratio of 1.0 Volt to 32.4 Volts. Measure
the voltage at TP28 with respect to TP22. It should
remain at 0.0 + 0.2 Vdc as the output voltage goes from
minimum to maximum signifying there are no DC Cable or
Brake Coil grounds. Check the voltage at TP21 with

4-5
4.4.2 Functional Test (Cont’d)
respect to TP22. It is related to the DC current being
supplied to the brake and is scaled as 1/0 Volt per
10.0 amps DC.

Step 7 - Move the Drill Floor Power Selector Switch to the


“DRILL” position and check that the maximum Driller’s
Control input produces approximately 50% of the current
measured in the previous step.

Record TP21 to TP22 for


“DRILL” Position __________ Vdc ________ Adc
“TRIP” Position __________ Vdc ________ Adc

With the Drill Floor Power Selector Switch in the


“TRIP” position hold the Driller’s Control full “ON”.
After approximately 2 minutes the Yellow “DRILL ASSIST”
L.E.D. on the mimic panel will turn on and the DC
voltage to the Brake will start to ramp down.

After approximately 10 minutes the voltage will level


off at approximately 50% of the maximum or starting
value. Releasing the Driller’s Control handle will
return it to zero or the “OFF” position. This will
reset the Ramp Circuit and the next time the Control is
moved to maximum the output will also go to maximum.

Step 8 - To check an “OVER KILOWATT” indication, you must


simulate the condition by temporarily connecting a
decade resistance box, set to 250K ohms of resistance,
between TP30 and TP31 on the Firing Circuit Board.
Slowly increase the current using the Driller’s Control
and verify that the “OVER POWER” L.E.D. on the Firing
Circuit Board and “OVER KILOWATT” L.E.D. on the Mimic
Panel turns “ON” (Red). This simulates an abnormally
high kilowatt requirement (approximately 125% of
normal). Disconnect the Decade Box and push the reset
button on the Firing Board. The “OVER KILOWATT” L.E.D.
should reset to Green.
4-6
4.4.2 Functional Test (Cont’d)
Step 9 - To check an “OVER CURRENT” limit condition, you must
simulate the condition by temporarily connecting a
decade resistance box between TP21 and TP32 which are
both located on the Firing Circuit Board. Set the
decade box to 20K ohms of resistance. Slowly increase
the Driller’s Control. When the Firing Circuit “OVER
CURRENT” L.E.D. turns Red, the current limit (150% of
normal current) has been reached. Disconnect the
Decade Resistance Box and push the reset button on the
Firing Circuit Board. The “OVER CURRENT” L.E.D. should
reset to Green.

Step 10 - To test the Alarm Relay (if used), connect a jumper


between TP22 and J10-27 and check for continuity
between J6-1 and J6-4. Remove the jumper and the Alarm
Relay should release.

An “OVER KILOWATT”, “OVER CURRENT” or any of a number


of alarms generated by the Auxiliary Board/Mimic can
energize the Alarm Relay. The Relay provides a
normally open set of contacts that may be connected to
an external alarm panel or recording system.

Step 11 - The system should be in operating condition. A final


check of the Mimic Panel to see that all of the
indicator L.E.D.s are Green will confirm that the
system is operational.

4.5 HAZARDOUS AREA CONSIDERATIONS AND APPROVALS


4.5.1 General
Brake Control System components intended for
installation in hazardous areas are rendered
intrinsically safe by virtue of being connected to the
safe area portion of the System through approved zener
barriers which are physically located in the Intrinsic
Safety Barrier Assembly. Interconnecting cables must
be of size and type to comply with regulations,

4-7
4.5.1 General (Cont’d)
standards and practices in effect for the particular
installation. Total cable inductance and capacitance
must not exceed values published by certifying groups
for intrinsic safety at voltages used.

Caution should be used while working on equipment, as


shorting of interconnect cables could destroy zener
barrier devices and render portions of the system
inoperative.

4.5.2 Driller’s Control (Drawing #55858)


The Baylor Driller’s Control is rendered intrinsically
safe by means of operating through a zener type barrier
installed in the SCR Assembly (Drawing #55850-2).

4.5.3 Rig Floor Selector Switch (Drawing #55860)


The Rig Floor Selector Switch is rendered intrinsically
safe by means of operating through a zener type barrier
installed in the SCR Assembly (Drawing #55850-2).

4.6 APPROVALS
• Factory Mutual OV2HO.AX
• Underwriters Laboratories E152169
• Canadian Standards Association LR 77661-3
• PTB Certificate of Conformity NR.EX-83/2053X

(See the following pages)

4-8
SECTION 5
OPERATING INSTRUCTIONS

5.1 SCR POWER CONVERTER


The Eddy Current Brake, controlled by this Control System,
provides an actual braking effect controlled as required,
rather than a speed regulation which is limited to a certain
preselected degree of braking effect.

The Power Selector allows the operator to select the proper


range of braking effect for his drilling conditions. The
Selector divides the Control System's maximum braking
capability into two ranges: "DRILL" and "TRIP".

The mechanical friction brake lever on most drawworks is


located at the driller's right hand. It is usually
convenient for the driller to transfer his left hand from the
drum clutch controls to the eddy current brake control since
these two controls are normally operated alternately during
tripping cycles.

The operator should have complete control, with his left


hand, of the braking effect from zero to fully applied, while
his right hand is on the mechanical friction brake lever.

As the Driller's Control is advanced toward "FULL ON", the


voltage excitation to the brake magnet coils increases toward
a maximum. The Control System thus provides the driller with
controlled braking that is easily varied during any rotation
of the drawworks. By modulating the Driller's Control, the
maximum safe controlled speed of descent of each stand of
pipe into the hole is assured.

5-1
5.1 SCR POWER CONVERTER (Cont’d)
In the "TRIP" position of the Selector Switch, a small
variation of the Driller's Control effects a large change in
descent speed. This control effect is reduced in the Drill
Selector Switch position. For instance, with a light load on
the drawworks, operating in the
“DRILL” Selector Switch
position, gives the operator better speed control.
For typical operation proceed as follows:
1. Select the desired Selector Switch position for
the drawworks load conditions.
2. Pick the pipe up off the slips and start the
downward travel into the hole with the Driller's
Control left slightly "ON" until the load
accelerates.
3. Keep the rate of descent under control by moving
the control handle in the "FULL ON" direction to
decrease pipe speed or if the descent speed is too
slow, by moving the control handle in the "OFF"
direction.

CAUTION!

Since the load conditions may vary the amount of


braking required, even during the downward travel
of one stand of pipe, it is normal for the
driller to advance the control handle toward
“FULL ON” and return it towards “OFF” position
several times during the downward descent of a
stand of drill pipe to maintain a uniform safe
speed of descent.

4. As the stand nears the end of its downward travel and


the elevator approaches the rotary table, advance the
Driller's Control toward "FULL ON" to decelerate the
pipe. The mechanical brake is then used to hold the
load under complete control until the slips are set.

5-2
5.1 SCR POWER CONVERTER (Cont’d)
By keeping the load under control with the BAYLOR Eddy
Current Brake Control System, the driller is able to go
into the hole with optimum safe speed and with minimum
wear of the mechanical friction brake system on the
drawworks.

5-3
SECTION 6
MAINTENANCE
6.1 BRAKE AND CONTROL
The Control System should not require any maintenance other
than a periodic inspection for loose terminals or broken or
damaged wires.

NOTE!

Any inspection or preventive maintenance other


than operational checks should be performed with
power removed.

For the BAYLOR Brake Control System, one set of resistance


measurements (Table 6.1), and the following operational
voltage checks should be made and recorded at time of
installation:

Power Input Phase A to B = (240 Vac)

Power Input Phase A to C = (240 Vac)

Power Input Phase B to C = (240 Vac)

Terminal TB10-1 to TB10-2 = (120 Vac)

With the Brake Power Selector Switch in each of the two


positions and the Driller's Control at "FULL ON", the DC
voltage to the Brake should be recorded:

“DRILL” Positions: ___________ Vdc


“TRIP” Positions: ___________ Vdc
Max Driller’s Control input
(FTB1-4 to FTB1-1): ___________ Vdc

6-1
6.1 BRAKE AND CONTROL (Cont’d)
Because the output DC voltage is a function of the AC input
voltage, some variance will be noted for AC voltages other
than 240 Vac.

The above listed measurements should be made on a periodic


basis and at any time abnormal Brake operation is suspected.
Any difference in the measurements will be clues to use in
the trouble shooting of the Control System.

6-2
BRAKE MODEL NUMBER:
BRAKE SERIAL NUMBER: START DATE:________________
NOTE: Measurements should be made at the brake junction box with the coil
leads disconnected from the terminals.
DATE COIL RESISTANCE RESISTANCE TO GRD. COMMENTS
(OHMS) (MEG. OHM)
F1-F2 F3-F4 F5-F6 F7-F8 F1 F4 F5 F8

TABLE 6.1

6-3
SECTION 7
PARTS AND SERVICE
7.1 GENERAL
The recommended spare parts and supplies for the Control
System are provided in the following tables.

7.2 PARTS AND SERVICE


Parts and service are available from the factory:

NATIONAL OILWELL
500 Industrial Blvd.
Sugar Land, Texas 77478-2898
Telephone: (281) 240-6111
Fax: (281) 274-0426

Or from the following Service Centers:

NATIONAL OILWELL - HITEC NATIONAL OILWELL - NORWAY AS


266 Auchmill Road Lagerveien 16,
Bucksburn, Aberdeen P.O. Box 8181
Scotland AB21 9NB N-4069 Stavanger
Norway
Telephone: 01147 51 818181
Telephone: 44 1224 714499
Telefax: 01147 51 800547
Fax: 44 1224 714599

GE KEPPLE ENERGY SERVICES PTE LTD


No.2, Pioneer Sector 3,
Jurong, Singapore 2262

Telephone: 65 551 9500


Telefax: 65 861 2054

7-1
7.2 Parts and Service (Cont’d)

INTERSEL ENGINEERING RIMES ELECTRO MECANICA, C.A.


SERVICES Av. Intercomunal
P.O. Box 18092 Ciudad Ojeda 4019
Jebel Ali Zuilia, Venezuela
Dubai, United Arab Emirates
Phone: 58.65.411.763
Telephone: 011-971 488 33 661 Fax: 58.65.413.261
Telefax: 011-971 488 33 662

7.3 RECOMMENDED SPARE PARTS

7.3.1 SCR Assembly - 25 KW, Model 58858

QUANTITY PART NUMBER DESCRIPTION


1 55854 Firing Circuit P.C. Board

1 55856-2 Auxiliary, P.C. Board

3 6500-13-0003 Semi Pak SCR Assembly

3 55988 Dv/Dt Network Assembly

1 6425-05-0152 Relay 2PDT, 10K ohm Coil

1 Box 6525-25-0208 Fuse, 25 Amp

1 Box 6525-25-0211 Fuse, 1/2 Amp (Firing


Ckt. P.C.B.)

7-2
7.3.1 SCR Assembly - 25 KW, Model 58858 (Cont’d)

QUANTITY PART NUMBER DESCRIPTION


1 Box 6525-25-0069 Fuse, 1/2 Amp (Auxiliary
P.C.B.)

1 6425-06-0004 Zener Barrier (CH)

10 6375-10-0058 Lamp, Pilot Light

7.3.2 Miscellaneous
QUANTITY PART NUMBER DESCRIPTION
1 6575-95-0011 Driller’s Control Sensor

1 6525-75-1052 Operator, 2 Position

1 6525-51-0002 Contact, Normally Close

7-3
SECTION 8
DRAWINGS

Description Drawing Number


Outline and Mounting, 2025 Brake Control System.............56280

Assembly, 2025A Brake Control.............................55850-2


Bill of Material ............................... B/M 55850-2

Assembly, Panel, Inside Back SCR Mounting ..................56018


Bill of Material ..................................B/M 56018

Assembly, Heatsink 2025.....................................56022


Bill of Material...................................B/M 56022

Assembly, Panel, Right Side 2025A...........................56024


Bill of Material...................................B/M 56024

Wiring Diagram..............................................56043

Cable Diagram, Brake Control................................55846

Interconnection System Diagram, 2025A.......................56353

Assembly, PCB SCR Firing....................................55854

Schematic, PCB SCR Firing 2025..............................56041

Assembly & Schematic, PCB Firing Auxiliary................55856-2

Outline & Mounting, 55858 Driller’s Control.................56165

8-1
DRAWINGS (Cont'd)
Description Drawing Number
Assembly, Model 55858 Driller’s Control.....................55858
Bill of Material...................................B/M 55858

Wiring Diagram, Driller’s Control ..........................55859

Outline & Mounting, Power Selector Switch...................56483

Assembly, Rig Floor Selector Switch.........................55860


Bill of Material...................................B/M 55860

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