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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 Varco
500 INDUSTRIAL BLVD. SUGAR LAND TEXAS 77478-2898 TELEPHONE: (281) 240-6111 FAX: (281) 274-0426

04/05 Rev. C

TABLE OF CONTENTS Paragraph SECTION 1 INTRODUCTION AND DESCRIPTION 1.1 1.2 SCOPE OF MANUAL GENERAL DESCRIPTION SECTION 2 DESCRIPTION OF OPERATION 2.1 2.2 THEORY OF OPERATION DRILL FLOOR COMPONENTS 2.2.1 2.2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 Driller's Control (Drawing 55858) Rig Floor Selector Switch (Drawing 55860) SCR Power Converter Model 2025A (Drawing 55850-2) Auxiliary Printed Circuit Board System Block Diagram Intrinsic Safety SECTION 3 SPECIFICATIONS 3.1 3.2 3.3 3.4 GENERAL INPUT POWER REQUIREMENTS 3.2.1 Brake Power Controller Input AC INPUT SIGNAL REQUIREMENTS BRAKE CONTROLLER OUTPUT POWER 3-1 3-1 3-1 3-1 3-1 2-3 2-7 2-11 2-13 2-1 2-1 2-1 2-2 2-3 1-1 1-1 Page

SAFE AREA COMPONENTS

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TABLE OF CONTENTS (Cont'd) Paragraph SECTION 4 INSTALLATION 4.1 4.2 GENERAL HAZARDOUS AREA COMPONENTS 4.2.1 4.2.2 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.4.3 4.5 4.5.1 4.5.2 4.5.3 4.6 Driller's Control (Drawing #55858) Rig Floor Selector Switch (Drawing #55860) General Power Transformers Test Equipment Required Installation Checkout Functional Test General Driller’s Control (Drawing #55858) Rig Floor Selector Switch (Drawing #55860)

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4-1 4-1 4-1 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-9 4-11 4-11 4-11 4-12 4-12 SECTION 5 OPERATING INSTRUCTIONS

SAFE AREA COMPONENTS

INITIAL SYSTEM POWER-UP

HAZARDOUS AREA CONSIDERATIONS AND APPROVALS

APPROVALS

5.1

SCR POWER CONVERTER SECTION 6 MAINTENANCE

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6.1

BRAKE AND CONTROL

6-1

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TABLE OF CONTENTS (Cont'd) Paragraph SECTION 7 PARTS AND SERVICE 7.1 7.2 7.3 GENERAL PARTS AND SERVICE RECOMMENDED SPARE PARTS 7.3.1 7.3.2 SCR Assembly – 25KW Model 55850-2 Miscellaneous SECTION 8 DRAWINGS

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7-1 7-1 7-2 7-2 7-2

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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.

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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 when in the Current mode, approximately one half of the maximum current is supplied by the Brake Controller and in the “TRIP” position maximum current is supplied by the Brake Controller. When in the Voltage mode and in the “DRILL” position, approximately one half of the maximum voltage is supplied by the Brake Controller and in the “TRIP” position, maximum voltage is supplied by the Brake 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 2.2.1 DRILL FLOOR COMPONENTS 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 positioned in the lower

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2.2.1

Driller's Control (Drawing 55858) (Cont’d) section of the assembly in such a manner that the cam surface is approximately 0.020” 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 Controller through zener type barriers to establish intrinsic safety. The handle is arranged in such a manner that the output voltage is at maximum when the Driller’s Control is in the spring-returned “OFF” position. As the handle is pulled on, the output voltage reduces. This is done in case of a sensor failure or the Driller’s Control cable has be cut/disconnected, the brake controller’s output will be full on going to the brake. The typical voltage levels are from approximately -9.0 Vdc (“OFF” position) to 0.0 Vdc (“FULL ON”).

2.2.2

Rig Floor Selector Switch (Drawing 55860) The Selector Switch divides the maximum braking capability into two ranges; “DRILL” and “TRIP”. “DRILL” is 50 percent of braking capability. When in the Current mode, it is 50 percent of the Brake’s maximum rated current. When in the voltage mode, it is 50 percent of the Brake’s maximum rated voltage. This selector switch is connected through a zener type barrier to establish an intrinsic safe circuit.

NOTE!
“TRIP” position provides more braking than “DRILL” position.

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2.3 2.3.1

SAFE AREA COMPONENTS 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 50/60 Hz input from the The transformer primary secondary of a delta connected transformer source.

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 J2 J3 J4 J5 J6 J101 J201 J301 J-10 FTB1-1 FTB1-2 FTB1-3 FTB1-4 FTB1-5 FTB1-6 FTB1-7 FTB1-8 FTB1-9 FTB1-10 AC Current Input DC Voltage Sensing AC Voltage Sensing External Metering and Reset Activation of Throttle (2 Sets of Dry Contact) Firing PCB General Alarm SCR (2 Sets of Dry Contact) SCR Firing for A Phase SCR Module SCR Firing for B Phase SCR Module SCR Firing for C Phase SCR Module Auxiliary Board Interconnection (Ribbon Cable) Common 33% Power Selection - N/A 67% Power Selection - N/A Driller's Control Signal Input 50% Power Selection (+15V drill, -15V trip) Open -15 Vdc +15 Vdc Open +15 Vdc

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2.3.1

SCR Power Converter Model 2025A (Drawing 55850-2) (Cont’d) The Firing Circuit P.C. Board will come to the customer already set-up and adjusted. A minor adjustment may be needed to match the Driller's Control output with the Firing Circuit Board. Perform the following set up instructions for the Firing Circuit P.C. Board: 1. Verify that all connectors are properly plugged in and TB1 fanning strip is connected to FTB1. 2. Verify and/or set the following switches on the Firing Circuit PCB. S1 S2 - REV position. - to the LEFT (OFF). NOTE: See Schematic (DWG. #56041) for full explanation of this switch’s function. S3 S5 - VOLT position. - to the LEFT (OFF). Both switches for 315 Vdc max. - to the RIGHT (ON) Both switches for 250 Vdc max position. This switch is to match the information on the Eddy Current Brake nameplate in the box indicated “Input Volts”. S6 S7 - to the LEFT (OFF). All three switches. - Select switch position based on Eddy Current Brake model. The correct position for this switch is indicated on Drawing 56041, Sheet 5 of 6 in Section 8 of this manual. S8 - Select switch position based on Eddy Current Brake model. The correct position for this switch is indicated on Drawing 56041, Sheet 4 of 6 in Section 8 of this manual.

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2.3.1 SCR Power Converter Model 2025 (Cont’d) 3. Adjust the “ZERO” and “SPAN” Potentiometer. A. With the Driller’s Control in the OFF position, adjust R6 for +0.45 Vdc at TP29 with respect to TP22 (GND). B. With the Driller’s Control “FULL ON”, adjust R5 for –8.00 Vdc +/-0.50 Vdc at TP29 with respect to TP22 (GND). 4. Set up is now complete.

The 2025 SCR Power Converter operates in either “VOLTAGE” or “CURRENT REGULATED” modes. The “VOLTAGE” mode allows the voltage to rise to the commanded set point, based on the brake’s maximum rated voltage. Switch S5 selects the brake’s voltage to the brake’s maximum rated voltage. The “CURRENT” mode allows the voltage to rise to as much as 310 Vdc to force the current to the brake’s maximum rated current and then the voltage decays to a level to maintain the commanded brake current. The Voltage/Current modes 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 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. 2-5

2.3.1

SCR Power Converter Model 2025A (Drawing 55850-2) (Cont’d) 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 4 Coils (Normal) S2-1 Operational 3 Coils Only Operational 2 Coils Only Operational S2-2 S2-1 S2-2 S2-1 S2-2 [X] [X] [X] [ ] [ ] [ ] ON [ ] [ ] [ ] [X] [X] [X]

NOTE!

“OFF” is toggle to the left.

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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 SCR’s 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.)

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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.

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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.

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Figure 2-1 System Status and Mimic Display Panel 2-10

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.

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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 nonprotected 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.

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SECTION 3 SPECIFICATIONS 3.1 GENERAL The Brake Controller 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 in a NEMA Type 4 (IP42 rating) enclosure. 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 3.2.1 INPUT POWER REQUIREMENTS Brake Power Controller Input AC Input AC Power required: (Reference TABLE 3-1.) Note: See ABS Table 4/5.2 for proper cable sizing. 3.3 INPUT SIGNAL REQUIREMENTS There is 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.)

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TABLE 3-1 Supply Voltage, Circuit Breaker and Cable Size for Brakes

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BRAKE MODEL 15050 9650 7838 8350 7040 6032 5250 5032 3550 19RD130 9RD130 7RD150

BRAKE DC VOLTS 325 310 250 258 250 250 310 250 254 310 155 90

COILS PER BRAKE 4 4 4 4 4 4 4 4 4 2 1 2

CURRENT PER COIL 30.2 19.9 18.5 20.2 19.5 20.8 24.6 23.3 24.6 22.7 22.7 20.7 TABLE 3-2 #

COIL CONNECTIONS PARALLEL # # # # # # # # # # # SER/PAR SERIES

DC Voltage and Current for Brakes

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SECTION 4 INSTALLATION 4.1 GENERAL The 2025A Brake Controller System has two components mounted in the hazardous area and a Brake Controller enclosure 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 4.2.1

HAZARDOUS AREA COMPONENTS 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. The Rig Floor Selector Switch is designed to be mounted in sight of and easily accessible by the Driller.

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4.2.2

Rig Floor Selector Switch (Drawing #55860) 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 Controller #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 4.3.1

SAFE AREA COMPONENTS 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.

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4.3.2

Power Transformer The Power Transformer provided is to be wired in a 3 phase delta-delta bank to feed the SCR Brake Power Controller. Mount the transformer in any convenient location. Once the installation is accomplished, frequent access to the transformer 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 Installation Checkout 4.4.2.1 "No Power" Checks For the Model 2025 control system, the following resistance measurements should be made and recorded at the time of installation, without any power applied to the unit. Use a VOM or digital meter for the measurements. (Not a megger!)

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4.4.2.1 "No Power" Checks (Cont’d) Measuring Point Transformer Pri A Phase Transformer Pri B Phase Transformer Pri C Phase Transformer Sec A Phase Transformer Sec B Phase Transformer Sec C Phase Brake + DC leads Brake - DC leads Firing board TB1-4 Firing board TB1-1 Resistance to Ground __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ Expected Value Inf. Inf. Inf. 3.3K 3.3K 3.3K 500K 500K 30K 0 Ohms

4.4.2.2 "Powered" Checks (No current commanded) Before energizing the control, check that the power supply jumpers on the firing board are correct for the supplied voltage (240 Vac or 120 Vac). Upon energizing the control, there should be some L.E.D.'s turned "ON" in the top left corner of the firing board. If they are not, then turn "OFF" the control and investigate power integrity. All measurements are made with respect to TP22, electronics common, which should also be connected to ground. Proceed with the following power checks as measured with a VOM or digital meter:

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4.4.2.2 "Powered" Checks (No current commanded) (Cont’d) POWERED STATIC MEASUREMENTS Measuring Point TP6 - Electronics +15 Measured Value to TP22 __________ Expected Value +15±.15 Vdc

TP7 - Electronics -15

__________

-15±.15 Vdc

240 Vac A Phase 240 Vac B Phase

__________ __________

135 Vac 135 Vac

240 Vac C Phase

__________

135 Vac

TP2 (A Phase scaled) TP3 (B Phase scaled) TP4 (C Phase scaled) TP14 (Vin) TP8 - Cb firing ramp TP9 - Bc firing ramp TP10 - Ba firing ramp TP11 - Ab firing ramp

__________ __________ __________ __________ __________ __________ __________ __________ 4-5

3.20 Vac 3.20 Vac 3.20 Vac 9.50 Vdc approx 5 Vac approx 5 Vac approx 5 Vac approx 5 Vac

4.4.2.2 "Powered" Checks (No current commanded) (Cont’d) TP12 - Ca firing ramp TP13 - Ac firing ramp Firing Board TB1-4 __________ __________ __________ approx 5 Vac approx 4 Vac approx -9 Vdc

4.4.2.3 "Powered" Checks - Current commanded Make sure the controls are calibrated as indicated in Section 2.3.1 and then the following checks can be made as the control is varied from full "OFF" to full "ON". Please note these reading are based upon a nominal full output, and with no power reduction ("TRIP" mode): Measured Point Firing Board TB1-4 TP1 - Current Command TP29 - DC Signal TP5 - Control Voltage TP15 - A Phase Current TP16 - B Phase Current TP17 - C Phase Current TP21 - Current Feedback Measured Variance Variance -9.00 to -0.50 Vdc +0.45 to -8.00 Vdc +0.45 to -8.00 Vdc -5.00 to +5.00 Vdc 0 to 2.50 Vac 0 to 2.50 Vac 0 to 2.50 Vac 0 to 8.00 Vdc Expected

_____ to _____ _____ to _____ _____ to _____ _____ to _____ _____ to _____ _____ to _____ _____ to _____ _____ to _____

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4.4.2.3 "Powered" Checks - Current commanded (Cont’d) TP24 - Vout TP23 - Coil KW 4.4.2.4 "Auxiliary Board" Checkout One of the main functions of the Auxiliary board is to monitor the circuit operation of the rest of the controls. _____ to _____ _____ to _____ 0 to 7.5 Vdc 0 to 6.0 Vdc

4.4.2.4.1 Overall If the Auxiliary Board is operating correctly, the L.E.D. side of the Auxiliary Board will have all L.E.D.'s showing in Green. There are 2 L.E.D.’s that should not be "ON" at this time. They are identified as No. 2 and 3 in Figure 2-1. They are single color (Yellow) L.E.D.’s. They will turn "ON" as their function is activated. If any of the bicolor L.E.D.'s (identified as being frosted Grey or White) are not turned "ON" at all, the board is defective. Replace with the spare board. 4.4.2.4.2 Control Power If either of the control power L.E.D.'s are Red, verify proper operation of the plus and minus 15 volt power supplies. Make sure the fuse on the PC board is good. 4.4.2.4.3 Input Quality If the input voltage drops too low or loses a phase this L.E.D. will turn from Green to Red. If so, check TP14 - Vin for about 2.40 Vdc for an input of 240 Vac. An excessive amount of AC ripple would indicate a possible phase loss. Determine which by measuring TP's 2, 3, 4 looking for any irregularity. 4.4.2.4.4 AC Ground If any of the input voltages are reduced as the result of a ground, the respective L.E.D. turns from Green to Red. Measure test points 2, 3, 4 to make sure and then measure the phase voltages A, B, and C to insure there is a ground. Then turn off power and clear the ground. Note that disconnecting R1, R2, and R3 4-7

4.4.2.4.4 AC Ground (Cont’d) from ground inside the 2040 SCR enclosure and disconnecting J3 from the firing board should result in the input terminals being almost infinite resistance above ground. 4.4.2.4.5 SCR Misfiring This alarm works by comparing the current going through the individual SCR's to the average carried by all of the SCR's. Once set, the alarm turns the L.E.D. from Green to Red and stays that way until it again sees the proper level of current in the SCR's. 4.4.2.4.6 Coil Fuse This bicolor L.E.D. turns Red by unplugging J5 on the Auxiliary PCB. 4.4.2.4.7 Over Kilowatt This L.E.D. turns Red by the sensing of the electronics of 125% of brake coil allowed KW for a period exceeding a 20 second time interval. It is intended to signal the failure of the overall control signal. Resetting can be done with the door mounted or firing board mounted, reset switch. If the L.E.D. continually turns RED, replace the firing board. 4.4.2.4.8 Overcurrent This L.E.D. turns Red when the electronics senses a current level 150% that of normal, for a period of about 25 milliseconds. Such will usually result if an SCR shorts, a brake coil shorts, an input transient suppressor shorts, or two input power phases are grounded inside the rectifier cubicle. 4.4.2.4.9 Throttle Mismatch This L.E.D. turns Red when the electronics senses the brake control is putting out less than one half the current it should be putting out at that moment. This activates a relay that is used to enable the Battery Back Up unit, if one is installed. It will in any event, activate the alarm relay.

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4.4.2.4.10 Power Select and Drill Assist Power Select L.E.D. will turn "ON", Yellow, when the brake control is in a reduced "power selected" mode. When the driller selects "DRILL", this L.E.D. will turn "ON". The Drill Assist L.E.D. will turn "ON" Yellow after a period of approximately 2 minutes. 4.4.2.4.11 Battery Back Up This L.E.D. will turn Red when J4 on the Auxiliary PCB is unplugged. 4.4.3 Functional Test 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 should be +15.00 (+/-0.15 Vdc). Record reading TP6 Vdc

Place the Power Selector Switch on the "TRIP" 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 -9 (+/-1.0 Vdc) to -.50 (+/0.5 Vdc) at full "ON" with switch S1 in the "REVERSE" position. Record: Control "OFF" Control "FULL ON" Vdc Vdc

Change Switch S3 on the Firing Circuit Board to "VOLT". 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 320 + 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 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

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4.4.3 Functional Test (Cont’d) 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 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. 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. "DRILL" Position "TRIP" Position Vdc Vdc Adc 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. 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. 4-10

4.4.3 Functional Test (Cont’d) To check an "OVER CURRENT" limit condition, you must simulate the condition by temporarily connecting a decade resistance box between TP21 and TP32 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. to Green. The system should be in operating condition. A final check of the Mimic Panel to see that all of the L.E.D.’s are Green will confirm that the system is operational. 4.5 4.5.1 HAZARDOUS AREA CONSIDERATIONS AND APPROVALS 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, 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). Disconnect the Decade Resistance Box and push the reset button on the Firing Circuit Board. The "OVER CURRENT" L.E.D. should reset

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

(See the following pages)

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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 pre-selected 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.

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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. 2. Select the desired Selector Switch position for the drawworks load conditions. 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.

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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.

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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 Power Input Phase A to C Power Input Phase B to C Terminal TB10-1 to TB10-2 = = = = (240 Vac) (240 Vac) (240 Vac) (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: “TRIP” Positions: (FTB1-4 to FTB1-1): ___________ Vdc ___________ Vdc ___________ Vdc

Max Driller’s Control input

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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.

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

TABLE 6.1

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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 VARCO 500 Industrial Blvd. Sugar Land, Texas 77478-2898 Telephone: (281) 240-6111 Fax: (281) 274-0426 Factory Sales and Services personnel may also be directly contacted at the following e-mail address: Baylorsales-service@nov.com Factory Engineering personnel may also be directly contacted at the following e-mail address: Baylorengr@nov.com For a list of worldwide National Oilwell Varco locations and Service Centers go to www.nov.com and click “Contact Us”

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7.3

RECOMMENDED SPARE PARTS

7.3.1 SCR Assembly - 25 KW, Model 55850-2 QUANTITY 1 1 3 3 1 8 2 2 1 10 PART NUMBER 55854 55856-2 6500-13-0003 55988 6425-05-0152 6525-25-0208 6525-25-0211 6525-25-0205 6425-06-0004 6375-10-0058 DESCRIPTION Firing Circuit P.C. Board Auxiliary, P.C. Board Semi Pak SCR Assembly Dv/Dt Network Assembly Relay, 2PDT, 1.0K ohm Coil Fuse, 25 Amp Fuse, 1/2 Amp (Firing Ckt. P.C.B.) Fuse, 750ma Amp (Auxiliary P.C.B.) Zener Barrier (CH) Lamp, Pilot Light

7.3.2 Miscellaneous QUANTITY 1 1 1 PART NUMBER 6575-95-0011 6525-75-1052 6525-51-0002 DESCRIPTION Driller’s Control Sensor Operator, 2 Position Contact, Normally Close

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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 Schematic, PCB SCR Firing 2025........................................................................... 56041 Schematic, PCB Firing Auxiliary........................................................................... 55856-2 Outline & Mounting, 55858 Driller’s Control ............................................................ 56165

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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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