Injector Fail-Safe Brake

11/28/22, 8:20 AM Injector Fail-Safe Brake | LunchBox Sessions
Back to Session Your Account
INJECTOR FAIL-SAFE BRAKE
Objectives
Let's take a closer look at an important component on a coiled tubing injector: the fail-safe
brake!
In this lesson we will explain the purpose and function of the injector fail-safe brake.
https://www.lunchboxsessions.com/materials/coiled-tubing-units/injector-fail-safe-brake-lesson?lbs-link=true 1/50
And we will describe the steps for checking the fail-safe brake.
What is it?
The fail-safe brake is a hydraulic brake used to mechanically prevent the injector motors
from turning.
This state is usually desired in one of two circumstances;

1. When the operator control lever is in neutral.
2. When the hydraulic system that drives the injector fails.
This hydraulic brake is referred to as a fail-safe device because the brake engages
automatically if the injector hydraulics fail.
Where is it?
Fail-Safe Brake Location

Usually the fail-safe brake is directly coupled to the hydraulic motor(s) that drives the
injector chains.
On some injector models the fail-safe brake will be coupled to the planetary gearbox on
the opposite side from the motor.
In either case, it will be located up high on the injector unit, and it will be in-line in some
way with the shaft or shafts that drive the upper head sprockets.
Hydraulic Hoses
The fail-safe brake typically only has one hydraulic hose connected.
This single hose will supply the pressurized fluid to release the brake, or bleed away fluid
when the brake is applied.
How Does it Work?
Plate
Disk
The fail-safe brake is a series of friction plate and disk pairs.
Splined Shaft
The disks are mounted to the splined shaft that runs through the center of the unit.
A Rod
The plates are prevented from rotating because they are loosely indexed to the case by a
rod.
When the brake is released, all of the disks and plates are allowed a small movement along
the shaft axis of the unit.
Spring
When the brake is applied, powerful springs on one end of the unit force all pairs of disks
and plates together.
Because the disks are on the shaft, and the plates are indexed to the case, the shaft is now
prevented from turning.
The brakes will release when pressurized fluid enters here...
Piston
...and forces this piston...
Primary Plate
Set Spring
...to push against this larger primary plate.
This in turn compresses the set springs allowing the stationary plates and disks to
separate, and the brake to release.
The brakes will engage when the fluid pressure is not adequate to move the piston, or
when the operator activates the brake.
The springs force all of the stationary plates and brake disks against each other, effectively
locking the injector motors.
Try It Out
Try it out! Release and engage the brake with the controls.
Be sure to note how spaces develop between the disks and the plates when the brake is
released.
Review
What is the purpose of injector fail-safe brakes?
To provide a positive mechanical motion lock when chain motion is desired.
To mechanically prevent the injector motors from turning.
Back to Session Submit Your Account
The fail-safe brake is
applied by springs and released by hydraulic pressure.
applied by hydraulic pressure and released by springs.
Back to Session Submit Your Account
Checking the Fail-Safe Brake Function
3
3
2 4 2 4
1 5
1 5
0 6
x100 PSI
0 6
x1000 PSI
Injector Brake
Release Pressure Injector Motor Pressure
Apply
In-Hole
Release
Injector
Emergency Brake
Max. Injector Pressure Adjust Out-Hole
With the injector stopped and the joystick in neutral, read the Injector Brake Release
Pressure gauge on the control panel.
It should read zero PSI.
3
3
2 4 2 4
1 5
1 5
0 6
x100 PSI
0 6
x1000 PSI
Injector Brake
Apply
In-Hole
Release
Injector
Emergency Brake
Move the joystick in either direction and increase the maximum injector pressure for the
chosen direction.
Injector brake release pressure should now rise to approximately 300 PSI for the mode
you've chosen.
Check the brake pressure gauge that is mounted directly on the injector.
This gauge should indicate the same reading as the brake pressure gauge in the control
cabin.
If the readings are not the same, check the quick couplers on the injector bulkhead to
ensure that they are correctly connected to each other.
Testing the Fail-Safe Brake
This process is used to make sure the fail-safe brakes are working correctly.
RELEASE APPLY
1. Ensure that the injector skates are backed off (tubing secured) and are not applying
traction to the tubing.
3
3
2 4 2 4
1 5
1 5
0 6
x100 PSI
0 6
x1000 PSI
Injector Brake
Apply
In-Hole
Release
Injector
Emergency Brake
2. Check the brake pressure gauge to make sure that the brake pressure is at zero.
Fail-Safe Brake Location
3. Now close the brake isolation valve on the injector.
3
3
2 4 2 4
1 5
1 5
0 6
x100 PSI
0 6
x1000 PSI
Injector Brake
Apply
In-Hole
Release
Injector
Emergency Brake
4. Move the joystick to about half way for either in-hole or out-hole motion.
Now dial up the Max Injector Pressure Adjust valve.
Both the Injector Motor Pressure and the injector brake release pressure should rise, but
the chains should not rotate.
If the chains remain stationary, this is an indication that the fail-safe brake is holding.
Caution - Do not exceed 3000 PSI in-hole or out-hole pressure for this test.
5. With this first test complete, return all controls to neutral. Open the isolation valve for
the brake.
Now repeat the test steps with the isolation valve open.
This time, when the injector brake release pressure gauge indicates a pressure reading, the
injector chains should rotate.
Final Review
The fail-safe brake is meant to prevent injector motor and chain movement when the
operator control lever is in neutral or in the event of a failure with the hydraulic system.
It is not intended to bring the injector to a stop during normal operation.

The fail-safe brake is spring applied and released by hydraulic pressure.

W E H O P E YO U E N J OY E D I N J EC TO R FA I L - SA F E B R A K E

Injector Fail-Safe Brake - LunchBox Sessions

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Injector Fail-Safe Brake - LunchBox Sessions

Uploaded by

Copyright:

Available Formats

11/28/22, 8:20 AM Injector Fail-Safe Brake | LunchBox Sessions

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

This state is usually desired in one of two circumstances;

1. When the operator control lever is in neutral.

2. When the hydraulic system that drives the injector fails.

Back to Session Your Account

Back to Session Your Account

Fail-Safe Brake Location

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

How Does it Work?

The fail-safe brake is a series of friction plate and disk pairs.

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

The brakes will release when pressurized fluid enters here...

Back to Session Your Account

...and forces this piston...

Back to Session Your Account

...to push against this larger primary plate.

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

What is the purpose of injector fail-safe brakes?

To provide a positive mechanical motion lock when chain motion is desired.

To mechanically prevent the injector motors from turning.

Back to Session Submit Your Account

Back to Session Your Account

The fail-safe brake is

applied by springs and released by hydraulic pressure.

applied by hydraulic pressure and released by springs.

Back to Session Submit Your Account

Back to Session Your Account

Checking the Fail-Safe Brake Function

Max. Injector Pressure Adjust Out-Hole

It should read zero PSI.

Back to Session Your Account

Max. Injector Pressure Adjust Out-Hole

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Back to Session Your Account

Testing the Fail-Safe Brake

Back to Session Your Account

Back to Session Your Account

Max. Injector Pressure Adjust Out-Hole

Back to Session Your Account

Fail-Safe Brake Location

3. Now close the brake isolation valve on the injector.