‘Manual No. 165-57820 it f, NATIONAL OILWELL INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS FOR BAYLOR EDDY CURRENT BRAKE, MODEL 7838 W/ REV. JUNCTION BOX EQUIPMENT FURNISHED National Oilwell 500 INDUSTRIAL BLVD. SUGAR LAND TEXAS 77478-2898, TELEPHONE: (281) 240-6111 FAX: (281) 240-0426 % NOLLOAS n mm 0 d 3 Zz o n m 9 a ° Zz bAYLO: ‘TABLE OF CONTENTS PARAGRAPH PAGE SECTION t INTRODUCTION 11 Scope Of Manual 14 12 General Description of Equipment 1 SECTION 2 wo SPECIFICATIONS m QO 2.1 Summary of Specifications, 7838 Brake 21 a 5 Z SECTION 3 N INSTALLATION 3.1 General 3el : 3.2 Brake Alignment 3-8 wn 3.3 Shaft Alignment 38 m 3.4 Cooling Water Quality 3410 0 3.5 Cooling System ‘Capacity Calculation 3-12 —a 3.6 Brake Field Coil Polarity 3-15 3 3.7 Certification for Hazardous Location 3-22 Zz SECTION 4 & ‘TREORY OF OPERATION ‘ 41 General 4-1 42 Brake Operation on Rig 4-2 . 2 SECTION 5 ‘ACCESSORIES AND OPTIONS 5.1 General 5-1 5.1.1 Brake Controller 5-1 §.1.2 Special Brake Shaft 5-1 5.1.3 Brake Cooling Packages 51AYLOR ‘TABLE OF CO! Paragraph General 5.14 Cooling Water Alarm 3.13. Safety Monitoring Devices 5-2 o 5.16 Parts and Service 5-2 nm ie) ad SECTION 6 Oo MAINTENANCE AND SERVICE z 6.1 — General Service 61 N 6.1.1 Lubrication 61 6.1.2 Breather 6-1 6.13. Air Gap 6-3 6.1.4 Overflow Outlet 6-4 wo Water Outlet Drain 6-5 m Preparation of Brake for Rig Stacking 6-6 0 Removing A Brake From Storage 67 4 62 Maintenance and Repairs 6-8 8 6.2.1 Water System Problems 6-8 6.2.2 Bearing Removable and Replacement 6-9 o 63 Electrical Problems and Troubleshooting 6-13 ‘ 6.4 — Mechanical Problems and Troubleshooting 6-14 6.5 Inspection and Maintenance 6-18 § 6.5.1 Daily Inspection 6-18 C 6.5.2 Weekly Inspection 619 - 6.5.3 Monthly Inspection 6-19 ¢ 6.5.4 Quarterly Inspection 6-20 3 SECTION 7 7 PARTS AND SUPPLIES 7.1 General TH SECTION 8 DRAWINGS 8.1 Drawings, 7838 Brake 8-1SAFETY FIRST! Before placing this equipment in operation, certain basic rules of safety should be observed. Tt should be noted that no safety rules and no amount of safety equipment will make operating this ‘equipment safe, unless the operator enforces the rules and proper uses of the equipment. MACHINE OPERATION 1. Only responsible persons, trained to do so, should operate this equipment, 2. Any person operating this equipment should be throughly familiar with the manufacturer’s recommended operating instructions 1. Periodic cleaning of the equipment may reveal potential mechanical trouble spots such as loose or missing bolts, fittings, etc. 2, Keep the area around the equipment clear of loose tools, trash, extraneous matter, etc. 3. Shut the equipment down before servicing or cleaning unless the service work requires the equipment be operating 4, Allow only an experienced mechanic to service the equipment. 5. Ifa mechanical problem or deficiency is found, correct or report it before continuing operation 6, Before working under or between components that are suspended by hoists or slings, securely block or erib.them, 7, When working in an area of potential head injury, wear an approved safety helmet. CAUTION! MANY PARTS ARE HEAVY OR DIFFICULT TO HANDLE. PLAN LIFTS AND MOVES CAREFULLY TO AVOID SEVERE. PERSONAL INJURY. PROVIDE SAFE SUPPORTS FOR DISASSEMBLED PARTS. iii1a 12 BAYLOF SECTION 1 INTRODUCTION AND DESCRIPTION SCOPE OF MANUAL This manual provides a source of important reference information regarding the installation, ‘operation, and maintenance of the BAYLOR COMPANY EDDY CURRENT BRAKES and should be given careful consideration and study before operating the BAYLOR BRAKE. It is impossible to anticipate every kind of problem or condition that may be encountered in the use of the brake, but compliance with the instructions and suggestions set forth in this, operating manual will assist the operator in successfully operating this equipment. Failure to operate and maintain the Brake in accordance with this operating manual may void the warranty covering this equipment, The information contained in this operating manual shall not in any way relieve the operator of the responsibility for exercising reasonable care and prudence in the operation of this equipment. WARNING! Failure to comply with the instructions in this operating manual could result in serious property damage, severe injury, or death! Any alteration or unauthorized repair work to the brake or control system will VOID ANY ‘WARRANTY expressed in the terms and conditions of sale, and will void HAZARDOUS AREA CERTIFICATION. All applicable schematics, flow diagrams, and major assembly drawings are contained in the last section ofthis manual ‘GENERAL DESCRIPTION OF EQUIPMENT The BAYLOR COMPANY Eddy Current Brakes are auxiliary braking devices for Drilling Rig Drawworks. This braking is produced entirely electrically without the aid of friction brake devices, slip rings, or other wearing elements. The brakes are water cooled. 11BAYEL OP Section 2 ‘Summary of Specifications Model 7838 Eddy Current Brake 24 Specifications Principal of operation Torque-Maximum. Induced Eddy Current Braking ~ 117,000 Ib-ft (158,631 n-m) Torque-At 50 RPM. 98,000 Ib-ft (130,159 n-m) Number of Magnets... 2 Number of Coils per Magnet : 2 Coil Internal Resistance @ 68° F (20° C) 13.4-13.9 Ohms Prior to July 1985, . 7 a 11.0-11.5 Ohms Total Brake Input Resistance @ 68°F (20°C) 3.9-4.1 Ohms Prior to July 1985 2.8-2.9 Ohms Brake Excitation’ Voltage ... Sate a os 250 Volts DC Current-Coil Temperature @ 68° F (20 °C) onsen See 74.07 Amps DC Power-Input @ 68° F (20° C) . Saat 18.5 kW Prior to July 1985 89.29 Amps/22.3 KW Cooling Water Requirements: Flow @ 100° F (38 Deg. C) At Brake Inle' pH a Maximum Discharge Temperature ... Cooling Water Piping: 180 gpm (568 Ipm) 70-75 165° F (74°C) UMC on (2) 2" NPT Outlet. (2) 4" NPT Overflow... (2) 4.114" NPT Overall Sizes: Height See — = sossecne 78 in (1,981 mm) Width... ee : scart 38 in (965 mm) Weight....... seesaae eee aes 28,000 Ib (12,701 kg) .. 37,938 Ib-ft? (15,987,118 kg-cm’) ae . 6458 Ib (2929 kg) snes, 7-500 intch Diameter with 1-1/4 Inch Taper per foot ‘mm Diameter with 32mm Taper per 305 mm) Oilfield Standard Average Rotor Radial Clearance (Air Gap) Inertia (WK)-Shaft and Rotor Weight-Shaft and Rotor Shaft Size. Over Magnets (Without Paint or Other BUIIdUP)...... ..0,055-0.065 in (1.397-1.651 mm) Maximum RPM. snes eee ae 600 24 aeBAYLOR Section 2 I q AUNCTION BOX: aan ~ COL CAVITY VENT TOP & BOTTOM OR MAY BOTTOM ONLY ON SOME (PICA, BOTH SES) | FIELD COILS (EACH SIDE veut ovERFLOW AR GAP INSPECTION HOLES (1) EACH SIDE (EACH SIDE Typical Construction Figure 2-1 22BAYLOR 3. SECTION 3 INSTALLATION GENERAL The BAYLOR BRAKE should be cradle mounted on the drawworks structure, The drawworks manufacturer fumishes the adapter mounting components as well as the disengaging coupling between the Brake and the drumshaft of the drawworks. The necessary shifting mechanism and related accessories should be furnished by the customer. CAUTION! Heat removal from the rotor in the BAYLOR Brake is accomplished by cooling water. The movement of the rotor through the water is necessary to keep the rotor and magnet from overheating. To avoid damage to the brake, use a coupling that allows rotation of the rotor in either direction at all times. DO NOT USE AN OVERRUNNING A standard mounting flange on the outboard bearing cap is provided by BAYLOR COMPANY for mounting water and/or air tube assemblies, The required tube assemblies are furnished by the drawworks manufacturer and should be installed in accordance with their instructions Electrical control wiring and cooling system water piping should be installed in accordance with the drawings contained in this section, A minimum of five-thread engagement should be ‘maintained on all threaded connections. Figure 3-1 illustrates a standard Brake cooling configuration, Figure 3-2 illustrates a typical closed loop cooling system which provides the greatest and best degree of protection against corrosion/erosion with adequate flow and atBAYLOR i 3.1 GENERAL (CONT'D) ‘temperature protection for the Baylor Brake. These closed loop systems are manufactured to provide proper cooling for the particular size Baylor Brake and can also be capacity sized to cool other portions of the drawworks drive. i Figure 3-3 shows the electrical connections for the magnet coils and power input to the J junction box. Caution! = ‘The water outlet(s) at the bottom of the brake should not be * hard piped or othe fed. This should be a free- - flowing, gravity drain, A funnel-type drain as indicated in figure 3-4 is preferred. Do not plug, pipe, connect hoses to,or otherwise obstruct the water overflow outlets, located on the brake just below the shaft centerline, These overflow outlets Provide a warning of improper water flow conditions. Removal of heat from the Brake is most important, Absence of proper cooling water flow could damage the rotor. Proper cooling water flow at all times will prolong Brake life for many years, As illustrated in Figure 3-4 the Baylor Eddy Current Brake allows cooling water to flow over the lower sections of the magnets and rotor before it exits at the bottom. If the cooling water outlets are restricted, the water level inside the Brake will increase to a level which could damage the Bearing grease seals and permit water to enter the bearing cavity with ultimate damage resulting to the bearings. 32: BAYLOR Caution! ‘The Baylor Company Eddy Current Brake is not designed to operate with the cooling water internal of the brake at other than atmospheric pressure, For proper brake operation insure that brake cooling water flows unrestricted through the brake with gravity discharge and unrestricted flow back to the cooling water reservoir. 33re aunts z + 1 Se ss vam Y aoe See goE a aD 2 L OL WL ® “W130 3YON YOd SOLWAIHOS WGISAS ONMOOD U3LVM DAVE "WNL @ tore 4 ‘SLNGNGWNDZY HSUMLIVSNNYN SHYOMMYEO JONSNOD 3S¥FId ® 7 L_ m)° om so1us34 10N 00 ® Toe om *SNOWONGD ® pane2y 3 HAD na 30d A= aang @ ‘HLM “O3MINOIY FUNSSBYd ONY C: 2] = ‘SNOUYOLO3ES © MRSS | ‘SURUALIVINNVA SHAOWHVHD OL ONIGYOIOW 13S - SNA 43a i" SHOLYDICEES WOE BLM OL OWORKAON zs - 2AM a © ih n2® SHOLYOUCEES MOU BLM OL ONGUOIDY VE - IAA 31ND @ Q “Shui oem SueND Cw 2a oe oF nS a Sa as Se ey Ges aa x Lac aac) “SZION iota fomeral aaa [arses] aa Tesi [rem [rea [sme [seem [reve [sm Tease Tema yl @ i) tent @ TAY vent ‘t/a | Sue | 7 ue Town 7 me | an 7 nia | a 7 nu Bam | wae | ne | wees | Bae | Bela nao [raa [rem [wae [eam | noe as osos) BERL 0s96 ‘OvOL ose: e009 OL1OY6L | OCLOH6 3-4z-¢ emnbra TW TH (sis MGA ONT LT a somomtti TL oe} oerptica / "apna€-€ eanota © + £ oe nL mbes [* ByM8 OstaBAYLOR i] / rt n—_ (a —\L | / evi WATER OUTLET —— = BACK PRESSURE 7 nnietring FUNNEL FIGURE 3-4 DRAIN 37: BAYLOR j i tn ts 3.2 BRAKE ALIGNMENT The Brake should be aligned to the drum shaft in keeping with good machinery practice and in accordance with the recommendations of the drawworks manufacturer NOTE: If the Brake is correctly aligned on the drawworks, the only loading on the bearings is the weight of the shaft and assembly since the magnetic attraction when the brake is { energized is radially equal in all directions. Improper alignment results in bearing wear and premature failure. je 3.3. SHAFT ALIGNMENT i 1, Angular misalignment and offset misalignment between directly-connected shafts often cause increased bearing loads and vibration, even when the connection is made 3 by means of flexible coupling. Shaft alignment is especially critical if the coupling is to be operated at high speed Le 2. Angular misalignment: Angular misalignment should not exceed 0.010 inch fi (0.0025mm) total indicator reading Refer to the illustration in Figure 3-5 LS 3. Offset Misalignment: Total indicator run out of offset misalignment should not r exceed 0.010 inch (0,0025mm) Refer to the illustration in Figure 3-6. f NOTE: When conditions make it impossible to check alignment with a dial indicator, a rough a check can be made with a straight edge and feeler gages. Check anguler misalignment by ‘ inserting feeler gages between the faces of the coupling hubs at four equi-distant points cae Check offset misalignment by placing a straight edge across the machined diameter of both { 7 coupling hubs. 38BAVL OF? 2 COUPLING HUBS, FIGURE 3-5 ANGULAR MISALIGNMENT ;DIAL INDICATOR _ i FIGURE 3-6 OFFSET MISALIGNMENT 3-9BAYLOR 34 COOLING WATER QUALITY 3.4.1 Scope 3.4.2 3.4.3 In order to function properly, the cooling water used in Baylor Eddy Current Brakes must meet four basic requirements. 1) Frmust adequately transfer heat energy from the rotor to the heat exchanger used for cooling, 2.) It must not form scale or sledge deposits in the Brake or in the cooling system 3.) It must not cause corrosion in the Brake or cooling system. 4) Temust not deteriorate any of the seals or gaskets used in the Brake or cooling system, These requirements are normally met by combining a suitably de-mineralized water with a reliable corrosion inhibitor. Under extreme operating conditions it may be necessary to use an antifreeze coolant. In this case the cooling liquid should be a mixture of the ethylene glycol type antifreeze, de- mineralized water, and an adequate corrosion inhibitor Water Quality Standards ‘The water used in Baylor Eddy Current Brakes should meet the following requirements. 1) No undissolved particles such as sand, grit, or silt. 2.) ApH level between 7.0 and 7.5 3.) A maximum dissolved chlorides content of 40 parts per million 4.) A maximum dissolved sulfates content of 100 parts per million. 5.) A total dissolved solids content of 340 parts per million. 6.) A total hardness of 170 pants per million. Water that does not meet these standards should be treated by softening, de- mineralization, or de-ionization before being used to cool the Brake Corrosion Inhibitor Baylor does not recommend the use of “home made” type inhibitors. The ready availabilty of suitable commercialproducts makes these “home made” formulations impractical and 3-10BAYLOR 3.4.3 Corrosion Inhibitor (Cont'd) unnecessary. The use of soluble oil type inhibitors is also not recommended due to the effect ; they have on ethylene glycol type antifreeze additives and the fact that they are detrimental 10 efficient heat transfer. Commercially available corrosion inhibitors are generally of three types; chromate based, } borate-nitrite based, and silicate-nitrite based. Of these, the chromate based and the borate nitrite based are the most common. It is important to note that there are environmental had restrictions on the disposal of these types of inhibitors due to the chromium and boron content. The silicate-nitrate inhibitor is basically non-polluting, Be sure and check with national, state, and local authorities before disposing of any water treated with inhibitors. Be a sure to follow the manufacturer's recommendations for applying the inhibitor, both for new be untreated water and for maintenance of already treated water. st Due to the successful use in Baylor Company Eddy Current Brakes, the following corrosion r inhibitor is recommended for use by Baylor: € PENCOOL 2000 (Previously Called Nalcool 2000) aoe The Penray Companies E 440 Denniston Court ae Wheeling, Illinois 60090 em It is recommended that this inhibitor be purchased through a local distributor so that proper field support in their use is readily available, USAGE OF ANTIFREEZE STANDARDS - Only ethylene glycol type antifieezes are to be used in Baylor Company Eddy Current Brakes due to the operating temperature generated k i [ ott (