430

Electric Auxiliary Brakes for Drawworks

Baylor manufactured its first electric brake more than 25 years ago and has been the auxiliary brake company ever since. Baylor Brakes have proven their performance on thousands of rigs all around the world allowing operators to drill deeper, faster and more safely, Designed to give the driller positive control over drill string speed, the Baylor Brake develops exceptionally high braking torque at both high and very low rotational speeds without friction devices of any kind. A free-spinning drum inside the brake is coupled directly to the drawworks shaft. When the driller operates the brake control, a magnetic field is produced by four electromagnetic coils mounted concentrically inside the drum. By changing the amount of current to these stationary coils, he controls the amount of braking torque applied to the rotating drum. Because the brake is deactivated by simply turning it off, no overrunning clutch is required. Baylor Brakes are manufactured in four standard sizes for nominal drilling depths up to 30,000 feet. Each consists of a steel drum attached directly to the drawworks shaft by a flexible coupling or disconnect clutch. The drum shaft rotates in two sets of oversized spherical roller bearings. And the brake is connected to the drawworks structure by adapter cradle mounts fun,.shed by the drawworks manufacturer, The maximum power requirement ranges from about 10 to 21 kw, which is easily supplied by standard AC light plants. All rig floor components are explosion-proof.

The 7838 Baylor Brake, the largest of the five standard models Baylor manufactures, has a rated nominal drilling depth capacity of 30,000 feet.

8400 IS'" Driller's Control The new 8400 IS driller's control simplifies operation and facilitates faster training of drillers, Because control operation is linear, the control position is matched to the amount of voltage applied to the coil (e.g., when the control is in the halfway position, half of the voltage is applied). Rig operation is safer and more efficient because the driller gets a better feel for the brake more quickly. The control is also intrinsically safe in any hazardous area.

The new 8400 IS driller's control gives the driller a much better feel for the braking power applied.

PWM - CL Brake Power Supply Baylor's new air-cooled brake power supply mounts off the rig floor where a controlled atmosphere and reduced vibration increase reliability, Passive, convection-flow cooling eliminates blowers and reduces maintenance to minor routine checkouts.

431

Baylor Brakes
The PWM-CL is self-protected from both high input voltages and accidental short circuits in the output. Separate outputs for each magnet allow continued brake operation despite a dead short in one circuit. The PWM-CL power supply with a battery-powered backup and the driller's control are fully compatible with all Baylor Brakes currently in use.

TM

Battery-Power Backup Model PWM-CL brake power supplies are equipped with battery connections and internal circuitry to accommodate backup power for uninterrupted emergency brake operation in the event of AC power failure. The size of the battery pack (supplied by customer) depends upon the brake's rated capacity and the contractor's needs.

Brake Cooling System The fresh water required to cool the brake should be low in mineral content, sufficient in quantity and low enough in temperature to dissipate the heat adequately.

Savior's PWM-CL air-cooled controls require minimal preventive maintenance.

Principles of Operation

Electrical control and brake cooling systems

AC

Magnetic lines of force Airgap

PWM brake control supply Transformer Driller's CO itrol

C 1[? Drawworks

Coils

Magnets Baylor Brake

Rotor sea|

Q
r

IE

Y
rn

f\\
HI
N

Rotor

Relief valve

r-rn
| |

Centrifugal pump

Fresh water 5ply

tfii Baylor s jpplied components

7838 Brake ( 30,000ft)

7040 Brake ( 20.000ft)

6032 Brake (~ 15,000 ffl

5032 Brake ( 12,000ft)

432

Baylor Brake Torque Curves and Specifications

TKO 6032 Broke

50

100

150

200

250

300

50

Draw works shaft speed] rpm]

100 150 200 Drawworks shall speed(rpm)

250

300

50

100 150 200 Drawworks shaft speed (rpm)

250

300

7838 Brake

7040 Brake

6032 Brake

I
50 100 150 200 Drawworks shaft speed (rpm] 250 300

5032 Brake

B-

___________5032 Brake

6032 Broke 55,500

7040 Brake

7838 Brake

Maximum torque (ft-lbs,KNm) Nominal drilling depth (ft, m)* Nominal power requirements (kw) Cooling water requirements

39,000

52.9

75.3 84,000

113.9117,000 158.6

12,000 3658

15,0004572 20,000 609630,000 9144

18

21

(gpm, l/min) Weight (Ibs, kg)

Dimension A (in, mm) Dimension B (in, mm)

50

190

75

285

140

530

150

570

9,0004082 50 1 270 42 1067

12,000 5443 24,00010886 28,00012701 60 1524 71 1803 78 1 981 45 1143

57 1 448

57 1448

"Based on a drill pipe weight of 20 Ibs/ft (29.76 kg/m). The number of lines strung, drum

diameter and other variables can offset rated capacities.

433

Boylor Brakes
Baylor Brake Performance Curves
Baylor Brakes operate according to the performance curves below, based on the following conditions: the brake is in good condition; it is adequately cooled; and the second wrap of wireline is over Lebus grooving. These curves are calculated according to common drum and wireline sizes with applicable friction factors. Other curves based on specific customer applications are available on request.

3000

1000

2000

Fast line speed (fpm)

100 200 300 400

Fast line speed (fpm) 200 300

Block speed (fpml

Block speed [fpm)

21" dia drum, 1V wireline

2000

2000

3000

Fast line speed (fpm)

100 200 300 400

Fast line speed (fpm)

200 , ,
f

300

Block speed (fpm)

Block speed (tpm)

434

Hydro-Torque
Hydraulic Auxiliary Braking Systems
Baylor now offers two hydraulic auxiliary braking systems designed to economically govern drawworks speed on drilling or workover/well-servicing rigsthe Hydro-Torque 2200 and the new Hydro-Torque 1500. With the Hydro-Torque 2200 producing 12,000 ft-lbs of torque at 700 rpm and the Hydro-Torque 1500 producing 6,000 ft-lbs at 1400 rpm, both models provide more torque than any comparable system. They also weigh less and are narrower than competitive units although their mountings are directly interchangeable* Designed with the latest state-of-the-art turbine research, the Hydro-Torque brakes are much simpler in design and contain only 14 component parts, greatly simplifying field service. Both models can be assembled in less than an hour, and shaft location and rotation direction can be reversed in the field without any additional parts. The major rotary sealing surfaces use a double-lip seal, and the lubrication systems assist in sealing the bearing assemblies. Like other Baylor auxiliary brakes, the Hydro-Torque brakes slow the drill string without friction devices of any kind. Instead of belts, slip rings, brake pads or bands, braking torque is produced by water circulated between the vaned pockets of the impeller and the facing vaned pockets of a stationary member. The brakes can be used with either an overrunning clutch or an air-purging system for tripping out of the hole.
"An adapter plate is provided when interchanging the Hydro-Torque 1500 with the Parmac 15" D.R.
Water supply valve
(at driller's console)

This Hydro-Torque 2200 is being installed on a rig working in Oklahoma.

Pilot valve (t driller's console)

I, Boytor supplied

components

Support/Control Systems

Hydro-Torque Model
Torque (ft-lbs, KNm)
6,000 400 18.25

1500 8.135 181.44 463.55

2200
12,000 16.270 (at 700 RPM)

(at 1400 RPM)

Mox Speed1500 Rf

Weight (Ibs, kg) Dimension A (in, mm)

Dimension B* (in, mm)

850
25.75 22.62

385.56
654.05 574.55

20

508.00

50

100

200

300

500

700

1000

1500 2000

3000

40 50

100

200

300

500

700

1000

Brake shaft speed (rpm]

Brake shaft speed [ipm)

"Shafts other than the one shown are provided to customer specification.

435

Thyrig Systems

A typical SCR, the heart of every Baylor Thyrig system.

1000-hp DC motors

Baylor driller's control

Mud system

Efficient SCR Rig Power

The pioneer in the use of silicon-based electronics for efficiently converting AC power into the speedcontrollable DC power required by drilling rigs, Baylor introduced the first SCR system to the oilfield 15 years ago. And that first Thyrig SCR system is still operating in the hostile environment of Alaska's Upper Cook's Inlet, Today's new generation of Thyrig SCRs can be found in operation on every type of rig in every part of the world. In planning a rig's configuration, Baylor assists the contractor in taking advantage of every cost-cutting measure and in sizing the SCR for optimum rig performance. This attention to detail and care in the design of SCR-powered rigs can provide the contractor fuel savings of 18 to 48 percent over similarly rated mechanical rigs.1 Rigs equipped with a Baylor SCR cost less to operate: Fewer engines are on line at any one time. Auxiliary engines, including the light plant, are eliminated. Fast, linear rotary speed/torque control eliminates overshoot.
'Hunt, Stephen G., "Obtaining maximum efficiency with SCR rig
power," World Oil, May 1981, pp. 164-167.

Rigs equipped with a Baylor SCR make hole faster: Fast throttle response speeds trip times, Torque limiters protect the drill string and other valuable equipment. All drilling functions including auxiliaries are independently controlled from the rig floor. Rigs equipped with a Baylor SCR set up faster: Absence of engines on the rig floor facilitates selfelevating substructures, No realignment, leveling or rigging of compounds is required. Fewer loads are necessary during rig moves. Power cables plug in and bolt on. Rig/mud system design is not dictated by compound configurations. Rigs equipped with a Baylor SCR provide simpler maintenance and extended rig life: SCR bridges draw out. All systems use standard, readily available Easier, Woodward and Texas Instruments components. Full over-speed, over-temperature, over-current, under-frequency and reverse-power protection is incorporated into the system, Each SCR bridge is capable of multi-load assignments, Solid copper bus with silver-plated connections extends service life.

436

Thyrigger SCR
Compact AC-to-DC Rig Power Systems
The Thyrigger, Baylor's most compact SCR system, is specifically designed for shallow- to medium-depth drilling rigs and workover rigs. More SCR in less space offers the contractor increased installation options. Three- or four-bay (motor) systems supply from 0 to 750v DC at 1200 amps continuous, 1500 amps intermittent at 50C ambient temperature. The system accommodates up to three engine/ generator sets, each up to 1500 kva at 600v AC. Operator-conscious design simplifies operation and training. Go/No-Go diagnostic center is included on each SCR bay. One-glance centralized engine/generator meters and controls ease synchronization and status monitoring. Linear throttle provides unique low-speed torque control. Advanced design extends rig life. Constant power dynamic braking allows soft stops, reducing stress on the drawworks chain and related components. All motor speeds are controlled without tachometers. Full-conduction gate drive assures SCR firing reliability. Drilling operations continue at reduced power in the event of SCR cooling blower failure. Service-conscious design simplifies maintenance and field service. All user-serviceable components are accessible from the front. Interchangeable electronic DC control modules allow for quick troubleshooting, while test jacks provide easy measurement of critical signals.

p. .
m ..** "

i^^yi
,.^SSS

One glance at this Go/No-Go panel indicates the status of the SCR bay.
M Bovlor Brake control Thyrigger SCR/ generator controls h/

120/208V __

lighting paneT~~
AC plugboard [interchangeable wtthDC]

^
1

If 03.

\ 480v AC motor control center)

Genercjtot connection windows [either siOe)

' II

11

M,
-

300 or 500 k.

The Thyrigger and the motor control center can be ordered for mounting in a customer-supplied structure. Plugboards are fully

All Thyrigger system functions are controlled from this compact drill-

cabled and the system is completely tested before del^ery.

er's console. Quick-connect wiring throughout the system speeds rig-up.

437

Thyrig' III SCR

Maximum SCR Flexibility for Greater Depths
Thyrig III, Baylor's workhorse SCR system, powers medium-depth to deep drilling rigs for both land and marine applications. Available in several standard configurations to meet a variety of drilling needs, the system can be furnished free-standing or completely packaged in a Savior-built SCR house. Because of its design flexibility, the Thyrig III can be easily adapted to most drilling rigs. For a custom SCR system at a relatively low cost, standardized cubicles can be quickly assembled on a common deck rail to

meet individual requirements. Completion items can then be added as required. Thyrig III offers the contractor greater flexibility. Three- or four-bay systems supply from 0 to 750v DC at 1850 amps continuous and 2500 amps intermittent at 50C ambient temperature for drawworks duty. The system accommodates two, three or four engine/generator sets, 2000 kva each at600vAC.

Driller's console provides total system control with all meters and indicators clearly visible.

SCR bridge and DC contactor sections are packaged as a unitized module, and all user-serviceable components are accessible from the front of the bays.

Motor Control Center Air Handler Air Handler

)(

Plugboard

0"

-X,.
Thyrig III SC ^/Generator Co trals

AIC F Compressor '

sformer

[
1T i

1
1

AC

mi

Transformer

Compressor

Atypical Thyrig III SCR house (generator windows available on either side)
Baylor-powered rig drilling in
South Texas.

438

Thyrig III-PM SCR

SCRs for Marine Applications
Baylor's most sophisticated system, the compact Thyrig III-PM is designed to provide the greatest amount of flexibility in complex marine applications including drilling, propulsion, jacking and mooring. Because a solid-state programmable controller centralizes all logic functions in the same bay, wiring throughout the system has been simplified and reduced, and most electromechanical logic relays have been eliminated. More SCR in less space offers increased installation options. Multiple bay systems supply from 0 to 750v DC up to 2500 amps drawworks duty at 50C ambient temperature to effectively power dual-motor loads. The system accommodates multiple engine/ generator sets up to 2500 kw and/or 3100 kva at
600vAC,60Hz.

Versatile design allows SCR/generator or SCR/ feeder combinations in any bay with the arrangement of the bays according to the customer's requirements. Operator-conscious design simplifies operation and training. A Go/No-Go diagnostic center is included on each SCR bay. Linear throttle provides unique low-speed torque control. Constant-power dynamic braking allows soft stops, reducing shock to the drawworks chain. Drilling operations continue at reduced power in the event of SCR cooling blower failure. Automatic sequencer provides state-of-the-art system control without requiring a computer technician for service. Texas Instruments 5TI sequencer controls all logic functions. The sequencer's "hard" memory is not erased by power loss. Adding rig machinery or sensors requires only simple field reprogramming with little or no wiring changes. Input-Output (I/O) modules replace most electromechanical logic relays; eliminate sensitivity to dust and mechanical wear; and are easily accessible in the service bay.

A rig in Louisiana powered by a Thyrig III-PM system.

Top view Contactor access Contactor access

Cable entry

Cable entry

Cable entry

Cable entry

"
r
LI

^
Eng ne<g enerator

^
Sync.'feederbay

^
Engine. gjnerator contrc bay

c t

Service bay
Feeder'b eakerbay

contrc Ibay Service bay

(can be placet at either end) \

SCR bay

SCR bay

SCR bay

SCR bay

a1 i B
I

Bna
D Ql . f .

n a ^'
I
B

a a j'

van a a a at
8*BS!

i
i
(488 mm

|M|

i8

y
c^

c=

E E

'
M

n1

b '

a1

'a' b

46 " 1219 mm) 5359mm

Atypical Thyrig III-PM layout with four SCR bays.

All functions of the system are controlled from the driller's console,

10

439

Custom Products Group

Full Project Management Capabilities for Your Toughest Jobs
Based on our experience in the development of the oilfield's first SCRs and electromagnetic brakes, Baylor has the engineering expertise and manufacturing capabilities to produce a broad range of products and equipment according to your individual needs and requirements. We call the experts who make up this team the Baylor Custom Products Group, and they are backed by Baylor's 30 years' proven versatility in the development of a full-range of products for a wide variety of applications. Baylor's design innovation stretches back to the early 1960s when a major oil company contracted us to design a control system for thrust units which provided auxiliary maneuvering thrust, propulsion assistance, and main propulsion on drilling vessels. Installed on the coring vessel "Eureka," Baylor's dynamic positioning system was instrumental in the later development of the oil industry's first drill ships which did not require traditional anchored mooring. Other custom mechanical products engineered and manufactured by Baylor include a variety of offshore drilling equipment, including windlasses, fair-

load-stress instrumentation for jackup-leg stress monitoring. We've designed and installed ballast control equipment for semisubmersibles. And we've completely outfitted pipe-inspection trucks with pipehandling equipment and electronic instrumentation for field pipe inspection. But the experience of Baylor Custom Products Group is not limited to the oilfield. For instance, we applied our experience to the successful design of a complete line of mining production, service and personnel hoists mounted on skids innovative packaging common to the oilfield but unprecedented in the mining industry. We have designed a long list of industrial products

leads and winches. Both on land and offshore, we've built virtually everything from mud pumps to BOP stacks and associated hose reels. Baylor's electronics and electrical engineers have made important contributions with the development of oceanographic instrumentation, including an environmental and vessel motion data-gathering system. These Baylor systems have been designed for measuring vessel heave, wave action, anchor tension and ocean currents. In fact, Baylor was responsible for the successful design and manufacture of the special oceanographic/meteorological instrumentation used on the prototype of the Exxon compliant platform (guyed tower), constructed for use in the Gulf of Mexico's Block 280. In the early development and use of jack-up rigs, Baylor was a pioneer in the development of electronic

as well, including hoists and conveyors, materialhandling equipment (such as pipe bundlers and transfer systems), SCR systems for large motors, switchgear (low, medium and high voltages) and control consoles. From purchasing professionals to industrial engineers to skilled machinists, the Baylor Custom Products Group has the people and talents to provide you with a total project management package. And in each stage of operations, every project is subject to Baylor's strict quality-assurance requirements. The result of Baylor's "Q + " program is top-grade products, prompt delivery and cost savings for the customer.

11

440

Testing, Training and Service

supplied by experienced Baylor personnel. Depending on the product line, the length of training sessions varies from two to five days, and a class can be set up on short notice.

Testing
All Baylor SCR systems are full-load tested through all assignments before shipping. This full-load test facility uses a Baylor Brake coupled to two typical DC drilling motors to fully simulate all drilling functions.

Service
Baylor's staff of highly trained electrical and mechanical service people are available on a 24-hour basis from our Houston headquarters. While all Baylor equipment is designed for minimum field service, the Houston service center is equipped with special troubleshooting gear and an inventory of parts for all products. Always the emphasis is on preventive maintenance and service making sure the equipment keeps on working rather than fixing it after it goes down.
The information and data in this catalog are accurate to the best of our knowledge and belief but are intended for general information only. Applications suggested tor the materials described are made solely to permit the reader to make his own evaluation and decision and are neither guarantees nor to be construed as express or implied warranties of fitness for these or other applications. All specifications are subject to change without notice.

Customer Training Baylor's classroom facilities are equipped with audiovisual equipment and simulators for all major products to provide hands-on training. Formal instruction is

Headquarters
P.O. Box 36326, Houston, Texas 77236 713/240-6111 Telex 762232
1985 Baylor Company, All rights reserved. BAY 82792Y

Printed in USA