430

Electric Auxiliary Brakes for Drawworks

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

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

Baylor manufactured its first electric brake morethan 25 years ago and has been the auxiliary brakecompany ever since. Baylor Brakes have proven theirperformance on thousands of rigs all around theworld — allowing operators to drill deeper, faster andmore safely,

Designed to give the driller positive control overdrill string speed, the Baylor Brake develops excep-tionally high braking torque at both high and very lowrotational speeds without friction devices of any kind.A free-spinning drum inside the brake is coupleddirectly to the drawworks shaft. When the driller oper-ates the brake control, a magnetic field is producedby four electromagnetic coils mounted concentrical-ly inside the drum. By changing the amount of currentto these stationary coils, he controls the amount ofbraking torque applied to the rotating drum. Becausethe brake is deactivated by simply turning it off, nooverrunning clutch is required.

Baylor Brakes are manufactured in four standardsizes for nominal drilling depths up to 30,000 feet.Each consists of a steel drum attached directly to thedrawworks shaft by a flexible coupling or disconnectclutch. The drum shaft rotates in two sets of oversizedspherical roller bearings. And the brake is connectedto the drawworks structure by adapter cradle mountsfun,.shed by the drawworks manufacturer, Themaximum power requirement ranges from about 10to 21 kw, which is easily supplied by standard AC lightplants. All rig floor components are explosion-proof.

8400 IS'" Driller's ControlThe new 8400 IS driller's control simplifies operation

and facilitates faster training of drillers, Because con-trol operation is linear, the control position is matchedto the amount of voltage applied to the coil (e.g.,when the control is in the halfway position, half of thevoltage is applied). Rig operation is safer and moreefficient because the driller gets a better feel for thebrake more quickly. The control is also intrinsicallysafe in any hazardous area.

PWM ™ - CL Brake Power SupplyBaylor's new air-cooled brake power supply mounts

off the rig floor where a controlled atmosphere andreduced vibration increase reliability, Passive,convection-flow cooling eliminates blowers andreduces maintenance to minor routine checkouts.

Baylor Brakes431TM

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

Battery-Power BackupModel PWM™-CL brake power supplies are equipped

with battery connections and internal circuitry to accom-modate backup power for uninterrupted emergencybrake operation in the event of AC power failure. The sizeof the battery pack (supplied by customer) dependsupon the brake's rated capacity and the contractor'sneeds.

Brake Cooling SystemThe fresh water required to cool the brake should

be low in mineral content, sufficient in quantity andlow enough in temperature to dissipate the heatadequately.

Electrical control and brake cooling systemsAC

supply Transformer

Driller's CO

C

c

tfii Baylor s

1 ————— [?Drawworks —

H r(

itrol

PWM brake•

control

QBaylor Rotor sea|Brake rn

IE

Relief valver-rn

f\\N

| | Centrifugal pump

jpplied components

HIFresh

V

Y

water5ply

Savior's PWM™-CL air-cooled controls require minimal preven-tive maintenance.

Principles of Operation

Airgap

Magnets

Magnetic lines of force

Coils

Rotor

7838 Brake(± 30,000ft)

7040 Brake(» 20.000ft)

6032 Brake(~ 15,000 ffl

5032 Brake(± 12,000ft)

432

Baylor Brake Torque Curves and Specifications

50 100 150 200 250 300Draw works shaft speed] rpm]

TKO 6032 Broke

50 100 150 200 250 300Drawworks shall speed(rpm)

50 100 150 200 250 300Drawworks shaft speed (rpm)

7838 Brake 7040 Brake 6032 Brake

I

B-

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

5032 Brake

___________5032 Brake 6032 Broke 7040 Brake 7838 Brake

Maximum torque(ft-lbs,KNm)

Nominal drillingdepth (ft, m)*

39,000 52.9 55,500 75.3 84,000 113.9117,000 158.6

12,000 3658 15,0004572 20,000 609630,000 9144

Nominal powerrequirements (kw)

Cooling waterrequirements(gpm, l/min)

18 21

50 190 75 285 140 530 150 570

Weight (Ibs, kg) 9,0004082 12,000 5443 24,00010886 28,00012701Dimension A (in, mm) 50 1 270 60 1524 71 1803 78 1 981

Dimension B (in, mm) 42 1067 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, drumdiameter and other variables can offset rated capacities.

433

Boylor Brakes

Baylor Brake Performance CurvesBaylor Brakes operate according to the perform-

ance 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 groov-

ing. These curves are calculated according to com-mon drum and wireline sizes with applicable frictionfactors. Other curves based on specific customerapplications are available on request.

3000Fast line speed (fpm)

100 200 300 400

Block speed (fpml

1000 2000Fast line speed (fpm)

200 300

Block speed [fpm)

2000Fast line speed (fpm)

100 200 300 400

21" dia drum, 1V wireline

2000 3000Fast line speed (fpm)

200 , , f 300

Block speed (fpm) Block speed (tpm)

434

Hydro-Torque

Hydraulic Auxiliary Braking Systems

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

Pilot valve(•t driller's console)

Water supply valve(at driller's console)

I, Boytor suppliedcomponents

Support/Control Systems

Baylor now offers two hydraulic auxiliary braking sys-tems designed to economically govern drawworksspeed on drilling or workover/well-servicing rigs—theHydro-Torque 2200 and the new Hydro-Torque 1500.With the Hydro-Torque 2200 producing 12,000 ft-lbs oftorque at 700 rpm and the Hydro-Torque 1500 produc-ing 6,000 ft-lbs at 1400 rpm, both models provide moretorque than any comparable system. They also weighless and are narrower than competitive units althoughtheir mountings are directly interchangeable*

Designed with the latest state-of-the-art turbineresearch, the Hydro-Torque brakes are much simpler indesign and contain only 14 component parts, greatlysimplifying field service. Both models can be assem-bled in less than an hour, and shaft location and rota-tion direction can be reversed in the field without anyadditional parts. The major rotary sealing surfaces usea double-lip seal, and the lubrication systems assist insealing the bearing assemblies.

Like other Baylor auxiliary brakes, the Hydro-Torquebrakes slow the drill string without friction devices of anykind. Instead of belts, slip rings, brake pads or bands,braking torque is produced by water circulatedbetween the vaned pockets of the impeller and thefacing vaned pockets of a stationary member. Thebrakes can be used with either an overrunning clutchor an air-purging system for tripping out of the hole.

"An adapter plate is provided when interchanging the Hydro-Torque 1500 with the Parmac15" D.R.

Mox Speed—1500 Rf

Hydro-Torque ModelTorque (ft-lbs, KNm)

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

1500

6,000 8.135(at 1400 RPM)400 181.44

18.25 463.55

20 508.00

2200

12,000 16.270(at 700 RPM)

850 385.56

25.75 654.05

22.62 574.55

a 50 100 200 300 500 700 1000 1500 2000 3000 40 50 100 200 300 500 700 1000Brake shaft speed (rpm] Brake shaft speed [ipm)

"Shafts other than the one shown are provided to customerspecification.

435

Thyrig Systems

A typical SCR, the heart ofevery Baylor Thyrig system.

Mud system

1000-hp DC motors

Baylor driller's control

Efficient SCR Rig PowerThe pioneer in the use of silicon-based electronics

for efficiently converting AC power into the speed-controllable DC power required by drilling rigs, Baylorintroduced the first SCR system to the oilfield 15 yearsago. And that first Thyrig SCR system is still operating inthe hostile environment of Alaska's Upper Cook's Inlet,Today's new generation of Thyrig SCRs can be foundin operation on every type of rig in every part ofthe world.

In planning a rig's configuration, Baylor assists thecontractor in taking advantage of every cost-cuttingmeasure and in sizing the SCR for optimum rig per-formance. This attention to detail and care in thedesign of SCR-powered rigs can provide the contrac-tor fuel savings of 18 to 48 percent over similarlyrated 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 rigpower," 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 inde-

pendently controlled from the rig floor.Rigs equipped with a Baylor SCR set up faster:

• Absence of engines on the rig floor facilitates self-elevating substructures,

• No realignment, leveling or rigging of compoundsis required.

• Fewer loads are necessary during rig moves.• Power cables plug in and bolt on.• Rig/mud system design is not dictated by com-

pound configurations.Rigs equipped with a Baylor SCR provide simpler main-tenance and extended rig life:

• SCR bridges draw out.• All systems use standard, readily available

Easier, Woodward and Texas Instrumentscomponents.

• Full over-speed, over-temperature, over-current,under-frequency and reverse-power protection isincorporated into the system,

• Each SCR bridge is capable of multi-load assign-ments,

• Solid copper bus with silver-plated connectionsextends service life.

436

Thyrigger™ SCR

Compact AC-to-DC Rig Power SystemsThe Thyrigger, Baylor's most compact SCR system, is

specifically designed for shallow- to medium-depthdrilling rigs and workover rigs.More SCR in less space offers the contractor in-creased installation options.

• Three- or four-bay (motor) systems supply from 0 to750v DC at 1200 amps continuous, 1500 ampsintermittent at 50°C ambient temperature.

• The system accommodates up to three engine/generator sets, each up to 1500 kva at 600v AC.

Operator-conscious design simplifies operation andtraining.

• Go/No-Go diagnostic center is included on eachSCR bay.

• One-glance centralized engine/generator metersand controls ease synchronization and statusmonitoring.

• Linear throttle provides unique low-speed torquecontrol.

Advanced design extends rig life.• Constant power dynamic braking allows soft stops,

reducing stress on the drawworks chain andrelated components.

• All motor speeds are controlled without tach-ometers.

• Full-conduction gate drive assures SCR firingreliability.

One glance at this Go/No-Go panel indicates the status of the SCRbay.

M Bovlor Brake control

120/208V __lighting paneT~~

AC plugboard —[interchangeablewtthDC]

Thyrigger SCR/controls

generator h/

\̂ 480v AC motor control center)

If—03-

.

Genercjtot connection windows [either siOe)

1 ' II 11 i M,- 300 or 500 k.

• Drilling operations continue at reduced power inthe event of SCR cooling blower failure.

Service-conscious design simplifies maintenanceand field service.

• All user-serviceable components are accessiblefrom the front.

• Interchangeable electronic DC control modulesallow for quick troubleshooting, while test jacksprovide easy measurement of critical signals.

i^^yip. .m ..** - " ,.^SSS

The Thyrigger and the motor control center can be ordered formounting in a customer-supplied structure. Plugboards are fullycabled and the system is completely tested before del^ery.

All Thyrigger system functions are controlled from this compact drill-er's console. Quick-connect wiring throughout the system speedsrig-up.

437

Thyrig' III SCR

Maximum SCR Flexibility for Greater DepthsThyrig III, Baylor's workhorse SCR system, powersmedium-depth to deep drilling rigs for both land andmarine applications. Available in several standardconfigurations to meet a variety of drilling needs, thesystem can be furnished free-standing or completelypackaged in a Savior-built SCR house.

Because of its design flexibility, the Thyrig III can beeasily adapted to most drilling rigs. For a custom SCRsystem at a relatively low cost, standardized cubiclescan be quickly assembled on a common deck rail to

meet individual requirements. Completion items canthen 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 ampsintermittent at 50°C ambient temperature fordrawworks duty.

• The system accommodates two, three or fourengine/generator sets, 2000 kva each at600vAC.

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

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

0"

[

Plu

gboa

rd

1 ————— i

Air Handler

T

Motor Control Center

1Thyrig III SC

1

1^/Generator Co

!

Air Handler

trals

) —————— (

mi

N-X,.

Transformer

AIC FCompressor '

sformer

ACCompressor L

Atypical Thyrig III SCR house (generator windows available on either side)

Baylor-powered rig drilling inSouth Texas.

438

Thyrig III-PM SCR

SCRs for Marine ApplicationsBaylor's most sophisticated system, the compact

Thyrig III-PM is designed to provide the greatestamount of flexibility in complex marine applications—including drilling, propulsion, jacking and mooring. Be-cause a solid-state programmable controller central-izes all logic functions in the same bay, wiringthroughout the system has been simplified and re-duced, and most electromechanical logic relays havebeen eliminated.More SCR in less space offers increased installationoptions.

• Multiple bay systems supply from 0 to 750v DC upto 2500 amps drawworks duty at 50°C ambient

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

Top viewContactor access Contactor access

Service bay

Service bay(can be placetat either end)

\

/

Cable entry

^

Eng ne<gcontrc

SCR bay

iD

I

iQ

a 1B

i i

Cable entry

^

enerator Sync.'feeIbay

SCR bay

BnaD Ql

.f.

|M|

'M(488 mm

n a

^'

n1

I

c=

Cable entry

^

derbay Engine. g«contrc

SCR bay

B

b'

461219

"mm)

5359mm

a aj'

a1

Cable entry

^

jnerator Feeder'bbay

SCR bay

vana at

i88*BS!

1

a

iay

'a'

c^

"

rLI

c•t

eakerbay

b

EE

1§

temperature to effectively power dual-motorloads.

• The system accommodates multiple engine/generator sets up to 2500 kw and/or 3100 kva at600vAC,60Hz.

• Versatile design allows SCR/generator or SCR/feeder combinations in any bay with the arrange-ment of the bays according to the customer'srequirements.

Operator-conscious design simplifies operation andtraining.

• A Go/No-Go diagnostic center is included oneach SCR bay.

• Linear throttle provides unique low-speed torquecontrol.

• Constant-power dynamic braking allows softstops, reducing shock to the drawworks chain.

• Drilling operations continue at reduced power inthe event of SCR cooling blower failure.

Automatic sequencer provides state-of-the-art sys-tem control without requiring a computer technicianfor service.

• Texas Instruments 5TI sequencer controls all logicfunctions.

• The sequencer's "hard" memory is not erased bypower loss.

• Adding rig machinery or sensors requires only sim-ple field reprogramming with little or no wiringchanges.

• Input-Output (I/O) modules replace most electro-mechanical logic relays; eliminate sensitivity todust and mechanical wear; and are easily acces-sible in the service bay.

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 JobsBased on our experience in the development of the

oilfield's first SCRs and electromagnetic brakes, Baylorhas the engineering expertise and manufacturingcapabilities to produce a broad range of productsand equipment according to your individual needsand requirements. We call the experts who make upthis team the Baylor Custom Products Group, and theyare backed by Baylor's 30 years' proven versatility inthe development of a full-range of products for a widevariety of applications.

Baylor's design innovation stretches back to theearly 1960s when a major oil company contracted usto design a control system for thrust units which pro-vided auxiliary maneuvering thrust, propulsion assist-ance, and main propulsion on drilling vessels. Installedon the coring vessel "Eureka," Baylor's dynamic posi-tioning system was instrumental in the later develop-ment of the oil industry's first drill ships which did notrequire traditional anchored mooring.

Other custom mechanical products engineeredand manufactured by Baylor include a variety of off-shore drilling equipment, including windlasses, fair-

load-stress instrumentation for jackup-leg stress moni-toring. We've designed and installed ballast controlequipment for semisubmersibles. And we've com-pletely outfitted pipe-inspection trucks with pipe-handling equipment and electronic instrumentationfor field pipe inspection.

But the experience of Baylor Custom Products Groupis not limited to the oilfield. For instance, we applied ourexperience to the successful design of a complete lineof mining production, service and personnel hoistsmounted on skids — innovative packaging commonto the oilfield but unprecedented in the mining indus-try. We have designed a long list of industrial products

leads and winches. Both on land and offshore, we'vebuilt virtually everything from mud pumps to BOP stacksand associated hose reels.

Baylor's electronics and electrical engineers havemade important contributions with the developmentof oceanographic instrumentation, including an envi-ronmental and vessel motion data-gathering system.These Baylor systems have been designed for measur-ing vessel heave, wave action, anchor tension andocean currents. In fact, Baylor was responsible for thesuccessful design and manufacture of the specialoceanographic/meteorological instrumentation usedon the prototype of the Exxon compliant platform(guyed tower), constructed for use in the Gulf of Mexi-co'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, material-handling equipment (such as pipe bundlers and trans-fer systems), SCR systems for large motors, switchgear(low, medium and high voltages) and control consoles.

From purchasing professionals to industrial engi-neers to skilled machinists, the Baylor Custom ProductsGroup has the people and talents to provide you witha total project management package. And in eachstage of operations, every project is subject to Baylor'sstrict quality-assurance requirements. The result of Bay-lor's "Q + " program is top-grade products, promptdelivery and cost savings for the customer.

11

440

Testing, Training and Service

TestingAll Baylor SCR systems are full-load tested through all

assignments before shipping. This full-load test facilityuses a Baylor Brake coupled to two typical DC drillingmotors to fully simulate all drilling functions.

Customer TrainingBaylor's classroom facilities are equipped with au-

diovisual equipment and simulators for all major prod-ucts to provide hands-on training. Formal instruction is

supplied by experienced Baylor personnel. Depend-ing on the product line, the length of training sessionsvaries from two to five days, and a class can be set upon short notice.

ServiceBaylor's staff of highly trained electrical and me-

chanical service people are available on a 24-hourbasis from our Houston headquarters. While all Baylorequipment is designed for minimum field service, theHouston service center is equipped with specialtroubleshooting gear and an inventory of parts for allproducts. Always the emphasis is on preventivemaintenance and service — making sure the equip-ment keeps on working rather than fixing it after itgoes down.

The information and data in this catalog are accurate to the best of our knowledge andbelief but are intended for general information only. Applications suggested tor the materialsdescribed are made solely to permit the reader to make his own evaluation and decision andare neither guarantees nor to be construed as express or implied warranties of fitness forthese or other applications. All specifications are subject to change without notice.

HeadquartersP.O. Box 36326, Houston, Texas 77236 • 713/240-6111 • Telex 762232

®1985 Baylor Company, All rights reserved.BAY 82792Y Printed in USA