Manual No.

165-08386

NATIONAL OILWELL

INSTAllATION, OPERATION
AND
MAINTENANCE INSTRUCTIONS
FOR
BAYLOR EDDY CURRENT BRAKE
MODEL 5032

EQUIPMENT FURNISHED
BY

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

Rev. B
04/03
 NATIONAL OILWELL
Table of Contents

Section 1 Introduction and Description

1.1 Scope of Manual 1-1
1.2 General Description of Equipment 1-1

Section 2 Summery of Specification

2.1 Specifications 2-1

Section 3 Installation
3.1 General 3-1
3.2 Brake Alignment 3-6
3.3 Shaft Alignment 3-6
3.4 Cooling Water Quality 3-7
3.4.1 Scope 3-7
3.4.2 Water Quality Standards 3-7
3.4.3 Corrosion Inhibitor 3-7
3.4.4 Usage of Antifreeze Standards 3-8
3.5 Cooling System Capacity Calculation : 3-8
3.6 Brake Field Coil Polarity 3-10
3.7 Certification for Hazardous Location 3-14

Section 4 Theory of Operation

4.1 General 4-1
4.2 Brake Operation on Rig 4-1
4.2.1 Drill Assist Operation 4-2

Section 5 Accessories and Options

5.1 General 5-1
5.1.1 Brake Controller 5-1
5.1.2 Special Brake Shafts 5-1
5.1.3 Brake Cooling Packages 5-1
5.1.4 Cooling Water Alarm 5-1
5.1.5 Safety Monitoring Device 5-1
5.1.6 Parts and Service 5-2

ii
 ~ NATIONAL OILWELL
Section 1
Introduction and Description

1.1 Scope of Manual Any alteration or unauthorized repair work to

This manual provides a source of important the brake or control system will VOID ANY
WARRANTY expressed in the terms and
reference information regarding the installation,
conditions of sale and will void HAZARDOUS
operation, and maintenance of the BAYLOR
Eddy Current Brakes and should be given AREA CERTIFICATION. All applicable
careful consideration and study before schematics, flow diagrams, and major
assembly drawings are contained in SECTION
operating the BAYLOR brake. It is impossible
8 of this manual.
to anticipate every kind of problem or condition
that may be encountered in the use of the
1.2 General Description if Equipment
brake, but compliance with the instructions and
suggestions set forth in this operating manual The BAYLOR Eddy Current Brakes are
will assist the operator in successfully auxiliary braking devices for the Drilling Rig
operating this equipment. Dra~orks. ~his braking is produced entirely
Failure to operate and maintain the brake in electrically Without the aid of friction brake
devices, slip rings, or other wearing elements.
ac?ordance with this operating manual may The brakes are water cooled.
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!

1-1
 NATIONAL OILWELL
Section 2
Summary of Specifications
Model 5032 Eddy Current Brake

2.1 Specification
Principal of Operation Induced Eddy Current Braking
Torque-Maximum 39,000 Ib-ft @ 250 RPM (52,877 n-m)
Torque @ 50 RPM 31,550 Ib-ft (42,708 n-m)
Number of Magnets 2
Number of Coils per Magnet. 2
Coil Internal Resistance @ 68° F (20° C) 5.1-5.4 Ohms
Total Brake Input Resistance @ 68° F (20° C) 5.16 Ohms
Brake Excitation:
Voltage 250 Volts DC
Current-Coil Temperature @ 68° F (20° C) 48.45 Amps DC
Power Input @ 68° F (20° C) 12.11 kW
Cooling Water Requirements:
Flow @ 100° F (38 Deg. C) At Brake Inlet 50 gpm (1891pm)
pH 7.0-7.5
Maximum Discharge Temperature 165° F (74° C)
Cooling Water Piping:
Inlet (2) 1" NPT
Outlet. (1) 4" NPT
Overflow (2) 1" NPT
Overall Sizes:
Height. 50 in (1,270 mm)
Width 32 in (813 mm)
Weight 9,000 Ib (4,082 kg)
Inertia (WK2)-Shaft and Rotor. 5,861 Ib-ft2 (2,482,053 kg-cm2)
Weight-Shaft and Rotor 2533 Ib (1149 kg)
Shaft Size 7 .500 inch Diameter with 1-1/4 inch Taper per foot
(191 mm Diameter with 32 mm Taper per 305 mm) Oilfield Standard
Average Rotor Radial Clearance (Air Gap)
Over Magnets (Without Paint or Other Buildup) 0.040-0.045 in
(1.016-1.143 mm)
Maximum RPM 600

2-1
 Section 3
Installation

3.1 General
Figure 3-3 shows the electrical connections for
The BAYLOR Brake should be cradle mounted the magnet coils and power input to the
on the drawworks structure. The drawworks junction box.
manufacturer furnishes the adapter mounting
components as well as the disengaging
coupling between the brake and the drum shaft CAUTION!
of the drawworks. The necessary shifting
mechanism and related accessories should be The water outlet(s) at the bottom of the brake
furnished by the customer. should not be hard piped or otherwise restricted.
This should be free-flowing, gravity drain. A
funnel-type drain as illustrated in Figure 3-4 is
preferred. Do not plug, pipe, connect hoses to,
CAUTION! otherwise obstruct the water overflow outlets,
located on the brake just below the shaft
Heat removal from the rotor in the BAYLOR
centerline. These overflow outlets provide a
Brake is accomplished by cooling water. The warning of improper water flow conditions.
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 Removal of heat from the Brake is most
either direction at all times. DO NOT USE AN
OVERRUNNING TYPE CLUTCH. 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.
A standard mounting flange on the outboard
As illustrated in Figure 3-4 the BAYLOR Eddy
bearing cap is provided by National Oilwell for
Current Brake allows cooling water to flow over
mounting water and/or air tube assemblies.
the lower sections of the magnets and rotor
The required tube assemblies are furnished by
the drawworks manufacturer and should be before it exits at the bottom. If the cooling
water outlets are restricted, the water level
installed in accordance with their instructions.
inside the Brake will increase to a level which
Electrical control wiring and cooling system could damage the Bearing grease seals and
water piping should be installed in accordance permit water to enter the bearing cavity with
with the drawings contained in this section. A ultimate damage resulting to the bearing.
minimum of five-thread engagement should be
maintained on all threaded connections. Figure
3-1 illustrates a standard Brake cooling CAUTION/
configuration without a heat exchanger. Figure
3-3 illustrates a standard Brake cooling system The BAYLOR Eddy Current Brake is not
with a heat exchanger. A typical closed loop designed to operate with the cooling water
internal of the brake at other than atmospheric
cooling system which provides the greatest
pressure. For proper brake operation insure that
and best degree of protection against corrosion brake cooling water flows unrestricted through
/ erosion with adequate flow and temperature the brake with gravity discharge and unrestricted
protection for the BAYLOR Brake. These flow back to the cooling water reservoir.
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

3- 1
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SUPPORT SIZE
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RESERVOIR ~LL

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fOUNOATION OR SUPPORT PAO LOCATION
TOTAL OUANTITY SIX (6) REQUIRED . EACH SUPPORT MUST 8E DESCNED
TO CARRY A MINIMUM STATIC LOAD OF 4000LBS [1818 KG]
NOTE: SUPPORT PADS ARE CLIENT FURNISHED :e
SCALE: 1/8 m
TOP VIEW
THERMOMETER

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SEA WATER IN
4" 1501 RF
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[IWI) TEMPERATURE SWITCH

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~ fM: : "::-"1lISfIIl ~t5 ~ •.•.)..15 BRAKE WATER COOLING SYSTEIil

APPROX. WEIGHT - 6600 L8S. DRY [2994 KG] HDn 0&$'1 I'SOIIle. tc:H.I we ??oo. NO. MY
11854 LBS. WET [5377 KG] . 52142 1 12 0 ,.., 111' 1 0
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!:I, NATIONAL OILWELL Section 3

ROTOR

WATER INLET

MAGNET
" ,;

e----J)••• (1~
•
4tI'---

WATER OUTLET ~
~ BACK PRESSURE
INHIBITING FUNNEL

Figure 3-4
Drain

3-5
 Section 3

3.4 Cooling Water Quality 6. A total hardness of 170 parts per

million. Water that does not meet
3.4.1 Scope these standards should be treated
In order to function properly, the cooling by softening, de-mineralization, or
water used in SAYLOR Eddy Current de-ionization before being used to
Brakes must meet four basic cool the Brake.
requirements: 3.4.3 Corrosion Inhibitor
1. It must adequately transfer heat National Oilwell does not recommend the
energy from the rotor to the heat
use of "home made" type inhibitors. The
exchanger used for cooling.
ready availability of suitable commercial
2. It must not form scale or sledge products makes these "home made"
deposits in the Brake or in the formulations impractical and
cooling system. unnecessary. The use of soluble oil type
3. It must not cause corrosion in the inhibitors is also not recommended due
Brake or cooling system. to the effect they have on ethylene glycol
type antifreeze additives and the fact that
4. It must not deteriorate any of the they are detrimental to efficient heat
seals or gaskets used in the Brake transfer.
or cooling systems.
These requirements are normally met by Commercially available corrosion
combining a suitably demineralized water inhibitors are generally of three types;
with a reliable corrosion inhibitor. Under chromate based, borate-nitrite based,
extreme operating conditions it may be and silicate-nitrite based. Of these, the
necessary to use an antifreeze coolant. chromate based and the borate nitrite
In this case the cooling liquid should be a based are the most common. It is
mixture of the ethylene glycol type important to note that there are
antifreeze, de-mineralized water, and an environmental restrictions on the disposal
adequate corrosion inhibitor. of these types of inhibitors due to the
chromium and boron content. The
3.4.2 Water Quality Standards silicate-nitrate inhibitor is basically non-
polluting. Be sure and check with
The water used in BAYLOR Eddy Current national, state, and local authorities
Brakes should meet the following before disposing of any water treated
requirements: with inhibitors. Be sure to follow the
1. No undissolved particles such as manufacturer's recommendations for
sand, grit, or silt. applying the inhibitor, both for new
untreated water and for maintenance of
2. A ph level between 7.0 and 7.5. already treated water.
3. A maximum dissolved chlorides
content of 40 parts per million. Due to the successful use in BAYLOR
4. A maximum dissolved sulfates Eddy Current Brakes, the following
content of 100 parts per million. corrosion inhibitor is recommended for
use by National Oilwell:
5. A total dissolved solids content of
340 parts per million.

3-7
 NATIONAL OILWELL Section 3

Eddy Current Brake Coolant Flow

Required to Maintain Outlet Temp of 1650 F.

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Inlet Temperature (OF)

Model
NO.5
NO.3
NO.2
EC
Curve
EC
Curve If7838/9650
7040/8350
6032/5250
5032/3550
NO.4
NO.7
NO.6
EC
higher flow ratesONE-THIRD
Brake*
Brake
19RD130
Brake
7RD150 are required, contactOUTLETNationalTEMP OF 1650
Oilwell with F.
specific coolant
BASED
housing. ON MAX TORQUE @ AVG SPD 250 RPM
requirements.
*Curves
Model'sare19RD130
extended& only
7RD150 calculations
to maximum GPMbased
flow on
Figure average
rate
3-7 speed
capability of 1000
of the R.P.M.
specific brake model water

3-9
 Section 3

d. Observing meter lead polarity, connect • For the following Brake Models, move the
meter leads to a pair of Field Coil Leads handle "half way" through its total travel:
as indicated in Table I.
3630 3550

Brake Model" 5.1

6.1
5.9
15.5
13.0
13.4
10.8
4.9
4.86.7
4.4
6.7OHMS
Coil
OHMS
OHMS
OHMS TOTO5.4
6.5
6.3
16.4
13.5
Internal
TO TO 13.9
11.2
7.1
5.2 OHMS
Resistance
4.8
7.1
OHMS
OHMS
OHMS 5032 5250
32
150
130
40 be 11.0-11.5
2For Model prior
7838 to
atbrakes
July ohms.
68°F1985,
manufactured
(20°0)coil resistance will
30
0
838
130
50 6032 19RD130

• For the following Brake Models, move the

handle "full on" position:
7040 15050
8350 7RD150
7838 9RD130
9650

NOTE: Those brakes requIring only half on

position of driller's control have coils which are
connected series-parallel and therefore require
only half value of applied control voltage for full
saturation. Reference drawing 056772, sheets
1 and 2.

g. Observe positive meter deflection. If in

agreement with Table I, move Driller's
Control handle to "off' position. Turn off
AC power to Brake Control System, lock
out circuit breakers. Remove meter leads
FIGURE 3·15 and move to next pair of Field Coil Leads.
If not in agreement. with Table I, move
e. Set meter scale as indicated in Table I for Driller's Control handle to "off' position.
specific Field Coil Leads selected. Turn off AC power to Brake Control
+F8
F2
F4 --+
- VDC - System, lock out circuit breakers. Swap
F7- "( F8
F3 F2
F4 +
1F1
Positive
Positive
VDC
1- P1ositive
-10 -10 I
Table
50
F1 Field Coil identification tags on Field Coil
being measured, and connect meter
leads to another pair of Field Coil Leads
for polarity test per Table I.

h. Repeat steps d, e, f, and g until all Field

Coil Leads have been tested and are in
agreement with Table I.

i. Turn off AC power to Brake Control

System, lock out circuit breakers.
f. Insure that disconnected coil leads not Reconnect Field Coil Leads to junction
being tested are not in contact with each box terminal strip per drawing 056772,
other or surrounding surfaces. Unlock sheets 1 and 2.
circuit breakers for Brake Control and
energize the Control circuit. Move the
Driller's Control handle to a position as
indicated below:

3 - 11
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BRAKE .AJNCTlON BOX
BRAKE JUNClllN BOX BRAKE JUNCOON BOX
T(RI,lINAL BLOCX

000000 T£RIjINAl BlOCl( TERI.lINAl BtOCK

OCt OC-
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BRAKE TO 1010 BRAKE CONTROL BRAKE TO 1040 BRAKE CONTROL BRAKE TO 2040 BRAKE CONTROL
c.v

....•.

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SHRINK
TUBING

REO
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S~NI(
SHRINK ~NG
TUBING
SHRINK BRAKE JUNCnON BOX
1V~NG TERMiNAl IlLOCK

BRN<E JtwCTlOH BOX

TERWINAlIll.OCI(
__ TlONBOX BRAKE JUNCTION BOX

TERMiNAl 1lL0CI( TEflI,IINAL BLOCK

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CONTROl '1.50 )
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•. 1/' mu:

BRAKE
tlMTOH
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TO
DIAGRAM.

BRAKE CONTROL

BRAKE TO 1025 BRAKE CONTROL ~"'52142

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 !I' NATIONAL OILWELL Section 3

APPROVED PRODUCT - REVISION REPORT

OR ADDRESS/CONTACTCHANGE REPORT

=se=N=o=e"'R=:
==:;Fo;==rw=a=:rd=:w';;ith~uP=d;=at;=e'7d
3:dr=aw5i:::ng=s'=o;:r
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======AIJ~dlif~i~on~a;F1 fo~rm~s~m~a':y
be~====~F~O)jR~WNAAiRRDD1T'OO~:
======;=========
appropriate change information 10the requested !ly wriling to the FACTORY MUTUAL RESEARCH
attention of the Approvals Division. Original attention of the 1151 Boston.Providence Turnpike
will be returned showing course of action taken. Factory Mutual Stockroom. P.O.Box 9102
Piease type below your Company Nam•• Address, City. Stat. & Zip Code. Norwood MA 02062

,
Attention: Mr. Stephen Long . Attention: Roger P; Lutfy
0•••
r BA'lLOR COMPANY
.June 6, 1991
P.O. Box 36j26 . FORWARD.ED BY
Houston, TX 77236 Mr. Stephen Lo~g
TITlE

J MOD FFE

3550,3630,5032,5250,6032
7040,i838,8350,9650;15050
PRODUCT(1lJ..~DDY
. Current Brakes 19RDl30 and 7RDl50
INOI ATE FA RY MU ALJOB
IS A FACTORYMUTUAL LISTED MODElJTYPE NO. RE·VISEDBY IDENTIFICATION(S) AFFECTED
THIS·CHANGE? IF YES, EXPLAIN (USE SEPARATESHEET IF REQUIRED): DYES I[]NO

HAS THE MANUFACTURING LOCATION, LISTING ADDRESS, TELEPHONE OF7A4.AE and.OG7AO:AE

NUMBER OR CONTACTPERSON CHANGED? IF YES,.EXPLAIN BELOW: DYES KlNO

REV!S,ON DETAILS DWG NO.AFFECTED NEW DWG. NO.

The documentation file and test notebook for the subject equipment were examined and
all requirements of Factory Mutual Research Corporation Approval Standards Class
Number 3~OO and 3615 (March 1989), effective date January 1, 1992, are currently
being met.

Refer to Pages 2 through 5 of thi$ Revision Report for the critical documentation
list for .the s.ubject equipment.

REASON FOR CHANGE(SVCOMMENTS:

Baylor Company's EDDY Current Brakes, Models 3550, 3630, 5032, 5250, 6032, 7040,
7838, 8,350, 9650, 15050, 19RD130 and 7RD150, continue to meet Factory ~utual
Research Corporation Approval r~quirements.

* Revision report prepared by FMRC to show compliance with the referenced standards .
...:....~------'-------------:B;;:E:;"L';:O::;W;-;F;;:O;;;R;-:;F;;A;:CT;;O::;:R;;;Y:-;M;;U;:;T:;;UA;;;-L;;US;;;E~----------------"""--
cOMMENTS: REVISION RPr. J.I. REVISION NOTICE NO. CLASS NO.

No additional testing is required. OT8H4.AE 3615

FORWARD APPROVAL AGREEMENT

DYEs!£gNO
'REVISION
ACcEPTeD

797 (6-ll7)FMRC' PRINTED IN USA

3 - 15
 NATIONAL OILWELL Section 3

Revision Report J.I.OWOAS.AE- 12/12/91 - BAYLOR COMPANY - D. Lefler/AL.

Page 2 of 2

4. Explosionproof characteristics of Model 9RDl30 is similar to that of Model

19RD130 which is already FMRC Approved, therefore no testing is required on Model
9RD130 Eddy Current Brake. The following documents depict Model 9RD130 Eddy
Current Brake. Drawing 3-05-02-4006 is for Models 9RD130 and 19RD130 Eddy
Current Brakes.

OUTI.INEjMOUNTING DIM •.M/9R:Dl30 New Drawing 55166 12/10/91

ASSEMBLY, M/9RD130 BRAKE New Drawing 55280 12/10/91
WATER. PIP DIAG, M/9RD130 New Drawing 55356 12/10/91
RING FOR MAG CTR, M/l9RD130 New Drawing 3-05-02-4006 12/16/81

3 -17
 /NSTALLAnON /NSTRLlCnON
1. INSTAllATION OF MOUNTING PLATE ASSEMBLY' (SEE OWG 0478601

A. REMOVE THE TOP lWO 3/8" MOUNTING BOLTS AND LOOSEN THE BOnOM
lWO 3/8" MOUNTING BOLTS WHICH FASTEN THE BRAKE COIL JUNCTIOO BOX.
B. LOOSEN THE UNIONS IN THE COIL LfAO PIPE ON BOTH SIDES OF THE BRAKE.
C. m THE JUNCTION BOX FORWARDTO GEl CLfARANCE FOR INSTAlLATION
Of THE MOUNTING PlATE ASSEMBLY 0 47860.
O. SLIP THE BOnOM OF THE MOUNTING PLATE BEHIND THE EXISTING JUNCTION BOX.
E. REPlACE AND TIGHTEN THE FOUR BOLTS.
F. ADD STIFFENING BRACKET, TIGHTEN FOUR BOLTS.

2. INSTALlATION OF FLOW SWITCH ASSEMBLY' (SEE DWG. 046873)

A. REMOV£ INLET WATER PIPING AS NEEDED TO PROVIDE A LOCATION IN

THE PIPING FOR THE FLOW SWITCH ASSEMBLY.
B. INSTAlL THE n.OW SWITCH ASSEMBLY USING REDUCER BUSHINGS SUPPLIED.
C. INSTAlL A UNILET ON THE n.OW SWITCH AS SHOWN ON THE INSTAllATION
OWG. D 47915.
O. SPUCE THE WIRES IN THE UNILET AS SHOWN ON SHEET 2 OF DWG. 047915.
E. TIGHTEN THE CORD GRIP RTnNGS TO GET A WATER TICHT SEAl ON THE CABLES.
F. INSTAlL THE UNILET COVER WITH THE GASKET.

3. INSTALlATION OF TEMPERATURE SWITCH TO DRAIN:

THE 4 X 4 X 1/2 NIPPLE ASSEMBLY MUST BE INSTAlLED IN DRAIN PRIOR

o o TO INSTAlLATION OF THE TEMPERATURESWITCH.

01 10 A. INSTAlL THE 4 X 4 X 1/2 NIPPLE TO THE THRfAOED 4" DRAIN PIPE.

o 0 B. INSTAlL A TEMPERATURE SWITCH IN THE 1/2" HALF COUPLING AS SHOWN
ON OWG. 0 47915.
C. INSTAlL A UNllET ON THE TEMPERATURE SWITCH AS SHOWN ON THE
INSTALLATION DRAWING.
w O. SPLICE THE WIRES IN THE UNILET AS SHOWN ON SHEET 2 OF OWG. 0 47915.
E. TIGHTEN THE CORD GRIP RTnNG TO GEl A WATER TIGHT SEAl ON THE CABLE.
....•. F. INSTAlL THE UNllET COVER WITH THE GASKET.

<0 4.~
A. OPEN THE JUNCTION BOX OF MOUNTING PLATE ASSEMBLY 0 47860.
B. CONNECT 120 VAC TO TERMINAl TBH &: TBI-2.
C. CONNECT RED WIRE OF THE CABLE TO TERMINAl TBI-3 AND BLACK
WIRE OF THE CABLE TO TERMINAl TBI-4.
O. USE SCHEMATIC DIAGRAM C 47937 AND INSTALLATION DIAGRAM 0 47915
BAYLOR BRAKE FOR REFERENCES.

NOTES:
1. EXISTING BRAKE OUTLINE IS SHOWN IN BROKEN LINES.
2. SOLID LINES INDICATE INSTALLATIONASSEMBLY FOR COOLING WATER AlARM SYSTEM.
3. n.OW SWITCHES MUST BE ALGNEO WITH THE n.OW DIRECTION. DOUBLE HfAOED
ARROW WILL BE RIGHT ANGLE TO PADDLE SWITCH.
4. USE RED AND BLACK WIRES OF THE CABLE TO CONNECT THE FLOW SWITCH AND
TEMPERATURE SWITCH.
5. TEST THE COOLING WATER AlARM SYSTEM BY TURNING OFF THE INLET WATER.
6. WITH NO WATER n.OW, THE AlARM WILL SOUND AND THE RED LIGHT WILL BE ON.
PRESS THE BUnON TO SILENCE THE AlARM, LEAVING THE LIGHT ON. RESTORING
THE WATER FLOW WILL RESET THE AlARM SYSTEM.
7. WHEN THIS SYSTEM IS INSTALLED ON AN EDDY CURRENT BRAKE, THE BRAKE MEETS
REOUIREMENTS OF FACTORY MUTUAl AND WARNS OPERATOR WHEN THE OUTlET TEMP.
EXCEEDS 165'F.

-.
_.-
.--
4" THRfAOED DRAIN PIPE
..
~
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~ ~ COI\APANY
.l'/1T1ll1: "Y'"'"LC:>~
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-"Ills 90186
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en
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eN
 Section 4
Theory of Operation

4.1 General 4.2 Brake Operation on Rig

When the steel rotor rotates through the When a BAYLOR Eddy Current Brake is
stationary magnetic field, currents are induced installed on a rig its response may vary
in the rotor. These currents, commonly called depending upon the following items:
"eddy currents", produce a magnetic field
• Brake torque capacities may vary + or -
which interacts with the stationary field. This 5% between individual units.
field interaction produces a force, which
opposes rotor rotation, and provides the • When the brake becomes overheated it
braking torque for the BAYLOR Brake. will lose some of its torque capacity.
• Normal reaction time for the brake to
The Eddy Current Brake provides high braking reach maximum braking torque is
torque at low rotor speeds. This is a distinct approximately 2 seconds. This may vary
advantage over other types of braking systems depending upon the Brake Control
such as the water brake. The braking torque of System employed.
the Eddy Current Brake is dependent on the • Normal reaction time for the brake to
strength of the stationary magnetic field, rotor
decay to zero braking torque is
speed, and rotor temperature. Torque
approximately 1-2 seconds. This may
increases with magnetic field strength and with
vary depending upon the Brake Control
rotor speed. Torque decreases as rotor
System employed.
temperature rises and the rotor expands which
widens the air gap. The strength of the • As the brake ages, the air gap between
stationary magnetic field is controlled by the the rotor and the magnets may increase
field coil in proportion to the braking due to rust or erosion which will cause a
requirements. decrease in brake output torque.
With all these factors in mind, the operator
The eddy currents induced in the rotor produce must learn and get a feel for the brake
heat. This rotor heat must be kept within response time during the early stages of
acceptable limits or braking torque will be tripping when the loads are lighter.
reduced. To maintain rotor temperature within
When the load exceeds the brake capacity
acceptable limits, a cooling system is required. note that the brake will not be able to control or
A steady flow of water is directed into the area properly decelerate the load.
containing the rotor, as illustrated in Figure 3-4.
The movement of the rotor through this water Proper operation of the brake is to apply the
as it turns provides uniform cooling of the rotor Eddy Current Brake before releasing the main
surface. If the flow of cooling water fails while drawworks friction brake when tripping into the
the brake is in operation the rotor will become bore hole.
overheated. In this state the rotor will be
damaged if a safe cooling procedure is not
followed. Consult Section 6 of this manual for CAUTION!
the proper procedure to use. When the brake is being used close to its
Maximum torque capacity apply the Eddy
Current Brake before releasing the main
drawworks friction brake when tripping into
the bore hole.

4-1
 Section 5
Accessories and Options

5.1 General
5.1.3 Brake Cooling Packages
In striving to satisfy the needs of all custom~rs, Each Eddy Current Brake needs a
National Oilwell offers the following
cooling system to remove the heat from
accessories and options.
the brake while the brake is being used.
5.1.1 Brake Controller National Oilwell builds brake water
cooling systems to meet a variety of
Each Eddy Current Brake requires a
operational and regulatory requirements.
brake controller which supplies voltage to
the field coils. The brake controller is a In addition to cooling water for the
BAYLOR Eddy Current Brake, extra
variable DC voltage power supply which
controls the amount of excitation capacity can be designed into the system
delivered to the brake field coils as a for the main drawworks friction brake, top
function of the position of a driller's drives, electric drive motors, and other rig
cooling requirements.
control lever. A complete controller
system consists of an isolated power 5.1.4 Cooling Water Alarm
transformer, a power control unit, and a
driller's control. A cooling water alarm system is available
to monitor flow and temperature of the
5.1.2 Special Brake Shafts coolant to the brake. This system warns
the operator whenever cooling to the
Certain applications may require an
brake has been impaired. It can prevent
optional special shaft on the brake.
the need for expensive repairs.
Double-ended shafts and special
coupling features have be~n 5.1.5 Safety Monitoring Device
manufactured in the past. If the brake IS
A safety monitor system manufactured by
required to operate in highly regulated
National Oilwell which signals the
areas such as the North Sea, then
potentially dangerous loss of control of
special shafts may be required to brake excitation is available for BAYLOR
conform to low temperature Brakes.
requirements. One of these may fit your
needs; if not, a new "special" can be
designed to your specifications.

If there is a need for further information about any of the afor~menti~ned items,
or if you have other special requirements, please contact National Ollwell Sales
Department or Service Department.
Telephone Number in the U.S.A. (281) 240-6111
Fax Number: (281) 274-0426

These Numbers are in operation 24 hours/day, 7 days/week

5-1
 NATIONAL OILWELL
Section 6
Maintenance and Service

6.1 General
An Inspection and Maintenance Schedule is CAUTION!
provided at the end of this section. The accumulation of moisture in the coil
6.1.1 Lubrication cavities caused by plugged breathers will
result in early deterioration of the coils.
To maintain the lubricant volume, add
These breathers should be cleaned as
approximately 2 ounces of grease to
outlined above and must always be pointed
each bearing cavity each 24-hour period,
downward for proper drain.
or before each trip into the hole with pipe.
There is a grease fitting for each of the
two bearings, and each must be
GREASE FITTIN
independently lubricated (See Figure 6- BREATHER/VENT
TOP & BOTTOM OR
(TYPICAL BOTH SIDES)
1). The recommended grease is a NLGI MAY BE BOTTOM ONLY
ON SOME MODELS
NO.2, water resistant (Lithium base) (TYPICAL BOTH SIDES)
grease. A good grade of lithium or
sodium base ball and roller bearing
grease may be used. The bearings and
seals will not be harmed by excess
grease. It will simply enter the cooling
water stream by momentarily lifting the
seal lip to relieve pressure. Orawworks
manufacturers and users may connect
the grease inlet holes in the bearing caps Figure 6-1
to lubrication header blocks with tubing to Inboard Side
facilitate lubrication from a remote point.
This is satisfactory if the tubing is 6.1.3 Air Gap
regularly inspected, and it is determined
that the required amount of grease is If there is erosion/corrosion in the air gap
actually reaching the bearing. between the rotor 1.0. and the magnet
6.1.2 Breather 0.0. due to the use of poor quality
cooling water, this gap distance may
Figure 6-1 shows a breather on the upper gradually increase to a point where rated
and / or lower exterior face of each torque will be reduced. In making any
magnet assembly. These breathers field check of this gap distance, it is
should be inspected periodically to insure necessary to allow for any pitting and for
that they are clean and have free access any scale build-up to determine the
to air to minimize condensation and to effective gap distance. Any scale present
prevent any accumulation of moisture in does not provide an effective magnetic
the coil cavity. They should be removed path so it must be deducted from the gap
and cleaned with kerosene at least once distance measurement. This air gap
a month. should be checked monthly. The effective
air gap is the average of all
measurements taken.

6-1
 NATIONAL OILWELL Section 6

6.1.6 Preparation of Brake for Storage 6.1.7 Removing a Brake from Storage
If a brake is to be stacked, stored, or If a brake has been in storage, either after
inactive for any long period, proper field use or as shipped from the plant, for
precautions should be taken to prevent more than three months, it will need a
the rotor assembly from becoming stuck through inspection to make sure it has not
to the magnet assemblies because of been damaged in any way and all parts
scale, rust, or salt growth. As an initial are properly in place. Failure to observe
step, both bearing cavities should be the following points can result in serious
pumped completely full of grease to damage.
protect the bearings during storage.
1. Remove all plugs and drain
If water of doubtful nature had been preservative fluid from the brake.
circulated in the brake before being
2. Rotate shaft and verify that the rotor
inactivated, it should first be flushed with
turns freely.
good clean water. The interior of the
brake should then be sprayed with a fluid 3. Check the bearings and seals.
which will inhibit rust and/or salt growth.
4. Replace seals if they have been in
Clean oil, kerosene, diesel fuel, or other
place for more than three years.
similar petroleum products will serve this
purpose if a specific inhibitor is not 5. Check and tighten all the bolts.
available. Spraying the interior of the 6. Grease the bearings and seals.
brake can be accomplished by inserting a
spray gun nozzle into each of the air gap 7. Remove clean magnet breathers
inspection holes which are equally and re-install. Replace if unable to
spaced in each of the end rings at the clear breather obstructions.
rotor diameter, as illustrated in
If the brake has been in storage for
Figure 6·2. approximately one year or more, megger
the windings and check coil internal
resistance before energizing the coils.
CAUTION! Coil internal resistance values may be
Do not remove coil breather / vents and obtained from values listed in Section 3,
Figure 3-15. Coil resistance to ground
introduce any fluid or substance into the coil
should not be less than 5 megohms
cavity. This could attack the coil insulation (tested with 500 VDC megger and with all
and greatly reduce the life expectancy of the
interconnecting wires disconnected from
brake coils. See Figure 6-1. coil leads).
Note: Coil leads will normally read low
due to humidity or other moisture which
Plug all ports and continue to spray until can accumulate in the brake junction box.
the rotor is well coated with the preserving If readings are low enough to cause
fluid. Rotate the shaft once each month to
concern, use heat source such as hair
distribute the bearing grease and blow drier to reduce moisture in leads. If
preserving fluid internal coating. Spray this process does not help resistance
more preserving fluid into the brake air readings, call National Oilwell or licensed
gap inspection holes if necessary. Service Companies listed in Section 5.
Additionally, all exposed surfaces of the
shaft should be coated with Rust-Ban 373
or an equivalent rust preventative.

6-3
 Section 6

The inner race of the bearings has an

NOTE! interference fit with the shaft, and
hydraulic pulling equipment is usually
Care should be taken to exert even pressure required to remove the bearing when cold.
on the four pusher bolts. This will move the If the bearing is to be discarded, it may be
plate out evenly and avoid damage. The removed by other methods if proper care
model 6032 brake center plate is cast iron. is taken to insure that the shaft is not
Be especially careful not to exert uneven damaged. The outer race may be cut off
pressure on the pusher bolts or the center and the rollers removed. The inner race
plate may crack due to its brittle, cast iron, may then be heated and removed. Any
construction. The bearing is now clear and time a bearing is replaced, it is
may be removed by conventional procedures. recommended that the related seal be
replaced as well as its seal sleeve in order
to provide adequate protection for the new
bearing.
To remove a bearing, proceed as follows:
1. Install new seal sleeve on shaft.
Note: ~ heat seal sleeves or
bearings with heating torch. The
point source of heat of a heating
torch is in the range of 6000 degrees
F. This high temperature small area
contact with bearing tempered alloy
steel will cause a micro structure
change to occur which will greatly
reduce the life expectancy of the
Figure 6·5 bearing or seal sleeve. Heat
Bearing Assembly bearings and seal sleeves in an
Inner
Bearing
Center Seal
MachinedPlateRetainer
Lock
areas with all
NutInstalled
with requiring
and
Jacking oven or a container of clean oil. Heat
Grease
Item Rotor
Sleeve,
Spherical
End
One Ring
Cylindrical
Bearing
No. Seal
ofwith
the
CapShaft
twoDescriDtion
Roller
Brake Bearing
Magnets
Housing
Lockwasher range is 200-250 degrees F. After
10
84329657
12 Screws
threads
sealant installed
when assemblinq
11 heating the seal sleeve and
installing on the shaft, place a good
quantity of clean bearing grease on
the seal sleeve. Before installing the
seal retainer with the seal over the
seal sleeve, also hand-coat the seal
with clean bearing grease. Install
retainer and seal over seal sleeve.
Insure that seal lip is turned in right
direction with respect to bearing
cavity. (If in doubt, look at assembly
drawing in this manual. Some brake
models have more than one seal.)
2. Heat and install new bearing.
3. Install the snap ring or bearing
lockwasher and locknut.

Note: The tightness of the locknut

should be checked after the bearing
has cooled.

6-5
 ~' NATIONAL OILWELL Section 6

6.3 Electrical Problems and There is no difference in the inboard and

Troubleshooting outboard magnets. The leads are numbered for
convenience in wiring and to assist in proper
All electrical problems must be in one or more
coil lead connection to insure proper coil
of these components.
polarity. Outboard magnet leads are F1, F2, F3,
1. Interconnect cables and wiring. and F4. Inboard magnet leads are F5, F6, F7,
and FB. If there is a need to convert an inboard
2. Brake (coils, lead wires, or terminations).
magnet to outboard or vice-a-versa the
3. Control System (Refer to Control System following table should be used:
Manual).
Leads F1 = FB, F3 = F6
Experience has shown that about 90% of all F2 = F7, F4 = F5
problems can be traced to interconnect cables
and wiring, therefore it is suggested that these Therefore, the inboard and outboard magnets
be checked first. are mechanically and electrically
interchangeable. Refer to Figure 3-3
With power removed, use a 500 VDC megger
Most problems can be solved with the
to check for grounds. Wiring and interconnect
preceding information. Additional checks which
cables should be a minimum 1 megohm to
ground. may be useful are included in the voltage and
resistance checklist in the BAYLOR Brake
Individual magnet coils should be a minimum of Control System Manual.
5 megohms to ground. An ohmmeter should be
used to check the coils for open or short
circuits. Coil resistance is listed in the
specifications summary in Section 2.

6-7
 NATIONAL OILWELL Section 6

Loss of torque capacity due to Overheating the rotor will increase the magnet! rotor gap. This
overheating the brake. decreases the brake output torque. Overheating the magnet
will increase the coil resistance. This decreases the coil
current, and this reduces magnetic flux. This will also reduce
the torque.

1. If the water flow rate is below the recommended level,

then raise the input GPM to the specified level.
2. If the amount of cooling water is not sufficient to maintain
the system at or below 165°F maximum brake discharge
temperature, then add water to the tank. Be sure the
volume of the tank is at or above the recommended
capacity. NOTE: In extremely hot working areas,
additional volume may be required.
3. If no water is applied to a brake that is full on, damage to
the coils or rotor will occur.

If this happens, the rotor will be overheated in a matter of

No cooling water to brake - minutes. If cold water is turned on an overheated rotor the
cooling on overheated rotor.
rotor will distort and may lock up on the magnets. To cool an
overheated rotor:
a) Let the rotor air cool to 200 to 250°F
b) Then turn the water on while turning the rotor slowly. This
procedure may salvage the rotor.
Torque not at full capacity due to
If coils are connected incorrectly, refer to Section 3 of this
incorrect coil polarity
manual. Check for coil polarity and connections.

1. If an over-voltage is applied to a coil, see electrical

Torque reduced due to loss of
one or more coils troubleshooting in brake controller manual.
2. The coils may have an insulation failure due to
condensation in the coil cavity. To prevent condensation
from becoming a problem, remove the coil cavity drain
plugs and/ or breather plugs and clean them periodically.

NOTE: Undue flow from the drain plugs and/ or breather plugs
would indicate the magnets not working properly.

6.5 Inspection and Maintenance Schedule If cutting back on flow rate results in
too high temperature on brake water
6.5.1 Daily Inspection
at outlet (165 degrees Fahrenheit),
1. Cooling Water Flow Rate check on brake discharge water line
Inspection to see if it has become restricted.
Flow rates from brake should be
Observe brake water overflow vent
unrestricted.
while lowering drill string into hole. If
constant flow is observed coming
from vent, slowly begin to reduce
rate until constant flow is no longer
observed coming out of vent.

6-9
 'I
!Pi NATIONAL OILWELL Section 6

6.5.4 Quarterly Inspection

NOTE!
1. Voltage and Resistance Check
Remove only one set of leads at a time, for
Check brake coil voltages at brake
example, F1 and F2. Mark their position
junction box as described in voltage
carefully; check the coil and then return the
check. After voltage check is
leads to their exact same position. Failure to
complete (see 6.5.2), turn off main
return all leads to their correct position could
supply voltage to brake control
result in incorrect polarity which would
system. Disconnect each coil from
seriously decrease the braking effort.
the electrical control system by
Readings for the individual coils should be as
removing coil leads from their
listed under coil resistance in summary of
installed position in brake junction
specifications. See Section 2.
box. The coils should read 5
megohms or higher to ground when
checked with a 500 Volt DC megger
electrical insulation tester.

Cut here and place near Maintenance area Cut here and place near Maintenance area Cut here and place near Maintenance area

BAYLOR Eddy Current Brake

Maintenance Schedule
INSPECT
VOLTAGE
DC
DRAIN
AIR VOL
DISCONNECT
LUBRICATE
GAP ELECTRICAL
AND
COOLING
TAGE
/ BREATHERRESISTANCE
CHECK
INSPECTION
CLUTCH SYSTEM.
BEARINGS. CHECK
INSPECTION
INSPECTION
3. 2.
2. 3.
DAILY SCHEDULE
1. 1. WEEKL Y SCHEDULE
QUARTERLY SCHEDULE
1. 1.
MONTHL Y SCHEDULE

6 - 11
 Section 7
Parts and Supplies

7.1 General

The recommended spare parts and supplies for the 5032 BAYLOR Brake are provided in the
following table:

1555-1
1030-20-0001
0-0001
1420-20-0028
07940
1690-20-0028
1420-20-0040
1075-10-0003
1555-10-0002
08410
1030-20-0002
06614
1690-20-0040 Part No. Breather/Drain
Seal, Outboard
Inboard
Locknut,
Sleeve,
Bearing,
Housing, Outboard
Seal,
Inboard
Outboard
Outboard
Lockwasher, Inboard
Inboard
Outboard
Breather
Inboard
Description
Recommended Spare Parts
BAYLOR Eddy Current Brake

7-1
 NATIONAL OILWELL
Section 8

Drawings - 5032 Brake

8.1 Drawing List

008386 Assembly - Model 5032 Eddy Current Brake with Standard Shaft

BIM 08386 Bill of Material- Model 5032 Eddy Current Brake Assembly

D 46101 Outline and Mounting - Model 5032 Eddy Current Brake

C 10712 Schematic - Brake Water Cooling System

8-1
 Section 8

0( u

\,
\,
\,
\ \

0( III u o

8-3
--6101"* AS Of
PIPE
0
**10712**
**56776,,*
WIRE DIAG
DIAQ
00
oaASSEMBLY
2.000
a54
99952
4.000
58
12.000
1.
75
~.OOO
ITEM74
69
2. 0&
01
a0
.000
12.000
1. 67
78
66
1.000
DEFAULT
NO.2.000
61
65
8.000
63
60'
2.000
70
76
77
50 0- I~
.050
1.000
4.000 M
DATE
,9,0
Z",
2.0001.000
62
55
56
.2.000
57
59 000
BRAKE OFF
REV:
000
.500
.0,00
6/09/98
QTYPER t.1000
1320-06-0016
DAYS
COMPONENT'S
1.000
1.000
1.1.
8/11/82
'1.000NN
X000
000
11/04/83
1/10/89
4/13/91
2/16/89
2/06/85
6/13/88
ASSY,
EfFECTIV
231591-63 FACTR
1998
LI,200,2.MDATABAS
1885-05-0008
REFERENCE
NN
Ell.
YN
NN
LB
DATE EA
TIES,P
REFERENCE
X
OPCODE:
ST
EA P
M
FS
UNION,
NAMETAG,
WASHER,
SUPPORT,
BRAKE
YIELD6/09/98
8./31/81
10/18/85
1,000 EP
PACKET,
HHCS,
NIPPLE, NN
.050
YN
DESCRIPTION
F5032
CONDUIT,
GREASE,
PLUG,
SEALANT, 1
CABLE
,99/99/99
99/99/99
OBSOLETE
NAMEPLATE,
LOCKWASHER,
MARKER,
PACKING,
YN UM
CAPLUG,
NN
8/26/81BAYLOR
ELBOW, SC
FITTING, PIPE
Qf 11
LUBE
PLAIN
SHIP 1o1.184
0
SILICONE
STO
BRAKE
COIL
NGLI#2
3/8-16
PIPE1~1/4
1-1/4
WIRE
99/99/99'
4" 1-1/4
SEALING
GROUND
COMPANY
,90 HEL
FIBER
1" QUANTITY
CNDPLASTIC
1-1/4NPT A
DOCUMENTATION
UNCLASSIfIED
1. 000
.500 oP B 3/4
RV
E
2,.
SEQ
4WIDE
RIGHT
5032
3/8
SfT
WIRING
LEAD
XSELF-LAM
X
SQ SPR
1-1/4" GALV
SS
PERMATEX
S5
SCH40
CLOSE
HD CP 7.5"
HAND
9.75
COMPOUND
3/8
SET
Y
GALV CI
SCH40
STL55
Fl-F6
SEALING
HI
l\.PP'. 5 p...~ 0
DESIGNATOR
GALVLG BILL Of MATERIAL

D"lJ~¥t{q{~3
f. ) 5/Vf -2
PAGE NO:
FINAL APPVL.
RELEASE
Pt 1M N ". 'T- J~
CHK.~<P-f~
~-'O-9 e
(. $(Ywn(.Q,' '
~
)I i

t.A
(1)
n
=
o::l
co
 LECENO:
& GATE VALVE - SIZE ACCORDING TO WATER FLOW TO BAND BRAKE
AND DRAWWORKS MANUFACTURER SPECIFICATIONS.

& GATE VALVE - 1"

40-50 PSI RECOMMENDED & GATE VALVE - 1"

BY DRAWWORKS MANUFACTURER
MODEL &, RELIEF VALVE
5032
BRAKE
.&, PUMP - SIZE FOR GPM REQUIRED AND PRESSURE REQUIRED, WITH
ROTARY SOME SAFETY FACTOR INCLUDED.
CONNECTION
&. RESERVOIR - NOMINAL CAPACITY-WILL VARY WITH DRILLING CONDITIONS,
1" INLET IIOUTLET
4" Ill" INLET AMBIENT TEMPERATURE, ETC.

& FLOW SWITCH - CONNECT PER BAYLOR DRAWING B4676S.

& I U I
,-,.:r,-l
I FLOW I
I SWITCH I
&
L J MAX. DISCHARGE

2"-50 GPM - 1DOT MAX. & TEMP. 16S' F

SEE NOTE 4
RELIEF
ex>
I VALVE MIN. 4"
--.J OUT
&, ~ SET AT NOTES:
IN
SO P.5.1.
MAINTAIN A
DISCHARGE TEMPERATURE
1. OPEN VALVE NO. &
OF 165'1 MAXIMUM 2. WITH VALVE NO. .6 CLOSED, ADJUST VALVE NO. .& FOR 25 GPM - OPEN VALVE NO. .6 UNTIL
....l..QQJ!.PM FULL FLOW, 50 GPM, IS OBTAINED.
100' F
MAX.
3. TIGHTEN STEM PACKING ON VALVES AND REMOVE HAND WHEELS ON VALVE NUMBERS & AND &.
4. THIS DISCHARGE LINE MUST DRAIN TO GRAVITY -- DO NOT RESTRICT, AS DAMAGE TO BEARING WILL
DISCHARGE FRESH WATER RESULT.
&.

•
75 BBL
PH 7.0 TO 7.5 5. ALL LINE SIZES SHOWN ARE NOMINAL, AND CAN VARY WITH LENGTH ON RUNS.

6. TO MEET FACTORY MUTUAL REQUIREMENTS FOR USE ON THE S032 BRAKE IN CLASS I, DIVISION I,
SUCTION
GROUP C AND D LOCATION, A LOSS OF WATER FLOW ALARM SYSTEM WILL HAVE TO BE SUPPLIED
AND INSTALLED BY THE USER REFERENCE BAYLOR DRAWING B4676S FOR RECOMMENDED FM
APPROVED PARTS. SEE DRAWING 47915 FOR BAYLOR RECOMMENDED FLOW AND TEMPERATURE
MOTOR-PUMP
ALARM SYSTEMS.

APPROVED
REDRAWN TO A-CAD

,m:l:.OO5 :t: I/Ie· ~ ""-L~F=l

.n :l:.020
OEOllALTlX..ERANCE:EXCEPTN~~
.le :t..05O
llR .010
NoICULM
CO/\/lPAI'JV
fHSH 1~ :l: '/2 HOUSTON TEXAS U.S.A. en
00 NOT ~ DRAWiMO mu: SCHEMATIC, CD
ss""''' 9 J/97 BRAKE WATER COOLING SYSTEM (')
- t.40DEL S032 BRAKE !:!:
~ o::J
10712 ••. 1 ,,1 G
nll5 DOCUl.IENT IS AND COKTAINS COfof1OEJffi.AL ANtI TAAD[ SECRET INFORw.nON Of THE BAYlOR COl.IPANY. 500 INOlJSTRlAl BLW.,
SUGAR I..NIO,TIXAS n<478-2896. THIS OOCUl.lENT IS LCW£I) FOR LIMITED PURPOSES ONLY, AND REMAINS THE PROPEJm' OF CO
ll£ ,"YlOR (X)t,lPANY. IT IS TO lIE REltIRNED UPON REQUEST AND'" All. MKI'.i IA'ON COMPL.ET1ON CFlllE PURPOSE or THE 1..l::w.I.
NEITHER IT NOR THE rNFORw,llOH IT CONTAINS t.lAY BE REPROOVCED, USED, OR DISCLOSEO TO PERSONS NOT ~V1NC A TO reo
KNOW CONSISTENT WfTH lliE PURPOSE OF THE L~. WITHOUT WRmEN CONSENT OF lHE &,'flOR CONPf<NY.