Fail-Safe Brake Device (FBD)

Installation and Operation Manual

Manual Part Number: FBDMANUAL

Manual Revision: 1

Release Date: January 2022

Table of Contents
Fail-Safe Brake Device (FBD) Manual............................................ Error! Bookmark not defined.
About This Manual ................................................................................................................ 3
Definitions .....................................................................................................................................3
Notes, Cautions, and Warnings.......................................................................................................3
Illustrations and Photographs.........................................................................................................3
Safety Guidelines................................................................................................................... 4
Description ............................................................................................................................ 4
Theory of Operation .............................................................................................................. 6
Specifications ........................................................................................................................ 7
Installation Procedure ........................................................................................................... 9
Mounting (Mechanical) Installation .............................................................................................. 10
Wiring the Equipment .................................................................................................................. 11
About This Manual

Definitions

FBD Fail-Safe Brake Device

PMD Permanent Magnet Drivehead
PCP Progressing Cavity Pump
BRB Brake Resistor Bank
LOTO Lock Out Tag Out safety procedure to ensure no energy (electrical and/or
mechanical) is present while working on equipment

Notes, Cautions, and Warnings

Notes, cautions and warnings are used throughout this manual to provide readers with additional
information and to advise the reader to take specific action to protect personnel from potential
injury or lethal conditions. They are also used to inform the reader of actions necessary to prevent
equipment damage. Please pay close attention to these messages.

Notes provide useful information and tips that can make the operator’s job
easier. Those are identified with the symbol on the left.

Cautions are identified with the caution symbol (symbol on the left), this
indicates that the potential damage to equipment or injury to personnel exists.
Extreme care should be taken when performing operations or procedures
preceded by this caution symbol.

Warnings are identified with the warning symbol (symbol on the left), this
indicates a definite risk of equipment damage or danger to personnel. Failure
to observe and follow proper procedures could result in serious or fatal injury
to personnel, significant property loss, or significant equipment damage.

Illustrations and Photographs

The illustrations and photographs in this manual provide graphical examples of equipment. These
examples are not intended to represent every possible situation and will vary in appearance to
the actual equipment.
Safety Guidelines
Observe the minimum safety precautions listed below and all safety precautions provided
throughout this manual. Following these precautions will protect you and others from injury or
death and prevent equipment damage and environmental impact.

 Follow all customer safety guidelines.

 Stand upwind when installing or dismantling equipment.

Hydrogen sulfide gas (H2S) may be present in high concentrations. You must
have proper H2S detection equipment with you and practice all
recommended safety precautions when working around wellheads.

 Live or discharging electrical equipment poses an electrocution hazard.

You MUST turn off power to the enclosure and follow proper lockout / tagout
procedures before opening the VSD enclosure. Failure to heed this warning
can result in severe injury or death.

If it is necessary to work on or around live electrical equipment, you must

wear electrical hot gloves, a blast shield and fire-retardant clothing in addition
to regular PPE. Failure to do so could result in severe injury or death.

 Permanent Magnet Driveheads can become generators, ensure the unit is properly locked.

You MUST ensure that the Permanent Magnet Drivehead is completely stop
and whenever possible install a rod lock device or remove the polished rod
clamp from the rotor. Failure to heed this warning can result in severe injury
or death.

Description
The Permanent Magnet Drivehead (PMD) is a direct couple hollow shaft drive unit that provides
direct movement to a Progressing Cavity Pump system. The PMD is designed to be controlled by
a Variable Speed Drive, and to be braked by either a dynamic VFD braking system and/or a passive
electric braking system.

The Fail-safe Brake Device (FBD) was developed to provide passive electric braking control to a
PMD during normal operation, as well as, during those conditions where electrical power is not
present. The main purpose of the FBD is to protect personnel and all equipment connected to
the PMD in case of a complete power failure.
The FBD is comprise of two (2) main components:
(Figure 1) Control Junction Box
(Figure 2) Passive Brake Resistor Bank

Figure 1 - Fail-Safe Brake Device - Control Junction Box

Figure 2 - Fail-Safe Brake Device – Passive Brake Resistor Pack

Theory of Operation
On a Progressing Cavity Pump (PCP) System the connection between the downhole pump and
the surface equipment is the rod string. To operate the downhole pump, the drivehead provides
rotational kinetic energy to the rod string to twist it and start the movement of the pump
downhole.

Every time the PCP system is stopped, the kinetic energy stored on the rod string and the weight
of the fluid inside the tubing create a downward and reverse force that generates what it is
known as backspin, as shown on Figure 1. The backspin is a sudden rotation of the system
counterclockwise once the rod string has reached a zero-speed, that needs to be controlled to
protect the equipment and the personnel around the well. The intensity and speed of the
backspin is affected by the size of the rod string, size of the downhole pump, size of tubing, etc.

With the implementation of PMD into PCP systems, the Variable Speed Drive (VSD) has been
upgraded to dynamically control the backspin generated by the rod string. However, in many
cases some VSDs are not equipped to dynamically control the energy generated by the backspin.

The FDB has been designed to operate with and without power. When power is available, the
FBD will communicate with the VSD to engage the PMD and allow for normal operation. Once
the VSD sends a stop command to the FDB, it will automatically disengage the PMD from the
VSD, and will engage the PMD with the Brake Resistor Bank (BRB), this will limit the maximum
speed and torque that the PMD is allow to rotate on backspin and at the same time will dissipate
the kinetic energy as heat over time.

In the event of a power outage or any other critical failure on the VFD, the FBD will automatically
disengage the PMD from the VSD and will engage the PMD to the BRB. The PMD will stop and
enter a controlled backspin to dissipate the kinetic energy. Once power is back into the system,
a monitor device will

Figure 3 - Backspin example

Specifications
The FBD systems has been designed to be installed on a non-classified area.

Dimensions, weights, and other specifications

Fail-Safe Brake Device Cabinet:

Length: 19.69” (500mm)

Width: 8.31” (211.15mm)
Height: 23.62in (600mm)
Weight: 56lbs (25.4kg)

FBD12380 FDB12415 FBD12480

Rated Voltage 380V 415V 480V
Rated Frequency 50/60Hz 50/60Hz 60Hz
Input Current 0.4A 0.4A 0.4A
Max Brake Current 80A 80A 80A

Figure 4 - Fail-Safe Brake Device Dimensions

Passive Brake Resistor Bank:

Length: 25.0” (635mm)

Width: 26.75” (679.45mm)
Height: 20.0” (508mm)
Weight: 90lbs (40.8kg)

Nominal resistance: 3 x 2.0ohm ±10% with ±365 TCR

Operating temperature: -55°C to +415°C (-67°F to 779°F)
Nominal Ambient Temperature: 40°C (104°F)
Nominal power: 12kW ( 3 x 4kW per leg, star connected)
Nominal Current: 3 x 45Amp

Figure 5 - Passive Brake Resistor Bank Dimensions

Installation Procedure (Block Diagram)
Installation Procedure

The installation procedure describe herein is based on recommended practices.

Use the installation suggestions as a guideline. Follow the local Electrical Code
and the customer’s best practices during installation, commissioning, and
operation.

Install a polished rod brake clamp on the well’s polished rod to prevent any
unwanted rotation of the PMD or disconnect the polished rod from the top of
the PMD while electrical work is being performed.

Mounting (Mechanical) Installation

Install Fail-Safe Brake cabinet closer to the VFD. Preferably on the side of the VFD enclosure, or
on a support unit near the VFD cabinet.

Perform a LOTO on the main power feeder to the VFD cabinet.

You MUST turn off power to the enclosure and follow proper lockout / tagout
procedures before opening the VFD enclosure. Failure to heed this warning
can result in severe injury or death.
Install the FBD cabinet with bolts and nuts to the fixture.

Close any opening to prevent ingress of dust, water, or other contaminants to the FBD cabinet

Determine the best path for the power and instrumentation cables to exit/enter the VFD cabinet

Holepunch the bottom of the FBD to feed the following:

 Feed power cable from VFD input to FBD input (Voltage will match the field’s power grid voltage
rating. Use cable size suitable for the nominal input current)
 Instrumentation control cable from FBD to VFD
o Two pair. VFD permissive dry contact. VFD enable dry contact.
 Power cable from VFD output to FBD
 Power cable from PMD to FBD
 Power cable from Resistor bank to FBD
Install resistor bank on a well ventilate area.

It is recommended to install the resistor bank on the top of the VFD to allow
proper ventilation of the resistor bank.

For installation on top of the VFD cabinet, it is recommended to use strut channel and leave a
minimum of 2in (51mm) clearance between the bottom of the resistor bank and the VFD.

Holepunch a side of the resistor bank (on the terminal side) to pass the power cable that goes to
the FBD.

Suggested location
for power cable
access.

Figure 6 - Hole punch on FBD Resistor Bank

Wiring the Equipment

The FBD needs to be wire between the two FBD components and the VFD.

Perform a LOTO on the main power feeder to the VFD cabinet.

You MUST turn off power to the VFD and FBD enclosures and follow proper
lockout / tagout procedures before opening the VFD and FBD enclosures.
Failure to heed this warning can result in severe injury or death.

Use the installation suggestions as a guideline. Follow the local Electrical Code
and the customer’s best practices during installation, commissioning, and
operation.
The Fail-Safe Brake Device Cabinet has two sets of terminals, one for power terminal and the
second one for the control terminals. Refer to Figure 7 for location of terminal blocks

Figure 7 - Fail-Safe Brake Device Cabinet - General View

Power Terminals:

The power terminals are located on the left-hand side of the cabinet, refer to Figure 8.

Figure 8 - Fail-Safe Brake Device Cabinet - Power Terminals

Connect the power cable from the VFD Output to the terminal labeled U1, V1, W1.
Connect the power cable that feeds the drivehead into terminals labeled U2, V2, W2.
Connect the power cable that feeds the Passive Brake Resistor Bank into terminals labeled R1,
R2, R3.
All connections must be connected to ground on terminal PE.

Control terminals:

The control terminals are located on the right-hand side of the cabinet, refer to Figure 9.

Figure 9 - Fail-Safe Brake Device Cabinet - Control Terminals

Connect the power feed from the VFD power supply (main breaker – single phase) to the terminal
labeled L1 and L2.

Connect the control cable connected to the VFD permissive (the digital signal that will allow the
VFD to start the drivehead when all the energy has been released) to terminal block labeled 12,
32.

Connect the control cable connected to the VFD Start command. This is a dry contact output from
the VFD cabinet that will control the closure of the spring-loaded contactor. Connect the output
to the terminal labeled 01, 02.

MUST follow the local Electrical Code and the customer’s best practices for
grounding the equipment to prevent the risk of electrical shock.

The Passive Brake Resistor Bank will need to be connected to the Fail-Safe Brake Device cabinet.
Refer to Figure 10.
 Terminals for
drivehead leads.

Resistor Leg
connected into a star
termination

Figure 10 - Passive Brake Resistor Bank

The Passive Brake Resistor Bank is shipped without any cable connection, you
MUST ensure that the star connection is completed between the three legs of
the resistor bank to avoid any operational issues.

As indicated on Figure 10, ensure wires are connected on the bottom part of the resistor legs.
Ensure the cable is suitable for high temperature operation.

Terminate the power cable with a suitable cable gland on the side of the resistor bank. Connect
the power cable to the remaining three terminal legs on the resistor bank.

Connect each leg to U, V and W.

Applied the appropriate bolt torque to the terminal screws to prevent

damages to the electrical connections.

Ensure the enclosure is properly grounded before energizing the system.

Finally, inspect that all connections are properly terminated before removing the polished rod
brake clamp from the wellhead.