Loss of brake control power during drilling operations leaves the driller without the ability to bring the travelling block to a safe stop. The RCP Elmagco Brake Monitor Unit (BMU) is a PLC-based system that actively monitors critical brake control components, power supply status, and cooling circuit flow and temperature — performing continuous self-checks to detect faults before they become failures.
On detection of a critical fault such as phase loss or command signal mismatch, the BMU immediately activates battery backup, connecting batteries across the brake coils to maintain full braking capability and allow the operator to bring the blocks to a controlled stop.
RCP Elmagco Brake Monitor – Faceplate
RCP Elmagco Brake Monitor
RCP Elmagco Brake Monitor
RCP Elmagco Brake Monitor – PLC System
Fault Detection & Response
The BMU distinguishes between critical and non-critical faults, responding proportionally to the severity of each condition.
Non-critical faults activate audible and visual alarms in the Driller’s Cabin, alerting the operator without interrupting operations. Critical faults — including loss of control power phase and signal mismatch between the brake handle input and output current applied to the eddy current brake coils — immediately trigger battery backup contactor activation.
Typical monitored points include:
- AC Phase Status
- PLC Status
- Battery Backup Available
- Charger Healthy
- Brake Coil Failure 1 & 2
- Earth Fault 1 & 2
- Command Signal Mismatch
- High Temperature Alarm
- Brake Cooling Circuit Temperature & Level
Disc Brake Monitor
RCP also supplies a disc brake monitor for drilling rigs operating hydraulic disc brake systems. The disc brake monitor applies the same continuous monitoring philosophy as the eddy current BMU, with critical component surveillance covering HPU pressures, hydraulic fluid temperatures, and fluid levels. Audible and visual alarms alert the driller to abnormal conditions, and the system is configurable to the specific hydraulic and control architecture of the installation.
Applications
- Offshore and land drilling rigs with eddy current auxiliary brake systems
- Drilling operations requiring continuous brake health monitoring and automated fault response
- Rigs requiring battery backup protection against control power loss
- Hydraulic disc brake installations requiring HPU and fluid condition monitoring
