Roughneck roughneckDetails

TECHNICAL SPECIFICATIONS

2

SAFETY INFORMATION Pinch Point Hazards

3

OPERATION PROCEDURES Proper Positioning of ST-80C on Drill Pipe/Drill Collar Connections Making Connections Breaking Connections

4 6 8

STORAGE AND MAINTENANCE Lubrication Lifting and Transport

10 15

TROUBLESHOOTING

18

APPENDIX Lubricant Specifications Rig Solutions Aftermarket Service Phone Numbers

24 25

Iron Roughneck ST-80C

D392004720-MKT-001 Rev 01 Tally Book ST-80C Iron Roughneck OP.indd 1

8/29/2012 10:56:16 AM

Technical Specifications

Assembly Weight Hydraulic Requirements Tubular Connection OD Range Spin Speed Spin Torque Maximum Make-Up Torque Maximum Break-Out Torque Connection Height Horizontal Travel Casing Ready

7,800 lbs (3,538 kg) 28 GPM @ 2,100 psi (106 LPM @ 145 bar) min 40 GPM @ 2,500 psi (151 LPM @ 172 bar) max 4¼" to 8½” 75 RPM (nominal on 5" DP) 1,750 ft-lbs (2,373 Nm) 60,000 ft-lbs (81,500 Nm) 80,000 ft-lbs (108,500 Nm) 23" to 59" (584 mm to 1,498 mm) 60” (1,524 mm) No

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Pinch Point Hazards Keep all body parts clear of pinch points.


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Proper Positioning of ST-80C on Drill Pipe/ Drill Collar Connections Adjusting Procedure

! Before operating the ST-80C for the first time, be sure to remove the transport pin and place it in its storage position.

i

The ST-80C requires adjustment whenever the connection or pipe diameter changes and requires periodic verification per step 5 of adjustment procedure. 1. Push the extend/retract lever (on top of the carriage) to the fully retracted position. 2. On the control console, pull forward on the BACK/FWD handle forward to fully extend the ST-80C. 3. Move the UP/DOWN handle to raise the ST-80C to position the top of the box above the lower dies and below the spin rollers.

i Special attention is necessary if hard banding is present. Do not grip on hard banding. 4. Pull the Extend/Retract handle (on top of the carriage) to adjust the ST-80C until the base plate touches the connection diameter. Verify that the base plate is on the connection diameter and not on the taper or pipe. Adjust elevation as necessary, staying within the guidelines of step 3.

! Over extension will show contact with the base plate, but will tilt the wrench out of alignment. 5. Verify correct adjustment: Use the BACK/FWD handle to retract and extend ST-80C, a full stroke. Lightly swing the ST-80C by placing your left hand on top of controls guard, and your right hand on the front of lower left jaw body. Listen and feel for bumping contact against the connection and verify the bubble is within window.

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Extend/Retract Lever

Connection Pin Bubble Level 2 places

Torque Gauge P/N 30160681-1 Control Console

Spin Rollers P/N 30160614

BACK FWD

UP DOWN

TW UNCLAMP BREAK SW CLAMP MAKE

Box Shoulder Range

IN OUT

Upper Dies Set P/N 30174222 Lower Dies Set P/N 30172029 Lower Die Holder P/N 30160383

Connection Box

Max. difference in diameter pin larger than box.

D + 5/8" max.

D - 3/8" min.

D

D

Max. difference in diameter pin smaller than box.

Drill Pipe Allowable Tool Joint Differentials


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Making Connections

1 Use the control panel UNCLAMP/CLAMP lever, to clamp the jaws on the connection, Then release the lever. 2 Hold the TW/SW lever in the SW position. Wait 1 second before spinning. 3 Spin the connection IN. 4 Hold the TW/SW lever in the TW position. Wait 1 second before torquing. 5 Hold the BREAK/MAKE lever in the MAKE position until the desired torque is achieved.

i

If the wrench does not reach the desired value in one stroke, repeat. 6 UNCLAMP the jaws. 7 Recycle the torque wrench to BREAK to prepare for the next connection.

i If the wrench does not reach the desired value in one stroke, repeat.

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Left Right Right Hand Hand Hand 4

6

7

2 1 5 3 Left Right Right Right Hand Hand Hand Hand

Control Panel Levers


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Breaking Connections

1 Use the control panel UNCLAMP/CLAMP lever, to clamp the jaws on the connection, then release the lever. 2 Hold the TW/SW lever in the TW position. Wait 1 second before torquing. 3 Hold the BREAK/MAKE lever in the BREAK position until the connection is broken. 4 Hold the TW/SW lever in the SW position. Wait 1 second before spinning. 5 Spin the connection OUT. 6 UNCLAMP the jaws. 7 Recycle the torque wrench to MAKE to prepare for the next connection.

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Left Right Right Right Hand Hand Hand Hand 2 6 3 5

4 1 7 Left Right Right Hand Hand Hand

Control Panel Levers


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Lubrication Gearbox Procedure 1. Remove the fitting and view the oil level. 2. Oil level should be approximately 2-1/2 inches below the top surface of the top plate.

Spinner Gearbox Check oil level. See Lubricant Specifications Table for Recommended Gear Oil in the Appendix. Replace gear oil every 6 months or if dirty/contaminated.

Grease Fitting (2 places)

Grease Fitting (1 each side)

Daily

Daily


Grease Fitting (1 each side)

Daily

Daily BACK FWD

UP DOWN

TW UNCLAMP BREAK CLAMP MAKE SW

IN OUT

Torque Adjustment PRV., P/N 94817-3AN; PRV Knob, P/N 16498-1

Daily Grease Fitting (2 places)

Daily


Daily Grease Fitting


Front View

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i Replace gear oil every 6 months or if oil is dirty/contaminated.

Arm Pins (12 Places)

Daily

Guide Pins Brush mating surfaces with grease.

Daily Grease Fitting (1 each side)

Daily


Side View Side Guard Removed, displaying Lubrication


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Lubrication (continued)

(12) Pinkeepers P/N/ AR06-03-13

* P/N 30171622-500 (3) P/N 30171622-510 (3) P/N 30171622-511 (3) * P/N 30171622-501 (3)

R.H. Clamp Cylinder Upper: P/N 30174118 L. H. Clamp cylinder Upper: P/N 30172503

ST-80C/CL ST-80C/CL ValveValve Control Control

Clamp Cylinder: P/N 30160444 R.H. Torque Cylinder: P/N 30160685

* (ST-80-GENIII)

(L.H. Torque Cylinder: P/N 30160684)

Turntable Bearing: P/N 30170581-1

Side View Side Guard Removed, displaying Part Numbers

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8/29/2012 10:57:00 AM

i

Each grease fitting is to be greased until clean grease is seen extruding from the related component.

Grease Fitting

Daily

Daily Daily Grease Fitting

Grease Fitting

Daily Grease Rear View Fitting


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This page is intentionally left blank.

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Lifting and Transport Lifting

%HIRUHOLIWLQJWKH67&HQVXUH WKHSHGHVWDOLVLQWKHIXOOGRZQ SRVLWLRQDQGWKHWUDQVSRUWSLQ LVLQVWDOOHGLQWKHWUDQVSRUWSRVLWLRQ ,QVWDOOWKHWUDQVSRUWIUDPHRQWKH SHGHVWDOWRHQDEOHGUDJJLQJWKH 67&WKURXJKWKH9GRRURQWR WKHGULOOIORRU $OZD\VXVHWKH67&OLIWLQJOXJV DQGVKDFNOHV1RRWKHUSDUWLV UDWHGIRUQRULQWHQGHGWRVXSSRUW WKHIXOOZHLJKWRIWKH67& 129UHFRPPHQGVXVLQJDGRXEOH FKDLQVOLQJZLWKPDVWHUOLQNZKHQ OLIWLQJWKH67& Transpor t (QVXUHWKH67&UHPDLQVYHUWLFDO DQGVXSSRUWHGLQDVWDEOHPDQQHU 1HYHUOD\WKH67&RQLWVVLGH )RUVWDELOLW\DOZD\VWUDQVSRUWWKH 67&ZLWKWKHWUDQVSRUWIUDPH DQGVNLGLQVWDOOHG)RUDGGHGVHFXULW\ VWUDSVFDQEHDWWDFKHGWRPDMRU VWUXFWXUDOFRPSRQHQWVDVUHTXLUHG 1HYHUDWWDFKVWUDSVWRQRUGUDSH VWUDSVDFURVVWKHFRQWURODVVHPEO\ RUVLGHJXDUGV7KHVHFRPSRQHQWV PD\EHFRPHGDPDJHGDQGXQVDIH to operate.


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Lifting and Transport (continued)

Pedestal ,QIXOOGRZQ position Transport Frame

Lifting Shackles 8QLW:HLJKW OEV ST-80C Right Cover P/N 30180461-200 Rear View of Support Pedestal

Pi P/

! Perform lifting operations with extreme caution. Cylinder Dampener P/N 30179558

Left Cover P/N 30180461-100

Jackscrew %RWKVLGHV P/N 30170645 (2)

Cotter Pins SODFHV P/N 114320-8 (2)

Lock Pin SODFHV P/N 30171613 Transport Pins P/N 30170733-100 Socket Flange and Base Assembly P/N 30172616 Floor Socket P/N 30173380

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Rear View of Support Pedestal

! Perform lifting operations with extreme caution.

Transpor t Frame and Skid Transport Pin Installed in stored position for operation.

Pin Keeper P/N AR06-03-13

1. +RLVWWKHWUDQVSRUWIUDPH

XSDQGLQWRWKHKROHLQ WKHWRSRIWKHSHGHVWDO DVVHPEO\ ,QVWDOOWKHIUDPHWUDQVSRUWSLQ ,QVWDOOWKHIUDPHFRWWHUSLQ /LIWWKH67&DQGSODFH LWRQWKHWUDQVSRUWVNLG ,QVHUWWKHVNLGWUDQVSRUWSLQV Filter Element P/N 82749

ns .

ns 00

Cotter pin Transport Frame P/N 30181717 Transport Skid P/N 30180482


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Troubleshooting When troubleshooting the ST-80C, make sure the hydraulic pressure is between 2,100 and 2,150 psi at the gauge on the back of the ST-80C. Check the back pressure of the tank line (ensure the pressure does not exceed 30 psi). 1. Ensure that all hoses and QDs are properly connected. 2. Check manifold, fittings, QDs and hoses for leaks or damage. 3. Ensure the tool is lubricated per Chapter 5, Maintenance. The most important things to check after each rig move and before operating the ST-80C are: 1. Ensure that the ST-80C is fully inserted in the socket. 2. Ensure all QDs are fully engaged. 3. Ensure the operating pressures are correct. 4. Verify the condition of the filter. 5. Check all fittings for leaks. 6. Lubricate entire ST-80C and check the condition of the filter per Chapter 5, Maintenance.

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Operating Mode Problems Symptom

Probable Cause

Remedy

Tool runs slowly.

Control Cable worn out

Replace cable

Hydraulic quick disconnect supply or return lines not fully shouldered.

Tighten until fully shouldered.

Power unit not delivering full flow.

Check power supply flow while spin out valve is actuated. Flow should be 40 GPM.

Power unit return line filter dirty.

Replace filter element of HPU.

Pressure filter dirty.

Replace filter element of ST-80C.

Torque pressure set too low.

Increase pressure setting.


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8/29/2012 10:57:37 AM

Troubleshooting (continued) Vertical Positioning Problems Symptom

Probable Cause

Remedy

Vertical positioning assembly moves without anyone functioning the unit

High back pressure

Check all quick disconnects are fully shouldered

Lift cylinder damaged or dirty. Binding of carriage in pedestal. Push/Pull cable broken.

Clean or repair cylinder. Lubricate or replace side rollers. Replace cable.

Counterbalance valve out of adjustment.

Replace, or adjust counterbalance valve to maintain vertical position. Replace seals.

Does not maintain vertical position

Lift cylinder leak.

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Troubleshooting with Torque Wrench Symptom Probable Cause Torque cylinders do Torque valve set too not makeup. low. Torque valve or pressure reducing valve stuck closed, dirty, or damaged. Torque cylinders already at end of stroke. Torque setting damaged. Torque cylinders do Push/Pull cable broken not breakout. Sticking or worn main operating valve.

Dirty return filter in power supply. Torque gauge does Dirty inlet port or not indicate torque gauge. during makeup Dump valve stuck open (depressed, pressure does not build up) or set incorrectly. Torque cylinders reached end of stroke and actuated dump valve. Gauge damper closed.

Remedy Increase setting. Check valves, clean or replace.

Recycle the upper jaw for next bite. Check, clean, or replace. Replace cable Disassemble valve, inspect for contamination or wear, and repair or replace. Replace filter element. Clean inlet port or replace gauge. Adjust full CW test if still no pressure reading, replace, readjust 1/4 turn from full CCW position. Reset for additional stroke.

Open damper located on top front of gauge (rotate counterclockwise).


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Troubleshooting (continued) Troubleshooting with Torque Wrench (continued) Symptom

Probable Cause

Remedy

Torque gauge goes not return to zero.

Gauge not adjusted to zero.

Rotate zero adjust knob on back of gauge case. Recheck torque setting.

Tank line pressure.

Check and correct.

Defective gauge.

Replace.

Hydraulic pressure too low.

Make sure the pressure at the manifold is set to 2,100 - 2,150 psi.

Check valves on manifold contaminated or defective.

Clean, repair, or adjust valves.

Lack of lubrication.

Lube all grease fittings.

Push/Pull cable broken or out of adjustment

Replace cable or adjust

Torque wrench clamp cylinders too slow or uneven.

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Troubleshooting the Spinner Assembly Symptom Spinner assemblies do not clamp or unclamp and/or motors do not run. Spin rollers do not turn with motor running, or have insufficient power.

Probable Cause Flow restricted.

Remedy Locate cause or restriction and correct.

Sheared drive roller key.

Replace key.

Nut that keeps bevel gear in place on motor shaft is backed off. Motor seal blown.

Remove motor, retighten nut and secure nut with lock tab. Replace motor seals. Check that motor drain lines are open to tank. Locate cause of restriction and correct. Replace bearings.

Flow restricted to motor. Defective roller bearings. Defective motor.

Spin rollers slip or back-off of pipe

Motor Drive shaft broken. Insufficient clamping pressure.

Repair motor. Replace Shaft. Check pressure at manifold set to 2,1002,150 psi. Check for leaks in clamping lines and replace as required. Replace and check relieving valves in manifold (CB8, CB9 and RV1). Replace seal.

Defective seal on spin clamp cylinder piston. Slippery connection.

Clean connection.

Spin rollers worn.

Replace spin rollers.


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Appendix Lubricant Specifications Selecting a Lubricant Recommended Gear Oil

Ambient Temperature Range -6° to 16° C

7° to 30° C

Above 21° C

Alpha LS-68

Alpha LS-150

Alpha LS-320

(20° to 60° F)

(45° to 85° F)

(Above 70° F)

Manufacturer Castrol Chevron

NL Gear 68

NL Gear 150

NL Gear 320

Exxon

Spartan EP68

Spartan EP150

Spartan EP320

Gulf

EP Lube HD68

EP Lube HD150

EP Lube HD320

Mobil

MobilGear 626

MobilGear 629

MobilGear 632

Omala 68

Omala 150

Omala 320

Statoil

Loadway EP68

Loadway EP150

Loadway EP320

Texaco

Meropa 68

Meropa 150

Meropa 320

Shell

Total

Carter EP 68

Carter EP 150

Carter EP 320

Union

Extra Duty NL2EP

Extra Duty NL4EP

Extra Duty NL6EP

2EP

4EP

6EP

68

150

320

Viscosity Index AGMA ISO Viscosity Grade

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Rig Solutions Aftermarket Service Phone Numbers Corporate Headquarters 7909 Parkwood Circle Drive Houston, Texas 77036 United States Phone: 713 375 3700 Fax: 713 346 7687

UK NOV Service and Repair (Aberdeen/ Montrose) Forties Road Montrose Scotland DD10 9ET +44 1674 677222 +44 7711 415485 (after hours) +44 7739 170079 (workshop) +44 7713 643012 (spare parts)

Rig Solutions 10000 Richmond Avenue Houston, Texas 77042 United States Phone: 713 346 7500 Fax: 713 435 2195

Middle East UAE NOV Service and Repair (Abu Dhabi) Varco Al Mansoori Services LLC P. O. Box 27011 Abu Dhabi, UAE +971 2 555 2668 +971 2 554 2280 (fax) +971 50 811 6083 (service) +971 50 617 1235 (workshop)

United States Colorado NOV Service and Repair (Colorado) 420 South Ash St. Fruita, CO 81521 +1 970 858 4522 +1 281 569 3050 (after hours)

NOV Service and Repair (Dubai) P.O. Box 61490 R/A No.13, Plot MO 0682 Daimler Chrysler Street Jebel Ali Free Zone Dubai, UAE +971 4 883 8776 +971 4 883 8795 (fax)

Louisiana NOV Service and Repair (Covington) 73765 Penn Mill Rd. Covington, Louisiana 70435 +1 985 892 8216 (direct) +1 800 722 4425 (toll free) (Cranes: AmClyde, Unit, OS National, Dreco, Kingpost) +1 985 871 8609 (service) +1 985 871 8603 (parts)

NOV Service and Repair (Badr City) IMPEC (Sea Harvest Company) Part B, 47 Acer Area Badr City, Cairo, Egypt +20 2 231 08001 +20 2 231 08002 +20 2 231 08003 (fax)


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Appendix (continued) Rig Solutions Aftermarket Service Phone Numbers (continued) NOV Service and Repair (New Iberia) 5212 Highway 90 Service Road West New Iberia, Louisiana 70560 +1 337 374 1400 (legacy Varco and NOI equipment and all NOV spare parts)

North Africa NOV Service (Algeria) Overseas Equipment Service Africa BP 852 Zone Industrielle Algerie Hassi Messaoud Ouargla Algeria 30500 +213 29 75 54 75 +213 29 75 41 05 (fax)

Oklahoma NOV Service and Repair (Oklahoma City) 7713 North West 3rd St. Oklahoma City, Oklahoma 73127 +1 405 495 1000 +1 281 569 3050 (after hours)

Saudi Arabia NOV Service and Repair (Al-Khobar) Al-Khalidiyah District Khobar ~ Dammam Highway (at the back of Tawuniya) P. O. Box 20754, Al-Khobar 31952 Saudi Arabia +966 3 847 5206 +966 3 847 3938 (fax)

Minnesota NOV Service (St. Paul) 240 East Plato Blvd. St. Paul, Minnesota 55107 (lifting and handling equipment) +1 651 293 4745 (service) +1 651 293 4776 (service) +1 651 293 4600 (parts) +1 651 293 4603 (parts)

Europe France NOV Service +33 24 068 3600 +33 24 068 3611 +33 24 068 3600 (after hours) +33 677 790 943 (after hours)

North Dakota NOV Service and Repair (Williston) 611 58th Street West Williston, ND 58801 +1 701 774 0454

Norway NOV Service (Asker) Blakstadmarka 26 1374 Asker – Norway +47 6400 5000 +47 6400 5001 (after hours)

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Pennsylvania NOV Service (Pittsburgh) 1349 Saw Mill Run Blvd. Pittsburgh, Pennsylvania 15226 +1 412 884 1027 +1 281 569 3050 (after hours)

NOV Service (Kristiansand) Skibaasen 2 4636 Kristiansand – Norway +47 3819 2000 +47 3819 2482 (after hours) NOV Service (Molde) Granfjaera 24 6415 Molde – Norway +47 7120 2020 +47 9169 9664 (after hours)

Texas NOV Service and Repair (Alice) 2351 Energy Avenue Alice, Texas 78380 +1 361 668 4154 +1 281 569 3050 (after hours)

NOV Repair (Stavanger) Dusavik Base Midtre Basevei 4 4029 Stavanger – Norway +47 5183 5600 NOV Service (Stavanger) Lagerveien 8 4069 Stavanger – Norway +47 5181 8181 +47 4140 0041 (after hours) +47 9511 8181 (24/7 eHawk remote support)

NOV Service and Repair (Houston) 5100 North Sam Houston Parkway West Houston, Texas 77086 +1 281 569 3050 (24/7 technical support) +1 281 569 3051 (eHawk remote support) Wyoming NOV Service and Repair (Casper) 1080 North Robertson Road Casper, Wyoming 82601 +1 307 473 8888 +1 281 569 3050 (after hours)

Asia China NOV Service Suite 1603-1606, Air China Plaza No. 36 Xiaoyun Road, Chaoyang District Beijing 100027 PRC +86 139 0121 9392 +86 108 0081 05109 (24/7 technical support)


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Appendix (continued) Rig Solutions Aftermarket Service Phone Numbers (continued) Canada NOV Service and Repair (Leduc/ Edmonton) 6621 – 45 Street Leduc, Alberta, Canada T9E 7E3 +1 780 986 1712 +1 780 986 5556 +1 780 665 0200 (parts) +1 780 619 5579 (parts)

India NOV Service and Repair R-619, TTC Industrial Area Rabale, MIDC Navi Mumbai – 400 401 Maharashtra, India +91 982 009 1322 +91 983 349 6154 (after hours)

Americas Brazil NOV Service and Repair (Macaé) Rod. Amaral Peixoto, s/n KM164,5 Imboassica – Macaé – RJ – Brazil CEP 27920-025 +55 22 2773 0600 +55 22 9974 7081 (after hours) +55 22 9974 7057 (NOV drilling equipment) +55 22 2773 0640 (NOV lifting and handling equipment) +55 22 9974 7056 (PCE/Shaffer equipment) +55 22 9974 7083 (workshop)

Singapore NOV Service and Repair 29 Tuas Bay Drive Singapore 637429 +65 6594 1000 +65 6594 1222 (24/7 technical support)

Venezuela NOV Rental and Service (Maturin, Monagas) Varco International de Venezuela Top Drive Rental and Service +58 291 651 6489 +58 414 394 2784 (mobile) +58 291 651 4384 (fax)

Russia NOV Service and Support 5, Ulansky Lane Moscow, 101000 Russia +7 495 775 2540 +7 985 410 5272 (mobile) +7 495 981 3470 (fax) +7 985 997 3545 (24/7 technical support)

© 2012 National Oilwell Varco

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Roughneck roughneckDetails

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