www.nov.com

Service Manual

ST-100 Iron Roughneck

Reference Reference Description

This document contains proprietary and confidential information which is the property of National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design or distribution of this information to others is not permitted without the express written consent of NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was loaned. This document and the information contained and represented herein is the copyrighted property of NOV. National Oilwell Varco

National Oilwell VarcoRIG SOLUTIONS11000 Corporate Centre DriveHouston, TX 77041

Document Number Rev.

D811003994-MAN-001 05

Form D811001123-GEN-001/07Revision History

05 01.10.2013 Engineering Update A. Donovan J. Adkins J. Adkins

04 20.06.2013 Engineering Update A. Donovan J. Adkins J. Adkins

03 18.06.2012 Engineering Update J. Roman J. Adkins J. Walker

02 13.02.2012 Engineering Update T. Drake J. Adkins J. Walker

01 06.06.2011 First Issue T. Drake J. Adkins J. Walker

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

Change Description

Revision Change Description

01 First Issue: Original Instructions

02

Corrected conversion error to weight specification (page 2-13). Added and/or updated the following:

Orientation illustrations showing new control panel (page 2-11 and page 2-12). Arm assembly illustration to show Hydraulic E-Stop Lanyard and new gauge (page 2-27). Hydraulic assemblies illustration to show Hydraulic E-Stop Pressure Gauge (page 2-30). Manual Control Console to show modified panel components (page 2-34). Electrical Controls illustration for clarity (page 2-32). E-Stop precaution (page 4-43). Manual Control Console reference art (page 4-47). E-Stop information to Manual Control Console section (page 4-53). Diffuse sensor equipment shutdown information (page 4-65). E-Stop information to Pedestal-Mounted Control Console section (page 4-66). Maintenance Pins information and illustration (page 5-82 and page 5-84).

Made the following additional compliance checklist changes: Added emission of noise information for checklist item 2.8 (page 1-8 and page 4-44). Added location of instructions information for checklist item 3.7 (page 1-9 and page 3-40). Added safe disposal information for items 2.11 and 4.6 (page 1-9, page 3-41, and page 5-81). Added reminder cards, stickers, or labels information for checklist item 4.5 (page 2-17).www.nov.com

D811003994-MAN-001Revision 05

Form D811001123-GEN-001/0703

Added E-Stop Symbol to (page 1-2), (page 4-44) and to illustration (page 2-26). Added Lightning Precaution table to Safe Equipment Operation (page 1-7). Added Modifications section and warning to (page 1-9). Added descriptive paragraphs to (page 2-31), (page 3-38), (page 4-68) and restructured (page 4-68) Added Footnote to Torque Wrench Specifications (page 2-14). Changed descriptive paragraph (page 2-20) and (page 4-56). Corrected N-m to Torque Assembly and changed die size to paragraph (page 2-24). Changed illustration to show separate die configurations (page 2-25). Added (section titled "ST-100 Quick Reference" on page 4-45). Changed Making and Breaking Connections procedures (page 4-60) through (page 4-61). Add and changed top views to (page 4-49) and change illustration text (page 4-72). Added OEM Precaution caution table (page 5-82). Changed illustrations on (page 5-84), (page 5-87), (page 5-95) and (page 5-103). Added table to Monthly Inspection (page 5-85), Added illustrations (page 5-101) and (page 5-105). Rearrange and changed Probable Cause and Remedy tables from (page 6-114) through (page 6-

117).

04

Updated template, advisory symbols, and page numbering (Entire Book) Added Counter Balance Valve section (Page 7) Added Hydraulic Requirements note (Page 13) Updated Tong Die and Die Retainer (2) Lower Jaws callout to Front View on Figure 2-9 (Page 25) Updated Lifting Info breakout on Figure 3-1 (Page 39) Added Leveling the Head Assembly section (Page 42) Updated the Test display on the Control Console for Figure 4-9 and 4-10 (Page 55 and 56) Added Humidity and Altitude rows to Operating and Survival Environment tables (Page 80) Added NOV policy information to Spare Parts You May Need section (Page 81) Added monthly roughneck maintenance note (Page 88) Added Malfunction Log section (Page 111) Added Torque wrench unclamps... row on Troubleshooting Table (Page 116)

05

Added Operational Environment section to Chapter 1, General Information (Page 5) Added red zone reference to Warning (Page 6) Updated the Adjusting Arm Assembly Target Positions section (Page 64) Updated Figure 4-15. Adjusting Arm Assembly Target Positions (Page 64) Updated Diffuse Sensor Interlock section to clarify that Once a diffuse sensor has activated, only the

arm functions are disabled. (Page 69)

Change Description (continued)

Revision Change Descriptionwww.nov.com

D811003994-MAN-001Revision 05

Table of Contents

Chapter 1: General InformationOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Safe Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Counter Balance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Equipment Documentation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Chapter 2: DescriptionIntroduction to the ST-100 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Equipment Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Electrical Requirements (Remote Control Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14Equipment Operating Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Nameplate and Warning Plaques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17Equipment Pinching Hazard Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18Operator Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28www.nov.com

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Hydraulic Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Electrical Assemblies (Remote Control Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31Socket Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Table of Contents

Operator Control Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Manual Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Pedestal-Mounted Remote Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Chapter 3: InstallationTransporting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Drill Floor Position Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Removing and Installing the Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Installation and Commissioning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Storing the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Returning Equipment to Service After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Leveling the Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Chapter 4: OperationIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43Operating Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43ST-100 Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Pre-Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Normal Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Normal Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Manual Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Manual Operation Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Manual Control Console Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Manual Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47Positioning and Adjusting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48Setting and Adjusting Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Emergency Stop (E-Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Stopping the Equipment in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Restarting the Equipment After a Hydraulic E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Remote Control Console Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Pedestal-Mounted Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Sequential Tripping Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Setting and Adjusting Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Adjusting Arm Assembly Target Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64www.nov.com

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Object Detection Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65Emergency Stop (E-Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Stopping the Equipment in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66Restarting the Equipment After an Electrical E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Interlock Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Interlock Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Hydraulic Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Electrical Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Hydraulic Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70Rotating the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71Releasing the Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73Releasing the Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75Moving the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Electrical Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79Securing Equipment on a Floating Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Chapter 5: MaintenancePre-Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81Spare Parts You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81Spare Parts and Fluids Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82Securing the Equipment for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Inspection Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Inspection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87Equipment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90Spin Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90Spin Wrench Support Structure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91Torque Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92Arm Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93Column Assembly Carriage Guide Roller Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94Socket Base Slew Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95www.nov.com

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Table of Contents

General Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96Nord-Lock Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98Replacing Torque Wrench Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99Replacing Spin Wrench Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102Spin Wrench Rollers Assembly - Retention Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105Changing the Hydraulic Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Removing the Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107Removing the Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Carriage Lift Counterbalance Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . .109

Chapter 6: TroubleshootingIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111Malfunction Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112Determining the Nature of the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Pre-Troubleshooting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114www.nov.com

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Table of Contentswww.nov.com

v D811003994-MAN-001Revision 05

1General Information

OverviewThis service manual is part of the National Oilwell Varco (NOV) documentation package for your NOV equipment. Along with a description of the equipment, the service manual contains information for the installation, operation, maintenance, and troubleshooting of the equipment.

Intended AudienceThis manual is intended for use by field engineering as well as installation, operation, and maintenance personnel. The procedures within this manual should never be performed by untrained individuals.Reference: For more information about training, see the Safety Requirements section (in this chapter).

DisclaimerWhile every reasonable effort has been made to ensure the accuracy of the information contained herein, NOV makes no representations or warranties as to the accuracy or completeness of the information. NOV reserves the right to revise this manual at any time without the obligation to notify any person or organization.

NOV shall not be liable for any damages arising from the use of this manual. It is the responsibility of the owner/operator to ensure safe usage and operation of the equipment. All operators must be properly trained before they handle or operate the equipment.

The illustrations in this manual may not be drawn to scale.

Reference: For your rig-specific configurations, see the technical drawings included with your NOV documentation.1D811003994-MAN-001Revision 05www.nov.com

1 General InformationConventionsThis section of the chapter describes the service manual conventions.

AdvisoriesThe graphical symbols within this manual indicate advisories that provide the user (intended audience) with additional information about a topic or inform the user of the potential or definite risks to personnel or equipment and the necessary action the user should or should not take to avoid the risks. The following lists the symbols and an explanation of each:

Note

Caution

Warning

Hot Surface

Pinch Point

The note symbol indicates details or additional information that may be useful for better understanding the related topic.

This symbol indicates a potential risk of injury to personnel or damage to equipment. Failure to follow instructions explicitly and use extreme care when performing operations and procedures could result in injury to personnel, damage to equipment, or rig downtime.

The warning symbol indicates a definite risk of equipment damage or danger to personnel. Failure to follow safe work procedures could result in serious or fatal injury to personnel, significant equipment damage, or extended rig down time.

This symbol indicates the presence of a potentially hot surface or component. Failure to allow the hot surface or component to cool before touching it could result in bodily injury.

The pinch point symbol indicates the potential for part of the body becoming caught or pinched between two objects. Failure to avoid pinch point areas while the equipment is operating or use extreme care around the pinch points could result in serious or fatal bodily injury.

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2 D811003994-MAN-001Revision 05

General Information 1ConventionsAdvisoriesElectrostatic Discharge

E-Stop

IllustrationsThe illustrations (figures) provide a graphical representation of equipment components or screenshots for use in identifying parts or establishing nomenclature. These illustrations may not be drawn to scale. Reference: For your rig-specific configurations, see the technical drawings included with your NOV documentation.

This symbol indicates the potential for electrostatic discharge (ESD). Always remove static electricity prior to working on ESD sensitive components or in flammable environments. Failure to do so could result in ESD: Damaging or destroying sensitive electronic components Setting off explosions or fires in flammable environments

E-Stop symbol indicates that an emergency stop device is present. Emergency stop (or E-stop) devices are located on the NOV control panel and may be present at several other areas on NOV equipment. These provide a method for rapidly disconnecting the energy source from the equipment, immediately stopping any movement, to protect rig floor personnel.D811003994-MAN-001Revision 05

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1 General InformationSafety RequirementsNOV equipment is installed and operated in a controlled drilling-rig environment involving hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures in the manuals are the recommended methods for performing installation, operations, maintenance, and troubleshooting.

Proper UseNOV equipment is designed for specific functions and applications and, therefore, should be used only for its intended purposes.

Safe LiftingOperators and maintenance personnel should be properly trained in safe lifting procedures and in the inspection of material handling equipment and lifting components. When lifting and handling NOV equipment or components, always: Follow all federal, state, and local rules, industry and company standards, and rig-specific safety

guidelines. Use approved safe lifting procedures and safe methods.

To avoid injury to personnel or damage to equipment, carefully observe the requirements outlined in this section.

NOV recommends using the supplied sling with master link when lifting the iron roughneck. When lifting the iron roughneck, always use the lifting lugs and shackles provided. No other part of the iron roughneck or shipping skid is rated for, nor intended to support the full weight of the iron roughneck. Before beginning, make sure the shackles are secure and that slings are rated for the appropriate weight.

Lifting equipment improperly creates a hazardous working environment. To avoid lifting hazards, lift equipment only with material handling equipment rated for the expected load and from the designated lift points. Failure to follow safe lifting guidelines may result in serious or fatal injury to personnel, significant damage to equipment, and extended rig downtime.

Safe lifting recommendations provided in this manual do not take precedence over local safety rules and regulations, OSHA regulations, or instructions issued by the manufacturers of rig hoisting equipment and other tools on the rig.

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4 D811003994-MAN-001Revision 05

General Information 1Safety RequirementsPersonnel TrainingTo ensure their safety, all personnel performing installation, operations, maintenance, or repair procedures on or in the vicinity of the equipment should be trained in rig safety and equipment operation and maintenance. This tool should not be used by untrained personnel.

Reference: For more information about personnel training, contact the NOV training department.

Recommended ToolsWhen an operation requires a specific tool recommended by the manufacturer, the use of that tool should be enforced, and the tool should be used in a manner that: Follows the procedures for the operation Safeguards personnel and equipment

Operational EnvironmentThe operator of the ST-100 should never enter the red zone of the other equipment. If the operator inadvertently enters the red zone of other equipment, work should cease and the operator should evacuate to a safe location until the conflict of red zones has been cleared.

Additionally, it is the responsibility of the owner to create procedures, rig layouts or any other required documentation to ensure the operator of the ST-100 does not enter the red zone of other equipment.

This manual is and should be treated as part of the equipment. As such, the manual should be passed on to subsequent users.!D811003994-MAN-001Revision 05

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1 General Information Safety RequirementsSafe Equipment Operation

General System Safety PracticesThe equipment discussed in this manual may require or contain one or more utilities, such as cooling water or electrical, hydraulic, or pneumatic utilities.

Replacing ComponentsWhen replacing components:

Verify that components such as cables and hoses are tagged and labeled during assembly and disassembly of equipment to ensure correct installment.

Replace failed or damaged components with original manufacturer-certified components.

Make sure that all personnel are clear of the equipmentoperating path before operating or restarting theequipment. If the tool moves unexpectedly, shut downthe equipment and lock out hydraulics immediately.Inspect equipment for damage. Failure to adhere tothis precaution may result in severe injury.

Under no circumstances should anyone place theirhands or limbs in any part of the iron roughneck red zone while the equipment is enabled or operating. Failure toadhere to this precaution may result in severe injury.

Replace damaged or worn guards. Do not operate thetool with guards that are damaged.

Before installing, operating, or troubleshooting equipment or performing maintenance, read and follow these guidelines to avoid endangering exposed persons or damaging the equipment: Isolate energy sources before beginning work. Avoid performing maintenance or repairs while the equipment is in

operation. Wear proper protective equipment during equipment installation,

operations, maintenance, and repair.

Failure to replace failed or damaged components could result in injury to personnel or damage to equipment.

WARNINGWARNINGWARNINGWARNING

WARNINGWARNINGWARNINGWARNING

WARNINGWARNINGWARNINGWARNING

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6 D811003994-MAN-001Revision 05

General Information 1Counter Balance ValveThe Counter Balance (CB) valves are load-holding devices.

Routine MaintenanceEquipment must be routinely maintained.

Equipment Documentation LocationThe User Manual provided with the equipment order contains this service manual, the engineering installation and commissioning procedures, the Technical Drawing Package (TDP), along with specifications, parts lists, and other instructions. These documents must be used by the installation and commissioning crew, equipment operators, and maintenance personnel. Make sure an equipment User Manual is available in the location where the equipment is being installed, commissioned, operated, and maintained.

Equipment DisposalThe equipment owner is responsible for disassembling and removing the equipment at the end of the equipments useful operating life. It is also the equipment owners responsibility to conform to applicable regulatory policies and standards, as well as recycling guidelines, when removing the equipment and when disassembling equipment components and disposing of fluids and consumable spare parts after scheduled and unscheduled equipment maintenance.

Service CentersFor a directory of NOV service centers, see Service Center Directory, document number D811001337-DAS-001 in the NOV documentation package.

This link provides after-hours and 24-hour contact information for emergencies or equipment issues requiring an immediate response from NOV service personnel: www.nov.com/contact_us/24hr_EmergencyList.asp.

If adjusted, the load can possibly fall. Prior to adjusting the CB valves, ensure the load is in safe condition and all personnel are aware of the potential outcome.

If the CB is removed while a load is suspended, the valve could be projected at high speeds. Failure to ensure the load is safe could result in injury to personnel or damage to equipment.

Failure to conduct routine maintenance could result in injury to personnel or damage to equipment.

WARNINGWARNINGWARNINGWARNING

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D811003994-MAN-001Revision 05

2Description

Introduction to the ST-100 Iron RoughneckThe ST-100 Iron Roughneck is a drill floor tool used to make up and break out drill string connections. This durable iron roughneck is designed for use on both offshore rigs and land-based rigs. It allows clearance around well center and the mousehole when in standby and parked positions. It can also be controlled manually or remotely, depending on the equipment option ordered. Other equipment options include an extend and retract scissor-arm system that can deploy to 5 feet (ft) (1.5 meters [m]) or 8 ft (2.5 m).

OverviewThe ST-100 Iron Roughneck can make up or break out drill collar connections from 4 inches to 9-3/4 inches outside tool joint diameter (OD) and handle drill pipe from 3-1/2 inches up to 7 inches OD. The torque wrench provides up to 100,000 foot-pounds (ft-lb) (135,581 Newton-meters [N-m]) of makeup torque and 120,000 ft-lb (162,698 N-m) of breakout torque. The spin wrench can spin in and spin out connections at speeds up to 60 rpm while providing up to 3,000 ft-lb (4,067 N-m) of torque. (Spin speed will vary based on pipe size and flow rate.)The ST-100 Iron Roughneck is installed with a single, floor-mounted socket base assembly (with no hanging cable). When not in use, the iron roughneck can be rotated into a parked position.

The ST-100 Iron Roughneck consists of the following components:

Head Assembly Connected to the arm assembly, the head assembly consists of the spin wrench and torque wrench assemblies. A control console is installed on the front of the head assembly, if the iron roughneck is equipped with the manual control console option. (See the section titled "Head Assembly" on page 21.) Spin Wrench Assembly Consists of rollers that grip the pipe and spin in or spin out

tubular connections. (See the section titled "Spin Wrench Assembly" on page 23.) Torque Wrench Assembly Supports clamping jaws that make up and break out tubular

connections. (See the section titled "Torque Wrench Assembly" on page 24.)

This manual provides basic operation and maintenance information for the ST-100 Iron Roughneck. Rig personnel must be thoroughly trained and familiar with this iron roughneck before operating and maintaining this or any associated equipment.

Always park the iron roughneck when it is not being used.

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2 Description Introduction to the ST-100 Iron RoughneckOverview Arm Assembly Supports and provides horizontal travel for the head assembly. The arm assembly extends and retracts as necessary for accurate positioning of the head assembly at well center, the mousehole, or in the parked position. (See the section titled "Arm Assembly" on page 26.)

Column Assembly Provides vertical travel for the iron roughneck. The column assembly is connected to the floor-mounted socket base assembly. (See the section titled "Column Assembly" on page 28.)

Hydraulic Assemblies Support all iron roughneck hydraulic functions, such as clamping and unclamping the torque wrench, moving the carriage assembly up and down the column, spinning the rollers, and extending and retracting the arms. (See the section titled "Hydraulic Assemblies" on page 29.)

Electrical Assemblies If equipped with the remote operator control option, the iron roughneck has an additional I/O J-box, sensors, along with other electrical and hydraulic components. (See the section titled "Electrical Assemblies (Remote Control Option)" on page 31.)

Socket Base Assembly Provides platform support and rotational travel for the iron roughneck. The floor-mounted socket base assembly allows the iron roughneck to rotate and align with the mousehole or well center. (See the section titled "Socket Base Assembly" on page 33.)

Operator Control Assemblies There are multiple operator control options for the ST-100 Iron Roughneck. Manually controlled models have a console installed on the front of the unit, on either the left or right side. Remotely controlled units include a pedestal-mounted control console. If the iron roughneck is remotely controlled, the manual control console assembly is not present. (See the section titled "Operator Control Options" on page 20.)

Figure 2-1 shows the orientation of the ST-100 Iron Roughneck. Figure 2-2 on page 12 shows the location for major equipment components.

The illustrations in this manual are general in nature and may not show the exact equipment configuration. Always refer to the Technical Drawing Package (TDP) for rig-specific information and engineering drawings specific to the equipment order.www.nov.com

10 D811003994-MAN-001Revision 05

Description 2Introduction to the ST-100 Iron RoughneckEquipment Orientation

Figure 2-1. Equipment Orientation

ST1000001

Left

Front

Rear

Right

Right

Rear

Front

Left

Front View

Rear View

Head Assembly

Arm Assembly

Socket Base Assembly

Column Assembly

The manual control console model is shown in this illustration.D811003994-MAN-001Revision 05

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2 Description Introduction to the ST-100 Iron RoughneckComponent Locations

Figure 2-2. Component Locations

ST1000002

Spin WrenchAssembly

Spin Wrench Manifold

Arm Assembly

Torque Gauge

Head AssemblyControls

Arm AssemblyControls

Torque WrenchAssembly

Column Assembly

Rear Guard (removable)

Torque Wrench Rubber Guard

Hydraulic EnableManifold Assembly

Carriage LiftCylinder Assembly

Transfer Barrier Assembly (Option)

Socket Base Assembly

Control ConsoleAssembly (Option)

Torqe WrenchMain Functions

Manifold

Front View

Rear View

The manual control console model is shown in this illustration.www.nov.com

12 D811003994-MAN-001Revision 05

Description 2Specifications

Weight

Hydraulic Requirements

Manually Controlled ST-100(tool only)

11,500 lb (5,216 kg)

Remotely Controlled ST-100(tool only)

12,000 lb (5,443 kg)

Socket Base Assembly 1,190 lb (540 kg)

Operating Pressure 2,500 psi (172 bar)Minimum Input Pressure 2,500 psi (172 bar)Maximum Input Pressure 3,000 psi (206 bar)Minimum Flow Rate 35 gpm (132 lpm)Maximum Flow Rate 45 gpm (170 lpm)Inlet Connections 1 inch; supply pressure

11/4 inch; return to tank 1/2 inch; drain

The ST-100 Iron Roughneck has hydraulic fluid in all the lines and the amount of hydraulic fluid required is up to the customer. It is based on the available HPU and the amount of equipment it is running.The quantity of hydraulic fluid required to operate the ST-100 is dependent on the HPU supply hydraulic power to the tool. The required volume should be sufficient to fill the reservoir and the supply lines up until they reach the tool. The hydraulic lines on board the ST-100 are full when the tool ships. D811003994-MAN-001Revision 05

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2 Description SpecificationsSpin Wrench

Torque Wrench

Electrical Requirements (Remote Control Option Only)

Speed (5-inch OD tubular) 60 rpm at 35 gpm (132 lpm) 80 rpm at 45 gpm (170 lpm)

Torque (5-inch OD tubular) 3,000 ft-lb (4,067 N-m)Pipe Range 3 1/2" to 9 3/4" (tubular diameter)

Makeup Torque 100,000 ft-lb (135,582 N-m)Breakout Torque 120,000 ft-lb (162,698 N-m)Connection Range 4" to 9 3/4" (tool joint diameter) ** See page (page 24) for further information.

Power (stand-alone equipment)

230 VAC, 20 Amps

Cables (integrated equipment) Fiber cable for communication 7-conductor E-Stop cablewww.nov.com

14 D811003994-MAN-001Revision 05

Description 2SpecificationsEquipment Operating Dimensions

Figure 2-3. Equipment Operating Dimensions (1 of 2)

ST1000003

Socket Base Assembly

Front View

55 in (1397 mm)

18.1 in (460 mm)

30.3 in (770 mm)

57.1 in (1450 mm)

Rear Slew Radius31.6 in (803 mm) w/guard29.1 in (739 mm) no guard

Front Slew Radius42.6 in (1082 mm)

Optional ManualControl Console

Optional ManualControl Console

standard mounting location

alternate mounting location

Center ofRotation

134.6 in (3419 mm)

Raised (max)

98.6 in (2504 mm)

Lowered (min)

48.6 in (1234 mm)

Raised (max)12.6 in

(320 mm)Lowered (min)

66.4 in (1687 mm)

Raised (max)30.4 in

(772 mm)Lowered (min)

removableRear Guard

Rig Floor Rig Floor

ConnectionHeight

Top ViewFully Retracted

Side ViewRaised/Lowered

For Reference Only. Refer to the General Arrangement drawing in the TDP for rig-specific equipment operating dimensions and spaceconsiderations.D811003994-MAN-001Revision 05

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2 Description SpecificationsEquipment Operating DimensionsFigure 2-4. Equipment Operating Dimensions (2 of 2)

ST1000004

3.50 inPipe Connection

9.75 inPipe Connection

Console Swivel Radius17.18 in (436 mm)

Center ofRotation

Slew Radius(extended)

135.5 in (3442 mm)

133.5 in (3391 mm)

Raised (max)

126.2 in (3205 mm)

Fully Extended

30.2 in (767 mm)

Fully Retracted

18.4 in (467 mm)

95.5 in (2426 mm)

Lowered (min)

50.2 in (1275 mm)

Raised (max)

14.2 in (361 mm)

Lowered (min)Rig Floor

92.8 in (2357 mm)

Raised (max)

56.8 in (1443 mm)

Lowered (min)

For Reference Only. Refer to the General Arrangement drawing in the TDP for rig-specific equipment operating dimensions and spaceconsiderations.

Side View

Top ViewFully Extended

Socket Base Assemblywww.nov.com

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Description 2Nameplate and Warning PlaquesFigure 2-5 shows the equipment nameplate and examples of warning plaques fastened to the equipment. These plaques identify hazards and must be cleaned or replaced if they become worn, dirty, or otherwise illegible.

Figure 2-5. Equipment Nameplate and Warning Plaques

ST1000054

Pinching HazardWarning Plaque(P/N 30170758)

Hot Surface HazardWarning Plaque

(P/N M364000292)

Equipment Nameplate(P/N M364001411)

If an equipment plaque is worn, dirty, or otherwise illegible, clean it or order a new plaque. Failure to adhere to this warning could result in severe injury to rig personnel.

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2 DescriptionEquipment Pinching Hazard Locations

Figure 2-6 shows the locations for pinch points on the ST-100 Iron Roughneck.

Pinch points exist in certain locations on the iron roughneck. In these locations, part of the body can be caught between moving parts of the equipment, between the moving and stationary parts of the equipment, or between material being handled and part of the equipment. Take extreme care around pinch points. Avoid these areas while the equipment is operating.

In addition to pinch points, the potential exists to be caught between the iron roughneck and the rig structure or other equipment. Other than the operator, make sure to keep all personnel away from the equipment when it is operating, moving to standby, or rotating to a parked position. Refer to the General Arrangement drawing in the TDP to identify all areas of motion for the iron roughneck. Failure to adhere to this warning could result in serious injury or death.

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Description 2Equipment Pinching Hazard LocationsFigure 2-6. Equipment Pinch Points

ST1000014

Take extreme care around equipment pinch points. Avoid these areas while the equipment is operating.

The manual control console model is shown in this illustration.D811003994-MAN-001Revision 05

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2 DescriptionOperator Control OptionsThe ST-100 Iron Roughneck is available with either manual or remote control.

Manual ControlThe manual control console is mounted on the front of the iron roughneck (on either the left or right side). Figure 2-2 on page 12 shows the console location on the iron roughneck. The console can pivot out to 90 for better control panel access. The console provides separate joystick controls for the arm and head assemblies. Each joystick control provides pilot pressure to the hydraulic valves on the unit. When actuated, these valves support all iron roughneck functions. Figure 2-15 on page 34 shows manual control console.

Refer to Chapter 4, titled "Operation" for additional operator control information.

Remote ControlA remote control console is mounted on a pedestal away from the iron roughneck (Figure 2-16). A derrick J-box umbilical cable connects the iron roughneck to the control console. Buttons and joysticks on the remote console send electrical signals to actuate hydraulic valves on the unit. This stand-alone system is not integrated into the Amphion multi-tool controller system, if used.

Figure 2-16 on page 35 shows the pedestal-mounted remote control console.

In the event of a control system or electrical failure, emergency controls on the iron roughneck can be used to release the torque wrench, retract the arms, and rotate the unit into the parked position. For additional information, refer to the section titled "Electrical Failure Operation" on page 79.www.nov.com

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Description 2Major ComponentsThe following assemblies and components make up the ST-100 Iron Roughneck:

Head Assembly Spin Wrench Assembly Torque Wrench Assembly

Arm Assembly Column Assembly Primary Hydraulic Manifold Assemblies

Torque Wrench Main Functions Manifold Assembly Spin Wrench Manifold Assembly Arm Functions Manifold Assembly Hydraulic Enable Manifold Assembly Transfer Barrier Assembly (manual option)

Electrical Assemblies (remote option) Socket Base Assembly Operator Control AssembliesThe following sections show each of these ST-100 Iron Roughneck assemblies and components.

Head AssemblyThe ST-100 Iron Roughneck head assembly consists of the spin wrench and torque wrench assemblies. The head assembly provides backup and torque capability for making up and breaking out pipe connections, along with spinning in and spinning out connections.

Many of the illustrations shown in this manual are general in nature. Refer to the engineering drawings included in the TDP for rig-specific information about the equipment order.

The NOV components are constantly being improved and their design may change over time. Make sure to refer to the TDP for current engineering drawings and component details.D811003994-MAN-001Revision 05

21www.nov.com

2 Description Major ComponentsThe head assembly attaches to a scissor-arm assembly that provides horizontal travel, allowing the head to be aligned with well center or the mousehole. A control console is installed on the front of the head assembly, if the iron roughneck is equipped with the manual control console option.

Figure 2-7. Head Assembly

ST1000005

Spin WrenchManifold

Torque WrenchAssembly

Torque WrenchMain Functions

Manifold

Spin WrenchAssembly

Take extreme care around equipment pinch points. Avoid these areas while the equipment is operating.www.nov.com

22 D811003994-MAN-001Revision 05

Description 2Major ComponentsHead AssemblySpin Wrench AssemblyThe spin wrench assembly has four drive rollers. Each roller is powered by a direct-drive hydraulic motor. The spin wrench supports 3-1/2 inch OD drill pipe up to 9-3/4 inch OD drill collars, with no adjustments. Its floating-mount design compensates for minor pipe misalignment.The spin speed can be reduced when working with drill collars (remote control option). When operating manually, the proportional spin wrench control can be feathered to spin at a lower spin speed.

Figure 2-8. Spin Wrench Assembly

ST1000006

Hydraulic Motor (4)

Drive Roller (4)

Hydraulic Manifold

Clamp Cylinder

Pinching Hazard. Make sure hydraulic power is OFF to the ST-100 before touching or getting near the spin wrench for maintenance and repairs.

Rollers become hot when operating. Make sure to allow rollers to cool off before touching them or getting near the equipment for maintenance and repairs.

Objects can get caught in the rollers. Make sure that tools, clothing, or personal equipment do not contact the rollers during operation. These objects can get tangled in the rollers and cause serious injury and/or equipment damage.

Front View

Rear View

WARNINGWARNINGWARNINGWARNINGD811003994-MAN-001Revision 05

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2 Description Major ComponentsHead AssemblyTorque Wrench AssemblyThe ST-100 Iron Roughneck torque wrench assembly is an open-throat design, eliminating all gates and latches. It consists of upper and lower clamping jaws that provide a maximum of 100,000 ft-lb (135,582 N-m) of makeup torque and 120,000 ft-lb (162,698 N-m) of breakout torque.There are four hydraulic cylinders used in the torque wrench assembly:

A torque cylinder is mounted on each side of the assembly. These two torque cylinders are attached at the front and back of the upper and lower clamping jaws. The cylinders turn the upper jaws to make up or break out the connection.

Upper and lower clamp cylinders are mounted at the rear of the assembly. These two clamp cylinders provide the clamping force for the upper and lower jaws.

When the two clamp cylinders actuate, the upper and lower jaws close and grip the connection. With the lower jaws gripping the pipe, the torque cylinders actuate. Torque cylinder actuation causes rotary motion of the upper jaw, turning the tool joint in one direction or the other, making up or breaking out the connection.

Die assemblies are bolted to each clamping jaw. These consist of easily removable tong dies and die retainers. The die retainers must be swapped out if the pipe is changed and the tool joint diameter falls outside of the range for the dies installed. All four (4) die assemblies must be a matched set on the torque wrench.

The following ranges apply to the tool joint diameter that the torque wrench clamps on: 5-1/2 to 9-3/4 (140 mm to 248 mm) tool joint diameter Die set for large diameter tool joint (P/

N 86711-1 supplied) 4 to 6 (102 mm to 152 mm) tool joint diameter Die set for small diameter tool joint (P/N

86711-2 supplied)Adjust tool joint spacer as shown in Figure 5-11 on page 101

Figure 2-9 shows the torque wrench assembly.

The two die sets supplied with the equipment support the full range of pipe sizes that can be used with this iron roughneck. Do not use dies interchangeably.www.nov.com

24 D811003994-MAN-001Revision 05

Description 2Major ComponentsHead AssemblyTorque Wrench Assembly

Figure 2-9. Torque Wrench Assembly

ST1000007

Tong Die and Die Retainer (2)Upper Jaws

Torque Cylinder (2)

Roughly Flush

Roughly 1 Proud

Clamp Cylinder (2)

Tong Die and Die Retainer (2)Lower Jaws

86711-1

Top View

Front View

86711-2

Pinching Hazard. Make sure hydraulic power is OFF to the ST-100 before touching or getting near the torque wrench for maintenance and repairs.D811003994-MAN-001Revision 05

25www.nov.com

2 Description Major ComponentsArm AssemblyThe arm assembly supports and provides horizontal travel for the head assembly. The scissor-arms extend and retract the head assembly to well center, to mousehole, and can then fully retract to bring the head back to the home (parked) position. The arms extend and retract at about one foot per second.

The well center and mousehole positions are set by the operator. Refer to the following sections for further information about positioning the equipment.

Manually Controlled See the section titled "Positioning and Adjusting the Iron Roughneck" on page 48 for instructions.

Remotely Controlled See the section titled "Adjusting Arm Assembly Target Positions" on page 64 for instructions.

Figure 2-10 shows the arm assembly along with its primary components.www.nov.com

26 D811003994-MAN-001Revision 05

Description 2Major ComponentsArm AssemblyFigure 2-10. Arm Assembly

ST1000008

Arm FunctionsManifold Assembly

Transfer BarrierAssembly (option)

Hydraulic EnableManifold Assembly

Hydraulic E-Stop Lanyard (2)

Arm Extend/RetractCylinder Assembly (2)

FrontD811003994-MAN-001Revision 05

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2 Description Major ComponentsColumn AssemblyThe column assembly provides vertical travel for the iron roughneck. Vertical movement allows the iron roughneck to be positioned at different heights for makeup or breakout operations. The column assembly is connected to the floor-mounted socket base assembly.

Figure 2-11. Column Assembly

ST1000009

Hydraulic SupplyShutoff Lever

Column Assembly

Carriage Assembly

Carriage LiftCylinder Assembly

Rearwww.nov.com

28 D811003994-MAN-001Revision 05

Description 2Major ComponentsHydraulic AssembliesThe ST-100 Iron Roughneck hydraulic assemblies support all iron roughneck hydraulic functions, such as clamping and unclamping the torque wrench, moving the carriage assembly up and down the column, spinning the rollers, and extending and retracting the arms.

One of these hydraulic assemblies, the Transfer Barrier Cylinder, is used in manually controlled iron roughnecks to preset a deploy travel limit for the arm assembly. This allows the iron roughneck to be deployed completely, without the operator having to make further travel adjustments once the head gets close to well center. Once iron roughneck operations are complete, this component also allows the unit to be fully retracted to the standby position, instead of being held at a partially deployed position. (Remotely controlled iron roughnecks use proximity sensors to achieve these results.)Refer to the section titled "Specifications" on page 13 for hydraulic requirements.

The following assemblies are shown in Figure 2-12:

Main Functions Manifold Torque Wrench Manifold Torque Wrench Cylinders Spin Wrench Manifold Arm Functions Manifold Arm Extend/Retract Cylinders Hydraulic Enable Manifold Transfer Barrier Cylinder (manual option) Torque CylindersThe pilot manifold used on remotely controlled iron roughneck models is shown in Figure 2-13 on page 32. The slew manifold is on the socket base assembly and is shown in Figure 2-14 on page 33. D811003994-MAN-001Revision 05

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2 Description Major ComponentsHydraulic AssembliesFigure 2-12. Hydraulic Assemblies

ST1000010

Arm FunctionsManifold

Transfer BarrierCylinder (option)

Main FunctionsManifold

Shutoff Valve Handle

Hydraulic Filter

SystemPressure Gauge

Tank

Pressure

Drain

Hydraulic EnableManifold Assembly

Torque Wrench Manifold

Spin WrenchManifold

Frontwww.nov.com

30 D811003994-MAN-001Revision 05

Description 2Major ComponentsElectrical Assemblies (Remote Control Option)The following electrical devices are installed only on remotely controlled ST-100 Iron Roughnecks. Refer to Chapter 4, titled "Electrical Interlocks" for interlocks associated with these devices.

Extend/Retract Proximity Sensors (3) Home Proximity Sensor Provides feedback to the control system that the

ST-100 arm is in the home position when this sensor detects its target. Position 1/Position 2 Proximity Sensor Provides feedback to the control system that

the ST-100 arm has reached the kickdown position when this sensor detects its target. This feature slows down arm deployment as the unit nears the pipe. The ST-100 is equipped with a kickdown sensor for the well center and mousehole position (see page 64 for setup procedure).Position feedback from these sensors can also be sent to the Zone Management System (ZMS), if the iron roughneck is part of an integrated ZMS-enabled NOV control system.

Carriage Up/Down Proximity Sensor Provides position feedback for vertical arm position once the arm has reached a pre-defined height. (May also be used with a ZMS-enabled control system.) The light on the back of sensor will turn on when a target is detected.

Non-driven Motion Pressure Transducer Provides feedback for non-driven motion, by monitoring the pressure inside the carriage lift cylinder.

Slew Proximity Sensors (2) Provide position feedback once slewing has reached the well center or mousehole positions. The ST-100 must be slewed to one of these positions and sensor must detect its target, before the unit can be operated. Slew position is adjustable. The proximity device senses the slew stops mounted on the drill floor and determines the position based on which sensor is activated. The light on the back of the sensor will turn on when a target is detected.

Torque Pressure Transducer Provides pressure feedback for applied torque (0 to 3,000 psi [207 bar]).

System Pressure Transducer Provides pressure feedback for system pressure (0 to 3,000 psi [207 bar]).

Torque Wrench Proximity Sensor (1) Provides makeup and breakout end-of-stroke feedback for the upper torque wrench.

Pipe Detection Sensor Provides feedback when a pipe is detected. Object Detection Diffuse Sensors (2) Provides feedback if an object is in the collapse zone

of the arm. Triggering this sensor shuts down all functions.Figure 2-13 shows several of the sensors used on the remotely controlled iron roughneck

Refer to the engineering drawings in the TDP for the locations of all electrical components used on the remotely controlled ST-100 Iron Roughneck.D811003994-MAN-001Revision 05

31www.nov.com

2 Description Major ComponentsElectrical Assemblies (Remote Control Option)Figure 2-13. Electrical Assemblies (Remote Control Option)

ST1000011

I/O J-Box

Extend/RetractProximity Sensors

Hazardous AreaBeacon/Strobe Light

Object DetectionDiffuse SensorAssembly (2)

Slew ProximitySensor (2)

Carriage Up/DownProximity Sensor

Carriage Up/DownProximity Sensor

Target

Torque WrenchProximity Sensor

Pilot ManifoldAssembly

EquipmentE-Stop Buttons

Pipe Detection Sensor

Frontwww.nov.com

32 D811003994-MAN-001Revision 05

Description 2Major ComponentsSocket Base AssemblyThe ST-100 Iron Roughneck is installed on the drill floor using a single, floor-mounted socket. The socket base assembly enables the iron roughneck to be rotated and aligned with well center or the mousehole.

Figure 2-14. Socket Base Assembly

ST1000012

TankPressure

Drain

Motor Guard

Column Connecting Pin (2)

Slew Manifold Assembly

Floor Socket

Socket Flange

Hydraulic Motorwith Brake (2)

Rear

included with the shipping packageD811003994-MAN-001Revision 05

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2 Description Major ComponentsOperator Control Assemblies

Manual Control Console

Figure 2-15. Manual Control Console

ST1000013

UPCARRIAGE

DOWN

RETRACTDEPLOYEXTEND

CWSLEWCCW

RETRACTADJUSTEXTEND

BREAKTW

MAKE

UNCLAMPSW

CLAMP

OUTSWINSW MODE

UNCLAMPTW

CLAMP

Torque AdjustmentKnob

Valve Body

System PressureGauge

Hydraulic Enable

Hydraulic E-Stop

Head AssemblyControls

Arm AssemblyControls

Hydraulic ConnectionsAccess Panel

Front

Head Assembly Functions

Arm Assembly Functions

Rearwww.nov.com

34 D811003994-MAN-001Revision 05

Description 2Major ComponentsOperator Control AssembliesPedestal-Mounted Remote Control Console

Figure 2-16. Pedestal-Mounted Remote Control Console

ST1000027D811003994-MAN-001Revision 05

35www.nov.com

Description2This page is intentionally blank.36www.nov.com

D811003994-MAN-001Revision 05

3Installation

Transporting the Iron RoughneckWhen transporting the iron roughneck, make sure the equipment remains vertical and stable. Always transport the iron roughneck secured to the shipping skid to increase equipment stability. See section titled "Removing and Installing the Shipping Skid" on page 37 for additional information about the shipping skid.

Drill Floor Position RecommendationsFor optimum equipment performance, the ST-100 Iron Roughneck should be positioned as follows:

8-foot arm model Position the equipment at a minimum of 89 inches (226 cm) and a maximum of 122 inches (310 cm) away from well center and the mousehole.

5-foot arm model Position the equipment at a minimum of 71 inches (183 cm) and a maximum of 89 inches (226 cm) away from well center and the mousehole.

The iron roughneck must be secured to the rig floor and the supporting structure should be able to support the weight and overturning moment of the equipment. Refer to the section titled "Specifications" on page 13 and the General Arrangement engineering drawing in the Technical Drawing Package (TDP) for dimensions, weights, rig-floor loading, and rig-floor layout drawings.

Removing and Installing the Shipping Skid

Always keep the iron roughneck in an upright position. Never place the iron roughneck on its side or back. Placing the iron roughneck on its side or back will damage the equipment.

NOV recommends using the supplied sling with master link when lifting the iron roughneck. When lifting the iron roughneck, always use the lifting lugs and shackles provided. No other part of the iron roughneck or shipping skid is rated for, nor intended to support the full weight of the iron roughneck. Before beginning, make sure the shackles are secure and that slings are rated for the appropriate weight.

!37D811003994-MAN-001Revision 05www.nov.com

3 Installation Removing and Installing the Shipping SkidRemoval1. Using the two lifting shackles and the supplied sling, hoist the iron roughneck slightly so the

weight is off the shipping skid.2. Remove the front and rear shipping pins.3. Hoist the iron roughneck away from the shipping skid and move it to its operating location.4. Remove the storage pin when the iron roughneck is ready for operation.5. Place the shipping skid and all pins in storage.

Installation1. Fully retract the iron roughneck and disconnect all hydraulic lines connecting the column to the

socket base assembly.2. Install the storage pin.3. Place the shipping skid on a hard and level surface.4. Attach the supplied sling to the two lifting shackles.5. Remove the two column connecting pins connecting the column to the socket base assembly

(see Figure 2-14 on page 33).6. Hoist and center the iron roughneck over the shipping skid.

a. Align the iron roughneck rear column base support with the rear supports on the shipping skid.

b. Align the bottom of the torque wrench base plate with the front supports on the shipping skid.

7. Insert the front and rear shipping pins (and cotter pins) securing the iron roughneck.8. Using the supplied sling, hoist and move the iron roughneck to the proper location.9. Place wood blocks between spin wrench and torque wrench.10.Using ratchet strap supplied in shipping kit to secure spin wrench so it does not shift while

transporting.

Make sure to remove the storage pin before operating the iron roughneck.!www.nov.com

38 D811003994-MAN-001Revision 05

Installation 3Removing and Installing the Shipping SkidFigure 3-1. Shipping Skid

ST1000025

Shipping Skid Front Shipping Pin

Rear Shipping Pin

Storage Pin

Lifting Shackle

Lifting ShackleD811003994-MAN-001Revision 05

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3 InstallationInstallation and Commissioning Procedures

Engineering installation and commissioning procedures are developed for each ST-100 Iron Roughneck configuration. These installation and commissioning procedures are included in the equipment User Manual. Refer to the Installation Procedure, ST-100 or the Installation Procedure, ST-100 Remote for rig-specific installation information.

The User Manual provided with the equipment order contains this service manual, the engineering installation and commissioning procedures, the Technical Drawing Package (TDP), along with specifications, parts lists, and other instructions. These documents must be used by the installation and commissioning crew, equipment operators, and maintenance personnel. Make sure an equipment User Manual is available in the location where the equipment is being installed, commissioned, operated, and maintained.

!www.nov.com

40 D811003994-MAN-001Revision 05

Installation 3Storing the Iron RoughneckLong Term Storage Palletize the iron roughneck and store it indoors. A cargo container would be appropriate

for storage. Avoid wide variations in temperature and high humidity. The preferred storage

environment is clean and dry at 60F (16C) ambient temperature. If high humidity is unavoidable, an ambient storage temperature of 70F (21C) is recommended.

All exposed unpainted metal surfaces are coated with a rust preventive at the factory prior to shipment. Coat all unpainted metal surfaces with rust preventative prior to storage or transport.

The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent.

All openings should be covered to prevent water or dust from entering. Make sure the cover allows for air circulation around equipment. NOV does not recommend using a silica gel or a dehydrating agent.

During storage, lubricant drains from the top half of the roller bearings, allowing corrosion on the exposed areas. To prevent corrosion, periodically rotate the unit to distribute lubricant over the top of the bearings. Perform this at three-month intervals if the iron roughneck is stored indoors and at monthly intervals if stored outdoors.

Returning Equipment to Service After Storage Before placing the iron roughneck back into service, the following tasks should be completed and verified:

Remove all rust preventative and any corrosion, taking special care with all load-carrying components.

Blow out all dust and dirt from equipment as required with clean, dry air. A complete system test and adjustment should be performed as detailed in the ST-100 Iron Roughneck Commissioning Procedure.

Equipment DisposalThe equipment owner is responsible for removing and dismantling the equipment at the end of the equipments useful operating life. It is also the equipment owners responsibility to conform to all applicable regulatory policies, standards, and recycling guidelines when removing the equipment, dismantling equipment components, disposing of fluids, and disposing of consumable spare parts after periodic maintenance.D811003994-MAN-001Revision 05

41www.nov.com

3 InstallationLeveling the Head AssemblyThe ST-100 head level can be adjusted. Ensure the head assembly for the iron roughneck is level to the drill floor. If the head needs to be adjusted forward or backward, remove the leveling cam retention bolt (see Figure 3-2). With the bolt removed, tilt the head assembly forward or backward until it is level. Once the head assembly is level, rotate the leveling cam until it is tangent with head frame. Reinsert the retaining bolt, and ensure the leveling cam on the other side of the unit is rotated the same amount.

Figure 3-2. Leveling The Head Assembly

ST1000057

Leveling CamRetention Bolt

HeadAssembly

Use an adjustable wrench to remove the leveling bolt. Bolt cannot be removed by hand.

Leveling Camwww.nov.com

42 D811003994-MAN-001Revision 05

4Operation

IntroductionThere are two operator interface methods typically used to control the ST-100 Iron Roughneck.

Manual Control ConsoleRefer to the section titled "Manual Control Console Operation" on page 47 for operating instructions.

Pedestal-Mounted Remote Control ConsoleRefer to the section titled "Pedestal-Mounted Control Console" on page 55 for operating instructions.

Operating ConsiderationsPlease make note of the following before operating the iron roughneck.

Precautions

This chapter provides basic operating information for the ST-100 Iron Roughneck. Rig personnel must understand the information provided in this chapter and be thoroughly trained before operating this equipment.

Identify all emergency stops (E-Stops) on the various iron roughneck models (see page 53 or page 66) and understand how to operate them. Failure to adhere to this precaution may result in severe injury or death.

Make sure that all personnel are clear of the equipment operating path before operating or restarting the equipment. If the tool moves unexpectedly, shut down the equipment and lock out hydraulics immediately. Inspect equipment for damage. Failure to adhere to this precaution may result in severe injury.

!

WARNINGWARNINGWARNINGWARNING

WARNINGWARNINGWARNINGWARNING43D811003994-MAN-001Revision 05www.nov.com

4 Operation Operating ConsiderationsPrecautionsUnder no circumstances should anyone place their hands or limbs in any part of the iron roughneck while the equipment is enabled or operating. Failure to adhere to this precaution may result in severe injury.

E-Stop tool in the event if any unsafe condition occurs or if the ST-100 Iron Roughneck does something unexpected.

An iron roughneck, top drive, and pipe racking system may reach unsafe noise levels when operating together on the rig floor. Always use hearing protection when operating the iron roughneck during normal drilling operations.

Shut down the equipment when it is not being used.

WARNINGWARNINGWARNINGWARNING

!

!www.nov.com

44 D811003994-MAN-001Revision 05

Operation 4Operating ConsiderationsST-100 Quick ReferenceInformation on this page is supplied to be a quick reference and does not replace the need for the operator to read and understand this manual in its entirety. The subsequent sections of this manual discuss these topics in much greater detail and must be read and understood before the equipment is operated.

Pre-Operation Checks Make sure the iron roughneck is secure in the floor socket. Make sure the storage pin is removed. Make sure all quick-disconnect couplings (QDs) are fully engaged. Make sure operating pressures are correct. Check all fittings for leaks. Lubricate the entire iron roughneck and check the condition of the filter. Refer to Chapter 5 for

lubrication and filter replacement procedures. Refer to Recommended Lubricants and Fluids (D811000719) in the equipment User Manual for recommended lubricants and hydraulic fluids.

For remotely controlled iron roughnecks, verify that all control cables are properly connected to the I/O J-box and remote control console.

Dos Donts

Actuate E-Stop (hydraulic or electronic) if the equipment exhibits any abnormal behavior, and investigate the cause. Take care when restartingequipment after E-Stop.

Read and understand this manual before operating the ST-100.

Shut down equipment when not in use. Ensure storage pin is removed before operation. Ensure tool joint diameter is tangent to the

throat of the torque wrench before clamping. Ensure the torque wrench and spin wrench are

fully open before extending/retracting to/from pipe.

Ensure arm adjustment procedures are followed.

Ensure replacement parts are OEM parts. Perform scheduled maintenance and inspection

per guidelines in this manual. Ensure ST-100 torque is set properly for desired

connection make up torque. Check warning plaques and ensure they are

legible. Replace if necessary.

Do not operate equipment when personnel are in the path of the equipment.

Do not place hand or limbs in the iron roughneck while the equipment is enabled or operating.

Do not clamp toque wrench dies on hard banding.

Do not use ST-100 as a backup device for the Top Drive, Rotary Table, or any external torque device.

Do not reuse Nord-Lock washers. Do not perform maintenance unless hydraulic

power is completely removed and locked from the ST-100.

Do not perform maintenance unless the arm has been locked by installing the maintenance pins.

Do not use die assemblies that are not sized for the tubular being used.

Do not interchange die assemblies. All die assemblies on the torque wrench should match.

Do not operate spin wrench on spiral collars or any non circular tubular.

Do not clamp spin wrench on stabilizers or bottom hole assembly tools.

Do not modify the tool in any way.D811003994-MAN-001Revision 05

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4 Operation Operating ConsiderationsNormal SoundsThe following may occur during normal operation:

Humming When the iron roughneck slews there may be a humming sound coming from the slewing system.

Whooshing When the arm is extending or retracting, the transfer barrier may make a whooshing noise.Operating Considerations

Normal OccurrencesThe following may occur during normal operation:

When going to the full makeup position, the torque gauge will drop to zero. When other functions are operating, the spin rollers may rotate very slowly. When operating on angled mouseholes, the head assembly will pivot once the torque wrench

jaws clamp on the pipe.

Manual Control Lever OperationManually controlled iron roughnecks are controlled via proportionally controlled hydraulic valves. Based on the manner in which the joysticks are operated, iron roughneck functions can occur gradually or abruptly.

Arm assembly control levers must be worked carefully when extending and retracting the arms for this feature to work properly. Immediately pushing or pulling a lever all the way to the stop will result in the arms immediately extending or retracting at full speed. Pushing or pulling the lever gradually will result in smooth and controlled equipment operation.

Manual Operation VerificationMake sure the following are verified before beginning the manual breakout or makeup operations described in the following sections:

The iron roughneck is fully retracted and the carriage is in its lowest position. The required makeup torque has been set (see the section titled "Setting and Adjusting Makeup

Torque" on page 50). The arm extension has been set (see the section titled "Positioning and Adjusting the Iron

Roughneck" on page 48). The torque wrench jaws and the spin wrench are fully opened. The tool is properly aligned with the drill pipe connection at well center using the slew function.

Component motion that may occur when operating other functions is due to high return pressure.

To take advantage of the ramped-up start velocity feature for manually controlled iron roughnecks, move the arm assembly control levers gradually to the full deploy position when extending/retracting the arms near the extension/retraction limits.www.nov.com

46 D811003994-MAN-001Revision 05

Operation 4Manual Control Console OperationThis section provides manual operating instructions for the ST-100 Iron Roughneck.

Manual Control Console

Figure 4-1. Manual Control Console

ST1000015

BREAKTW

MAKE

UNCLAMPSW

CLAMP

OUTSWINSW MODE

UNCLAMPTW

CLAMP

UPCARRIAGE

DOWN

RETRACTDEPLOYEXTEND

CWSLEWCCW

RETRACTADJUSTEXTEND

Head Assembly Controls

Arm Assembly ControlsD811003994-MAN-001Revision 05

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4 Operation Manual Control Console OperationPositioning and Adjusting the Iron Roughneck

Figure 4-2. Positioning and Adjusting the Iron Roughneck

ST1000016

UPCARRIAGE

DOWN

RETRACTDEPLOYEXTEND

CWSLEWCCW

RETRACTADJUSTEXTEND

LeftHand

RightHand

Left

Hand

LeftHand

RightHand

RightHand

Hold the SLEW lever until the tool aligns with well center or the mousehole, as required.

Hold the DEPLOY lever in the RETRACT position until the arm deploy cylinder is fully retracted. Then, hold the ADJUST lever in the RETRACT position for an additional 30 seconds. (This ensures the transfer barrier piston is fully stroked.)

While holding the ADJUST lever in the EXTEND position, push the DEPLOY lever to the EXTEND position. The arm deploy cylinder should extend slowly.

Release the ADJUST lever when the head reaches well center. Release the DEPLOY lever.

Hold the CARRIAGE lever in the UP or DOWN position to align the torque wrench vertically with the drill pipe.

During operation, use the DEPLOY lever for consistent alignment with the drill pipe.

Procedure Arm Assembly Controls

!Before operating the ST-100 Iron Roughneck for the first time, make sure to remove the storage pin and place it in a secure location. Do not operate the iron roughneck with the storage pin installed.

Special attention is necessary if hard banding is present. Do not grip on hard banding.

This procedure only needs to be completed when changing to a new destination or changing pipe sizes. After adjustment is complete, the arm will extend and stop at the destination.

!The drill pipe must be tangent to the throat of the torque wrench as shown. Proper distance from home to the deployed location will vary with pipe diameter.www.nov.com

48 D811003994-MAN-001Revision 05

Operation 4Manual Control Console OperationPositioning and Adjusting the Iron RoughneckFigure 4-3. Positioning the Iron Roughneck

ST1000017

4.0 in (102 mm)

Box Shoulder Range

Pin-EndConnection

Box-EndConnection

Lower DieAssembly (2)

Die set for small tool joint4 to 6 diameter

(102 mm to 152 mm)

Die set for large tool joint5-1/2 to 9-3/4 diameter

(140 mm to 248 mm)

Upper DieAssembly (2)

Use the controls to center the torque wrench assembly on the drill pipe.

!The drill pipe must be tangent to the throat of the torque wrench as shown. Proper distance from home to the deployed location will vary with pipe diameter.D811003994-MAN-001Revision 05

49www.nov.com

4 Operation Manual Control Console OperationSetting and Adjusting Makeup Torque

Figure 4-4. Setting and Adjusting Makeup Torque (Manual Models)

ST1000020

BREAKTW

MAKE

PUSH TO STOP

ST-100HYDRAULIC

E-STOP

HYDRAULIC ENABLE

TORQUE DISPLAY TORQUEADJUSTMENTSYSTEM PRESSURE

UNCLAMPSW

CLAMP

OUTSWINSW MODE

UNCLAMPTW

CLAMP

UPCARRIAGE

DOWN

RETRACTDEPLOYEXTEND

CWSLEWCCW

RETRACTADJUSTEXTEND

If not already completed, position a tubular (drill pipe or drill collar) in the throat of the torque wrench and spin in the connection.

Turn the torque adjustment knob counterclockwise (decreasing torque) until it stops.

Verify that the torque gauge reads zero.

Position the reference indicator (red needle) at the desired torque value.

Actuate the TW lever in the BREAK position until it stops.

While holding the TW CLAMP and TW MAKE levers, turn the torque adjustment knobs clockwise until the desired torque value is set.

Procedure

Manual Control Console

Torque Wrench (TW)BREAK/MAKE Lever

Torque Adjustment Knob

Torque Gauge

If the torque cylinders reach end of stroke during a makeup cycle and the gauge reads zero, recycle the jaws and re-torque.

Breakout torque is applied at system pressure and is not set or adjusted.www.nov.com

50 D811003994-MAN-001Revision 05

Operation 4Manual Control Console OperationMaking Connections

Figure 4-5. Making Connections

ST1000018

BREAKTW

MAKE

UNCLAMPSW

CLAMP

OUTSWINSW MODE

UNCLAMPTW

CLAMP

RightHand

RightHand

LeftHand

RightHand

Left

Hand

RightHand

RightHand

LeftHand

Hold the SW MODE lever to the down position and activate TW lever in CLAMP position until the lower jaws make contact on the drill pipe. Release.

Hold the SW lever in the CLAMP position.

While holding the SW-CLAMP lever, hold SW lever in the IN position until the drill pipe shoulders. Release.

Hold the SW lever in the UNCLAMP position to fully retract the roller carriers.

Hold the TW lever in the BREAK position until the upper wrench is aligned in the READY-MAKE position. Release.

Hold the TW lever in the CLAMP position until the upper jaws make contact with the drill pipe.

While holding TW-CLAMP, move TW lever to the MAKE position until the required torque is reached.

Hold the TW lever in the UNCLAMP position to retract jaws. Release.

Procedure Head Assembly Controls

If the wrench does not reach the required torque value in one stroke, unclamp and repeat steps 5, 6, and 7.

The arm must be deployed to the pipe and centered on the connection before beginning the following procedure.

Refer to the section titled Adjusting Makeup Torque for information about setting the correct makeup torque.D811003994-MAN-001Revision 05

51www.nov.com

4 Operation Manual Control Console OperationBreaking Connections

Figure 4-6. Breaking Connections

ST1000019

BREAKTW

MAKE

UNCLAMPSW

CLAMP

OUTSWINSW MODE

UNCLAMPTW

CLAMP

Left

Hand

LeftHand

RightHand

RightHand

Left

Hand

LeftHand

RightHand

RightHand

To place the upper torque wrench in position for breaking out a connection, hold the TW lever in the MAKE position until the wrench stops rotating. (This is READY-BREAK.) Release.

Hold the TW lever in CLAMP position.

While holding TW-CLAMP, move the TW lever to BREAK position until the connection is broken.

Hold the SW MODE lever in the down position until the upper jaws retract from the pipe. Release.

Hold the SW lever in CLAMP position.

While holding at SW-CLAMP, move the SW lever to the OUT position until the connection spins free. Release.

Move the SW lever to UNCLAMP to retract the spin rollers. Release.

Move the TW lever to the UNCLAMP position to retract the clamping jaws. Release.

Procedure Head Assembly Controls

The arm must be deployed to the pipe and centered on the connection before beginning the following procedure.

Breakout torque requires no adjustment.Breakout occurs at full system pressure.

If the spin wrench will not spin out the connection, repeat steps 1, 2, and 3.www.nov.com

52 D811003994-MAN-001Revision 05

Operation 4Manual Control Console OperationEmergency Stop (E-Stop)

Stopping the Equipment in an Emergency

Figure 4-7. E-Stop Component Locations (Manual Models)ST1000050

Press the E-Stop Button or pull one of the E-Stop lanyards.

Verify that the System Pressure Gauge on the console (if equipped) or on the inlet manifold shows that hydraulic pressure has been released from the system.

Clear the emergency stop situation.

E-Stop Procedure

System PressureGauge (Console)

Hydraulic Enab