roughneck roughneckdetails

Iron RoughneckST-80C

TECHNICAL SPECIFICATIONS 2

SAFETY INFORMATIONPinch Point Hazards 3

OPERATION PROCEDURESProper Positioning of ST-80C on Drill Pipe/Drill Collar Connections 4 Making Connections 6 Breaking Connections 8

STORAGE AND MAINTENANCELubrication 10 Lifting and Transport 15

TROUBLESHOOTING 18

APPENDIXLubricant Specifi cations 24Rig Solutions Aftermarket ServicePhone Numbers 25

D392004720-MKT-001 Rev 01 Tally Book ST-80C Iron Roughneck OP.indd 1D392004720-MKT-001 Rev 01 Tally Book ST-80C Iron Roughneck OP.indd 1 8/29/2012 10:56:16 AM8/29/2012 10:56:16 AM

2

Assembly Weight 7,800 lbs (3,538 kg)

Hydraulic Requirements 28 GPM @ 2,100 psi (106 LPM @ 145 bar) min

40 GPM @ 2,500 psi (151 LPM @ 172 bar) max

Tubular Connection OD Range 4¼" to 8½”

Spin Speed 75 RPM (nominal on 5" DP)

Spin Torque 1,750 ft-lbs (2,373 Nm)

Maximum Make-Up Torque 60,000 ft-lbs (81,500 Nm)

Maximum Break-Out Torque 80,000 ft-lbs (108,500 Nm)

Connection Height 23" to 59" (584 mm to 1,498 mm)

Horizontal Travel 60” (1,524 mm)

Casing Ready No

Technical Specifi cations


3

Keep all body parts clear of pinch points.

Pinch Point Hazards


4

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.

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.

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.

Over extension will show contact with the base plate, but will tilt the wrench out of alignment.

!!

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

!!

The ST-80C requires adjustment whenever the connection or pipe diameter changes and requires periodic verification per step 5 of adjustment procedure.

i

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

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Adjusting Procedure

Proper Positioning ofST-80C on Drill Pipe/Drill Collar Connections


5

BoxShoulder

RangeBACKFWD

UPDOWN

UNCLAMPCLAMP

BREAKMAKE

INOUT

TWSW

ConnectionPin

Extend/Retract Lever

ConnectionBox

Torque GaugeP/N 30160681-1

ControlConsole

BubbleLevel

2 places

Spin RollersP/N 30160614

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

Upper Dies SetP/N 30174222

Drill Pipe Allowable Tool Joint Differentials

D + 5/8" max.

D

D - 3/8" min.

D

Max. difference in diameterpin larger than box.

Max. difference in diameterpin smaller than box.


6

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.

6 UNCLAMP the jaws.7 Recycle the torque wrench to BREAK to prepare for the next connection.

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

i

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

i

Making Connections


7

6

RightHand

4

LeftHand

7

RightHand

1 RightHand

2 Left

Hand

5 RightHand

3 RightHand

Control Panel Levers


8

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.

Breaking Connections


9

Control Panel Levers

6

RightHand

2

LeftHand

3

RightHand

5

RightHand

1 RightHand

4 Left

Hand

7 RightHand


10

Gearbox Procedure

Front View

BACKFWD

UPDOWN

UNCLAMPCLAMP

BREAKMAKE

INOUT

TWSW

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.

GreaseFitting

(2 places)

SpinnerGearbox

Check oil level.See Lubricant

Specifications Table for Recommended Gear Oil

in the Appendix. Replace gear oil every 6 monthsor if dirty/contaminated.

GreaseFitting

(2 places)

DailyGreaseFitting

(2 places)

Daily

GreaseFitting

(1 each side)

Daily

GreaseFitting

(1 each side)

Daily

Daily

GreaseFitting

(2 places)

Daily

GreaseFitting

(2 places)

Daily

GreaseFitting

Daily

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

Lubrication


11

Side ViewSide Guard Removed, displaying Lubrication

i

DailyGreaseFitting

(2 places)

Daily

GreaseFitting

(1 each side)

Daily

Guide PinsBrush matingsurfaces with

grease.

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

Daily

Arm Pins(12 Places)


12

Side ViewSide Guard Removed, displaying Part Numbers

(12) PinkeepersP/N/ AR06-03-13

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

ST-80C/CLValveControl

ST-80C/CLValve

Control

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

* (ST-80-GENIII)

Turntable Bearing:P/N 30170581-1

R.H. Clamp Cylinder Upper: P/N 30174118

L. H. Clamp cylinder Upper: P/N 30172503

Clamp Cylinder: P/N 30160444

R.H. Torque Cylinder: P/N 30160685

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

Lubrication (continued)


13

Rear View

GreaseFitting

GreaseFitting Grease

Fitting

GreaseFitting

iEach grease fitting is to be greased until clean grease is seen extruding

from the related component.

Daily

Daily

Daily

Daily


14

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15

Lifting

to operate.

Transport

Lifting and Transport


16

Transport PinsP/N 30170733-100

LiftingShackles

Socket Flangeand Base Assembly

P/N 30172616Floor SocketP/N 30173380

Cotter Pins

P/N 114320-8 (2)

Lock Pin

P/N 30171613Jackscrew

P/N 30170645 (2)

Pedestal

position

TransportFrame

Rear View ofSupport Pedestal

Perform lifting operationswith extreme caution.

!

ST-80C Right CoverP/N 30180461-200

Cylinder DampenerP/N 30179558

Left CoverP/N 30180461-100

PiP/

Lifting and Transport (continued)


17

TransportPin

Installedin stored

position foroperation.

TransportFrame

P/N 30181717

Cotterpin

Transport SkidP/N 30180482

ns00

Transport Frame and Skid1.

ns.

Filter ElementP/N 82749

Pin KeeperP/N AR06-03-13

Rear View ofSupport Pedestal

Perform lifting operationswith extreme caution.

!


18

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, fi ttings, 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 fi lter.

5. Check all fi ttings for leaks.

6. Lubricate entire ST-80C and check the condi-tion of the fi lter per Chapter 5, Maintenance.


19

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 deliver-ing full fl ow.

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

Power unit return line fi lter dirty.

Replace fi lter element of HPU.

Pressure fi lter dirty. Replace fi lter element of ST-80C.

Torque pressure set too low.

Increase pressure setting.


20

Vertical Positioning Problems

Symptom Probable Cause RemedyVertical positioning assembly moves without anyone functioning the unit

High back pressure Check all quick disconnects are fully shouldered

Lift cylinder damaged or dirty.

Clean or repair cylinder.

Binding of carriage in pedestal.

Lubricate or replace side rollers.

Push/Pull cable broken. Replace cable.

Does not maintain vertical position

Counterbalance valve out of adjustment.

Replace, or adjust counterbalance valve to maintain vertical position.

Lift cylinder leak. Replace seals.

Troubleshooting (continued)


21

Troubleshooting with Torque WrenchSymptom Probable Cause RemedyTorque cylinders do not makeup.

Torque valve set too low.

Increase setting.

Torque valve or pressure reducing valve stuck closed, dirty, or damaged.

Check valves, clean or replace.

Torque cylinders already at end of stroke.

Recycle the upper jaw for next bite.

Torque setting damaged.

Check, clean, or replace.

Torque cylinders do not breakout.

Push/Pull cable broken Replace cable

Sticking or worn main operating valve.

Disassemble valve, inspect for contamination or wear, and repair or replace.

Dirty return fi lter in power supply.

Replace fi lter element.

Torque gauge does not indicate torque during makeup

Dirty inlet port or gauge.

Clean inlet port or replace gauge.

Dump valve stuck open (depressed, pressure does not build up) or set incorrectly.

Adjust full CW test if still no pressure reading, replace, readjust 1/4 turn from full CCW position.

Torque cylinders reached end of stroke and actuated dump valve.

Reset for additional stroke.

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


22

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.

Torque wrench clamp cylinders too slow or uneven.

Check valves on manifold contaminated or defective.

Clean, repair, or adjust valves.

Lack of lubrication. Lube all grease fi ttings.

Push/Pull cable broken or out of adjustment

Replace cable or adjust

Troubleshooting (continued)


23

Troubleshooting the Spinner AssemblySymptom Probable Cause RemedySpinner assemblies do not clamp or unclamp and/or motors do not run.

Flow restricted. Locate cause or restriction and correct.

Spin rollers do not turn with motor running, or have insuffi cient power.

Sheared drive roller key.

Replace key.

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

Remove motor, retighten nut and secure nut with lock tab.

Motor seal blown. Replace motor seals. Check that motor drain lines are open to tank.

Flow restricted to motor.

Locate cause of restriction and correct.

Defective roller bearings.

Replace bearings.

Defective motor. Repair motor.

Motor Drive shaft broken.

Replace Shaft.

Spin rollers slip or back-off of pipe

Insuffi cient clamping pressure.

Check pressure at manifold set to 2,100-2,150 psi. Check for leaks in clamping lines and replace as required. Replace and check relieving valves in manifold (CB8, CB9 and RV1).

Defective seal on spin clamp cylinder piston.

Replace seal.

Slippery connection. Clean connection.

Spin rollers worn. Replace spin rollers.


24

Appendix

Ambient Temperature Range

Manufacturer

Viscosity Index

CastrolChevronExxonGulfMobilShellStatoilTexacoTotalUnion

AGMAISO Viscosity Grade

Above 21° C(Above 70° F)

Alpha LS-320

NL Gear 320

Spartan EP320

EP Lube HD320

MobilGear 632

Omala 320

Loadway EP320

Meropa 320

Carter EP 320

Extra Duty NL6EP

6EP

320

7° to 30° C(45° to 85° F)

Alpha LS-150

NL Gear 150

Spartan EP150

EP Lube HD150

MobilGear 629

Omala 150

Loadway EP150

Meropa 150

Carter EP 150

Extra Duty NL4EP

4EP

150

-6° to 16° C(20° to 60° F)

Alpha LS-68

NL Gear 68

Spartan EP68

EP Lube HD68

MobilGear 626

Omala 68

Loadway EP68

Meropa 68

Carter EP 68

Extra Duty NL2EP

2EP

68

Lubricant SpecificationsSelecting a LubricantRecommended Gear Oil


25

Rig Solutions Aftermarket Service Phone Numbers

Corporate Headquarters7909 Parkwood Circle DriveHouston, Texas 77036United StatesPhone: 713 375 3700Fax: 713 346 7687

UKNOV Service and Repair (Aberdeen/Montrose)Forties RoadMontroseScotlandDD10 9ET+44 1674 677222+44 7711 415485 (after hours)+44 7739 170079 (workshop)+44 7713 643012 (spare parts)

Rig Solutions10000 Richmond AvenueHouston, Texas 77042United StatesPhone: 713 346 7500Fax: 713 435 2195

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

United StatesColoradoNOV 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 61490R/A No.13, Plot MO 0682Daimler Chrysler StreetJebel Ali Free ZoneDubai, UAE+971 4 883 8776+971 4 883 8795 (fax)

LouisianaNOV 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 AreaBadr City, Cairo, Egypt+20 2 231 08001+20 2 231 08002+20 2 231 08003 (fax)


26

Appendix (continued)Rig Solutions Aftermarket Service Phone Numbers (continued)

NOV Service and Repair (New Iberia)5212 Highway 90 Service Road WestNew Iberia, Louisiana 70560+1 337 374 1400(legacy Varco and NOI equipment andall NOV spare parts)

North AfricaNOV Service (Algeria)Overseas Equipment Service AfricaBP 852 Zone Industrielle AlgerieHassi Messaoud OuarglaAlgeria 30500+213 29 75 54 75+213 29 75 41 05 (fax)

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

MinnesotaNOV 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)

EuropeFranceNOV Service+33 24 068 3600+33 24 068 3611+33 24 068 3600 (after hours)+33 677 790 943 (after hours)

North DakotaNOV Service and Repair (Williston)611 58th Street WestWilliston, ND 58801+1 701 774 0454

NorwayNOV Service (Asker)Blakstadmarka 261374 Asker – Norway+47 6400 5000+47 6400 5001 (after hours)


27

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

NOV Service (Kristiansand)Skibaasen 24636 Kristiansand – Norway+47 3819 2000+47 3819 2482 (after hours)NOV Service (Molde)Granfjaera 246415 Molde – Norway+47 7120 2020+47 9169 9664 (after hours)

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

NOV Service and Repair (Houston)5100 North Sam Houston Parkway WestHouston, Texas 77086+1 281 569 3050 (24/7 technical support)+1 281 569 3051 (eHawk remote support)

NOV Repair (Stavanger)Dusavik BaseMidtre Basevei 44029 Stavanger – Norway+47 5183 5600NOV Service (Stavanger)Lagerveien 84069 Stavanger – Norway+47 5181 8181+47 4140 0041 (after hours)+47 9511 8181 (24/7 eHawk remote support)

WyomingNOV Service and Repair (Casper)1080 North Robertson RoadCasper, Wyoming 82601+1 307 473 8888+1 281 569 3050 (after hours)

AsiaChinaNOV ServiceSuite 1603-1606, Air China PlazaNo. 36 Xiaoyun Road, Chaoyang DistrictBeijing 100027 PRC+86 139 0121 9392+86 108 0081 05109 (24/7 technical support)


© 2012 National Oilwell VarcoD392004720-MKT-001 Rev. 01

28

Appendix (continued)Rig Solutions Aftermarket Service Phone Numbers (continued)

CanadaNOV Service and Repair (Leduc/Edmonton)6621 – 45 StreetLeduc, Alberta, CanadaT9E 7E3+1 780 986 1712+1 780 986 5556+1 780 665 0200 (parts)+1 780 619 5579 (parts)

IndiaNOV Service and RepairR-619, TTC Industrial AreaRabale, MIDCNavi Mumbai – 400 401Maharashtra, India+91 982 009 1322+91 983 349 6154 (after hours)

AmericasBrazilNOV Service and Repair (Macaé)Rod. Amaral Peixoto, s/n KM164,5Imboassica – Macaé – RJ – BrazilCEP 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)

SingaporeNOV Service and Repair29 Tuas Bay DriveSingapore 637429+65 6594 1000+65 6594 1222 (24/7 technical support)

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

RussiaNOV Service and Support5, Ulansky LaneMoscow, 101000Russia+7 495 775 2540+7 985 410 5272 (mobile)+7 495 981 3470 (fax)+7 985 997 3545 (24/7 technical support)


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