iron roughneck st-80c

7/21/2019 Iron Roughneck ST-80C

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Mech. Engineering BENTEC GmbH Drilling & Oilfield Systems

Department BOE / M

Prepared: I.T.

Date: Sep.08

Deilmannstr. 1

48455 Bad Bentheim

Germany

Phone: +49 5922 72 80

www.Bentec.de

TECHNICAL MANUAL

LAND DRILLING RIG

350T BENTEC AC DRILLING RIG


2/145


Department BOE / M

Prepared: I.T.

Date: Sep.08

Deilmannstr. 1

48455 Bad Bentheim

Germany

Phone: +49 5922 72 80

www.Bentec.de

TECHNICAL MANUAL

LAND DRILLING RIG



3/145


Department BOE / M

Prepared: I.T.

Date: Sep.08

Deilmannstr. 1

48455 Bad Bentheim

Germany

Phone: +49 5922 72 80

www.Bentec.de

TECHNICAL MANUAL

LAND DRILLING RIG



4/145

Mech. Engineering

Department BOE/M

Prepared: A.I.

Date: Aug.08

BENTEC GmbH Drilling & Oilfield Systems

Deilmannstr. 1

48455 Bad Bentheim

Germany

Phone: +49 5922 72 80

www.Bentec.de

dSystems,

Deilmannstr.

1,

484

55BadBentheim

,Germany.

Thismanualisdesignedfortheoperatorofthefacility/mach

ineanditspersonnel.Itcontains

duplicated

,distributedorcomm

unicatedinanyotherway.

Equipment Data

Type: ST-80C

Depth: 59,6 in. 1.514 mm

With: 66,0 in. 1.676 mm

Height: 86,6 in. 2.200 mm

Weight: 7000 lb 3.175 kg

Hydraulic:

Operating pressure: 2100 psi 145 bar


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Department BOE / M

Prepared: I.T.

Date: Sep.08

Deilmannstr. 1

48455 Bad Bentheim

Germany

Phone: +49 5922 72 80

www.Bentec.de

TECHNICAL MANUAL

LAND DRILLING RIG



6/145

User Manual

ST-80C

Iron Roughneck


7/145

D811000124-MAN-001

Revision 01

Revision History

01 11.05.2007 New Issue P. Solovyov K. Schmidt B.Winter

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

Change Description

Revision Change Description


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Table of Contents

D811000124-MAN-001

Revision 01

Page i of iv

Chapter 1: General InformationIntended Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2: OverviewTool Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Iron Roughneck Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

ST-80C Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2ST-80C Tall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

ST-80C Range of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Pinch Point Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Tool Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6


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Table of Contents

D811000124-MAN-001

Revision 01

Page ii of iv

Iron Roughneck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Installing the Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Positioning the Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Installing the Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Installing the Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Hoist/Lower Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Iron Roughneck Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . 3-20

HPU Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20Controls Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Storing the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Transporting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22Using an Iron Roughneck on Floating Vessels . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Chapter 4: OperationOperating the ST-80C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Checking System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Hoist/Lower Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Positioning ST-80C for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Making and Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Adjusting the Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6


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Table of Contents

D811000124-MAN-001

Revision 01

Page iii of iv

Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11Changing Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12Replacing Spin Rollers and Slide Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Adjusting Torque Gage Responsiveness. . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Chapter 6: TroubleshootingTroubleshooting the ST-80C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Operating Mode Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Vertical Positioning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Troubleshooting the Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3Troubleshooting the Spinner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Chapter 7: Service LocationsNational Oilwell Varco Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1


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Table of Contents

D811000124-MAN-001

Revision 01

Page iv of iv

This page is intentionally blank


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D811000210-MAN-001Revision 01Page 1-1 of 6

General Information 1

Intended Audience

This manual is intended for use by field engineering, installation, operation, and repair

personnel. Every effort has been made to ensure the accuracy of the informationcontained herein. National Oilwell Varco(NOV), will not be held liable for errors in thismaterial, or for consequences arising from misuse of this material.

Conventions

Notes, Cautions, and Warnings

Notes, cautions, and warnings provide readers with additional information to advise thereader to take specific action to protect personnel from potential injury or lethal conditions.

They may also inform the reader of actions necessary to prevent equipment damage.Please pay close attention to these advisories.

Note:

Caution:

i

The note symbol indicates that additional information is

provided about the current topics.


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General Information1D811000210-MAN-001

Revision 01

Page 1-2 of 6

Conventions

Illustrations

Illustrations (figures) provide a graphical representation of equipment components orscreen snapshots for use in identifying parts or establishing nomenclature, and may ormay not be drawn to scale. For component information specific to your rig configuration,

see the Technical Drawing Packageincluded with your NOV documentation.


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Safety Requirements

National Oilwell Varco equipment is installed and operated in a controlled drilling rig

environment involving hazardous situations. Proper maintenance is important for safe andreliable operation. Procedures outlined in NOV manuals are the recommended methods of

performing operations and maintenance.

Personnel Training

All personnel performing installation, operations, repair, or maintenance procedures on theequipment, or those in the vicinity of the equipment, should be trained on rig safety, tool

operation, and maintenance to ensure their safety.

To avoid injury to personnel or equipment damage,

carefully observe requirements outlined in this section.

Personnel should wear protective gear during installation,maintenance, and certain operations.


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Revision 01

Page 1-4 of 6

Safety Requirements

General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, suchas electric, hydraulic, pneumatic, or cooling water.

Isolate energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.

Wear proper protective equipment during equipment installation, maintenance, or

repair.

Replacing Components Verify that all components (such as cables, hoses, etc.) are tagged and labeled

during assembly and disassembly of equipment to ensure correct installation.

Replace failed or damaged components with NOV certified parts. Failure to do socould result in equipment damage or injury to personnel.

Read and follow the guidelines below before installingequipment or performing maintenance to avoid

endangering exposed persons or damaging equipment.


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This page is intentionally blank.


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Revision 01

Page 1-6 of 6



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Overview 2

Tool Description

The ST-80C iron roughneck is an oil-rig tool used for make-up and break-out of drilling

tubular connections. Designed for use on smaller rigs where floor space is limited, thedurable ST-80C iron roughneck features a extend/retract scissor-arm system and is

available in standard and tall models. With the tall pedestal iron roughneck model, theoperator has the capability of raising the iron roughneck above the deck crews head in theparked position. Thus, the ST-80C allows clearance around well center and mousehole

both during use and when placed in the parked position.

The control console, which mounts on the front left or right side of the iron roughneckcarriage, operates the all-hydraulic components safely and quickly providing up to

80,000 ft.-lbs. of torque to make-up and break-out drilling tubular connections.

The ST-80C is installed on the drill floor and uses either a single, floor-mounted socket ora floor-mounted bearing and upper mast attachment for elevated storage. No hanging

cable is needed. The ST-80C works at well center and the mousehole. This automatediron roughneck can be rotated by hand about the pedestal for storage when not in use.

i

For safety considerations, the ST-80C iron roughneckcannot be operated when placed in the parked position.

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Overview2D811000124-MAN-001

Revision 01

Page 2-2 of 16

Tool Description

Iron Roughneck Components

ST-80C Standard

Carriage

The carriage is connected to the pedestal and is a compact, heavy-duty enclosure for the

iron roughneck components. The control console support is located on the front of the

carriage.

Control Console

The ST-80C iron roughneck operator-controlled control console is installed on the front of

the iron roughneck carriage. The control console can be mounted on the front left or front

right side, depending on space requirements of the rig floor.

Pedestal

The pedestal, which is mounted on the drill floor, provides vertical and rotational travel forthe iron roughneck for required alignment with either the mousehole or well center.

Scissor-Arm

Capable of extending and retracting, the scissor arm assembly supports and provideshorizontal travel of the iron roughneck for positioning at the mousehole, well center, and

parked/standby positions.

Torque Wrench with Spin Rollers

The ST-80C uses a combination spinner and torque wrench. The dies of the upper jawsl d b h i ll Th i ll i h i d i i h

D811000124 MAN 001


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Overview 2

Tool Description

ST-80C Range of Operation

The ST-80C is compact and flexible for positioning as required according to rig floorspecifications and dimensions. Models are available in standard and tall pedestal heights.The tall pedestal model can be raised to a high parked position using a hoist/lower kit.

Refer toChapter 4, Hoist/Lower Kit.

i

Information and illustrations in this document feature the

Tall pedestal model. However, information can be used forthe ST-80C standard pedestal model or tall pedestal model.

R46.5

R19.111.5

8.5" Pipe

Connection

4.25" Pipe

Connection

R102.6

89 7 (F ll E t d d)

53.0"

D811000124 MAN 001


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Revision 01

Page 2-4 of 16

Tool Description

Pinch Point Hazards


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D811000124-MAN-001


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Revision 01

Page 2-6 of 16

General Description

The ST-80C iron roughneck can make-up or break-out tubular connections from 4-1/4" to

8-1/2" outside diameter, and can handle drill pipe from 3-1/2" up to 6-5/8". It can alsomake-up and break-out stabilizers, spiral collars, and other bottom hole assembly (BHA)

components with sufficient connection length.

Pedestal

Transport

Frame

Carriage

D811000124-MAN-001


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D811000124 MAN 001Revision 01Page 2-7 of 16

Overview 2

General Description

Socket Flange

The ST-80C is installed on the dril l floor using a single, floor-mounted socket. The socketflange enables the iron roughneck to be rotated for proper placement over the well centeror mousehole.

Socket Flange

and

Base Assembly

D811000124-MAN-001


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Overview2D811000124 MAN 001

Revision 01

Page 2-8 of 16

General Description

Carriage

The iron roughneck carriage attaches to the scissor-arm which provides horizontal travelto align the iron roughneck with the well center or mousehole. The scissor-arm is

retractable and can place the iron roughneck in operating, standby, or parked positions.

i

The controls can be installed on either the left or right sideof the ST-80C carriage. Refer to Chapter 3, Installing the

Control Console.

Hydraulic

Manifold

Valve Bank

GuideCarriage

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Revision 01Page 2-9 of 16

Overview 2

General Description

Pedestal

The pedestal support is mounted on the dril l floor using a single, floor-mounted socket or afloor-mounted bearing and upper mast attachment. The pedestal provides vertical androtational travel to align the iron roughneck with the well center or mousehole.

Shut Off ValveWith Lockout Feature

Hydraulic

Filter

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Overview2 Revision 01Page 2-10 of 16

General Description

Wrench

The ST-80C uses a combination spinner and torque wrench. The dies of the upper jawsare located between the spin rollers. The spin rollers grip the connection and spins with a

torque of 1,750 ft.-lb.

The torque wrench can make up the connection with a maximum torque of 60,000 ft.-lb.The wrench can break out connections with a maximum torque of 80,000 ft.-lb.

Follow general safety precautions when working around wrench spin rollers. Failure tofollow the precautions in these warnings may result in serious injury to personnel and/ordamage to equipment.

Ensure power is OFF to the wrench/spin rollers beforetouching or performing repairs and maintenance. Spin

rollers present pinching hazards.

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Overview 2

General Description

Wrench

Upper Jaw Dies

1 each side

Centralizer

Plate

Clamp Cylinder

2 l s

2D811000124-MAN-001


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General Description

Controls Positioning Range

The ST-80C control console can be located on the right or left side and can be adjustedout 64.

R 19

64

Position

Range

D811000124-MAN-001R i i 01 O er ie 2


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Overview 2

General Description

Control Console

BACK

FWD

UP

DOWN

TW

SW

UNCLAMP

CLAMP

BREAK

MAKE

OUT

IN

30171793-1 Rev B

TWSW

Engagestorque wrenchor spinning wrench

TorqueGauge

BREAK

MAKEMakesor breaksaconnection

Detail of Control Panel

O i2D811000124-MAN-001

R i i 01


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General Description

Hoist/lower Kit (ST-80C Tall)

The ST-80C Tall model includes a hoist/lower kit. The hoist/lower valve enables theoperator to move the iron roughneck between the parked/stored and operating positions.Refer to Chapter 4, Hoist/Lower Kit.

Whenever hoisting or lowering the iron roughneck, ensure

all personel and equipment are clear of the operating area.

Failure to follow this warning may result in injury to

personnel or damage to equipment.

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Overview 2



Revision 01


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D811000124-MAN-001Revison 01 Installation 3


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Revison 01Page 3-1 of 24

Installation 3

Pre-Installation and Setup

The information in this chapter assumes that all pre-installation planning and rig-up has

been accomplished prior to installation of the iron roughneck.

Requirements

Although many installation layout arrangements are possible, critical preparation and

installation consideration must be preformed before attempting to install the ironroughneck.

Before installing the iron roughneck system, consider the ideal location of the iron

roughneck, HPU, and service loop to ensure accessibility and safety. Installationconsiderations help to prevent possible restrictions.

Prior to field installation, ensure all iron roughneck components are included and are in

serviceable condition. Fill all lubricants systems to correct levels with specified lubricants.

Initial Inspection

After unpacking all iron roughneck components and parts, inspect as follows:

1. Inventory all components and parts. Notify National Oilwell Varco if parts aremissing or incorrect. Refer to Chapter 7, Contact Information.

2. Inspect all components and parts for shipment damage and corrosion. Notify the

carrier if components or parts were damaged during shipment.

Customer Verification of Hydraulic

Fluid Cleanliness

Installation3D811000124-MAN-001


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Installation3

Pre-Installation Requirementsand Procedures

Hydraulic System and ComponentsHydraulic systems and components are designed for the intended use in the drilling

industry. The hydraulic operating pressure for this equipment is 2,100 psi.

Before beginning work on any portion of the hydraulic system, familiarize yourselfwith the hydraulic schematics. Refer to the Technical Drawing Package.

Isolate, lock out, and tag the hydraulic power controls.

Take precautions when bleeding down residual system pressure, when using bleed

valves or equivalent techniques. Properly discharge all system stored fluid pressure.

Collect all residual hydraulic fluid in a container to prevent rig or environmentalcontamination.

Take precautions to prevent hydraulic oil from leaking into other open mechanical

components such as junction boxes.



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Page 3-3 of 243

Pre-Installation Requirementsand Procedures

Special ToolsThe following table lists special tools and support equipment required to install and

commission an iron roughneck.

Equipment Motion Hazards

The iron roughneck equipment travels either horizontally or vertically.

Description Supplier and

Model No.

Accuracy Range

Hydraulic Pressure Test gage Various 3-5%-FS 0-3000psi (0-206 Bar)

Avoid placing objects in or near the path of motion for

this equipment. Such interference could cause seriousinjury and/or death to personal and/or damage to the

equipment.



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3

Installation

Floor Socket Location

Before installing the floor socket support for the iron roughneck, determine the proper floorsocket location. The placement and installation of the floor socket is specific to the rig.

Figure 3-1. Floor socket Location Layout

Rig

Specific

Allowable Socket

Center Position

Stay toward center toallow for tolerances.

Well Center

Mouse Hole

R71.0R89.0

R89.0

R71.0



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Page 3-5 of 243

Installation

Floor Socket Location

Install the iron roughneck clear of the well center and mousehole position for tongapplications.

The following illustration shows the iron roughneck in the closest installation position to the

well center and mousehole.

TongSweep

Tong

R60.0

R48.0



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3

Installation

Floor Socket Installation

Install the floor socket into the rig floor as shown in the Figure 3-4. Ensure the floor socketis positioned to receive the iron roughneck pedestal facing forward.

Drill

Floor

Socket

Flange

.5 - 1.5"

Top of Drill Floorto Bottom ofSocket Flange

Optional: Add boxing plates

to structure to increase

welding areafor the floor socket.

D811000124-MAN-001Revison 01P 3 7 f 24

Installation 3


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Page 3-7 of 24

Installation

Reach Extender Plate (Optional)

25.0

'X' DIM

'Y' DIM

ST-80C COLUMN

COLUMN BASE ASSY

TURNTABLE BEARINGS

REACH EXTENDER



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Installation

Use of Optional Reach Extender

Floor Socket

Reach Extender

(optional)

WellCenter

D811000124-MAN-001Revison 01Page 3 9 of 24

Installation 3


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Page 3-9 of 24

Installation

Lifting the Iron Roughneck

Before lifting the iron roughneck, ensure that the pedestal is in the full down position andthat the transport pin is installed in the transport position. When the iron roughneck is inuse, store the transport pin in the brackets located on the back of the pedestal. Use a

lifting device attached to the two lifting shackles attached to lugs on top of the support armwhen lifting the iron roughneck.

National Oilwell Varco recommends using a double chain sling with master link when lifting

the iron roughneck.

The ST-80C has a transportation skid that can be used to hoist the iron roughneck throughthe V-door onto the drill floor, where the ST-80C will be installed in the floor socket.

When lifting the iron roughneck, always use the lifting lugsand shackles provided. No other part of the iron roughneck

is rated for, nor intended to support the full weight of theiron roughneck (7,420 lbs.)



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Installation

Lifting the Iron Roughneck

LiftingShackles

Unit Weight 7,420 lbs.

TransportPin

Install in stored

positionfor operation.

PedestalIn full down

position

Transport

Frame

Rear View of Support Column

D811000124-MAN-001Revison 01Page 3-11 of 24

Installation 3


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Page 3 11 of 24

Installation

Removing Transport Frame and Skid

1. Pull out hairpins from the lock pins.Pins are located on the left side of the carriagewhen viewing the roughneck from the front.

2. Pull out lock pins (3 places).3. Hoist the transport frame up and out of the hole in the

top of the pedestal assembly.

4. Use lifting equipment and hoisting shackles tosafely move the roughneck to the required location.

Remove Transport Frame and Skid

Lifting

Shakles



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Installation

Iron Roughneck Installation

For detailed information on installing the iron roughneck, refer to the Technical DrawingPackage for ST-80C iron roughneck assembly.

1. With the iron roughneck positioned over the rig floor, remove the transport frame

and shipping pin. Refer to Chapter 3, Lifting the Iron Roughneck.

2. Align the bottom of the pedestal with the floor socket collar and insert the collar pins(2 places.) Refer to Figure 3-9.

3. Disengage lifting device and remove lifting link and turnbuckle from lugs.

4. Remove the shipping/parking lock pins and place them in the pin storage position.

Ensure the pedestal is level and perpendicular to the floorsocket collar.


Installation 3


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g

Installation

Iron Roughneck Installation

Ensure the pedestal islevel andperpendicular to the floor socket collar.


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Installation 3


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Installation

Installing the Control Console

R 19

64

Position

Range



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Installation

Installing the Service Loops

Refer to the following ST-80C hydraulic system configurations: Customer System Configuration

NOV System Configuration

1. Check that all circuit breakers at the Hydraulic Power Unit (HPU) are OFF.

2. Locate the hydraulic service loops. Connect the hydraulic supply and return hose

from the HPU to the iron roughneck.

All equipment should be shut down, isolated and tagged"OUT OF SERVICE" before any maintenance procedure is

performed. Any unexpected start-up of equipment duringoperation can cause serious injury or death to personnel

and / or damage to the equipment.

Exercise extreme caution when performing maintenance


Installation 3


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Installation

Installing the Hydraulic Power Unit (HPU)

Refer to the Hydraulic Schematic included in the ST-80C Technical Drawing Package fordetails.

1. Locate the HPU and isolate incoming power OFF.

All equipment should be shut down, isolated andtagged "Out of Service" before any maintenance

procedure is performed. Any unexpected start-up ofequipment during operation can cause serious injuryor death to personnel and/or damage to the

equipment.

i

Before connecting and/or disconnecting hydraulic



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Installation

Hoist/Lower Kit

The ST-80C Tall model includes a hoist/lower kit. The hoist/lower valve enables theoperator to move the iron roughneck between the parked/stored and operating positions.Refer to Chapter 4, Hoist/Lower Kit.

Whenever hoisting or lowering the iron roughneck, ensure

all personel and equipment are clear of the operating area.

Failure to follow this warning may result in injury to

personnel or damage to equipment.


Installation 3


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Checkout Procedure

Iron Roughneck Installation Checkout

Procedure

Ensure that the iron roughneck is fully inserted in the socket and column is verticallyaligned.

Grease all iron roughneck grease points.

Check that all service loop hydraulic lines are connected.

Make sure all hose quick disconnects (QD) are properly engaged.

HPU Installation Checkout Procedure

Check the HPU hydraulic service loop. Ensure the hydraulic hoses are properlysecured and free from snag hazards, leaks, and crimping.

Check the hose quick-disconnect coupling connection between the HPU and the

iron roughneck to ensure that coupling connections are tightened.

Check the fluid level in HPU.

Ensure the hydraulic filter, which is located in the rear of the pedestal, is in proper

condition.

Controls Installation Checkout Procedure Check the HPU hydraulic service loop. Connect the hydraulic supply (1 hose) and

return (1 hose) from the HPU to the iron roughneck.


Installation 3


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Storing the Iron Roughneck

Palletize the iron roughneck for indoor storage. A cargo container is appropriate for

indoor or outdoor storage.

Avoid wide temperature and humidity variations. The ideal environment for storingthe iron roughneck is clean and dry with an ambient temperature of 60F (16C). Ifhigh humidity cannot be avoided, National Oilwell Varco recommends storing the

iron roughneck at 70F (21C).

All exposed, unpainted metal surfaces are coated with rust preventative at thefactory prior to shipment. Coat all unpainted metal surfaces with rust preventative

prior to storage or transport.

Cover all openings to prevent water or dust from entering. National Oilwell Varco

does not recommend using silica or dehydrating agents.

When the iron roughneck is not being used for more than 3 months, perform thefollowing maintenance:

1. Clean the iron roughneck.

2. Grease the iron roughneck as described in Chapter 5, Inspection andLubrication.



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Transporting the Iron Roughneck

When transporting the iron roughneck, ensure the unit remains vertical and is a stable.

Always transport the iron roughneck with the transportation skid installed to increasestability.

Attach tie-down straps to the two lifting shackles attached on the side of the iron

roughneck frame. Additional straps can be attached to major structural components of theiron roughneck as required.

Never position the iron roughneck on its side. Failure toheed this caution will cause damage to the equipment.

Never attach straps to, nor drape straps across thecontrol assembly or side guards of the iron roughneck.

Th d i d i d d


Installation 3


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Using an Iron Roughneck on Floating Vessels

When operating an ST-80C on a floating vessel, high waves and wind cause the ST-80C to

make sudden and unexpected movements. When high waves and wind occur,

immediately stop operation, move the ST-80C to standby position, and tighten the baseassembly jackscrews to prevent pedestal rotation. Refer to Chapter 4, Securing theST-80C on a Floating Vessel.



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Operating Instructions 4


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Operating the ST-80C

Checking System Pressure

Procedure1. Remove the cover plate to gain access to the main manifold.

2. Attach a pressure gage to test port LC on the main manifold.

3. Clamp the ST-80C using the clamp lever. It is not necessary to

have a pipe in the jaws. Read the pressure on the gage, while

holding the lever in the clamp position. The pressure should be

1,900-1,950 psi.

4. Remove the gage and replace the cover plates.

Perform the following procedure when the system pressure isnotbetween 1,900 and 1,950 psi.1. Remove the tamper resistent cover from the PRV cartridge.

2. Follow steps 1 through 3 as described above.

3. One person needs to hold the clamp lever in the clamp position.

4. Another person adjusts hex socket on the PRV cartridge.

(Clockwise to increase pressure, counterclockwise to decrease

pressure.)

5. Remove gage and replace tamper resistant cover and cover

plates.

Operating Instructions4D811000124-MAN-001

Revision 01

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Control Console

The operation procedures in this chapter require the use of the control console.

BACK

FWD

UP

DOWN

TW

SW

UNCLAMP

CLAMP

BREAK

MAKE

OUT

IN

30171793-1 Rev B

TWSW

Engagestorque wrenchor spinning wrench

TorqueGauge

BREAKMAKE

Makesor breaks

a connection

Detail of Control Panel




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Hoist/Lower Kit

The ST-80C Tall model includes a hoist/lower valve that enables the operator to move theiron roughneck between the parked/stored and operating positions.

1. Retract the ST-80C to the parked position: On

the control panel, move the BACK FWD lever to

the BACK position,

2. On the right side of the ST-80C, locate the

hydraulic hoist /lower valve.

3. Raise the ST-80C to the parked (fully raised)

position: Turn the hoist/lower directional valve

handle counterclockwise.

4. When the ST-80C is fully raised, install the

Procedure

Whenever hoisting or lowering the iron roughneck,

ensure all personnel and equipment are clear of theoperating area. Failure to follow this warning may

result in injury to personnel and/or damage to

equipment.

Ensure that there is proper clearance for the

ST-80C to be elevated to the stored position.


Revision 01

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Positioning ST-80C for Operation

Connection

Pin

Bubble

Level

2 places

Extend/Retract

Lever

Procedure

Before operating the ST-80C for the firsttime, be sure to remove the transport pinand place it in itsstorage position.

The ST-80C requires adjustment

whenever the connection or pipe diameter

changes and requires periodic verificationper step 5 of adjustment procedure.

1. Push the extend/retract lever(on top of the carriage) to the fullyretracted position.

2. On the control console, pull forward onthe BACK/FWD handle forward to fullyextend the ST-80C.

3. Move the UP/DOWN handle toraise the ST-80C to position the top ofthe box above the lower dies and belowthe spin rollers.

Use the control console leverstoperform steps2, 3, and 5 on thispage.Use the control console leverstoperform steps2, 3, and 5 on thispage.

!




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Making and Breaking Connections

MakingConnections

If the wrench doesnot reach thedesired value in one stroke, repeat.

1 Use the control panel UNCLAMP/CLAMP lever, to clamp the

jawson the connection, then release the lever.

2 Hold the TW/SW lever in the SW position. Wait

1 second before torquing.

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 isachieved.

6 UNCLAMP the jaws.

7 Recycle the torque wrench to BREAK to prepare for thenext connection. 1

RightHand

2

LeftHand

6

RightHand

4

LeftHand

7

RightHand

5

RightHand

3

RightHand


Revision 01

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Adjusting the Makeup Torque

PRV AdjustmentKnob

Torque

Gage

ReferenceIndicator

(Red)

Zero Adjustlocated backside

of torque gage




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Adjusting Torque Gage

TorqueGage Adjustment

K b

DO NOT operate the TORQUE lever

while zeroing the torque gage dial.

Zero out the torque gage every time youstart up

the ST-80C, or when the torque setting has

changed.

Return line pressure affectsthe gage reading.

See the Chapter 6, Troubleshootingfor gageresponsivenesssetting.

National Oilwell Varco offersan additional gage kit

that can be installed in the drillerscabin (Remote

Torque Gage kit, (P/N 30173445).

Procedure

1. Rotate the knobon the backside of the gage tozero out the torque gage dial.

2. Open the hydraulic shut-off valve handle to allow

pressure to the system.

3. Rotate the small knobon the back of the gage so

that it showszero.

!

!


Revision 01

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Securing the ST-80C on a Floating Vessel

When operating an ST-80C on a floating vessel, high waves and wind cause the

ST-80C to make sudden and unexpected movements. Refer to procedures in Figure 4-8.

1. Stop operation.2. On the control panel, move the BACK/FWD lever to

the BACK position: move the ST-80C to parked position.3. Turn the base assembly jackscrews(2 places)

clockwise until they tighten against the base plate toprevent pedestal rotation.

Procedure

When ST-80C operation can proceed safely, turn the

base assembly jackscrews(2 places) counterclockwise

to allow pedestal rotation.




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Maintenance 5

i S ifi i


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Lubricant Specifications

Selecting A Lubricant

Use the following two tables to select the appropriate lubricant for your specific application.

Recommended General Lubricants

Above -20 C(Above -4 F)

Below -20 C(Below -4 F)

MP GreaseAvi-Motive

Lidok EP2

Gulf Crown EP32

Mobilux EP2

Alvania EP2

Uniway EP2N

Multifak EP2

Multis EP2

Unoba EP2

N/RAvi-Motive W

Lidok EP1

Gulf Crown EP31

Mobilux EP1

Alvania EP1

Uniway EP1N

Multifak EP1

Multis EP1

Unoba EP1

Ambient Temperature Range

Manufacturer

Viscosity Index

CastrolChevron

Exxon

Gulf

Mobil

Shell

Statoil

Texaco

Total

Union

Maintenance5D811000124-MAN-001

Revision 01

Page 5-2 of 14

L b i t S ifi ti


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Lubricant Specifications

Selecting a Lubricant

Recommended Gear Oil

Ambient Temperature Range

Manufacturer

Viscosity Index

Castrol

Chevron

Exxon

Gulf

Mobil

Shell

Statoil

Texaco

Total

Union

Above 21 C(Above 70 F)

AlphaLS-320

NL Gear 320

Spartan EP320

EP Lube HD320

MobilGear 632

Omala320

Loadway EP320

Meropa320

Carter EP 320

ExtraDuty NL6EP

7 to 30 C(45 to 85 F)

AlphaLS-150

NL Gear 150

Spartan EP150

EP Lube HD150

MobilGear 629

Omala150

Loadway EP150

Meropa150

Carter EP 150

ExtraDuty NL4EP

-6 to 16 C(20 to 60 F)

AlphaLS-68

NL Gear 68

Spartan EP68

EP Lube HD68

MobilGear 626

Omala68

Loadway EP68

Meropa68

Carter EP 68

ExtraDuty NL2EP


Maintenance 5

I ti d L b i ti


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Inspection and Lubrication

Inspecting Hardware and Fittings

Visually inspect the ST-80C for loose or missing hardware and fittings daily. Make sure all

lock safety wire is undamaged and that the safety cable between the 3 guiding pins of thelower jaws is present.

Check the inline pressure filter weekly. Replace as necessary if the indicator is red duringoperation.

Inspect all hoses for wear or damage. Replace as necessary.

Lubricating the ST-80C

The lubrication intervals described in this manual are based on lubricant supplierrecommendations. Severe conditions such as extreme loads or temperature, corrosiveatmosphere, etc., may require more frequent lubrication.

W b hi bi di t t l ti d th b l diti i di t

i

All hoses are clearly labeled. Consult hose kit drawings forproper routing and hose specification and always label

when replacing hoses on the ST-80C.


Revision 01

Page 5-4 of 14

I ti d L b i ti


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Daily

Each grease fitting isto be greased until clean grease

isseen extruding from the related component.

Grease

Fitting(1 each side)

Grease

Fitting(1 each side)

Guide Pins

Brush matingsurfaceswith grease

Grease

Fitting(2 places)

GreaseFitting

(2 places)

Arm Pins

(12 places)


Maintenance 5



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Weekly


Revision 01

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Monthly

SpinnerGearbox

Check oil level

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.

Procedure


Maintenance 5



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6 Months

Changing Oil

RH Spinner

Assembly Manifold

SpinnerAssembly

Pivot Pin

Spinner

Gearbox

Fill Plug

Spinner

Gearbox

LH Spinner

Assembly Manifold


Revision 01

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MPI Inspections

PI inspect bore every two yearsfor linear indicationsand

repair asnecessary.Disassembly isrequired.

MPI inspect bore every two yearsfor linear indicationsand

repair asnecessary.Disassembly isrequired.

MPI inspect radiusincludingoverlap of one inch on topand bottom surfacesyearly

for linear indicationsandrepair asnecessary.

Disassembly isnot required.


Maintenance 5

Disassembly and Assembly


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Precautions

Disassembly procedures are performed when replacing damaged components that arecausing a tool function to fail. Whenever performing a disassembly, practice preventive

maintenance by:

Cleaning and inspecting all disassembled parts.

Replacing all worn and damaged parts before they can cause another failure.

Installing thread protectors on exposed threads.

Transport hydraulic components to a clean, dust-freeservice area before disassembling for service.


Revision 01

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Precautions

Release all hydraulic oil pressure before

disconnecting hydraulic lines. Hydraulic oil underpressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean

the work area. Maintain system cleanliness bypromptly capping all disconnected lines. Dirt isextremely harmful to hydraulic system components

and can cause equipment failure and subsequentinjury to personnel.

Ensure all hydraulic lines are isolated and the ball

valve is closed before any work is performed on theST-80C.

If air is introduced into the duplex extend cylinder, useextreme caution when extending the platform for the

first time. As the load moves over center, the air willcompress causing the support arm to extend rapidly.


Maintenance 5



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Changing Dies

Proc

edure

Caution the die can slip out of the die holder

once itsfree of the housing.

ReplacingUpper Dies1. Clean the areaaround the diesand remove the two screwsholding

each die and discard screws.

2. Remove worn die.3. Clean the backing surfaceswith wire brush, inspect and grease

lightly.4. Install new diesand screws, torque to 138-152 ft.-lb.

ReplacingLower Dies

1. Remove all main socket head screw (2 per die carrier) and all set

screws(4 per die carrier) from both die carriers.2. Screw handtight 1 socket head screw in each of the 4 corners.

3. Advance each of the 4 socket head screws1/2 turn at atime in anX pattern until die carrier comesfree.

4. Remove die and socket head screwsfrom die carrier.5. Discard the existing screws, set screws, and diesafter disassembly.

6. Clean receiving pocket and die holder thoroughly, and liberallyapply anti-seize to all mating surfacesbefore reinstalling them.

Carriage


Revision 01

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Replacing Spin Rollers and Slide Rings

RH SpinnerAssemblyManifold

SpinnerAssembly

Pivot Pin

Spinner

Lift Thread1/2-UNC

Disassembly


Maintenance 5

Adjusting Torque Gage


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djust g o que GageResponsiveness

If the torque gage isnot responding or is

too sensitive, adjust the needle valve onthe torque gage until the gage reactswith

the desired response.

If the torque gage isnot responding or is

too sensitive, adjust the needle valve onthe torque gage until the gage reactswith

the desired response.

Screw

Jam Nut


Revision 01

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Troubleshooting 6

Troubleshooting the ST-80C


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g

This section describes general troubleshooting methods and provides tables for

troubleshooting specific problems or components.

Wh t bl h ti th ST 80C k th h d li i b t 1 900

Make sure all hydraulic lines are isolated and the ball valve

is closed before any work is performed on the ST-80C.

Whenever hoisting or lowering or operating the ironroughneck, ensure all personnel and equipment are clear

of the operating area. Failure to follow this warning may

result in injury to personnel or damage to equipment.

Troubleshooting6D811000124-MAN-001

Revision 01

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Troubleshooting Tables

Operating Mode Problems

Symptom Probable cause Remedy

Tool runs slowly.

Hydraulic quick disconnect on

supply or return lines not fully

shouldered.

Tighten until fully shouldered.

Power unit not delivering full

flow.

Check power supply flow while spin out valve is

actuated. Flow should be 35 GPM minimum.

Power unit return line filterdirty.

Replace filter element of HPU.

Pressure filter dirty. Replace filter element of ST80.

Torque pressure set too low. Increase pressure setting.

Vertical Positioning Problems

Symptom Probably cause Remedy

Vertical positioning assembly

moves in one direction only or

does not move at all

Power supply not operating, or

pressure too low.Re-establish hydraulic power.


Troubleshooting 6



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Troubleshooting the Torque Wrench

System Probable cause Remedy

Torque 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 ofstroke.

Recycle the upper jaw for next bite.

Torque setting damaged. Check, clean, or replace.

Torque cylinders do not

breakout.

Torque setting pressure reducing

valve stuck closed, dirty or

damaged.

Check valves, clean or replace.

Torque cylinders drift in

makeup direction.

Sticking or worn main operating

valve.

Disassemble valve, inspect for

contamination or wear, and repair orreplace.

Torque cylinders drift in

breakout direction.

Excessive back pressure on return

line.

Check for restriction in return line. Check

hydraulic power supply. Check for other

equipment using same tank line


Revision 01

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Troubleshooting the Torque Wrench (cont)


Jaws slip on tool joint. Worn or broken dies. Replace dies.

Hydraulic pressure too low.Make sure the pressure at the manifold is

set to 1,900-1,950 psi.

Upper torque wrench body lifts

while cycling in makeup or

breakout mode.

Interference between upper and

lower body sets.Check and remove interference.

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 fittings.

Push/Pull cable broken. Replace cable.

Troubleshooting the Spinner Assembly

Symptom Probable cause Remedy


Troubleshooting 6

Troubleshooting the ST80C


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Troubleshooting the Spinner Assembly (cont)


Spin rollers do not turn with

motor running, or have

insufficient 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.

Loss of power, torque. Power supply not operating.

Check power supply pressure gage for

indication. Ensure that supply pressure

remains high with operating valve

energized


Revision 01

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Thi i i t ti ll bl k


Contact Information 7

National Oilwell Varco Contacts


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Americas Europe

NOV Service (Houston)12950 W. Little YorkHouston, Texas 77429+1 713 856 4128

NOV Service and Repair (Aberdeen/Montrose)Forties RoadMontroseScotlandDD10 9ET+44(0)1674 677 222

NOV Repair (Houston)5900 Brittmoore Road

Houston, Texas 77041+1 281 847 9990

NOV Service (Kristiansand)Skibaasen 2

4636 Kristiansand - Norway+47 38 19 20 00

NOV Service and Repair (Houston)Facility Under Construction5100 North Sam Houston Parkway WestHouston, Texas

NOV Service (Stavanger)Lagerveien 84069 Stavanger - Norway+47 51 81 81 81

NOV Service and Repair (New Iberia, Hwy 90)8404 West Hwy. 90

New Iberia, Louisiana 70560+1 337 359 8000

NOV Service (Molde)Granfjaera 24

6415 Molde - Norway+47 71 20 20 20

NOV Service and Repair (Broussard)1030 Cruise Avenue

NOV Service (Asker)Blakstadmarka 26

Appendix7D811000124-MAN-001Revision 01

Page 7-2 of 2


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Mech. Engineering BENTEC GmbH Drilling & Oilfield SystemsDepartment BOE / M

Prepared: I.T.

Date: Sep.08

Deilmannstr. 1

48455 Bad Bentheim

Germany

Phone: +49 5922 72 80

www.Bentec.de


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TECHNICAL MANUAL

LAND DRILLING RIG



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Mech. Engineering BENTEC GmbH Drilling & Oilfield SystemsDepartment BOE / M

Prepared: I.T.

Date: Sep.08

Deilmannstr. 1

48455 Bad Bentheim

Germany

Phone: +49 5922 72 80

www.Bentec.de


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TECHNICAL MANUAL

LAND DRILLING RIG



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Technical Drawing Package

ST-80C

IRON ROUGHNECK

Document number D811000123-DOS-001Revision 02Page 2

REVISION HISTORY


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REVISION HISTORY

02 06.12.2007 Revised by Engineering P. Solovyov K. Schmidt B. Winter

01 11.05.2007 First Issue P. Solovyov K. Schmidt B. Winter

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

CHANGE DESCRIPTION

Revision Change Descript ion01 First Issue

02 1. Insert content in Latest TDP Template: D811000461-GEN-001/012. Change Reference Number from 30179800 to 30171800.3. Change Revision Number from 01 to 02.4. Insert additional Wrench Assembly drawings. See lists: Manifold Assembly through

Lower Jaw Assembly.


TECHNICAL DRAWING PACKAGE


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TECHNICAL DRAWING PACKAGEThis document provides a list of drawings for the ST-80C: Short and Tall Column Models. The actualdrawings are arranged in the binder, in numerical order.

Drawings by Assembly

Short Column

Drawing Descripti on Drawing Number

Top Assembly....................................................................................................... 30181800

ST-80C Assembly ............................................................................................. 30179200Socket Flange Assembly................................................................................... 30172616

Platform Assembly ......................................................................................... 30176064

Carriage Assembly......................................................................................... 30179883

Wrench Assembly....................................................................................... 30174930

Manifold Assembly ............................................................................... 30154910-2

Upper Die Set Package........................................................................... 30174222

Lower Die Set Package........................................................................... 30172029

Die Holder Assembly............................................................................... 30160384

LH Spin Wrench Assembly...................................................................... 30160387



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Drawings by Assembly

Tall Column


Top Assembly....................................................................................................... 30181800

ST-80C Assembly ............................................................................................. 30179800

Socket Flange Assembly................................................................................... 30172616

Platform Assembly ......................................................................................... 30180452Carriage Assembly......................................................................................... 30179883

Wrench Assembly....................................................................................... 30174930

Manifold Assembly ............................................................................... 30154910-2

Upper Die Set Package........................................................................... 30174222

Lower Die Set Package........................................................................... 30172029

Die Holder Assembly............................................................................... 30160384

LH Spin Wrench Assembly...................................................................... 30160387

LH Transmission Assembly.................................................................. 30160389

RH Spin Wrench Assembly ..................................................................... 30160390



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Drawings in Numerical Order

Short Column


Top Assembly....................................................................................................... 30181800

Manifold Assembly ............................................................................................ 30154910-2

Die Holder Assembly ............................................................................................ 30160384

LH Spin Wrench Assembly................................................................................... 30160387

LH Transmission Assembly.................................................................................. 30160389

RH Spin Wrench Assembly .................................................................................. 30160390

RH Transmission Assembly ................................................................................. 30160392

Clamp Cylinder Assembly .................................................................................... 30160444

SW Clamp Cylinder Assembly.............................................................................. 30160658

LH Torque Cylinder Assembly.............................................................................. 30160684

RH Torque Cylinder Assembly ............................................................................. 30160685

Control Valve Assembly ....................................................................................... 30171621




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Tall Column


Top Assembly....................................................................................................... 30181800

Manifold Assembly ............................................................................................ 30154910-2

Die Holder Assembly ............................................................................................ 30160384

LH Spin Wrench Assembly................................................................................... 30160387

LH Transmission Assembly.................................................................................. 30160389RH Spin Wrench Assembly .................................................................................. 30160390

RH Transmission Assembly ................................................................................. 30160392

Clamp Cylinder Assembly .................................................................................... 30160444

SW Clamp Cylinder Assembly.............................................................................. 30160658

LH Torque Cylinder Assembly.............................................................................. 30160684

RH Torque Cylinder Assembly ............................................................................. 30160685

Control Valve Assembly ....................................................................................... 30171621

ST-80C Assembly................................................................................................. 30171800

Lower Die Set Package 30172029


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iron roughneck st-80c

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