ST-80 ST-80

SM00995
Roughneck
Service Manual
3
4
General Information
Specifications
Maintenance
Troubleshooting
1
2
3
4
General Information
Specifications
Maintenance
Troubleshooting
1
2
1
General Information
1-1
3
4
General Information
1
2
Preface................................................................ 1-3
Manual conventions ...................................................... 1-3
Note ................................................................................... 1-3
Caution .............................................................................. 1-3
Warning ............................................................................. 1-3
Product bulletins ............................................................ 1-3
Overall equipment safety requirements......................... 1-3
Personnel training.............................................................. 1-4
Systems safety practices ................................................... 1-4
Hydraulic systems and components ............................ 1-4
General safety ................................................................... 1-5
Equipment motion hazards 1-5
Proper use of equipment .............................................. 1-6
Tool orientation .................................................. 1-7
ST-80 general information.................................. 1-8
ST-80 carriage assembly .............................................. 1-9
Pedestal assembly ........................................................ 1-10
ST-80 wrench assembly ................................................ 1-11
Control System.............................................................. 1-12
Operating the ST-80............................................ 1-14
Making and breaking connections ................................. 1-14
Adjusting the makeup torque......................................... 1-16
Adjusting the stabbing guide ......................................... 1-17
Adjusting torque gauge responsiveness........................ 1-18
Storing the ST-80................................................ 1-19
1
General Information
1-2
3
4
5
General Information
1
2
1
General Information
1-3
Preface
Manual conventions
This Preface contains the conventions used throughout this manual.
Avoid injury to personnel and/or equipment damage by reading this
manual and related documents before operating, inspecting, or
servicing the equipment.
Notes, cautions, and warnings
The following examples explain the symbols for notes, cautions, and
warnings. Please pay close attention to these important advisories.
Note
i
Provides additional information on procedures involving little or no
risk of injury to personnel or equipment damage.
Caution
!
Alerts the reader to procedures involving a risk of equipment
damage.
Warning
Warns the reader of procedures involving a definite
risk of injury to rig personnel.
Product bulletins
The Product Bulletin tab, if included in your manual, defines a
section of the manual in which you can store Product and Safety
bulletins that may be issued by Varco.
Overall equipment safety requirements
Varco drilling equipment is installed and operated in a controlled
drilling rig environment that involves hazardous operations and
situations.
i
To avoid injury to personnel or equipment damage, carefully observe
the following safety requirements.
1
General Information
1-4
Personnel training
All personnel installing, operating, repairing, or maintaining
equipment, or those in the vicinity of this equipment, should be
trained in rig safety, tool operation, and maintenance as applicable.
This measure helps ensure the safety of everyone exposed to the
equipment for whatever purpose.
i
During installation, operation, maintenance, or repair of this
equipment, personnel should wear protective equipment.
Contact the Varco Service Department to arrange for training for
equipment operation and maintenance.
Systems safety practices
The equipment covered by this manual may require or contain one
or more utilities such as electrical, hydraulic, and cooling water.
i
Before installing or performing maintenance or repairs on the
equipment, read the following instructions to avoid endangering
exposed persons or damaging equipment.
Isolate all energy sources before beginning work.
Avoid performing maintenance and repairs while the
equipment is in operation.
Wear proper protective equipment during the installation,
maintenance, or repair of this equipment.
Hydraulic systems and components
Hydraulic systems and components are designed for specific use in
the drilling industry. The hydraulic pressure for this equipment can
be as high as 3,000 psi.
Before beginning work on any portion of the hydraulic system,
familiarize yourself with the hydraulic and electrical
schematics.
Isolate, lock out, and tag the hydraulic and electrical power
and controls.
Take precautions when bleeding down residual system
pressure, using bleed valves or equivalent techniques.
1
General Information
1-5
Hydraulic fluids can be extremely hot and under high
pressure.
Properly discharge all system accumulators.
Collect all residual hydraulic fluid in a container to prevent rig or
environmental contamination.
Take precautions to prevent hydraulic oil from leaking into other
open electrical or mechanical components, such as junction
boxes.
Pneumatic systems and components
Pneumatic systems and components are designed for specific use
in the drilling industry. The pneumatic pressure for this equipment
can be as high as 150 psi.
Prior to beginning work on any portion of the pneumatic system,
familiarize yourself with the pneumatic and electrical
schematics.
Isolate, lock out, and tag the pneumatic and electrical power and
controls.
Take precautions when bleeding down residual system pressure
using bleed valves or equivalent techniques.
Properly discharge all system accumulators.
General safety
Equipment motion hazards
Some of the Varco equipment travels either horizontally, vertically on
rails, or both.
i Avoid placing objects in or near the path of motion for this
equipment. Such interference could cause personnel to be trapped
or crushed by equipment.
i Keep the working envelope/zone of the equipment free from
personnel.
1
General Information
1-6
When replacing components
During disassembly and reassembly of any equipment, verify
all components such as cables, hoses, etc. are tagged and
labeled to ensure reinstalling the components correctly.
Replace failed or damaged components with Varco certified
parts. Failure to do so could result in a hazard, equipment
damage, or personal injury.
During routine maintenance
Equipment must be maintained on a regular basis. See the body of
the service manual for maintenance recommendations.
i
Failure to conduct regular maintenance can result in a hazard,
equipment damage, or injury to personnel.
Visibility of equipment operation
Clear, unobstructed visibility of all equipment functions is critical to
safe operation. Do not block or impair the equipment operators
field of view. In cases where this is not possible, the customer must
install video cameras to ensure adequate visibility.
Proper use of equipment
Varco equipment is designed for specific functions and applications
and should be used only for the intended purpose.
i Do not hoist personnel using this equipment.
Contact the Varco service center for questions regarding equipment
operation, maintenance, hazards, and designed function.
1
General Information
1-7
Tool orientation
Front Left
Rear Right
1
General Information
1-8
ST-80 general information
The ST-80 Roughneck can make or break all tool connections from
4 1/4" to 8 1/2" outside diameter, and can handle nominal drill pipe
from 3 1/2" up to 6 5/8". It can also make and break bits, stabilizers,
spiral colors and other bottom hole assembly (BHA) components.
The ST-80 Roughneck consists of the following major assemblies:
ST-80 carriage assembly
Pedestal assembly
ST-80 wrench assembly
ST-80 controls
Upper and lower motion control
ST-80 Carriage
Assembly
Upper Motion
Control
Lower Motion
Control
Not Visible
Wrench
Assembly
ST80 Controls
Pedestal
Assembly
1
General Information
1-9
ST-80 general information
ST-80 carriage assembly
The carriage assembly can move vertically to position the ST-80
properly at the tool joint.
Hydraulic
Manifold Stabbing
Guide
Wrench
Assembly
Carriage
Controls
1
General Information
1-10
ST-80 general information
Pedestal assembly
Lift Cylinder
Transport
Pin
Stowed Position
Transport
Lock
Insert Transport
Pin Prior to Transport
Extend/Retract
Duplex Cylinder
Socket
Flange
Turntable
Bearing
1
General Information
1-11
ST-80 general information
ST-80 wrench assembly
The ST-80 uses a combination spinning and torque wrench. The
dies of the upper jaws are located in between the spinner rollers.
The spinner rollers grip the pipe and spin in connections with a
torque of 1,750 ft lb.
After spinning, the torque wrench can torque 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.
Upper Jaw
Dies
1 each side
Lower Die
and Die Holder
1 each side
Spin Rollers
2 each side
1
General Information
1-12
ST-80 general information
Control System
The ST-80 controls are mounted on the carriage. They include the
following:
JAWS: UN-CLAMP, CLAMP. Clamps or unclamps the wrench
on a tubular.
MODE: SPIN, TORQUE. Determines whether the wrench
spins or torques connections. The operator must hold this
control in the desired postion while performing these
operations.
TORQUE: MAKE, BREAK. Determines whether the wrench
makes or breaks connections.
SPIN: IN, OUT. Determines whether the wrench spins in or
out.
ST-80: UP, DOWN. Adusts the vertical height of the ST-80.
ADJUST: EXTEND, RETRACT. Adjusts the travel distance of
the ST-80 when extending or retracting the tool.
ST-80: EXTEND, RETRACT. Selects whether the tool extends
or retracts.
1
General Information
1-13
ST-80 general information
Jaws
Clamp, Unclamp
Mode
Spin, Torque
Torque
Make, Break
Spin
In, Out
Torque
Gage
ST-80
Up, Down
Adjust
Extend, Retract
ST-80
Extend, Retract
1
General Information
1-14
Operating the ST-80
Making and breaking connections
!
Before operating the ST-80
for the first time, be sure to
remove the transport pin.
1. Completely extend the tool using
the ST-80 EXTEND/ RETRACT control.
2. Adjust the vertical position of the
wrench on the connection using
ST-80 UP/DOWN control.
3. Use the ADJUST control to precisely
position the ST-80 horizontally.
The correct position is when the lower
guide plate contacts the tubular.
This is typically adjusted only
once per trip.
ST-80
Up, Down
Adjust
Extend, Retract
ST-80
Extend, Retract
Tubular
Pin
Tubular
Box
Rollers
4 places
Vertical Adjustment
1
General Information
1-15
Operating the ST-80
Making and breaking connections
i
If the wrench does not reach the desired
value in one stroke, recycle the torque
wrench and repeat steps 4 and 5.
UN-CLAMP
JAWS
CLAMP
SPIN
MODE
TORQUE
MAKE
TORQUE
BREAK
IN
SPIN
OUT
UN-CLAMP
JAWS
CLAMP
SPIN
MODE
TORQUE
MAKE
TORQUE
BREAK
IN
SPIN
OUT
1 Clamp the jaws on the tubular.
Making Connections
2 Hold the MODE control in
the SPIN position.
3 SPIN the connection IN.
4 Hold the MODE control in
the TORQUE position.
5 Hold the TORQUE control in the MAKE
position until the desired torque is achieved.
6 UN-CLAMP the jaws and recycle the
torque wrench to prepare for the
next connection.
6 UN-CLAMP the jaws and recycle the
torque wrench to prepare for the
next break.
1
2 6
1
6
3 5
Hold
4
Hold
4
Hold
1 Clamp the jaws on the tubular.
Breaking Connections
2 Hold the MODE control in
the TORQUE position.
3 Hold the TORQUE control in the BREAK
position until the connection is broken.
4 Hold the MODE control in
the SPIN position.
5 SPIN the connection OUT.
2 3 5
Hold
1
General Information
1-16
Operating the ST-80
Adjusting the makeup torque
i
!
PRV Adjustment Knob
Torque Gauge
Reference Indicator
Use the following procedure to adjust the
ST-80 make up torque:
1. Back the adjustment knob on the
pressure reducing valve (PRV) all of the
way out.
Turning the PRV adjustment knob counter
clockwise decreases torque. Turning the
PRV adjustment knob clockwise increases
the torque.
2. Clamp onto a tubular.
3. Spin the connection in.
4. Torque the connection.
5. While holding the torque, turn the PRV
adjustment knob clockwise while
watching the torque gauge until the
desired torque is achieved.
Do not adjust the torque if one of the
torque cylinders is at its end of stroke.
6. Position the reference indicator (red
needle) on the torque gauge at the
desired torque value.
1
General Information
1-17
Operating the ST-80
Adjusting the stabbing guide
Use the following procedure to adjust the stabbing guide:
1. Use the horizontal travel and vertical travel controls to position
the torque wrench on the tool joint box.
2. Clamp onto the tubular.
3. Stab the next stand.
4. Loosen two adjusting nuts and align the inside edge of the
stabbing guide with the outer circumference of the pipe. Tighten
the nuts.
i
When coming out of the hole or when handling drill collars, unscrew
the front nuts and push the guide back, out of the way.
Stabbing Guide
Adjusting Nuts
1
General Information
1-18
Operating the ST-80
Adjusting torque gauge responsiveness
Adjust the needle valve on the torque gauge until the gauge reacts
with the desired response speed.
Torque Gauge
Needle Valve
1
General Information
1-19
Storing the ST-80
Palletize the ST-80 for indoor storage. A cargo container is
appropriate for indoor or outdoor storage.
Avoid wide temperature and humidity variations. The ideal
environment for storing the ST-80 is clean and dry with an ambient
temperature of 60F (16C). If high humidity is unavoidable, Varco
recommends storing the ST-80 at 70F (21C).
All exposed, unpainted metal surfaces are coated with rust
preventive at the factory prior to shipment. Coat all unpainted metal
surfaces with rust preventive prior to storage or transport.
Cover all openings to prevent water or dust from entering. Varco
does not recommend using silica or dehydrating agents.
When the ST-80 is not being used for more than 3 months, perform
the following:
1. Clean the ST-80.
2. Grease the ST-80 as described in the Maintenance section of
this manual.
3. Clean and cap all hydraulic quick disconnects (QDs).
i
Varco recommends Kendall Grade 5 (GE-D6C6A1) rust preventive,
or an equivalent.
! Replace the shipping pin prior to storage and/or moving the
ST-80.
1
General Information
1-20
2
Specifications
2-1
3
4
Specifications
1
2
General specifications ....................................... 2-3
Hydraulic requirements ................................................. 2-4
Wrench assembly .......................................................... 2-4
Shipping data (approx., allowing for crate/palette) ........ 2-4
2
Specifications
2-2
3
4
1
Specifications
2
2
Specifications
2-3
General specifications
62.8
51.3 33.2
95.6 80.0
59.0
2
Specifications
2-4
General specifications
Hydraulic requirements
Hydraulic operating pressure (max.) 2,600 psi
Hydraulic operating pressure (min.) 2,000 psi
Hydraulic flow rate required (min.) 28 gpm @ 1000 psi
Hydraulic flow rate required (max.) 40 gpm (150 l/min)
Supply connections (min.) 1" JIC
Return connections 1 1/4" JIC
Wrench assembly
Motor spinning roller ratio 2:1
Spin speed (rollers) 190 rpm
Spin speed (8 1/2" pipe) 90 rpm
Make up torque 60,000 ft lb max.
Break out torque 80,000 ft lb max.
Shipping data (approx., allowing for crate/palette)
Height 88"
Width 60"
Depth 65"
Weight 6,800 lb
3
Maintenance
3-1
3
4
Maintenance
1
2
Lubricant specifications..................................... 3-3
Selecting a lubricant ...................................................... 3-3
Recommended general lubricants..................................... 3-3
Recommended hydraulic fluids ......................................... 3-3
Inspection and lubrication ................................. 3-4
Inspecting hardware and fittings.................................... 3-4
Lubricating the ST-80 .................................................... 3-4
Disassembly and assembly ................................ 3-6
Precautions ................................................................... 3-6
Changing dies ............................................................... 3-7
3
Maintenance
3-2
3
4
Maintenance
1
2
3
Maintenance
3-3
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 Grease
Avi-Motive
Lidok EP2
Gulf Crown EP32
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
2
N/R
Avi-Motive W
Lidok EP1
Gulf Crown EP31
Mobilux EP1
Alvania EP1
Uniway EP1N
Multifak EP1
Multis EP1
Unoba EP1
1
Ambient Temperature Range
Manufacturer
Viscosity Index
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
NGLI
Recommended hydraulic fluids
Hyspin AWS-46
AW Hyd oil 46
Nuto H46
Harmony 46AW
DTE 25
Tellus 46
Hydraway HMA 46
Rando oil HD46
Azolla ZS 46
Unax AW46
46
Hyspin AWS-32
AW Hyd oil 32
Nuto H32
Harmony 32AW
DTE 24
Tellus 32
Hydraway HMA 32
Rando oil HD32
Azolla ZS 32
Unax AW32
32
-10 to 85 C
(14 to 185 F)
-15 to 75 C
(5 to 167 F)
Oil Temperature Range
Manufacturer
Viscosity Index
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
ISO Viscosity Grade
3
Maintenance
3-4
Inspection and lubrication
Inspecting hardware and fittings
Visually inspect the ST-80 for loose or missing hardware and
fittings daily. Make sure all safety wire is undamaged.
Check the inline pressure filter daily. Replace as necessary if the
indicator is red.
Lubricating the ST-80
The lubrication intervals described in this manual are based on
lubricant supplier recommendations. Severe conditions such as
extreme loads or temperature, corrosive atmosphere, etc., may
require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other
abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example, too
much grease forced into a fitting can pop out a bearing seal. Over
lubrication can also affect safety since over lubricated parts can
drip, creating a potential slipping hazard for personnel.
Apply grease daily to all grease fittings as shown on the following
page.
3
Maintenance
3-5
Inspection and lubrication
Daily
Daily
Grease
Fitting
1 each side
Daily
Inline Pressure
Filter
Replace if indictor is red
Daily
Grease
Fitting
1 each side
Daily
Motion Control
Brush mating surfaces
with grease
Daily
Grease
Fitting
2 each side
Grease
Fitting
1 each side
Daily
Grease
Fitting
Daily
Grease
Fitting
1 each side
3
Maintenance
3-6
Disassembly and assembly
Precautions
! Only authorized Varco repair technicians should perform the
following major disassembly and assembly procedures.
! Transport hydraulic components to a clean, dust-free service
area before disassembling for service.
i
Disassembly pr ocedur es ar e usually per for med when r eplacing
damaged components that ar e causing a tool function to fail.
Whenever per for ming a disassembly , practice pr eventive
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.
!
Tor que all fasteners to the limits given in DS 00008 (Design
Specification Design T or que Standar d) unless an alter native tor que
value is given in the pr ocedur e.
Release all hydraulic oil pressure before
disconnecting hydraulic lines. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
Before opening the hydraulic system, thoroughly clean
the work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent
injury to personnel.
3
Maintenance
3-7
Disassembly and assembly
Changing dies
!
Carriage
Assembly
Die Holder
1 each side
Set Screw
2 each side
Screw
2 each side
Lower
Die
1 each side
Screw
2 each side
Upper
Die
1 each side
Use the following procedure to replace upper and lower
dies:
Replacing upper dies
1. Remove the 2 screws holding each die.
Replacing lower dies
1. Remove the 2 screws on each die holder.
2. Screw in the set screws forcing the die holder out.
3. The die will now slid from the die holder.
Caution the die can slip out of the die holder once its
free of the housing.
3
Maintenance
3-8
4
Troubleshooting
4-1
3
4
Troubleshooting
1
2
Troubleshooting the ST-80 ................................. 4-3
Theory of operation ....................................................... 4-4
4
Troubleshooting
4-2
3
4
Troubleshooting
1
2
4
Troubleshooting
4-3
Troubleshooting the ST-80
i
When testing the ST -80 without pipe , reduce the o verall pressure
setting to 250 psi.
Make sure all hydraulic lines are isolated and the ball
valve is closed before ANY work is carried out on the
ST-80.
When troubleshooting the ST-80, make sure the hydrualic pressure
is between 2,000 and 2,600 psi at the inlet of the manifold. Check
the back pressure of the tank line (make sure the pressure does not
exceed 30 psi).
Make sure that all hoses and QDs are properly connected.
Check to see if oil leakage is visible at the manifold, QDs or hoses.
Make sure the tool is lubricated per the Maintenance section of this
manual.
Refer to the theory of operation and schematic when
troubleshooting specific ST-80 components or functions.
4
Troubleshooting
4-4
Troubleshooting the ST-80
Theory of operation
(((TBD Engineering will supply when Hydraulic Schematic is
released)))
4
Troubleshooting
4-5
Troubleshooting the ST-80
(((TBD Hydraulic Schematic in revision)))
4
Troubleshooting
4-6