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Iron Roughneck

ST-80C
TECHNICAL SPECIFICATIONS 2
SAFETY INFORMATION
Pinch Point Hazards 3
OPERATION PROCEDURES
Proper Positioning of ST-80C on Drill
Pipe/Drill Collar Connections 4
Making Connections 6
Breaking Connections 8
STORAGE AND MAINTENANCE
Lubrication 10
Lifting and Transport 15
TROUBLESHOOTING 18
APPENDIX
Lubricant Specications 24
Rig Solutions Aftermarket Service
Phone Numbers 25
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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 4" to 8
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
Tec hni c al Spec i c at i ons
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3
Keep all body parts clear
of pinch points.
Pi nch Poi nt Hazar ds
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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 frst 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.
i
Ad j u s t i n g Pr o c e d u r e
Pr oper Posi t i oni ng of
ST-80C on Dr i l l Pi pe/
Dr i l l Col l ar Connec t i ons
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5
Box
Shoulder
Range
BACK
FWD
UP
DOWN
UNCLAMP
CLAMP
BREAK
MAKE
IN
OUT
TW
SW
Connection
Pin
Extend/Retract
Lever
Connection
Box
Torque Gauge
P/N 30160681-1
Control
Console
Bubble
Level
2 places
Spin Rollers
P/N 30160614
Lower Dies Set P/N 30172029
Lower Die Holder P/N 30160383
Upper Dies Set
P/N 30174222
Dri l l Pi pe Al l owabl e Tool Joi nt Di fferenti al s
D + 5/8" max.
D
D - 3/8" min.
D
Max. difference in diameter
pin larger than box.
Max. difference in diameter
pin smaller than box.
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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
Mak i ng Connec t i ons
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6
Right
Hand
4
Left
Hand
7
Right
Hand
1
Right
Hand
2
Left
Hand
5
Right
Hand
3
Right
Hand
Control Panel Levers
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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.
Br eak i ng Connec t i ons
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Control Panel Levers
6
Right
Hand
2
Left
Hand
3
Right
Hand
5
Right
Hand
1
Right
Hand
4
Left
Hand
7
Right
Hand
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Gear box Pr oc edur e
Front View
BACK
FWD
UP
DOWN
UNCLAMP
CLAMP
BREAK
MAKE
IN
OUT
TW
SW
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.
Grease
Fitting
(2 places)
Spinner
Gearbox
Check oil level.
See Lubricant
Specifications Table for
Recommended Gear Oil
in the Appendix. Replace
gear oil every 6 months
or if dirty/contaminated.
Grease
Fitting
(2 places)
Daily
Grease
Fitting
(2 places)
Daily
Grease
Fitting
(1 each side)
Daily
Grease
Fitting
(1 each side)
Daily
Daily
Grease
Fitting
(2 places)
Daily
Grease
Fitting
(2 places)
Daily
Grease
Fitting
Daily
Torque
Adjustment PRV.,
P/N 94817-3AN;
PRV Knob,
P/N 16498-1
Lubr i c at i on
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Side View
Side Guard Removed, displaying Lubrication
i
Daily
Grease
Fitting
(2 places)
Daily
Grease
Fitting
(1 each side)
Daily
Guide Pins
Brush mating
surfaces with
grease.
Replace gear oil every 6 months
or if oil is dirty/contaminated.
Daily
Arm Pins
(12 Places)
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Side View
Side Guard Removed, displaying Part Numbers
(12) Pinkeepers
P/N/ AR06-03-13
* P/N 30171622-500 (3)
P/N 30171622-510 (3)
ST-80C/CL
Valve
Control
ST-80C/CL
Valve
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)
Lubr i c at i on (c ont i nued)
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Rear View
Grease
Fitting
Grease
Fitting
Grease
Fitting
Grease
Fitting
i
Each grease f i t ting i s to be greased
until cl ean grease i s seen extruding
from the rel ated component .
Daily
Daily
Daily
Daily
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Before lifting the ST-80C, ensure
the pedestal is in the full down
position and the transport pin
is installed in the transport position.
nstall the transport frame on the
pedestal to enable dragging the
ST-80C through the V-door onto
the drill floor.
Always use the ST-80C lifting lugs
and shackles. No other part is
rated for, nor intended to support
the full weight of the ST-80C.
NOV recommends using a double
chain sling with master link when
lifting the ST-80C.
L i f t i n g
Ensure the ST-80C remains vertical
and supported in a stable manner.
Never lay the ST-80C on its side.
For stability, always transport the
ST-80C with the transport frame
and skid installed. For added security,
straps can be attached to major
structural components as required.
Never attach straps to, nor drape
straps across the control assembly
or side guards. These components
may become damaged and unsafe
to operate.
Tr a n s p o r t
Li f t i ng and Tr anspor t
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Transport Pins
P/N 30170733-100
Lifting
Shackles
Unit Weight
7,420 lbs.
Socket Flange
and Base Assembly
P/N 30172616
Floor Socket
P/N 30173380
Cotter Pins
2 places
P/N 114320-8 (2)
Lock Pin
2 places
P/N 30171613 Jackscrew
Both sides
P/N 30170645 (2)
Pedestal
n full down
position
Transport
Frame
Rear View of
Support Pedestal
Perform lifting operations
with extreme caution.
!
ST-80C Right Cover
P/N 30180461-200
Cylinder
Dampener
P/N 30179558
Left Cover
P/N 30180461-100
Pi
P/
Li f t i ng and Tr anspor t
(c ont i nued)
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Transport
Pin
Installed
in stored
position for
operation.
Transport
Frame
P/N 30181717
Cotter
pin
Transport Skid
P/N 30180482
ns
00
Tr a n s p o r t Fr a me a n d Sk i d
1. Hoist the transport frame
up and into the hole in
the top of the pedestal
assembly.
2. nstall the frame transport pin.
3. nstall the frame cotter pin.
4. Lift the ST-80C and place
it on the transport skid.
5. nsert the skid transport pins.
ns
.
Filter Element
P/N 82749
Pin Keeper
P/N AR06-03-13
Rear View of
Support Pedestal
Perform lifting operations
with extreme caution.
!
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Tr oubl eshoot i ng
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, 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 lter.
5. Check all ttings for leaks.
6. Lubricate entire ST-80C and check the condi-
tion of the lter per Chapter 5, Maintenance.
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Operating Mode Problems
Symptom Probable Cause Remedy
Tool runs
slowly.
Control Cable worn out Replace cable
Hydraulic quick
disconnect supply or
return lines not fully
shouldered.
Tighten until fully
shouldered.
Power unit not deliver-
ing full ow.
Check power supply ow
while spin out valve is
actuated. Flow should
be 40 GPM.
Power unit return line
lter dirty.
Replace lter element
of HPU.
Pressure lter dirty. Replace lter element of
ST-80C.
Torque pressure set
too low.
Increase pressure
setting.
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Vertical Positioning Problems
Symptom Probable Cause Remedy
Vertical positioning
assembly moves
without anyone
functioning the unit
High back pressure Check all quick
disconnects are fully
shouldered
Lift cylinder damaged
or dirty.
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.
Tr oubl eshoot i ng (continued)
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Troubleshooting with Torque Wrench
Symptom 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 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 lter in
power supply.
Replace 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).
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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 ttings.
Push/Pull cable
broken or out of
adjustment
Replace cable or adjust
Tr oubl eshoot i ng (continued)
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Troubleshooting the Spinner Assembly
Symptom Probable Cause Remedy
Spinner 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 insufcient 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
Insufcient 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.
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Appendi x
Ambient Temperature Range
Manufacturer
Viscosity Index
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
AGMA
ISOViscosity 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 Specifications
Selecting a Lubricant
Recommended Gear Oil
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Rig Solutions Aftermarket Service Phone Numbers
Corporate Headquarters
7909 Parkwood Circle Drive
Houston, Texas 77036
United States
Phone: 713 375 3700
Fax: 713 346 7687
UK
NOV Service and Repair (Aberdeen/
Montrose)
Forties Road
Montrose
Scotland
DD10 9ET
+44 1674 677222
+44 7711 415485 (after hours)
+44 7739 170079 (workshop)
+44 7713 643012 (spare parts)
Rig Solutions
10000 Richmond Avenue
Houston, Texas 77042
United States
Phone: 713 346 7500
Fax: 713 435 2195
Middle East
UAE
NOV Service and Repair (Abu Dhabi)
Varco Al Mansoori Services LLC
P. O. Box 27011
Abu Dhabi, UAE
+971 2 555 2668
+971 2 554 2280 (fax)
+971 50 811 6083 (service)
+971 50 617 1235 (workshop)
United States
Colorado
NOV Service and Repair
(Colorado)
420 South Ash St.
Fruita, CO 81521
+1 970 858 4522
+1 281 569 3050 (after hours)
NOV Service and Repair (Dubai)
P.O. Box 61490
R/A No.13, Plot MO 0682
Daimler Chrysler Street
Jebel Ali Free Zone
Dubai, UAE
+971 4 883 8776
+971 4 883 8795 (fax)
Louisiana
NOV Service and Repair
(Covington)
73765 Penn Mill Rd.
Covington, Louisiana 70435
+1 985 892 8216 (direct)
+1 800 722 4425 (toll free)
(Cranes: AmClyde, Unit, OS
National, Dreco, Kingpost)
+1 985 871 8609 (service)
+1 985 871 8603 (parts)
NOV Service and Repair (Badr City)
IMPEC (Sea Harvest Company)
Part B, 47 Acer Area
Badr City, Cairo, Egypt
+20 2 231 08001
+20 2 231 08002
+20 2 231 08003 (fax)
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Appendi x (continued)
Rig Solutions Aftermarket Service Phone Numbers
(continued)
NOV Service and Repair (New
Iberia)
5212 Highway 90 Service Road
West
New Iberia, Louisiana 70560
+1 337 374 1400
(legacy Varco and NOI equipment
and
all NOV spare parts)
North Africa
NOV Service (Algeria)
Overseas Equipment Service Africa
BP 852 Zone Industrielle Algerie
Hassi Messaoud Ouargla
Algeria 30500
+213 29 75 54 75
+213 29 75 41 05 (fax)
Oklahoma
NOV Service and Repair
(Oklahoma City)
7713 North West 3rd St.
Oklahoma City, Oklahoma 73127
+1 405 495 1000
+1 281 569 3050 (after hours)
Saudi Arabia
NOV Service and Repair (Al-Khobar)
Al-Khalidiyah District
Khobar ~ Dammam Highway (at the
back of Tawuniya)
P. O. Box 20754, Al-Khobar 31952
Saudi Arabia
+966 3 847 5206
+966 3 847 3938 (fax)
Minnesota
NOV Service (St. Paul)
240 East Plato Blvd.
St. Paul, Minnesota 55107
(lifting and handling equipment)
+1 651 293 4745 (service)
+1 651 293 4776 (service)
+1 651 293 4600 (parts)
+1 651 293 4603 (parts)
Europe
France
NOV Service
+33 24 068 3600
+33 24 068 3611
+33 24 068 3600 (after hours)
+33 677 790 943 (after hours)
North Dakota
NOV Service and Repair
(Williston)
611 58th Street West
Williston, ND 58801
+1 701 774 0454
Norway
NOV Service (Asker)
Blakstadmarka 26
1374 Asker Norway
+47 6400 5000
+47 6400 5001 (after hours)
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Pennsylvania
NOV Service (Pittsburgh)
1349 Saw Mill Run Blvd.
Pittsburgh, Pennsylvania 15226
+1 412 884 1027
+1 281 569 3050 (after hours)
NOV Service (Kristiansand)
Skibaasen 2
4636 Kristiansand Norway
+47 3819 2000
+47 3819 2482 (after hours)
NOV Service (Molde)
Granfjaera 24
6415 Molde Norway
+47 7120 2020
+47 9169 9664 (after hours)
Texas
NOV Service and Repair (Alice)
2351 Energy Avenue
Alice, Texas 78380
+1 361 668 4154
+1 281 569 3050 (after hours)
NOV Service and Repair
(Houston)
5100 North Sam Houston
Parkway West
Houston, Texas 77086
+1 281 569 3050 (24/7 technical
support)
+1 281 569 3051 (eHawk remote
support)
NOV Repair (Stavanger)
Dusavik Base
Midtre Basevei 4
4029 Stavanger Norway
+47 5183 5600
NOV Service (Stavanger)
Lagerveien 8
4069 Stavanger Norway
+47 5181 8181
+47 4140 0041 (after hours)
+47 9511 8181 (24/7 eHawk remote
support)
Wyoming
NOV Service and Repair (Casper)
1080 North Robertson Road
Casper, Wyoming 82601
+1 307 473 8888
+1 281 569 3050 (after hours)
Asia
China
NOV Service
Suite 1603-1606, Air China Plaza
No. 36 Xiaoyun Road, Chaoyang
District
Beijing 100027 PRC
+86 139 0121 9392
+86 108 0081 05109 (24/7 technical
support)
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2012 National Oilwell Varco
D392004720-MKT-001 Rev. 01
28
Appendi x (continued)
Rig Solutions Aftermarket Service Phone Numbers
(continued)
Canada
NOV Service and Repair (Leduc/
Edmonton)
6621 45 Street
Leduc, Alberta, Canada
T9E 7E3
+1 780 986 1712
+1 780 986 5556
+1 780 665 0200 (parts)
+1 780 619 5579 (parts)
India
NOV Service and Repair
R-619, TTC Industrial Area
Rabale, MIDC
Navi Mumbai 400 401
Maharashtra, India
+91 982 009 1322
+91 983 349 6154 (after hours)
Americas
Brazil
NOV Service and Repair (Maca)
Rod. Amaral Peixoto, s/n
KM164,5
Imboassica Maca RJ Brazil
CEP 27920-025
+55 22 2773 0600
+55 22 9974 7081 (after hours)
+55 22 9974 7057 (NOV drilling
equipment)
+55 22 2773 0640 (NOV lifting
and handling equipment)
+55 22 9974 7056 (PCE/Shaffer
equipment)
+55 22 9974 7083 (workshop)
Singapore
NOV Service and Repair
29 Tuas Bay Drive
Singapore 637429
+65 6594 1000
+65 6594 1222 (24/7 technical support)
Venezuela
NOV Rental and Service (Maturin,
Monagas)
Varco International de Venezuela
Top Drive Rental and Service
+58 291 651 6489
+58 414 394 2784 (mobile)
+58 291 651 4384 (fax)
Russia
NOV Service and Support
5, Ulansky Lane
Moscow, 101000
Russia
+7 495 775 2540
+7 985 410 5272 (mobile)
+7 495 981 3470 (fax)
+7 985 997 3545 (24/7 technical
support)
D392004720-MKT-001 Rev 01 Tally Book ST-80C Iron Roughneck OP.indd 28 8/29/2012 10:57:37 AM

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