ST-80 ST-80SM00995 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 operator’s 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 60°F (16°C). If high humidity is unavoidable, Varco recommends storing the ST-80 at 70°F (21°C). 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