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Service Manual

ST-100 Iron Roughneck

Reference

Reference Description

This document contains proprietary and confidential


information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only
and remains the property of NOV. Reproduction, in whole or in
part, or use of this design or distribution of this information to
others is not permitted without the express written consent of
NOV. This document is to be returned to NOV upon request or
upon completion of the use for which it was loaned. This
document and the information contained and represented
herein is the copyrighted property of NOV.
National Oilwell Varco

www.nov.com

National Oilwell Varco


RIG SOLUTIONS
11000 Corporate Centre Drive
Houston, TX 77041

Document Number

Rev.

D811003994-MAN-001

05

Form D811001123-GEN-001/07

Revision History
05

01.10.2013

Engineering Update

A. Donovan

J. Adkins

J. Adkins

04

20.06.2013

Engineering Update

A. Donovan

J. Adkins

J. Adkins

03

18.06.2012

Engineering Update

J. Roman

J. Adkins

J. Walker

02

13.02.2012

Engineering Update

T. Drake

J. Adkins

J. Walker

01

06.06.2011

First Issue

T. Drake

J. Adkins

J. Walker

Rev

Date (dd.mm.yyyy)

Reason for issue

Prepared

Checked

Approved

Change Description
Revision

Change Description

01

First Issue: Original Instructions

02

Corrected conversion error to weight specification (page 2-13).


Added and/or updated the following:
Orientation illustrations showing new control panel (page 2-11 and page 2-12).
Arm assembly illustration to show Hydraulic E-Stop Lanyard and new gauge (page 2-27).
Hydraulic assemblies illustration to show Hydraulic E-Stop Pressure Gauge (page 2-30).
Manual Control Console to show modified panel components (page 2-34).
Electrical Controls illustration for clarity (page 2-32).
E-Stop precaution (page 4-43).
Manual Control Console reference art (page 4-47).
E-Stop information to Manual Control Console section (page 4-53).
Diffuse sensor equipment shutdown information (page 4-65).
E-Stop information to Pedestal-Mounted Control Console section (page 4-66).
Maintenance Pins information and illustration (page 5-82 and page 5-84).
Made the following additional compliance checklist changes:
Added emission of noise information for checklist item 2.8 (page 1-8 and page 4-44).
Added location of instructions information for checklist item 3.7 (page 1-9 and page 3-40).
Added safe disposal information for items 2.11 and 4.6 (page 1-9, page 3-41, and page 5-81).
Added reminder cards, stickers, or labels information for checklist item 4.5 (page 2-17).

D811003994-MAN-001
Revision 05
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Form D811001123-GEN-001/07

Change Description (continued)


Revision

03

04

05

D811003994-MAN-001
Revision 05
www.nov.com

Change Description

Added E-Stop Symbol to (page 1-2), (page 4-44) and to illustration (page 2-26).
Added Lightning Precaution table to Safe Equipment Operation (page 1-7).
Added Modifications section and warning to (page 1-9).
Added descriptive paragraphs to (page 2-31), (page 3-38), (page 4-68) and restructured (page 4-68)
Added Footnote to Torque Wrench Specifications (page 2-14).
Changed descriptive paragraph (page 2-20) and (page 4-56).
Corrected N-m to Torque Assembly and changed die size to paragraph (page 2-24).
Changed illustration to show separate die configurations (page 2-25).
Added (section titled "ST-100 Quick Reference" on page 4-45).
Changed Making and Breaking Connections procedures (page 4-60) through (page 4-61).
Add and changed top views to (page 4-49) and change illustration text (page 4-72).
Added OEM Precaution caution table (page 5-82).
Changed illustrations on (page 5-84), (page 5-87), (page 5-95) and (page 5-103).
Added table to Monthly Inspection (page 5-85), Added illustrations (page 5-101) and (page 5-105).
Rearrange and changed Probable Cause and Remedy tables from (page 6-114) through (page 6117).

Updated template, advisory symbols, and page numbering (Entire Book)


Added Counter Balance Valve section (Page 7)
Added Hydraulic Requirements note (Page 13)
Updated Tong Die and Die Retainer (2) Lower Jaws callout to Front View on Figure 2-9 (Page 25)
Updated Lifting Info breakout on Figure 3-1 (Page 39)
Added Leveling the Head Assembly section (Page 42)
Updated the Test display on the Control Console for Figure 4-9 and 4-10 (Page 55 and 56)
Added Humidity and Altitude rows to Operating and Survival Environment tables (Page 80)
Added NOV policy information to Spare Parts You May Need section (Page 81)
Added monthly roughneck maintenance note (Page 88)
Added Malfunction Log section (Page 111)
Added Torque wrench unclamps... row on Troubleshooting Table (Page 116)

Added Operational Environment section to Chapter 1, General Information (Page 5)


Added red zone reference to Warning (Page 6)
Updated the Adjusting Arm Assembly Target Positions section (Page 64)
Updated Figure 4-15. Adjusting Arm Assembly Target Positions (Page 64)
Updated Diffuse Sensor Interlock section to clarify that Once a diffuse sensor has activated, only the
arm functions are disabled. (Page 69)

Table of Contents
Chapter 1: General Information
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safe Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counter Balance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Equipment Documentation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 2: Description
Introduction to the ST-100 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Equipment Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Requirements (Remote Control Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Equipment Operating Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Nameplate and Warning Plaques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Equipment Pinching Hazard Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical Assemblies (Remote Control Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Socket Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Operator Control Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Manual Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pedestal-Mounted Remote Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Chapter 3: Installation
Transporting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drill Floor Position Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removing and Installing the Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation and Commissioning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Storing the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Returning Equipment to Service After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Leveling the Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 4: Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operating Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ST-100 Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pre-Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Normal Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Normal Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Operation Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Control Console Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Manual Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Positioning and Adjusting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Setting and Adjusting Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Emergency Stop (E-Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Stopping the Equipment in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Restarting the Equipment After a Hydraulic E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Remote Control Console Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pedestal-Mounted Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Sequential Tripping Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Setting and Adjusting Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Adjusting Arm Assembly Target Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Object Detection Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Emergency Stop (E-Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Stopping the Equipment in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Restarting the Equipment After an Electrical E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Interlock Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Interlock Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rotating the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Releasing the Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Releasing the Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Moving the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electrical Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Securing Equipment on a Floating Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Chapter 5: Maintenance
Pre-Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Spare Parts You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Spare Parts and Fluids Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Securing the Equipment for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Inspection Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inspection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Equipment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Spin Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Spin Wrench Support Structure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Torque Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Arm Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Column Assembly Carriage Guide Roller Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Socket Base Slew Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

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General Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Nord-Lock Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Replacing Torque Wrench Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Replacing Spin Wrench Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Spin Wrench Rollers Assembly - Retention Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Changing the Hydraulic Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Removing the Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Removing the Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Carriage Lift Counterbalance Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . . 109

Chapter 6: Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Malfunction Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Determining the Nature of the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Pre-Troubleshooting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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General Information

Overview
This service manual is part of the National Oilwell Varco (NOV) documentation package for your
NOV equipment. Along with a description of the equipment, the service manual contains
information for the installation, operation, maintenance, and troubleshooting of the equipment.

Intended Audience
This manual is intended for use by field engineering as well as installation, operation, and
maintenance personnel. The procedures within this manual should never be performed by
untrained individuals.
Reference: For more information about training, see the Safety Requirements section (in this
chapter).

Disclaimer
While every reasonable effort has been made to ensure the accuracy of the information contained
herein, NOV makes no representations or warranties as to the accuracy or completeness of the
information. NOV reserves the right to revise this manual at any time without the obligation to notify
any person or organization.
NOV shall not be liable for any damages arising from the use of this manual. It is the responsibility
of the owner/operator to ensure safe usage and operation of the equipment. All operators must be
properly trained before they handle or operate the equipment.
The illustrations in this manual may not be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.

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General Information

Conventions
This section of the chapter describes the service manual conventions.

Advisories
The graphical symbols within this manual indicate advisories that provide the user (intended
audience) with additional information about a topic or inform the user of the potential or definite
risks to personnel or equipment and the necessary action the user should or should not take to
avoid the risks. The following lists the symbols and an explanation of each:

Note
The note symbol indicates details or additional information that may be useful
for better understanding the related topic.

Caution

This symbol indicates a potential risk of injury to personnel or damage to


equipment. Failure to follow instructions explicitly and use extreme care when
performing operations and procedures could result in injury to personnel,
damage to equipment, or rig downtime.

Warning
WARNING
The warning symbol indicates a definite risk of equipment
damage or danger to personnel. Failure to follow safe work
procedures could result in serious or fatal injury to
personnel, significant equipment damage, or extended rig
down time.

Hot Surface
This symbol indicates the presence of a potentially hot surface or component.
Failure to allow the hot surface or component to cool before touching it could
result in bodily injury.

Pinch Point
The pinch point symbol indicates the potential for part of the body becoming
caught or pinched between two objects. Failure to avoid pinch point areas
while the equipment is operating or use extreme care around the pinch points
could result in serious or fatal bodily injury.

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Conventions
Advisories

Electrostatic Discharge
This symbol indicates the potential for electrostatic discharge (ESD). Always
remove static electricity prior to working on ESD sensitive components or in
flammable environments. Failure to do so could result in ESD:
Damaging or destroying sensitive electronic components
Setting off explosions or fires in flammable environments

E-Stop
E-Stop symbol indicates that an emergency stop device is present.
Emergency stop (or E-stop) devices are located on the NOV control panel and
may be present at several other areas on NOV equipment. These provide a
method for rapidly disconnecting the energy source from the equipment,
immediately stopping any movement, to protect rig floor personnel.

Illustrations
The illustrations (figures) provide a graphical representation of equipment components or
screenshots for use in identifying parts or establishing nomenclature. These illustrations may not
be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.

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General Information

Safety Requirements
NOV equipment is installed and operated in a controlled drilling-rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
in the manuals are the recommended methods for performing installation, operations,
maintenance, and troubleshooting.

To avoid injury to personnel or damage to equipment, carefully observe the


requirements outlined in this section.

Proper Use
NOV equipment is designed for specific functions and applications and, therefore, should be used
only for its intended purposes.

Safe Lifting
Operators and maintenance personnel should be properly trained in safe lifting procedures and in
the inspection of material handling equipment and lifting components. When lifting and handling
NOV equipment or components, always:
Follow all federal, state, and local rules, industry and company standards, and rig-specific safety
guidelines.
Use approved safe lifting procedures and safe methods.
NOV recommends using the supplied sling with master link when lifting the iron
roughneck. When lifting the iron roughneck, always use the lifting lugs and
shackles provided. No other part of the iron roughneck or shipping skid is
rated for, nor intended to support the full weight of the iron roughneck.
Before beginning, make sure the shackles are secure and that slings are rated
for the appropriate weight.

WARNING
Lifting equipment improperly creates a hazardous working
environment. To avoid lifting hazards, lift equipment only
with material handling equipment rated for the expected
load and from the designated lift points. Failure to follow
safe lifting guidelines may result in serious or fatal injury to
personnel, significant damage to equipment, and extended
rig downtime.
Safe lifting recommendations provided in this manual do not take precedence
over local safety rules and regulations, OSHA regulations, or instructions issued
by the manufacturers of rig hoisting equipment and other tools on the rig.

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Safety Requirements

General Information

Personnel Training
To ensure their safety, all personnel performing installation, operations, maintenance, or repair
procedures on or in the vicinity of the equipment should be trained in rig safety and equipment
operation and maintenance. This tool should not be used by untrained personnel.

This manual is and should be treated as part of the equipment. As such, the
manual should be passed on to subsequent users.

Reference: For more information about personnel training, contact the NOV training department.

Recommended Tools
When an operation requires a specific tool recommended by the manufacturer, the use of that tool
should be enforced, and the tool should be used in a manner that:
Follows the procedures for the operation
Safeguards personnel and equipment

Operational Environment
The operator of the ST-100 should never enter the red zone of the other equipment. If the operator
inadvertently enters the red zone of other equipment, work should cease and the operator should
evacuate to a safe location until the conflict of red zones has been cleared.
Additionally, it is the responsibility of the owner to create procedures, rig layouts or any other
required documentation to ensure the operator of the ST-100 does not enter the red zone of other
equipment.

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Safety Requirements

General Information

Safe Equipment Operation


WARNING
Make sure that all personnel are clear of the equipment
operating path before operating or restarting the
equipment. If the tool moves unexpectedly, shut down
the equipment and lock out hydraulics immediately.
Inspect equipment for damage. Failure to adhere to
this precaution may result in severe injury.

WARNING
Under no circumstances should anyone place their
hands or limbs in any part of the iron roughneck red zone
while the equipment is enabled or operating. Failure to
adhere to this precaution may result in severe injury.

WARNING
Replace damaged or worn guards. Do not operate the
tool with guards that are damaged.

General System Safety Practices


The equipment discussed in this manual may require or contain one or more utilities, such as
cooling water or electrical, hydraulic, or pneumatic utilities.

Before installing, operating, or troubleshooting equipment or performing


maintenance, read and follow these guidelines to avoid endangering exposed
persons or damaging the equipment:
Isolate energy sources before beginning work.
Avoid performing maintenance or repairs while the equipment is in
operation.
Wear proper protective equipment during equipment installation,
operations, maintenance, and repair.

Replacing Components
When replacing components:
Verify that components such as cables and hoses are tagged and labeled during assembly and
disassembly of equipment to ensure correct installment.
Replace failed or damaged components with original manufacturer-certified components.

Failure to replace failed or damaged components could result in injury to


personnel or damage to equipment.

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Counter Balance Valve


The Counter Balance (CB) valves are load-holding devices.

WARNING
If adjusted, the load can possibly fall. Prior to adjusting the
CB valves, ensure the load is in safe condition and all
personnel are aware of the potential outcome.
If the CB is removed while a load is suspended, the valve
could be projected at high speeds. Failure to ensure the
load is safe could result in injury to personnel or damage
to equipment.

Routine Maintenance
Equipment must be routinely maintained.

Failure to conduct routine maintenance could result in injury to personnel or


damage to equipment.

Equipment Documentation Location


The User Manual provided with the equipment order contains this service manual, the engineering
installation and commissioning procedures, the Technical Drawing Package (TDP), along with
specifications, parts lists, and other instructions. These documents must be used by the
installation and commissioning crew, equipment operators, and maintenance personnel. Make
sure an equipment User Manual is available in the location where the equipment is being installed,
commissioned, operated, and maintained.

Equipment Disposal
The equipment owner is responsible for disassembling and removing the equipment at the end of
the equipments useful operating life. It is also the equipment owners responsibility to conform to
applicable regulatory policies and standards, as well as recycling guidelines, when removing the
equipment and when disassembling equipment components and disposing of fluids and
consumable spare parts after scheduled and unscheduled equipment maintenance.

Service Centers
For a directory of NOV service centers, see Service Center Directory, document number
D811001337-DAS-001 in the NOV documentation package.
This link provides after-hours and 24-hour contact information for emergencies or equipment
issues requiring an immediate response from NOV service personnel:
www.nov.com/contact_us/24hr_EmergencyList.asp.

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Description

Introduction to the ST-100 Iron Roughneck


The ST-100 Iron Roughneck is a drill floor tool used to make up and break out drill string
connections. This durable iron roughneck is designed for use on both offshore rigs and land-based
rigs. It allows clearance around well center and the mousehole when in standby and parked
positions. It can also be controlled manually or remotely, depending on the equipment option
ordered. Other equipment options include an extend and retract scissor-arm system that can
deploy to 5 feet (ft) (1.5 meters [m]) or 8 ft (2.5 m).

This manual provides basic operation and maintenance information for the ST100 Iron Roughneck. Rig personnel must be thoroughly trained and familiar
with this iron roughneck before operating and maintaining this or any
associated equipment.

Overview
The ST-100 Iron Roughneck can make up or break out drill collar connections from 4 inches to
9-3/4 inches outside tool joint diameter (OD) and handle drill pipe from 3-1/2 inches up to 7 inches
OD. The torque wrench provides up to 100,000 foot-pounds (ft-lb) (135,581 Newton-meters [N-m])
of makeup torque and 120,000 ft-lb (162,698 N-m) of breakout torque. The spin wrench can spin in
and spin out connections at speeds up to 60 rpm while providing up to 3,000 ft-lb (4,067 N-m) of
torque. (Spin speed will vary based on pipe size and flow rate.)
The ST-100 Iron Roughneck is installed with a single, floor-mounted socket base assembly (with
no hanging cable). When not in use, the iron roughneck can be rotated into a parked position.

Always park the iron roughneck when it is not being used.


The ST-100 Iron Roughneck consists of the following components:
Head Assembly Connected to the arm assembly, the head assembly consists of the spin
wrench and torque wrench assemblies. A control console is installed on the front of the head
assembly, if the iron roughneck is equipped with the manual control console option. (See the
section titled "Head Assembly" on page 21.)
Spin Wrench Assembly Consists of rollers that grip the pipe and spin in or spin out
tubular connections. (See the section titled "Spin Wrench Assembly" on page 23.)
Torque Wrench Assembly Supports clamping jaws that make up and break out tubular
connections. (See the section titled "Torque Wrench Assembly" on page 24.)

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Description

Introduction to the ST-100 Iron Roughneck


Overview

Arm Assembly Supports and provides horizontal travel for the head assembly. The arm
assembly extends and retracts as necessary for accurate positioning of the head assembly at
well center, the mousehole, or in the parked position. (See the section titled "Arm Assembly" on
page 26.)
Column Assembly Provides vertical travel for the iron roughneck. The column assembly is
connected to the floor-mounted socket base assembly. (See the section titled "Column
Assembly" on page 28.)
Hydraulic Assemblies Support all iron roughneck hydraulic functions, such as clamping and
unclamping the torque wrench, moving the carriage assembly up and down the column,
spinning the rollers, and extending and retracting the arms. (See the section titled "Hydraulic
Assemblies" on page 29.)
Electrical Assemblies If equipped with the remote operator control option, the iron
roughneck has an additional I/O J-box, sensors, along with other electrical and hydraulic
components. (See the section titled "Electrical Assemblies (Remote Control Option)" on page
31.)
Socket Base Assembly Provides platform support and rotational travel for the iron
roughneck. The floor-mounted socket base assembly allows the iron roughneck to rotate and
align with the mousehole or well center. (See the section titled "Socket Base Assembly" on page
33.)
Operator Control Assemblies There are multiple operator control options for the ST-100
Iron Roughneck. Manually controlled models have a console installed on the front of the unit, on
either the left or right side. Remotely controlled units include a pedestal-mounted control
console. If the iron roughneck is remotely controlled, the manual control console assembly is not
present. (See the section titled "Operator Control Options" on page 20.)
Figure 2-1 shows the orientation of the ST-100 Iron Roughneck. Figure 2-2 on page 12 shows the
location for major equipment components.
The illustrations in this manual are general in nature and may not show the
exact equipment configuration. Always refer to the Technical Drawing
Package (TDP) for rig-specific information and engineering drawings specific
to the equipment order.

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Introduction to the ST-100 Iron Roughneck

Description

Equipment Orientation
Left

Rear

Head Assembly

Front

The manual control console


model is shown in this illustration.

Front View

Right

Right
Front

Arm Assembly

Column Assembly

Socket Base Assembly

Rear

Rear View

Left
ST1000001

Figure 2-1. Equipment Orientation

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Description

Introduction to the ST-100 Iron Roughneck

Component Locations
Spin Wrench Manifold
Spin Wrench
Assembly
Torqe Wrench
Main Functions
Manifold
Control Console
Assembly (Option)
The manual control console
model is shown in this illustration.

Torque Gauge

Head Assembly
Controls
Arm Assembly
Controls

Socket Base Assembly

Torque Wrench
Assembly
Front View

Transfer Barrier
Assembly (Option)
Column Assembly
Arm Assembly
Hydraulic Enable
Manifold Assembly
Carriage Lift
Cylinder Assembly

Torque Wrench
Rubber Guard
Rear Guard
(removable)
Rear View
ST1000002

Figure 2-2. Component Locations

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Description

Specifications
Weight
Manually Controlled ST-100
(tool only)

11,500 lb (5,216 kg)

Remotely Controlled ST-100


(tool only)

12,000 lb (5,443 kg)

Socket Base Assembly

1,190 lb (540 kg)

Hydraulic Requirements
Operating Pressure

2,500 psi (172 bar)

Minimum Input Pressure

2,500 psi (172 bar)

Maximum Input Pressure

3,000 psi (206 bar)

Minimum Flow Rate

35 gpm (132 lpm)

Maximum Flow Rate

45 gpm (170 lpm)

Inlet Connections

1 inch; supply pressure


11/4 inch; return to tank
1/2 inch; drain

The ST-100 Iron Roughneck has hydraulic fluid in all the lines and the amount
of hydraulic fluid required is up to the customer. It is based on the available
HPU and the amount of equipment it is running.
The quantity of hydraulic fluid required to operate the ST-100 is dependent on
the HPU supply hydraulic power to the tool. The required volume should be
sufficient to fill the reservoir and the supply lines up until they reach the tool.
The hydraulic lines on board the ST-100 are full when the tool ships.

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Specifications

Description

Spin Wrench
Speed (5-inch OD tubular)

60 rpm at 35 gpm (132 lpm)


80 rpm at 45 gpm (170 lpm)

Torque (5-inch OD tubular)

3,000 ft-lb (4,067 N-m)

Pipe Range

3 1/2" to 9 3/4" (tubular diameter)

Torque Wrench
Makeup Torque

100,000 ft-lb (135,582 N-m)

Breakout Torque

120,000 ft-lb (162,698 N-m)

Connection Range

4" to 9 3/4" (tool joint diameter) *

* See page (page 24) for further information.

Electrical Requirements (Remote Control Option


Only)
Power (stand-alone
equipment)

230 VAC, 20 Amps

Cables (integrated equipment)

Fiber cable for communication


7-conductor E-Stop cable

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Description

Specifications

Equipment Operating Dimensions


Rear Guard
 removable

Top View
Fully Retracted

Center of
Rotation

Optional Manual
Control Console
 alternate mounting
location
Front Slew Radius
42.6 in (1082 mm)

55 in
(1397 mm)

Optional Manual
Control Console
 standard mounting
location

18.1 in
(460 mm)
Rear Slew Radius
31.6 in (803 mm) w/guard
29.1 in (739 mm) no guard

30.3 in
(770 mm)

For Reference Only. Refer to the General


Arrangement drawing in the TDP for rig-specific
equipment operating dimensions and space
considerations.

57.1 in
(1450 mm)

134.6 in
(3419 mm)
Raised (max)

Front View

98.6 in
(2504 mm)
Lowered (min)

Connection
Height
66.4 in
(1687 mm)
Raised (max)

48.6 in
(1234 mm)
Raised (max)

Rig Floor
Side View
Raised/Lowered

12.6 in
(320 mm)
Lowered (min)

Rig Floor

30.4 in
(772 mm)
Lowered (min)

Socket Base
Assembly
ST1000003

Figure 2-3. Equipment Operating Dimensions (1 of 2)

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Specifications

Description

Equipment Operating Dimensions

Console Swivel Radius


17.18 in (436 mm)

126.2 in
(3205 mm)
Fully Extended

30.2 in
(767 mm)
Fully Retracted

18.4 in
(467 mm)

3.50 in
Pipe Connection

9.75 in
Pipe Connection

Top View
Fully Extended

Slew Radius
(extended)
135.5 in (3442 mm)

Center of
Rotation

For Reference Only. Refer to the General


Arrangement drawing in the TDP for rig-specific
equipment operating dimensions and space
considerations.

133.5 in
(3391 mm)
Raised (max)

92.8 in
(2357 mm)
Raised (max)

95.5 in
(2426 mm)
Lowered (min)

56.8 in
(1443 mm)
Lowered (min)

Rig Floor

50.2 in
(1275 mm)
Raised (max)

Side View

14.2 in
(361 mm)
Lowered (min)

Socket Base
Assembly
ST1000004

Figure 2-4. Equipment Operating Dimensions (2 of 2)

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Description

Nameplate and Warning Plaques


Figure 2-5 shows the equipment nameplate and examples of warning plaques fastened to the
equipment. These plaques identify hazards and must be cleaned or replaced if they become worn,
dirty, or otherwise illegible.

Equipment Nameplate
(P/N M364001411)
Hot Surface Hazard
Warning Plaque
(P/N M364000292)

Pinching Hazard
Warning Plaque
(P/N 30170758)

WARNING

If an equipment plaque is worn,


dirty, or otherwise illegible, clean it
or order a new plaque. Failure to
adhere to this warning could result
in severe injury to rig personnel.
ST1000054

Figure 2-5. Equipment Nameplate and Warning Plaques


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Description

Equipment Pinching Hazard Locations


Pinch points exist in certain locations on the iron roughneck. In these
locations, part of the body can be caught between moving parts of the
equipment, between the moving and stationary parts of the equipment, or
between material being handled and part of the equipment. Take extreme
care around pinch points. Avoid these areas while the equipment is operating.

WARNING
In addition to pinch points, the potential exists to be caught
between the iron roughneck and the rig structure or other
equipment. Other than the operator, make sure to keep all
personnel away from the equipment when it is operating,
moving to standby, or rotating to a parked position. Refer
to the General Arrangement drawing in the TDP to identify
all areas of motion for the iron roughneck. Failure to
adhere to this warning could result in serious injury or
death.
Figure 2-6 shows the locations for pinch points on the ST-100 Iron Roughneck.

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Equipment Pinching Hazard Locations

Take extreme care around equipment


pinch points. Avoid these areas while
the equipment is operating.

Description

The manual control console


model is shown in this illustration.

ST1000014

Figure 2-6. Equipment Pinch Points

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Description

Operator Control Options


The ST-100 Iron Roughneck is available with either manual or remote control.

Manual Control
The manual control console is mounted on the front of the iron roughneck (on either the left or right
side). Figure 2-2 on page 12 shows the console location on the iron roughneck.
The console can pivot out to 90 for better control panel access. The console provides separate
joystick controls for the arm and head assemblies. Each joystick control provides pilot pressure to
the hydraulic valves on the unit. When actuated, these valves support all iron roughneck functions.
Figure 2-15 on page 34 shows manual control console.
Refer to Chapter 4, titled "Operation" for additional operator control information.

Remote Control
A remote control console is mounted on a pedestal away from the iron roughneck (Figure 2-16). A
derrick J-box umbilical cable connects the iron roughneck to the control console. Buttons and
joysticks on the remote console send electrical signals to actuate hydraulic valves on the unit. This
stand-alone system is not integrated into the Amphion multi-tool controller system, if used.
In the event of a control system or electrical failure, emergency controls on the
iron roughneck can be used to release the torque wrench, retract the arms,
and rotate the unit into the parked position. For additional information, refer to
the section titled "Electrical Failure Operation" on page 79.
Figure 2-16 on page 35 shows the pedestal-mounted remote control console.

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Description

Major Components
The following assemblies and components make up the ST-100 Iron Roughneck:
Head Assembly
Spin Wrench Assembly
Torque Wrench Assembly
Arm Assembly
Column Assembly
Primary Hydraulic Manifold Assemblies
Torque Wrench Main Functions Manifold Assembly
Spin Wrench Manifold Assembly
Arm Functions Manifold Assembly
Hydraulic Enable Manifold Assembly
Transfer Barrier Assembly (manual option)
Electrical Assemblies (remote option)
Socket Base Assembly
Operator Control Assemblies
The following sections show each of these ST-100 Iron Roughneck assemblies and components.
Many of the illustrations shown in this manual are general in nature. Refer to
the engineering drawings included in the TDP for rig-specific information
about the equipment order.
The NOV components are constantly being improved and their design may
change over time. Make sure to refer to the TDP for current engineering
drawings and component details.

Head Assembly
The ST-100 Iron Roughneck head assembly consists of the spin wrench and torque wrench
assemblies. The head assembly provides backup and torque capability for making up and
breaking out pipe connections, along with spinning in and spinning out connections.

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Major Components

Description

The head assembly attaches to a scissor-arm assembly that provides horizontal travel, allowing
the head to be aligned with well center or the mousehole. A control console is installed on the front
of the head assembly, if the iron roughneck is equipped with the manual control console option.

Spin Wrench
Manifold

Take extreme care around equipment


pinch points. Avoid these areas while the
equipment is operating.

Spin Wrench
Assembly

Torque Wrench
Main Functions
Manifold

Torque Wrench
Assembly

ST1000005

Figure 2-7. Head Assembly

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Description

Major Components
Head Assembly

Spin Wrench Assembly


The spin wrench assembly has four drive rollers. Each roller is powered by a direct-drive hydraulic
motor. The spin wrench supports 3-1/2 inch OD drill pipe up to 9-3/4 inch OD drill collars, with no
adjustments. Its floating-mount design compensates for minor pipe misalignment.
The spin speed can be reduced when working with drill collars (remote control option). When
operating manually, the proportional spin wrench control can be feathered to spin at a lower spin
speed.
Hydraulic Motor (4)

WARNING

Objects can get caught in the rollers.


Make sure that tools, clothing, or personal
equipment do not contact the rollers during
operation. These objects can get tangled in
the rollers and cause serious injury and/or
equipment damage.

Drive Roller (4)

Hydraulic Manifold
Front View

Clamp Cylinder

Pinching Hazard. Make sure hydraulic power


is OFF to the ST-100 before touching or getting
near the spin wrench for maintenance and
repairs.

Rear View

Rollers become hot when operating. Make


sure to allow rollers to cool off before touching
them or getting near the equipment for
maintenance and repairs.
ST1000006

Figure 2-8. Spin Wrench Assembly

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Description

Major Components
Head Assembly

Torque Wrench Assembly


The ST-100 Iron Roughneck torque wrench assembly is an open-throat design, eliminating all
gates and latches. It consists of upper and lower clamping jaws that provide a maximum of
100,000 ft-lb (135,582 N-m) of makeup torque and 120,000 ft-lb (162,698 N-m) of breakout torque.
There are four hydraulic cylinders used in the torque wrench assembly:
A torque cylinder is mounted on each side of the assembly. These two torque cylinders are
attached at the front and back of the upper and lower clamping jaws. The cylinders turn the
upper jaws to make up or break out the connection.
Upper and lower clamp cylinders are mounted at the rear of the assembly. These two clamp
cylinders provide the clamping force for the upper and lower jaws.
When the two clamp cylinders actuate, the upper and lower jaws close and grip the connection.
With the lower jaws gripping the pipe, the torque cylinders actuate. Torque cylinder actuation
causes rotary motion of the upper jaw, turning the tool joint in one direction or the other, making up
or breaking out the connection.
Die assemblies are bolted to each clamping jaw. These consist of easily removable tong dies and
die retainers. The die retainers must be swapped out if the pipe is changed and the tool joint
diameter falls outside of the range for the dies installed. All four (4) die assemblies must be a
matched set on the torque wrench.
The following ranges apply to the tool joint diameter that the torque wrench clamps on:
5-1/2 to 9-3/4 (140 mm to 248 mm) tool joint diameter Die set for large diameter tool joint (P/
N 86711-1 supplied)
4 to 6 (102 mm to 152 mm) tool joint diameter Die set for small diameter tool joint (P/N
86711-2 supplied)
Adjust tool joint spacer as shown in Figure 5-11 on page 101
The two die sets supplied with the equipment support the full range of pipe
sizes that can be used with this iron roughneck. Do not use dies
interchangeably.
Figure 2-9 shows the torque wrench assembly.

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Description

Major Components
Head Assembly

Torque Wrench Assembly


Tong Die and Die Retainer (2)
Upper Jaws

Top View

Front View
Torque Cylinder (2)
86711-1
Roughly Flush

Tong Die and Die Retainer (2)


Lower Jaws
Pinching Hazard. Make sure hydraulic power
is OFF to the ST-100 before touching or getting
near the torque wrench for maintenance and
repairs.

Clamp Cylinder (2)

86711-2
Roughly 1 Proud
ST1000007

Figure 2-9. Torque Wrench Assembly

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Description

Major Components

Arm Assembly
The arm assembly supports and provides horizontal travel for the head assembly. The scissorarms extend and retract the head assembly to well center, to mousehole, and can then fully retract
to bring the head back to the home (parked) position. The arms extend and retract at about one
foot per second.
The well center and mousehole positions are set by the operator. Refer to the following sections for
further information about positioning the equipment.
Manually Controlled See the section titled "Positioning and Adjusting the Iron Roughneck" on
page 48 for instructions.
Remotely Controlled See the section titled "Adjusting Arm Assembly Target Positions" on
page 64 for instructions.
Figure 2-10 shows the arm assembly along with its primary components.

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Description

Major Components
Arm Assembly

Arm Functions
Manifold Assembly
Transfer Barrier
Assembly (option)

Hydraulic Enable
Manifold Assembly
Front

Arm Extend/Retract
Cylinder Assembly (2)

Hydraulic E-Stop
Lanyard (2)

ST1000008

Figure 2-10. Arm Assembly

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Major Components

Description

Column Assembly
The column assembly provides vertical travel for the iron roughneck. Vertical movement allows the
iron roughneck to be positioned at different heights for makeup or breakout operations. The
column assembly is connected to the floor-mounted socket base assembly.

Column Assembly

Carriage Lift
Cylinder Assembly

Carriage Assembly

Hydraulic Supply
Shutoff Lever

Rear
ST1000009

Figure 2-11. Column Assembly

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Description

Hydraulic Assemblies
The ST-100 Iron Roughneck hydraulic assemblies support all iron roughneck hydraulic functions,
such as clamping and unclamping the torque wrench, moving the carriage assembly up and down
the column, spinning the rollers, and extending and retracting the arms.
One of these hydraulic assemblies, the Transfer Barrier Cylinder, is used in manually controlled
iron roughnecks to preset a deploy travel limit for the arm assembly. This allows the iron roughneck
to be deployed completely, without the operator having to make further travel adjustments once the
head gets close to well center. Once iron roughneck operations are complete, this component also
allows the unit to be fully retracted to the standby position, instead of being held at a partially
deployed position. (Remotely controlled iron roughnecks use proximity sensors to achieve these
results.)
Refer to the section titled "Specifications" on page 13 for hydraulic requirements.
The following assemblies are shown in Figure 2-12:
Main Functions Manifold
Torque Wrench Manifold
Torque Wrench Cylinders
Spin Wrench Manifold
Arm Functions Manifold
Arm Extend/Retract Cylinders
Hydraulic Enable Manifold
Transfer Barrier Cylinder (manual option)
Torque Cylinders
The pilot manifold used on remotely controlled iron roughneck models is shown in Figure 2-13 on
page 32. The slew manifold is on the socket base assembly and is shown in Figure 2-14 on page
33.

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Major Components

Description

Hydraulic Assemblies

Transfer Barrier
Cylinder (option)
Torque Wrench
Manifold

Main Functions
Manifold

Arm Functions
Manifold

Spin Wrench
Manifold

Drain
Shutoff Valve Handle
Pressure

Front

Hydraulic Filter
Tank
System
Pressure Gauge
Hydraulic Enable
Manifold Assembly

ST1000010

Figure 2-12. Hydraulic Assemblies

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Major Components

Description

Electrical Assemblies (Remote Control Option)


The following electrical devices are installed only on remotely controlled ST-100 Iron Roughnecks.
Refer to Chapter 4, titled "Electrical Interlocks" for interlocks associated with these devices.
Extend/Retract Proximity Sensors (3)
Home Proximity Sensor Provides feedback to the control system that the
ST-100 arm is in the home position when this sensor detects its target.
Position 1/Position 2 Proximity Sensor Provides feedback to the control system that
the ST-100 arm has reached the kickdown position when this sensor detects its target. This
feature slows down arm deployment as the unit nears the pipe. The ST-100 is equipped
with a kickdown sensor for the well center and mousehole position (see page 64 for setup
procedure).
Position feedback from these sensors can also be sent to the Zone Management System
(ZMS), if the iron roughneck is part of an integrated ZMS-enabled NOV control system.
Carriage Up/Down Proximity Sensor Provides position feedback for vertical arm position
once the arm has reached a pre-defined height. (May also be used with a ZMS-enabled control
system.) The light on the back of sensor will turn on when a target is detected.
Non-driven Motion Pressure Transducer Provides feedback for non-driven motion, by
monitoring the pressure inside the carriage lift cylinder.
Slew Proximity Sensors (2) Provide position feedback once slewing has reached the well
center or mousehole positions. The ST-100 must be slewed to one of these positions and sensor
must detect its target, before the unit can be operated. Slew position is adjustable. The proximity
device senses the slew stops mounted on the drill floor and determines the position based on
which sensor is activated. The light on the back of the sensor will turn on when a target is
detected.
Torque Pressure Transducer Provides pressure feedback for applied torque
(0 to 3,000 psi [207 bar]).
System Pressure Transducer Provides pressure feedback for system pressure (0 to 3,000
psi [207 bar]).
Torque Wrench Proximity Sensor (1) Provides makeup and breakout
end-of-stroke feedback for the upper torque wrench.
Pipe Detection Sensor Provides feedback when a pipe is detected.
Object Detection Diffuse Sensors (2) Provides feedback if an object is in the collapse zone
of the arm. Triggering this sensor shuts down all functions.
Figure 2-13 shows several of the sensors used on the remotely controlled iron roughneck
Refer to the engineering drawings in the TDP for the locations of all electrical
components used on the remotely controlled ST-100 Iron Roughneck.

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Major Components

Description

Electrical Assemblies (Remote Control Option)

Extend/Retract
Proximity Sensors
I/O J-Box
Hazardous Area
Beacon/Strobe Light
Object Detection
Diffuse Sensor
Assembly (2)

Equipment
E-Stop Buttons

Carriage Up/Down
Proximity Sensor
Carriage Up/Down
Proximity Sensor
Target

Pilot Manifold
Assembly

Torque Wrench
Proximity Sensor

Front
Pipe Detection Sensor

Slew Proximity
Sensor (2)

ST1000011

Figure 2-13. Electrical Assemblies (Remote Control Option)

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Description

Major Components

Socket Base Assembly


The ST-100 Iron Roughneck is installed on the drill floor using a single, floor-mounted socket. The
socket base assembly enables the iron roughneck to be rotated and aligned with well center or the
mousehole.

Hydraulic Motor
with Brake (2)

Motor Guard
Column
Connecting Pin (2)

Drain
Tank
Pressure

Floor Socket
 included with the
shipping package

Slew Manifold
Assembly
Rear

Socket Flange

ST1000012

Figure 2-14. Socket Base Assembly

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Major Components

Description

Operator Control Assemblies


Manual Control Console

System Pressure
Gauge
Torque Adjustment
Knob
Valve Body
Hydraulic Enable
Hydraulic E-Stop
Head Assembly
Controls

Arm Assembly
Controls
Hydraulic
Connections
Access Panel

Rear

Front

UNCLAMP
TW
CLAMP

BREAK
TW
MAKE

OUT
SW
IN

SW MODE

UNCLAMP
SW
CLAMP

Head Assembly Functions

UP
CARRIAGE
DOWN

RETRACT
DEPLOY
EXTEND

CW
SLEW
CCW

RETRACT
ADJUST
EXTEND

Arm Assembly Functions


ST1000013

Figure 2-15. Manual Control Console

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Description

Major Components
Operator Control Assemblies

Pedestal-Mounted Remote Control Console

ST1000027

Figure 2-16. Pedestal-Mounted Remote Control Console

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Description

This page is intentionally blank.

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Installation

Transporting the Iron Roughneck


When transporting the iron roughneck, make sure the equipment remains vertical and stable.
Always transport the iron roughneck secured to the shipping skid to increase equipment stability.
See section titled "Removing and Installing the Shipping Skid" on page 37 for additional
information about the shipping skid.

Always keep the iron roughneck in an upright position. Never place the iron
roughneck on its side or back. Placing the iron roughneck on its side or back
will damage the equipment.

Drill Floor Position Recommendations


For optimum equipment performance, the ST-100 Iron Roughneck should be positioned as follows:
8-foot arm model Position the equipment at a minimum of 89 inches (226 cm) and a
maximum of 122 inches (310 cm) away from well center and the mousehole.
5-foot arm model Position the equipment at a minimum of 71 inches (183 cm) and a
maximum of 89 inches (226 cm) away from well center and the mousehole.
The iron roughneck must be secured to the rig floor and the supporting structure should be able to
support the weight and overturning moment of the equipment. Refer to the section titled
"Specifications" on page 13 and the General Arrangement engineering drawing in the Technical
Drawing Package (TDP) for dimensions, weights, rig-floor loading, and rig-floor layout drawings.

Removing and Installing the Shipping Skid


NOV recommends using the supplied sling with master link when lifting the
iron roughneck. When lifting the iron roughneck, always use the lifting lugs
and shackles provided. No other part of the iron roughneck or shipping
skid is rated for, nor intended to support the full weight of the iron
roughneck. Before beginning, make sure the shackles are secure and that
slings are rated for the appropriate weight.

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Installation

Removing and Installing the Shipping Skid

Removal
1. Using the two lifting shackles and the supplied sling, hoist the iron roughneck slightly so the
weight is off the shipping skid.
2. Remove the front and rear shipping pins.
3. Hoist the iron roughneck away from the shipping skid and move it to its operating location.
4. Remove the storage pin when the iron roughneck is ready for operation.
5. Place the shipping skid and all pins in storage.

Make sure to remove the storage pin before operating the iron roughneck.

Installation
1. Fully retract the iron roughneck and disconnect all hydraulic lines connecting the column to the
socket base assembly.
2. Install the storage pin.
3. Place the shipping skid on a hard and level surface.
4. Attach the supplied sling to the two lifting shackles.
5. Remove the two column connecting pins connecting the column to the socket base assembly
(see Figure 2-14 on page 33).
6. Hoist and center the iron roughneck over the shipping skid.
a. Align the iron roughneck rear column base support with the rear supports on the
shipping skid.
b. Align the bottom of the torque wrench base plate with the front supports on the shipping
skid.
7. Insert the front and rear shipping pins (and cotter pins) securing the iron roughneck.
8. Using the supplied sling, hoist and move the iron roughneck to the proper location.
9. Place wood blocks between spin wrench and torque wrench.
10.Using ratchet strap supplied in shipping kit to secure spin wrench so it does not shift while
transporting.

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Removing and Installing the Shipping Skid

Installation

Lifting Shackle

Lifting Shackle

Storage Pin

Rear Shipping Pin

Shipping Skid

Front Shipping Pin

ST1000025

Figure 3-1. Shipping Skid

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Installation

Installation and Commissioning


Procedures
Engineering installation and commissioning procedures are developed for each ST-100 Iron
Roughneck configuration. These installation and commissioning procedures are included in the
equipment User Manual. Refer to the Installation Procedure, ST-100 or the Installation Procedure,
ST-100 Remote for rig-specific installation information.

40

The User Manual provided with the equipment order contains this service
manual, the engineering installation and commissioning procedures, the
Technical Drawing Package (TDP), along with specifications, parts lists, and
other instructions. These documents must be used by the installation and
commissioning crew, equipment operators, and maintenance personnel.
Make sure an equipment User Manual is available in the location where the
equipment is being installed, commissioned, operated, and maintained.

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Installation

Storing the Iron Roughneck


Long Term Storage

Palletize the iron roughneck and store it indoors. A cargo container would be appropriate
for storage.

Avoid wide variations in temperature and high humidity. The preferred storage
environment is clean and dry at 60F (16C) ambient temperature. If high humidity is
unavoidable, an ambient storage temperature of 70F (21C) is recommended.

All exposed unpainted metal surfaces are coated with a rust preventive at the factory prior
to shipment. Coat all unpainted metal surfaces with rust preventative prior to storage or
transport.

The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall
Grade 5 (GE-D6C6A1) or equivalent.

All openings should be covered to prevent water or dust from entering. Make sure the
cover allows for air circulation around equipment. NOV does not recommend using a silica
gel or a dehydrating agent.

During storage, lubricant drains from the top half of the roller bearings, allowing corrosion
on the exposed areas. To prevent corrosion, periodically rotate the unit to distribute
lubricant over the top of the bearings. Perform this at three-month intervals if the iron
roughneck is stored indoors and at monthly intervals if stored outdoors.

Returning Equipment to Service After Storage


Before placing the iron roughneck back into service, the following tasks should be completed and
verified:

Remove all rust preventative and any corrosion, taking special care with all load-carrying
components.

Blow out all dust and dirt from equipment as required with clean, dry air.

A complete system test and adjustment should be performed as detailed in the ST-100 Iron
Roughneck Commissioning Procedure.

Equipment Disposal
The equipment owner is responsible for removing and dismantling the equipment at the end of the
equipments useful operating life. It is also the equipment owners responsibility to conform to all
applicable regulatory policies, standards, and recycling guidelines when removing the equipment,
dismantling equipment components, disposing of fluids, and disposing of consumable spare parts
after periodic maintenance.

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Installation

Leveling the Head Assembly


The ST-100 head level can be adjusted. Ensure the head assembly for the iron roughneck is level
to the drill floor. If the head needs to be adjusted forward or backward, remove the leveling cam
retention bolt (see Figure 3-2). With the bolt removed, tilt the head assembly forward or backward
until it is level. Once the head assembly is level, rotate the leveling cam until it is tangent with head
frame. Reinsert the retaining bolt, and ensure the leveling cam on the other side of the unit is
rotated the same amount.

Head
Assembly

Leveling Cam
Retention Bolt

Use an adjustable wrench to remove the


leveling bolt. Bolt cannot be removed by
hand.

Leveling Cam

ST1000057

Figure 3-2. Leveling The Head Assembly

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Operation

Introduction
There are two operator interface methods typically used to control the ST-100 Iron Roughneck.
Manual Control Console
Refer to the section titled "Manual Control Console Operation" on page 47 for operating instructions.
Pedestal-Mounted Remote Control Console
Refer to the section titled "Pedestal-Mounted Control Console" on page 55 for operating instructions.

This chapter provides basic operating information for the ST-100 Iron
Roughneck. Rig personnel must understand the information provided in this
chapter and be thoroughly trained before operating this equipment.

Operating Considerations
Please make note of the following before operating the iron roughneck.

Precautions
WARNING
Identify all emergency stops (E-Stops) on the various iron
roughneck models (see page 53 or page 66) and
understand how to operate them. Failure to adhere to this
precaution may result in severe injury or death.

WARNING
Make sure that all personnel are clear of the equipment
operating path before operating or restarting the
equipment. If the tool moves unexpectedly, shut down the
equipment and lock out hydraulics immediately. Inspect
equipment for damage. Failure to adhere to this precaution
may result in severe injury.

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Operating Considerations

Operation

Precautions

WARNING
Under no circumstances should anyone place their hands
or limbs in any part of the iron roughneck while the
equipment is enabled or operating. Failure to adhere to this
precaution may result in severe injury.
E-Stop tool in the event if any unsafe condition occurs or if the ST-100 Iron
Roughneck does something unexpected.

44

An iron roughneck, top drive, and pipe racking system may reach unsafe
noise levels when operating together on the rig floor. Always use hearing
protection when operating the iron roughneck during normal drilling
operations.

Shut down the equipment when it is not being used.

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Operation

Operating Considerations

ST-100 Quick Reference


Information on this page is supplied to be a quick reference and does not replace the need for the
operator to read and understand this manual in its entirety. The subsequent sections of this
manual discuss these topics in much greater detail and must be read and understood before the
equipment is operated.
Dos

Donts

Actuate E-Stop (hydraulic or electronic) if the


equipment exhibits any abnormal behavior, and
investigate the cause. Take care when restarting
equipment after E-Stop.
Read and understand this manual before
operating the ST-100.
Shut down equipment when not in use.
Ensure storage pin is removed before operation.
Ensure tool joint diameter is tangent to the
throat of the torque wrench before clamping.
Ensure the torque wrench and spin wrench are
fully open before extending/retracting to/from
pipe.
Ensure arm adjustment procedures are
followed.
Ensure replacement parts are OEM parts.
Perform scheduled maintenance and inspection
per guidelines in this manual.
Ensure ST-100 torque is set properly for desired
connection make up torque.
Check warning plaques and ensure they are
legible. Replace if necessary.

Do not operate equipment when personnel are


in the path of the equipment.
Do not place hand or limbs in the iron roughneck
while the equipment is enabled or operating.
Do not clamp toque wrench dies on hard
banding.
Do not use ST-100 as a backup device for the
Top Drive, Rotary Table, or any external torque
device.
Do not reuse Nord-Lock washers.
Do not perform maintenance unless hydraulic
power is completely removed and locked from
the ST-100.
Do not perform maintenance unless the arm has
been locked by installing the maintenance pins.
Do not use die assemblies that are not sized for
the tubular being used.
Do not interchange die assemblies. All die
assemblies on the torque wrench should match.
Do not operate spin wrench on spiral collars or
any non circular tubular.
Do not clamp spin wrench on stabilizers or
bottom hole assembly tools.
Do not modify the tool in any way.

Pre-Operation Checks
Make sure the iron roughneck is secure in the floor socket.
Make sure the storage pin is removed.
Make sure all quick-disconnect couplings (QDs) are fully engaged.
Make sure operating pressures are correct.
Check all fittings for leaks.
Lubricate the entire iron roughneck and check the condition of the filter. Refer to Chapter 5 for
lubrication and filter replacement procedures. Refer to Recommended Lubricants and Fluids
(D811000719) in the equipment User Manual for recommended lubricants and hydraulic fluids.
For remotely controlled iron roughnecks, verify that all control cables are properly connected to
the I/O J-box and remote control console.

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Operation

Operating Considerations

Normal Sounds
The following may occur during normal operation:
Humming When the iron roughneck slews there may be a humming sound coming from the
slewing system.
Whooshing When the arm is extending or retracting, the transfer barrier may make a
whooshing noise.Operating Considerations

Normal Occurrences
The following may occur during normal operation:
When going to the full makeup position, the torque gauge will drop to zero.
When other functions are operating, the spin rollers may rotate very slowly.
When operating on angled mouseholes, the head assembly will pivot once the torque wrench
jaws clamp on the pipe.
Component motion that may occur when operating other functions is due to
high return pressure.

Manual Control Lever Operation


Manually controlled iron roughnecks are controlled via proportionally controlled hydraulic valves.
Based on the manner in which the joysticks are operated, iron roughneck functions can occur
gradually or abruptly.
Arm assembly control levers must be worked carefully when extending and retracting the arms for
this feature to work properly. Immediately pushing or pulling a lever all the way to the stop will
result in the arms immediately extending or retracting at full speed. Pushing or pulling the lever
gradually will result in smooth and controlled equipment operation.
To take advantage of the ramped-up start velocity feature for manually
controlled iron roughnecks, move the arm assembly control levers gradually to
the full deploy position when extending/retracting the arms near the extension/
retraction limits.

Manual Operation Verification


Make sure the following are verified before beginning the manual breakout or makeup operations
described in the following sections:
The iron roughneck is fully retracted and the carriage is in its lowest position.
The required makeup torque has been set (see the section titled "Setting and Adjusting Makeup
Torque" on page 50).
The arm extension has been set (see the section titled "Positioning and Adjusting the Iron
Roughneck" on page 48).
The torque wrench jaws and the spin wrench are fully opened.
The tool is properly aligned with the drill pipe connection at well center using the slew function.

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Operation

Manual Control Console Operation


This section provides manual operating instructions for the ST-100 Iron Roughneck.

Manual Control Console

UNCLAMP
TW
CLAMP

BREAK
TW
MAKE

OUT
SW
IN

SW MODE

UNCLAMP
SW
CLAMP

Head Assembly Controls

UP
CARRIAGE
DOWN

RETRACT
DEPLOY
EXTEND

CW
SLEW
CCW

RETRACT
ADJUST
EXTEND

Arm Assembly Controls


ST1000015

Figure 4-1. Manual Control Console

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Manual Control Console Operation

Operation

Positioning and Adjusting the Iron Roughneck

!
Before operating the ST-100 Iron
Roughneck for the first time, make
sure to remove the storage pin
and place it in a secure location.
Do not operate the iron roughneck
with the storage pin installed.

This procedure only needs to be


completed when changing to a new
destination or changing pipe sizes.
After adjustment is complete, the
arm will extend and stop at the
destination.

Procedure




Arm Assembly Controls

Hold the SLEW lever until the


tool aligns with well center or
the mousehole, as required.
Hold the DEPLOY lever in the
RETRACT position until the arm
deploy cylinder is fully retracted.
Then, hold the ADJUST lever in
the RETRACT position for an
additional 30 seconds. (This
ensures the transfer barrier
piston is fully stroked.)

Left
Hand

Left
Hand

Right
Hand

Right
Hand

UP
CARRIAGE
DOWN

RETRACT
DEPLOY
EXTEND

CW
SLEW
CCW

RETRACT
ADJUST
EXTEND

While holding the ADJUST lever


in the EXTEND position, push
the DEPLOY lever to the
EXTEND position. The arm
deploy cylinder should extend
slowly.
Release the ADJUST lever
when the head reaches well
center. Release the DEPLOY
lever.

!
The drill pipe must be
tangent to the throat of the
torque wrench as shown.
Proper distance from home
to the deployed location will
vary with pipe diameter.

Special attention is necessary if hard


banding is present. Do not grip on
hard banding.







Left
Hand

Right
Hand

Hold the CARRIAGE lever in the


UP or DOWN position to align
the torque wrench vertically with
the drill pipe.

During operation, use the DEPLOY


lever for consistent alignment with
the drill pipe.
ST1000016

Figure 4-2. Positioning and Adjusting the Iron Roughneck

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Manual Control Console Operation

Operation

Positioning and Adjusting the Iron Roughneck

!
The drill pipe must be
tangent to the throat of the
torque wrench as shown.
Proper distance from home
to the deployed location
will vary with pipe diameter.

Use the controls to center the torque


wrench assembly on the drill pipe.

Die set for small tool joint


4 to 6 diameter
(102 mm to 152 mm)

Pin-End
Connection

Die set for large tool joint


5-1/2 to 9-3/4 diameter
(140 mm to 248 mm)

Upper Die
Assembly (2)

4.0 in
(102 mm)
Box Shoulder
Range

Box-End
Connection

Lower Die
Assembly (2)

ST1000017

Figure 4-3. Positioning the Iron Roughneck

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Manual Control Console Operation

Operation

Setting and Adjusting Makeup Torque


Torque Adjustment Knob

Torque Gauge

Procedure








If not already completed, position


a tubular (drill pipe or drill collar)
in the throat of the torque wrench
and spin in the connection.

SYSTEM PRESSURE

TORQUE
ADJUSTMENT

TORQUE DISPLAY

HYDRAULIC
ENABLE

Turn the torque adjustment knob


counterclockwise (decreasing
torque) until it stops.

ST-100
HYDRAULIC
E-STOP

Verify that the torque gauge


reads zero.
PUSH TO STOP

Position the reference indicator


(red needle) at the desired
torque value.

UNCLAMP
TW
CLAMP

BREAK
TW
MAKE

OUT
SW
IN

SW MODE

UNCLAMP
SW
CLAMP

Actuate the TW lever in the


BREAK position until it stops.
While holding the TW CLAMP
and TW MAKE levers, turn the
torque adjustment knobs
clockwise until the desired torque
value is set.
UP
CARRIAGE
DOWN

RETRACT
DEPLOY
EXTEND

CW
SLEW
CCW

RETRACT
ADJUST
EXTEND

If the torque cylinders reach end of


stroke during a makeup cycle and the
gauge reads zero, recycle the jaws
and re-torque.

Torque Wrench (TW)


BREAK/MAKE Lever

Breakout torque is applied at system


pressure and is not set or adjusted.

Manual Control Console


ST1000020

Figure 4-4. Setting and Adjusting Makeup Torque (Manual Models)

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Operation

Manual Control Console Operation

Making Connections

The arm must be deployed to the pipe


and centered on the connection before
beginning the following procedure.

Refer to the section titled Adjusting


Makeup Torque for information about
setting the correct makeup torque.

Procedure







Hold the SW MODE lever to the


down position and activate TW
lever in CLAMP position until the
lower jaws make contact on the
drill pipe. Release.
Hold the SW lever in the
CLAMP position.
While holding the SW-CLAMP
lever, hold SW lever in the IN
position until the drill pipe
shoulders. Release.

Head Assembly Controls

Left
Hand

Right
Hand

Right
Hand

UNCLAMP
TW
CLAMP

BREAK
TW
MAKE

SW MODE

OUT
SW
IN

UNCLAMP
SW
CLAMP




Left
Hand

Right
Hand

Hold the SW lever in the


UNCLAMP position to fully
retract the roller carriers.
Hold the TW lever in the BREAK
position until the upper wrench
is aligned in the READY-MAKE
position. Release.
Hold the TW lever in the CLAMP
position until the upper jaws
make contact with the drill pipe.
While holding TW-CLAMP, move
TW lever to the MAKE position
until the required torque is
reached.




Left
Hand

Right
Hand

Right
Hand

If the wrench does not reach the


required torque value in one stroke,
unclamp and repeat steps 5, 6, and 7.

Hold the TW lever in the


UNCLAMP position to retract
jaws. Release.
ST1000018

Figure 4-5. Making Connections

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Manual Control Console Operation

Operation

Breaking Connections

The arm must be deployed to the pipe


and centered on the connection before
beginning the following procedure.

Breakout torque requires no adjustment.


Breakout occurs at full system pressure.

Procedure







To place the upper torque


wrench in position for breaking
out a connection, hold the TW
lever in the MAKE position until
the wrench stops rotating. (This
is READY-BREAK.) Release.
Hold the TW lever in CLAMP
position.

Left
Hand

Right
Hand

Left
Hand

Right
Hand

UNCLAMP
TW
CLAMP

BREAK
TW
MAKE

OUT
SW
IN

UNCLAMP
SW
CLAMP

SW MODE

While holding TW-CLAMP, move


the TW lever to BREAK position
until the connection is broken.
Hold the SW MODE lever in the
down position until the upper
jaws retract from the pipe.
Release.
Hold the SW lever in CLAMP
position.
While holding at SW-CLAMP,
move the SW lever to the OUT
position until the connection
spins free. Release.

If the spin wrench will not spin out the


connection, repeat steps 1, 2, and 3.

Head Assembly Controls




Right
Hand

Left
Hand

Left
Hand




Right
Hand

Move the SW lever to UNCLAMP


to retract the spin rollers.
Release.
Move the TW lever to the
UNCLAMP position to retract the
clamping jaws. Release.
ST1000019

Figure 4-6. Breaking Connections

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Operation

Manual Control Console Operation

Emergency Stop (E-Stop)


Stopping the Equipment in an Emergency
System Pressure
Gauge (Console)

Hydraulic Enable
Knob

E-Stop Button

System Pressure
Gauge
(Inlet Manifold)

E-Stop Procedure




Press the E-Stop Button or pull one


of the E-Stop lanyards.
Verify that the System Pressure
Gauge on the console (if equipped)
or on the inlet manifold shows that
hydraulic pressure has been
released from the system.

Hydraulic E-Stop
Lanyard (2)

Clear the emergency stop situation.


ST1000050

Figure 4-7. E-Stop Component Locations (Manual Models)

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Manual Control Console Operation

Operation

Emergency Stop (E-Stop)

Restarting the Equipment After a Hydraulic E-Stop


Hydraulic Enable
Knob
System Pressure
Gauge

SYSTEM PRESSURE







TORQUE
ADJUSTMENT

TORQUE DISPLAY

Restart Procedure

HYDRAULIC
ENABLE

Verify that the emergency stop


situation has been cleared.
Reset the E-Stop button that was
activated.

ST-100
HYDRAULIC
E-STOP

Turn the Hydraulic Enable Knob


clockwise (increasing system
pressure) until it stops.
Verify that the System Pressure
Gauge registers system pressure.

PUSH TO STOP

UNCLAMP
TW
CLAMP

BREAK
TW
MAKE

OUT
SW
IN

SW MODE

UNCLAMP
SW
CLAMP

Begin normal operation.

E-Stop Button

UP
CARRIAGE
DOWN

RETRACT
DEPLOY
EXTEND

CW
SLEW
CCW

RETRACT
ADJUST
EXTEND

Manual Control Console


ST1000049

Figure 4-8. Restarting After a Hydraulic E-Stop (Manual Models)

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Operation

Remote Control Console Operation


This section provides operating instructions for an ST-100 Iron Roughneck operated remotely from
a pedestal-mounted control console.

Pedestal-Mounted Control Console


All switches on the remote control
console return to center.

page 56

page 57

page 58

page 59

Figure 4-9. Pedestal-Mounted Control Console (1 of 5)

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Operation

Remote Control Console Operation


Pedestal-Mounted Control Console

Figure 4-10. Pedestal-Mounted Control Console (2 of 5)

Mode
Slow Press to initiate Slow Mode for spinning in drill collars and HT and XT type drill
pipe. Slow mode reduces the speed of the spin wrench rollers by half (80 rpm to 40 rpm).
The green indicator lights when in this mode.
SW Backup Press to put the torque wrench in backup mode. In this mode, the lower
torque wrench soft clamps, providing additional stability for spin wrench operations without
deforming the box. The green indicator lights in this mode.
Interlock
When the Interlock status indicator is red, press and hold the Override button to momentarily
override the interlock condition. See the section titled "Interlock Conditions" on page 68 for
precautions and additional information about this function.
Test
Lamp Test Turn and hold the switch to test all lights on the panel.
Spare (Three Total) These modes have currently been left as SPARE (no function). The
modes may be assigned a function in future iterations.
Gauge
Tool Joint Length (Optional) Used to adjust the tool joint length for models equipped with
the tool joint finder.
Torque Shows the torque being applied during iron roughneck operations. To adjust
torque, refer to "Setting and Adjusting Makeup Torque" on page 63.

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Remote Control Console Operation

Operation

Pedestal-Mounted Control Console

Figure 4-11. Pedestal-Mounted Control Console (3 of 5)

Trip
Out indicator Green indicates the current operating mode is tripping out.
Out / In Turn and release the switch to select Trip In or Trip Out mode. Once the mode is
selected, you can start a sequential tripping operation (see the section titled "Sequential
Tripping Operation" on page 62). When used for a non-sequential operation, select the
mode and use the associated console controls to manually control the tripping operation.
In indicator Green indicates the current operating mode is tripping in.
Arm
Retract / Extend Turn and hold the switch to extend to the target destination or retract to
home position.
Down / Up Turn the switch to move the carriage up or down, raising or lowering the arm
assembly.
Spin Wrench
Unclamp / Clamp Turn switch to unclamp the jaws or clamp on drill pipe.
Out / In Turn switch to spin out or spin in a drill pipe connection.

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Operation

Remote Control Console Operation


Pedestal-Mounted Control Console

Figure 4-12. Pedestal-Mounted Control Console (4 of 5)

Slew
CCW / CW Turn the switch to slew the iron roughneck counterclockwise or clockwise to
Position 1 (this is typically well center) or Position 2.
Well Center / Position 1 Green indicates the iron roughneck has reached the Position 1
target destination. This is typically Well Center.
Position 2 Green indicates the iron roughneck has reached the preset Position 2 target
destination.
Torque Wrench
Unclamp / Clamp Turn the switch to unclamp or clamp the torque wrench jaws.
Break / Make Turn the switch when clamped on a connection, to make up or break out the
connection.

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Operation

Remote Control Console Operation


Pedestal-Mounted Control Console

Figure 4-13. Pedestal-Mounted Control Console (5 of 5)

Tool On
Press to take ownership of the iron roughneck. Hydraulic power will be enabled. Green indicates the
iron roughneck is hydraulically enabled and ready for operation.
Sequence
Refer to the section titled "Sequential Tripping Operation" on page 62 for additional information about
using this feature.
Start / Continue Press to start a new sequence or continue to the next step in a running
sequential operation.
Ready / Continue status light Steady green indicates a sequential operation has started
and is in progress. Flashing green indicates a system request for operator input. When
flashing green, the operator should press the Start /Continue button to initiate the next step
in a sequential operation.
Emergency Stop (E-Stop)
Pressing the E-Stop button stops hydraulic power to the iron roughneck. Once the emergency
condition is cleared, pull the button to release the E-Stop and press the Tool On button to enable
hydraulic power.

WARNING
Identify all emergency stop (E-Stop) components on the
unit (refer to page 66) and understand how they operate.
Failure to adhere to this precaution may result in severe
injury or death.

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Operation

Remote Control Console Operation

Making Connections
Verify the following before beginning this procedure:
The iron roughneck is fully retracted.
The required torque has been set.
The arm designation target positions have been set.
The torque wrench jaws and the spin wrench are fully opened.
The tool is properly aligned with the drill pipe connection at well center (using the slew function).
Complete the following steps to make up a connection using the iron roughneck:
1. Extend the arms using the Arm Extend switch. The head assembly will be deployed to the
preset target destination.
2. Raise the torque wrench using the Arm Up switch and center the upper and lower jaws on
the tool joint (adjust as necessary see Figure 4-3 on page 49). If the torque wrench is already
raised, verify that the upper and lower jaws are centered on the tool joint.
3. Press the SW Backup button to activate spin wrench backup mode.
4. Turn the Torque Wrench Unclamp/Clamp switch to Clamp. The lower torque wrench jaw will
soft clamp to provide stability for spin wrench operations.
5. Turn the Spin Wrench Unclamp/Clamp switch to Clamp.
6. Turn the Spin Wrench Out/In switch to In until the connection is shouldered. Once the
connection is shouldered, release switch.
7. Turn the Spin Wrench Unclamp/Clamp switch to Unclamp to release the spin wrench clamp
from the pipe.
8. Turn the Torque Wrench Break/Make switch to Break until the upper wrench is aligned in the
READY-MAKE position.
9. Press the SW Backup button to turn off spin wrench backup mode.
10.Turn the Torque Wrench Unclamp/Clamp switch to Clamp. The upper and lower jaws clamp
on the connection.
11.Turn the Torque Wrench Break/Make switch to Make. The upper jaws rotate the pipe
clockwise (as viewed from above).
12.Once the torque gauge shows the correct makeup torque, release both Torque Wrench
switches. (If correct makeup torque setting is not reached and/or the torque gauge drops to
zero, repeat step 8 through step 12.)
13.Turn the Torque Wrench Unclamp/Clamp switch to Unclamp. The upper and lower jaws
retract.
14.Retract the arms to the home position using the Arm Retract switch.

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Operation

Breaking Connections
Verify the following before beginning this procedure:
The iron roughneck is fully retracted.
The arm designation target positions have been set.
The torque wrench jaws and the spin wrench are fully opened.
The tool is properly aligned with the drill pipe connection at well center (using the slew function).
Complete the following steps to break out a connection using the iron roughneck:
1. Extend the arms using the Arm Extend switch. The head assembly will be deployed to the
preset target position.
2. Raise the torque wrench using the Arm Up switch and center the upper and lower jaws on
the tool joint (adjust as necessary see Figure 4-3 on page 49). If the torque wrench is already
raised, verify that the upper and lower jaws are centered on the tool joint.
3. Turn the Torque Wrench Break/Make switch to Make until the upper wrench is aligned in the
READY-BREAK position.
4. Turn the Torque Wrench Unclamp/Clamp switch to Clamp. The upper and lower jaws clamp
on the connection.
5. Turn the Torque Wrench Make/Break switch to Break. The upper jaws rotate the pipe
counterclockwise (as viewed from above). Stay clamped on the connection during the breakout
operation. This will keep the wrench from slipping on the pipe.

If the connection does not break, repeat steps 3 through 5.


6. Once the connection is broken, release the Break switch.
7. Press the SW Backup button to activate spin wrench backup mode. The upper torque wrench
jaw retracts.
8. Turn the Spin Wrench Unclamp/Clamp switch to Clamp.
9. Turn the Spin Wrench Out/In switch to Out until the connection is unthreaded. Once the
connection unthreads, release switch.

Repeat Steps 3 through 9 if connection does not spin out.


10.Turn the Spin Wrench Unclamp/Clamp switch to Unclamp. The spin wrench opens.
11.Turn the Torque Wrench Unclamp/Clamp switch to Unclamp. The lower torque wrench jaws
retract.
12.Retract the arms to the home position using the Arm Retract switch.Remote Control Console
Operation

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Operation

Remote Control Console Operation


Breaking Connections

Sequential Tripping Operation


The Sequence control function allows the iron roughneck to cycle through a pre-programmed
makeup or breakout sequence by simply pressing the Start/Continue button instead of using
individual function switches.
Sequential operations use feedback from electronic components, operator input, and logic
programmed into the system. Refer to Figure 4-13 on page 59 for the location of this function on
the console.
During the sequential tripping operation, the arms extend, the torque wrench clamps on the
connection, it makes or breaks the connection, and then the spin wrench clamps on and spins the
connection in or out. The Ready/Continue status light will flash at each sequence in the operation.
To complete a sequential tripping operation:
1. Turn the Trip switch to select the desired tripping mode (In or Out).
2. Press the Sequence Start/Continue button. The tripping operation will begin.
3. When the green Ready/Continue status light flashes, press the button to initiate the next step.
The Ready/Continue status light will flash several times during the operation
for operator input. Depending on the iron roughneck model and the amount of
sensors installed, there may be up to six operator input requests.

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Operation

Remote Control Console Operation

Adjustment Procedures
Setting and Adjusting Makeup Torque
To set or adjust makeup torque for the iron roughneck, complete the following steps:
1. If not already completed, position a tubular (drill pipe or drill collar) in the throat of the torque
wrench and spin in the connection.
2. Turn the adjustment knob counterclockwise (decreasing torque) until it stops (see Figure 4-14).
Verify that the torque gauge reads zero.
3. Position the reference indicator (red needle) at the desired torque value.
4. Turn the Torque Wrench Break/Make switch to the Break position and hold it.
5. While holding Torque Wrench Clamp and Torque Wrench Make, turn the adjustment knob
clockwise to the desired torque setting.
6. When set, release the Break position switch and unclamp the torque wrench jaws and the spin
wrench.

Torque Adjustment
Knob

Breakout torque is applied at system


pressure and is not set or adjusted.

ST1000033

Figure 4-14. Setting and Adjusting Makeup Torque (Remotely Controlled Models)

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Remote Control Console Operation

Operation

Adjustment Procedures

Adjusting Arm Assembly Target Positions


Once the deploy target sensors identify the arm assembly targets, the arm speed will decrease.
The arm assembly targets are arm-speed kickdown sensors.
To set or adjust the arm assembly targets, complete the following steps:
1. Extend the arm assembly to Position 1.
2. Adjust the Position 1 target as shown in Figure 4-15.
3. Retract the arm assembly to the fully retracted (home) position.
4. With no pipe at Position 1, extend the arm to the location set for Position 1. Confirm that the
arm speed is reduced prior to the ST-100 reaching Position 1, and that the tool stops when the
Position 1 sensor no longer detects the Position 1 target.
Repeat all steps to set the location for Position 2. (Two positions can be set.)

The magnified view shows the


sensors and targets as they would
appear when the iron roughneck is
extending to Target Position 1.
(Position 1 is typically well center.)
Sensor
Fully Retracted
Sensor
Position 1

Sensor
Position 2

Target
Fully Retracted

Target
Position 2

Target
Position 1

ST1000048

Figure 4-15. Adjusting Arm Assembly Target Positions

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Remote Control Console Operation

Operation

Object Detection Equipment Shutdown


There are diffuse sensors on the iron roughneck that stop the equipment if a sensor light beam is
broken, indicating that an object is in the arm assembly collapse zone. Figure 2-13 on page 32
shows the location of these diffuse sensors on the equipment.
Complete the following steps to restart the equipment after sensor shutdown:
1. Clear the object from the arm assembly collapse zone and verify that there are no objects in the
path of equipment travel.
2. Reset the emergency stop circuit by pushing one of the E-Stop buttons and then pulling the
button back out.
3. Initialize the tool:
a. Unclamp the Torque Wrench.
b. Unclamp the Spin Wrench.
c. Actuate the Torque Wrench to make or break.
4. Begin normal operation.

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Operation

Emergency Stop (E-Stop)


Stopping the Equipment in an Emergency
Equipment
E-Stop Buttons

System Pressure
Gauge

E-Stop Procedure





Press the console E-Stop button,


press one of the equipment E-Stop
Buttons, or pull one of the E-Stop
lanyards.
Verify that the System Pressure
Gauge shows hydraulic pressure is
released from the system.
Clear the emergency.

Hydraulic E-Stop
Lanyard (2)
ST1000051

Figure 4-16. E-Stop Component Locations (Pedestal-Mounted Console Models)

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Operation

Emergency Stop (E-Stop)

Restarting the Equipment After an Electrical E-Stop

Restart Procedure






Pull out the console E-Stop button or


the E-Stop button on the equipment
(see previous figure).
Press the Tool On button.
Verify that the System Pressure
Gauge registers system pressure.
Initialize the tool:
Unclamp the Torque Wrench.
Unclamp the Spin Wrench.
Actuate the Torque Wrench to
make or break.
Begin normal operation.
ST1000052

Figure 4-17. Restarting After an Electrical E-Stop (Pedestal-Mounted Console Models)

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Operation

Interlock Conditions
This section describes the rules within the ST-100 control system that govern the interlock
functions.
Integrated sensors and interlocks enable the ST-100 to perform several functions without operator
intervention. Interlocks also prevent an operator from inadvertently initiating inappropriate
operating sequences.

Interlock Considerations
For the safety of rig personnel and the protection of equipment, several components on the iron
roughneck will not operate under certain conditions. These interlock conditions are provided
below.

Hydraulic Interlocks
These interlocks are present on both ST-100s remote and manual control.

Torque Wrench Clamp Interlock If the torque wrench is clamped the Arm extend/retract,
Slew left/right and Carriage up/down functions are disabled. When the torque wrench is
unclamped, the functions are enabled. See the hydraulic schematic head functions manifold
section for diagnostics.

Electrical Interlocks
WARNING
Electronic interlock conditions can be overridden using the
override function on the remote control console. Always
check the area of operation for rig personnel and
equipment before overriding an interlock condition. Failure
to do so may result in severe injury, death, and/or
equipment damage.
Slew Interlock The slew function is disabled when the arm is extended. Slewing can only be
done when the Home Extend/Retract Proximity Sensor detects its target. This interlock
condition protects the slewing system. See Figure 2-13 on page 32 for the locations of the Slew
Proximity Sensors and refer to section titled "Electrical Assemblies (Remote Control Option)" on
page 31 for description.
Lift Cylinder Pressure Interlock The carriage lift cylinder pressure is monitored by a
pressure transducer. If the pressure deviates from the pre-set working range, the torque wrench
and spin wrench open. This protects the tool from non-driven motion (i.e. lowering the pipe while
the ST-100 is still clamped). See the interconnect diagram and assembly drawing for locations of
each sensor on the I/O J-box.

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Interlock Conditions

Operation

Electrical Interlocks

Carriage Interlock The carriage must be raised two inches before head functions can be
activated. Head functions are activated once the Carriage Up/Down Proximity Sensor does NOT
detect its target. This interlock ensures the ST-100 is operated at a height that provides enough
room for the torque wrench to unclamp before it reaches the fully lowered position in the event of
non-driven motion (i.e. lowering pipe while the ST-100 is still clamped). See Figure 2-13 on page
32 for the location of the Carriage Proximity Sensor and refer to section titled "Electrical
Assemblies (Remote Control Option)" on page 31 for description.
System Pressure Interlock Hydraulic system pressure is monitored by a pressure
transducer. If pressure drops below 2,000 psi, the system pressure interlock is activated and the
current function is aborted. This protects the tubular by ensuring the torque wrench and spin
wrench do not slip, as well as ensuring accurate make up torque. See the interconnect diagram
and assembly drawing for locations of each sensor on the I/O J-Box, and refer to section titled
"Electrical Assemblies (Remote Control Option)" on page 31 for description.
Torque Wrench Clamp Interlock The arm functions are disabled while the torque wrench is
clamped. This interlock protects the tool from damage and is based on last software command
sent to the torque wrench. An UNCLAMP command must be given to deactivate this interlock.
Spin Wrench Interlock The arm functions are disabled while the spin wrench is clamped.
This interlock protects the tool from damage and is based on last software command sent to the
spin wrench. An UNCLAMP command must be given to deactivate this interlock.
Diffuse Sensor Interlock The Object Detection Diffuse Sensors detect objects that have
entered into the crush zone of the arm. Once a diffuse sensor has activated, only the arm
functions are disabled. See page 31 for description and locations of the Object Detection Diffuse
Sensors. Refer to section titled "Object Detection Equipment Shutdown" on page 65 for the
reset procedure that must be performed after this interlock is triggered.
In addition to the interlocks, the remotely controlled ST-100 Iron Roughneck
automatically stops moving when it has reached its preset target destination
or if an emergency stop (E-Stop) is initiated.
For iron roughnecks that are integrated into a complete rig-equipment Zone
Management System (ZMS), there may be additional interlocks based on
where iron roughneck is located on the rig, relative to other drilling equipment.
These interlocks may impact the operation of the iron roughneck.

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Operation

Hydraulic Failure Operation


Safety Precautions
Review and adhere to the following safety precautions before operating the iron roughneck under
hydraulic failure conditions.
Review all precautions in the section titled "Safety Requirements" on page 4."
Identify all equipment pinch points as described in the section titled "Equipment Pinching
Hazard Locations" on page 18.

WARNING
Hydraulic failure operating procedures must only be
performed in emergency conditions. Manual operation
includes procedures that will slow production and may
cause injury to personnel and damage to equipment.
Perform manual operating procedures with extreme
caution.

WARNING
Bleed all hydraulic pressure from the iron roughneck
before disconnecting hydraulic lines. Hydraulic oil under
pressure can penetrate skin and cause serious injury.

Shut off hydraulic supply and disconnect lines from the iron roughneck before
performing any of the procedures in this section. Refer to the section titled
"Hydraulic Assemblies" on page 29 for the location of the hydraulic shutoff
valve. Once the hydraulic supply is shut off, actuate all iron roughneck
functions to bleed hydraulic pressure from the unit.
During operation, surfaces may become hot enough to injure personnel. Allow
surfaces to cool before touching or working around the equipment.

70

This advisory indicates that potential damage to equipment, or injury to


personnel exists. Follow instructions explicitly. Extreme care should be taken
when performing operations or procedures preceded by this caution symbol.

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Hydraulic Failure Operation

Operation

Safety Precautions

Rotating the Iron Roughneck


In the event of hydraulic failure, the iron roughneck may need to be rotated away from its last
location. Complete the following steps to manually rotate (slew) the socket base assembly:
1. If necessary, extend the arm assembly to allow access to the base.
2. Turn the switch on the hand pump manifold assembly from Normal Mode to Hand Pump
Mode. (see Figure 4-18).
3. Connect the hand pump to the quick-disconnect (QD) fitting HP on the front face of the hand
pump manifold assembly.
4. Actuate the hand pump to release the brake. Once the brake is released, you should be able to
rotate the iron roughneck.
5. Rotate the iron roughneck into the desired position.
6. Release hydraulic pressure on the brake by depressurizing the pump.
7. Disconnect the hand pump from the manifold and turn the switch to Normal Mode. (see Figure
4-18)

The hand pump switch must remain in Normal Mode during normal iron
roughneck operation. Failure to do so could result in unreliable slew motor
and brake operation.

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Hydraulic Failure Operation

Operation

Rotating the Iron Roughneck

Hand Pump
Quick-Disconnect Fitting

HP
HAND
PUMP
MODE
NORMAL
MODE
Front

Hand Pump
Manifold Switch

Hand Pump
 included with recommended
operating spares
ST1000021

Figure 4-18. Hand Pump Manifold Assembly

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Operation

Hydraulic Failure Operation

Releasing the Torque Wrench


In the event of hydraulic failure, the clamping action of the torque wrench may need to be released
by manually retracting the clamp cylinders. To manually retract the clamp cylinders, plugs are
removed from the clamp cylinder manifolds.
Complete the following steps to remove plugs and manually retract the clamp cylinders:
1. Locate the EU port on the upper clamp cylinder manifold.
2. Locate the EL port on the lower clamp cylinder manifold.
3. Slowly remove the plugs or fittings from EU and EL ports on the upper and lower clamp cylinder
manifolds.

WARNING
Remove clamp cylinder plugs slowly so hydraulic pressure
is released gradually. If a plug is removed too quickly, it
could be projected at high velocity. Always wear protective
eye wear when working on hydraulic components.

WARNING
Pressurized hydraulic oil can penetrate skin and cause
serious injury to personnel. Always wear protective
clothing when working on hydraulic components.
4. After releasing hydraulic pressure from the cylinders, use a pry bar to retract the clamp
cylinders from the drill pipe.
5. Once the torque wrench is unclamped replace all plugs/fittings.
Figure 4-19 shows the location of the EU and EL ports on the clamp cylinder manifolds.

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Hydraulic Failure Operation

Operation

Releasing the Torque Wrench

EU Port

EU Plug

Torque Wrench Top

Upper Clamp
Cylinder Manifold

EL Port
EL Plug
 end of manifold
not shown

Torque Wrench Bottom

Lower Clamp
Cylinder Manifold

ST1000022

Figure 4-19. Torque Wrench Clamp Cylinder Manifold Ports

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Operation

Hydraulic Failure Operation

Releasing the Spin Wrench


In the event of hydraulic failure, the spin wrench may need to be released by manually retracting
the spin wrench clamp cylinders. To manually retract the clamp cylinders, fittings are loosened on
the clamp cylinder to release hydraulic pressure.
Complete the following steps to remove plugs and manually retract the clamp cylinders:
1. Slowly and carefully loosen the fittings on the spin wrench clamp cylinder.

WARNING
Loosen the fittings slowly so hydraulic pressure is
released gradually. If a fitting is loosened and removed too
quickly, it could be projected at high velocity. Always wear
protective eye wear when working on hydraulic
components.

WARNING
Pressurized hydraulic oil can penetrate skin and cause
serious injury to personnel. Always wear protective
clothing when working on hydraulic components.
2. After releasing hydraulic pressure from the cylinders, disconnect the hydraulic connections
from the spin wrench clamp cylinder.
3. Use a pry bar to move the drive rollers away from the drill pipe.
4. Once the cylinder is retracted, replace all fittings and/or hoses.
Figure 4-20 shows the location of the relief fittings on the spin wrench clamp cylinder.

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Hydraulic Failure Operation

Operation

Releasing the Spin Wrench

Fittings

Clamp Cylinder

Rear View

ST1000023

Figure 4-20. Spin Wrench Clamp Cylinder Relief Fittings

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Hydraulic Failure Operation

Operation

Moving the Arm Assembly


In the event of hydraulic failure, the arm assembly may need to be manually extended or retracted.
To move the arm assembly, hydraulic pressure must be released from the extend/retract cylinders.

This procedure may result in hydraulic fluid being expelled from cylinder
manifold ports when the arms are moved. Take precautionary measures to
catch or contain the hydraulic fluid. Spilled hydraulic fluid can cause slip-andfall injuries and environmental contamination. Collect and clean up any spilled
or escaping oil. Dispose of excess hydraulic fluids, lubricants, and cleaning
material appropriately.

Complete the following steps to release pressure from the extend/retract cylinders and move the
arm assembly:
1. Identify the test fittings on each extend/retract cylinder. There are two test fittings on each
cylinder (Figure 4-21).
2. Slowly screw Stauff test couplings on all four cylinder test fittings to slowly release pressure
from the cylinders.
3. After releasing hydraulic pressure from the cylinders, remove the Stauff test couplings from
the cylinders (or see option below).
As an option, consider attaching open-ended hoses to the test couplings.
Place the open end of each hose in a container to catch hydraulic fluid that
may be expelled when the arm assembly is manually extended or retracted.
4. Push or pull the head assembly in the required direction to manually extend or retract the arm
assembly. (Alternatively, lifting up on the shackles will cause the arm to retract.)
Figure 4-21 shows the location of the test fittings on the arm assembly extend/retract cylinder.

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Operation

Hydraulic Failure Operation


Moving the Arm Assembly

Shackle (2)

Arm Assembly

Arm Extend/Retract
Cylinder Assembly
 2 cylinders; one on each arm

Test Fitting 1

Test Fitting 2
ST1000024

Figure 4-21. Test Fittings on the Extend/Retract Cylinders

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Operation

Electrical Failure Operation


In the event of electrical failure or controller failure, a remotely controlled iron roughneck can be
operated using an emergency control panel located on the equipment. This control panel is for use
only when there is an electrical failure and there is still hydraulic power available for the equipment.

WARNING

This control panel must only be used


when there is an electrical or remote
control failure. Failure to adhere to this
warning could result in severe injury to
rig personnel.

Rig hydraulic power must be available to


operate the equipment using these controls.

Procedure

Install the supplied lever into the


ENABLE panel function and
move it to ON. It must be held in
the ON position to use the other
controls.

Install a lever into the first panel


function required to move the iron
roughneck out of the way.

Continue to use each panel


function as needed until the iron
roughneck is in a safe area.

!
Enabling hydraulics using
this method will cause
the torque wrench and
spin wrench to unclamp
without warning.

ST1000026

Figure 4-22. Emergency Control Panel (Remote Control Option)


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Operation

Securing Equipment on a Floating Vessel


Floating vessels are subject to wave action and wind, resulting in unpredictable rig floor motion.
Unpredictable rig floor motion can cause the iron roughneck to make sudden and unexpected
movements. When this begins to occur, stop operating the iron roughneck and secure it in standby
position.
The following table provides the environmental limits for normal operation. When conditions
exceed these values, immediately stop operation, secure the iron roughneck in standby position,
and install the storage (parking) pin (see Figure 3-1 on page 39).
Operating Environment
Condition

Parameter

Roll/Pitch

Roll:
Pitch:

Heave

2% acceleration force

Temperature

-20 C to +55 C

Ice Thickness

None

Humidity

None

Altitude

None

4 pitch, single amplitude with a 10 second period


50 foot roll center, below rig floor

The following table provides the environmental limits for the iron roughneck secured in position
with the storage pin installed (Figure 3-1 on page 39).
Survival Environment
Condition

Parameter

Roll/Pitch

Roll:
Pitch:

Heave

30 ft. with a 10 second period

Temperature

-20 C to +55 C

Ice Thickness

None

Humidity

None

Altitude

None

20 pitch, single amplitude with a 10 second period


50 foot roll center, below rig floor

Contact your NOV representative if the iron roughneck is installed and may be
operated where the environmental conditions exceed any values provided.

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Maintenance

Pre-Maintenance Checklist
Documentation You Will Need
Make sure you have the following reference documentation available prior to beginning
maintenance procedures:
Hydraulic Schematics
Electrical Interconnects (remote option)
ST-100 Technical Drawing Package
ST-100 User Manual
Recommended Lubricants and Hydraulic Fluids (D811000719)
Design Specification, Design Torque Standard (DS00008)
Safety Wiring Procedure (ASP00019)

Spare Parts You May Need


Refer to the recommended spare parts list in your User Manual and contact your NOV
representative or an NOV Service Center. It is NOV policy to support spares for as long as the
equipment is active.

Spare Parts and Fluids Disposal


The equipment owner is responsible for conforming to applicable regulatory policies and standards
when removing the equipment, dismantling equipment components, disposing of fluids, and
disposing of consumable spare parts during and after maintenance.

The equipment owner is responsible for the recycling guidelines when


removing the equipment.

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Maintenance

Safety Precautions
Avoid equipment damage or injury to personnel by paying close attention to the important safety
notes highlighted as Notes, Cautions, and Warnings used throughout this manual.
To avoid serious injury or death, read and understand the following warning advisories before
performing maintenance or troubleshooting procedures.

WARNING
Secure the equipment with the maintenance pins prior to
starting maintenance (see section titled "Securing the
Equipment for Maintenance" on page 84).
Surfaces may become hot enough during operation to cause injury. Allow
surfaces to cool before touching them.

WARNING
Under no circumstances should work be performed on the
ST-100 while the hydraulic lines are connected. Even with
the hydraulic power unit shut off, residual pressure may
remain in the ST-100 hydraulic circuit that could cause
unsafe motion resulting in serious injury. Always shut off
hydraulic power, cycle all operator valves, and remove
hydraulic lines prior to working on the ST-100 Iron
Roughneck.

WARNING
Complete all appropriate job safety analysis (JSA)
worksheets, permits, and crew safety briefings
immediately prior to each maintenance activity or session.
If, at any point during maintenance tasks, the planned
tasks change for any reason, review the job safety
requirements again to ensure the crew involved is aware of
the changes. Make sure all appropriate personal safety
equipment is in good condition and used when necessary.

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Maintenance

Safety Precautions

WARNING
Replacement parts shall be OEM parts. Failure to use OEM
parts can result in damage to the equipment or injury to
personnel.

WARNING
Unless specifically noted in this manual, properly lock out
the main power source before performing lubrication,
inspection, or replacement procedures.

Wear protective glasses to prevent eye injuries from fluids


under pressure, as well as other hazards.

Read and understand all safety precautions and warnings


before performing maintenance procedures.
Do not attempt repairs you do not understand.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil under
pressure escaping from a hole can be nearly invisible and
can penetrate skin causing serious injury. Always check
for leaks with a piece of wood or cardboard and always
wear protective eye wear when working on hydraulic
components.

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Maintenance

Securing the Equipment for Maintenance


Two pins are provided for use when equipment maintenance procedures are required. These pins
lock down the arm assembly when installed in the unit as shown in Figure 5-1. The maintenance
pins are attached and stored on the equipment when not in use.
Maintenance Pins

WARNING

Lock out hydraulic power to the tool


before beginning any maintenance or
removing any guards.
Ball Valve

WARNING

Make sure to install both maintenance


pins prior to beginning equipment
maintenance. Failure to adhere to this
warning could result in severe injury to
rig personnel.

The maintenance pins pass through two


components to lock down the arm
assembly. The arms may need to be
extended or retracted until the component
holes line up correctly for pin installation.
ST1000053

Figure 5-1. Maintenance Pins

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Maintenance

Equipment Inspection
Inspection Schedules
The following provide the recommended intervals and components to inspect on the iron
roughneck. Refer to the section titled "Equipment Lubrication" on page 88 for recommended
lubricants, lubrication intervals, and lubrication points.
The following inspection intervals are based on average operating conditions.
More frequent service intervals may be required for severe environmental
conditions.

Daily
Inspection

Make sure the equipment and work area are clean. Remove corrosives and
contaminants (salt, sand, mud, oil, and grease). Dispose of components properly.

Check the die assemblies in the torque wrench jaws for wear or damage. See the
section titled "Replacing Torque Wrench Dies" on page 99.

Function each E-Stop to ensure proper operation. Do not operate tool if E-Stop is
not functioning. See the section titled "Inspection Points" on page 87.

If equipped, check diffuse sensors for proper operation. Do not operate tool if
diffuse sensor is not functioning.

Weekly
Inspection

Check all fasteners for looseness and tighten to proper torque. Replace all missing
fasteners.

Check all quick-disconnect (QD) fittings. Tighten all hose connections.

Replace damaged, leaking, or kinked hoses.

Check for loose electrical connectors (remote option).

Check for worn or damaged rollers in the spin wrench assembly. See the section
titled "Replacing Spin Wrench Rollers" on page 102.

Check for worn or damaged rollers in the carriage assembly. If rollers show
excessive wear or damage, contact the NOV representative or Service Center.

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Maintenance

Equipment Inspection
Inspection Schedules

Monthly
Inspection

86

Inspect the hydraulic inlet manifold filter. Replace the filter if the differential
pressure (DP) indicator has popped up. See the section titled "Changing the
Hydraulic Filter Element" on page 106.

Check main spin wrench support screw torque on all four (4) rollers. Torque should
be 430 ft-lb. See page 102 for assembly details.

Check equipment plaques for weariness, dirty or legible, otherwise clean it or order
a new plaque. See Chapter 2, titled "Nameplate and Warning Plaques."

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Maintenance

Equipment Inspection

Inspection Points
Overall Inspection
 Make sure the equipment and the area
Take extreme care around equipment
around the equipment are clean (daily).
pinch points. If possible, avoid these areas
Remove corrosives and contanimants.
while the equipment is operating.
 Check all fasteners for looseness (weekly).
Tighten to correct torque. Replace missing
fasteners.
 Check all hoses and QD fittings (weekly).
Tighten connections. Replace damaged,
The remotely controlled ST-100 model is
leaking, or kinked hoses.
shown in this illustration.
 (Remote option) Check all electrical cables
and connections (weekly).
Carriage Rollers (4 places)
Tighten connections. Replace damaged
cables.
 Inspect rollers for damage or wear.
Spin Wrench Rollers (4 places)
Repair or replace as necessary.
 Check main spin wrench support
Weekly
screw torque. See Page 109.
Should be 430 ft-lb.
Monthly
E-Stop
 Check or test valve.
Repair or replace
as necessary.
Daily

Monthly
Hydraulic Inlet Manifold Filter
 Check the differential pressure (DP)
pop-up indicator.
Replace filter element as necessary.
Daily
Weekly

E-Stop (2 places)
Spin Wrench Rollers (4 places)  Check or test E-Stop assuring
Die Assemblies (4 places)
 Inspect rollers for damage or wear. cable is secured.
Secure or replace if necessary.
 Inspect dies for damage or wear. Repair or replace as necessary.
Repair or replace as necessary.
Daily

ST1000034

Figure 5-2. Equipment Inspection Points

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Maintenance

Equipment Lubrication
WARNING
Properly lock out the hydraulic power source before
performing lubrication, inspection, or replacement
procedures.

WARNING
Wear protective glasses to prevent eye injuries from fluids
under pressure, as well as other hazards.

WARNING
Use caution when draining lubricant. It can be hot.

Recommended Lubricants
Refer to Recommended Lubricants and Fluids (D811000719) in the equipment User Manual for
recommended lubricants and hydraulic fluids for all derrick-mounted equipment.
The lubrication intervals described in this manual are based on lubricant supplier
recommendations. Severe conditions such as extreme loads or temperature, corrosive
atmosphere, and so on, may require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more
frequent lubrication is necessary.

Lubrication Schedules
The following lubrication intervals are based on average operating conditions.
More frequent lubrication intervals may be required for severe environmental
conditions.
Pump grease into the fitting until clean grease is seen extruding from the
component. This makes sure that old grease is purged and that the
component is completely lubricated.
The ST-100 Iron Roughneck needs approximately 1.66 liters of grease per
month.

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Maintenance

Equipment Lubrication
Lubrication Schedules

Weekly
Lubrication
Spin
Wrench
Assembly

Grease the external fittings on the motor and roller guards, that
lubricate the upper and lower bearings.

Grease the fittings on the spin wrench bogey arms.

Grease the fitting on the compression spring strut.

Refer to the section titled "Spin Wrench Assembly Lubrication" on page


90 for component and grease fitting locations.
Spin
Wrench
Support
Structure

Grease the fittings on the spin wrench mount.

Grease the fittings on the link hanger pins.

Grease the track roller fittings.

Refer to the section titled "Spin Wrench Support Structure Lubrication"


on page 91 for component and grease fitting locations.
Torque
Wrench
Assembly

Arm
Assembly

Column
Assembly

Grease the fittings on the clamping jaws.

Grease the fittings on the torque cylinder.

Refer to the section titled "Torque Wrench Assembly Lubrication" on


page 92 for component and grease fitting locations.

Grease all fittings on the arm assembly.

Refer to the section titled "Arm Assembly Lubrication" on page 93 for


component and grease fitting locations.

Grease the carriage guide rollers.

Refer to the section titled "Column Assembly Carriage Guide Roller


Lubrication" on page 94 for component and grease fitting locations.

Monthly
Lubrication
Socket
Base
Assembly

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Grease the slew bearing in the socket base assembly.

Refer to the section titled "Socket Base Slew Bearing Lubrication" on


page 95 for component and grease fitting locations.

89

Equipment Lubrication

Maintenance

Lubrication Procedures
Spin Wrench Assembly Lubrication
Spin Wrench
Assembly

Rear

Weekly
Spin Wrench Bogey Arm
 3 places each side (6 places total)
Weekly
Compression Spring Strut (1 place)

Weekly
Spin Roller Assembly
Upper Bearings
 2 places each side (4 places total)

Weekly

Front

Spin Roller Assembly


Lower Bearings
 2 places each side (4 places total)
ST1000035

Figure 5-3. Lubricating the Spin Wrench Assembly

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Maintenance

Equipment Lubrication
Lubrication Procedures

Spin Wrench Support Structure Lubrication

Spin Wrench
Support Structure

Weekly
Spin Wrench Mount
 2 places each side
(4 places total)

Weekly
Hanger Link Pins
 2 places each side
(4 places total)

Weekly
Rear Track Rollers
 1 place each side
(2 places total)

Weekly
Front Track Rollers
 1 place each side
(2 places total)
ST1000037

Figure 5-4. Lubricating the Spin Wrench Support Structure

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Equipment Lubrication

Maintenance

Lubrication Procedures

Torque Wrench Assembly Lubrication

Torque Wrench
Assembly

Upper Clamping Jaws


 3 places on one side
1 place on the other side
(4 places total)
Weekly

Torque Wrench
Rubber Guard

Lift the rubber guards


to access the torque
cylinder grease fittings.

Front
Weekly

Weekly
Lower Clamping Jaws
 3 places on one side
1 place on the other side
(4 places total)

Torque Cylinder
 2 places each side
(4 places total)

ST1000036

Figure 5-5. Lubricating the Torque Wrench Assembly

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Maintenance

Equipment Lubrication
Lubrication Procedures

Arm Assembly Lubrication

Take extreme care around equipment


pinch points.

Timing Link Pins


 2 place each side
(4 places total)
Weekly

All Timing Link Pin grease fittings


are accessible only when the arm
assembly is retracted.

Weekly
Weekly

Upper Arm Pins


 2 place each side
(4 places total)

Upper Arm Pins


 2 place each side
(4 places total)

Weekly
Head Pivot Pin
 1 place each side
(2 places total)

Weekly
Head Tilt Cam Pin
 1 place each side
(2 places total)
Weekly
Lower Arm Pins
 2 place each side
(4 places total)

Weekly
Extend Cylinder Pin
 1 place each side
(2 places total)

ST1000038

Figure 5-6. Lubricating the Arm Assembly

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Equipment Lubrication

Maintenance

Lubrication Procedures

Column Assembly Carriage Guide Roller Lubrication


Carriage Guide
Assembly

Take extreme care around equipment


pinch points.

Weekly
Carriage Rollers
 2 places each side
(4 places total)

ST1000039

Figure 5-7. Lubricating the Carriage Guide Rollers

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Maintenance

Equipment Lubrication
Lubrication Procedures

Socket Base Slew Bearing Lubrication

Socket Base Assembly

Take extreme care around equipment


pinch points.

Monthly
Slew Bearing
 2 places each side
(4 places total), then
slew ST-100 and
grease again.
Repeat through full
range of slew rotation.

ST1000040

Figure 5-8. Lubricating the Socket Base Slew Bearing

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Maintenance

General Maintenance Procedures


Precautions

Before beginning to disassemble hydraulic components, move the


components to a safe, clean, and dust-free service area.

Disassembly procedures are performed when replacing damaged components that are causing a
tool function to fail. Whenever completing a disassembly procedure, practice preventive
maintenance as follows:
Clean and inspect all disassembled parts.
Replace all worn and damaged parts before they can cause another failure.
Install thread protectors on exposed threads.
Install bolts with anti-seize compound and tighten based on the Design
Torque Standard (DS00008), unless an alternative torque value is given in the
procedure. The Design Torque Standard is included in the equipment User
Manual.

WARNING
Release all hydraulic pressure before disconnecting
hydraulic lines. Oil under pressure can penetrate skin
causing serious injury. Always wear protective clothing
and eye wear when working on hydraulic components.

WARNING
Before opening the hydraulic system, thoroughly clean the
work area. 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.

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Maintenance

General Maintenance Procedures


Precautions

WARNING
Make sure all hydraulic lines are isolated and the hydraulic
inlet shutoff valve is closed before any work is performed
on the iron roughneck.

WARNING
If air is introduced to the extend cylinders, use extreme
caution when extending the unit for the first time. As the
load moves over well center, the air will compress, causing
the arm assembly to extend rapidly. Support the unit with a
tugger and stand to the side until air is purged from the
cylinders.
During operation, surfaces may become hot enough to cause injury. To
reduce the risk of injury from a hot component, allow the surface to cool
before touching.

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Maintenance

General Maintenance Procedures

Nord-Lock Washers
Equipment components may use a Nord-Lock bolt securing system to safely lock bolted joints.
This system consists of a pair of washers with wedge-locking action.
The rise of the cams between these washers is greater than the pitch of the bolt. When the bolt is
tightened, the teeth grip and seat the mating surfaces. The bolt cannot rotate loose because of the
wedge effect of the cams.
When the bolt is loosened with a wrench, the pair of washers expand more than the corresponding
pitch of the bolt thread, allowing the bolt to rise.

Do not reuse Nord-Lock washers. Always replace used Nord-Lock washers


with new washers after completing any disassembly procedures.

Secured Bolt

Top Washer

Bottom Washer

Figure 5-9. Nord-Lock Washer

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General Maintenance Procedures

Maintenance

Replacing Torque Wrench Dies

Once the screws are removed the die may slip out of the die carrier. Secure
the die to avoid injury or damage.
Replace all dies and die carriers. Check all fasteners and associated
components for wear and replace if needed.

Complete the following steps to replace dies in the torque wrench. Figure 5-10 shows the location
of components disassembled in this procedure.
1. Using the Unclamp function on the operator controls, completely open the jaws.

Lock out hydraulics to disable equipment operation and to avoid injury or


equipment damage.

2. Remove hydraulic power from the equipment.


3. Reduce hydraulic pressure to zero.
4. Clean the area around the dies and die carriers.
5. Remove the two mounting bolts from the die carrier and remove the carrier.
If the carrier is difficult to pull out, remove the two outer plugs and use an Allen wrench to tighten the
pry-out set screws. This will force the die carrier out of the socket. Make sure the set screws are flush
with the rear surface of the die carrier before it is reinstalled in the socket.
6. Remove the mounting bolts from the two die keepers.
7. Remove the die.
8. Using a wire brush, clean the die groove on the carrier and the carrier socket in the torque
wrench body.
9. Inspect and lightly grease the die carrier.
10.Install the new die in the carrier.
11.Install the die keepers against the new die and tight the bolts.
12.Install the die carrier in its socket and secure the mounting bolts as specified in the Design
Torque Standard (DS00008).
13.Complete this procedure for the other dies and die carriers.

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General Maintenance Procedures

Maintenance

Replacing Torque Wrench Dies

Torque Wrench
Assembly

Take extreme care around equipment


pinch points.

Die Keeper Bolt (2)

Die Carrier

Die Keeper (2)

Outer Plug (2)


Die
Die Carrier
Mounting Bolt (2)
ST1000041

Figure 5-10. Replacing Torque Wrench Dies

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Maintenance

General Maintenance Procedures


Replacing Torque Wrench Dies

Take extreme care around equipment


pinch points.
Torque Wrench
Assembly

Jaw Assembly (4)

Pipe Guard
Assembly

Tool Joint Guide


Mounting Bolt (2)

Tool Joint Guide


Tool Joint Guide
Mounting Bolt (2)

ST1000055

Figure 5-11. Adjusting Tool Joint Guide for Use with Small Diameter Tool Joints

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Maintenance

General Maintenance Procedures

Replacing Spin Wrench Rollers

!
!

Lock out hydraulic supply pressure to disable the equipment before working
on the Spin Wrench. Failure to lock out hydraulics may result in injury or
equipment damage.
Parts may slip from the Spin Wrench once they are loosened. For instance,
when loosening the screws for the Lower Bearing Housing, make sure to
support the bearings, the lower drive hub, and other parts that make up the
Lower Bearing Assembly. Secure and place all parts removed in a clean, safe
location.

Complete the following steps to replace a spin wrench roller. Figure 5-12 shows the components
referenced in the following procedure.
1. Remove the plug from the lower cover plate.
2. Use the roller torque tool to keep the roller from turning.
3. Remove the large support screw inside the cover plate.
4. Remove the screws to release and remove the lower cover plate, lower drive hub, and lower
bearing assembly.
5. Remove the spin roller.
6. Clean the spin wrench assembly.
7. Install the new roller. When a roller is correctly installed, the roller grooves are interlaced with
the opposing roller.
8. Use the roller torque tool to keep the roller from turning.
9. Install the cover plate, lower drive hub, and lower bearing assembly.
10.Slightly oil the washer, and install the washer and the large support screw in the bottom of the
lower bearing assembly. Torque the large support screw to 430 ft-lb.
While the spin rollers are disassembled, worn or damaged bearing
assemblies and other parts should be replaced. Refer to the Figure 5-13 on
page 104 for an exploded view of the spin wrench roller assembly.

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Maintenance

General Maintenance Procedures


Replacing Spin Wrench Rollers

Spin Wrench
Assembly

Roller Torque Tool

Roller Inspection Notes


 Minimum allowable spin roller
diameter is 6.9 inches (17.5 cm). This
equates to 1/8-inch of radial wear
(3.175 cm).
 Replace all spin rollers with new rollers.
 Replace worn screws with new screws.
 Clean and inspect parts and hardware
for damage and wear. Replace damaged
parts and hardware.
 Torque large support screw 430 ft-lb.
(585 N-m).
 Re-check large support screw and torque
after 5 hours of spin wrench operation.

Spin Wrench Roller

Lower Bearing
Assembly
Lower Bearing
Housing

Lower Drive
Hub

Lower Cover Plate


Nord-Lock Washers (4)

Seal
Hex Head
Mounting Screws (4)
Bearing

Nord-Lock Washers (4)


Socket Head
Mounting Screws (4)

Bearing
Nord-Lock Washer
Large Support Screw

Retaining Ring

Plug

Lower Bearing Assembly

ST1000042

Figure 5-12. Replacing the Spin Wrench Rollers

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General Maintenance Procedures

Maintenance

Replacing Spin Wrench Rollers

Upper Bearing Assembly


Retaining Ring
Hydraulic Motor
Bearing
Bearing
Bearing
Seal

Upper Bearing
Housing

Upper Drive Hub

Upper Bearing
Assembly

Lower Bearing Assembly


Grooved Roller
Lower Drive Hub
Seal

Bearing
Lower Bearing
Assembly
Bearing
Retaining Ring

Lower Bearing
Housing

Seal

Cover Plate

Large Support
Screw

Bearings
 When replacing bearings,
note the orientation of the
bearings and seal.

Plug
ST1000043

Figure 5-13. Spin Wrench Roller Assembly - Exploded View

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General Maintenance Procedures

Maintenance

Spin Wrench Rollers Assembly - Retention Bolt

Grooved Roller

Roller Torque Tool


3 Months
Large Support Screw
 Torque to 430 ft-lb (585 N-m)
and always use a calibrate torque
wrench. 2 places each side
(4 places total)
Plug

Remove to access
Large Support Screw
ST1000056

Figure 5-14. Spin Wrench Roller Assembly - Bolt Maintenance

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Maintenance

General Maintenance Procedures

Changing the Hydraulic Filter Element


WARNING

Lock out hydraulic supply pressure


before replacing the filter. Failure to
lock out hydraulics may result in injury
or equipment damage.

Filter Cap

Differential Pressure (DP)


Pop-Up Indicator
Hydraulic Manifold
Shutoff Handle

Procedure







Shut off hydraulic pressure to the


equipment using the manifold
shutoff handle.
Bleed any residual pressure from
the system.
Remove the filter cap.
Replace the filter element.
Install the filter cap.
ST1000044

Figure 5-15. Replacing the Hydraulic Filter Element

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Maintenance

Disassembly Procedures
Removing the Spin Wrench Assembly

WARNING

Spin Wrench
Hanger Links

Lock out hydraulic supply pressure before


removing the spin wrench assembly.
Failure to lock out hydraulics may result in
injury or equipment damage.

Hanger
Link Pin (2)

Spin Wrench
Manifold

Spin Wrench
Assembly

Procedure






Disconnect the hydraulic hoses at


the spin wrench manifold.
Using a crane, support the weight
of the spin wrench.
Disconnect the spin wrench
hanger links from the hanger.
Lift and remove the spin wrench.

ST1000045

Figure 5-16. Removing the Spin Wrench Assembly

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Disassembly Procedures

Maintenance

Removing the Torque Wrench Assembly

!
Lock out hydraulic supply pressure before
removing the torque wrench assembly.
Failure to lock out hydraulics may result in
injury or equipment damage.

Procedure








Disconnect all hydraulic lines going to


the two torque cylinders and the two
clamp cylinders.
Remove the torque wrench shims
and the torque wrench cover.
Remove the torque wrench guide
ring.

Cover Bolt (4)

Attach lifting lugs to the lift points on


the top of the torque wrench. While
lifting, support the weight of the
torque wrench through the lifting lugs.
Unbolt the torque wrench mount base
from the torque wrench frame.
Pull the torque wrench from the head
assembly and set on a level surface
to perform cylinder maintenance.
Shims

Cover
Guide Ring

Lifting Points

Mount Base
Mount Base
Bolt (8)
ST1000046

Figure 5-17. Removing the Torque Wrench Assembly

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Maintenance

Carriage Lift Counterbalance Valve


Adjustment Procedure

The procedure for adjusting the counterbalance valve on the carriage lift
cylinder should only be done by a qualified NOV technician.

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Troubleshooting

Introduction
This chapter provides guidelines to inspect and troubleshoot the mechanical, hydraulic, and
electrical components and circuits for the ST-100 Iron Roughneck.

All procedures and methods provided in this manual are superseded by the
procedures and methods approved for use at the location where the
equipment is installed and commissioned.
Refer to the Maintenance chapter in this service manual for specific
maintenance procedures and other information that may help you identify the
cause of the issue.
For remotely controlled iron roughnecks, verify that all control cables are
properly connected to the I/O J-box and remote control console. Many issues
can be resolved simply by securing these connections.

Service Centers
When problems cannot be solved, contact an authorized NOV Service Center. For a directory of
NOV Service Centers, see NOV document number D811001337-DAS-001, titled Service Center
Directory. This document is located in the equipment User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx

Malfunction Log
It is the users responsibility to keep and maintain a Malfunction Log, to include information such as
date, description, solution, parts replaced, etc.

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Introduction

Troubleshooting

Personnel Qualifications
Personnel conducting the troubleshooting procedures should be experienced and thoroughly
familiar with this iron roughneck. The personnel conducting troubleshooting procedures must read
and understand the information in all equipment documentation as well as understand all the
functions of the iron roughneck.

Follow the general system safety practices included in this manual before
troubleshooting or performing maintenance on the iron roughneck.

Personnel troubleshooting the iron roughneck must be experienced and


thoroughly familiar with its function, operation and maintenance requirements.

WARNING
Failure to follow safe work procedures could result in
serious or fatal injury to personnel, significant equipment
damage, and/or extended rig down time.

Determining the Nature of the Problem


When troubleshooting the iron roughneck, determine the nature of the problem using the
troubleshooting tables, detailed theory of operation information for components, and diagnostic
procedures. Potential component failure for most iron roughnecks falls into the following
categories:
Mechanical System components
Hydraulic System components
Electrical System components
Lubrication components
Make sure to have all engineering schematic drawings available before
beginning troubleshooting procedures.

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Pre-Troubleshooting Inspection
Make sure to review the following information before starting troubleshooting procedures.

WARNING
Whenever hoisting, lowering and operating the iron
roughneck, ensure all personnel and equipment are clear
of the operating area. Failure to follow this warning may
result in personal injury or equipment damage.

Make sure all hydraulic lines are isolated and the hydraulic shutoff valve is
closed before any work is performed on the iron roughneck. Refer to Figure 212 on page 30 for the location of the inlet valve assembly.

Make sure the iron roughneck is fully inserted in the floor socket.
Make sure the storage pin is removed.
Make sure all hoses and quick-disconnect couplings (QDs) are properly connected.
Check manifold, fittings, QDs, and hoses for leaks or damage.
Make sure operating pressures are correct.
Check all fittings for leaks.
Lubricate the entire iron roughneck and check the condition of the filter.
Refer to Chapter 5 for lubrication and filter replacement procedures. Refer to Recommended
Lubricants and Fluids (D811000719) in the equipment User Manual for recommended lubricants and
hydraulic fluids.
For remotely controlled iron roughnecks, verify that all control cables are properly connected to
the I/O J-box and remote control console. Many issues can be resolved simply by securing
these connections.
When troubleshooting the iron roughneck, make sure there is 2,500 psi of
hydraulic pressure at the hydraulic enable inlet. Check the back pressure of
the tank return line and make sure it does not exceed 100 psi.

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Troubleshooting

Troubleshooting Tables
The tables in this section provide the symptoms, possible causes, and troubleshooting information
for issues that may be encountered when operating the iron roughneck.
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 (132 lpm)
minimum.

Hydraulic power unit


(HPU) return line filter dirty

Replace HPU filter element.

Pressure filter dirty

Replace ST-100 hydraulic filter element.

Power supply not


operating, or pressure too
low

Re-establish hydraulic power.

Lift cylinder damaged or


dirty

Clean or repair cylinder.

Carriage guide binds in


column

Check for obstruction.


Lubricate or replace side rollers.

Pilot pressure is set too


low

Check pressure and adjust.

Counterbalance valve out


of adjustment

Replace, or adjust counterbalance valve to


maintain vertical position*.

Lift cylinder leak

Replace seals.

Tool does not brake (slew)

Brake manifold set to


Manual mode

Set to manifold to Normal mode.

Tool does not raise

Torque wrench hydraulic


interlock activated

Unclamp torque wrench.

E-Stop activated
(remote control model)

Reset E-Stop (see page 67).

Hydraulic E-Stop activated


(remote and control
models)

Reset Hydraulic E-Stop (see page 54)

Vertical positioning
assembly moves in one
direction only or does not
move at all

Does not maintain vertical


position

* See Warning on page 7.

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Troubleshooting Tables

Symptom

Probable Cause

Remedy

Tool does not rotate (slew)

Base assembly quick disconnect


couplings are not connected

Fully connect all base assembly quick


disconnect couplings.

Torque wrench hydraulic


interlock activated

Unclamp torque wrench.

Brake manifold set to Manual


mode

Set manifold to Normal mode.

E-Stop activated
(Remote Control Model)

Reset E-Stop (see page 67).

Hydraulic E-Stop activated


(Remote and Control models)

Reset Hydraulic E-Stop (see page 54).

Obstruction

Make sure storage pin is removed.

Low system pressure

Verify system pressure is set to 2,500


psi.

Transfer barrier not set up


correctly.

Set up transfer barrier (see page 48).

Torque wrench hydraulic


interlock activated

Unclamp torque wrench.

E-Stop activated
(Remote Control Model)

Reset E-Stop (see page 67)

Hydraulic E-Stop activated


(Remote and Control models)

Reset Hydraulic E-Stop (see page 54)

Low system pressure

Verify system pressure is set to 2,500


psi.

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 another bite.

Torque valve damaged

Check, clean, or replace.

Torque cylinders do not


break out connections

Low system pressure

Verify system pressure is set to 2,500


psi.

Torque cylinders drift in


makeup direction

Sticking or worn main operating


valve

Disassemble valve, inspect for


contamination or wear, and repair or
replace.

Torque cylinder does not


move or moves slowly

Dirty return filter in hydraulic


power supply

Replace filter element.

Tool does not extend

Torque cylinders do not


make up connections

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Troubleshooting Tables

Troubleshooting

Symptom

Probable Cause

Remedy

Torque gauge does not


indicate pressure during
makeup operation

Dirty inlet port or gauge

Clean inlet port or replace gauge.

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).

Gauge not adjusted to zero

Rotate zero adjust knob on back of


gauge case. Recheck torque setting.

High tank line pressure

Check and correct.

Worn or broken dies

Replace dies.

Hydraulic pressure too low

Verify system pressure is set to 2,500


psi.

Clamping on hard banding

Reposition torque wrench so dies do


not contact hard banding.

Not holding torque wrench


clamp while torquing

Hold torque wrench clamp during


torquing operation.

Incorrect die holder installed

Install correct die holder (see page 24).

Check valves on manifold


contaminated or defective

Clean, repair, or adjust valves.

Lack of lubrication

Lubricate all grease fittings.

Torque wrench unclamps


after clamping with interlock
lamp

Non-driven motion Pressure


Transducer (PT)

Verify that real non-driven motion


condition does not exist.
Compare PT reading to gauge
reading.
Check wiring.
Replace PT.

Spin wrench assemblies do


not clamp or unclamp and/
or motors do not run

Flow restricted

Locate cause or restriction and correct.

Power supply defective

Check power supply.

Spin wench assemblies or


motor creep with valve in
neutral position

Leaking or sticky valve

Return valve to center position


manually. If problem persists, inspect
valve spool for wear or contamination.
Repair or replace.

High tank line pressure

Check and correct.

Contaminated motor

Repair motor or replace.

Bent shaft

Repair motor or replace.

Torque gauge does not


return to zero

Jaws slip on tool joint

Torque wrench clamp


cylinders too slow or
uneven

Motor runs irregularly

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Troubleshooting

Troubleshooting Tables

Symptom

Probable Cause

Remedy

Rollers do not turn with


motor running or have
insufficient power.

Damaged motor spline

Check motor spline.

Motor seal blown

Replace motor seals.

Flow restricted to motor

Locate cause of restriction and correct.

Defective roller bearings

Replace bearings.

Defective motor

Repair motor.

Motor drive shaft broken

Replace motor.

Power supply not operating

Read power supply pressure gauge.


Make sure that pressure remains high
with operating valve energized.

Restricted hydraulic lines

Check for pinched, clogged, or


otherwise obstructed hydraulic lines.
Clear obstruction.

Worn cylinder seals

Replace seals.

Drill pipe or collars rub


against spin wrench motor
during spinning

Rollers worn excessively

Replace rollers.

Rollers slip

Insufficient clamping pressure

Check pressure at manifold set to 2,500


psi. Check for leaks in clamping lines
and replace as required.

Defective seal on spin clamp


cylinder piston

Replace seal.

Slippery connection

Clean connection.

Rollers worn

Replace rollers.

Grease on rollers.

Remove grease.

Not holding spin wrench clamp


while spinning.

Hold spin wrench clamp during


spinning operation.

Loss of power and torque

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