IRON ROUGHNECK IR30380

Product Picture (size graphic frame vertically as needed)

Owner’s Manual IR3080 & IR30120 with 55” & 88” Arm Assembly Customer - Rig Name Variable

Reference

Reference Description

WITH 55” & 88” ARM ASSEMBLY 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 12950 West Little York Houston, TX 77041

Document Number

Rev.

D811000084-MAN-001

01

D811000084-MAN-001 Revision 01

Revision History

01

Rev

12.07.2007

Create 1 Manual for All IR3080 & IR30120

Date (dd.mm.yyyy)

Change Description Revision

www.nov.com

Change Description

Reason for issue

K Staten K Schmidt B Winter Writer Name

Checker Name

Release Approval Name

Prepared

Checked

Approved

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Table of Contents Chapter 1: General Information Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2: Description General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Wrench Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Spinner Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Spinner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Spinner Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Column-Guide-Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Major Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Rotate Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Hydraulic Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Inline Hydraulic High-Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Wrench Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Wrench Lift Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Move In-Out Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Move In-Out Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Rotation Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 IR3080 with 88” Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Automated Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Automated Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Link Assembly with Tilting Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Vertical Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Automated Arm Hydraulic Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Automated Arm Hydraulic Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Inline Hydraulic High-Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Lift Cylinder Cross Port Relief Valve (if equipped) . . . . . . . . . . . . . . . . . . . . 2-25 Linkage Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Move In-Out Cylinders and Manifold Valve (if equipped) . . . . . . . . . . . . . . . 2-25

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Table of Contents Remote Control Console Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Iron Roughneck Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 with 55” Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 with 88” Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR3080 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 with 55” Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 55” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 with 88” Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IR30120 / 88” Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-26 2-28 2-28 2-29 2-29 2-29 2-30 2-31 2-32 2-33 2-34 2-34 2-34 2-35 2-36 2-37 2-38 2-39 2-39 2-39 2-40 2-41 2-42 2-43 2-44 2-44 2-44 2-45 2-46 2-47 2-48

Chapter 3: Installation Pre-installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Verification of Hydraulic Fluid Cleanliness . . . . . . . . . . . . . . . . . . Equipment Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing The Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Remote Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-1 3-1 3-1 3-1 3-1 3-2 3-3 3-4 3-4 3-5 3-6 3-7 3-9

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Table of Contents Installing the Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Customer System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 NOV System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Checkout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 HPU Installation Checkout procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Controls Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Startup Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 System Setting Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Limit Switches Settings Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Chapter 4: Operation Controls And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Control System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Remote Control Console Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Limit Switch J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Extend / Retract Limit Switch J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Setting Extend / Retract Limit Switch J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Positioning the Iron Roughneck for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Torque Setting Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Adjusting the Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Adjusting the Jaw Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Hydraulic Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Hydraulic Rotation Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Rotate Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Setting the Rotation Target Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Rotation Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Rotation Manifold Override System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Makeup and Breakout Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Makeup Initial Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Normal Makeup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Breakout Initial Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Normal Breakout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Emergency Stop Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Start after Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Chapter 5: Maintenance Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Preventive / Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Lubrication and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

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Table of Contents Wrench Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Column-Guide-Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Automated Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Wrench Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Column-Guide-Arm Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Automated Arm Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Spinner Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Remote Control Console Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Day-to-Day Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Safety Warnings And Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Recommended Lubricants And Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Hazard Descriptions and Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 General Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 General Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Electrical Checks / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Electrical Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Major Repairs and Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Iron Roughneck General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Replacement of Wear Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Main Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Hydraulic Hose and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Functional Testing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 General Storage Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 General Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Storing and Preservation of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Long Term Storage of Iron Roughneck Equipment . . . . . . . . . . . . . . . . . . 5-27 Initial Storage Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Storage Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Preparing Equipment for Operation After Storage . . . . . . . . . . . . . . . . . . . 5-30 Major Component Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Wrench Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Replacing Dies in Top and Bottom Wrench Assemblies . . . . . . . . . . . . . . . 5-31 Remote Control Console Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Specified Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Chapter 6: Troubleshooting Troubleshooting Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identifying Troubleshooting Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Circuits and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical and Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Operation Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 6-2 6-2 6-2 6-2 6-3

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Table of Contents Operating Mode Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Move In-Out Positioning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Vertical Positioning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Troubleshooting Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Troubleshooting Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Spinner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Troubleshooting Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Hydraulic Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Torque Setting Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Troubleshooting System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Electrical and Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

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Table of Contents

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General Information Conventions This manual is intended for use by field engineering, installation, operation, and repair personnel. Every effort has been made to ensure the accuracy of the information contained herein. National Oilwell Varco (NOV), will not be held liable for errors in this material, or for consequences arising from misuse of this material.

Notes, Cautions, and Warnings Notes, cautions, and warnings provide readers with additional information, and to advise the reader to take specific action to protect personnel from potential injury or lethal conditions. They may also inform the reader of actions necessary to prevent equipment damage. Please pay close attention to these advisories. Note:

i The note symbol indicates that additional information is provided about the current topic.

Caution:

! The caution symbol 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.

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.

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Illustrations Illustrations (figures) provide a graphical representation of equipment components or screen snapshots for use in identifying parts, or establishing nomenclature, and may or may not be drawn to scale. For component information specific to your rig configuration, see the technical drawings included with your Varco documentation.

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Safety Requirements The National Oilwell Varco equipment is installed and operated in a controlled drilling rig environment involving hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in the equipment manuals are the recommended methods of performing operations and maintenance.

! To avoid injury to personnel or equipment damage, carefully observe requirements outlined in this section.

Personnel Training All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool operation, and maintenance to ensure their safety.

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

Contact the National Oilwell Varco training department for more information about equipment operation and maintenance training.

Recommended Tools Service operations may require the use of tools designed specifically for the purpose described. The equipment manufacturer recommends that only those tools specified be used when stated. Ensure that personnel and equipment safety are not jeopardized when following service procedures and that personnel are not using tools that were not specifically recommended by the manufacturer.

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

! Read and follow the guidelines below before installing equipment or performing maintenance to avoid endangering exposed persons or damaging 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, maintenance, or repair.

Replacing Components Verify that all components (such as cables, hoses, etc.) are tagged and labeled during assembly and disassembly of equipment to ensure correct installment. Replace failed or damaged components with original equipment manufacturer certified parts. Failure to do so could result in equipment damage or injury to personnel.

Routine Maintenance Equipment must be maintained on a routine basis. See product-specific service manuals for maintenance recommendations.

! Failure to conduct routine maintenance could result in equipment damage or injury to personnel.

Proper Use of Equipment National Oilwell Varco equipment is designed for specific functions and applications, and should be used only for its intended purpose.

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Description General Description This Operation and Maintenance Manual describes the day-to-day care and operation of the Iron Roughneck. It is essential that the equipment operators have the required knowledge, education and training before using the system. The Iron Roughneck is a lightweight, compact, modular roughneck, which is mounted on the rig floor and uses a hydraulic powered Automated Arm Assembly (patent pending) to extend the roughneck, toward the mouse hole or well center, or retract the roughneck back to the standby / park position. A column assembly allows the roughneck to move in a vertical direction, as well as allowing it to rotate to align with either the mouse hole or well center. An Extend/Retract Limit Switch J-box mounted on the column is used to select either the mouse hole or the well center as the destination for the Iron Roughneck. This switch determines the reach distance by the Automated Arm assembly. A locking pin in the column allows the operator to manually rotate the Iron roughneck to face either the mouse hole or well center. The Iron Roughneck is capable of performing makeup and breakout operations using any of a number of different size drill pipe/drill collars ranging from 3.5" to 8.5" (3.5” to 9.75” if equipped with IR30120 wrenches) nominal drill pipe/drill collars size with one set of Vdies. The Iron Roughneck system’s makeup and breakout tools are hydraulic pressure operated. The spinner assembly, which utilizes a floating suspension system, allows the spinner assembly to follow drill pipe/drill collars movement as threaded connections are spun in or out. The torque wrench assembly, which utilizes a combination top wench and bottom wrench assemblies, apply the clamp force and rotational force to hold and rotate the drill pipe/drill collars to allow makeup or breakout the connections. The Iron Roughneck uses an operator-controlled, electrically powered Remote Control Console (RCC) located several feet away from the roughneck. A Hydraulic Enclosure (HE), mounted on the frame of the Iron Roughneck, is available for use during setting of torque and clamp pressure or during maintenance periods when the RCC is not available. The HE is located on the Iron Roughneck. A Torque Setting Panel is mounted on top of the HE. The Torque Setting Panel is used to adjust the torque setting for the Torque Wrench assembly.

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Description

Spinner Assembly

Torque Setting Panel Arm Assembly

Torque Wrench Assembly

Hydraulic Enclosure ERLS J-Box

MAKEU P TORQU E

SYSTEM PRESS

SPINNER ROTATION IN

OUT

250

FT* LB x100

300

SPIN NER

PSI x10

IR MOVE

BOTTOM JAW

GRIP OFF

SPIN

0

OPEN

CLOSE

1

START

MAKEUP REPEAT

IN

OUT

MAKE UP

Remote Control Console

WRENCH UP DOWN

BREAK OUT E−STOP

MAK EUP COMPLETE

3

2

RN 300018

Figure 2-1. Typical Iron Roughneck Major Assemblies

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Table 2.1 Typical Iron Roughneck Major Assemblies COMPONENT

DESCRIPTION

Torque Wrench Assembly

The Torque Wrench is a combination assembly of a top wrench and bottom wrench. The top wrench rotates relative to the bottom wrench by a single hydraulic cylinder. Each wrench has two hydraulic cylinders directly connected to jaw clamping dies. When two sections of pipe are being made-up or broken out, this applies torque to the upper section of pipe.

Spinner Assembly

The Spinner Assembly is an integrated hydraulic powered roller assembly for rotating pipe connections. The Spinner assembly utilizes upper and lower rollers that are hydraulic motor driven. The spinner assembly is spring suspended for self-adjustment on the pipe, which allows the spinner assembly to follow drill pipe/drill collars movement as threaded connections are spun in or out.

Column-Guide-Arm Assembly

The Automated Arm assembly is a folding arm that is used for horizontal movement to extend and retract the roughneck’s Spinner/Wrench assemblies. The Automated arm allows horizontal movement to the two adjustable locations (mousehole and well center) from the standby park position. A hydraulic lift cylinder on the Automated Arm column allows vertical movement of the Automated Arm Assembly. Remote Control Console is used to remotely control the Iron Roughneck.

Controls

Hydraulic Enclosure contains the electro- hydraulic control valves. The electro hydraulic control system can be remotely controlled from the remote console, or locally controlled at the electro-hydraulic control manifold. Torque Setting Panel is used to adjust make-up torque limits. A local emergency shutdown is also located on the Torque Setting Panel. ERLS J-Box is used to select mousehole or well center as the destination of the roughneck.

Hydraulic Power Unit

The Hydraulic Power Unit supplies hydraulic power at 3000 psi to the Roughneck.

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Description

Wrench Assembly Description The Wrench Assembly is the component used to apply makeup or breakout torque to the pipe (drill pipe/drill collars) being handled. The wrench assembly is controlled at the Remote Control Console by using the four-position Makeup/Breakout selector switch. The Wrench Assembly consists of top and bottom wrench assemblies. The bottom wrench assembly, which supports the top wrench assembly, is mounted to the automated arm assembly. The top wrench and the bottom wrench use two opposing hydraulic cylinders to force die heads against the tool joint of the pipe (drill pipe/drill collars), holding the pipe in place. The bottom and top jaw cylinders use two separate pressurized fluid supply lines to control clamping. Table 2.2 Wrench Assembly Specifications DESCRIPTION

MEASUREMENT IR3080

IR30120

Length

36”

36”

Width

56-7/8”

62-1/8”

Height

27-1/8”

27-18”

Weight

3300 lbs

3600LBS

Table 2.3 Wrench Operational Parameters DESCRIPTION

MEASUREMENT IR3080

Size Range of drill pip/drill collars handled

3-1/2” to 8-1/2”

Maximum torque (makeup)

60,000 ft - lbs

Maximum torque (breakout)

80,000 ft - lbs

IR30120

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Description

Spinner Assembly

Torque Setting Panel Arm Assembly

Torque Wrench Assembly

Hydraulic Enclosure ERLS J-Box

MAK EUP TORQUE

SYSTEM PRESS

SPINNER ROTATION OUT

250

IN

FT* LB x100

300 BOTTOM JAW

SPINNER

PSI x10

IR MOVE

GRIP OFF

SPIN

0

CLOSE

OPEN

1

STAR T

MAKEUP REPEAT

OUT

MAKE U P

IN

Remote Control Console

WR ENCH DOWN UP

BREAK OU T E−STOP

MAKEUP COMPLETE

3

2

RN 300018

Figure 2-2. Wrench Assembly

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Description

Rear Wear Block

Front Wear Block

Top Wrench Assembly

Front Wear Block

Torque Cylinder Assembly

View with BW top plate

BOTTOM WRENCH ASSEMBLY Bottom Jaw Manifold BW Body Weldment

Stop Pin Rod Pin

Cylinder Stop Jaw Dies Cylinder (WD4) Die Holder Lock Plates

Cylinder

View without BW top plate RN300022

Figure 2-3. Bottom Wrench Assembly

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Spinner Assembly Description Spinner Assembly The Spinner is mounted above the Wrench Assembly (see Figure 2.1) and is used to spin a drill pipe/drill collar connection IN prior to makeup torquing, and spin a drill pipe/drill collar connection OUT after breakout torquing. The pipe spinner has four sets of two drive rollers each. Two hydraulic motors drive each set. This system can reach and centralize any diameter drill pipe/drill collar between 3-1/2" to 8-1/2" size. The clamping is done with one hydraulic cylinder.

Spinner Support Assembly The Spinner Support Assembly (see Figure 2.4), which supports the Spinner Assembly is socket mounted to the Wrench Frame Assembly. The Spinner Support assembly, which utilizes a floating suspension system, allows the spinner assembly to follow drill pipe/drill collars movement as threaded connections are spun in or out. Table 2.6 Pipe Spinner Assembly Specifications DESCRIPTION

MEASUREMENT

Length

36-5/8"

Width

35"

Height

26-1/2"

Weight

1250 lbs

Hydraulic Pressure Line

3/4" ID

Hydraulic Return Line

3/4" ID

Table 2.7 Pipe Spinner Operational Parameters DESCRIPTION

MEASUREMENT

Size Range of drill pipe/drill collars handled

3-1/2" to 8-1/2"

Maximum Spinner rpm

80 rpm (On 5-1/2" Drill Pipe)

Maximum Spinner Torque

2250 ft - lbs

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Description

Spring Assembly Upper Pin

Spring Suspesion Assembly

Spinner Assembly

Balance Spring

Wrench Frame Interlock Pin Hole

Spring Assembly Lower Pin

RN300023

Figure 2-4. Spinner and Support Assembly

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Column-Guide-Arm Assembly Description The column-guide-arm assembly is a mechanical positioning unit of the Iron Roughneck system. At various times during drilling operations, the Iron Roughneck System needs to be moved between several locations on the rig, including the well centerline, one or more mouse holes, and a parking or storage position. The Iron Roughneck's positioning movements are achieved by the column-guide-arm assembly. The column-guide-arm assembly provides the vertical and horizontal movement of the Iron Roughneck. All extend, retract, or lift operational movements for positioning the Iron Roughneck systems to the rig positions, are controlled through a remote electro-hydraulic control system, or by the onboard manual override hydraulic control system. Additionally, the automated arm section of the column-guide-arm assembly holds the wrench assembly in the vertical position at all extension points.

General Arrangement The Iron Roughneck's Column-Guide-Arm Assembly consists of the following assemblies and components: Column Assembly; Guide Assembly; Arm Assembly; and hydraulic components. The column assembly consists of a column base, column weldment and column turntable bearing. The column bearing is mounted directly between the column base and column weldment surfaces. Equipped on some models is a turntable bearing with an external gear for Column Rotation Systems. The column assembly is attached into the drill floor by means of the column base that is stabbed into a socket mount in the rig floor. The guide assembly is mounted over the column structure and a self-balanced, automated arm assembly is attached to the column guide assembly at a first connection point with a wrench assembly attached at a second connection point. A pair of hydraulic cylinders is used for extension and retraction of the arm assembly and a single trunnion mounted cylinder is used for the guide assembly lift. Hydraulic circuit components properties vary on some models refer to the hydraulic schematic diagram in the parts list section of the manual for rig specific column-guide-arm hydraulic circuit components.

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Figure 2-5. Typical Column/Guide/Arm Assembly General Arrangement

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Description

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Figure 2-6. Typical Column Assemblies

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Major Component Description Column Assembly The column assembly provides four key functions to the operations of the Iron Roughneck: 1. The Iron Roughneck's column base assembly is mounted into the drill floor socket, which provides structural support for the Iron Roughneck. 2. The column structure lower end provides an attachment point for the guide assembly lift cylinder. 3. The column weldment is fitted with two track rails to support the guide frame weldment and to provide a guiding surface on which the guide assembly cam follower bearings ride against for vertical travel. 4. When in a connection operations the column's turntable bearing allows the Iron Roughneck system to be positioned easily between orientation points of well center, mousehole, and park position.

Rotate Column Assembly Some IR models are equipped with a remote hydraulic rotation column system (see Figure 2.6). This feature allows the Iron Roughneck to be hydraulic rotated around the turntable until it stops automatically at one of the rotation index position points (well center or mousehole). To rotate the column assembly, hydraulic power is applied to the drive motor, which in turn drives the pinion gear. Since the ring gear bearing assembly is bolted directly between the column base and column weldment seating surfaces the pinion gear and drive motor rotate around the ring gear, which allows for precise positioning and stopping around the column assembly. The column rotation system consists of a column structure weldment with a drive motor mounting, a hydraulic drive motor with brake, a pinion gear and ring gear. The ring gear is part of the turntable bearing assembly. The column rotation system brake is used to hold the Iron Roughneck's column assembly in a park position during connection operations are being preformed.

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Description

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Figure 2-7. Arm Assembly

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Arm Assembly The Iron Roughneck's Automated Arm assembly utilizes a hydraulic self-balanced, dual synchronized four-sided arm assembly that is equipped with two hydraulic cylinders, to extend or retract the arm links, and one hydraulic cylinder to lift the guide assembly. The Iron Roughneck Automated Arm Assembly allows Iron Roughneck's wrench and spinner assemblies to be positioned horizontally and vertically during drilling operations. The Iron roughneck's Arm Assembly Links are a group of linking arms that are connected in a parallel linking arrangement consisting of six link arms that are joined to a center connecting weldment that hold the link arms parallel with a common axis. The Arm Assembly Links allow the Iron Roughneck's wrench and spinner assemblies to reach maximum extension distance and rotation points between well center, mousehole, and parking positions. The Arm Assembly Links allow the Iron Roughneck's Automated Arm Assembly to travel in a linear direction parallel to the drill floor, and allows the Automated Arm Assembly to retract into a compact envelope to park the Iron Roughneck wrench and spinner assemblies during drilling operations.

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Figure 2-8. Automated Arm Retract and Extend Positions

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Description

2

Guide Assembly The Guide Assembly provides two key functions to the operation of the Iron Roughneck system. First, the Guide Assembly lifts the Iron Roughneck tools vertically, and in addition also transfers the Iron Roughneck load to the column structure. The hydraulic cylinder provided with the column-guide-arm assembly is used to perform the guide assembly lifting operations. Secondly the Guide Assembly provides the pivotal connection points for the Arm Assembly Links and extend-retract hydraulic cylinders. The guide assembly which is directly mounted to the column structure consists of a guide weldment frame with four cam follower bearings and wear pads. The Guide frame guide pads are dimensionally space against the column guide track for cam follower bearing alignment and loading. The trunnion mounted lift cylinder that lifts the guide assembly vertically along the column's guide tracks is attached to guide frame at one connection point with lift cylinder's second connection point attached at the column weldment base.

Figure 2-9. Typical Guide Fram Assembly

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Description

Hydraulic Circuit Components

i Iron Roughneck equipment features may vary on some models. Refer to the hydraulic schematic diagram in the parts list section of this manual for IR hydraulic components requirements.

Inline Hydraulic High-Pressure Filter Mounted on the guide frame assembly directly below the lower left link assembly is an inline hydraulic high pressure filter assembly with a visual indicator. The Iron Roughneck's onboard hydraulic high pressure filter assembly is immediately down stream from the Iron Roughneck's hydraulic inlet connection. The inline hydraulic high pressure filter is used to filter the hydraulic supply fluid prior to circulating through the Iron Roughneck's hydraulic components.

Wrench Lift Cylinder

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Mounted on the guide frame assembly is a Lift Cylinder, which is used to lift the guide assembly vertically to position the Iron Roughneck wrench and spinner assemblies.

Wrench Lift Manifold Assembly Mounted down stream from the lift cylinder is a wrench lift manifold assembly with cartridge type relief valve, counterbalance valve and flow valve. The relief valve is used to set the "up load" hydraulic pressure setting to the lift cylinder. The counterbalance valve, is used to prevent an "over running" load from moving the lift cylinder. The flow valve, is used regulate the hydraulic flow to the lift cylinder.

Move In-Out Cylinders Mounted on the guide frame assembly are two hydraulic cylinders, which are used to extend or retract the automated arm assembly.

Move In-Out Manifold Assembly Mounted down stream from the move in-out cylinders is a move in-out manifold assembly with cartridge type cross over relief valves and pilot operated check valve. The cross-over relief valves are used to set extend and retract hydraulic pressure setting to the move inout cylinders. The pilot operated check valve in the move in-out manifold assembly is used to hold the load. Mounted down stream from the move in-out manifold assembly on each side of the move in-out hydraulic circuit are two needle valves. The primary functions of the needle valves are to regulate the hydraulic flow to the move in-out cylinders. The needle valves are factory set and normally no further adjustment is required unless the move in-out cylinders and/or the valves has been serviced or repaired.

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Description

2

Rotation Manifold Assembly Mounted on the guide frame assembly on some models is a rotation manifold assembly, which is used to control the column assembly hydraulic rotation circuit. The rotation manifold assembly is an integrated hydraulic manifold with directional valves, counterbalance valves, shuttle valves .pressure reducing relief valve and a hand pump for manual override to allow rotation operations to be controlled locally at the rotation manifold assembly.

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Description

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IR3080 with 88” Arm Assembly Automated Arm Assembly

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Figure 2-10. Automated Arm Assembly

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Description

2

Automated Arm Assembly The Iron Roughneck Automated Arm Assembly consists of the following main assemblies and components: Link Assembly; Guide Assembly; Vertical Track Assembly, and hydraulic components. The Iron Roughneck's Automated Arm assembly utilizes a hydraulic self-balanced, dual synchronized four-sided arm assembly that is equipped with two hydraulic cylinders, to extend or retract the arm links, and one hydraulic cylinder to lift the guide assembly. The Iron Roughneck Automated Arm Assembly allows Iron Roughneck's wrench and spinner assemblies to be positioned horizontal and vertical during drilling operations.

Figure 2-11. Automated Arm Retract and Extend Positions

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Description

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Link Assembly The Iron roughneck's Link Assembly is a group of linking arms that are connected in a parallel linking arrangement consisting of five link arms that are joined to a center connecting weldment that hold the link arms parallel with a common axis. The Link Assembly allows the Iron Roughneck's wrench and spinner assemblies to reach maximum extension distance and rotation points between well center, mousehole, and parking positions. The Link Assembly allows the Iron Roughneck's arm assembly to travel in a linear direction parallel to the drill floor, and allows the link assembly to retract into a compact envelope to park the Iron Roughneck wrench and spinner assemblies during drilling operations.

Figure 2-12. Link Assembly

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Description

2

Link Assembly with Tilting Feature The Link Arm Assembly with titling feature (if equipped) enables the lower right link assembly to pivot the Iron Roughneck's wrench and spinner assemblies from the vertical position to tilted axis angle position, for mousehole alignment. The tilting hydraulic circuit consists of two hydraulic tilting cylinders that are mounted to the lower right link assembly that are hydraulic energized when the hydraulic limit valve is triggered. The hydraulic flow to the tilting cylinders is maintained and regulated by an upstream mounted needle valve. The pivot axis angle of the automated arm's titling system is controlled by the mechanical positioning target bracket that is mounted on the automated arm assembly to target and trigger the hydraulic limit valve. The hydraulic limit valve is triggered when the Iron roughneck's link arm is extended beyond the set point of the well center. The Iron Roughneck's wrench and spinner assembly return to a vertical position when the automated arm assembly is retracted to the set point of well center, or when the automated arm is retracted to the parking position.

Figure 2-13. Link Assembly with Tilting Feature

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Description

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Guide Assembly The Guide Assembly provides two key functions to the operation of the Iron Roughneck. First, the Guide Assembly guides the Iron Roughneck vertically, and in addition also transfers the Iron Roughneck load to the vertical track assembly. The Guide Assembly uses four cam followers and four guide pads dimensionally spaced against the vertical track assembly, which allows the guide assembly to guide the Iron roughneck along the vertical tracks. Second, the Guide Assembly provides the pivotal connection points for the Automated Arm Links and hydraulic cylinders. Attached to the Guide Assembly are two hydraulic manifold assemblies (See Figure 2.19) the cross-port relief and the move in-out relief manifolds.

Figure 2-14. Guide Assembly

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Description

2

Vertical Track Assembly The Vertical Track Assembly provides four key functions to the operations of the Iron Roughneck. First, the Iron Roughneck's vertical track assembly's base is mounted into the drill floor socket, which provides structural support for the Iron Roughneck. Second, the vertical track assembly's rotating bearing allows the Iron Roughneck to be positioned easily between orientation points of well center, mousehole, and parking positions. Third, the Vertical Track Assembly provides attachment points for the Guide Assembly lift cylinders. Four, the Vertical Track Assembly is fitted with four corner track rails, which allow the cam follower to move in a smooth and linear travel.

Figure 2-15. Vertical Track Assembly

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Description

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Automated Arm Hydraulic Circuit Components

Figure 2-16. Hydraulic Circuit Components

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Description

2

Automated Arm Hydraulic Circuit Components Inline Hydraulic High-Pressure Filter Mounted on the guide assembly weldment directly below the lower left link assembly is an inline hydraulic high pressure filter assembly with a visual indicator. The Iron Roughneck's onboard hydraulic high pressure filter assembly is immediately down stream from the Iron Roughneck's hydraulic inlet connection. The inline hydraulic high pressure filter is used to filter the hydraulic supply fluid prior to circulating through the Iron Roughneck's hydraulic components.

Lift Cylinder Mounted on the guide assembly weldment is a Lift Cylinder, which is used to lift the guide assembly vertically to position the Iron Roughneck wrench and spinner assemblies. Mounted on the lift cylinder on the "UP" side is a counterbalance valve. The primary function of the counterbalance valve is to prevent an "over running" load from moving the cylinder. The counterbalance valve is factory set and normally no further adjustment is required unless the lift cylinder and /or the valve has been serviced or repaired.

Lift Cylinder Cross Port Relief Valve (if equipped) Mounted down stream from the lift cylinder is a cross over port relief valve, which is used to set the up and down pressure setting of the hydraulic lift cylinder.

Linkage Cylinders Mounted on the guide assembly weldment are two hydraulic cylinders, which are used to extend or retract the automated arm assembly.

Move In-Out Cylinders and Manifold Valve (if equipped) The hydraulic valve connected to the move in-out cylinders is a relief valve, which is used to set the retract pressure setting of the hydraulic move in-out cylinders. Mounted on the move in-out cylinders on the "MOVE-IN" side are counterbalance valves. The primary function of the counterbalance valve is to prevent an "over running" load from moving the cylinder. The counterbalance valve is factory set and normally no further adjustment is required unless the move in-out cylinders and/or the valves has been serviced or repaired.

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Description

Remote Control Console Description The remote control console (RCC) shown in Figure 2.20 is typical of those provide by National Oilwell Varco. The operator can perform makeup and breakout of drill pipe/drill collar connections using the RCC. The RCC is either freestanding on the drill floor or located in or close to the Driller's Cabin, and positioned to where the jaws of the IR can be observed while operating the Iron Roughneck. The remote control console panel contains the IR selector switches, Emergency stop pushbutton switch, status lamps, and readouts to operate the Iron Roughneck. The remote control console (RCC) contains the control circuitry that controls the movements of various mechanical components of the Iron Roughneck. All operational movements of the IR are controlled by one operator. These movements are controlled by appropriate inputs from the operator's remote control console (RCC) and positioning limit sensors. The IR operator can perform following actions from the remote control console (RCC): Extend or retract the IR automated arm assembly. Raise or lower the wrench assembly. Clamp or unclamp the bottom or top jaws. Actuate the make and break torque cylinder. Actuate the grip rollers and rotation of the spinner assembly. Stop the IR and shutdown the hydraulic and electrical systems.

i Jaw pressure setting is controlled from the torque setting panel.

All signal, control and power wiring connect to the RCC enters and leaves through the cable entry ports of the cabinet. A 24 VDC, 10 AMP, power supply source is connected to the RCC, and the plug and cable assembly connects the RCC to the Iron Roughneck solenoid J-Box. Refer to the electrical control system documentation and electrical diagrams for detail electrical information.

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Description

2

Figure 2-17. Remote Control Console

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Description

Technical Specifications Iron Roughneck Technical Specifications Table 2.11 Iron Roughneck Products IRON ROUGHNECK

WRENCH PACKAGE

ARM LENGTH

AUTO-ROTATION

TOP LEVEL NUMBER

3080

55”

YES

1100005

x

x

1100006

x

x

x

x

x

1100011

30120

x

88”

NO

x

1100012

x

x

1100014

x

x

1100016

x

x

1100017

x

x

1100018

x

x

x x x x x

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Description

2

IR3080 with 55” Arm General Specifications Table 2.12 80K / 55" IR3080 Components DESCRIPTION

MEASUREMENT

Weight

7,600 (3,447 kg)

Spinner Drill Pipe/Collar Capacity

3.5" - 8.5"

Spin Speed (5" pipe dia.)

80 rpm

Spin Torque

2,250 ft / lbs (3,050 N-m)

Wrench Drill Pipe/Collar Capacity

3.5" - 8.5"

Makeup Torque (maximum)

60,000 ft /lbs (81,349 N-m)

Breakout Torque (maximum)

80,000 ft / lbs (108,465 N-m)

Connection Height (maximum)

68" (172.72 cm) maximum

Connection Height (minimum)

30" (76.2 cm) minimum

Horizontal Travel

55.5" (141 cm)

Vertical Travel

38" (96.5 cm)

Utility Requirements Table 2.13

80K / 55" IR3080 Utility Requirements

UTILITY

MEASUREMENT

Hydraulic System Pressure

3000 psi (206.8 bar)

Hydraulic System Flow rate

40 gpm (151 Ipm)

Electrical Control Requirements

24VDC (w/customer supplied HPU)

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Description

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IR3080 / 55” Size Specifications Maximum Extend, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-18. IR3080 / 55” Maximum Extend, Side Dimensions

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Description

IR3080 / 55” Size Specifications Maximum Extend, Maximum Lift, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-19. IR3080 / 55” Maximum Extend, Maximum Lift, Side Dimensions

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Description

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IR3080 / 55” Size Specifications Maximum Extend, Top Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-20. IR3080 / 55” Maximum Extend, Top Dimensions

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Description

2

IR3080 / 55” Size Specifications Maximum Retract, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-21. IR3080 / 55” Maximum Retract, Side Dimensions

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Description

IR3080 with 88” Arm General Specifications Table 2.14 80K / 88" IR3080 Components DESCRIPTION

MEASUREMENT

Weight

10,000 (4,536 kg)

Spinner Drill Pipe/Collar Capacity

3.5" - 8.5"

Spin Speed (5" pipe dia.)

80 rpm

Spin Torque

2,250 ft / lbs (3,050 N-m)

Wrench Drill Pipe/Collar Capacity

3.5" - 8.5"

Makeup Torque (maximum)

60,000 ft /lbs (81,349 N-m)

Breakout Torque (maximum)

80,000 ft / lbs (108,465 N-m)

Connection Height (maximum)

73.5" (186.8cm) maximum

Connection Height (minimum)

35.5" (90.2cm) minimum

Horizontal Travel

88.4" (224.6cm)

Vertical Travel

38" (96.5 cm)

Utility Requirements Table 2.15 80K / 88" IR3080 Utility Requirements UTILITY

MEASUREMENT

Hydraulic System Pressure

3000 psi

Hydraulic System Flow rate

40 gpm

Electrical Control Requirements

24VDC (w/customer supplied HPU)

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Description

2

IR3080 / 88” Size Specifications Maximum Extend, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-22. IR3080 / 88” Maximum Extend, Side Dimensions

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Description

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IR3080 / 88” Size Specifications Maximum Extend, Maximum Lift, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-23. IR3080 / 88” Maximum Extend, Maximum Lift, Side Dimensions

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Description

2

IR3080 / 88” Size Specifications Maximum Extend, Top Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-24. IR3080 / 88” Maximum Extend, Top Dimensions

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Description

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IR3080 / 88” Size Specifications Maximum Retract, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-25. IR3080 / 88” Maximum Retract, Side Dimensions

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Description

2

IR30120 with 55” Arm General Specifications Table 2.16 120K / 55" IR30120 Component Capacities DESCRIPTION

MEASUREMENT

Weight

8,000 lbs (3,629 kg)

Spinner Drill Pipe/Collar Capacity

3.5" - 9.75"

Spin Speed (5" pipe diameter)

80 rpm

Spin Torque

2,250 ft-lbs (3,050 N-m)

Wrench Drill Pipe/Collar Capacity

3.5" - 9.75"

Makeup Torque (maximum)

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

Breakout Torque (maximum)

120,000 ft-lbs (162,699 N-m)

Connection Height (maximum)

68" (172.7cm) maximum

Connection Height (minimum)

30" (76.2cm) minimum

Horizontal Travel

55.4" (141cm)

Vertical Travel

38" (96.5 cm)

Utility Requirements Table 2.17 120K / 55" IR30120 Utility Requirements UTILITY

MEASUREMENT

Hydraulic System Pressure

3000 psi

Hydraulic System Flow rate

40 gpm

Electrical Control Requirements

24VDC (w/customer supplied HPU)

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Description

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IR30120 / 55” Size Specifications Maximum Extend, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-26. IR30120 / 55” Maximum Extend, Side Dimensions

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Description

2

IR30120 / 55” Size Specifications Maximum Extend, Maximum Lift, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-27. IR30120 / 55” Maximum Extend, Maximum Lift, Side Dimensions

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Description

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IR30120 / 55” Size Specifications Maximum Extend, Top Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-28. IR30120 / 55” Maximum Extend, Top Dimensions

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Description

2

IR30120 / 55” Size Specifications Maximum Retract, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-29. IR30120 / 55” Maximum Retract, Side Dimensions

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Description

IR30120 with 88” Arm General Specifications Table 2.17 120K / 88" IR30120 Component Capacities DESCRIPTION

MEASUREMENT

Weight

10,400 lbs (4,536 kg)

Spinner Drill Pipe/Collar Capacity

3.5" - 9.75"

Spin Speed (5" pipe diameter)

80 rpm on 5” Pipe OD

Spin Torque

2,250 ft-lbs (3,050 N-m)

Wrench Drill Pipe/Collar Capacity

3.5" - 9.75"

Makeup Torque (maximum)

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

Breakout Torque (maximum)

120,000 ft-lbs (162,699 N-m)

Connection Height (maximum)

73.75" (186.8 cm) maximum

Connection Height (minimum)

35.75" (90.8 cm) minimum

Horizontal Travel

88.4" (244.6 cm)

Vertical Travel

38" (96.5 cm)

Utility Requirements Table 2.17 120K / 88" IR30120 Utility Requirements UTILITY

MEASUREMENT

Hydraulic System Pressure

3000 psi

Hydraulic System Flow rate

40 gpm

Electrical Control Requirements

24VDC, 10A & 120VAC, 2A

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IR30120 / 88” Size Specifications Maximum Extend, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-30. IR30120 / 88” Maximum Extend Dimensions

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Description

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IR30120 / 88” Size Specifications Maximum Extend, Maximum Lift, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-31. IR30120 / 88” Maximum Extend, Maximum Lift, Side Dimensions

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IR30120 / 88” Size Specifications Maximum Extend, Top Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-32. IR30120 / 88” Maximum Extend, Top Dimensions

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Description

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IR30120 / 88” Size Specifications Maximum Retract, Side Dimensions ALL DIMENSIONS ARE IN INCHES. ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS, UNLESS OTHERWISE SPECIFIED.

Figure 2-33. IR30120 / 88” Maximum Retract, Side & Top Dimensions

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Description

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Description

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Installation Pre-installation Procedures Requirements and Procedures The following assumes that all pre-installation planning and rig-up has been accomplished prior to installation of the Iron Roughneck.

General Requirements Although many installation layouts arrangements are possible critical preparation and installation consideration must be preformed before attempting to install the Iron roughneck. Before installing the Iron Roughneck system, consider the ideal location of the Iron Roughneck, HPU, Service Loop, and Remote Control Console to ensure location accessibility and safety. Installation considerations help to prevent clearance possible restrictions. Prior to field installation operation, check over that the Iron Roughneck assembly and controls, to assure all components are included and in serviceable condition. Fill all lubricants systems to correct levels with specified lubricants

Initial Inspection After unpacking all components and parts, Inspect as follows: 1. Inventory all components and parts. In case of missing or incorrect parts, notify National Oilwell Varco. 2. Inspect all components and parts for shipment damage and corrosion. If damage to a component or part occurred during shipment, notify the carrier. If corrosion beyond reasonable limits is present, notify National Oilwell Varco.

Customer Verification of Hydraulic Fluid Cleanliness Prior to attaching any National Oilwell Varco equipment the customer's hydraulic plumbing, the customer must ensure that the hydraulic fluid/system cleanliness is at a level of ISO 440615/12 or better.

Equipment Differences The Nov IR3080 Iron Roughneck is manufactured in different arm reach range versions. Each IR3080 models are hydraulically and electrically similar. The illustrations and text in this section do not cover on any one version but rather covers the common systems and components.

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Installation

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Electrical System and Components The IR3080 control system requires 24VDC with customer supplied HPU. For detailed information, refer to the electrical documentation book. Refer to the Iron Roughneck electrical documentation book for grounding the Iron Roughneck's electrical components and associated accessories. Electrical systems are designed for the intended purpose the drilling industry. All electrical wiring, junction boxes, sensors, glands, and related equipment are designed for the specific application, environment and particular operating zone. Before beginning work on this equipment, familiarize yourself with the electrical schematics, as well as the equipment power and voltage requirements When performing installation, maintenance, or repairs on the equipment, isolate all power. Lock out switches and tag them to prevent injury. Prior to connecting or disconnection wires, cables, verify all wires, cables are properly labeled to ensure proper reconnection.

Hydraulic System and Components Hydraulic systems and components are designed for the intended use in the drilling industry. The hydraulic pressure for this equipment can be as high as 3,000 psi. Before beginning work on any portion of the hydraulic system, familiarize yourself with the hydraulic and electrical schematics. Isolate, lock out, and tag the hydraulic an electrical power controls. Take precautions when bleeding down residual system pressure, using bleed valves or equivalent techniques. Properly discharge all system stored fluid pressure. Collect all residual hydraulic fluid in a container to prevent rig or environmental contamination. Take precautions to prevent hydraulic oil from leaking into other open electrical or mechanical components such as junction boxes.

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3

Installation

Special Tools The following table lists special tools and support equipment required to install and commission an Iron Roughneck. Table 3.1 Special Tools and Support Equipment DESCRIPTION

SUPPLIER& MODEL

ACCURACY

RANGE

Fluke

Various