Maintenance Manual - Varco ST-80 Roughneck (2)

ST-80

Roughneck Service Manual

SM00995

General Information

1

Specifications

2

Maintenance

3

Troubleshooting

4

1

General Information

2

Specifications

3

Maintenance

4

Troubleshooting

General Information

General Information

Preface ................................................................ 1-3 Manual conventions ...................................................... 1-3 Note ................................................................................... 1-3 Caution .............................................................................. 1-3 Warning ............................................................................. 1-3 Product bulletins ............................................................ 1-3

1

2

Overall equipment safety requirements ......................... 1-3 Personnel training .............................................................. 1-4 Systems safety practices ................................................... 1-4 Hydraulic systems and components ............................ 1-4 General safety ................................................................... 1-5 Equipment motion hazards 1-5 Proper use of equipment .............................................. 1-6

3

Tool orientation .................................................. 1-7 ST-80 general information .................................. 1-8 ST-80 carriage assembly .............................................. 1-9

4

Pedestal assembly ........................................................ 1-10 ST-80 wrench assembly ................................................ 1-11 Control System .............................................................. 1-12 Operating the ST-80............................................ 1-14 Making and breaking connections ................................. 1-14 Adjusting the makeup torque ......................................... 1-16 Adjusting the stabbing guide ......................................... 1-17 Adjusting torque gauge responsiveness........................ 1-18 Storing the ST-80 ................................................ 1-19

1-1

General Information

General Information

1 1

2

3

4

5

1-2

General Information

Preface Manual conventions This Preface contains the conventions used throughout this manual. Avoid injury to personnel and/or equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment. Notes, cautions, and warnings The following examples explain the symbols for notes, cautions, and warnings. Please pay close attention to these important advisories.

Note

i

Provides additional information on procedures involving little or no risk of injury to personnel or equipment damage.

Caution

!

Alerts the reader to procedures involving a risk of equipment damage.

Warning

Warns the reader of procedures involving a definite risk of injury to rig personnel.

Product bulletins The Product Bulletin tab, if included in your manual, defines a section of the manual in which you can store Product and Safety bulletins that may be issued by Varco.

Overall equipment safety requirements Varco drilling equipment is installed and operated in a controlled drilling rig environment that involves hazardous operations and situations.

i

To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.

1-3

1

General Information

Personnel training All personnel installing, operating, repairing, or maintaining equipment, or those in the vicinity of this equipment, should be trained in rig safety, tool operation, and maintenance as applicable. This measure helps ensure the safety of everyone exposed to the equipment for whatever purpose.

1

i

During installation, operation, maintenance, or repair of this equipment, personnel should wear protective equipment. Contact the Varco Service Department to arrange for training for equipment operation and maintenance.

Systems safety practices The equipment covered by this manual may require or contain one or more utilities such as electrical, hydraulic, and cooling water.

i

Before installing or performing maintenance or repairs on the equipment, read the following instructions to avoid endangering exposed persons or damaging equipment. ❏

Isolate all energy sources before beginning work.

❏

Avoid performing maintenance and repairs while the equipment is in operation.

❏

Wear proper protective equipment during the installation, maintenance, or repair of this equipment.

Hydraulic systems and components Hydraulic systems and components are designed for specific use in the drilling industry. The hydraulic pressure for this equipment can be as high as 3,000 psi.

1-4

❏

Before beginning work on any portion of the hydraulic system, familiarize yourself with the hydraulic and electrical schematics.

❏

Isolate, lock out, and tag the hydraulic and electrical power and controls.

❏

Take precautions when bleeding down residual system pressure, using bleed valves or equivalent techniques.

General Information

Hydraulic fluids can be extremely hot and under high pressure. ❏

Properly discharge all system accumulators.

❏

Collect all residual hydraulic fluid in a container to prevent rig or environmental contamination.

❏

Take precautions to prevent hydraulic oil from leaking into other open electrical or mechanical components, such as junction boxes.

Pneumatic systems and components Pneumatic systems and components are designed for specific use in the drilling industry. The pneumatic pressure for this equipment can be as high as 150 psi. ❏

Prior to beginning work on any portion of the pneumatic system, familiarize yourself with the pneumatic and electrical schematics.

❏

Isolate, lock out, and tag the pneumatic and electrical power and controls.

❏

Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques.

❏

Properly discharge all system accumulators.

General safety Equipment motion hazards Some of the Varco equipment travels either horizontally, vertically on rails, or both.

i

i

Avoid placing objects in or near the path of motion for this equipment. Such interference could cause personnel to be trapped or crushed by equipment.

Keep the working envelope/zone of the equipment free from personnel.

1-5

1

General Information

When replacing components ❏

During disassembly and reassembly of any equipment, verify all components such as cables, hoses, etc. are tagged and labeled to ensure reinstalling the components correctly.

❏

Replace failed or damaged components with Varco certified parts. Failure to do so could result in a hazard, equipment damage, or personal injury.

1

During routine maintenance Equipment must be maintained on a regular basis. See the body of the service manual for maintenance recommendations.

i

Failure to conduct regular maintenance can result in a hazard, equipment damage, or injury to personnel. Visibility of equipment operation Clear, unobstructed visibility of all equipment functions is critical to safe operation. Do not block or impair the equipment operator’s field of view. In cases where this is not possible, the customer must install video cameras to ensure adequate visibility. Proper use of equipment Varco equipment is designed for specific functions and applications and should be used only for the intended purpose.

i

Do not hoist personnel using this equipment.

Contact the Varco service center for questions regarding equipment operation, maintenance, hazards, and designed function.

1-6

General Information

Tool orientation 1

Rear

Right

Left

Front

1-7

General Information

ST-80 general information The ST-80 Roughneck can make or break all tool connections from 4 1/4" to 8 1/2" outside diameter, and can handle nominal drill pipe from 3 1/2" up to 6 5/8". It can also make and break bits, stabilizers, spiral colors and other bottom hole assembly (BHA) components.

1

The ST-80 Roughneck consists of the following major assemblies: ❏

ST-80 carriage assembly

❏

Pedestal assembly

❏

ST-80 wrench assembly

❏

ST-80 controls

❏

Upper and lower motion control

Pedestal Assembly

Upper Motion Control

ST-80 Carriage Assembly

Wrench Assembly

ST80 Controls Lower Motion Control Not Visible

1-8

General Information

ST-80 general information ST-80 carriage assembly The carriage assembly can move vertically to position the ST-80 properly at the tool joint.

Stabbing Guide

Hydraulic Manifold

Controls

Wrench Assembly

Carriage

1-9

1

General Information

ST-80 general information Pedestal assembly

1

Lift Cylinder

Extend/Retract Duplex Cylinder

Transport Pin Stowed Position

Transport Lock Insert Transport Pin Prior to Transport

Socket Flange Turntable Bearing

1-10

General Information

ST-80 general information ST-80 wrench assembly The ST-80 uses a combination spinning and torque wrench. The dies of the upper jaws are located in between the spinner rollers. The spinner rollers grip the pipe and spin in connections with a torque of 1,750 ft lb. After spinning, the torque wrench can torque the connection with a maximum torque of 60,000 ft lb. The wrench can break out connections with a maximum torque of 80,000 ft lb.

Upper Jaw Dies 1 each side

Spin Rollers 2 each side

Lower Die and Die Holder 1 each side

1-11

1

General Information

ST-80 general information Control System

1

The ST-80 controls are mounted on the carriage. They include the following: ❏

JAWS: UN-CLAMP, CLAMP. Clamps or unclamps the wrench on a tubular.

❏

MODE: SPIN, TORQUE. Determines whether the wrench spins or torques connections. The operator must hold this control in the desired postion while performing these operations.

❏

TORQUE: MAKE, BREAK. Determines whether the wrench makes or breaks connections.

❏

SPIN: IN, OUT. Determines whether the wrench spins in or out.

❏

ST-80: UP, DOWN. Adusts the vertical height of the ST-80.

❏

ADJUST: EXTEND, RETRACT. Adjusts the travel distance of the ST-80 when extending or retracting the tool.

❏

ST-80: EXTEND, RETRACT. Selects whether the tool extends or retracts.

1-12

General Information

ST-80 general information 1

Torque Gage

Jaws Clamp, Unclamp Mode Spin, Torque Torque Make, Break Spin In, Out

ST-80 Up, Down Adjust Extend, Retract ST-80 Extend, Retract

1-13

General Information

Operating the ST-80 Making and breaking connections

1

!

Before operating the ST-80 for the first time, be sure to remove the transport pin.

1. Completely extend the tool using the ST-80 EXTEND/ RETRACT control.

ST-80 Up, Down

2. Adjust the vertical position of the wrench on the connection using ST-80 UP/DOWN control.

Adjust Extend, Retract

3. Use the ADJUST control to precisely position the ST-80 horizontally. The correct position is when the lower guide plate contacts the tubular. This is typically adjusted only once per trip.

ST-80 Extend, Retract

Vertical Adjustment Tubular Pin Rollers 4 places

Tubular Box

1-14

General Information

Operating the ST-80 Making and breaking connections

1 Making Connections 1

Clamp the jaws on the tubular.

2

Hold the MODE control in the SPIN position.

3

SPIN the connection IN.

4

Hold the MODE control in the TORQUE position.

5

Hold the TORQUE control in the MAKE position until the desired torque is achieved.

i 6

Hold 2

6

UN-CLAMP the jaws and recycle the torque wrench to prepare for the next connection.

UN-CLAMP

SPIN

MAKE

IN

JAWS

MODE

TORQUE

SPIN

CLAMP

TORQUE

BREAK

OUT

Breaking Connections 1

Clamp the jaws on the tubular.

2

Hold the MODE control in the TORQUE position.

3

Hold the TORQUE control in the BREAK position until the connection is broken.

4

Hold the MODE control in the SPIN position.

5

SPIN the connection OUT.

6

UN-CLAMP the jaws and recycle the torque wrench to prepare for the next break.

3

4 Hold

1

If the wrench does not reach the desired value in one stroke, recycle the torque wrench and repeat steps 4 and 5.

5

Hold 4

6

2 Hold

1

3

5

UN-CLAMP

SPIN

MAKE

IN

JAWS

MODE

TORQUE

SPIN

CLAMP

TORQUE

BREAK

OUT

1-15

General Information

Operating the ST-80 Adjusting the makeup torque Use the following procedure to adjust the ST-80 make up torque: 1. Back the adjustment knob on the pressure reducing valve (PRV) all of the way out.

1 Torque Gauge

i Reference Indicator

Turning the PRV adjustment knob counter clockwise decreases torque. Turning the PRV adjustment knob clockwise increases the torque. 2. Clamp onto a tubular. 3. Spin the connection in. 4. Torque the connection. 5. While holding the torque, turn the PRV adjustment knob clockwise while watching the torque gauge until the desired torque is achieved.

! Do not adjust the torque if one of the torque cylinders is at its end of stroke. 6. Position the reference indicator (red needle) on the torque gauge at the desired torque value.

PRV Adjustment Knob

1-16

General Information

Operating the ST-80 Adjusting the stabbing guide

1

Use the following procedure to adjust the stabbing guide: 1. Use the horizontal travel and vertical travel controls to position the torque wrench on the tool joint box. 2. Clamp onto the tubular. 3. Stab the next stand. 4. Loosen two adjusting nuts and align the inside edge of the stabbing guide with the outer circumference of the pipe. Tighten the nuts.

i

When coming out of the hole or when handling drill collars, unscrew the front nuts and push the guide back, out of the way. Adjusting Nuts

Stabbing Guide

1-17

General Information

Operating the ST-80 Adjusting torque gauge responsiveness

1

Adjust the needle valve on the torque gauge until the gauge reacts with the desired response speed.

Needle Valve Torque Gauge

1-18

General Information

Storing the ST-80 Palletize the ST-80 for indoor storage. A cargo container is appropriate for indoor or outdoor storage. Avoid wide temperature and humidity variations. The ideal environment for storing the ST-80 is clean and dry with an ambient temperature of 60°F (16°C). If high humidity is unavoidable, Varco recommends storing the ST-80 at 70°F (21°C). All exposed, unpainted metal surfaces are coated with rust preventive at the factory prior to shipment. Coat all unpainted metal surfaces with rust preventive prior to storage or transport. Cover all openings to prevent water or dust from entering. Varco does not recommend using silica or dehydrating agents. When the ST-80 is not being used for more than 3 months, perform the following: 1. Clean the ST-80. 2. Grease the ST-80 as described in the Maintenance section of this manual. 3. Clean and cap all hydraulic quick disconnects (QDs).

i

Varco recommends Kendall Grade 5 (GE-D6C6A1) rust preventive, or an equivalent.

!

Replace the shipping pin prior to storage and/or moving the ST-80.

1-19

1

General Information

1

1-20

Specifications

Specifications

General specifications ....................................... 2-3 Hydraulic requirements ................................................. 2-4

1

Wrench assembly .......................................................... 2-4 Shipping data (approx., allowing for crate/palette) ........ 2-4

2

3

4

2-1

Specifications

Specifications

1

2 2

3

4

2-2

Specifications

General specifications

59.0

62.8

2

95.6

33.2

80.0

51.3

2-3

Specifications

General specifications Hydraulic requirements

2

Hydraulic operating pressure (max.)

2,600 psi

Hydraulic operating pressure (min.)

2,000 psi

Hydraulic flow rate required (min.)

28 gpm @ 1000 psi

Hydraulic flow rate required (max.)

40 gpm (150 l/min)

Supply connections (min.)

1" JIC

Return connections

1 1/4" JIC

Motor spinning roller ratio

2:1

Spin speed (rollers)

190 rpm

Spin speed (8 1/2" pipe)

90 rpm

Make up torque

60,000 ft lb max.

Break out torque

80,000 ft lb max.

Wrench assembly

Shipping data (approx., allowing for crate/palette)

2-4

Height

88"

Width

60"

Depth

65"

Weight

6,800 lb

Maintenance

Maintenance

Lubricant specifications..................................... 3-3 Selecting a lubricant ...................................................... 3-3

1

Recommended general lubricants ..................................... 3-3 Recommended hydraulic fluids ......................................... 3-3 Inspection and lubrication ................................. 3-4 Inspecting hardware and fittings .................................... 3-4

2

Lubricating the ST-80 .................................................... 3-4 Disassembly and assembly ................................ 3-6 Precautions ................................................................... 3-6

33

Changing dies ............................................................... 3-7

4

3-1

Maintenance

Maintenance

1

2

3

4

3-2

Maintenance

Lubricant specifications Selecting a lubricant Use the following two tables to select the appropriate lubricant for your specific application.

Recommended general lubricants Ambient Temperature Range Below -20˚ C

Above -20˚ C

(Below -4˚ F)

(Above -4˚ F)

N/R

MP Grease

Avi-Motive W

Avi-Motive

Lidok EP1

Lidok EP2

Manufacturer Castrol Chevron Exxon

Gulf Crown EP31

Gulf Crown EP32

Mobil

Mobilux EP1

Mobilux EP2

Shell

Alvania EP1

Alvania EP2

Statoil

Uniway EP1N

Uniway EP2N

Texaco

Gulf

Multifak EP1

Multifak EP2

Total

Multis EP1

Multis EP2

Union

Unoba EP1

Unoba EP2

1

2

3

Viscosity Index NGLI

Recommended hydraulic fluids Oil Temperature Range -15˚ to 75˚ C

-10˚ to 85˚ C

(5˚ to 167˚ F)

(14˚ to 185˚ F)

Hyspin AWS-32

Hyspin AWS-46

AW Hyd oil 32

AW Hyd oil 46

Nuto H32

Nuto H46

Harmony 32AW

Harmony 46AW

DTE 24

DTE 25

Manufacturer Castrol Chevron Exxon Gulf Mobil

Tellus 32

Tellus 46

Statoil

Hydraway HMA 32

Hydraway HMA 46

Texaco

Rando oil HD32

Rando oil HD46

Total

Azolla ZS 32

Azolla ZS 46

Union

Unax AW32

Unax AW46

32

46

Shell

Viscosity Index ISO Viscosity Grade

3-3

Maintenance

Inspection and lubrication Inspecting hardware and fittings Visually inspect the ST-80 for loose or missing hardware and fittings daily. Make sure all safety wire is undamaged. Check the inline pressure filter daily. Replace as necessary if the indicator is red.

Lubricating the ST-80 The lubrication intervals described in this manual are based on lubricant supplier recommendations. Severe conditions such as extreme loads or temperature, corrosive atmosphere, etc., may require more frequent lubrication.

3

Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more frequent lubrication is necessary. Be careful not to over lubricate parts. For example, too much grease forced into a fitting can pop out a bearing seal. Over lubrication can also affect safety since over lubricated parts can drip, creating a potential slipping hazard for personnel. Apply grease daily to all grease fittings as shown on the following page.

3-4

Maintenance

Inspection and lubrication Inline Pressure Filter Replace if indictor is red Daily Grease Fitting 1 each side

Motion Control Brush mating surfaces with grease Daily

Daily Grease Fitting 1 each side Daily

3

Daily Grease Fitting 2 each side Daily Grease Fitting 1 each side

Daily Grease Fitting 1 each side

Daily Grease Fitting

3-5

Maintenance

Disassembly and assembly Precautions

3

!

Only authorized Varco repair technicians should perform the following major disassembly and assembly procedures.

!

Transport hydraulic components to a clean, dust-free service area before disassembling for service.

i

Disassemblypr ocedur esar eusuallyper for medwhenr eplacing damagedcomponentsthatar ecausingatoolfunctiontofail. Wheneverper for mingadisassembly ,practicepr eventive maintenanceby:

!

❏

Cleaning and inspecting all disassembled parts.

❏

Replacing all worn and damaged parts before they can cause another failure.

❏

Installing thread protectors on exposed threads.

Tor queallfastenerstothelimitsgiveninDS00008(Design SpecificationDesignT or queStandar d)unlessanalter valueisgiveninthepr ocedur e.

nativetor

que

Release all hydraulic oil pressure before disconnecting hydraulic lines. Hydraulic oil under pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean the work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.

3-6

Maintenance

Disassembly and assembly Changing dies Use the following procedure to replace upper and lower dies:

Carriage Assembly

Replacing upper dies 1. Remove the 2 screws holding each die. Replacing lower dies 1. Remove the 2 screws on each die holder. 2. Screw in the set screws forcing the die holder out. 3. The die will now slid from the die holder.

! Caution the die can slip out of the die holder once its free of the housing.

Upper Die 1 each side

Screw 2 each side

Set Screw 2 each side Die Holder 1 each side Lower Die 1 each side

Screw 2 each side

3-7

3

Maintenance

3

3-8

Troubleshooting

Troubleshooting

Troubleshooting the ST-80 ................................. 4-3 Theory of operation ....................................................... 4-4

1

2

3

4

4-1

Troubleshooting

Troubleshooting

1

2

3

4 4

4-2

Troubleshooting

Troubleshooting the ST-80

i

When testing the ST -80 without pipe , reduce the o verall pressure setting to 250 psi.

Make sure all hydraulic lines are isolated and the ball valve is closed before ANY work is carried out on the ST-80. When troubleshooting the ST-80, make sure the hydrualic pressure is between 2,000 and 2,600 psi at the inlet of the manifold. Check the back pressure of the tank line (make sure the pressure does not exceed 30 psi). Make sure that all hoses and QDs are properly connected. Check to see if oil leakage is visible at the manifold, QDs or hoses. Make sure the tool is lubricated per the Maintenance section of this manual. Refer to the theory of operation and schematic when troubleshooting specific ST-80 components or functions.

4-3

4

Troubleshooting

Troubleshooting the ST-80 Theory of operation (((TBD Engineering will supply when Hydraulic Schematic is released)))

4

4-4

Troubleshooting

Troubleshooting the ST-80 (((TBD Hydraulic Schematic in revision)))

4

4-5

Troubleshooting

4

4-6