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User Manual

ST-120 – Iron Roughneck

Customer References Customer: Central Panuco Rig / Hull: Uxpanapa Tag Number: N/A

National Oilwell Varco References: SO Number / Project Number: 194415/SO-190787 Document Number: 10862028-MAN Revision: 01 Volume: 1

www.nov.com

Document number Revision Page

10862028-MAN 01 2

REVISION HISTORY

01

08.01.2016

Rev

Date (dd.mm.yyyy)

For Information

CHANGE DESCRIPTION Revision 01

Change Description Initial Release

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Reason for issue

I. Vargas Prepared

L. Krajenbrink Checked

J. Adkins Approved

TABLE OF CONTENTS

Document Number:

10862028-MAN TOC

Revision:

01

Page:

1

Vol.

Chapter/ Section

Title

1

1

General Information

1

2

Installation, Operation, & Maintenance

1

2.1

Procedures

1

2.2

Spare Parts List

1

3

Technical Documents & Drawings

1

3.1

General/Mechanical Drawings

1

3.2

System/Process Diagrams

1

3.3

Electrical/Instrument

1

3.4

Performance Data

Section Not Applicable

1

4

Vendor Documentation

Chapter Not Applicable

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Remarks

TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

1

General Information

ST-120 Auto Functional Design Specification

Document Number:

10862028-MAN TOC 1

Revision:

01

Page:

1

Document Number

Rev.

D364000049-SPC-001

04

ST-120 Auto Functional Design Specification

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. 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 NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.

CURRENT DRAWN CHECKED APPVD DATE

TITLE

ST-120 AUTO

INITIAL

A. JONES

B. WINTER

J. WALKER

J. WALKER

A. JONES

B. WINTER

10/30/2013

3/5/2008

Functional Design Specification SIZE

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TABLE OF CONTENTS TABLE OF CONTENTS ...........................................................................................................................2 TABLE OF FIGURES ...............................................................................................................................4 OVERVIEW ..............................................................................................................................................5 SPECIFICATIONS ...................................................................................................................................7 FEATURES ..............................................................................................................................................9 Head Functions Manual Pilot Controls ...................................................................................................................................................... 9 Arm Functions Manual Pilot Controls ..................................................................................................................................................... 10 Electric Controls......................................................................................................................................................................................... 10 Wireless Operator Controls ...................................................................................................................................................................... 11 Thread Compensation ............................................................................................................................................................................... 11 Tool Joint Sensing ...................................................................................................................................................................................... 11 Slow Mode ................................................................................................................................................................................................... 12 Service Loop ............................................................................................................................................................................................... 12

OPERATION .......................................................................................................................................... 12 Configuration Setup ................................................................................................................................................................................... 13 General Operation ..................................................................................................................................................................................... 13 Manual vs. Maintenance Mode ................................................................................................................................................................. 14 Interlocks .................................................................................................................................................................................................... 14

ELECTRICAL COMPONENTS .............................................................................................................. 16 Feedback Devices ....................................................................................................................................................................................... 16 E-STOP ....................................................................................................................................................................................................... 17

PERFORMANCE ................................................................................................................................... 17 Arm Travel ................................................................................................................................................................................................. 17 Slewing ........................................................................................................................................................................................................ 18 Required User Defined Input .................................................................................................................................................................... 18 SIZE

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Spin Wrench Spinning in and Spinning Out ........................................................................................................................................... 18

INITIAL SETUP ...................................................................................................................................... 19 Rig Floor Setup ........................................................................................................................................................................................... 19 Arm Extend Adjust Procedure (Auto) ..................................................................................................................................................... 19 Torque Set Procedure (Auto): ................................................................................................................................................................... 19 Torque Set Procedure (Manual Procedure): ........................................................................................................................................... 19

OPERATING PROCEDURES ................................................................................................................ 20 Makeup Sequence (Manual-Electric) ....................................................................................................................................................... 20 Break Out Sequence (Manual-Electric) ................................................................................................................................................... 21 Auto Sequence Matrices ............................................................................................................................................................................ 23

ST-120 FUNCTIONS .............................................................................................................................. 26 Multi-Valve Section Mounted on Head Unit ............................................................................................................................................ 26 Multi-Valve Section Mounted on Carriage .............................................................................................................................................. 26

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TABLE OF FIGURES

Figure 1. Basic components of ST-120.....................................................................................................5 Figure 2. Upper/lower wrench and torque cylinders..................................................................................6 Figure 3. Torque wrench positions............................................................................................................6 Figure 4. ST-120 controls layout for spin wrench and torque wrench functions ........................................9 Figure 5. ST-120 controls layout for arm functions .................................................................................10 Figure 6. Wireless Controller ..................................................................................................................11 Figure 7. ST-120 Hydraulic Service Loop Interface ................................................................................12 Figure 8. ST-120 torque adjustment knob ..............................................................................................20

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OVERVIEW The ST-120 is the next generation of Iron Roughnecks featuring improved tubular handling capabilities and increased operating efficiency. Figure 1 below outlines the basic components which make up the ST-120.

Column

Carriage Raise/ Lower Cylinder

Extend/Retract Cylinder

Arm Spin Wrench

Slew Motor/Brake Socket Torque Wrench

Figure 1. Basic components of ST-120

The ST-120 torque wrench is capable of making and breaking connections at 100,000 ftlbs and 120,000 ft-lbs, respectively, and handles tool joint connections ranging from 3-7/8” to 10” outer diameter. Each torque wrench consists of a three cylinder clamping system. The upper and lower torque cylinders operate in series, giving the ST-120 a full 60 degrees of rotation. The upper torque wrench rotates 30 degrees either direction of center, while the lower torque wrench remains stationary. The clamping circuit is “dynamic”, in that the clamping pressure increases as the torque setting is increased. This is controlled automatically through the hydraulic system and requires no input from the user, other than the desired torque setting. Figure 2 identifies the upper and lower wrench and the pair of the torque cylinders.

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Figure 2. Upper/lower wrench and torque cylinders

Figure 3 below is an illustration of the different positions of the torque wrench. The wrench center position is how the torque wrench is oriented in home. The torque wrench must be in the wrench center position before the tool is extended to or retracted from the drill pipe. Since the torque wrench can rotate 30 degrees either direction from the wrench center position, it is not necessary on smaller drill pipe connections to rotate the upper wrench to the makeup or breakout positions for a makeup or breakout cycle. For larger connections, or connections requiring high torque, the operator should take advantage of the full 60 degrees rotation to reduce makeup/breakout time. This can be accomplished by beginning a high torque operation in either the breakout ready or makeup ready position, depending on the operation to be performed.

Figure 3. Torque wrench positions SIZE

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SPECIFICATIONS Performance Tool Joint Diameter Tubular Types

Max. Torque Wrench Connection Height Max Spin Wrench Height Travel Cycle Time Service Loops Variable Clamp Force

3-7/8” to 10” OD. Tools to be defined specifically by Customer to ensure performance of ST-120 to Customer’s desires 75.4” [1,915 mm] from top of rotary 144.9” [3,680 mm] from top of rotary table Sufficient to move clear of Well Center and/or multiple Foxhole®/Mousehole locations. 38 second complete travel and connection time (assumes 120” travel and skilled operator) Required length to rear of column Clamp force varies proportionally to torque setting

Instrumentation Torque Readout Vertical Position Deploy Position Position Accuracy

Ft-lbs Torque wrench relative to datum position Position relative to datum Positive position to +/-10mm at datum

Physical Specification As Shipped Maximum Height: Width: Depth: ST-120 Weight: Service Loop Kit Weight: Floor Socket Weight:

104.3” [2,649 mm] fully lowered 64.5” [1,638 mm] 93.4” [2,372 mm] fully retracted 20,500 lbs [9,298 kg] tool only 200 lbs [90 kg] 1,200 lbs [544 kg]

Service Requirements Hydraulic operating pressure min: Hydraulic operating pressure max: Hydraulic flow rate min: Hydraulic flow rate max: Pneumatic Utilities required: Electrical Utilities required:

2,500 psi [172 bar] 3,000 psi [207 bar] 45 gpm [170 lpm] 65 gpm [246 lpm] None Provided from ST-120 Control System

Spin Wrench Minimum pipe size capacity: Maximum pipe size capacity: Open width: Number of spinner motors: Spin speed: Number of driven rollers: Spin-in speed max (6-5/8" DP): Spin-out speed max (6-5/8" DP): Spin-in torque at stall: Spin-out torque at stall:

3-1/2" (drill pipe) 10" (drill collar) 12" [304 mm] roller to roller 4 80 rpm nominal on 5” drill pipe 4 60 rpm 60 rpm 3,000 ft lb [4,067 Nm] nominal on 5" drill pipe 3,000 ft lb [4,067 Nm] nominal on 5" drill pipe SIZE

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Torque Wrench Minimum pipe size capacity: Maximum pipe size capacity: Makeup torque (maximum): Breakout torque (fixed): Torque range adjustable: Clamp force adjustable: Degrees of rotation: Length of stroke (torque): Length of stroke (clamp): Cylinder bore (torque): Cylinder bore (clamp):

3 7/8” tool joint OD 10" (drill collar) 100,000 Ft-lb [135,582 Nm] 120,000 Ft-lb [162,698 Nm] Yes A function of Torque setting 60° 10" [254 mm] 4.5" [114 mm] 5" [127 mm] 7" [178 mm]

Horizontal Movement Deploy type: Number of deploy cylinders: Arm Speed:

Hydraulic 2 12”/sec [0.30 m/sec.], nominal

Vertical Movement Drive type: Number of cylinders: Vertical movement: Up Speed: Down Speed

Hydraulic 1 42" [1,067 mm] 5"/sec [127 mm/sec] nominal 7"/sec [127 mm/sec] nominal

Main materials of construction (Type and grade) Main body: MS 00001 Grade 150-135 (similar to 4320) Torque Wrench die holders: 4130/4140 Steel Torque Wrench die: 8620 Steel Spinner rollers: 4140 Steel Cylinders Body: Piston: Rod: Seals: Hydraulic tube: Hydraulic tube/hose fittings:

ASTM A36 Steel ASTM A36 Steel 17-4 PH, chrome plated BUNA-N Stainless steel Cadmium-plated steel

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FEATURES The ST-120 auto version is equipped with manual and electric controls. In the event of an electrical issue that hinders the use of the electronic controls, the ST-120 can still be operated manually via local control. This may need to be installed on the tool as it is shipped separately on the auto version. Head Functions Manual Pilot Controls The ST-120 is controlled via manually actuated pilot valves that directly act on main stage hydraulic spool valves. All valves are spring returned center with no detent position. Figure 4 below shows the controls layout for the spin wrench (SW) and torque wrench (TW) functions.

Figure 4. ST-120 controls layout for spin wrench and torque wrench functions

The controls are identified from left to right as shown in the picture above: 1. TW Unclamp/Clamp – Unclamps and clamps the upper and lower torque wrench jaws. 2. TW Break/Make – Rotates the upper wrench relative to the lower wrench, to breakout or makeup the drill pipe. 3. Mode Center/SW – Centers the upper torque wrench relative to the lower torque wrench in the wrench center position as shown in Figure 3. SW represents Spin Wrench Mode which retracts the upper jaws only. Also when Spin Wrench Mode is activated, it prevents the upper jaws from closing when TW Clamp is activated. 4. SW In/Out – Rotates the spin wrench rollers clockwise or counterclockwise. 5. SW Unclamp/Clamp – Unclamps and clamps the spin wrench from the drill pipe. 6. SW Up/Down – Raises and Lowers the spin wrench relative to the torque wrench. SIZE

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Arm Functions Manual Pilot Controls The arm functions are controlled with the lower row of manual pilot controls. Figure 5 illustrates the controls layout for the arm functions.

Figure 5. ST-120 controls layout for arm functions

The manual pilot controls are identified from left to right as shown in the picture above: 1. Carriage Up/Down - Raises and lowers the carriage relative to the column 2. Deploy Retract/Extend – Extend/Retracts the arm in and out 3. Slew Left/Right – Rotates the entire ST-120 clockwise or counterclockwise The rear of the tool is equipped with a hydraulic pressure gauge for monitoring system pressure, a ball valve for shutting down pressure to the tool, and a manual/auto enable switch. When manual is selected, the wireless remote functionality is disengaged and the manual pilot controls can be operated at the front of the tool. When auto is selected, the wireless controls can be used and the manual pilot controls are disengaged. Electric Controls The ST-120 comes standard with Amphion SBC or Cyberbase PLC controls. The wireless remote controls will be the standard controls for the ST-120 Auto model and the wireless controller will have the same “manual” features as the manual pilot controls. The ST-120 may also be controlled via the driller’s chair.

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Wireless Operator Controls The auto version of the tool is equipped with a wireless remote control. From the wireless controller, the tool can be operated manually or in auto sequence mode. The wireless remote is equipped with an e-stop and an on/off switch. It is also equipped with a digital screen for displaying torque, setup messages, and warnings/alerts. The wireless control box can be carried by the user (lap belt).

Figure 6. Wireless Controller

Thread Compensation The spin wrench lift circuit is equipped with a nitrogen-charged accumulator which allows the spin wrench to travel with the drill pipe while spinning in and out. Before a makeup cycle, the spin wrench must be elevated at least six inches so the accumulator can compensate for pipe travel. The spin wrench automatically elevates to the proper level for drill pipe when in AUTO mode. Tool Joint Sensing The tool joint length must be entered by the user, similar to procedures for the AR series Iron Roughnecks. The tool joint sensor is mounted on the bottom of the torque wrench, and a relationship between the tool joint center and the location of the tool joint sensor must be developed. To do this using the Auto Sequence, the tool will start off completely lowered and retracted. Next, the arm will extend to the drill pipe. Once at the drill pipe, the tool joint sensing device will contact the drill pipe normal to the surface. As the ST120 is raised at 5 inches per second nominal, the tool joint device will depress (once in contact with the drill pipe upset), thus disengaging a proximity switch. The tool joint location will be known based on a preprogrammed tool joint length entered by the user and the “snapshot” value of the carriage up/down linear transducer. The software adjusts the vertical height of the roughneck accordingly so that the make/break sequence can begin. SIZE

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Slow Mode The spin wrench speed is proportionally controlled to reduce speed by half while spinning in drill collars. Acceleration is ramped accordingly to prevent slipping while spinning in connections. Service Loop The hydraulic service loop is kept close to the drill floor and does not travel with the ST120 as it moves up/down and in/out. The service loop does need space to coil such that the tool is free to rotate +/- 90 degrees from center. Hydraulic requirements for the ST120 are 45GPM at 2500psi minimum, 65GPM at 3000psi maximum. The hydraulic service lines are 1” pressure, 1-1/4” return, and ½” drain as seen in Figure 6. The electric service loop location is on the left side of the tool and moves with the carriage as it raises and lowers. The electric service loop consists of 4 cables (one profibus cable, one 37 conductor cable, one 24 twisted shielded pair cable, and one single conductor ground cable) bundled together in a protective wrap.

Drain Supply Return Figure 7. ST-120 Hydraulic Service Loop Interface

OPERATION The Amphion control system provides interfaces for both Wireless and Remote (Cabin) operator control stations. If an Amphion or Cyberbase chair is provided, the ST-120 may also be controlled from the chair. The Amphion system facilitates operator control input for the following functions:  Turn the ST-120 on and off. (For an HMI take ownership)  Override Interlocks. (Most interlocks can be overridden)  Operate the ST-120 for maintenance / emergency. (Ignore all interlocks)  Manually opening and closing the torque wrench  Manually rotating the torque wrench to make up and break out positions  Manually opening and closing the spin wrench SIZE

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           

Manually rotating the spin wrench rollers to spin pipe in and spin pipe out Manually hoisting and lowering the main carriage Manually hoisting and lowering the spin wrench carriage Manually extending and retracting the arm Manually slewing the ST-120 clockwise and counterclockwise Initiating and continuing semi-automatic sequences Setting / selecting tool joint lengths. Any tool joint length from 0" (manual positioning) to 26" can be preset. The operator presets the tool joint length so that the ST-120 can find the tool joint during an automated sequence. Setting the ST-120 to work with power slips (specifically PS16). When a power slip is being used the ST-120 can adjust its main carriage height to clear the power slip at well center. Setting the ST-120 to backup a Top Drive up to 20,000 ft-lbs. The ST-120 can hold backup torque for a Top Drive when drilling ahead. The ST-120 will keep the string from spinning down hole. Setting the ST-120 to backup for spinning. The ST-120 can hold its own backup for making and breaking tubulars at a Foxhole® /Mousehole where no backup is provided. Teaching the ST-120 to locate up to three different programmable hole destinations. Selecting destination, setting trip mode, setting torque, selecting normal or slow mode.

Configuration Setup The following configuration and setup functions are available with every ST-120:  Deploy Linear Transducer Calibration - synchronizes deploy physical position and transducer  Spin Wrench Carriage Linear Transducer Calibration - synchronizes Spin Wrench physical position and transducer  Main Carriage Linear Transducer Calibration - synchronizes Main Carriage and transducer  Torque Meter Calibration - synchronizes torque and analog pressure transducer  Setup Home Position - home / home deploy  Setup Duck Position - overhead obstructions deploy and “duck” height are fixed  Setup Well Center Position – Sets arm deploy distance and slew position for Well Center position.  Setup Foxhole®/Mousehole Positions - Sets arm deploy distance and slew position for Foxhole®/Mouseholes  Slew encoder calibration General Operation General operation of the ST-120 is defined as (sequenced) semi-automatic or manual. When operated manually, the operator is in constant control of the ST-120 through use of switches or joysticks. Semi-automatic sequences are initiated by and require minimum input from the operator. All operations are initiated from either the Wireless Operator Controls or through the driller’s chair. All operations without limitations can be performed from either location but only one station can be in control at any one time. The ST-120 operates at a hydraulic pressure setting of 2,500 psi. (172 bar). Integrated sensors and interlocks enable the tool to perform several functions sequentially. SIZE

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Manual vs. Maintenance Mode Manual control of the ST-120 via the wireless controller requires operator initiation of all functions. While in manual control all interlocks are functional to prevent inadvertent damage to the equipment. Most interlocks can be overridden, exceptions are opening the torque wrench and spin wrench at the bottom and top end of stroke. As the name implies Maintenance Mode operation of the ST-120 is enabled via operator’s screen for ST-120 integrated into the rig’s control system or via a keyed switch located on the control station box for a standalone ST-120. No interlocks are enforced in this mode as this type of operation is intended to be used for maintenance and emergencies only. Interlocks Integrated sensors and interlocks enable the ST-120 to perform several functions when either in manual (serial) or semi-automatic (sequentially) without operator intervention. Interlocks also prevent an operator from inadvertently initiating inappropriate operating sequences. A general list of interlocks is as follows: 1. Torque Wrench / Spin Wrench Clamp Interlock – If the torque wrench and/or the spin wrench are clamped on the drill pipe, the following will be disabled: arm extend/retract, slew left/right, main carriage up/down, spin wrench clamp up/down (only when spin wrench is clamped on drill pipe). A combination of pressure transducers and timer enables the control system to detect the clamp/unclamp state of the torque wrench and the spin wrench. 2. Non Driven Motion Interlock – If the carriage up/down linear transducer changes in value while the torque wrench and/or spin wrench is clamped on drill pipe, all torqueing functions will cease immediately and the torque wrench jaws and spin wrench will be unclamped immediately. This will aid to protect the tool from damage, as in the case when the driller inadvertently lifts the drill pipe via the drawworks, or the drill pipe slips in the slips. 3. Slewing Interlock - The slew function is interlocked when the arm is extended beyond 18 inches. This is to protect the slewing system and ensure that the arm does not “run-away” when trying to bring it to a stop, i.e. listing drill ship/semisubmersible. The control system looks at the arm linear transducer to determine the arm position. 4. Spin Wrench Clamp Interlock – The up/down adjustment of the spin wrench is disabled while the spin wrench is clamped. The control system utilizes timers to detect the clamp and unclamp state of the SW. 5. Torque Sequence Interlock – This interlock does not allow the torque sequence to begin until the clamp pressure has reached a steady state (about 75% of intended clamp pressure). If the drill pipe is off center in the torque wrench, two of the three dies may make contact first giving the operator a false impression that the dies are seated. The third die still needs to make contact. Once all dies have contacted the drill pipe, the intensifier must be given time to increase the clamp pressure to the proper level which usually takes less than two seconds. The clamp pressure transducer will monitor clamp pressure and will not allow the operator to torque until the clamp pressure has reached a steady state. 6. Wrench Center Interlock – When the torque wrench is not centered, the arm cannot be deployed. The two proximity sensors located on the torque wrench and the end-ofSIZE

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stroke pressure transducer allows the control system to know if the torque wrench is centered or at either full makeup or breakout position. 7. Unclamp Interlock – The jaws cannot be unclamped from the drill pipe unless the make/break function has been de-energized. This will minimize damage to the dies and scaring of the drill pipe. 8. Carriage Interlock – When the ST-120 is fully raised or fully lowered, the jaws cannot be clamped on the drill pipe. The control system monitors the location of the carriage through the carriage linear transducer mounted in the column. See bullets about nondriven motion in the following scenarios: spin wrench carriage and main carriage. 9. Safety Curtain and Bumper Interlock – All functions are disabled when the safety curtain (laser beam) is broken or/and when the safety bumper is depressed with a force greater than three pounds. See E-stop section for instructions on re-activating the ST-120 after a safety curtain or bumper interlock. If the Spin Wrench is closed;  The ST-120 is not allowed to deploy forward or reverse or slew  The Main Carriage is not allowed to hoist or lower  The Spin Wrench Carriage is not allowed to hoist or lower  And if the ST-120 detects non-driven motion of more than 1” up or down, or reaches the Carriage Interlock at the end of stroke, the Spin Wrench will be forced open (Note: End of stroke detection forcing the SW open is NOT override-able) If the Torque Wrench is closed;  The ST-120 is not allowed to deploy forward or reverse or slew  The Main Carriage is not allowed to hoist or lower  And if the ST-120 detects non-driven motion of more than 1” up or down, or reaches the Carriage Interlock at the end of stroke, the Torque Wrench will be forced open (Note: End of stroke detection forcing the TW open is NOT override-able) If the ST-120 has been taught that an Overhead Obstruction Exists;  The Main Carriage is not allowed to hoist into the obstruction  And if the ST-120 is above the obstruction height the ST-120 is not allowed to deploy forward or reverse (Note: Normal operation of the forward or reverse command will activate main carriage lower until the ST-120 is clear of the obstruction, then it will deploy) If the ST-120 has been set to work with Power Slips;  The Main Carriage is not allowed to lower into the power slips  And if the ST-120 is below the power slips height the ST-120 is not allowed to traverse forward into the power slips area (Note: Normal operation of the forward or reverse command will activate main carriage hoist until the ST-120 is clear of the power slips, then it will deploy) If the ST-120 has been set to backup torque from a Top Drive;  The Spin Wrench is not allowed to close  The upper jaws of the Torque Wrench are not allowed to close If the ST-120 has been set to backup for spinning;  The Upper Torque Wrench Jaw will not close SIZE

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If the ST-120 has not been initialized;  None of the automated sequences will be allowed to start (Note: Initialization of the ST-120 means that all mechanical components of the ST-120; deploy, Torque Wrench & Spin Wrench carriages and Torque Wrench & Spin Wrench bodies have been moved and monitored and their current positions and status are known by the control system. See operator’s manual for initialization instructions.) If the ST-120 is performing an automated sequence;  And any ZMS Interlock is received, the sequence will be aborted.  And the non-driven motion interlock is received on main carriage, the sequence will be aborted, and the torque wrench and spin wrench will open if clamped. If the ST-120 is performing any movement;  And a ZMS Interlock is received that is directed at that movement, the movement will be aborted In addition to interlocks, the ST-120 will automatically stop movement when it has reached its preset travel point destinations, when the main carriage or spin wrench carriage reaches its high or low limits, and when input from the operator is required during auto sequence. If the system is not properly configured or not fully powered up prior to attempting operation, an appropriate message will be displayed. However, this may simply be information to the operator and not an interlocking condition. ELECTRICAL COMPONENTS Feedback Devices 1. Deploy Extend/Retract Linear Profibus Transducer – Provides position feedback for arm horizontal travel 2. Carriage Up/Down Linear Profibus Transducer – Provides position feedback for arm vertical travel 3. Spin Wrench Up/Down Linear Profibus Transducer – Provides position feedback for Spin Wrench vertical travel 4. Slew Left/Right Profibus Encoder – Provides position feedback for slewing 5. System Pressure Transducer – Provides pressure feedback for system pressure 03000 psi 6. Makeup/Breakout Pressure Transducer – Provides pressure feedback to determine full make up or breakout position (via pressure at end of stroke), 0-3000psi 7. Torque Pressure Transducer – Provides pressure feedback for applied torque, 0-3000 psi 8. Clamp Pressure Transducer – Provides pressure feedback for applied clamp, 0-6000 psi 9. Hydraulic Override Pressure Transducer – Provides feedback to determine if tool is being controlled by manual pilot controls. 10. Torque Wrench Proximity Sensors – Two proximity sensors provide location feedback for the upper torque wrench, i.e. wrench center, makeup ready and breakout ready locations.

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11. Tool Joint Proximity Switch – One proximity sensor provides feedback of when a tool joint is sensed. 12. Safety Curtain and Bumper Sensors – Provides feedback to shut down the tool for safety when the safety curtain beams are broken or safety bumper is pressed. 13. Flow Switch – Provides feedback for determining if any functions are consuming flow which signifies an operation is occurring. When the flow switch senses no flow, it signifies operation have completed. E-STOP Three E-STOP buttons are located on each side of the tool. One is located at the rear of the tool on the junction box and two are at the front of the torque wrench on the left and right side of the torque wrench. Another E-STOP button is located on the wireless controls. In addition to the E-stops is a light curtain on the left and right sides of the tool. The transmitter/receiver is mounted to the main carriage and transmits a signal to a reflector mounted on the torque wrench. If at any time the beam is interrupted, the tool will be shut down. There is also a safety bumper located on the secondary lower arm, that when activated, can shut down the tool as well. When the light curtain or the safety bumper is used to stop the tool, to restart operation, any of the e-stop mounted on the tool will have to be recycled by depressing and pulling the e-stop before the tool can be operational. PERFORMANCE Arm Travel The operator can store three operating locations for positioning of the ST-120. They are as follows: 1. Home Position - This position is set by the operator, and is assumed to be set where the tool is retracted away from wellcenter/foxhole clear of other drill floor equipment. There is a specific Home Position for each destination, i.e, for wellcenter and each Foxhole. 2. Well Center – This position is preset by the operator 3. Foxhole 1 – This position is preset by the operator 4. Foxhole 2 – This position is preset by the operator The velocity of the arm will be ramped when starting from a stationary position. It also ramps down the velocity of the arm upon approach of its destination(extended or retracted). Ramping the extend/retract commands will ensure smooth operation and that the ST-120 reaches the preset operating position precisely every time without undershoot or overshoot. The arm velocity is to be set at a nominal 1 foot per second.

SIZE

DWG NO

A SCALE

REV

D364000049-SPC-001 NONE

WT LBS

SHEET

17

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DCF0045 (REV B)

Slewing The ST-120 can be rotated about the center of the column via a hydraulic slewing motor. The slew system consists of a motor, spring applied-hydraulic release brake, and a gearbox. When the slewing function is actuated, the brake is hydraulically released and the ST-120 will begin to slew in the desired direction, clockwise (CW) or counterclockwise (CCW). When the function is released, the ST-120 will stop slewing and the brake will set. Maximum slewing speed is set at one revolution per minute, though the speed can be proportionally controlled between zero and one revolution per minute. As viewed from facing the control panel, activating the SLEW-CW function rotates the tool clockwise, and activating the SLEW-CCW function rotates the tool counter-clockwise. The slew encoder is mounted atop the hydraulic slew motor. Up to three slewing positions are stored by the user; wellcenter, foxhole 1, and foxhole 2. The slewing speed will be reduced to a slower speed (less than 1 RPM) when arm is extended beyond home position (Do note that the slew interlock will have to be overridden to slew when the arm is extended beyond home position. Slew speed is ramped at both acceleration and deceleration to ensure precise control and smooth operation. Required User Defined Input The user will be required to input the following information for the ST-120: 1. Torque setting 2. Wellcenter Destination (requires set value from arm extend/retract linear transducer and slewing encoder) 3. Foxhole 1 Destination (requires set value from arm extend/retract linear transducer and slewing encoder) 4. Foxhole 2 Destination (requires set value from arm extend/retract linear transducer and slewing encoder) 5. Home Position (requires set value from arm extend/retract linear transducer and slewing encoder) 6. Tool Joint Length (for tool joint sensing) 7. Slow Mode – this mode reduces spin speed of the spin wrench rollers by exactly half (from 80 rpm to 40 rpm) for drill collars and HT/XT drill pipe 8. Slips Mode 9. Tool Mode(Includes spin wrench mode, TDS backup mode and normal mode)

Spin Wrench Spinning in and Spinning Out During the auto sequence, the spin wrench will sense when the drill pipe is shouldered, and when the drill pipe is spun out. During spinning in, the feedback from the spin wrench linear transducer will be monitored. When a change in position is no longer detected and no flow is detected on the flow switch, the spin wrench will stop. When the spin wrench is spinning out the connection, the spin wrench will stop spinning when there is no longer a change in elevation and when a bump is detected, i.e. on the last thread. A combination of timer and linear transducer position feedback is used to determine when then fully spun out or fully shouldered state of a tool joint.

SIZE

DWG NO

A SCALE

REV

D364000049-SPC-001 NONE

WT LBS

SHEET

18

04 OF

26

DCF0045 (REV B)

INITIAL SETUP Rig Floor Setup For optimum performance, the ST-120 should be positioned on the drill floor at a minimum 140” away from Well Center and/or Foxhole and a maximum of 190”. The ST120 should be secured to the drill floor and supporting structure should be of sufficient strength for the loading information given. Please reference the appropriate ST-120 GA drawing for reference dimensions, weights, rig floor loading, and rig floor layout. Arm Extend Adjust Procedure (Auto) To align the ST-120 to a tubular (wellcenter, foxhole 1, foxhole 2), the following must be performed: 1. Extend the arm until the drill pipe is centered in the wrench opening using the EXTEND function

2. Once the tool is centered on the drill pipe, the operator will store this location. Values from the slew encoder and deploy linear transducer will automatically be stored for each location. 3. If a new location is desired, i.e., foxholes 1 and 2, repeat steps 1 thru 2 Torque Set Procedure (Auto): The ST-120 is equipped with a two way valve at the rear of the tool which when turned to the “AUTO” position, will bypass the setting of the manual relief valve mounted on the manual pilot controls box and allow the torque pressure to be set via the wireless controls. The user will dial in the torque using the INCREASE/DECREASE switch while holding the TORQUE ADJ switch to which the torque value will be displayed on the digital display. Torque Set Procedure (Manual Procedure): The ST-120 is equipped with a two way valve at the rear of the tool that when turned to the “MANUAL” position, it will bypass the setting on the wireless remote and allows the torque pressure to be set via the manual pilot controls box. To adjust the torque setting, perform the following: 1. Turn the adjustment knob, shown in Figure 7, located on the main control panel counterclockwise (decrease) until it stops 2. Verify that the torque gauge reads zero SIZE

DWG NO

A SCALE

REV

D364000049-SPC-001 NONE

WT LBS

SHEET

19

04 OF

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DCF0045 (REV B)

3. Actuate the TW function in the break position until it stops. While holding the TW BREAK function, turn the torque adjustment knob clockwise until the desired torque is set. 4. Position the reference indicator (red needle) on the torque gage at the desired torque value

Figure 8. ST-120 torque adjustment knob

OPERATING PROCEDURES The following operating procedures are based on the use of the manual-electric controls. These steps do not coincide with the auto sequence which is outlined in the next sequence. Makeup Sequence (Manual-Electric) 1. The starting position for the Iron Roughneck is fully retracted, fully lowered. The torque value has been preset per the Torque Set Procedure. The arm extension has been adjusted via the Arm Extend Adjust Procedure. The torque wrench is centered (home position) with jaws fully opened and the spin wrench open and fully lowered. The tool is aligned with the drill pipe properly via the slewing system. 2. Extend the tool using the DEPLOY-EXTEND function. The tool extends to the user preset location. 3. The operator raises the tool using the CARRIAGE-UP/DOWN function until the upper and lower wrench is centered about the tool joint. The ST-120 is now ready for the makeup cycle. NOTE: Auto sequence uses tool joint sensor to determine connection height. 4. Raise the spin wrench 6 inches to allow for thread compensation. 5. Ensure the tool is in SW backup mode and clamp the Lower TW using the TW CLAMP function. Note: This only applies if TW is required to backup SW torque. 6. Once the TW is fully clamped on the pipe, release the clamp function but do not unclamp the TW putting the jaw in a soft clamp state where it clamps on the pipe with minimal clamping force enough to back up the spin wrench torque.

SIZE

DWG NO

A SCALE

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D364000049-SPC-001 NONE

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DCF0045 (REV B)

7. Clamp the spin wrench on the pipe using the SW-CLAMP function. While the SWCLAMP function is active, activate the SW-IN function to spin in the drill pipe until shouldered. Once the drill pipe is shouldered, release both the SW-IN and SWCLAMP functions and activate the SW-UNCLAMP function to unclamp the spin wrench from the drill pipe. 8. Index the torque wrench to the MAKE-UP READY position by using the TW-BREAK function, causing the upper torque wrench to rotate counter-clockwise (as viewed from above the wrench). NOTE: This step only applies when operating on high torque connections, otherwise this step can be skipped. 9. If TW was used to backup SW torque, ensure SW backup mode is Switch to Normal mode. 10. Activate the torque wrench to clamp on the tubular using the TW-CLAMP function and hold. With the unit in Normal mode, both the upper and lower jaws will clamp on the pipe at proper clamping pressure. 11. Activate the torque wrench to the make position using the TW-MAKEUP function. The upper torque wrench is rotated clockwise (as viewed from above the wrench). Once desired torque is reached, the TW-MAKEUP and TW-CLAMP functions should be released. NOTE: If the desired torque is not reached and/or the torque gauge drops to zero, unclamp the upper torque wrench and repeat steps 8 thru 11. 12. Activate the TW-UNCLAMP, to retract the upper and lower jaws away from the drill pipe. 13. Once the torque wrench and spin wrench are unclamped and the torque wrench has been returned to the “wrench center” position, activate the CARRIAGE-DOWN and the SW- DOWN functions to lower the tool and the spin wrench, respectively, before retracting the arm from the drill pipe. 14. Once the tool is lowered, retract the arm using the DEPLOY-RETRACT function and return to a home position. Break Out Sequence (Manual-Electric) 1. The starting position for the Iron Roughneck is fully retracted, fully lowered. The torque value should be set approximately 10% higher than required makeup torque. The torque wrench is centered (home position) with jaws fully opened and the spin wrench open. The tool is aligned with the drill pipe properly via the slewing system. 2. Extend the tool using the DEPLOY-EXTEND function. The tool extends to the user preset location. 3. The operator adjusts the tool using the CARRIAGE-UP/DOWN function until the upper and lower wrench is centered about the tool joint. The ST-120 is now ready for the break cycle. NOTE: Auto sequence uses tool joint sensor to determine connection height. 4. The upper torque wrench is indexed to the BREAK-OUT position by using the TWMAKE function, causing the upper torque wrench to rotate clockwise (as viewed from above the wrench). NOTE: This step only applies when operating on high torque connections, otherwise this step can be skipped. 5. Activate the torque wrench to clamp on the tubular using the TW-CLAMP function. This clamps the upper and lower jaws on the drill pipe. 6. Activate the torque wrench to the break out position using the TW-BREAKOUT function. The upper torque wrench is rotated counter-clockwise (as viewed from above the wrench). SIZE

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7. Once the connection has been broke, the TW-BREAKOUT function should be released and the TW-UNCLAMP function should be activated. NOTE: If the connection does not break, increase the torque setting until connection is broke. Also, If torque wrench is needed to backup SW torque, activate the SW BACKUP mode and hold while activating the TW unclamp function. This unclamps the upper jaw while the lower jaw stays clamp. Release the clamp function but do not unclamp the TW putting the lower jaw in a soft clamp state where it clamps on the pipe with minimal clamping force enough to back up the spin wrench torque. 8. Activate the spin wrench to clamp on the drill pipe using the SW-CLAMP function. Activate the SW-OUT function to spin out the drill pipe. Once the drill pipe is unthreaded, release the SW-OUT function and activate the SW-UNCLAMP function to unclamp the spin wrench from the drill pipe. NOTE: If the spin wrench cannot spin out the connection, unclamp spin wrench and repeat steps 4 thru 7. 9. Once the torque wrench and spin wrench are unclamped and the torque wrench has been returned to the “wrench center” position, activate the CARRIAGE-DOWN and the SW- DOWN functions to lower the tool and the spin wrench, respectively, before retracting the arm from the drill pipe. 10. Once the tool is lowered, retract the arm using the DEPLOY-RETRACT function and return to a home position.

SIZE

DWG NO

A SCALE

REV

D364000049-SPC-001 NONE

WT LBS

SHEET

22

04 OF

26

DCF0045 (REV B)

Auto Sequence Matrices The following sequence matrices illustrate the commands which are energized at each of the nine steps of the makeup and breakout sequence. The commands have been optimized such that functions which consume large flow do not operate simultaneously, thus optimizing the ST-120 makeup/breakout times. X X X X

Action Required by tool to move to next step Maintained from start or previous step Spin wrench raised to certain elevation (refer to thread compensation section) Tool raised until tool joint sensed (refer to tool joint sensing section) Requires confirmation from operator that function is complete before moving to next step

Table 1. Auto Makeup Sequence

Extend Retract TW Clamp TW Unclamp Raise Lower SW Raise SW Lower Make Break Spin In Wrench Center SW Clamp SW Unclamp

1 X

Auto Makeup Sequence, Assuming all user info is Preset 2 3 4 5 6 7 8

9

X

X

X

X

X X

X X

X

X

X

X

X

X

X

X X

X

X X

X

X X X

X

X

X

X

X

X

X

X

X

X

Table 2. Auto Breakout Sequence

Extend Retract TW Clamp TW Unclamp Raise Lower SW Raise SW Lower Make Break Spin Out Wrench Center SW Clamp SW Unclamp

1 X

Auto Breakout Sequence, Assuming all user info is Preset 2 3 4 5 6 7 8

9

X

X

X

X

X X

X

X X

X

X

X

X X X

X X X

X

X

X

X X X

X

X

SIZE

X

X

X

X

X

DWG NO

A SCALE

X

REV

D364000049-SPC-001 NONE

WT LBS

SHEET

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DCF0045 (REV B)

Table 3. Auto Makeup Sequence (SW Backup Mode) Auto Makeup Sequence, Assuming all user info is Preset 1 2 3 4 5 6 7 8 Extend X Retract X TW Clamp X X X TW Unclamp X X X X X Raise X Lower X SW Raise X X SW Lower Make X Break X X X X Spin In X SW Mode X X X X Wrench Center X X X SW Clamp X X SW Unclamp X X X X X X

9 X X

X X

Table 4. Auto Breakout Sequence (SW Backup Mode) Auto Breakout Sequence, Assuming all user info is Preset 1 2 3 4 5 6 7 8 Extend X Retract X TW Clamp X X X X TW Unclamp X X X X Raise X Lower X SW Raise X SW Lower Make X X Break X Spin Out X SW Mode X X Wrench Center X X X SW Clamp X X X X SW Unclamp X X X X

SIZE

X X

X X

DWG NO

A SCALE

9

REV

D364000049-SPC-001 NONE

WT LBS

SHEET

24

04 OF

26

DCF0045 (REV B)

Table 5. Auto Power Slips Mode Sequence Auto Power Slips Mode Sequence, Assuming all user info is Preset 1 2 3 4 5 6 7 8 Extend X Retract TW Clamp X X TW Unclamp X X X X X X Raise X Lower X SW Raise X SW Lower X Make X X Break X Spin Out X Wrench Center X X X SW Clamp X X X X SW Unclamp X X X X

9 X X

X X

Table 6. Auto TDS Backup Sequence Auto TDS Backup Sequence, Assuming all user info is Preset 1 2 3 4 5 6 7 8 Extend X Retract X X TW Clamp X X TW Unclamp X X X X X X Raise X Lower SW Raise SW Lower Make Break Spin Out Wrench Center X X X SW Clamp SW Unclamp

SIZE

X X

X

DWG NO

A SCALE

9

REV

D364000049-SPC-001 NONE

WT LBS

SHEET

25

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DCF0045 (REV B)

ST-120 FUNCTIONS Multi-Valve Section Mounted on Head Unit 1. Spin Wrench (Proportional) a. In – Spins pipe in make-up direction b. Out – Spins pipe in break-out direction 2. Torque Wrench (Bang-Bang) a. Clamp – clamps both upper and lower clamp cylinders on drill pipe b. Unclamp – unclamps both upper and lower clamp cylinders from drill pipe 3. Torque Wrench (Bang-Bang) a. Make – makes drill pipe connection b. Breaks – breaks drill pipe connection 4. Mode (Bang-Bang) a. Center – centers upper wrench b. Spin Wrench Mode –unclamps upper clamp cylinders 5. Spin Wrench (Bang-Bang) a. Clamp – clamps spin wrench on tubular b. Unclamp – unclamps spin wrench from tubular 6. Spin Wrench (Proportional) a. Down – lowers spin wrench b. Up – raises spin wrench Torque Control: Controls Pressure of valve section number three via a proportional ATOS relief valve. Multi-Valve Section Mounted on Carriage 1. Carriage (Proportional) a. Down – Moves Carriage Down b. Up – Moves Carriage Up 2. Deploy (Proportional) a. Extend – Extends tool towards tubular b. Retract – Retracts tool to home position 3. Adjust (NOT USED FOR AUTO VERSION OF TOOL – WILL BE BLANKED OFF) a. Extend – Extends tool towards tubular b. Retract – Retracts tool to home position 4. Slew (Proportional) a. Left – rotates tool clockwise b. Right – rotates tool counter-clockwise Hydraulic Enable: Enables hydraulics only when tool is enabled by driller. It is disabled when any E-STOP is activated.

SIZE

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D364000049-SPC-001 NONE

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TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

2

Installation, Operation & Maintenance

1

2.1

Procedures

1

2.2

Spare Parts List

www.nov.com

Document Number:

10862028-MAN TOC 2

Revision:

01

Page:

1

TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

2.1

Procedures

www.nov.com

Document Number:

10862028-MAN TOC 2.1

Revision:

01

Page:

1

Document Number

Rev.

The Use of and Application of Safety Wire for Secondary Retention

ASP00019

A

ST-120 Installation Procedure Automated Model

D364000170-PRO-001

03

Commissioning Procedure Automated Model

D364000171-PRO-001

03

Service Manual ST-120 Iron Roughneck

D811000557-MAN-001

06

Recommended Lubricants Guide

D811000719-PRO-001

06

Flow Switch - Adjustment Procedure

D854000017-PRO-001

01

Design Torque Standard

DS00008

G

Hydraulic Fluid Cleanliness

SM00081

C

PROCEDURE THE USE OF AND APPLICATION OF SAFETY WIRE FOR SECONDARY RETENTION

RIG/PLANT

ADDITIONAL CODE

SDRL CODE

TOTAL PGS

REMARKS MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER CLIENT DOCUMENT NUMBER

Client Document Number

This document contains proprietary and confidential information which belongs to National Oilwell Varco; it is loaned for limited purposes only and remains the property of National Oilwell. 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 National Oilwell Varco. This document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned.  National Oilwell Varco

National Oilwell Varco Rig Solutions 11000 Corporate Centre Dr. Houston TX 77041 USA Phone +1 (281) 854-0647 Fax +1 (281) 854-0508

DOCUMENT NUMBER

REV

ASP00019

A

Document number Revision Page

ASP00019 A 2

REVISION HISTORY

A Rev

15/04/2011 10/03/1995 Date (dd.mm.yyyy)

SEE ECN First Issue Reason for issue

CHANGE DESCRIPTION Revision A

Change Description First Issue SEE ECN

C. SILVA KTK Prepared

T. GORMSEN K DAW Checked

T. GORMSEN JES Approved

Document number Revision Page

ASP00019 A 3

TABLE OF CONTENTS 1 2 3

4 5

1

SCOPE .............................................................................................................................. 3 APPLICABLE DOCUMENTS ........................................................................................... 4 REQUIREMENTS ............................................................................................................. 4 3.1 MATERIAL AND SIZE ............................................................................................ 4 3.2 GENERAL REQUIREMENTS ................................................................................. 5 3.3 LOCK-WIRING METHODS..................................................................................... 6 3.4 OTHER APPLICATIONS ........................................................................................ 7 3.5 ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION .................................. 8 QA PROVISIONS.............................................................................................................. 9 NOTES .............................................................................................................................. 9

SCOPE

Document number Revision Page

ASP00019 A 4

This procedure establishes the method for the selection and application of safety wire. Lock wiring is the application of wire to prevent relative movement of structure or other critical components subject to vibration, tension, torque, etc. This procedure is intended to help eliminate the risk of dropped objects in components or parts manufactured. Bolts, Nuts and Screws are the common type of fasteners used on NOV equipment. They need to be locked (secondary retention) against loss of torque / pretension. Use of safety wire to prevent rotation of fasteners is a safe and primarily recommended secondary retention method for fasteners. It is the most preferred method because it not only prevents fasteners from loosening but also keeps them from falling in case of primary retention failure (bolt head Breaks off) and effectively prevents dropped objects. Note that the secondary retention will work only if the primary retention method is properly in place, i.e. bolts and screws are tightened and torqued as per specifications, and there is no play between the mating elements. Secondary retention methods aim in preventing any compromise in primary retention, loss of pre-tension in assembled fasteners, loosening and backing out.

Definitions: Secondary Retention – The means of effectively retaining a fastener/joining component such that the operating loads do not compromise the integrity of the primary fastening component. 2

APPLICABLE DOCUMENTS DS00008-DES DESIGN TORQUE STANDARDS Machinery’s Handbook 27th Edition

3

3.1

REQUIREMENTS

MATERIAL AND SIZE 3.1.1 Material Lock wire must be aircraft quality stainless steel 302/304 condition A. 3.1.2 Lock-wire sizes

Document number Revision Page

a. b. c. d. e.

3.2

ASP00019 A 5

0.5080 mm (0.020 inch) diameter 0.8128 mm (0.032 inch) diameter NOV P/N Z6000.8 1.1938 mm (0.047 inch) diameter NOV P/N Z6000.9 1.2950 mm (0.051 inch) diameter NOV P/N Z6001 3.1750 mm (0.125 inch) diameter NOV P/N Z6002

GENERAL REQUIREMENTS

3.2.1 Safety wire shall be new upon each application. 3.2.2 Parts shall be lockwired in such a manner that the lockwire shall be put in tension when the part tends to loosen. 3.2.3 The lockwire should always be installed and twisted so that the loop around the head stays down and does not tend to come up over bolt head and leave a slack loop. 3.2.4 Care shall be exercised when installing lockwire to ensure that it is tight but not over stressed. 3.2.5 Properly twisted lockwire will have 7-12 twists per inch for .032 wire and 6-8 turns for .052 wire. More twists will over stress the wire and cause fatigue and breakage. 3.2.6 A pigtail should be ½” to 5/8” in length (4-8 twists) at the end of the wiring. This pigtail shall be bent back or under to prevent it from becoming a snag. 3.2.7 As per the Machinery’s Handbook 27th edition the following rules apply: a) No more than three (3) bolts may be tied together. b) Bolt heads may be tied as shown only when the female thread receiver is captive.(see figure 1) c) Lockwire must fill a minimum of 50% of the drilled hole provided for the use of lockwire. d) Diameter of lockwire is determined by the thread size of the fastener to be lockwired. 1) Thread sizes of 6 mm (0.25 inch) and smaller use 0.508mm (0.020 inch) wire. 2) Thread sizes of 6 mm (0.25 inch) to 12 mm (0.5 inch) use 0.8128 mm (0.032 inch) wire. 3) Thread sizes > 12 mm (0.5 inch) use 1.1938 mm (0.047 inch) OR 1.295mm (0.051) wire. The larger wire may be used in smaller bolts in cases of convenience, but smaller wire must not be used in larger fastener sizes.

Document number Revision Page

ASP00019 A 6

Figure 1: Safety Wire / Lock Wire

3.3

LOCK-WIRING METHODS 3.3.1 The method involves threading a wire through holes in the fastener to lock it against being rotated loose. The wire is twisted before being threaded and is locked to next bolt. Safety wire should be placed in and around bolt head to maintain the pre-load. The use of safety wire ties is illustrated in figure 1 above. The illustrations assume the use of right-hand threaded fasteners. 3.3.2 The double-twist method: The double-twist method of lock-wiring shall be used as the common method of lock-wiring. CAUTION: screws in closely spaced geometric which secure hydraulic or air seals, hold hydraulic pressure, or used in critical areas of clutch mechanism should use double twist method of lock-wiring. Make sure that the wire is so installed that it can easily be broken when required in an emergency situation. 3.3.3 Lock-wiring widely spaced multiple groups by the double twist method. a) When the multiple fasteners are from 4-6 inches apart, three (3) fasteners shall be the maximum number in a series that can be safety wired together. b) When the multiple fasteners are spaced more than 6 inches apart, the multiple fastener application specified in Figure 1 shall not be used unless tie points are provided on adjacent parts to shorten the span of the wire to less than 6 inches. c) One end of the safety wire shall be inserted through one set of lockwire holes in the head of the bolt. The other end of the safety wire shall be looped around the bolt head in the tightening direction.

Document number Revision Page

ASP00019 A 7

d) The strands, while taut, shall be twisted until the twisted part is just short of the nearest hole in the next bolt. The twisted portion shall be within 1/8” of the holes in each bolt as shown in figure 1 above. e) After wiring the last bolt, the wire shall be twisted to form a pigtail of 2-4 twists. The excess wire shall be cut off. The pigtail shall be bent back or under the part to prevent it from becoming a snag. 3.3.4 Single wire method: The single wire method may be used in a closely spaced, closed geometrical pattern (triangle, square, circle, etc.) on parts in an electrical system, and in places that would make the single-method more advisable as shown in figure 2 below. Closely spaced shall be considered a maximum of two inches between centers. Maximum length of wire shall not exceed 24” in total length.

Figure 2: Safety Wire / Lock Wire Single

3.4

OTHER APPLICATIONS

Document number Revision Page

ASP00019 A 8

3.4.1 Hollow head bolts are safety wired in the manner prescribed for regular bolts. 3.4.2 Drain plugs and cocks may be wired to a bolt, nut, or other part having a free lock hole in accordance with the general instructions contained herein. 3.4.3 External snap rings may be locked if necessary in accordance with the general locking principles contained herein. 3.4.4 Internal snap rings shall never be lockwired. 3.4.5 Bolts and hardware may be wired using SAFE-T-Cable. Follow procedure D744000087-PRO-001. Safe-T-Cable® can be used similar to Safety/Lock wire to secure Fasteners. The safety cable installation procedure is shown in Figure. The safety cable comes in pre-cut lengths with stubs on one end. After sewing through the holes in the fasteners they are tightened and crimped using a ferrule cartridge and crimping tool. They are more convenient to use and take only a fraction of the time to secure fasteners as compared to safety wire as no wire twisting is required. However additional tools like ferrule cartridge and crimping tool are required. For additional information refer Safe-TCable® (website http://www.dmctools.com/Catalog/safe_t_cable.htm).

Figure 3: Safety Cable Installation Procedure

3.5

ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION

Document number Revision Page

4

QA PROVISIONS

5

NOTES

ASP00019 A 9

ST-120 Installation Procedure Automated Model

RIG/PLANT

ADDITIONAL CODE

REFERENCE

SDRL CODE

TOTAL PGS

REMARKS

MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER

CLIENT DOCUMENT NUMBER

Client Document Number

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 DOCUMENT NUMBER

D364000170-PRO-001

www.nov.com

National Oilwell Varco RIG SOLUTIONS 11000 Corporate Centre Drive Houston, TX 77041 Phone +1281-854-0400

REV

03

Document number Revision Page

D364000170-PRO-001 03 2

REVISION HISTORY 03

13.08.2015

Added Slew Stop Installation Info

02

02.03.2013

See EN

01

25.06.2010

Initial Release

Rev

Date (dd.mm.yyyy)

M. Teel

P. Giacona

P. Giacona

A.HASTINGS

J.WALKER

J.WALKER

J. WALKER

Reason for issue

Prepared

A. O-JONES A. O-JONES Checked

Approved

CHANGE DESCRIPTION

Revision

Change Description

01

First Issue

02

SEE EN “Technical Drawing Package” references have been changed to “User Manual”. Section 1.6 Special Tools has been updated. Added installation of Slew Stop Kit in section 2.5 Iron Roughneck Installation.

03

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TABLE OF CONTENTS 1 

2 

3 

PRE-INSTALLATION AND SETUP .................................................................................. 5  1.1  Requirements ......................................................................................................... 5  1.2  Initial Inspection ...................................................................................................... 5  1.3  Customer Verification of Hydraulic Fluid Cleanliness ............................................. 5  1.4  Equipment Differences ........................................................................................... 5  1.5  Hydraulic System and Components........................................................................ 6  1.6  Special Tools .......................................................................................................... 6  INSTALLATION ................................................................................................................ 7  2.1  Floor Socket Location ............................................................................................. 7  2.2  Test Fitting the Socket Flange and the Floor Socket ............................................ 10  2.3  Installing the Socket Base Assembly .................................................................... 11  2.4  Lifting the Iron Roughneck .................................................................................... 15  2.5  Iron Roughneck Installation .................................................................................. 16  2.6  Installing the Hydraulic Service Loop .................................................................... 18  2.7  Installing the Electrical Service Loop .................................................................... 19  2.8  Socket Base Assembly Hydraulic Connection ...................................................... 23  2.9  Adjusting the Torque Wrench and Spin Wrench ................................................... 28  2.9.1  Adjusting the Torque Wrench .................................................................... 28  2.9.2  Shimming the Spin Wrench ....................................................................... 29  CHECKOUT PROCEDURE ............................................................................................ 31  3.1  Iron Roughneck Installation Checkout Procedure ................................................. 31 

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TABLE OF FIGURES Figure 1: Floor Socket Location Layout ....................................................................................... 7  Figure 2: Floor Socket Placement ................................................................................................ 8  Figure 3: Tong Sweep for ST-120 at Installation.......................................................................... 9  Figure 4: Socket Flange Installation ........................................................................................... 10  Figure 5: Socket Flange Installed on Floor Socket .................................................................... 10  Figure 6: Socket Base Assembly ............................................................................................... 11  Figure 7: Socket Flange Alignment ............................................................................................ 12  Figure 8: Socket Flange Seated in Floor Socket........................................................................ 13  Figure 9: Manual Slew Hydraulic Connection ............................................................................ 14  Figure 10: ST-120 Lift Points ..................................................................................................... 15  Figure 11: ST-120 Installation .................................................................................................... 17  Figure 12: Service Loop Installation ........................................................................................... 18  Figure 13: Electrical Service Loop ............................................................................................. 20  Figure 14: Tool Side Service Loop Pigtail Routing ..................................................................... 21  Figure 15: Remote Control......................................................................................................... 22  Figure 16: Encoder Mounting..................................................................................................... 24  Figure 17: Lock Plate Installation ............................................................................................... 25  Figure 18: Quick Disconnect Fittings (1 of 2) ............................................................................. 26  Figure 19: Quick Disconnect Fittings (2 of 2) ............................................................................. 27  Figure 20: Adjusting the Head ................................................................................................... 28  Figure 21: Shimming the Spin Wrench (1 of 2) .......................................................................... 29  Figure 22: Shimming the Spin Wrench (2 of 2) .......................................................................... 30 

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1

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PRE-INSTALLATION AND SETUP The information in this document assumes that all pre-installation planning and rig-up has been accomplished prior to installation of the iron roughneck.

1.1

Requirements Many installation layout arrangements are possible, therefore critical preparation and installation consideration must be performed before attempting to install the iron roughneck. Before installing the iron roughneck system, consider the ideal location of the iron roughneck, HPU, and/or service loop to ensure accessibility and safety. Installation considerations help to prevent possible performance and operation restrictions. Prior to field installation, ensure all iron roughneck components are included and are unserviceable condition. Fill all lubricants systems to correct levels with specified lubricants. Refer to “Recommended Lubricants and Fluids” document.

1.2

Initial Inspection After unpacking all iron roughneck components and parts, inspect as follows: 1. Inventory all components and parts. Notify National Oilwell Varco if parts are missing or incorrect. 2. Inspect all components and parts for shipment damage and corrosion. Notify the carrier if components or parts were damaged during shipment. 3. Ensure that the manuals and spare dies are removed from the shipping containers and stored in a secure place.

1.3

Customer Verification of Hydraulic Fluid Cleanliness Prior to attaching any National Oilwell Varco equipment to 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.

1.4

Equipment Differences This installation procedure applies to the electrically controlled, standard column ST-120 with floor socket mount.

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1.5

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Hydraulic System and Components Hydraulic systems and components are designed for the intended use in the drilling industry. The minimum required hydraulic operating pressure for this equipment is 2500 psi. 1. Before beginning work on any portion of the hydraulic system, familiarize yourself with the hydraulic schematics. Refer to the User Manual. 2. Isolate, lock out, and tag the hydraulic power controls. 3. Take precautions when bleeding down residual system pressure, using bleed valves or equivalent techniques. 4. Properly discharge all system stored fluid pressure. 5. Collect all residual hydraulic fluid in a container to prevent rig or environmental contamination. 6. Take precautions to prevent hydraulic oil from leaking into other open mechanical components such as junction boxes. 7. Under no circumstance is work to be performed on the ST-120 while it is in elevated position, even with hydraulic power unit shut off and residual pressure bled from the system.

1.6

Special Tools The following lists special tools and support equipment required to install and commission an iron roughneck. 1. Calibrated hydraulic pressure gage, 0-3000psi (0-206 Bar) 2. Calibrated hydraulic pressure gage, 0-6000 psi (0-413 Bar) 3. Accumulator charging and gaging assembly for checking accumulator pre charge pressure of 100 psi. NOV Recommends P/N 114446-500. 4. NOV recommends pressure test kit P/N 940315-1000. 5. Optional Special Tools kit P/N M364001199 includes all items stated above and additional parts to aid in assembly, installation, and service of the ST-120.

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2

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INSTALLATION

2.1

Floor Socket Location Before installing the floor socket support for the iron roughneck, determine the proper floor socket location. The placement and installation of the floor socket is specific to the rig. The appropriate general arrangement drawing should be referenced for loading and location considerations. For standard placement, see Figure 1 and Figure 2.

Figure 1: Floor Socket Location Layout

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Figure 2: Floor Socket Placement

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Figure 3: Tong Sweep for ST-120 at Installation

Figure 3 shows the iron roughneck completely retracted in the closest installation position to the well center and mouse hole. Install the iron roughneck clear of the well center and mouse hole position for tong operation.

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2.2

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Test Fitting the Socket Flange and the Floor Socket Test fit the socket flange into the floor socket by rotating the socket flange until the notch indexes on the shear tab welded to the floor socket as shown in Figure 4. Visually inspect that the shear tab fully engages in the socket flange notch by looking down the ID of the socket flange as shown in Figure 5. Grind the socket flange notches as needed to ensure full engagement.

SOCKET BASE ASSEMBLY

NOTCH ON SOCKET FLANGE ROTATE TO INDEX ON SHEAR TAB ON FLOOR SOCKET

SHEAR TAB ON FLOOR SOCKET

Figure 4: Socket Flange Installation

1.00" TOP OF SOCKET TO TOP OF DRILL FLOOR

RIG FLOOR

FLOOR SOCKET

OPTIONAL: ADD BOXING PLATES TO STRUCTURE TO INCREASE WELDING AREA FOR FLOOR SOCKET

Figure 5: Socket Flange Installed on Floor Socket

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2.3

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Installing the Socket Base Assembly 1. Lift the socket base assembly and position such that the socket flange is aligned with the floor socket. The socket base assembly should be lifted using the column lock pins. See Figure 6.

COLUMN LOCK PINS (2)

Figure 6: Socket Base Assembly

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2. Check that the notches on the socket flange are aligned with the shear tabs in the floor socket. See Figure 7.

SOCKET BASE ASSEMBLY

SOCKET FLANGE

SOCKET FLANGE NOTCH

FLOOR SOCKET

SHEAR TAB

Figure 7: Socket Flange Alignment

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3. Slowly lower the socket base assembly. As the socket base assembly nears its fully seated position, slightly rotate it to ensure that the notches on the socket flange are indexed onto the shear tabs in the socket flange. See Figure 8.

SHEAR TAB ON FLOOR SOCKET

Figure 8: Socket Flange Seated in Floor Socket 4. Once the notches have been aligned to the shear tabs, slowly lower the socket base assembly until it comes to rest on the socket flange. 5. Once the socket base assembly has been installed; remove the four (4) column lock pins and cotter pins. Retain pins and all mounting hardware for reassembly. See Figure 6.

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6. Ensure that the socket base assembly is aligned such that the ST-120 can be installed without interfering with any drill floor obstacles. If the socket base assembly needs to be rotated before the ST-120 is installed, please do the following: a. Connect lines A and B of the hydraulic slew motor. These lines are equipped with quick disconnects and should couple together. See Figure 9.

Figure 9: Manual Slew Hydraulic Connection b. Next, using a hydraulic power source of no more than 500psi, connect to the brake release line C and release the brake. Remove hose and attach to #6 male JIC fitting. c. Once the brake is released, the socket base assembly should be able to rotate. Rotate into the position desired and release hydraulic pressure to the brake. d. Next, disconnect the A and B lines of the hydraulic motor. Disconnect hydraulic power source from the brake and replace hose. 7. Before lifting the ST-120 onto the socket, ensure the hoses on the socket base assembly are secured such that they do not get damaged when lowering the ST-120 onto the socket base.

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2.4

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Lifting the Iron Roughneck Before lifting the iron roughneck, ensure that the ST-120 is in the fully lowered position and that the transport pin is installed in the transport position. Lift the iron roughneck using the lift points shown in Figure 10.

LIFT POINTS TRANSPORT PIN LOCATION

Figure 10: ST-120 Lift Points National Oilwell Varco 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 is rated for, nor intended to support the full weight of the iron roughneck. Care should be taken to ensure that the shackles are properly secured on the tool and the slings are rated for the appropriate weight.

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2.5

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Iron Roughneck Installation 1. With the iron roughneck suspended, position the iron roughneck such that the holes on the bottom of the column are aligned with the holes in the socket base assembly. See Figure 11. 2. Once aligned, reinstall four (4) column lock pins and cotter pins. Be sure not to damage bushings in column lugs and base lugs during installation. Apply a thin layer of grease to the pin to ease installation. Once pins are installed, ensure all cotter pins are installed correctly. 3. Once column lock pins have been installed, the lifting sling can be removed. The sling should be stored for future iron roughneck lifting operations. 4. Install Slew Stop Kit (M364000669) according to the instructions on kit drawing M364000669-KIT-001 NOTE: Ensure that the bolts supplied with the kit are used to attach the Slew Stop Weldment to the base assembly. Failing to do so may cause damage to equipment or injury to personnel. 5. Remove the transport pin shown in Figure 10.

!NOTE! Ensure the column is level and perpendicular to the floor socket.

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ALIGN HOLES

Figure 11: ST-120 Installation

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2.6

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Installing the Hydraulic Service Loop Please refer to the ST-120 hydraulic system schematic and the customer system schematic. 1. Check that all circuit breakers at the Hydraulic Power Unit (HPU) are OFF. ! WARNING ! All equipment should be shut down, isolated and tagged “OUT OF SERVICE” before any maintenance procedure is performed. Any unexpected start-up of equipment during operation can cause serious injury or death to personnel and/or damage to the equipment. 2. Locate the hydraulic service loops. Connect the hydraulic supply, return, and drain hose from the rig floor swivels to the iron roughneck. See Figure 12.

Figure 12: Service Loop Installation ! WARNING ! Exercise extreme caution when performing maintenance on the hydraulic system. Fluid escaping under pressure can cause serious injury or death to personnel and / or damage to equipment. Under no circumstance is work to be performed on the ST-120 while the hydraulic lines are connected. Even with the HPU turned off, residual pressure may remain in the ST-120 hydraulic circuit that could cause unsafe motion resulting in serious injury. Hydraulic power shall be removed from all ST-120, all operator valves cycled, and hydraulic lines removed prior to ST-120 maintenance. www.nov.com

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2.7

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Installing the Electrical Service Loop Please refer to the ST-120 interconnect diagram for proper wire termination 1. Install the service loop support in the derrick. Reference the ST-120 General Arrangement drawing for installation dimensions. See Figure 13. 2. Lift the Derrick Side of each electrical service loop, and install in the service loop support. Each service loop end is marked with “Derrick Side” and “Tool Side”. 3. Ensure all electrical service loops are oriented such that any curvature is along the natural path of the service loop. There should be no twist in the electrical service loops when the ST-120 is in the middle of its slew range. This will minimize the twist put into the service loop when the ST-120 is slewing to its limits. Loosen the service loop keepers and “clock” the service loop as needed, then re-tighten the service loop keepers. 4. Route the Tool Side service loop pigtails through the service loop guard and along the inside of the rear guard, see Figure 14. 5. Mount the Tool Side of the electrical service loops to the service loop guard and terminate to the junction box per the interconnect diagram. 6. Install the remote I/O junction box. Reference the ST-120 General Arrangement drawing for installation dimensions. ____________________________________________________________________ ! NOTE ! The remote I/O junction box must be installed in a safe area. 7. Terminate the Derrick Side of the electrical service loops to the remote I/O junction box per the interconnect diagram.

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Figure 13: Electrical Service Loop

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Figure 14: Tool Side Service Loop Pigtail Routing

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Figure 15: Remote Control

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2.8

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Socket Base Assembly Hydraulic Connection ! NOTE ! Use the Remote Control to operate the Iron Roughneck during installation procedures. See Figure 15. 1. Once the hydraulic and electrical service loops have been installed, turn the ball valve on the rear of the ST-120 to the ON position. 2. Take remote control ownership of the ST-120, see Figure 15: a. Ensure the SBC is turned on at the MTC cabinet or SBC control station. b. Turn the Operation Mode selector switch on the rear of the ST-120 to the AUTO position. c. Turn the key of the remote control to the ON position. d. Push the OVERRIDE button on the remote control to take ownership of the ST120. If the SBC is still booting up, wait until it has booted up then recycle the key and push the OVERRIDE button again. 3. Extend the arm, by activating the Deploy Extend lever on the remote control, to the point where the Arm Lock Plate can be installed. See Figure 17. 4. Install the Arm Lock Plate. 5. Turn the ball valve on the rear of the ST-120 to the OFF position. 6. Turn the remote control key to the OFF position. Turn the Operation Mode selector switch on the rear of the ST-120 to the MAN position. 7. Connect the quick disconnect fittings on the Socket Base Assembly to their respective quick disconnect fittings in the column. These fittings can be easily accessed from the front, while the unit is in fully lowered position. Do not raise the iron roughneck for making these connections. See Figure 18 and Figure 19. Also see drawing “Column Base Assembly,” last sheet. Drawings are included in the User Manual. 8. The slew encoder is shipped inside the ST-120 column. Pay special attention during unpacking of the slew encoder not to lose the coupling spider. Verify the coupling installation is per Figure 16, and install the coupling spider. 9. Locate the slew encoder and install onto the slew motor using four (4) #8-32 bolts and lock washers. 10. Remove the Arm Lock Plate and return it to its storage location.

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Figure 16: Encoder Mounting

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ARM LOCK PLATE

View showing arm retracted to a position close enough to rotate the locking arm.

ARM LOCK PLATE

View showing the locking arm rotated into the locked position.

Figure 17: Lock Plate Installation

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D364000170-PRO-001 03 26

Figure 18: Quick Disconnect Fittings (1 of 2)

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Figure 19: Quick Disconnect Fittings (2 of 2)

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TP GEAR BPX TAML

GEAR BOX TO TANK CONNECTION

TO SLEW BRAKE TANK

SLEW BRAKE TO TANK CONNECTION

TO SLEW BRAKE

TO SLEW BRAKE CONNECTION

TO CHAIN HOSE

CHAIN HOSE TO SLEW BRAKE CONNECTION

D364000170-PRO-001 03 27

TO GEAR BOX

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2.9

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Adjusting the Torque Wrench and Spin Wrench

2.9.1 Adjusting the Torque Wrench 1. To adjust the head properly, extend the ST-120 to well center and shut down the hydraulics. 2. Check the alignment of the ST-120 such that it is level with the drill floor. If the torque wrench is leaning forward or back, perform the following: a. Remove the keepers over the adjustment bolts on the front lower arm. b. Slowly turn each adjustment bolt on the left and right until the head is level. Do not turn each adjustment bolt more than 3 revolutions without adjusting the bolt on the other side the same. Clockwise tilts the head forward. Counterclockwise tilts the head back. c. Take a measurement on the adjustment bolt head and ensure that the same amount is protruding from left to right. d. Once the torque wrench is level with the drill floor, replace the keepers. See Figure 20.

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D364000170-PRO-001 03 29

2.9.2 Shimming the Spin Wrench 1. To shim the spin wrench properly, there must be drill pipe at well center. 2. Extend the ST-120 to well center and clamp on drill pipe with torque wrench and spin wrench. 3. Ensure that while clamped, the bogey arm hinge pins are centered in the torque reaction plate. If they are not centered, shim the head accordingly with the supplied shims. The weight of the spin wrench should be supported while adding or removing shims. a. To shim, loosen the bolts (do not remove bolts) on the spin wrench hanger. b. Remove or slide additional shims from the top into place. c. Tighten bolts and check that the bogey arm hinge pins are centered in the torque reaction plate. See Figure 21 and Figure 22.

SEE DETAIL B

TORQUE REACTION PLATE

BOGEY ARM HINGE PINS

DETAIL B Figure 21: Shimming the Spin Wrench (1 of 2) www.nov.com

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D364000170-PRO-001 03 30

SEE DETAIL C

BOLTS (3 PLACES)

SPIN WRENCH HANGER

DETAIL C

Figure 22: Shimming the Spin Wrench (2 of 2)

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3

D364000170-PRO-001 03 31

CHECKOUT PROCEDURE

3.1

Iron Roughneck Installation Checkout Procedure 

Ensure that the iron roughneck is fully inserted in the socket and column is vertically aligned.



Ensure all service loop hydraulic lines and are connected and all quick disconnects (QD) are properly engaged.



Ensure all electrical service loop lines are terminated.



Check for hydraulic leaks and tighten any loose fittings.



Ensure transport locking pin is removed prior to operation of the iron roughneck. See Figure 10. (This page concludes the ST-120 Installation Procedure.)

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ST-120 Commissioning Procedure Automated Model

RIG/PLANT

ADDITIONAL CODE

REFERENCE

SDRL CODE

TOTAL PGS

REMARKS

MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER

REFERENCE DESCRIPTION

This document contains proprietary and confidential information which belongs to 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 and in any event 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

National Oilwell Varco Rig Solutions 743 N Eckhoff Street Orange, CA 92868 Phone +1 (714) 978-1900

CLIENT DOCUMENT NUMBER

DOCUMENT NUMBER

REV

Client Document Number

D364000171-PRO-001

03

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D364000171-PRO-001 03 2

REVISION HISTORY

03

26-Jul-2012

02

08-23-2010

01

06-22-2010

Rev

Date (dd.mm.yyyy)

See EN

A.Hastings

A.Jones

A.Jones

Manual Control Console Operations

A.Odunfa

J. Walker

J. Walker

Initial Release

A. Odunfa

J. Walker

J. Walker

Prepared

Checked

Approved

Reason for issue

CHANGE DESCRIPTION Revision 01 03

Change Description First issue Added line about torque gage

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D364000171-PRO-001 03 3

TABLE OF CONTENTS A.

REFERENCE DOCUMENTATION SUGGESTED FOR COMMISSIONING PROCEDURE .......................... 4

B.

SCOPE ............................................................................................................................................................ 4

C.

INSTRUCTIONS .............................................................................................................................................. 4

D.

DEFINITIONS .................................................................................................................................................. 4

E.

PRE-TEST CHECKLIST.................................................................................................................................. 5

F.

ST-120 PHYSICAL CONDITION CHECKLIST ............................................................................................... 5

G.

HYDRAULIC SETUP AND FUNCTION TEST: ............................................................................................... 6

H.

ELECTRICAL SETUP AND FUNCTION TEST: ............................................................................................. 6

I.

ST-120 OPERATIONS (USING ST-120 REMOTE CONTROL CONSOLE) .................................................. 8

J.

ST-120 OPERATIONS (AUTO SEQUENCE MAKE-UP /BREAK-OUT TEST) ........................................... 10

K.

VERIFYING INTERLOCKS ........................................................................................................................... 13

L.

SAFETY DEVICES TEST: ............................................................................................................................ 19

M.

OPTIONAL MANUAL CONTROL CONSOLE OPERATIONS ..................................................................... 20

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D364000171-PRO-001 03 4

A. REFERENCE DOCUMENTATION SUGGESTED FOR COMMISSIONING PROCEDURE Drawing Description. Drawing Number 1.

General Assembly Drawing

D364000122-GAD-001

2.

Top Level Assembly

See appropriate top level drawing

3.

Arm Assembly

4.

Head Assembly

5.

Hydraulic Schematic

D854000013-SCH-001

6.

Electrical Interconnect Diagram

See appropriate top level drawing

B. SCOPE The commissioning procedure is provided as a checklist of operations to be performed to ensure the ST-120 operates as intended. This document does not contain detailed installation or operational instructions. The ST-120 user manual should be referenced for detailed instructions for installation and operation. Fluid temperature can affect the speed of the ST-120. If fluid temperature cannot reach 100degrees F due to ambient temperature, function speeds will be slow. C. INSTRUCTIONS  

Assembly or Test personnel are responsible for completing this test form. Stamp or signature in the “completed” column is required for each step identified below that has been completed. Comments regarding discrepancies found during the test process are to be added together with actions for corrections to the Punch List attached to this document. The punch list number (PLN) shall be noted in the column of the related checklist item. Stamp or signature in the “corrected” column is required for each corrective action that has been performed.

D. DEFINITIONS SW – Spin Wrench TW – Torque Wrench CW – Clockwise CCW – Counterclockwise TDS - Top Drive System

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D364000171-PRO-001 03 5

E. PRE-TEST CHECKLIST Completed / Date 1. Hydraulic supply lines run to installation position on rig floor. Pressure supply line to be 1” diameter minimum and tank line to be 1.25” diameter minimum. Hose end fittings are to be compatible with connections on back of ST-120. 2. Hydraulic supply pressure is 2500 PSI and supply capacity is 45 GPM minimum. 3. ST-120 support socket is installed plumb and within a margin of 160”190” from both well center and mousehole. See GA drawing for additional reference. 4. Verify that all electrical connections have been made in accordance with the electrical interconnect diagram, control system is connected, continuity check has been completed on all wiring.

F. ST-120 PHYSICAL CONDITION CHECKLIST 1. Perform visual inspection of the equipment and ensure that the quality of the ST-120 is of high quality and workmanship. 2. Inspect ST-120 for damage. Support column interface to be clean and smooth. Structure to be true and free of defects. 3. Inspect all hydraulic lines and fittings for kinks, abrasion, and cuts. Replace as necessary 4. Attach a hydraulic power supply and adjust the supply pressure for a minimum of 2500 psi and maximum of 3000 psi. Be sure that a minimum of 45GPM is available to the ST-120. 5. Turn ball valve to ON position. Turn ball valve to OFF position. Verify pressure gauge shows zero when ball valve is turned to OFF position. 6. Verify operation of 4 Emergency Stops (E-Stop) button/switch. (AUTO MODE ONLY) 7. Verify clogging indicators on main filter and intensifier filter indicate clean filters.

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G. HYDRAULIC SETUP AND FUNCTION TEST: 1. Open the shut-off valve on the ST-120 and set hydraulic supply pressure to 500 PSI. Inspect for hydraulic leaks and fix any found. 2. Increase supply pressure to 2500 PSI. Operate each hydraulic valve, starting with the spin control, to purge any air from the system and verify function. Recheck for leaks and correct. 3. Raise and extend arm to verify free motion 4. Verify accumulator precharge pressure is 100 psi.

H.

ELECTRICAL SETUP AND FUNCTION TEST: Perform the following functions with the Maintenance Mode Switch in the „OFF‟ position. Using the Wireless Remote Control, ensure that each function operates properly. Hydraulic fluid temperature could affect the outcome of this testing. 1. Arm Test:  Cycle carriage up and down for 3 cycles to ensure freedom of movement and even movement 

Fully raised



Fully lowered



Fully extended



Fully retracted



Verify that arm travels at least 144”

2. Spin Wrench (S.W.):  Cycle S.W. carriage up and down for 3 cycles to ensure freedom of movement 

Verify the S.W. fully clamps and unclamps



Verify the open throat distance between the front rollers in the

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D364000171-PRO-001 03 7

open position is 12 inches minimum 

Both rollers spin in and spin out



Fully raised



Fully lowered



Raise the spinning wrench fully and take a measurement to ensure differential travel is between 38” and 40”

3. Torque Wrench: (set torque to 50,000 ft-lbs)  Cycle T.W. to full make and break position for 3 cycles to ensure freedom of movement 

Fully clamp



Fully unclamp



Full-stroke Make position



Full stroke Break position

4. Slewing Verification  Slew CW 

Slew CCW

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I.

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ST-120 OPERATIONS (USING ST-120 REMOTE CONTROL CONSOLE) These tests can be performed at any one of the predefined destinations (i.e. well center, fox hole 1, or fox hole 2).

Setup  

Position an XT-57 drill pipe (if available) between 160” and 190” from center of Column. Input torque value via the wireless controller by moving the ADJUST TORQUE/TOOL JOINT switch to the TORQUE position and pushing the increase/decrease switch to the INCREASE or DECREASE direction until the desired set point is reached. (Ensure the torque value is less than the tool joint allowable torque value to avoid applying too much torque to the tool joint)

1. Making the connection in the following sequence:  With ST-120 fully retracted, fully lowered, verify the torque value on the remote control console is set. 

Extend the tool using the DEPLOY-EXTEND function. The tool extends to the user preset location.



Raise the tool using the CARRIAGE-UP/DOWN function until the upper and lower wrench is centered about the tool joint. The ST-120 is now ready for the make-up cycle.



Activate the spin wrench to clamp on the drill pipe using the SW-CLAMP function (If test stand cannot prevent the lower tool joint from spinning when the joints are shouldered, put the tool into SW Backup mode and clamp the lower TW jaw). Activate the SW-IN function to spin in the drill pipe until shouldered. Once the drill pipe is shouldered, release the SW-IN function and activate the SW-UNCLAMP function to unclamp the spin wrench from the drill pipe.



Rotate the upper torque wrench to the MAKE-UP READY position by using the TW-BREAK function, causing the upper torque wrench to rotate counter-clockwise



If the tool is in SW BACKUP mode, toggle mode to change it to NORMAL mode and activate the TW CLAMP function.

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D364000171-PRO-001 03 9



Activate the torque wrench to the make position using the TW-MAKEUP function. Once desired torque is reached, release the TW-MAKEUP function. If the desired torque is not reached and/or the torque gauge drops to zero, re-index the torque wrench and torque again until desired torque is reached. The ability for the torque gage to return to zero, when no function is being used, is dependent on tank pressure. This does not affect the torqueing function of the roughneck.



Activate the TW-UNCLAMP, to retract the upper and lower jaws away from the drill pipe.



Lower the ST-120 by activating the CARRIAGE-DOWN function and the SW- DOWN functions to lower the spinning wrench respectively.



Once the tool is lowered, retract the arm using the DEPLOYRETRACT function and return to a standby position.

2. Breaking the connection in the following sequence:  With ST-120 fully retracted, fully lowered, the torque value should be set approximately 10% higher than required makeup torque. 

Extend the tool using the DEPLOY-EXTEND function. The tool extends to the user preset location.



Raise the tool using the CARRIAGE-UP/DOWN function until the upper and lower wrench is centered about the tool joint. The ST-120 is now ready for the break-out cycle.



Rotate the upper torque wrench to the BREAK-OUT READY position by using the TW-MAKE function, causing the upper torque wrench to rotate clockwise.



Put the tool into NORMAL mode.



Activate the torque wrench to clamp on the tubular using the TW-CLAMP function.



Activate the torque wrench to the break out position using the TW-BREAKOUT function.

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D364000171-PRO-001 03 10



Once the connection has been broke, release the TWBREAKOUT function and activate the TW-UNCLAMP function until both the upper and lower jaws are fully retracted. (If SW needs to be backed up, toggle the mode to select SW BACKUP mode. Clamp TW, the upper TW should retract)



Activate the spin wrench to clamp on the drill pipe using the SW-CLAMP function. Activate the SW-OUT function to spin out the drill pipe. Once the drill pipe is unthreaded, release the SW-OUT function and activate the SW-UNCLAMP function to unclamp the spin wrench from the drill pipe. If the spin wrench cannot spin out the connection, unclamp spin wrench and re-break the joint.



Activate the CARRIAGE-DOWN and the SW- DOWN functions to lower the tool and the spin wrench respectively.



Once the tool is lowered, retract the arm using the DEPLOYRETRACT function and return to a standby position



Verify the above sequence performs effectively

J. ST-120 OPERATIONS (AUTO SEQUENCE MAKE-UP /BREAK-OUT TEST) 1. Automatic Make-up Test:  Move the tool to the home position and fully lower the carriage. Set or verify tool control switches are as follows: 

TOOL ON/OFF mode switch to ON.



POWER SLIP mode switch to OFF.



TOOL JOINT length to appropriate tool joint length.



TRIP-IN/OUT mode to TRIP-IN.



TOOL MODE set to NORMAL (If the test stand cannot prevent the lower joint from spinning when the joints are shouldered set TOOL MODE to SW BACKUP).

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Document number Revision Page



D364000171-PRO-001 03 11

TORQUE PRESET to 50,000 ft-lbs (or the tool joint torque rating).



Depress the AUTO SEQUENCE button. Verify that the tool moves towards well center, Torque Wrench moves to the wrench center position, and tool slows prior to reaching well center. After the tool reaches well center, verify that the Torque Wrench moves to the full break-out position and the tool positions upper and lower Torque Wrench jaws between tool joints.



Depress the AUTO SEQUENCE push button again (to confirm the Torque Wrench is at the correct height) and verify the tool performs the following operations:





Spinning Wrench clamps (and if TOOL MODE is SW BACKUP, the lower TW clamps).



Pipe is spun into box section.



Upper Torque Wrench jaws clamp onto pipe.



Correct make-up torque is applied (as selected by the TORQUE PRESET and indicated on the TORQUE DISPLAY).

Depress the AUTO SEQUENCE push button again (to confirm the correct torque was applied to the connection) and verify the tool performs the following operations: 

Torque Wrench simultaneously.



Torque Wrench moves to the wrench center position.



Tool moves to home position

and

Spinning

Wrench

unclamp

2. Automatic Break-out Test:  Move the tool to the home position and fully lower the carriage. Set or verify tool control switches are as follows: 

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TOOL ON/OFF mode switch to ON.

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D364000171-PRO-001 03 12



TOOL JOINT length to appropriate tool joint length.



TRIP-IN/OUT mode to TRIP-OUT.



TOOL MODE set to NORMAL (If the test stand cannot prevent the lower joint from spinning when the joints are shouldered set TOOL MODE to SW BACKUP).



TORQUE PRESET to above MAKE-UP torque preset value.



Depress the AUTO SEQUENCE push button. Verify the tool moves towards well center, and tool slows prior to reaching well center. After the tool reaches well center, verify that the Torque Wrench moves to the full break-out position and Torque Wrench automatically positions on joint.



Depress the AUTO SEQUENCE pushbutton again (to confirm the Torque Wrench is at the correct height). Verify the tool performs the following operations: 

Torque Wrench and Spinning Wrench clamp onto pipe simultaneously.



Break-out torque is applied.



Torque Wrench unclamps (if the TOOL MODE is SW BACKUP, only the upper TW unclamps).



Pipe is spun out of box section.



Spinning Wrench unclamps (if the TOOL MODE is SW BACKUP, the lower TW unclamps).



Torque Wrench moves to wrench center position.

Tool moves to home position

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D364000171-PRO-001 03 13

K. VERIFYING INTERLOCKS Interlocks  Torque Wrench / Spin Wrench Clamp Interlock.





Clamp TW. (Do not clamp on pipe)



Verify the Main Carriage does not move when TW UP or DOWN is activated.



Verify that the tool does not deploy when the DEPLOY EXTEND or RETRACT is activated



Retract the tool all the way (will need to hold OVERRIDE in order to retract), select a different destination than the one that the tool is currently facing. Verify that the tool does not slew when SLEW CW or CCW is activated in the direction of the selected destination.



Unclamp the TW and clamp the SW (Do not clamp on pipe)



Verify that the Main Carriage does not move when TW UP or DOWN is activated.



Verify that the SW does not move when SW UP or DOWN is activated.



Verify that the tool does not deploy when the DEPLOY EXTEND or RETRACT function is activated.



Retract the tool all the way (will need to hold OVERRIDE to retract), select a different destination than the one that the tool is currently facing. Verify that the tool does not slew when SLEW CW or CCW is activated in the direction of the selected destination.

Overhead Obstruction Interlock 

Teach a duck position pushing the TEACH button.



Extend the tool halfway between the destination and the home position. Hoist the tool approximately 10 inches.

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D364000171-PRO-001 03 14



Push TEACH to prepare the tool to teach the duck position. Then push AUTO to set the duck position. Push TEACH twice to exit the TEACH mode.



Lower the roughneck and retract it all the way to its home position.



Verify that the carriage does not move when the TW UP or DOWN function is applied.



Verify that the SW does not move when the SW UP function is applied.



Push OVERRIDE and hoist the tool until it is above the duck position.



Release OVERRIDE



Verify that the tool moves below the duck position before extending/ retracting when the DEPLOY EXTEND or RETRACT function is applied.



Lower the tool completely and extend it to its destination.



Hoist the carriage, and verify that it stops hoisting when the arm reaches the duck height.



Remove the duck position by putting the tool into TEACH mode (push TEACH to put it into TEACH mode).



Retract the tool to its home position and push TEACH to prepare to teach the duck position.



Push AUTO to set the duck position.



Push TEACH to prepare the tool to teach the home position.



Push AUTO to set the home position (when the duck position and the home position are set to the same position, this removes the duck position).

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 



D364000171-PRO-001 03 15

Push TEACH to exit the TEACH mode.

Power Slips Interlock 

Put the tool in POWER SLIPS mode by pushing the POWER SLIPS button. Extend the tool to its destination.



Verify that the Main carriage does not lower when activating TW DOWN.

End of Stroke Interlock (DO NOT SAVE OBJECTS WHEN FORCING VALUES IN THE CONTROL SYSTEM) 

Fully lower the main carriage, and then raise it an inch.



Clamp the TW and SW.



Force values into control system simulating the carriage being lowered to end of stroke.



Verify that the TW and SW unclamp when the Main carriage reaches the end of cylinder stroke.



Verify that the TW and SW cannot clamp when the TW CLAMP and SW CLAMP functions are activated.



Remove forced value simulating the carriage being lowered to end of stroke.



Verify forced value was removed



Fully raise the main carriage, and then lower the main carriage an inch.



Clamp the TW and SW.



Force value into control system simulating the carriage being raised to end of stroke



Verify that the TW and SW unclamp when the Main carriage reaches the end of cylinder stroke.



Verify that the TW and SW cannot clamp when the TW CLAMP

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D364000171-PRO-001 03 16

and SW CLAMP functions are activated. 

Remove forced value simulating the carriage being raised to the end of stroke.



Verify forced value was removed.



Lower the SW until it is 5 inches from the lower end of cylinder stroke.



Clamp the SW.



Force value into control system simulating the SW being lowered to the end of stroke



Verify SW unclamps when the carriage reaches the end of cylinder stroke.



Verify that the SW cannot clamp when the SW CLAMP function is activated.



Remove forced value simulating SW being lowered to end of stroke.



Verify forced value was removed.



Raise the SW carriage until it is 5 inches from the upper end of cylinder stroke.



Clamp the SW.



Force value into control system simulating the SW being raised to the end of stroke.



Verify that the SW unclamps when the carriage reaches the end of cylinder stroke.



Verify that the SW cannot clamp when the SW CLAMP function is activated.



Remove forced value simulating the SW being raised to the end of stroke.

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Document number Revision Page

 





D364000171-PRO-001 03 17

Verify forced value was removed.

Non Driven Motion Interlock 

Raise the tool about 20” from its fully lowered position



Clamp the TW and SW.



Force value into control system simulating the carriage being lowered.



Verify that both the TW and SW unclamp when the carriage lowers approximately an inch.



Remove forced value simulating carriage being lowered.



Verify forced value was removed.



Clamp the TW and SW.



Force value into control system simulating carriage being raised.



Verify that both the TW and SW unclamp when the carriage raises approximately an inch.



Remove forced value simulating carriage being raised.



Verify forced value was removed.

TDS Backup Interlock 

Put the tool into TDS BACKUP mode.



Verify that the SW cannot clamp when the SW CLAMP function is activated.

Traverse Too Far Interlock 

Extend the roughneck to its destination.

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Document number Revision Page

 





D364000171-PRO-001 03 18

Verify that the tool cannot slew when the SLEW CW and CCW function is activated.

Wrench Not Centered Interlock 

Rotate the TW to the full make up position.



Activate the DEPLOY EXTEND or RETRACT function and verify that the tool cannot extend or retract until the TW is centered.

Off Path Interlock 

Change the DESTINATION.



Verify that the tool cannot EXTEND or RETRACT when the DEPLOY EXTEND or RETRACT function is activated.



Verify that the Main carriage cannot raise when the TW UP function is activated.



Verify the SW cannot raise when the SW UP function is activated.

TW Make/Break Interlock  Activate the TW MAKE or BREAK function.  While activating the MAKE or BREAK function, verify that the TW cannot clamp or unclamp when the TW CLAMP or UNCLAMP function is activated.

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D364000171-PRO-001 03 19

L. SAFETY DEVICES TEST: 1. Mechanical Safety Devices:  Retract the arm completely and verify that the storage pin can be installed.  Ensure the locking plates on the arm can be installed to mechanically lock the lower primary and lower secondary arms in place 2. Hydraulic Enable Test:  Turn the valve selector on the enable manifold to MAN (Manual) and verify that the tool cannot be operated electrically via the wireless remote control.  Turn the valve selector on the enable manifold to AUTO and verify that the tool cannot be operated via the Pilot Valve Manual Controls. 3. Electrical Safety Devices:  In AUTO mode, ensure that all four (4) E-STOP buttons (two on the torque wrench, one on the electrical J-box and one on the remote control console) effectively stops the tool during any operation.  

Verify the four (4) safety bumpers effectively stop the tool during any operation by pushing-on the safety rubber. Verify the RETRO-REFLECTOR sensors (left and right sensors) stop the tool during any operation by blocking the beam between the sensor and the reflector

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M.

D364000171-PRO-001 03 20

OPTIONAL MANUAL CONTROL CONSOLE OPERATIONS The Automated ST-120 is shipped without the manual control console installed. If the customer wishes to use the manual control console during commissioning procedures, it must be installed on the unit. The following procedure details the steps to follow for manual control console operation commissioning. It is recommended that the manual control console be removed from the Automated ST120 after commissioning is complete. It is susceptible to being damaged or ripped off the ST-120 during automated operations if it comes in contact with rig structure or other equipment 1. With a connection in well center (mousehole optional), position the ST120 toward well center (or mousehole). 2. Use the Deploy lever to extend the tool until the torque wrench and spin wrench are aligned properly. Keep hands clear of the pipe! 3. Adjust the height of the tool using the carriage lever until the connection is located above the lower clamp dies, and below the upper clamp dies 4. Adjust the torque pressure valve by turning the adjustment knob located on the main control panel counterclockwise (decrease) until it stops. Verify the torque gage reads zero. Hold the TW lever in the BREAK position. While holding the TW lever, turn the adjustment knob until the desired torque is set. Position the reference indicator (red needle) on the torque gage at the desired torque value. 5. Make the connection in the following sequence: Raise the S.W. 6” to allow for thread compensation. 

Hold the MODE lever in the SW position and activate the TW lever in the 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 the SW lever in the IN position until the drill pipe shoulder. Release.



Hold the TW lever in the BREAK position until the upper wrench is aligned in the MAKE position. Release

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D364000171-PRO-001 03 21



Hold the TW lever in the CLAMP position until the upper jaws make contact with the drill pipe.



While holding TW-CLAMP, move the TW lever to the MAKE position until the required torque is reached



Move the TW lever to UNCLAMP to retract jaws. Release



Hold the MODE lever in the CENTER position until the upper wrench is centered. Release. 6. Break the connection in the following sequence: Break out torque should be set 10% higher than makeup torque 

To place the upper wrench in the “break-out” position, hold the TW lever in the MAKE position until the wrench stops rotating. Release



Hold the TW lever in the CLAMP position.



While holding TW-CLAMP, move the TW lever to the BREAK position until the connection is broken



Hold the MODE lever to the SW position until the upper jaws retract from the pipe. Release.



Hold the SW lever in the CLAMP lever, move the SW lever to the OUT position until the connection is unthreaded. Release



Hold the SW lever to the UNCLAMP



Hold the TW lever to UNCLAMP to retract the jaws. Release



Hold the MODE lever in the CENTER position until the upper wrench is centered. Release

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D364000171-PRO-001 03 22

The undersigned representatives hereby acknowledge that all checkout and testing work, as listed herein, has been successfully completed for this ST-120:

______________________________. NOV Representative ______________________________. Customer Representative ______________________________. ST-120 Model Number ______________________________. ST-120 Serial Number

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Service Manual ST-120 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.

D811000557-MAN-001

06

Form D811001123-GEN-001/07

Revision History 06

09.03.2015

Six Issue

M. Taylor

A. Sharma

J. Adkins

05

15.03.2014

Fifth Issue

M. Taylor

A. Sharma

A. Jones

04

21.09.2013

Fourth Issue

M. Taylor

A. Sharma

A. Jones

03

06.03.2010

Third Issue

P. Solovyov

A. Jones

J. Walker

02

16.01.2009

Second Issue

P. Solovyov

J. Walker

J. Walker

01

09.12.2008

First Issue

P. Solovyov

A. Jones

B. Winter

Rev

Date (dd.mm.yyyy)

Reason for issue

Prepared

Checked

Approved

Change Description Revision

Change Description

01

First Issue

02

• Added Section: Making Connections (Page 4-4). • Updated Arm Assembly Control plaque throughout document: From: Lever LEFT SLEW RIGHT To: CW SLEW CCW

03

• Update from “User Manual” to “Service Manual” throughout document and use current template. • Replaced figures with latest model. • Updated and added new procedures in Chapters 2 through 7.

04

05

06

D811000557-MAN-001 Revision 06 www.nov.com

• • • • • •

Updated to the current template. Added five steps under the General System Safety Practices section (Page 1-4). Added Information Note in Replacing Components section (Page 1-5). Added Figure 1-1 (Page 5-1). Added Safety Alert Advisory (page 5-25). Changed Figure 5-14, (page 5-26) and updated Changing Brake and Gearbox Oil procedure to reflect Safety Alert Product Bulletin number 10729506-PIB,  Rev 1. • Updated Removing Torque Wench procedure and illustration (Page 5-18 and 5-19) to reflect released Safety Alert Product Bulleting number 10731752-PIB. • Removed Service Center information from Troubleshooting Chapter since it is in Chapter 1. • • • • • • • •

Updated information for equipment revised design. Added optional equipment component (pipe centralizer). Added five year inspection procedures. Added Carriage-Down Locking procedure and illustration. Updated inspection, lubrication, and maintenance schedule. Updated description format of major components. Updated all illustrations to conform with Technical Publication guidelines. Updated Installation Chapter to include topics not covered or partially covered in separate installations document. • Added advisories where requested. • Updated Troubleshooting content. • Revised verbiage for Change Oil Guidelines “Note” on page 109 in the Maintenance chapter. • Updated to Technical Publication’s new standards and template • Updated revision number to 6.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safe Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 2: Description Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tool Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Mounting Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Floor Socket Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Floor Base Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Floor Socket Mount Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Floor Base Mount Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Iron Roughneck Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Pipe Centralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Control Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Floor Socket and Floor Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Hydraulic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Auxiliary Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Bit Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Pinch Point Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Table of Contents Chapter 3: Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Rig Specific Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Drill Floor Position Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Unpacking and Handling the ST-120 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . 35 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removing the Transport Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Lifting the ST-120 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Lifting Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 4: Operation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Quick Reference Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Do's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Don’ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Pre-operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Normal Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Normal Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Operating the ST-120 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Positioning and Adjusting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Disabling and Enabling the Hydraulic System from the Control Console . . . . . . . . . . . . . . . . . . . 46 Adjusting the Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Moving the Grounding Links to the Upper Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Setting up the Bit Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Using the Bit Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Locking Out the ST-120 Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Locking out the CARRIAGE-DOWN on the ST-120 Tall Column . . . . . . . . . . . . . . . . . . . . . . . . . 57 Hydraulic Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Slew Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Opening the Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Opening the Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Moving the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Securing the Iron Roughneck on a Floating Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Transporting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Removing the Transport Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Reinstalling the Transport Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Storing the ST-120 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Return to Service After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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Table of Contents Chapter 5: Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Installing or Removing Safety Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Maintaining Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 ST-120 Iron Roughneck General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Replacement of Worn or Damaged Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Equipment Main Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Hydraulic Hose and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Disposal of Worn Parts and Used Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Torquing Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Locking out the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Recommended Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Lubricating the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Inspection, Lubrication, and Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Inspecting Hardware and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Lubricating the Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Lubricating the Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Lubricating the Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Lubricating the Arm and Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Lubricating the Column Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Five Year Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Major Weldments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Inspecting Major Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Rig Floor Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Wear Due to Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 NDE Inspect the Torque Wrench Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 NDE Inspect the Jaw Assembly Cap Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 NDE Inspect the Jaw Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 NDE Inspect the Socket Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 NDE Inspect the Column Base Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Removing and Replacing Worn or Damaged Components . . . . . . . . . . . . . . . . . . . . . . 96 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Replacing the Wrench Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Removing Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Replacing Spin Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Disassembling the Spin Rollers for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Spin Wrench Rollers Assembly Retention Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Removing the Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Changing Intensifier Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Changing Inlet Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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Table of Contents Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Changing Oil Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Changing Brake and Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Chapter 6: Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Troubleshooting Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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List of Figures Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 2-7. Figure 2-8. Figure 2-9. Figure 2-10. Figure 2-11. Figure 2-12. Figure 2-13. Figure 2-14. Figure 2-15. Figure 2-16. Figure 2-17. Figure 2-18. Figure 2-19. Figure 2-20. Figure 2-21. Figure 2-22. Figure 2-23. Figure 2-24. Figure 4-1. Figure 4-2. Figure 4-3. Figure 4-4. Figure 4-5. Figure 4-6. Figure 4-7. Figure 4-8. Figure 4-9. Figure 4-10. Figure 4-11. Figure 4-12. Figure 4-13. Figure 4-14. Figure 4-15. Figure 4-16. Figure 4-17. Figure 4-18. Figure 4-19. Figure 4-20. Figure 5-1. Figure 5-2. Figure 5-3.

Iron Roughneck - front and rear view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Iron Roughneck sub-assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Floor socket assembly illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Floor base mount assembly illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Floor socket mount range of operation (1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Floor socket mount range of operation (2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Floor socket mount range of operation (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Floor socket mount range of operation (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Floor base mount range of operation (1 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Floor base mount range of operation (2 of 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Floor base mount option range of operation (3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . .13 Floor base mount option range of operation (4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . .14 ST-120 head assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Spin wrench (front and rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Torque wrench assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Pipe centralizer component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Control console (front and rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Arm assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Column assembly components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Floor socket assembly description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Floor base mount assembly description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 ST-120 hydraulic assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Bit breaker assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 ST-120 Iron Roughneck pinch point hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Positioning and adjusting the iron roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Positioning and adjusting the iron roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Head assembly control plaque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Head assembly controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Head assembly control plaque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Head assembly controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Manual control console with hydraulic enable valve . . . . . . . . . . . . . . . . . . . . . . . . . .38 Control console - front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Control console - rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Moving grounding links to the upper jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Bit breaker assembly set up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Torque wrench assembly interface with bit breaker assembly (1 of 2) . . . . . . . . . . . .45 Torque wrench assembly interface with bit breaker assembly (2 of 2) . . . . . . . . . . . .46 Arm assembly in unlocked and locked positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Carriage-down locking mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Manual slew hydraulic connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Opening torque wrench if a hydraulic failure occurs . . . . . . . . . . . . . . . . . . . . . . . . . .53 Opening spin wrench if a hydraulic failure occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Arm assembly extend cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Removing and reinstalling the Transport Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Head assembly lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Torque wrench assembly lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Spin Wrench lubrication points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

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List of Figures

Figure 5-4. Figure 5-5. Figure 5-6. Figure 5-7. Figure 5-8. Figure 5-9. Figure 5-10. Figure 5-11. Figure 5-12. Figure 5-13. Figure 5-14. Figure 5-15. Figure 5-16. Figure 5-17. Figure 5-18. Figure 5-19. Figure 5-20. Figure 5-21. Figure 5-22. Figure 5-23.

vi

Arm and column assembly lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Column base lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 NDE weldments inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 NDE inspection of the torque wrench rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 NDE inspection of the upper and lower cap plates . . . . . . . . . . . . . . . . . . . . . . . . . . .83 NDE inspection of the jaw spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 NDE inspection of the socket flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 NDE inspection of the column base flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Nord-lock bolt and washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Replacing the wrench dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Removing Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Disassembling and replacing the spin rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Disassembling the spin wrench assembly and bolt . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Disassembling the spin wrench assembly with shaft . . . . . . . . . . . . . . . . . . . . . . . . . .96 Servicing the spin wrench roller assembly and retention bolt . . . . . . . . . . . . . . . . . . .97 Removing the spin wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Changing intensifier hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Changing inlet hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Changing brake and gearbox reservoir oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Brake and gear box expansion oil tanks maintenance. . . . . . . . . . . . . . . . . . . . . . . .103

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List of Tables Table 4-1. Table 4-2. Table 5-1. Table 5-2. Table 6-1. Table 6-2. Table 6-3.

Operational Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Survival Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Maintenance Schedule listed by Major Components . . . . . . . . . . . . . . . . . . . . . . . . .79 Iron roughneck components to inspect after five years of operation . . . . . . . . . . . . . .87 Troubleshooting the Iron Roughneck in General . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Troubleshooting the Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Troubleshooting the Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

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List of Tables

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General Information

1

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 downtime.

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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General Information

Conventions Advisories

1

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

Illustrations The illustrations (figures) provide a graphical representation of equipment components or screen shots 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. 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.

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.

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. 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

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General Information

Safety Requirements

1

Safe Equipment Operation The following advisories are stated to ensure safe equipment operation and limit injury to personnel or damage to the equipment. Read and adhere to these advisories.

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

WARNING Under no circumstances should personnel place their hands or limbs in any part of the Iron Roughneck while it 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 Iron Roughneck with guards that are damaged.

!

Lock out the tool prior to replacing any guards.

!

Shut down the equipment when it is not being used.

!

Rig personnel must read and understand the information provided in this manual and be thoroughly trained before operating the Iron Roughneck.

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General Information

Safety Requirements

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.

Routine Maintenance Equipment must be routinely maintained.

!

6

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

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General Information

1

Equipment Disposal The equipment owner is responsible for disassembling and removing the equipment at the end of the equipment’s useful operating life. It is also the equipment owner’s 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: http://www.nov.com/

ContactUs/EmergencyContacts.aspx.

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General Information

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Description

2

Introduction This chapter describes the ST-120 Iron Roughneck tool assemblies and components. It is essential that the operators have the required knowledge, education, and training before operating this tool and related equipment systems. The ST-120 Iron Roughneck combines compact design with maximized reach and takes it to an unprecedented level. Completely retracted, this tool extends just over 5 feet from the pivot, minimizing its footprint and leaving more room on the rig floor. Fully extended, this tool travels a full twelve feet, allowing versatile layout configurations. With its trackless design, the ST-120 continues to improve drill floor safety. The ST-120 Iron Roughneck is a drill floor tool used for make up and break out of drilling tubular connections. Designed for use on offshore and large land rigs, the durable Iron Roughneck features a manually operated extend/retract scissor-arm system. The Iron Roughneck allows clearance around the well center and mousehole during use or when placed in the parked position. This tool can make or break all tool connections from 3-7/8-10 inches outside diameter, and can handle nominal drill pipe from 3-1/2" up to 10". The Iron Roughneck also makes and breaks stabilizers, spiral collars, and other bottom hole assembly (BHA) components with sufficient connection length. The head and arm assembly controls are used to operate the ST-120 Iron Roughneck. For convenient operation, the control console assembly can be mounted on the front left or right side of the ST-120 Iron Roughneck head assembly. The hydraulic control components safely and quickly provide up to 100,000 ft-lb makeup torque and 120,000 ft-lb breakout torque. The ST-120 works at well center and the mousehole. The tool can be rotated around the column into the storage position using the supplied controls. For detailed information on operating the ST-120 Iron Roughneck, refer to section titled Operating the ST-120 Iron Roughneck on page 41.

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2

Description

Tool Orientation The Iron Roughneck head assembly can be positioned over well center or mousehole for tubular makeup and breakout procedures. Rear

Left

Front

Right

Front View

Right

Rear

Front

Rear View

Left

Figure 2-1. Iron Roughneck - front and rear view

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2

Description

Tool Orientation

General Description The ST-120 sub-assemblies are identified in figure 2-2.

Arm assembly

Spin wrench assembly

Torque gauge Torque wrench assembly

Head assembly controls

Arm assembly controls

Front Front view

Column

Arm assembly extend/retract cylinder Arm function manifold (behind guard)

Guard

Rear

Rear view Figure 2-2. Iron Roughneck sub-assemblies

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Description

Specifications This section provides tool specifications for the Iron Roughneck main assemblies.

Hydraulic Requirements Required Operating Pressure

2,500 psi (172 bar)

Required Flow Rate

45 gpm (170 lpm)

Maximum Input Pressure

3,000 psi (206 bar)

Minimum Input Pressure

2,500 psi (172 bar)

Maximum Flow Rate

65 gpm (246 lpm)

Supply Connections

1" pressure, 1-1/4" tank, and 1/2" drain

Spin Wrench Speed

80 rpm on 5" OD Tubular

Torque

3,000 ft-lb (4,067 N-m) on 5" OD Tubular

Drill Pipe Diameter

3-1/2" to 10"

Torque Wrench

12

Makeup Torque

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

Breakout Torque

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

Tool Joint Connection Range

3-7/8 in. to 10 in.

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Description

Specifications

Mounting Assemblies The ST-120 Iron Roughneck has the following two options for mounting the equipment for operation: • The floor socket mount assembly • The floor base mount assembly

Floor Socket Mount Assembly With the floor socket mount assembly, the ST-120 Iron Roughneck can be installed on the drill floor using a single floor mounted socket with no hanging cable. Figure 2-3 shows this option.

Spin wrench assembly

Socket mounted column Arm assembly Guide

Torque wrench assembly

Floor socket assembly Figure 2-3.

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Drill floor

Floor socket assembly illustration

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Specifications

Description

Floor Socket Mount Option

Floor Base Mount Assembly With the floor mount assembly option, the ST-120 Iron Roughneck can be installed on the drill floor using a floor base assembly with an upper tieback assembly (as shown in figure 2-4) to secure the Iron Roughneck to the rig structure.

Upper tieback

Column extension for upper tie-back

Base mounted column

Spin wrench assembly Arm assembly

Guide

Torque wrench assembly

Floor mount assembly

Drill floor

Figure 2-4. Floor base mount assembly illustration

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Description

Specifications Floor Socket Mount Option

2

Floor Socket Mount Option The floor socket mount option is flexible for positioning the ST-120 according to the customer rig floor specifications. Figure 2-5 through figure 2-8 show range of operation for the floor socket mount option.

Fully Retracted Top View

*Maximum slew angle is ± 90° as s shown. For deviation, consult National Oilwell Varco Engineering.

89.64 in. (2277 mm) 62.42 [1585]

Tool Outline

R66.94 in. (R1700 mm)

51.20 in. (1300 mm)

4.50 in. 1638 mm)

±90° *

60° P34.77 in. (R883 mm)

Control Assembly Center of Rotation

47.03 in. 1195 mm

47.03 in. (1195 mm)

Fully retracted and lowered side view

Fully retracted and lowered front view

20.42 in. (519 mm)

Center of gravity

Center of spin wrench rollers

104.32 in. (2650 mm)

*59.15 in. (1502 mm)

47.03 in. (1200 mm)

Connection height

Floor socket

*31.40 in. (798 mm)

Drill floor

* *Vertical dimensions vary by ± 0.85" as the arm extends/retracts. Figure 2-5. Floor socket mount range of operation (1 of 4) D811000557-MAN-001 Revision 06 www.nov.com

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2

Specifications

Description

Floor Socket Mount Option

Fully extended top view 237.20 in. (6025 mm) 190.85 in. (4848 mm)

5800 in. (1473 mm) 64.50 in. (1638 mm)

Fully extended and fully lowered side view 112.36 in. (2854 mm)

Socket mounted column Arm assembly

42.00 in.

Spin (1067 mm) wrench

Center of gravity

Guide

Center of spin wrench rollers 105.22 in (2673 mm

6037 in. (1533 mm) 79.95 in. (2031 mm)

46.76 in. (1188 mm)

Floor socket assembly

60.86 in. (1546 mm) 26.55 in. (674 mm)

15.70 in. (399 mm)

Torque wrench

33.10 in. (841 mm)

Connection height

Socket center line Figure 2-6. Floor socket mount range of operation (2 of 4)

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Description

Specifications

2

Fully retracted top view

93.39 in. (2372 mm) R39.23 (R996 mm)

62.42 (1585 mm)

64.50 in. (1638 mm)

R66.94 in. (R1700 mm)

51.20 in. (1300 mm)

Center of rotation

47.03 in. (1195 mm)

Fully retracted and fully raised side view

Fully raised front view

47.06 in. (1195 mm)

Center of gravity Center of Spin wrench rollers

145.63 in. (3699 mm)

85.60 in. (2174 mm)

20.42 in. (519 mm)

Connection height

*101.15 in. (2569 mm)

*73.40 in. (1864 mm)

* *Vertical dimensions vary by ± 0.85" as the arm extends/retracts. a

Figure 2-7. Floor socket mount range of operation (3 of 4)

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Specifications

Description

Floor Base Mount Option

Fully extended top view 233.46 in. (5930 mm) 190.85 in. (4848 mm)

58.00 in. 64.50 in. (1473 mm) (1638 mm)

Fully extended and fully raised side view 112.36 in. (2854 mm) 42.00 in. (1067 mm)

Center of gravity

Center of spin wrench rollers

147.22 in. (3739 mm

145.63 in. (3699 mm)

102.37 in. (2600 mm)

121.95 in. (3097 mm)

Connection height

85.02 in. (2061 mm) 68.55 in. (1741 mm)

Socket center line

60.52 in. (1537 mm)

55.86 in. (1419 mm)

102.86 in. (2613 mm)

75.10 in. (1908 mm)

Rig Floor

Figure 2-8. Floor socket mount range of operation (4 of 4)

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Description

Specifications Floor Base Mount Option

Floor Base Mount Option The floor base mount option is flexible for positioning the ST-120 according to customer rig floor specifications. Figures 2-9 through figure 2-12 show the range of operation for the floor base mount option. Fully retracted and lowered top view 138.42 in. (3516 mm) 89.64 in. (2277 mm)

Column tie-back to rig

62.42 in. (3516 mm)

R66.94 in. (R1700 mm)

51.20 in. (1300 mm)

34.77 in. (R883 mm)

Center of rotation 76.00 in. (1930 mm)

47.03 in. (1195 mm)

Fully retracted and fully lowered front view

Fully retracted and fully lowered side view

47.03 in. (1195 mm) 20.42 in. (519 mm)

* *Vertical dimensions vary by ± 0.85" as the arm extends/retracts.

Center of gravity 155.75 in. (39.65 mm)

Center of spin wrench rollers

*60.15 in. (1528 mm)

48.33 in. (1228 mm)

*32.40 in. (823 mm)

Connection height These areas should be kept clear for tool operation.

Floor mount option only available with the tie-back rig.

Drill Floor

Figure 2-9. Floor base mount range of operation (1 of 4)

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Specifications

Description

Floor Base Mount Option

Fully extended top view

233.46 in. (5930 mm) 190.85 in. (4848 mm)

58.00 in. (1473 mm) 64.50 in. (1638 mm)

Fully extended side view

Column extension for upper tie-back 112.36 in. (2854 mm)

Floor base* mounted column

42.00 in.

Arm assembly

Spin (1067 mm) Wrench

Center of gravity

Guide

Center of Spin Wrench Rollers 106.22 in. (2698 mm)

61.37 in. (1559 mm)

47.76 in. 80.95 in. (1213 mm) (2056 mm)

61.86 in. (1571 mm) 27.55 in. (700 mm)

34.10 in. (866 mm)

19.52. in. (496 mm)

Torque wrench

14.86 in. (377 mm)

Connection height

Figure 2-10. Floor base mount range of operation (2 of 4)

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Description

Specifications

Fully retracted and fully raised top view 138.42 in. (3516 mm)

Column Tie-Back to Rig

89.64 in. (2277 mm) 62.42 in. (1585 mm)

R66.94 in. (R1700 mm)

51.20 in. (1300 mm)

R34.77 in. (R883 mm)

Center of Rotation 76.00 in. (1930 mm)

47.03 in. (1195 mm)

Fully retracted and fully raised front view

Fully retracted and fully raised side view 47.03 in. (1195 mm) 20.42 in. (519 mm)

* *Vertical dimensions vary by ± 0.85" as the arm extends/retracts.

Center of gravity Center of spin wrench rollers

146.63 in. (3724 mm)

86.60 in. (2200 mm)

*102.15 in. (2595 mm)

Connection height *74.40 in.

(1890 mm)

Column base

Rig floor

Figure 2-11. Floor base mount option range of operation (3 of 4)

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Specifications

Description

Fully extended and fully raised top view 233.46 in. (5930 mm) 190.85 in. (4848 mm)

58.00 in. (1473 mm) 64.50 in. (1633 mm)

Fully extended and fully raised side view 112.36 in. (2854 mm)

42.00 in. (1067 mm)

Center of gravity

Center of spin wrench rollers

5148.22 in. (3765 mm) 122.95 in. (3123 mm)

103.37 in. (2626 mm)

103.86 in. 86.02 in. (2185 mm) 69.55 in. (1767 mm)

Connection (2638 mm) height 76.10 in. 61.52 in. 56.86 in. (1563 mm) (1444 mm)

(1933 mm)

Figure 2-12. Floor base mount option range of operation (4 of 4)

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Description

2

Iron Roughneck Major Components The following assemblies make up the ST-120 Iron Roughneck: • Head assembly – Spin wrench assembly – Torque wrench assembly, which includes the pipe centralizer component if available on specific  ST-120 Iron Roughnecks • Control console • Arm assembly • Column assembly • Floor socket assembly and floor base assembly • Hydraulic assembly

Head Assembly The head assembly includes the spin wrench and torque wrench assemblies. It is connected to the arm assembly. Spin wrench hydraulic service loop drag chain

Spin wrench clamp manifold assembly

Intensifier hydraulic filter with ball valve

Spin wrench assembly

Torque wrench assembly

Front Figure 2-13. ST-120 head assembly components

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Iron Roughneck Major Components

Description

Spin Wrench Assembly The spin wrench rollers grip the connection and spins with a torque of 3000 ft-lb on 5" OD. . Guard

Motors (4)

Clamp cylinder

Spin rollers (4)

Front

Spin wrench hydraulic clamp manifold assembly

Rear Isometric View

Front Isometric View Rear Figure 2-14. Spin wrench (front and rear)

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Description

Iron Roughneck Major Components

Torque Wrench Assembly The torque wrench assembly can make up connections with a maximum torque of 100,000 ft-lb, and break out connections with a maximum torque of 120,000 ft-lb.

Torque cylinder (4 places)

Torque wrench assembly plate

Clamp cylinder (6 places)

Upper dies (3 places)

Right

Left

Lower dies (3 places)

Isometric view

Front

Figure 2-15. Torque wrench assembly components

Pipe Centralizer The pipe centralizer (if equipped on your ST-120 Iron Roughneck) enables the drill pipe head to be concentric around the tubular when making or breaking connections. The pipe centralizer assembly consists of: • One pair of centralizer jaw plates • A hydraulic cylinder assembly that opens and closes the centralizer The hydraulic supply line to the torque wrench clamp cylinders also provides hydraulic pressure to the centralizer clamp cylinder. When a torque wrench clamp command is given, the centralizer clamps on the tubular before the torque wrench dies come in contact with the tubular. The force of the centralizer positions the torque wrench properly around the tubular. D811000557-MAN-001 Revision 06 www.nov.com

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Iron Roughneck Major Components

Description

Head assembly Reference only

Front

Torque wrench assembly

Jaw plate

Pipe centralizer Rear

Cylinder assembly

Travel block

Jaw plate

Pipe centralizer Rear view

Figure 2-16. Pipe centralizer component

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Description

Iron Roughneck Major Components

2

Control Console Assembly The ST-120 Iron Roughneck control console is installed on the front of the head assembly and can be mounted on the front left or front right side of the head assembly and adjusted out 90° depending on the rig floor space accommodations.

Arm assembly control plaque

Hydraulic Enable

Head assembly control plaque

(If equipped)

Torque adjustment knob

Torque gauge

CENTER MODE SW

UNCLAMP SW CLAMP

UNCLAMP TW CLAMP

OUT SW IN

BREAK TW MAKE

UP SW DOWN

Head assembly controls

RETRACT ADJUST EXTEND

UP CARRIAGE DOWN

CW SLEW CCW

RETRACT DEPLOY EXTEND Control Console - Front View

Arm Assembly Controls

Control Console - Rear View

Figure 2-17. Control console (front and rear)

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Iron Roughneck Major Components

Description

Arm Assembly The ST-120 arm assembly extends and retracts the Iron Roughneck. It supports and provides horizontal travel of the head assembly for positioning at the well center, mousehole, and in parked or standby positions.

Center Support Weldment

Arm lock plate

Rear

Cylinder Assembly (2)

High Pressure Hydraulic Filter

Hydraulic Shut Off Valve

Arm Assembly Function Manifold Figure 2-18. Arm assembly components

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Description

Iron Roughneck Major Components

Column Assembly The column assembly, which is mounted either on a floor socket or floor base assembly, provides vertical and rotational travel for the ST-120 Iron Roughneck to align with either the mousehole or well center as required.

Column assembly

Hydraulic service loop (drag chain)

Column assembly lift cylinder Arm assembly

Arm assembly extend or retract duplex cylinder

Return line

Drain line Supply line

Figure 2-19. Column assembly components

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Description

Iron Roughneck Major Components

Floor Socket and Floor Base Assembly The floor socket and floor base assembly allows the Iron Roughneck to rotate for proper alignment over the well center or mousehole. The ST-120 Iron Roughneck can be installed on the drill floor using a single, floor-mounted socket or by using a floor base assembly with an upper tie-back to the rig structure. Figure 2-20 and figure 2-21 shows the floor socket and floor base components and their order of assembly.

Hydraulic motor

Hydraulic brake

Idler shaft (2 places)

Column lock pin (4 places)

Column base Turntable bearing Idler gear

Pinion gear

Figure 2-20. Floor socket assembly description

Figure 2-21. Floor base mount assembly description

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Iron Roughneck Major Components

2

Description

Hydraulic motor

Hydraulic brake

Idler shaft (2 places)

Column lock pin (4 places)

Column base

Turntable bearing Idler gear Pinion gear

U-joint ring

U-joint cross U-joint pin (2 places)

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Iron Roughneck Major Components

Description

Hydraulic Assembly The hydraulic assembly provides operation functions for movable components on the ST-120 Iron Roughneck. Figure 2-22 shows components on the equipment that are hydraulically controlled or components that are affected by the hydraulic system.

Hydro-pneumatic accumulator Hydraulic pressure intensifier

Spin wrench assembly

Arm assembly

Inlet high pressure hydraulic filter

Head unit function manifold Torque wrench assembly

Control console assembly

Arm assembly function manifold

Hydraulic shut-off valve

Rear Figure 2-22. ST-120 hydraulic assemblies

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Description

Iron Roughneck Major Components

Auxiliary Equipment This section describes the bit breaker assembly, which is auxiliary equipment used to makeup or breakout drill bit to the drill pipe string.

Bit Breaker Assembly Torque wrench connection

Bit breaker frame top open area

(4 places)

Uniform holes in the side panels can be used to adjust the height of the guide plates, lock plates, and adapter plates.

Bit Breaker Support

Clevis Pin

(1 each side)

Cotter Pin

Bit Breaker Frame

Lock plate (1 each side)

Retaining bar

Glider bar (1 each side)

Guide plate (1 each side)

PDC bit adapter plate Quick release pin with safety chain

Tri cone adapter plate Figure 2-23. Bit breaker assembly

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Description

Pinch Point Hazards Pinch point hazards are areas on the equipment that presents potential incidents for body parts to become caught or pinched between two objects. These areas should be avoided or personnel should use extreme care during any movement of the equipment to avoid serious or fatal bodily injury.

Keep all body parts clear of pinch point hazard areas.

Figure 2-24. ST-120 Iron Roughneck pinch point hazards

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Installation

3

Introduction

!

Before installing or removing the equipment or any of its components, you must read and understand the content in the General Information chapter, as well as the applicable installation advisories and procedures in this chapter.

Rig Specific Installation Procedures Depending on the equipment and rig configuration, rig-specific installation procedures are provided in the equipment drawing package included in the shipping package.

Drill Floor Position Recommendations The ST-120 Iron Roughneck must be secured to the rig floor and the supporting structure must support the weight of the equipment. For information on dimensions, weights, rig-floor loading, and rig-floor layout drawings, see the section titled Specifications and the General Arrangement Drawing (GAD) in the drawing package. Procedures for installing the ST-120 Iron Roughneck are provided in the drawing package included in the shipping documentation package.

Unpacking and Handling the ST-120 Iron Roughneck When unpacking and handling the equipment, special care is required. This section provides guidelines that must be followed prior to unpacking and handling the Iron Roughneck.

Requirements !

WARNING

Failure to adhere to requirements in this section while unpacking the equipment can cause serious injury or death to personnel or may result in damage to the equipment. • Ensure that the weight is independently supported prior to unpacking. • Ensure that the procedure for properly lifting the equipment is followed. Refer to the installation documentation included in the shipping package. • Inventory all components and parts to ensure that no equipment components are missing or incorrect. Contact the National Oilwell Varco Service Center if parts are missing or incorrect. For contact information, see the section titled Service Centers on page 7. • Inspect all components and parts for shipment damage and corrosion. Notify the shipment carrier if components or parts were damaged during shipment.

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Unpacking and Handling the ST-120 Iron Roughneck

Installation

Removing the Transport Skid When unpacking the ST-120 for installation purposes, the transport skid must be removed. For the procedure for removing the transport skid, see the section titled Removing the Transport Skid on page 66.

Lifting the ST-120 Iron Roughneck When lifting the Iron Roughneck, lift the equipment from designated lift points only. For lifting procedures, refer to the Installation supplement documentation in the SMDL included in the shipping package information.

Lifting Recommendations Always use the lifting lugs and shackles provided. No other part of the Iron Roughneck is rated for, nor intended to support the full weight of the equipment. Care should be taken to ensure that the shackles are properly secured on the tool, and the slings are rated for the appropriate weight.

!

WARNING

Always ensure that hoisting operations are conducted safely to avoid equipment damage or injury to personnel.

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Operation

4

Introduction

!

Before operating the equipment, ensure that you read and understand the content in the General Information chapter as well as the applicable operating advisories and procedures in this chapter.

The ST-120 Iron Roughneck has three operator interface methods used to control the equipment. Depending on the equipment and rig configuration, one or more of these methods can be used to access and operate the Iron Roughneck. The control options include the following: • Manual control console - For operating instruction on using the manual control console, see the section titled Control Console on page 41. • Wireless Remote Control - For operating instruction on using the wireless remote control, refer to the “Wireless Controller Manual” provided in the drawing package. • Amphion™ Control System - For detailed instructions on using the Amphion control system, refer to the Amphion Operator’s Guide supplied with the NOV equipment rig documentation package. This chapter contains the following information for operating the ST-120 Iron Roughneck: • Precautions • Operating the ST-120 Iron Roughneck • Hydraulic Failure Operation • Securing the Iron Roughneck on a Floating Vessel • Transporting the Iron Roughneck • Storing the ST-120 Iron Roughneck

Precautions Prior to operating the ST-120 Iron Roughneck, read and understand the following precautions to prevent personal injury or damage to the equipment. • Maintain awareness of pinch point hazards where body parts can get caught between moving and stationary parts of the equipment. If possible, avoid these areas when performing procedures with the equipment. • Wear personal protective equipment (PPE) when performing maintenance including eye protection, gloves, hard hat, and protective footwear. • Be familiar with the hydraulic schematics as well as the equipment flow and pressure requirements. • If draining fluids are necessary, properly discard used fluids. • Drain the hydraulic fluid reservoirs, carefully open hydraulic lines, and then drain the oil in a container to avoid floor spills.

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Fluid spills on the rig floor presents slip and fall hazards to personnel. All drained fluids need to be properly collected and discarded according to regulated standards. Failure to follow this caution could result in injury to personnel.

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Precautions

Operation

• Do not remove any hydraulic components or parts until pressure has been relieved. • Observe and obey all warning and caution labels and placards on the equipment. • Clean or replace all equipment plaques so that they are readable. • Clean the equipment of accumulated mud or debris as often as required. When operations at heights, the potential for personal injury or injury to personnel from dropped objects exists.

!

Adhering to the recommended guidelines in the secondary retention and prevention of dropped objects documents will greatly reduce the risk of falling objects from installed equipment components and will prevent injury to personnel working on the rig floor.

Reference: For more information on the secondary retention of equipment components, refer to the Design Guideline, Secondary Retention and Prevention of Dropped Objects documentation included in the equipment shipping package

WARNING Under no circumstances should personnel place their hands or limbs in any part of the iron roughneck while it is enabled or being operated. Failure to adhere to the warning may result in severe injury to personnel.

WARNING Ensure that all personnel are clear of the equipment operating path before operating or restarting the iron roughneck. If the tool moves unexpectedly, shut down the equipment, lock out the hydraulic system immediately, and inspect the equipment for damage. Failure to adhere to this warning may result in severe injury to personnel or damage to the equipment.

WARNING When operating the iron roughneck, ensure that objects such as clothing or personal tools does not come in contact with the spin rollers. If objects become entangled in the spin rollers, serious personal injury or damage to the equipment may occur.

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Precautions

Operation

Quick Reference Guidelines

4

Quick Reference Guidelines The information is this section is provided to assist the operator with quick references for permitted actions as well as those actions that should not be performed. In no way does the following information replace the need for the operator to read and understand this manual in its entirety.

Do's • Actuate E-stop (hydraulic or electronic) if the equipment exhibits any abnormal behavior, Always investigate the cause of abnormal behavior and use caution when restarting the equipment after an E-stop. • Shut down the equipment when not in use. • Ensure that the storage pin is removed before operating the equipment. • Ensure that the tool joint is evenly spaced within the torque wrench opening. The tubular must be within 1/2" (13 mm) of being centered between the clamp joints. For detailed information on positioning the tubular, see the section titled Positioning and Adjusting the Iron Roughneck on page 42. • Ensure that the torque wrench is fully clamped on the pipe before activating the make or break functions. • Ensure that the torque wrench and the spin wrench are fully open before extending or retracting to or from the pipe. • Ensure that the torque wrench is centered before extending or retracting to or from the pipe. • Ensure that the arm adjustment procedures are followed. • Ensure that replacement parts are OEM parts only. • Perform scheduled inspection and maintenance procedures according to the guidelines discussed in the Description chapter of this manual. • Ensure that the ST-120 torque is set properly for the desired connection make up torque. • Check the equipment nameplate and warning plaques to ensure that they are clean and legible. Replace if necessary.

Don’ts • Do not operate the equipment when personnel are in the path of operations. • Do not place hands or any other limbs in the Iron Roughneck while the equipment is enabled or operating. • Do not clamp the torque wrench dies on hard banding. • Do not reuse Nord-Lock washers. • Do not perform maintenance unless hydraulic power is completely removed and locked from the ST-120. • Do not perform maintenance while the equipment is elevated. • Do not perform maintenance unless the arm has been locked by installing the maintenance pins. • Do not operate the spin wrench on spiral collars or any non circular tubular. • Do not clamp the spin wrench on stabilizers or bottom hole assembly tools. • Do not modify the tool in any way.

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Precautions

Operation

Pre-operation Checks The following are guidelines for checking the Iron Roughneck prior to operating the equipment. • Ensure that the Iron Roughneck is secure in the floor socket. • Ensure that the storage pin is removed. • Ensure that the arm lock plate pins are removed on both sides. • Ensure that all quick disconnect couplings are fully engaged. • Ensure that operating pressure settings are correct. • Check all fittings to ensure that there are no leaks. • Lubricate the entire Iron Roughneck and check the condition of the filters. Reference: For more information on lubricating the Iron Roughneck, see the Lubricating the Iron Roughneck on page 78.

Normal Sounds The following sounds may occur when operating the Iron Roughneck. These sounds are normal and indicates no occurrence of equipment malfunctions. • Ticking—Ticking noise occurs when jaws make contact with the pipe and the intensifier is building pressure. • Whining—The torque wrench clamp flow dividers make whining noises when the jaws are being clamped prior to making contact with the pipe. The torque wrench also makes a whining noise when the output torque is set in the lower range. • Humming—A humming sound occurs when the Iron Roughneck slews.

Normal Occurrences The following occurrences are normal during operation of the Iron Roughneck and indicates no equipment malfunctions. • The torque wrench may cycle left or right slowly when operating other functions.* • The spin wrench may move up and down when operating other functions.* • The spin wrench may drift down when raised above the first stage of the telescopic cylinder.* • The torque gauge drops to zero when going to full make position. • The spin wrench rollers may rotate very slowly when operating the other Iron Roughneck functions. • Torque gauge may read an initial torque value up to 2,000 ft-lbs even before activating the torque wrench MAKE/BREAK functions. *Component motions that occur when operating other functions is due to high return pressure when operating the Iron Roughneck

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Operation

4

Operating the ST-120 Iron Roughneck This section provides instructions for operating the ST-120 Iron Roughneck.

Control Console The control console levers are used to manually operate the Iron Roughneck head assembly (torque wrench and spin wrench) and the arm assembly. For a complete description of the control console components, see figure 2-17 on page 2-27. For instructions on operating the control console, refer to the procedures in this chapter.

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Operating the ST-120 Iron Roughneck

Operation

Positioning and Adjusting the Iron Roughneck Figure 4-1 shows how to position the ST-120 Iron Roughneck to the drill pipe.

!

Before operating the ST-120 for the first time, be sure to remove the storage pin and place it in a secure location. Do not operate the iron roughneck when the storage pin is installed.

UP CARRIAGE DOWN

RETRACT DEPLOY EXTEND

S Special care is necessary if hard banding is present. Do not grip on hard banding. D

CW SLEW CCW

RETRACT ADJUST EXTEND

M364000425 REV 02

Arm Assembly Control Plaque How to Position and Adjust the IronRoughneck To operate the arm assembly control levers, complete the following steps: 1

Hold the SLEW lever until the tool aligns with either the well center or the mousehole as required.

Left Right Right hand hand hand

4

UP CARRIAGE DOWN

5

RETRACT DEPLOY EXTEND

1

CW SLEW CCW

RETRACT ADJUST EXTEND

M364000425 REV 02

2

Shift and hold the DEPLOY lever down to the EXTEND position until the cylinders reach full extension.

3

Hold the ADJUST lever down to the EXTEND position until the torque wrench and spin wrench are aligned properly with the drill pipe.

Wrench and proper pipe alignment

!

Center drill pipe in the wrench opening within 1/2” of the center before clamping to avoid damage to the drill pipe or the equipment..

2

3

Right hand

Right hand

Arm Assembly Controls 4

Hold the CARRIAGE lever in the UP or DOWN position to align the torque wrench vertically with the drill pipe.

5 5

During operation, use the DEPLOY lever to maintain consistent alignment with the drill pipe. Figure 4-1. Positioning and adjusting the iron roughneck

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4

Operation

Operating the ST-120 Iron Roughneck

Figure 4-2 shows how the iron roughneck is positioned on the tubular. The system control levers are used to align the iron roughneck with the tubular.

Spin rollers (4 Places)

Connection pin end Torque gage

Upper dies (3 Places)

UNCLAMP TW CLAMP

BREAK TW MAKE

CENTER MODE SW

OUT SW IN

UNCLAMP SW CLAMP

UP SW DOWN

M364000424 Rev -

UP CARRIAGE DOWN

Head assembly controls

RETRACT DEPLOY EXTEND

CW SLEW CCW

Box shoulder range

RETRACT ADJ EXTEND

M364000425 REV 02

Arm assembly controls 4.69 in. 119 mm Connection box end Lower dies (3 Places)

Figure 4-2. Positioning and adjusting the iron roughneck

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Operating the ST-120 Iron Roughneck

Operation

Making Connections Figure 4-3 describes the head assembly control plaque on the ST-120 Iron Roughneck. By default, all control levers are in center positions. Figure 4-4 illustrates the head assembly control levers sequence and directions used in making up drill pipe connections.

UNCLAMP TW CLAMP

BREAK TW MAKE

CENTER MODE SW

OUT SW IN

UNCLAMP SW CLAMP

UP SW DOWN

M364000424 Rev -

Figure 4-3. Head assembly control plaque

To makeup connections, complete the following steps: 1

Shift and hold the MODE lever down in the SW position and then shift the TW lever down to the CLAMP position until the lower jaws make contact on the drill pipe. Now release both levers.

2

Shift and hold the SW lever to the UP position until the spin wrench raises approximately 6 inches.

3

Now shift and hold the SW lever down in the CLAMP position.

4

While holding the SW-CLAMP lever down, shift and hold the SW lever down to the IN position to spin in the connection until the drill pipe shoulders. Release levers.

5

Shift and hold the SW lever up to the UNCLAMP position to retract the roller carriers.

6

Shift and hold the TW lever up to the BREAK position until the upper wrench is aligned in the MAKE position. Release lever.

7

Shift and hold the TW lever down to the CLAMP position until the upper jaws make contact with the drill pipe.

8

While holding the TW-CLAMP, shift down the TW lever to the MAKE position and hold until the required torque is reached. If the wrench does not reach the required torque value in one stroke, unclamp and repeat steps 6, 7, and 8.

9

Shift the TW lever up to the UNCLAMP position to retract the jaws and then release the lever.

10

Shift the MODE lever up to the CENTER position and hold until the upper wrench is centered. Release lever.

44

Left Right hand hand

9

UNCLAMP TW CLAMP

1 7

Right hand

Right hand

Right hand

6

10

5

2

BREAK TW MAKE

CENTER MODE SW

OUT SW IN

8

1

4

Right Right Left hand hand hand

UNCLAMP SW CLAMP

UP SW DOWN

3 Right hand

Left hand Figure 4-4. Head assembly controls

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Operation

Operating the ST-120 Iron Roughneck

Breaking Connections Figure 4-5 describes the head assembly control plaque on the ST-120 Iron Roughneck. By default, all control levers are in center positions. Figure 4-6 illustrates the head assembly control levers sequence and directions breaking out drill pipe connections.

UNCLAMP TW CLAMP

BREAK TW MAKE

CENTER MODE SW

OUT SW IN

UNCLAMP SW CLAMP

UP SW DOWN

M364000424 Rev -

Figure 4-5. Head assembly control plaque

To break out connections, complete the following steps: 1

2

To place the upper torque wrench in the break out position, shift down and hold the TW lever in the MAKE position until the wrench stops rotating. Release the lever. Shift down and hold the TW lever in the CLAMP position until all jaws make contact with the drill pipe.

3

While holding the TW-CLAMP position, move the TW lever up to the BREAK position until the connection is broken. If the connection is not broken in one stroke, repeat steps 1, 2, and 3.

4

Shift the MODE lever down to the SW position and hold until the upper jaws retract from the drill pipe and then release the lever.

5

Shift SW lever up to the UP position and hold until the spin wrench raises about 6 inches.

6

Shift the SW lever down to the CLAMP position and hold.

7

While holding the SW-CLAMP lever, shift the SW lever up to the OUT position until the connection is unthreaded and then release the lever.

8

Shift the SW lever up to the UNCLAMP position to retract the jaws and the roller carriers respectively.

9

Shift the TW lever up to the UNCLAMP position to retract the jaws and then release the lever.

10

Shift up and hold the MODE lever in the CENTER position until the upper torque wrench is centered and then release the lever.

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Left Right Right Left Right Right hand hand hand hand hand hand

9

3

10

7

OUT SW IN

UNCLAMP TW CLAMP

BREAK TW MAKE

CENTER MODE SW

2

1

4

Left Right Left hand hand hand

8

UNCLAMP SW CLAMP

5

UP SW DOWN

6 Right hand

Figure 4-6. Head assembly controls

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Operating the ST-120 Iron Roughneck

Operation

Disabling and Enabling the Hydraulic System from the Control Console Procedures for disabling and enabling the hydraulic system from the control console only apply if your ST-120 Iron Roughneck is equipped with the Hydraulic enable valve as shown in figure 4-7.

Disabling the Hydraulic System To disable the hydraulic system, complete the following steps: 1.

Pull out the hydraulic enable valve on the control console.

2.

Verify that the system pressure gauge located on the arm function manifold shows that the hydraulic pressure has been released. Hydraulic enable valve

Enabling the Hydraulic System To enable the hydraulic system, complete the following step: 1

2.

UNCLAMP TW CLAMP

BREAK TW MAKE

CENTER MODE SW

OUT SW IN

UNCLAMP SW CLAMP

RETRACT DEPLOY EXTEND

CW SLEW CCW

RETRACT ADJUST EXTEND

UP SW DOWN

Push in the hydraulic enable valve to enable the hydraulic system. If the hydraulic system was previously disabled, the hydraulic valve should be pulled out. Verify that the system pressure gauge located on the arm function manifold, registers the system pressure.

The ST-120 Iron Roughneck is ready to begin normal operation.

UP CARRIAGE DOWN

Figure 4-7. Manual control console with hydraulic enable valve

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Operating the ST-120 Iron Roughneck

Adjusting the Makeup Torque National Oilwell Varco offers an additional gauge kit that can be installed in the driller’s cabin (Remote Torque Gauge Kit, hydraulic - P/N M364001310 and electric - P/N M364000785). To adjust the makeup torque, complete the following steps: 1. Turn the adjustment knob located on the main console control panel counterclockwise (decrease) until it stops.-

Torque adjustment knob

Torque gauge

Torque gauge display detail

Head assembly controls

Arm assembly controls

Figure 4-8. Control console - front view D811000557-MAN-001 Revision 06 www.nov.com

Control console (front view)

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Operating the ST-120 Iron Roughneck

2. Verify that the torque gauge reads a value between 0 - 2,000 ft-lb. If not, using a pressure gauge, measure the pressure going into the torque gauge. Verify that the reading on the torque gauge is proportional to the corresponding pressure gauge reading (10 psi = 526.3 ft-lb). If not, rotate the adjust knob on the back of torque gauge (see figure 4-9) to match the corresponding pressure gauge value. If the torque gauge still reads greater than 2,000 ft-lb, refer to table 6-2 on page 116 or contact the NOV service center for further assistance. Adjustment knob

Figure 4-9. Control console - rear view

3. Position the reference indicator (red needle) on the torque gauge at the desired torque value. 4. Actuate the TW lever in the BREAK position until it stops. While holding the TW lever in the BREAK position, turn the torque adjustment knob clockwise until the desired torque is set. 5. If the torque cylinders reach end of stroke during a makeup cycle, and the gauge reads zero, recycle the jaws and re-torque.

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Operating the ST-120 Iron Roughneck

Operation

4

Moving the Grounding Links to the Upper Jaw For bit breaking function, the upper jaw remains stationary while the lower jaw rotates. The grounding links are transferred from the lower jaw to the upper jaw.

!

!

Before moving the grounding links to the upper jaw, ensure that the hydraulic ball valve that is located on the rear of the ST-120 Iron Roughneck is off and the control levers are actuated to bleed any residual pressure. Failure to adhere to this caution may result in personal injury or damage to the equipment. Lock out the hydraulics to disable the equipment movement and to avoid personal injury or damage to the equipment. The hot surface symbol indicates the presence of a hot surface or component. Touching this surface could result in bodily injury. To reduce the risk of injury from a hot component, allow the surface to cool before touching.

To move the grounding links to the upper jaws, complete the following steps: 1. Uninstall the bolt securing the frame retaining pin to the grounding frame.

!

Before completely removing this bolt, ensure that the frame is stabilized and secure. Once the bolt is removed, the frame retaining pin could fall out the bottom of the torque wrench and get damaged or cause damage to the equipment.

2. Remove the frame retaining pin from the grounding frame and the torque wrench frame. 3. Uninstall the jaw retaining pin securing the anti-rotation link to the lower jaw. The jaw retaining pin is retained by a cotter pin that can be removed through the side of the torque wrench frame. The jaw retaining pin can subsequently be removed downwards from beneath the torque wrench. 4. Remove the anti-rotation link from the lower jaw. 5. Turn the anti-rotation link upside down and install in the upper jaw. 6. Install the jaw retaining pin to secure the anti-rotation link to the upper jaw. 7. Install the frame retaining pin through the torque wrench frame, grounding frame and the  anti-rotation link. 8. Re-install the bolt securing the frame retaining pin to the grounding frame before returning the Iron Roughneck to operation. 9. Perform steps 1-8 for both sides of the torque wrench. Due to inverting the grounding frame from the lower wrench to the upper wrench, the makeup and breakout functions will operate backwards on the control console. 10.Torque all bolts to NOV recommended torque specifications.

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Operating the ST-120 Iron Roughneck

Operation

Moving the Grounding Links to the Upper Jaw

Figure 4-10 illustrates how to move the grounding links to the upper jaw.

Front

Frame retaining pin

Torque wrench frame

Anti-rotation link Bolt Grounding frame

Jaw retaining pin

Figure 4-10. Moving grounding links to the upper jaw

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Operating the ST-120 Iron Roughneck

Operation

4

Setting up the Bit Breaker Assembly To set up the bit breaker assembly, complete the following steps. See figure 4-11, 4-12, and 4-13 to view illustrations for setting up the bit breaker assembly. 1. Adjust the guide plate on the side panel to accommodate the bit. 2. Position the bit breaker such that the drill bit is in the bit breaker frame top open area. 3. Slide the PDC bit adapter plate through the guide plate on the side panel of the bit breaker. 4. Index the PDC bit adapter plate to the drill bit. 5. Position the ST-120 above the bit and the bit breaker assembly. 6. Index the bit breaker to the ST-120 Torque Wrench Frame. Figure 4-11 shows how to set up the bit breaker assembly.

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Operation

Operating the ST-120 Iron Roughneck Setting up the Bit Breaker Assembly

Drill pipe

Connecting threads

Drill bit

Glider bar (1 each side)

Guide plate (1 each side)

Torque wrench assembly support

Retaining bar

(2 places)

Lock plate PDC Bit Adapter Plate

Bit breaker frame

Tri-cone bit adapter plate

Quick release pin

Safety chain

Figure 4-11. Bit breaker assembly set up

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Operating the ST-120 Iron Roughneck

4

Operation

Using the Bit Breaker Assembly For bit connecting and breaking procedures, refer to the sections titled Making Connections and Breaking Connections. Figures 4-12 and 4-13 shows how the torque wrench assembly interfaces with the bit breaker assembly.

Spin wrench assembly Head assembly

Torque wrench assembly

Torque wrench assembly support (2 places)

Bit breaker assembly

Figure 4-12. Torque wrench assembly interface with bit breaker assembly (1 of 2) D811000557-MAN-001 Revision 06 www.nov.com

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Operation

Operating the ST-120 Iron Roughneck Using the Bit Breaker Assembly

Spin wrench assembly

Torque wrench assembly

Bit breaker assembly support (2 places)

Bit breaker assembly

Figure 4-13. Torque wrench assembly interface with bit breaker assembly (2 of 2)

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Operation

Operating the ST-120 Iron Roughneck

4

Locking Out the ST-120 Arm Assembly This section provides the procedure and illustrations for locking out the arm assembly on the ST-120 Iron Roughneck. Refer to the control console functions (figure 2-17) to assist in performing this procedure. Figure 4-14 illustrates the equipment in the unlocked and locked position.

WARNING Do not attempt any adjustments while the equipment is in operation mode. To lock out the arm assembly, complete the following steps: 1. Once the hydraulic service loop has been installed, turn the ball valve on the rear of the ST-120 to the ON position. 2. Extend the arm, by activating the DEPLOY EXTEND lever on the control console, to the point where the arm assembly lock plate can be installed. 3. Install the arm assembly lock plate. 4. Turn the ball valve on the rear of the ST-120 to the OFF position. 5. Actuate the spin wrench IN lever on the control console to bleed any residual pressure in the hydraulic system.

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Operation

Operating the ST-120 Iron Roughneck Locking Out the ST-120 Arm Assembly

Arm lockout plate

Arm retracted to a position close enough to rotate the locking arm

Arm lockout plate

Locking arm rotated into the locked position.

Figure 4-14. Arm assembly in unlocked and locked positions

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Operating the ST-120 Iron Roughneck

4

Operation

Locking out the CARRIAGE-DOWN on the ST-120 Tall Column This locking option is only available on the ST-120 Tall Column Iron Roughnecks. To lock out the carriage-down function, complete the following steps: 1. Once the hydraulic service loop has been installed, turn the ball valve on the rear of the ST-120 to the ON position. 2. Raise the carriage up to allow installation of the locking plate. 3. Install locking plates into the column slots on both sides as shown in Figure 4-15. 4. Lower the carriage down in a controlled manner, so that the carriage sits inside the notched slots in the locking plates. Move slowly to ensure that the carriage stops smoothly. 5. Verify that the carriage is level and that it sits evenly inside the locking plates on both sides. 6. Turn the ball valve on the rear of the ST-120 column to the OFF position. 7. Actuate the spin wrench IN lever on the control console to bleed any residual pressure in the hydraulic system.

Detail A

See detail A

Only available with the ST-120 Tall Column Figure 4-15. Carriage-down locking mechanism D811000557-MAN-001 Revision 06 www.nov.com

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Operation

Hydraulic Failure Operation If the hydraulic system fails, shut off the hydraulic supply and perform the appropriate actions to enable manual operation of components. Some procedures may be required to repair and  stabilize hydraulic system functions.

Precautions When performing any procedures with the hydraulic system, read, understand, and adhere to the following precautions.

WARNING Never use hands to check for hydraulic leaks. Always check for leaks with a piece of wood or cardboard and always wear protective eye wear when working on hydraulic components.

WARNING Do not use the Iron Roughneck for anything other than its intended purpose as described within this manual. Failure to heed this warning could result in injury to personnel and damage to equipment.

WARNING Always use caution when inspecting the Iron Roughneck. Ensure that the equipment is completely shut down, isolated, and tagged out-of-service. Any unexpected start up of the equipment during a maintenance procedure or any accidental or poorly timed operation can cause serious injury or death to personnel or may damage the equipment.

!

The hydraulic tank return connector must be connected before any system is operated; failure to do so could cause reservoir drain, fluid starvation and equipment damage.

Before performing hydraulic failure manual operations, refer to the following safety sections: • Safety Requirements • Pinch Point Hazards • Precautions

!

58

Procedures described in this section will result in hydraulic fluid leaks, that can expose personnel to possible slip-and-fall injuries. Lubricants that are not contained or cleaned up immediately can cause environmental contamination. Therefore, personnel must immediately collect and cleaned up any spilled or escaping oil. Personnel must dispose of excess hydraulic fluids and lubricants, and cleaning materials appropriately.

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Operation

Hydraulic Failure Operation Precautions

4

Before performing hydraulic failure procedures, ensure the hydraulic ball valve, located on the rear of ST-120 Iron Roughneck, is off and control levers are actuated to bleed any residual pressure.

WARNING Manual Iron Roughneck operating procedures must only be performed in emergency conditions. Manual operation includes procedures that slow production and may cause personal injury and equipment damage. Perform manual operation procedures with extreme caution.

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

WARNING Never perform maintenance on the ST-120 Iron Roughneck while it is in an elevated position, even with the hydraulic power unit shut off and the residual pressure bled from the system. Failure to adhere to this warning may lead to severe personal injury or death.

Slew Base Assembly If the socket base assembly needs to be rotated during hydraulic failure, please do the following: 1. Extend the arm, if necessary, to allow access to the column. See Moving the Arm Assembly on page 63. 2. Disconnect lines A and B of the hydraulic slew motor from the connection to the hoses in the column. 3. Connect lines A and B of the hydraulic slew motor. These lines are equipped with quick disconnect connections and should couple together. See figure 4-16. 4. Next, using a hydraulic power source of no more than 500 psi, connect to the brake release line C (#4 male JIC fitting) and release the brake. As an option to step 4, the hydraulic hand pump, provided with the optional special tools kit, can be used to release the brake manually by directly connecting the brake line using a Q.D. connection. 5. Once the brake is released, the socket base assembly should be able to rotate. Rotate into the position desired and release hydraulic pressure to the brake.

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Hydraulic Failure Operation Slew Base Assembly

6. Next, disconnect the A and B lines of the hydraulic motor and reconnect each to the appropriate hose in the column. Disconnect hydraulic power source from the brake and replace hose.

Figure 4-16. Manual slew hydraulic connection

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Operation

Hydraulic Failure Operation

4

Opening the Torque Wrench If the torque wrench clamp cylinders need to be retracted during a hydraulic failure, complete the following steps: 1. Deactivate the torque wrench clamp cylinders (see figure 4-17), locate and slowly remove the plugs in port “P” on all four forward clamp cylinders to gradually release hydraulic pressure. 2. Once all residual pressure is relieved, use a pry bar to retract clamp cylinders from drill pipe.

!

If the clamp cylinder plug is released quickly, it will be projected by extreme hydraulic pressure and cause a hazard for personnel. Hydraulic pressure should be relieved very slowly to ensure safety. Hydraulic oil under pressure can penetrate skin and cause serious personal ininjury.

Torque wrench assembly

Front

Lower jaw assembly

“P” Figure 4-17.

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Opening torque wrench if a hydraulic failure occurs

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Hydraulic Failure Operation

Operation

Opening the Spin Wrench If the spin wrench clamp cylinders need to be retracted during a hydraulic failure, complete the following steps: 1. Slowly and carefully loosen the fittings on the spin wrench clamp cylinder. See figure 4-18.

!

If the clamp cylinder plug is released quickly, it will be projected by extreme hydraulic pressure and cause a hazard for personnel. Hydraulic pressure should be relieved very slowly to ensure safety. Hydraulic oil under pressure can penetrate skin and cause serious personnel injury.

2. Once residual pressure is relieved, remove hydraulic connections from the spin wrench clamp cylinder. 3. Use a pry bar to move rollers away from drill pipe.

Clamp cylinder

Hydraulic fittings

Rear isometric view Rear

Figure 4-18. Opening spin wrench if a hydraulic failure occurs

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Hydraulic Failure Operation

Operation

4

Moving the Arm Assembly

!

Hydraulic fluid will be expelled from test fitting ports as the extend cylinders extend or retract. Take measures to contain spills.

If the arm assembly needs to be extended or retracted during a hydraulic failure, complete the following steps: 1. Use a Stauff test coupling to bleed pressure from extend cylinders. Slowly screw the test coupling onto each test fitting (4 fittings per cylinder) until all hydraulic pressure is relieved. 2. Once all pressure has been relieved, remove all test fittings from the extend cylinders. As an option to step 2, open-ended hoses can be connected to test fitting ports where open ends can be placed in a container to minimize hydraulic fluid spillage. 3. Extend or retract the ST-120 Arm Assembly by pushing or pulling the Head Assembly in the required direction. Figure 4-19 illustrates the arm assembly extend cylinder details.

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Operation

Hydraulic Failure Operation

Arm Assembly Extend Cylinder Detail

Test Fittings (4 on each cylinder)

Figure 4-19. Arm assembly extend cylinder

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4

Securing the Iron Roughneck on a Floating Vessel Floating vessels are subject to the actions of waves and wind, resulting in unpredictable floor motions. Such motions can cause an Iron Roughneck to make sudden and unexpected movements. When this begins to occur, operations should cease and the Iron Roughneck should be secured at standby position. Refer to the Storing the ST-120 Iron Roughneck. When conditions exceed the parameters listed under Operational Environment: 1. Immediately stop operation. 2. Retract the Iron Roughneck fully, install the storage pin, and secure the Iron Roughneck in a standby position. See table 4-1 and table 4-2 for maximum operational/survival conditions on floating vessels. For dynamic conditions in excess of the values listed in Tables 4-1 and 4-2, consult NOV Engineering.

Table 4-1.

Operational Environment

Condition

Parameter

Roll/Pitch



4° pitch, single amplitude on 10 second period



50 ft. roll center below rig floor

Heave

2% Acceleration force

Wind

No wind assumed on rig floor during operation

Design Temp

-20°C Min. to 40°C Max.

Ice Thickness

None

Table 4-2.

Survival Environment (ST-120 Iron Roughneck must be stored with storage pin installed.)

Condition

Parameter

Roll/Pitch



20° pitch, single amplitude on 10 second period



50 ft. roll center below rig floor (ST-120 in secured parked position)

Heave

30 ft. on 10 second period (ST-120 in secured parked position)

Wind

No wind assumed on rig floor during operation

Design Temp

-20°C Min. to 40°C Max.

Ice Thickness

None

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Transporting the Iron Roughneck When transporting the Iron Roughneck adhere to the following precautions.

Precautions WARNING Always keep the Iron Roughneck in an upright position to avoid equipment damage and personal injury or death.

!

NOV recommends using the supplied wire rope sling with a master link when lifting the Iron Roughneck.

!

For stability, always transport the Iron Roughneck with the Transport Frame Installed. For added security, straps can be attached to major structural components as required.

!

When transporting the Iron Roughneck, always use the Iron Roughneck lifting lugs and lifting shackles. No other part is rated for, nor intended to support the full weight of the Iron Roughneck.

Removing the Transport Skid To remove the transport skid, complete the following steps: 1. Use the lifting shackles to hoist the Iron Roughneck. 2. Remove the column lock pins and transport skid support cap. 3. Attach ST-120 Iron Roughneck wire rope sling to lifting shackles and hoist the Iron Roughneck to the required location. 4. Retain all transport skid components for future transporting of the equipment. For more information on removing the transport skid, see the installation documentation included in the shipping package.

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4

Reinstalling the Transport Skid Before moving the ST-120 Iron Roughneck for transporting from one location to another, ensure that the transport skid is installed. This section provides the procedure for installing the transport skid. It is assumed that the ST-120 Iron Roughneck is being removed from its service location on the rig and is being transported to another location. When moving the equipment, the shipping skid must be reinstalled. To reinstall the shipping skid, complete the following steps: 1. Ensure the Iron Roughneck is in the fully retracted position, and all hydraulic lines connecting the column to the base assembly have been disconnected. 2. Ensure the storage pin is installed. 3. Place the transport skid on a strong surface. 4. Attach ST-120 Iron Roughneck wire rope sling to the lifting shackles. 5. Remove the column lock pins connecting the column to the base assembly. 6. Hoist and move the equipment to center it on the transport skid: a. Align the column base support with the transport skid base supports. b. Align the bottom of the torque wrench base plate with the transport skid lower support. 7. Insert the column lock pins to connect the column support to the transport skid base supports. 8. Insert hairpin cotter pins. 9. Place the transport skid support cap on the inside edge of the torque wrench top plate. 10.Insert top lock washers and hex nuts on the top ends of each 8" threaded rods. 11.Insert threaded rods through the transport skid support cap and transport skid lower support. 12.Install lock washers and hex nuts on the bottom end of the threaded rods. 13.Tighten securely to the transport frame support column. Tighten to the appropriate torque. 14.Attach the wire rope sling to ST-120 Iron Roughneck lifting shackles and hoist and move the Iron Roughneck with the transport skid attached to the desired location.

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Transporting the Iron Roughneck

ST-120 Iron Roughneck and Transport Skid

ST-120 lifting shackles

Storage pin

(2 places)

Hex nut (4 places)

Threaded bar (2 places)

Transport skid support cap Torque wrench top plate Column lock pin (2 places)

Torque wrench bottom plate

Transport skid

Transport skid lower support

Front Figure 4-20. Removing and reinstalling the Transport Skid

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Storing the ST-120 Iron Roughneck The following sections provides guidelines for storing the equipment after periods of operations and returning it to operation after storage.

Long Term Storage • Palletize the ST-120 Iron Roughneck and store it in indoor storage. A cargo container would be an appropriate for indoor/outdoor storage. • Avoid wide variations in temperature and high humidity. The preferred environment is clean and dry at 60°F (16°C) ambient temperature. If high humidity is unavoidable, 70°F (21°C) ambient temperature 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. Ensure 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 column to slew 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.

Return 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-120 Iron Roughneck Commissioning Procedure.

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Introduction This chapter provides procedures, general guidelines, and illustrations needed to properly maintain the ST-120 Iron Roughneck for optimum performance and maximum safety.

!

Before performing maintenance on the equipment, service personnel must read and understand the content in the General Information chapter as well as the applicable maintenance advisories and procedures in this chapter.

As with most machinery, the longevity of equipment is directly related to performing recommended maintenance procedures at recommended scheduled intervals. These procedures may be modified to account for specific operating goals and conditions and may include selecting suitable lubricants and other fluids that enhance operating ranges. Compliance with maintenance procedures described in this chapter promotes optimum performance, minimum equipment wear or failure, and reduced risk of rig downtime. Important: More frequent service intervals are required if the equipment is operated under abnormal conditions such as maximum loads, corrosive or dusty atmospheres, or extreme temperatures. Reference: Procedures in this chapter are related only to NOV components. For the inspections, maintenance schedules, and procedures related to the original equipment manufacturer (OEM) parts, see the appropriate vendor-supplied documentation included in the equipment shipping package.

!

Major repairs and modifications should only be performed by NOV service technicians. Contact NOV regarding issues that extend beyond the scope of this manual. Reference: For service contact information, see the section titled Service Centers on page 7.

This chapter contains the following information for keeping the ST-120 Iron Roughneck in proper operating condition: • Maintenance Precautions • Reference Documents • Installing or Removing Safety Wire • Maintaining Equipment Maintenance Records • Recommended Lubricants • Lubricating the Iron Roughneck • Inspection, Lubrication, and Maintenance Schedule • Five Year Inspection • Removing and Replacing Worn or Damaged Components • Changing Oil

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Maintenance

Maintenance Precautions Before performing any maintenance procedures, carefully read, understand, and adhere to the following precautions. Failure to comply with precautions in this chapter may result in injury to personnel, damage to equipment, or rig downtime. It is assumed that iron roughneck operators and service technicians have read and understand all safety precautions before performing maintenance procedures. For more information on safety, review the section titled Safety Requirements on page 4. If a warning or caution advisory has been designated in a procedure or posted on the equipment, failure to comply could result in serious injury or death to personnel and damage to the equipment. This is always the case whether it is implicitly stated in the text or not. The following precautions, in addition to those already stated in previous sections of this manual, are of high priority. To avoid serious injury, personnel must comply with precautions at all times when performing maintenance tasks on the ST-120 Iron Roughneck.

WARNING Under no circumstance should work be performed on the ST-120 while it is elevated or while the hydraulic lines are connected. Even with the power unit in the shut-off mode, residual pressure may remain in the hydraulic circuit that could cause unsafe motion resulting in serious injury or death to personnel and damage to the equipment. Prior to any maintenance procedure, the unit should be fully lowered, the hydraulic power should be removed, all operator valves cycled, and the hydraulic lines should be disconnected. Failure to adhere to this warning may result in serious injury or death to personnel, significant equipment damage, or extended rig downtime.

WARNING After performing equipment maintenance procedures and before returning the equipment to operation, ensure that no loose bars, tools, or parts are lying in or on the ST-120. Failure to adhere to this warning may result in serious injury or death to personnel, or damage to the equipment.

WARNING Always use lifting tools such as supports, chains, and the lifting slings provided in the shipping package. Ensure that the chains have a minimum capacity or 1-1/2 times that of the object being lifted or supported. Failure to adhere to this warning can result in injury or death from falling or swinging equipment. Reference: For detailed information on safe lifting practices, see the section titled Safe Lifting on page 4.

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ST-120 Iron Roughneck General Maintenance

5

WARNING NOV discourages the use of substitute parts. Failure to use proper parts could result in severe injury or death to personnel and damage to the equipment or extended rig downtime.

WARNING Never use hands to check for hydraulic leaks. Oil under pressure escaping from a hole can be nearly invisible and can penetrate the 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.

WARNING Do not use the Iron Roughneck for anything other than its intended purpose as described within this manual. Failure to heed this warning could result in injury to personnel and damage to equipment.

WARNING Use extreme caution when performing welding maintenance on or near the Iron Roughneck. Always connect the welder’s ground cable so that the welding current does not flow through the equipment cables or structural assembly. The ground cable should be connected directly or as close as possible to the part being welded to prevent electrical currents from passing through the bearings in the Iron Roughneck as this will result in bearing damage and premature bearing failure. All power and control cabling should be disconnected prior to performing a welding task. Failure to observe this precaution will result in damage to the equipment.

WARNING Do not attempt any adjustments while the equipment is in operation mode.

WARNING Always use caution when inspecting the Iron Roughneck. Ensure that the equipment is completely shut down, isolated, and tagged out-of-service. Any unexpected start up of the equipment during a maintenance procedure or any accidental or poorly timed operation can cause serious injury or death to personnel or may damage the equipment. D811000557-MAN-001 Revision 06 www.nov.com

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Maintenance

Reference Documents NOV recommends the following documentation (included in the shipping package) for additional information on maintaining the ST-120 Iron Roughneck: ST-120 Iron Roughneck documentation package: • • • • •

Hydraulics Schematics Design Specification and Design Torque Standard Safety Wiring Procedure Recommended Lubricants document Fluid Cleanliness Specification

Installing or Removing Safety Wire Some procedures in this chapter require removing safety wire (lockwire) from or reinstalling it onto component fasteners when disassembling or reassembling the roughneck components. Reference: For lockwire installation procedures, refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual.

Maintaining Equipment Maintenance Records NOV recommends keeping records of all maintenance procedures performed on the ST-120. These records may contain the action taken, the date that the action was completed, a brief description of the action, and the name or initials of the technician who performed the action. Maintaining a record-keeping process can prove valuable for fault finding and problem-solving should a technical problem arise. Accurate maintenance records can be used to show compliance with required maintenance practices and intervals. Maintenance records are an essential element of a well-managed maintenance program. NOV does not provide customers with record-keeping materials; however, customers are encouraged to create and record performed maintenance activities.

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ST-120 Iron Roughneck General Maintenance

Maintenance

5

ST-120 Iron Roughneck General Maintenance This section provides brief information on general maintenance procedures for the ST-120 Iron Roughneck. Detailed information on maintaining the equipment can be found later in this chapter.

Cleaning Clean the iron roughneck with water once a day to remove accumulated mud. No other scheduled cleaning is required except as detailed elsewhere in this manual.

Lubrication Schedule Lubricate fittings on the iron roughneck with appropriate grease as recommended by NOV service guidelines. Lubricate all moving components. Threaded fasteners should be lubricated with antiseize compound. Inspection and lubrication schedules and procedures can be found in the Lubricating the Iron Roughneck on page 78.

Replacement of Worn or Damaged Parts For information on equipment replacement spare parts, refer to the recommended spare parts list in the ST-120 Iron Roughneck user manual or contact an NOV service center representative.

Equipment Main Overhaul If the iron roughneck requires overhauling, contact an NOV Service Center to schedule this service. For a detailed description, see the Five Year Inspection on page 88

Hydraulic Hose and Fittings All hydraulic hoses (particularly those which flex during normal operation of the equipment) should be inspected once daily when in operation. A thorough inspection of all hoses, fittings, and rigid tube lines should be performed at least once a month. Inspect hydraulic lines daily as a routine part of all active hydraulic system inservice inspections. Any hose, fitting, and rigid tube line deterioration should be carefully examined as to whether further use of the component would constitute a safety hazard. Conditions such as the following should be sufficient reason for consideration of replacement: • Any evidence of hydraulic oil leakage at the surface of a flexible hose at its junction with the metal end couplings • Any blistering or abnormal deformation of the outer covering of a hydraulic hose • Hydraulic oil leakage at any threaded or clamped joint that cannot be eliminated by normal tightening or recommended procedures If any evidence of excessive abrasions or scrubbing is found on the outer surface of a hose, rigid tube, or hydraulic fitting, take action immediately to eliminate the interference of these elements coming in contact with equipment components or otherwise protect the components.

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Disposal of Worn Parts and Used Fluids The ST-120 Iron Roughneck owner is responsible for conforming to applicable regulatory policies, standards, and recycling guidelines when dismantling and removing equipment components for disposal as well as disposing of fluids after maintenance services have been performed.

Torquing Standards When torquing bolts or other component fasteners for torquing values and anti-seize compound information, refer to the Design Torque Standard documentation included in the equipment shipping package, unless otherwise specified.

Locking out the Arm Assembly Install the arm assembly lock pins prior to performing work on the equipment. For detailed information on locking the ST-120 Iron Roughneck arm assembly, see the procedure, Locking Out the ST-120 Arm Assembly on page 55 in the Operation chapter.

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Recommended Lubricants Introduction Before operating the ST-120 Iron Roughneck, it is essential to ensure that the grade and quality of lubricant is appropriate for the minimum ambient temperature of operation. NOV provides supplement recommendations for selecting the appropriate grade and quality for hydraulic fluids, gear oil, and grease. Consult engineering for lubrication requirements for abnormal conditions, such as extreme operating temperatures, extreme pressure, or emergency lubrication requirements. Reference: For detailed information on recommended lubricants and hydraulic fluids, refer to the Recommended Lubricants and Hydraulic Fluids document (D811000719) found in the document package that is included in the ST-120 Iron Roughneck shipping package.

General Recommendations Adhere to the lubrication product information and instructions listed in or on: • The design notes on the assembly drawing in the supplier master document list (SMDL) • The equipment nameplate • The documentation of the original equipment manufacturer (OEM) NOV only provides a supplement list of lubricant specifications or required lubricant qualities; not particular brand names of recommended lubricants for the equipment. If none of the recommended lubricants have the correct properties for the ambient and operating temperature ranges at the rig location, contact an NOV service center for instructions. For application and maintenance information, see the original equipment manufacture (OEM) documentation or the NOV service manual. If the information is not available, contact your NOV representative.

!

When adding to or changing lubricants (gear oil or hydraulic oil), every precaution should be taken to prevent any contamination of the lubricants. Do not mix different types of fluids.

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Lubricating the Iron Roughneck The lubrication intervals described in this manual are based on lubricant supplier recommendations. Severe conditions such as extreme loads or extreme temperatures, a corrosive atmosphere, and any other abnormal operating condition may require more frequent lubrication. Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more frequent lubrication is necessary. Inspect all grease fittings daily. When lubricating the iron roughneck components, pump grease into the grease fitting until clean grease is observed extruding from the component. This ensures that old grease is purged and that the component is lubricated properly.

! !

During inspection and lubrication, lock out hydraulics to disable equipment operation. Failure to adhere to this caution may result in personal injury or equipment damage. Clean any grease which falls to the floor. Failure to adhere to this caution may result in personal injury due to slipping.

WARNING Release all hydraulic oil pressures prior to disconnecting hydraulic lines. Hydraulic oil under pressure can penetrate the skin and cause serious injuries. Failure to adhere to this warning can result in serious injury or death to personnel.

WARNING When performing inspection, lubrication, or replacement procedures, properly lock out the hydraulic power source. Failure to adhere to this warning may result in serious injury to personnel.

WARNING Before opening the hydraulic system, ensure that the work area is completely cleaned. Maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to the hydraulic system components and can cause equipment failure and subsequent injury to personnel.

WARNING If air is introduced into the extend cylinder, use extreme caution when extending the arm for the first time. As the load moves over center, the air will compress causing the arm to extend rapidly. Support the unit with a tugger and stand to the side until the air is purged. Failure to adhere to this warning may result in serious injury to personnel.

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5

The average grease consumption a month is 80 oz. Severe conditions may require more frequent lubrication resulting in a higher lubricant consumption.

Inspection, Lubrication, and Maintenance Schedule The inspection process helps to identify iron roughneck assemblies and components that fail to meet operation performance requirements as well as aid in preventative maintenance. Performing inspection procedures at recommended time intervals determines if repair or replacement of nonconforming parts is necessary. It is assumed that all the safety precaution advisories documented in the Safety Requirements on page 4 as well as the Maintenance Precautions on page 72 has been read and understood. Do not attempt any inspection or service procedure without becoming fully aware of all safety precautions defined in this manual.

Inspecting Hardware and Fittings Use the following procedure when inspecting hardware and fittings on the iron roughneck: 1. Inspect the iron roughneck for loose or missing hardware and fittings daily. 2. Check all lock safety wire to ensure that it is damage free. 3. Check the intensifier hydraulic indicator filter weekly. Replace the filter if the indicator is red during operation. 4. Check the inlet high pressure hydraulic filter indicator weekly. Replace the inlet filter if the indicator is red during operation. 5. Inspect all hoses for wear or damage. Replace hoses as necessary. 6. Tighten any fittings that appear to be leaking. All hoses are clearly labeled. Refer to the hose kit drawings for proper routing and hose specifications. Always read labels when replacing hoses on the iron roughneck. When changing hydraulic cartridge valves, refer to the hydraulic schematic for proper settings. A maintenance schedule for inspecting, lubricating, and maintaining the ST-120 Iron Roughneck is described in this section (Table 5-1). Power down the iron roughneck and allow hot surfaces to cool before performing inspection and maintenance procedures.

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Table 5-1.

Inspection, Lubrication, and Maintenance Schedule

Maintenance

Maintenance Schedule listed by Major Components

Item

Inspection

Lubrication

Maintenance

Schedule Major Components: Inspect the following components and perform general maintenance as listed. General: 1. Hardware and general components

Weekly

N/A

• Tighten to proper torque. • Replace if missing.

2. Hoses and connectors

Weekly

N/A

• Tighten connections if loose. • Replace if damaged, leaking, or kinked.

3. Equipment and work areas

Daily

N/A

• Ensure that equipment and work areas are clean. • Remove corrosives and contaminants: salt, sand, mud, oil, and grease. • Dispose of components properly.

1. Link hanger pin’s grease fittings

Weekly

Weekly

Lubricate the link hanger pin’s grease fittings. See the section titled Lubricating the Head Assembly.

2. Track roller grease fittings

Weekly

Weekly

Lubricate the track roller grease fittings. See the section titled Lubricating the Head Assembly.

3. Bulkhead grease fittings on the spin wrench carrier

Weekly

Weekly

Lubricate the bulkhead grease fittings. See the section titled Lubricating the Head Assembly.

4. Intensifier filter

Monthly

N/A

Change the intensifier filter.See the section titled Changing Intensifier Hydraulic Filter.

5. Accumulator

Monthly

N/A

Inspect the accumulator. Check the nitrogen pre-charge on accumulator. Add nitrogen as required to 100 psi. See figure 2-22 on page 32 to view the location of the accumulator.

Head Assembly

Table continues on next page

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Inspection, Lubrication, and Maintenance Schedule Table 5-1.

5

Maintenance Schedule listed by Major Components (continued)

Item

Inspection

Lubrication

Maintenance

Schedule Torque Wrench Assembly 1. Torque wrench grease fittings

Weekly

Weekly

Lubricate the grease fittings on the torque wrench assembly. See the section titled

Lubricating the Torque Wrench Assembly. 2. Torque wrench dies

Daily

N/A

Replace the torque wrench dies. See the section titled Replacing the Wrench Dies.

3. Die carriers

Every 3 months

N/A

Inspect upper and lower jaw side die carriers for signs of uneven wear. See the section titled Replacing the Wrench Dies.

1. Spin wrench assembly

Weekly

Weekly

Lubricate the spin wrench. See the section titled Lubricating the Spin Wrench Assembly.

2. Spin rollers

Weekly

N/A

Replaced if worn or damaged. See the section titled Replacing Spin Rollers

3. Large support screw

Every 3 months

N/A

Torque to 430 ft-lb (585 N-m). See the section titled Spin Wrench Rollers Assembly

Spin Wrench Assembly

Retention Bolts Arm Assembly 1. ST-120 system hydraulic filter

Monthly

N/A

Change the system hydraulic filter. See the section titled Changing Inlet Hydraulic Filter.

2. Arm pin fittings

Weekly

Weekly

Lubricate the arm pin fittings. See the section titled Lubricating the Arm and Column Assembly.

3. Arm deploy cylinder

Every 3 months

N/A

Inspect the clevis/rod to ensure that it is properly torqued to 460 ft-lb (624 N-m)

Weekly

Weekly

Lubricate the carriage guide rollers, grease fittings, and roller tracks. See the section titled

Column Assembly 1. Column assembly

Lubricating the Arm and Column Assembly. Table continues on next page

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Inspection, Lubrication, and Maintenance Schedule

Maintenance

Maintenance Schedule listed by Major Components (continued)

Item

Inspection

Lubrication

Maintenance

Schedule 2. Brake and gearbox expansion oil tank

Weekly (oil level)

Break in at 1st 50/100 hours of operation and then every 2500 hours or 12 months

Change oil in the brake and gearbox expansion oil tank. See the section titled Changing Oil.

1. Slew bearing grease fittings

Weekly

Weekly

Slew bearing grease fitting. See the section titled Lubricating the Column Base.

2. Slew idler grease fittings

Weekly

Monthly

Slew bearing grease fitting. Seethe section titled Lubricating the Column Base.

Column Base

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Inspection, Lubrication, and Maintenance Schedule

Lubricating the Head Assembly G Grease each fitting until clean grease is observed extruding from the related component. e

ST-120 Head Unit Hanger link pins grease fittings

During operation, surfaces may become hot enough to cause bodily injury. To reduce the risk of injury from a hot component, allow the surface to cool before touching.

Spin wrench guide rollers

Lube 1 place each side (2 places total)

Lube 4 outer rollers and 4 inner rollers (grease bulkheads on lower inner rollers 8 places total)

Weekly

Weekly Intensifier filter

Spin wrench assembly

Inspect monthly and change annually.

Torque wrench housing

Jaw spring* *The jaw spring may look slightly different on some wrench assemblies. ** See figure 5-2 for optional greasing, if equipped with wear pads.

Die holder (extend jaws)

Guide ring (2 places)

Torque Wrench Housing

Spring* Outer** Diameter (2 places)

Weekly

Torque Wrench** Housing Inner Diameter (Anti-Seize)

Rotate the upper jaw to apply grease to the inner diameter of the torque Wrench Housing and outer diameter of the spring.

Figure 5-1. Head assembly lubrication points

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Maintenance

Lubricating the Torque Wrench Assembly To lubricate the torque wrench assembly, apply appropriate lubrication where indicated in figure 5-2.

Top view of torque wrench assembly During operation, surfaces may become hot enough to cause bodily injury. To reduce the risk of injury from a hot component, allow the surface to cool before touching.

Cylinder pivot pin

Rocker arm pin grease fittings

Lube 2 places on the topside and 2 places on the under side (4 places total)

Lube 1 place on the top side and 1 place on the under side (2 places total)

Weekly

G Grease each fitting until clean grease is observed extruding from the related component. e

Weekly

Torque wrench upper jaw

Rocker arm

Rocker arm pin grease fittings

Weekly

(both sides)

Torque cylinder clevis

Lower jaw

Lube 2 places on upper wrench and 2 places on lower wrench (4 places total)

Weekly Torque wrench lower jaw

Weekly Wear pad

Front

(if equipped) Lube 2 places on the top side and 2 places on the under side (4 places total)

Rocker arm

IIf there are no wear pads, see Figure 5-1 for greasing the spring outer diameter. g

Front

Upper jaw

Weekly Side die guide

Weekly Guide link pivot pin

Lube 2 places on upper wrench and 2 places on lower wrench (4 places total)

Lube 2 places on upper wrench and 2 places on lower wrench (4 places total)

Bottom view of torque wrench assembly Figure 5-2. Torque wrench assembly lubrication points

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5

Lubricating the Spin Wrench Assembly Link pin Lube 1 place each side (2 places total)

Guide pin

Weekly

(if equipped) Lube 1 place each side (2 places total)

Upper bearings

!

Properly lock out all energy sources before performing inspection, lubrication, or part replacement procedures.

Weekly

Lube 2 places each side (4 places total)

Use extreme care around equipment pinch points.

Weekly I Inject grease into all grease zerks until each cavity is completely filled. u

Front

Weekly Compression spring strut

Weekly

(Lube 1 place)

Lower bearings Lube 2 places each side (4 places total)

Weekly Arm hinge pin lube 1 place each side (2 places total)

Weekly Arm hinge pin Lube one place each side (2 places total)

Weekly Clevis pin Lube 1 place each side (2 places total)

Figure 5-3. Spin Wrench lubrication points

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Maintenance

Lubricating the Arm and Column Assembly To lubricate the arm assembly inspect and grease daily all the marked areas indicated in  figure 5-4.

WARNING If air is introduced into the extend cylinder, use extreme caution when extending the platform for the first time, As the load moves over center, the air will compress causing the support arm to extend rapidly. Support the unit with a tugger and stand to the side until the air is purged.

WARNING Properly lock out the arm assembly before performing lubrication, inspection, or replacement procedures. Failure to adhere to this advisory may result in personal injury or damage to the equipment.

Cylinder pins

Track (both sides)

Weekly

Lube 2 places each side (4 places total)

Arm pin fittings Lube 17 places each side (34 places total)

Weekly

Weekly

Guide roller (4 Places)

Weekly

6 Months Slew gear box (in column base - gear oil)

ST-120 Side view (extended) Figure 5-4. Arm and column assembly lubrication points

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Lubricating the Column Base When inspecting the column base for a lubrication procedure, locate the areas to lubricate as indicated in figure 5-5. Lubricate at the time intervals recommended by NOV.

UNCLAMP TW CLAMP

BREAK TW MAKE

CENTER MODE SW

OUT SW IN

UNCLAMP SW CLAMP

UP SW DOWN

M364000424 Rev -

UP CARRIAGE DOWN

RETRACT DEPLOY EXTEND

CW SLEW CCW

RETRACT ADJ EXTEND

M364000425 REV 02

Weekly

Weekly

Column base grease fitting (behind plate)

Monthly

Front View

Column base grease fitting (behind plate)

Slew bearing (4 Places)

Figure 5-5. Column base lubrication points

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Five Year Inspection

Five Year Inspection NOV recommends an overhaul after five years of operating the ST-120 Iron Roughneck. Typically, the five year service overall is performed at an NOV service center. Contact an NOV service center representative for details on inspecting and servicing your iron roughneck after five years of operation. A service center directory is provided in your equipment shipping package. Table 5-2 provides a list of the components that should be inspected and replaced after five years of operating the iron roughneck. Table 5-2.

Iron roughneck components to inspect after five years  of operation

Component

Checklist

Bushings

Check bushings in all moving components of the iron roughneck. Replace bushings with recommended replacement parts.

Pins

Check all pins and connection plates for excessive wear. Replace as necessary. Excessive wear on components should be recorded and defective wear should be referred to NOV engineering for further investigation.

Column and guide track rollers and bearings

Remove the column and guide track rollers, and bearings and inspect for flat spots, damage, and wear. Replace as necessary.

Nondestructive Examination A nondestructive examination (NDE) of critical load bearing components should be performed every five years of equipment operation. The following items should be inspected and repaired or replaced if necessary. The Magnetic Particle Inspection (MPI) process is a nondestructive test method used to identify defects on the surface of parts. Figures 5-6 through 5-11 illustrates and provides procedures for performing MPI test on the ST-120 critical load components.

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Maintenance

Major Weldments NDE inspect all welds on the following items. See Figure 5-6 to identify locations of these items on the iron roughneck. • Column weldment • Guide weldment • Arm weldments (9): upper and lower primary, secondary, and front arm weldments • Arm mid-links (2): Primary and Secondary mid-links • Arm timing links (4) • Head carriage frame • Torque wrench frame • Spin wrench guides (2)

Spin wrench guide Guide weldment

(2 total)

Column weldment

Head carriage frame

Arm welment Primary midlink

Arm weldment

Arm welment (2 total)

(2 total)

Secondary midlink Timing links (4 total)

Arm weldment Arm weldment

Arm welment (2 total)

Torque wrench frame

Figure 5-6. NDE weldments inspection

Inspecting Major Assembly Components NDE inspect the following critical components for linear indications: • NDE Inspect the Torque Wrench Rocker Arm • NDE Inspect the Jaw Assembly Cap Plates • NDE Inspect the Jaw Spacer • NDE Inspect the Socket Flange • NDE Inspect the Column Base Flange D811000557-MAN-001 Revision 06 www.nov.com

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Maintenance

Five Year Inspection

Rig Floor Welds NDE inspect floor socket welds to the rig structure. This inspection is to be performed at the rig location by a qualified inspector.

Wear Due to Misuse Prolonged uneven gripping on drill pipe can cause asymmetrical wearing of the side die carriers and clamp cylinder rods. • NDE inspect two upper and two lower jaw side die carriers. If signs of uneven wear of the die carriers are present, replace the die carriers and other worn components. • Dimensionally inspect holes in the clamp cylinder rods. If the holes are deformed (oval in shape) or are out of drawing tolerance specifications, replace components.

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5

NDE Inspect the Torque Wrench Rocker Arm Figure 5-7 shows the ST-120 torque wrench rocker arm component and specifies the areas to inspect. Perform a magnetic particle inspection (MPI) by completing the following steps: 1. Inspect the radius (four places total) for worn or damaged surfaces, including an overlap of one inch on the top and bottom surfaces where indicated. Repair as necessary. 2. Inspect the bores (five places total) for linear indications. Ensure to inspect bore from top to bottom. Repair as necessary.

Radius (4 places)

Bore (5 places total)

Figure 5-7. NDE inspection of the torque wrench rocker arm

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Five Year Inspection

Maintenance

NDE Inspect the Jaw Assembly Cap Plates Figure 5-8 illustrates the jaw assembly cap plates (two upper and two lower) inspection area. Perform the MPI by completing the following steps: 1. Inspect each bore (19 places total) for linear indications. Ensure to inspect each bore from top to bottom. Repair as necessary. 2. Inspect shaded surfaces for wear or damage on top, bottom, and along the sides of the jaw assembly cap plates (3 places total). See figure 5-8. Repair as necessary.

Bores (19 places total)

Inspect surfaces (top, bottom and sides (3 places total)

Figure 5-8. NDE inspection of the upper and lower cap plates

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Five Year Inspection

5

NDE Inspect the Jaw Spacer Figure 5-9 illustrates the jaw spacer inspection area. Perform an MPI by completing the following steps: 1. Inspect each bore (12 places total) for linear indications, inspecting from top to bottom. Repair as necessary. 2. Inspect jaw spacer on the top, bottom, and along the sides (4 places total) for worn or damaged surfaces. Repair as necessary.

Top

Bores (12 places total)

Top, bottom, and along sides (4 places total)

Sides

Bottom

Figure 5-9. NDE inspection of the jaw spacer

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Five Year Inspection

Maintenance

NDE Inspect the Socket Flange Figure 5-10 illustrates the socket flange inspection areas. Perform the MPI by completing the following steps: 1. Inspect the radius, including a one-inch overlap on the adjacent surface for wear or damage. Repair as necessary. 2. Inspect socket flange at the top and bottom shaded circumference for worn or damaged surfaces. Repair as necessary.

Radius

Top and bottom circumference

Figure 5-10. NDE inspection of the socket flange

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Maintenance

NDE Inspect the Column Base Flange Figure 5-11 illustrates the column base flange.To perform an MPI on the column base flange, complete the following steps: 1. Inspect the radius (8 places total) for worn or damaged surfaces. Repair as necessary. 2. Inspect the shaded surfaces on the front, back, and along the sides (8 places total) for wear or damage. Repair as necessary. 3. Inspect bores (8 places total) for linear indications, ensuring to inspect bores from top to bottom. Repair as necessary.

Radius (8 places total)

Shaded surfaces (8 places total)

Bores (8 places total)

Figure 5-11. NDE inspection of the column base flange

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Maintenance

Removing and Replacing Worn or Damaged Components

Removing and Replacing Worn or Damaged Components Disassembly procedures are performed when replacing damaged components that are causing a tool function to fail. Whenever performing 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 This section describes and illustrates how to remove and replace ST-120 Iron Roughneck components they are worn or damaged.

General Safety Precautions

! !

Transport hydraulic components to a clean, dust-free service area before disassembling for service procedures. When re-assembling components, torque all fasteners to the limits given in the Design Specification Torque Standards documentation, unless an alternative torque value is given in the procedure. During operation, surfaces may become hot enough to cause bodily injury. To reduce the risk of injury from a hot component, allow the surface to cool before touching.

!

Do not reuse nord-lock washers after removing a bolt. Replace with properly assembled a new nord-lock washer.

Figure 5-12. Nord-lock bolt and washers

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Maintenance

5

Replacing the Wrench Dies When replacing wrench dies, follow these guidelines: • Install new dies in all die carriers. • Replace existing screws with new screws if necessary. • Clean and inspect parts and hardware for damage and wear. • Replace all worn or damaged parts.

!

Once screws are removed, dies may slip out of the die carrier. Secure the dies to avoid personal injury or equipment damage.

To replace the dies, complete the following steps: 1. Actuate the torque wrench lever to extend the clamp cylinders.

WARNING Lock out hydraulics and bleed residual pressure to disable equipment operation and avoid personal injury or equipment damage. 2. Remove the hydraulic power. 3. Clean the area around the die and die carriers. 4. Remove the upper die retention screw and then remove the die. If the die is stuck, remove the lower retention screw. 5. Using a wire brush, clean the die carrier. 6. Lightly grease the die carrier. See Recommended Lubricants. 7. Install the new die and the center die retaining plate. Apply anti-seize compound to the retention screws and then replace the retaining screw. 8. Torque screws to 57-81 ft-lb. Figure 5-13 shows how the wrench dies are replaced.

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Maintenance

ST-120 Head Unit

Spin Wrench Assembly

Side Dies (4 places)

Die Carrier

Wrench Assembly

(4 places)

Screw, Die Carrier (4 places)

Screw, Retention

Die

(8 places)

(4 places)

Center Dies Side Dies

(2 places)

(4 places)

Center Dies (2 places)

Die (2 places)

Center Die Carrier (2 places)

Center Die Retaining Plate (2 places)

Screw, Die Carrier

Screw, Retention (2 places)

(2 places)

Figure 5-13. Replacing the wrench dies

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Maintenance

5

Removing Torque Wrench Before performing the procedure for removing the torque wrench, adhere to the following advisory:

WARNING Lock out hydraulics and bleed residual pressure to disable equipment operation and avoid personal injury or equipment damage. To remove the torque wrench, complete the following steps: 1. Disconnect all hydraulic lines to all four torque cylinders. 2. Remove the pin keeper from the torque cylinders and remove the pivot pin to disengage the torque cylinder from the rocker arm. 3. To bleed residual hydraulic pressure prior to maintenance of the torque wrench, carefully complete the following steps: a. Remove the pressure-bleed fitting from Port Z of the clamp cylinder manifold, which is located on the top of the upper jaw assembly. Proceed in small increments of 1/2 turn counter clockwise at a time. b. Wipe away any fluid and do not continue until overflow has stopped. c. After completely relieving the trapped pressure, close the port with the pressure bleed fitting. d. Ensure that the bleed fitting is properly torqued prior to resuming maintenance on the iron roughneck. 4. Disconnect the hydraulic lines from the swivel fittings located on the top of the upper jaw and beneath the lower jaw. 5. Remove the grounding frames. 6. Attach a lifting eye to the top of the upper jaw and lift slightly with a crane. 7. Slide out the upper jaw from the torque wrench frame. 8. Slide out the lower jaw from the torque wrench frame. 9. Slide out the lower jaw from the torque wrench frame.

WARNING Safely release hydraulic pressure from Port Z of the hydraulic circuit in the torque wrench’s upper jaw assembly prior to performing maintenance on the torque wrench assembly. Carefully follow step 3 of this procedure, using caution to ensure that the pressure is completely released. Failure to adhere to this advisory can result in personal injury and damage to the equipment. Figure 5-14 shows how to remove the torque wrench components for the replacement procedure.

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Removing and Replacing Worn or Damaged Components

Maintenance

TOP view torque wrench assembly Torque wrench upper jaw

Rocker arm

Torque cylinder pivot pin

Z Port Lower jaw

Torque wrench cylinder

Front

Grounding frame Bottom view of the torque wrench assembly

Rocker arm pin

Torque wrench lower jaw

Passive spring (4 places)

Rocker arm

Upper jaw

Torque wrench cylinder Grounding frame

Front

Figure 5-14. Removing Torque Wrench

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Maintenance

5

Replacing Spin Rollers The minimum allowable spin roller diameter is 6.9". This equates to 1/8" radial wear. When replacing the ST-120 Iron Roughneck spin rollers, follow these guidelines: • Replace spin rollers with all new rollers at the same time. • Replace existing screws with all new screws, if necessary. • Clean and inspect parts and hardware for damage and wear. • Replace all worn or damaged parts. • Torque large support screw to 430 ft-lb (585 N-m). • Re-check large support screw and torque if needed after first 5 hours of spin wrench operation.

!

Parts may slip from the spin wrench assembly once they are loosened. Secure parts if removed and place them in a clean and safe location to avoid personal injury or damage to the equipment.

WARNING Lock out hydraulics and bleed residual pressure to disable equipment operation and avoid personal injury or equipment damage. Some rollers are fitted/equipped with the wear groove to help determine if replacement is necessary. Figure 5-15 provides the procedure for replacing the spin rollers and shows how to remove them.

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Removing and Replacing Worn or Damaged Components

Maintenance

How to Replace the Spin Rollers

Front Isometric View

Motors (4 total)

Front

1. 2. 3. 4.

Remove the plug from the lower cover plate. Use the roller torque tool to keep rollers from turning. Remove the large support screw inside the cover plate. On the bottom of the cover plate, remove screws to release and remove the cover plate, lower drive hub, and lower bearing assembly. 5. Remove spin rollers. 6. Clean the spin wrench assembly. 7. Install new rollers interlaced as shown. Rollers must interlace with opposing roller assembly. 8. Use the roller torque tool to keep rollers from turning. 9. Re-iInstall the cover plate, lower drive hub, and lower bearing assembly. 10. Slightly oil washer, and install it and the large support screw in the bottom of the lower bearing assembly. 11. Torque bolt to 430 ft.-lb.

Spin rollers

Rear Isometric View

(4 sets)

Guard Hydraulic manifold

Roller torque tool

Clamp cylinder

W While the spin rollers are disassembled, w worn or damaged bearing assemblies and other spin wrench assembly parts should be replaced.

Rear Figure 5-15. Disassembling and replacing the spin rollers

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5

Maintenance

Removing and Replacing Worn or Damaged Components

Disassembling the Spin Rollers for Service Figure 5-16 shows how the spin wrench roller carrier (with bolt) is disassembled for servicing.

Retaining ring

Hydraulic motor

Ball bearings (3 places)

Upper bearing housing

Ring seal

Upper drive hub

Upper bearing assembly Grease Port Grooved roller

(2 places)

(4 places)

Lower drive hub Ring seal

Carrier Roller

Grease port

Ball bearing

(2 places)

(2 places)

Cover plate screw (4 places)

Cover Plate

Plug

Retaining ring

Lower Bearing Housing

Large Support Screw

Lower Bearing Assembly

To replace ball bearings, ensure bearings align as shown below: Seal

Ball bearing frame

Figure 5-16. Disassembling the spin wrench assembly and bolt

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5

Maintenance

Removing and Replacing Worn or Damaged Components

Figure 5-17 shows how to disassemble the spin wrench roller carrier (with shaft) for servicing.

Hydraulic motor

Roller shaft Roller bearing Upper bearing housing

Ring seal Upper drive hub

Grooved roller

Roller carrier

Lower drive hub Ring seal

Roller bearing

Lower bearing housing

Lower bearing housing

Roller bearing Ball bearing Locking ring Retainer ring Ball bearing

Cover plate

Figure 5-17. Disassembling the spin wrench assembly with shaft

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Removing and Replacing Worn or Damaged Components

5

Maintenance

Spin Wrench Rollers Assembly Retention Bolts If the spin wrench roller assembly is equipped with retention bolts, it should be serviced as described in Figure 5-18.

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. Torque 2 places each side. (4 places total)

Plug

Remove plugs to access the large support screws. R

Figure 5-18. Servicing the spin wrench roller assembly and retention bolt D811000557-MAN-001 Revision 06 www.nov.com

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5

Removing and Replacing Worn or Damaged Components

Maintenance

Removing the Spin Wrench ST-120 Spin Wrench Assembly Rear View

Procedure

! Hanger link

Pressure, tank, and drain ports

WARNING

Lock out hydraulics to disable equipment operation. Failure to adhere to this warning may result in injury to personnel or damage to the equipment. 1. Disconnect the hydraulic connections to the spin wrench manifold. 2. On the bottom of the spin wrench assembly, remove the spring and the spring perch from the spin wrench hinge pin. 3. Using a crane, support the weight of the spin wrench. 4. Disconnect the spin wrench hanger link from the hanger. 5. Lift and remove the spin wrench.

Rear

Spin wrench hydraulic manifold

ST-120 Spin Wrench Front Isometric View

Hanger link

Spring Spring Spring perch

Front Figure 5-19. Removing the spin wrench

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Maintenance

Removing and Replacing Worn or Damaged Components

5

Changing Intensifier Hydraulic Filter To change the intensifier hydraulic filter, complete the steps described in figure 5-20.

Procedure 1. 2. 3. 4. 5.

!

WARNING

Lock out hydraulics to disable equipment operation. Failure to adhere to this warning may result in injury to personnel and damage to the equipment.

Turn off main ball valve and bleed residual pressure. Turn off intensifier ball valve. Remove hydraulic filter cap. Replace filter element. Install hydraulic filter cap.

Intensifier hydraulic filter Spin wrench assembly

Torque wrench housing

Intensifier hydraulic filter cap

Intensifier ball valve

Front

ST1200082

Figure 5-20. Changing intensifier hydraulic filter

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5

Maintenance

Changing Inlet Hydraulic Filter To change the inlet hydraulic filter, complete the steps described in figure 5-21.

How to Change the Inlet Hydraulic Filter 1. 2. 3. 4.

Turn off main ball valve and bleed residual pressure. Remove hydraulic filter cap. Replace filter element. Reinstall hydraulic filter cap.

!

Lock out the hydraulic system to disable equipment operation, avoiding personal injury or damage to the equipment.

Arm assembly hydraulic inlet manifold

Hydraulic inlet manifold detail

Inlet hydraulic filter cap

Rear

Main ball valve Figure 5-21. Changing inlet hydraulic filter

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Maintenance

5

Changing Oil WARNING Never perform maintenance on the ST-120 Iron Roughneck while it is in an elevated position, even with the hydraulic power unit shut off and the residual pressure bled from the system. Failure to adhere to this warning may lead to severe personal injury or death.

WARNING Lock out the hydraulics system to disable the equipment from operating and to avoid personal injury and damage to the equipment.

!

Before performing any hydraulic or mechanical work on the tool, ensure the hydraulic ball valve located on the rear of the ST-120 Iron Roughneck is in the off position and bleed residual pressure by actuating SW lever in either SPIN IN or SPIN OUT.

Changing Oil Guidelines • Oil changes must be carried out after first 50/100 hours of operation and subsequently after every 2,500 hours or at least every 12 months. Oil change intervals may be modified, depending on actual operating conditions. • During oil change, we recommend that the inside of the gear case is flushed out with flushing fluid recommended by the lubricant manufacturer. • Pay attention to oil and gear temperature during oil change, to avoid the risk of scalding. • Oil should be changed when hot to prevent build up of sludge deposit. • It is advisable to check oil level at least once per month. If more than 10% of total oil capacity has to be added, check hydraulic hoses and connections for oil leaks. • Do not mix oils of different types even if they are from the same manufacturer and never mix mineral oil and synthetic oils. • Be aware of the pollution hazard due to oil. The average gear oil consumption for each gear oil change is 2.4 gallons (9.2 liters). Severe conditions may require more frequent oil changes resulting in a higher consumption.

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5

Changing Oil

Maintenance

Changing Brake and Gearbox Oil When changing the brake and gearbox reservoir oil in the ST-120 Iron Roughneck, it is extremely important to reference the procedure for locking out the arm assembly. See the section titled Locking Out the ST-120 Arm Assembly on page 55 in the Operation chapter.

Brake Plug B Brake

Brake Plug A

Gearbox Plug B Gear Box

Gearbox Plug A

Figure 5-22. Changing brake and gearbox reservoir oil

To change the brake and gearbox oil, complete the following steps: 1. Ensure that the ST-120 Iron Roughneck is fully lowered and the arm assembly is locked out. The drain and fill ports can be easily accessed from the front of the column with the unit fully lowered. 2. To ease oil drainage, remove the constant vented breather from both oil expansion tanks located in the column assembly. 3. Turn the hydraulic ball valve located on the rear of the ST-120 to the OFF position. 4. Bleed the residual pressure by actuating the SW lever in either the SPIN IN or SPIN OUT position. 5. Carefully remove Plug A from the gearbox and Plug A from the brake.

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5

Maintenance

6. Once all the oil is drained and the gear case is flushed, install the gearbox Plug A and the brake Plug A. 7. Remove the gearbox Plug B and brake Plug B and fill with recommended oil. See the section titled Recommended Lubricants. 8. Fill the expansion tanks with oil until the specified height is achieved. View the top sight glass on the side of the expansion tank to observe oil levels. 9. Install the breather plug on the tanks.

W When adding oil to the expansion tank, allow time for the ffluid to make its way to the gearbox and brake.

Constantly vented breather

Sight glass

Sight glass

Extension pipe Lock nut Column Rear View (Cross Section)

System Hydraulic Expansion Oil Tank

Figure 5-23. Brake and gear box expansion oil tanks maintenance

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Maintenance

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Troubleshooting

6

Introduction The troubleshooting procedures in the troubleshooting tables to follow do not necessarily cover all issues, causes, and possible solutions. They do provide an insight to typical issues, causes, and possible solutions.

!

Before troubleshooting the equipment, ensure that you have read and understand the content in the General Information chapter as well as the applicable troubleshooting advisories and procedures in this chapter.

The information in the troubleshooting tables are categorized as follows: • Issue • Probable cause • Possible solution

Safety Precautions To avoid personal injury and damage to the equipment, adhere to the following advisories.

! !

Ensure that all hydraulic lines are isolated and the ball valve is closed before any work is performed on the Iron Roughneck. When hoisting or lowering as well as operating the Iron Roughneck, ensure that all personnel and equipment are clear of the operating area. Failure to follow this caution could result in personal injury or damage to the equipment.

!

WARNING

During operation, surfaces may become hot enough to cause bodily injury. To reduce the risk of injury from a hot component, allow the equipment surface to cool before touching.

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6

Introduction

Troubleshooting

Troubleshooting Checklist Before performing troubleshooting procedures, NOV recommends that you follow these guidelines:

114



Ensure that the hydraulic pressure is 2500 psi at the inlet of the manifold inlet. Check the back pressure of the tank line to ensure that it does not exceed 100 psi.



Ensure that all hoses and quick disconnects (QDs) are properly connected.



Check the manifold, fittings, QDs, and hoses for leaks or damage.



Ensure that the Iron Roughneck is lubricated according to the recommendations provided in the section titled Lubricating the Iron Roughneck on page 78.



Ensure that the equipment is securely installed in the floor socket or on the floor base, according to user equipment configuration.



Ensure that all QDs are fully engaged.



Ensure the operating pressures are correct.



Verify the condition of the filter. If necessary, change filters.



Check all fittings for leaks.

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Troubleshooting

6

Troubleshooting Tables Table 6-1.

Troubleshooting the Iron Roughneck in General

Issue

Probable Cause

Solution

The hydraulic quick disconnect on the supply or return lines are not fully shouldered.

Tighten the quick disconnects until they are fully shouldered.

The power unit is not delivering a full flow.

Check the power supply flow while the spin out valve is actuated. Flow should be 45 GPM minimum.

The power unit return line filter is dirty.

Replace the filter element of the HPU.

The pressure filter is dirty

Replace pressure filter element.

The power supply is not operating properly, or the pressure is too low.

Re-establish the hydraulic power.

The lift cylinder is damaged or dirty.

Clean, repair or replace the cylinder.

There is binding of the carriage guide in the column.

Lubricate or replace the side rollers.

The pilot pressure is set too low.

Check the pilot pressure and adjust accordingly.

The counterbalance valve is out of adjustment.

Adjust or replace the counterbalance valve to maintain the vertical position.

The lift cylinder leaks.

Replace the cylinder seals.

The Iron Roughneck fails to rotate (slew).

The base assembly quick disconnect couplings are not connected.

Fully connect all the base assembly quick disconnect couplings.

The Iron Roughneck does not extend.

There is an obstruction somewhere.

Ensure that the storage pin is removed. Also ensure that the arm lock plate is not installed and locking the arm.

The Iron Roughneck runs slowly.

The Iron Roughneck vertical positioning assembly moves in one direction only or does not move at all.

The Iron Roughneck does not maintain a vertical position.

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6

Troubleshooting Tables

Troubleshooting

Table 6-2.

Troubleshooting the Torque Wrench Assembly

Issue

Probable Cause

Solution

The torque setting is too low.

Increase the setting.

The torque valve or pressure reducing valve is stuck closed, is dirty, or is damaged.

Check the valves. Clean if necessary or replace if cleaning them does not resolve the problem.

The torque cylinders are already at the end of stroke.

Recycle the upper jaw for another bite.

Torque valve damaged

Check the valves. Clean or replace if required.

The torque setting pressure reducing valve is stuck closed, is dirty, or is damaged.

Check valves. Clean or replace if required.

The torque setting is too low.

Increase the torque setting.

The torque cylinders drift in the makeup direction.

The main operating valve is sticking or is worn.

Disassemble the valve and inspect for contamination or wear. Repair if possible or replace if required.

The torque cylinder fails to move or moves slowly.

The return filter in the power supply is dirty.

Replace filter element.

The inlet port or gauge is dirty.

Clean the inlet port or replace the gauge.

The torque cylinders reached end of stroke and actuated the dump valve.

Reset for additional stroke.

The gauge damper closed.

Open the damper located on the top front of the gauge and rotate counterclockwise.

The gauge is not adjusted properly.

See the section titled Adjusting the Makeup Torque on page 47 to adjust the torque gauge if required.

There is high tank line pressure.

Check the tank line pressure and correct as necessary.

The gauge is defective.

Replace the gauge.

The torque cylinders fail to make up.

The torque cylinders fail to break out.

The torque gauge does not indicate pressure during the makeup process.

The torque gauge does not return to  0 - 2,000 ft-lb.

Table continues on next page

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Troubleshooting

Troubleshooting Tables

Table 6-2.

Troubleshooting the Torque Wrench Assembly (continued)

Issue

The jaws slip on the tool joint.

The upper torque wrench body lifts while cycling in the makeup or breakout mode.

The torque wrench clamp cylinders are too slow or uneven.

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6

Probable Cause

Solution

The dies are worn or broken.

Replace the dies.

The hydraulic pressure is too low.

Make sure the pressure at the manifold is set to 2,500 psi.

The intensifier is not operating.

Ensure that the intensifier ball valve is on. Inspect it for functionality and replace if necessary.

The intensifier filter is dirty.

Check the intensifier filter and replace if necessary.

The intensifier is defective.

Ensure that the intensifier is doubling pressure to the clamp circuit.

There is interference between the upper and lower body sets.

Check for the interference and remove it.

Check the valves on the manifold to determine if they are contaminated or defective.

Clean the valves and adjust the valves. If problem persists, repair or replace valves as required.

There may be a lack of lubrication.

Lube all grease fittings.

The flow divider may not be operating properly.

Check for damaged lines or a damaged flow divider. Replace if necessary.

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6

Troubleshooting Tables

Troubleshooting

Table 6-3.

Troubleshooting the Spin Wrench Assembly

Issue

The spin wrench does not clamp or unclamp and the motors do not run.

Probable Cause

Solution

The flow is probably restricted.

Locate the cause of the restriction and remove the restriction.

The power supply may be defective.

Check the power supply to ensure that it is effective.

The valves are probably leaking or sticky.

Manually return the valve to the center position. If problem persists, inspect the valve spool for wear or contamination. Repair or replace as required.

There is high tank line pressure.

Check the pressure in the tank line and correct it.

The motor is contaminated.

Repair or replace the motor.

The shaft is bent.

Repair or replace the motor.

The motor spline is damaged.

Check motor spline. Repair or replace as required.

The motor seal is blown

Replace the motor seal.

The flow to the motor is restricted.

Locate the cause of the restriction and correct.

The roller bearings are defective.

Replace the bearings.

The motor is defective.

Repair the motor.

Motor Drive shaft broken

Replace the motor.

The power supply is not operating.

Check the power supply pressure gauge for indication of wear or damage. Ensure that the supply pressure remains high with the operating valve energized.

The hydraulic lines are restricted.

Check the hydraulic lines for pinched, clogged, or obstructions. Clear any obstruction.

The cylinder seals are worn.

Replace the seals.

The spin wrench motor creeps with the valve in the neutral position.

The motor runs irregularly.

Spin rollers fail to turn or has insufficient power with the motor running.

There is loss of power torque.

Table continues on next page

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Troubleshooting

Troubleshooting Tables

Table 6-3.

Troubleshooting the Spin Wrench Assembly (continued)

Issue

Probable Cause

Solution

The drill pipe or collars rub against the spin wrench motor during spinning operations.

The spin rollers are excessively worn.

Replace the spin rollers.

There is Insufficient clamping pressure.

Check the pressure at the manifold and set to 2,500 psi. Check for leaks in clamping the lines and replace if required.

The seal is defective on spin clamp cylinder piston.

Replace the seal.

The connections could be slippery.

Clean the connections.

The spin rollers are worn.

Replace the spin rollers.

There is grease on the spin rollers. The spin wrench clamp hold while spinning.

Clean the grease off the spin rollers.

The accumulator may need pre-charging

Check the nitrogen pre-charge on accumulator. Add nitrogen to 100 psi.

The spin rollers slip.

The spin wrench does not thread compensate.

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Recommended Lubricants Guide This guide is not all-inclusive. It is only intended to cover the recommended lubricants for the product lines and models specified within the guide.

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.

D811000719-PRO-001

06

Form D811001123-GEN-001/07

Revision History

06

23.04.2014

Engineering Update

A. Donovan

S. Blanco

S. Williams

05

15.08.2012

Engineering Update

B. Dominguez

S. Sobreira

R. Luher

04

21.02.2012

Engineering Update

B. Dominguez

B. Levay

B. Levay

03

30.11.2009

Engineering Update

B. Dominguez

P. Williams

P. Williams

02

09.14.2009

Publication update

B. Dominguez

P. Williams

P. Williams

01

10.01.2008

First Issue

TCD

BMD

BDW

Rev

Date (dd.mm.yyyy)

Reason for issue

Prepared

Checked

Approved

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Form D811001123-GEN-001/07

Change Description Revision

Change Description

02

1. Changed equipment reference to cover page. 2. Added temperature range reference to hydraulic fluids and gear lubricant pour point advisories to page 1. 3. Changed and added frequency of fluid changes for hydraulic fluids and gear lubricants to pages 4 and 8. 4. Changed Non-Arctic Service heading to Non-Arctic Service Fluids to page 6. 5. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Non-Arctic Service Fluid table to page 6. 6. Changed Arctic Service heading to Arctic Service Fluids to page 7. 7. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Arctic Service Fluid table to page 7. 8. Added “SUS” viscosities to best choice supreme grade arctic service hydraulic fluids to page 7. 9. Added “SUS” viscosities to alternative supreme grade arctic service hydraulic fluids to page 7. 10. Changed gearbox reference and added cross-reference information to operating temperature table for draining of gear oil to page 8. 11. Added “Conventional” reference to washpipe lubricant recommendation section to page 10. 12. Removed "AC" reference to page 10. 13. Removed grease brand example to page 11. 14. Added External Pinion and Gear Sets section with recommended grease information tables to page 9 and 10. 15. Changed “Viscosity” cell title to “Kinematic Viscosity” cell title in Lubricants and Fluids Reference Chart to pages 14 and 15. 16. Added "External Pinion and Gear Sets" component lubricant reference to page 15. 17. Removed "AC" reference from drilling motor bearings to page 15. 18. Changed all primary temperature degrees to Celsius and changed all reference temperature degrees to Fahrenheit.

03

1. Added caution note and contact information note to page 2. 2. Removed oil additive recommendation note to page 15.

04

1. Moved Motor Bearings Lubricating Greases section from page 11 to page 12. 2. Moved External Pinion & Gear Set Lubricating Greases section from page 12 to page 13. 3. Moved Air Lubricator Misting Oil section from page 13 to page 17. 4. Add Wire Rope Lubricant section with recommended wire rope lubricant information (Titled: Inspection, Lubricating, and Rope Lubricants) to page 14 through page 16. 5. Added Wire Rope reference information to Lubricants and Fluids Reference Chart to page 20.

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Form D811001123-GEN-001/07

Change Description (continued) Revision

Change Description

05

1. Corrected cross-reference page information on page 9 to refer to the table on page 10. 2. Placed ambient temperature minus symbol in front of 9 Celsius on column one, row two of Recommended Gear Oil for the Transmission Gearbox Table (page 10). 3. Placed ambient temperature minus symbol in front of 4 Celsius on column one, row three of Recommended Gear Oil for the Transmission Gearbox Table (page 10). 4. Changed ambient temperature -10 Celsius to -9 Celsius on column two, row three of Recommended Gear Oil for the Transmission Gearbox Table (page 10). 5. Corrected inverted primary (Celsius) and reference (Fahrenheit) temperature degree call-outs to column two, row four of Recommended Gear Oil for the Transmission Gearbox Table (page 10).

06

1. Updated the document to the latest Technical Publications template 2. Updated the title to “Recommend Lubricants Guide” 3. Removed the NOV product lines from the cover 4. Updated the overall text and tables to reflect the current information for the various products (whole guide) 5. Updated the Introduction section (page 1) 6. Created the Hydraulic Fluid Quick Reference table (page 4) 7. Added a note explaining the top drive lubrication in the Gear Oil section (page 5) 8. Updated the gear oil grade tables to differentiate between the PS Series, TDS-150, and TDH-150 top drive and the TDS, TDX, and IDS top drive product lines (pages 4 and 5) 9. Updated the lubricants and fluids reference tables by combining the relevant information for each component and placed them at the end of their corresponding sections (pages 2 through 14) 10. Added the Below -6°C (21°F) procedure to the gear oil grade tables and lubricants and fluids reference tables (pages 7 through 9) 11. Added the recommended procedures column to Table 1-5 and 1-6 (page 7 and 8) 12. Added Recommended Gear Oil for Top Drive, and Iron Roughneck and Pipe Racking sections (page 8 and 9) 13. Created the Gear Oil Quick Reference table (page 10) 14. Added the Landing Collar subsection to the External Pinion and Gear Set (page 12) 15. Added the Grease Quick Reference table (page 14) 16. Deleted the Wire Rope Lubricant section (page 15)

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Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic Fluid Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Recommended Top Drive Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Recommended Iron Roughneck and Pipe Racking Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gear Oil Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 IBOP/Kelly Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 External Pinion and Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Handling-Ring/Repositioner/RLA Pinion and Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Crowned Tooth Gear Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Landing Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 General Grease Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Grease Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Air Lubricator Misting Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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List of Tables Table 1-1. Table 1-2. Table 1-3. Table 1-4. Table 1-5. Table 1-6. Table 1-7.

Table 1-8. Table 1-9. Table 1-10. Table 1-11. Table 1-12. Table 1-13.

Approved product lines and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Recommended hydraulic fluids for non-arctic conditions: -12 to 52°C (10 to 125°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Recommended hydraulic fluids for arctic conditions: -40 to 17°C (-40 to 63°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Recommended hydraulic fluids (quick reference table) . . . . . . . . . . . . . . . . . . . . . . . .5 Recommended gear oil grades (PS and PS2 Series, TD-500PAC, TDS-150, and TDH-150 Top Drives) . . . . . . . . . . .7 Recommended gear oil grades and procedures [TDS (except for TDS-150), TDX, and IDS top drive series] . . . . . . . . . . . . . . . . . . . . .8 Recommended gear oil grades (ST-80 Series Iron Roughnecks, ST-120 Iron Roughneck, ST-160 Iron Roughneck, and STV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Gear oil specifications (quick reference table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Recommended grease for washpipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Recommended grease for crowned tooth gear coupling . . . . . . . . . . . . . . . . . . . . . .12 General recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Recommended grease for various components (quick reference table) . . . . . . . . . . .14 Recommended misting oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

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List of Tables

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Recommended Lubricants Guide

If the operating equipment service manual contains a Recommended Lubricants section, please disregard this guide and adhere to the section. Reason: This is a general guide; a Recommended Lubricants section within the service manual is specific to that particular equipment.

Introduction This guide contains the recommended lubricants to be used on the approved product lines and models listed in table 1-1. Reference: If the operating equipment is not listed in this table, see the equipment vendor documentation or contact an NOV representative. Table 1-1.

Approved product lines and models

Product line

Models

Fingerboard

All

Hydraulic Cathead

HC-26EV

Hydraulic Power Unit (HPU)

HP-45Q

Iron Roughneck

AR Series, ST-80 Series, ST-100, ST-120, and ST-160

Pipe Racking Systems (PRS)

Standard Transfer Vehicle (STV)

Power Rotating Bail Adapter (PRBA)

All

Power Rotating Hook Adapter (PRHA)

All

Rotary Table and Swivel

All

Top Drive System (TDS)/ Integrated Drilling System (IDS)

IDS-1, IDS-3, IDS-4A, IDS-350P, IDS-350PE, IDS350P+, PS and PS2 Series, TD-500PAC, TDS-150, TDH-150, TDS-3, TDS-3H, TDS-4, TDS-4S, TDS-4H, TDS-5, TDS-6S, TDS-8SA, TDS-9SA, TDS-10SA,  TDS-10SH, TDS-10SRR, TDS-11SA, TDS-11SH, TDS-1000, TDX-1000, and TDX-1250

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1

Introduction

Recommended Lubricants Guide

Before equipment operation, it is essential to determine the grade and quality of lubricant appropriate for the minimum ambient temperature of operation. To determine if this guide is applicable, refer to the General Recommendations section in this guide. This guide provides recommendations for selecting the appropriate grade and quality of the following lubricants: • Hydraulic Fluid • Gear Oil • Grease

• Air Lubricator Misting Oil Consult engineering for lubrication requirements in extreme conditions, such as: • Extreme service temperature • Extreme pressure • Emergency lubrication

General Recommendations Adhere to the lubrication product information and instructions listed in/on: • The design notes on the assembly drawing in the technical drawing package • The nameplate on the equipment • The documentation of the original equipment manufacturer (OEM) If there is no information for selecting the appropriate lubricant for the NOV equipment provided, refer to the NOV recommendations provided in this guide. This guide lists the specifications or required qualities, not particular brand names, of the recommended lubricants for the equipment. If none of the recommended lubricants have the correct properties for the ambient and operating temperature ranges at your location, contact an NOV service center for instructions. Reference: For application and maintenance information, see the OEM documentation or NOV service manual. If the application and maintenance information is not available, contact your NOV representative.

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Recommended Lubricants Guide

Hydraulic Fluid An anti-wear (AW) hydraulic fluid of the proper viscosity grade is recommended for the hydraulic system. The AW hydraulic fluid is typically mineral-based and contains AW additives along with rust and oxidation inhibitors. Selecting the appropriate fluid viscosity grade to operate a typical hydraulic system involves the consideration of the following interdependent variables: • The starting viscosity at the minimum ambient temperature • Verification that: – The pour point temperature of hydraulic fluid will be at least 17°C (30°F) lower than the expected minimum ambient temperature. – The hydraulic fluid pours freely at the minimum operating temperature. Operating the equipment in cold temperatures requires hydraulic fluid with a viscosity that allows the oil to flow freely and transmit power. If the ambient temperature approaches the hydraulic fluid pour point, a heater may be used to get the fluid flowing for proper lubrication of the component. • Maximum expected operating temperature limits • Permissible and optimum viscosity range for the component – Minimum viscosity at maximum ambient temperature and in severe duty-cycle operation – Maximum viscosity at cold start Use table 1-2 and table 1-3 as a general guide for selecting the hydraulic fluids for equipment operation in non-arctic or arctic conditions, respectively. Table 1-2.

Choice

Recommended hydraulic fluids for non-arctic conditions:  -12 to 52°C (10 to 125°F) Parameter

Unit

Kinematic viscosity

6.9 cSt @ 100°C (49 SUS @ 210°F)

Minimum viscosity index

105

Pour point

-30°C (-22°F)

ISO viscosity grade

46

Kinematic viscosity

6.9 cSt @ 100°C (49 SUS @ 210°F)

Minimum viscosity index

100

Pour point

-37°C (-35°F)

ISO viscosity grade

46

Best

Alternative

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Hydraulic Fluid

Recommended Lubricants Guide

Table 1-3.

Choice

Recommended hydraulic fluids for arctic conditions:  -40 to 17°C (-40 to 63°F) Parameter

Unit

Kinematic viscosity

5.5 cSt @ 100°C (44 SUS @ 210°F)

Minimum viscosity index

377

Pour point

-60°C (-76°F)

ISO/ASTM viscosity grade

15

Kinematic viscosity

3.72 cSt @ 100°C (39 SUS @ 210°F)

Minimum viscosity index

140

Pour point

-42°C (-44°F)

ISO viscosity grade

15

Kinematic viscosity

6.4 cSt @ 100°C (47.5 SUS @ 210°F)

Minimum viscosity index

155

Pour point

-50°C (-58°F)

ISO viscosity grade

32

Best

Alternative 1

Alternative 2

4

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3

2

1

Hydraulic Oil

---

---

---

---

---

---

NLGI

---

---

---

---

---

---

AGMA

Must be supreme grade high shear stability, anti-wear hydraulic oil with anti-rust and anti-wear additives

Must be premium shear stable high VI, anti-wear hydraulic oil

Grade 15

Grade 15

Hydraulic Oil3

-40°C to 0°C (-40°F to 32°F)

Grade 10W

AT Fluid

-30°C to 17°C) (-22°F to 63°F)

Grade 32

Hydraulic Oil2

Grade 46

Grade 46

Hydraulic Oil1 Hydraulic Transmission Oil

ASTM/ ISO-VG/ SAE

Lube Type

-30°C to 17°C (-22°F to 63°F)

-12°C to 52°C (-10°F to 125°F)

Environment

Recommended hydraulic fluids (quick reference table)

Must be premium grade with anti-rust and anti-wear additives

Typical hydraulic systems

Component

Table 1-4.

377

140

3.72 cSt @ 100°C (39 SUS @ 210°F) 5.5 cSt @ 100°C (44 SUS @ 210°F)

172

155

7.5 cSt @ 100°C (51 SUS @ 210°F)

6.4 cSt @ 100°C (47.5 SUS @ 210°F)

100 (min.)

105

6.9 cSt @ 100°C (49 SUS @ 210°F) 6.9 cSt @ 100°C (49 SUS @ 210°F)

Viscosity Index

Kinematic Viscosity

Use table 1-4 as a quick reference table for selecting the recommended hydraulic fluids information presented in this section.

Hydraulic Fluid Quick Reference Table

-60°C (-76°F)

-42°C (-44°F)

-48°C (-54°F)

-50°C (-58°F)

-37°C (-35°F)

-30°C (-22°F)

Pour Point

Hydraulic Fluid Recommended Lubricants Guide

5

Recommended Lubricants Guide

Gear Oil This section is a general guide for selecting the gear oil used on the top drive, iron roughneck, and pipe racking systems only. Reference: If the gearbox is not part of a top drive, iron roughneck, or pipe racking system, see the equipment vendor documentation or contact an NOV representative. Always use an extreme pressure (EP) gear oil when working with gearboxes. The EP gear oils are typically mineral oils that contain sulfur-phosphorous additives. Most EP gear oils meet the American Gear Manufacturers Association (AGMA) extreme pressure-performance requirements. The proper grade and type of gear oil is selected by viscosity. Reference: For the brand or trade name of the lubricant for the applicable viscosity range, consult the lubricant suppliers.

!

Using oil with a greater viscosity than required can damage: • The gearbox, as a result of reduced oil flow. • The oil pump, as a result of excessive load.

The pour point temperature of the oil should be at least 6°C (10°F) lower than the expected minimum ambient temperature. The gear oil must pour freely at its minimum operating temperature. Operating the equipment in low temperatures requires gear oil with a viscosity: • High enough to carry the load. • Low enough to allow the oil to circulate. At start-up, the oil should flow freely and not cause high torque. If the ambient temperature approaches the gear oil pour point, a heater may be used to get the fluid flowing and to ensure proper lubrication of components. This section will cover the following: • Recommended Top Drive Gear Oil • Recommended Iron Roughneck and Pipe Racking Gear Oil

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Recommended Lubricants Guide

Gear Oil

Recommended Top Drive Gear Oil Use table 1-5 as a general guide for selecting the recommended gear oil grades used for the following top drive models: • PS and PS2 Series • TD-500PAC • TDS-150 • TDH-150 Table 1-5.

Recommended gear oil grades  (PS and PS2 Series, TD-500PAC, TDS-150, and TDH-150 Top Drives)

Ambient temperature range

Minimum gear oil operating temperature

Recommended gear oil grade

10 to 52°C (50 to 125°F)

16°C (60°F)

AGMA no. 7 EP, ISO VG 460

-9 to 16°C (15 to 60°F)

4°C (40°F)

AGMA no. 6 EP, ISO VG 320

-29 to -4°C (-20 to 25°F)

-23°C (-9°F)

AGMA no. 4 EP, ISO VG 150

-46 to -18°C (-50 to 0°F)

-40°C (-40°F)

Synthetic AGMA no. 3 EP, ISO VG 100

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Gear Oil

Recommended Lubricants Guide

Recommended Top Drive Gear Oil

Use table 1-6 as a general guide for selecting the recommended gear oil grades and procedures used for the following top drive models: • TDS series (excluding TDS-150; see table 1-5) • TDX series • IDS series Table 1-6.

Recommended gear oil grades and procedures  [TDS (except for TDS-150), TDX, and IDS top drive series]

Ambient temperature range

Recommended gear oil grade

Above 21°C (Above 70°F)

AGMA no. 6 EP, ISO VG 320

7 to 30°C (45 to 86°F)

AGMA no. 4 EP, ISO VG 150

-6 to 16°C (21 to 61°F)

Synthetic AGMA no. 3 EP,  ISO VG 100 If synthetic AGMA no. 3 EP, ISO VG 100 is unavailable, use AGMA no. 2 EP (mineral base oil), ISO VG 68.

Below -6°C (Below 21°F)

See recommended procedures

Recommended procedures

--

--

If using AGMA no. 2 EP (mineral base oil), ISO VG 68, the oil must be changed every 1,000 operating hours or every four months.

The oil temperature will need to be raised above -6°C (21°F) by completing the following steps: 1. Warm the top drive up by rotating at a very light load and very slow speeds until the oil temperature is raised to  -6°C (21°F). 2. If specific instructions are needed for warming up the top drive, contact your local NOV service center.

Once the oil temperature has been raised above -6°C (21°F), refer to the -6 to 16°C ambient temperature range row in this table.

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Recommended Lubricants Guide

Gear Oil

Recommended Iron Roughneck and Pipe Racking Gear Oil Use table 1-7 as a general guide for selecting the recommended gear oil grades used for the following iron roughneck and pipe racking models: • ST-80 Series • ST-120 • ST-160

• STV Table 1-7.

Recommended gear oil grades (ST-80 Series Iron Roughnecks, ST-120 Iron Roughneck,  ST-160 Iron Roughneck, and STV)

Ambient temperature range

Recommended gear oil grade

Above 21°C (Above 70°F)

AGMA no. 6 EP, ISO VG 320

7 to 30°C (45 to 86°F)

AGMA no. 4 EP, ISO VG 150

-6 to 16°C (21 to 61°F)

AGMA no. 2 EP, ISO VG 68

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9

10

1

Grade 460

Grade 320

Grade 150

Grade 68

Grade 100

EP Gear Oil

EP Gear Oil

EP Gear Oil

EP Gear Oil

Synthetic Gear Oil ---

---

---

---

---

NLGI

95

95

95

102

30.3 cSt @ 100°C (150 SUS @ 210°F) 24.0 cSt @ 100°C (120 SUS @ 210°F) 14.5 cSt @ 100°C (78.1 SUS @ 210°F) 8.8 cSt @ 100°C (55.5 SUS @ 210°F) 14.4 cSt @ 100°C (77.1 SUS @ 210°F)

#2 EP #3 EP &  #3 S

#4 EP

#6 EP

#7 EP

149

Viscosity Index1

Kinematic Viscosity1

AGMA

Values are for reference only, and may vary slightly depending on manufacturer

ASTM/ ISO-VG/SAE

Gear oil specifications (quick reference table)

Lube Type

Table 1-8.

-46°C (-50°F)

-20°C (-4°F)

-23°C (-10°F)

-18°C (0°F)

-7°C (20°F)

Pour Point1

Use table 1-8 as a quick reference table for selecting the gear oil specifications used for the top drive, iron roughneck, and pipe racking systems listed in this section.

Gear Oil Quick Reference Table

Recommended Lubricants Guide

Gear Oil

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Recommended Lubricants Guide

Grease This section will cover the recommended grease for the general preventive maintenance for the following components. • Washpipe Assembly • Motor Bearings • IBOP/Kelly Valve Actuator • External Pinion and Gear Set For all other components requiring grease lubrication, see the General Grease Lubrication subsection.

Washpipe Assembly For general preventative maintenance of the washpipe assembly, use table 1-9 as a general guide for selecting the washpipe grease for moderate operating conditions or extreme operating conditions, such as high speed, pressure, or fluid temperature. Table 1-9.

Recommended grease for washpipe assembly

Moderate operating conditions

Extreme operating conditions

NLGI grade 2

NLGI grade 3

Non-soap based moly grease

Non-soap based moly grease

NOV part number 7806084

NOV part number 7806663

Motor Bearings Some motors are equipped with greased bearings, which must be lubricated at manufacturerrecommended intervals.

!

Always use the recommended lubrication product specified by the original equipment manufacturer.

Generally, the drilling motors and blower motors are vendor-supplied equipment; therefore, the motor housing may have a nameplate attached to it that provides the recommended lubrication product, amount to use, and lubrication intervals. Reference: If there is no nameplate, see the vendor documentation in the owner’s manual. If no vendor documentation is supplied, contact an NOV representative.

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11

Grease

Recommended Lubricants Guide

IBOP/Kelly Valve Actuator IBOP and Kelly valve actuators may be vendor-supplied equipment.

!

Always use the recommended lubrication product specified by the original equipment manufacturer. Using the incorrect lubrication product can cause damage to the equipment.

Reference: If the actuator assembly does not have a nameplate that lists the recommended grease, see the vendor documentation in the owner’s manual. If the vendor documentation does not list the recommended grease, use grease with properties that meet the NLGI grade 1.5 specifications.

External Pinion and Gear Set This subsection covers the recommended greasing procedures for the following components: • Handling-Ring/Repositioner/RLA Pinion and Gear Set • Crowned Tooth Gear Coupling • Landing Collar

Handling-Ring/Repositioner/RLA Pinion and Gear Set For all environmental conditions, coat the gear teeth with an extreme pressure lubricant, such as NOV Copper Top (Jet-Lube Kopr-Kote®) or equivalent.

Crowned Tooth Gear Coupling Use table 1-10 as a general guide for selecting the grease for moderate or extreme operating conditions, such as normal or high speed and torque: Table 1-10.

Recommended grease for  crowned tooth gear coupling

Operating conditions

NLGI grade

Moderate

1

Extreme

2

Landing Collar For all environmental conditions, coat the landing collar halves, main shaft grooves, and inside diameter of the retainer ring with a generous amount of NLGI Grade 2 Jet-Lube Arctic™ Extreme Service Grease, a Calcium 12- Hydroxystearate grease with exceptional resistance to salt water spray and wash-down.

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Recommended Lubricants Guide

Grease

General Grease Lubrication For all other components not specified in the Grease section, use EP, lithium-based, generalpurpose grease. Use table 1-11 as a general guide for selecting the appropriate NLGI grade. Table 1-11.

General recommended grease

Ambient temperature range

NLGI grade

0°C (32°F) and below

1

Above -20°C (-4°F)

2

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13

14

5

4

3

2

1

All

All

External Pinion and Gear Sets, and Elevator and Main Links Contact Surfaces

Landing Collar

---

---

Calcium 12Hydroxystearate5

---

Metalon  Hi-Tech 1.5 Grease3

EP Grease4

---

EP Grease2

Use Jet-Lube Arctic™ Extreme Service Grease or equivalent

For example: Jet-Lube Kopr-Kote or NOV Copper Top

Use the product specified by the original equipment manufacturer

Lithium base, general-purpose, extreme pressure grease

Polyurea-based grease or as specified by the motor manufacturer

All

IBOP/Kelly Valve Actuator

0°C (32°F)  and below

--

--

#1.5

#1

#2

---

EP Grease2

Above -20°C (-4°F)

General Grease Bearings

#2

EP Grease1

#2

#3

All

---

#2

Blower Motor Bearings

EP Grease1

Primrose Plus # 327 C

Extreme Operating Conditions

---

NLGI

All

Primrose Plus # 327

Moderate Operating Conditions

ASTM/ ISO-VG/ SAE

Drilling Motor Bearings

Lube Type

Environment

---

---

---

---

---

---

---

---

---

AGMA

---

---

---

---

---

---

---

---

---

Kinematic Viscosity

Recommended grease for various components (quick reference table)

Conventional Washpipe Packing Grease

Component

Table 1-12.

---

---

---

---

---

---

---

---

---

Viscosity Index

Use table 1-12 as a quick reference table for selecting the recommended grease information presented in this section.

Grease Quick Reference Table

---

---

---

---

---

---

---

---

---

Pour Point Recommended Lubricants Guide

Grease

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Recommended Lubricants Guide

Air Lubricator Misting Oil Along with table 1-13, it is recommended that the misting oils for the air lubricator have the following properties: • Turbine-quality lubricant • Long life • Rust and oxidation-inhibited Table 1-13.

1

Recommended misting oil

Parameter

Unit

Kinematic viscosity1

29-35 cSt @ 40°C (136-165 SUS @ 100°F)

Viscosity Index1

100-104

ISO viscosity grade

32

Values are for reference only, and may vary slightly depending on manufacturer

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Recommended Lubricants Guide

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Flow Switch – Adjustment Procedure

Flow Switch (M854000277) -Adjustment Procedure

RIG/PLANT

ADDITIONAL CODE

REFERENCE

SDRL CODE

TOTAL PGS

REMARKS

MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER

REFERENCE DESCRIPTION

This document contains proprietary and confidential information which belongs to 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 and in any event 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

National Oilwell Varco RIG SOLUTIONS 11000 Corporate Centre Dr. Houston, TX 77041 Phone + 1 281-854-0400 Fax + 1 281-854-0508

CLIENT DOCUMENT NUMBER

DOCUMENT NUMBER

REV

Client Document Number

D854000017-PRO-001

01

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Document number Revision Page

D854000017-PRO-001 01 2

REVISION HISTORY

01

31-10-2012

Rev

Date (dd.mm.yyyy)

Initial Release

CHANGE DESCRIPTION Revision 01

Change Description First issue

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Reason for issue

A. Sharma

A. Odunfa

J. Walker

Prepared

Checked

Approved

Document number Revision Page

D854000017-PRO-001 01 3

TABLE OF CONTENTS 1 

PURPOSE ......................................................................................................................... 4 

2 

REFERENCE DRAWING.................................................................................................. 4 

3 

GENERAL SAFETY.......................................................................................................... 4 

4 

PROCEDURE ................................................................................................................... 4  4.1 

Test Setup .............................................................................................................. 4 

4.2 

Test Sequence........................................................................................................ 4 

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D854000017-PRO-001 01 4

1 PURPOSE This procedure provides the method for adjustment of the flow switch, required during installation.

2 REFERENCE DRAWING The following drawing is required to perform the procedure specified in this document. Drawing Name

Part Number

Assembly, Flow Switch

M854000277-ASM-001

3 GENERAL SAFETY   

Wear suitable safety equipment at all times including safety glasses. Observe all required safety rules and practices. Observe good housekeeping practices to maintain safety and insure the hydraulic system is not subjected to the introduction of contamination.

4 PROCEDURE 4.1

Test Setup 4.1.1

Attach hydraulic power supply and adjust the supply pressure and flow to the system’s requirements.

4.1.2 Prior to making any flow switch adjustments, all hydraulic functions need to be inactive. 4.2

Test Sequence 4.2.1

Rotate the flow switch adjustment cup clockwise until it stops. Verify the proximity sensor light is off.

4.2.2 Activate the spin wrench function. Verify the proximity light comes on. 4.2.3 If the proximity sensor light does not come on when the spin wrench is activated, rotate the flow switch adjustment cup counter clockwise 1/8 turn.

4.2.4 Activate the spin wrench function. Verify the proximity light comes on.

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D854000017-PRO-001 01 5

4.2.5 Repeat steps 3 & 4 (use 1/8 turn increments) until the proximity sensor light comes on when the spin wrench is activated, and goes off when there is no function being activated.

Figure 1: FLOW SWITCH ASSEMBLY

Adjustment Cup (P/N 98398)

Figure 2: SECTION VIEW, FLOW SWITCH ASSEMBLY

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DS00008

Design Specification Design Torque Standard

THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P. 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 NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.

CURRENT DRAWN CHECKED APPVD DATE

TITLE

Design Torque Standard

INITIAL

B. Levay

A. Vargas

N. West

B. Levay

T. Mongomery

JB

2/13/15

11.13.1992

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 1

OF

16

DCF0045 (REV B)

NOTES

1. Unless noted, all values are based on light machine oil or anti-seize lubricated bolts (not high pressure lubes). 2. NOV does not recommend assembling bolts dry. 3. Proof strength is 92% of minimum yield strength. 4. Torque values given represent 70% and 80% of proof strength. 5. Clamp force is based on 75% of proof strength. 6. These torque values are to be followed unless otherwise specified. 7. If torqueing into aluminum, contact engineering for appropriate torque value. 8. After torqueing fasteners, identify by marking head. Follow with lockwire per ASP00019 for all drilled head fasteners. 9. Equations used to generate the values in this document: Clamp Force= (.75)(Proof Strength)(Thread Area) Torque= (Screw Diameter)(Clamp Force)(k) k= .0160min / .0176max for light oil or Loctite k= .0120min / .0132max for anti-seize 10. For fastener grades not listed in the following tables, use the equations in note 9, or use the table that most closely matches the screw’s proof strength (see note 3).

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 2

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS

GRADE 2 T.S. = 74,000 PSI to ¾” DIA PROOF STRENGTH = 55,000 PSI T.S. = 60,000 PSI 7/8” to 1-1/2” DIA PROOF STRENGTH = 33,000 PSI COARSE THREAD SERIES - UNC Max. Clamp Dia-Threads Min. Torque Torque Force Per Inch (ft-lbf) (ft-lbf) (lb) 1/4 – 20 5.2 5.8 1,312 5/16 – 18 10.8 11.9 2,162 3/8 – 16 19.2 21.1 3,197 7/16 – 14 31 34 4,385 1/2 – 13 47 52 5,853 9/16 – 12 68 74 7,508 5/8 – 11 93 103 9,323 3/4 – 10 165 182 13,778 7/8 – 9 160 176 11,435 1–8 240 264 14,999 1 1/8 – 7 340 374 18,884 1 1/4 – 7 480 528 23,983 1 3/8 – 6 626 689 28,463 1 1/2 – 6 835 918 34,774 FINE THREAD SERIES – UNF 1/4 – 28 6.0 6.6 5/16 – 24 12.0 13.2 3/8 – 24 21.7 23.9 7/16 – 20 34 38 1/2 – 20 53 58 9/16 – 18 75 83 5/8 – 18 106 116 3/4 – 16 185 203 7/8 – 14 176 194 1 – 14 (UNS) 269 296 1 1/8 – 12 381 419 1 1/4 – 12 531 584 1 3/8 – 12 716 788 1 1/2 – 12 939 1,033

1,502 2,393 3,622 4,896 6,596 8,374 10,560 15,386 12,598 16,805 21,186 26,557 32,546 39,130

SIZE

GRADE 5 T.S. = 120,000 PSI to 1” DIA PROOF STRENGTH = 85,000 PSI T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA PROOF STRENGTH = 74,000 PSI Min. Torque (ft-lbf) 8.1 16.7 30 47 72 104 144 256 412 618 762 1,076 1,404 1,871

Max. Torque (ft-lbf) 8.9 18.4 33 52 80 115 158 281 454 680 838 1,183 1,545 2,059

9.3 18.5 34 53 82 116 163 285 454 693 855 1,191 1,606 2,106

10.2 20.3 37 58 90 128 180 314 500 762 941 1,310 1,766 2,316

2,321 3,698 5,597 7,567 10,194 12,941 16,320 23,779 32,449 43,286 47,508 59,552 72,983 87,746

DWG NO

DS00008 NONE

7 7 7 7

REV

A SCALE

Clamp Force (lb) 2,027 3,341 4,941 6,777 9,046 11,603 14,408 21,293 29,453 38,633 42,347 53,780 7 63,825 7 77,978 7

WT LBS

SHEET

G 3

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS

GRADE 8 TENSILE STRENGTH = 150,000 PSI PROOF STRENGTH = 120,000 PSI

COARSE THREAD SERIES - UNC Max. Clamp Dia-Threads Min. Torque Torque Force Per Inch (ft-lbf) (ft-lbf) (lb) 1/4 – 20 11.4 12.6 2,862 5/16 – 18 23.6 25.9 4,716 3/8 – 16 42 46 6,975 7/16 – 14 67 74 9,567 1/2 – 13 102 112 12,771 9/16 – 12 147 162 16,380 5/8 – 11 203 224 20,340 3/4 – 10 361 397 30,060 7/8 – 9 582 640 41,580 1–8 873 960 54,540 1 1/8 – 7 1,236 1,360 68,670 1 1/4 – 7 1,744 1,919 87,210 1 3/8 – 6 2,277 2,505 103,500 1 1/2 – 6 3,035 3,338 126,450 FINE THREAD SERIES – UNF 1/4 – 28 13.1 14.4 3,276 5/16 – 24 26 29 5,220 3/8 – 24 47 52 7,902 7/16 – 20 75 82 10,683 1/2 – 20 115 127 14,391 9/16 – 18 164 181 18,270 5/8 – 18 230 253 23,040 3/4 – 16 403 443 33,570 7/8 – 14 641 705 45,810 1 – 14 (UNS) 978 1,076 61,110 1 1/8 – 12 1,387 1,525 77,040 1 1/4 – 12 1,931 2,125 96,570 1 3/8 – 12 2,604 2,864 118,350 1 1/2 – 12 3,415 3,756 142,290

SIZE

EXTREME STRENGTH TENSILE STRENGTH = 170,000 PSI PROOF STRENGTH = 136,000 PSI

7 7 7 7 7

Min. Torque (ft-lbf) 13.0 27 47 76 116 167 231 409 660 989 1,401 1,977 2,581 3,439

Max. Torque (ft-lbf) 14.3 29 52 83 127 184 254 450 726 1,088 1,541 2,174 2,839 3,783

Clamp Force (lb) 3,244 5,345 7,905 10,843 14,474 18,564 23,052 34,068 47,124 61,812 77,826 98,838 117,300 143,310

7 7 7 7 7

7 7 7 7 7 7

14.9 30 54 85 130 186 261 457 727 1,108 1,572 2,189 2,951 3,870

16.3 33 59 93 144 205 287 502 800 1,219 1,729 2,408 3,246 4,257

3,713 5,916 8,956 12,107 16,310 20,706 26,112 38,046 51,918 69,258 87,312 109,446 134,130 161,262

7 7 7 7 7 7

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 4

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS

300 SERIES / 18-8 STAINLESS TENSILE STRENGTH = 70,000 PSI PROOF STRENGTH = 27,600 PSI (YIELD = 30,000 PSI) COARSE THREAD SERIES - UNC Max. Dia-Threads Min. Torque Torque Per Inch (ft-lbf) (ft-lbf) 1/4 – 20 2.6 2.9 5/16 – 18 5.4 6.0 3/8 – 16 9.6 10.6 7/16 – 14 15 17 1/2 – 13 23 26 9/16 – 12 34 37 5/8 – 11 47 51 3/4 – 10 83 91 7/8 – 9 134 147 1–8 201 221 1 1/8 – 7 284 313 1 1/4 – 7 401 441 1 3/8 – 6 524 576 1 1/2 – 6 698 768

Clamp Force (lb) 658 1,085 1,604 2,200 2,937 3,767 4,678 6,914 9,563 12,544 15,794 20,058 23,805 29,084

FINE THREAD SERIES – UNF 1/4 – 28 3.0 3.3 5/16 – 24 6.0 6.6 3/8 – 24 10.9 12.0 7/16 – 20 17 19 1/2 – 20 26 29 9/16 – 18 38 42 5/8 – 18 53 58 3/4 – 16 93 102 7/8 – 14 148 162 1 – 14 (UNS) 225 247 1 1/8 – 12 319 351 1 1/4 – 12 444 489 1 3/8 – 12 599 659 1 1/2 – 12 785 864

753 1,201 1,817 2,457 3,310 4,202 5,299 7,721 10,536 14,055 17,719 22,211 27,221 32,727 7

STAINLESS ASTM F593U TENSILE STRENGTH = 135,000 PSI PROOF STRENGTH = 95,000 PSI

Min. Torque (ft-lbf) 9.1 18.7 33 53 81 117 161 286 461 691 979 1,381 1,803 2,403

Max. Torque (ft-lbf) 10.0 20.5 36 58 89 128 177 314 507 760 1,076 1,519 1,983 2,643

Clamp Force (lb) 2,266 3,734 5,522 7,574 10,110 12,968 16,103 23,798 32,918 43,178 54,364 69,041 81,938 100,106

7 7 7 7

10.4 20.7 38 59 91 130 182 319 508 774 1,098 1,529 2,061 2,704

11.4 22.7 41 65 100 143 201 351 559 851 1,208 1,682 2,267 2,974

2,594 4,133 6,256 8,457 11,393 14,464 18,240 26,576 36,266 48,379 60,990 76,451 93,694 112,646

7 7 7 7 7

F593 U

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 5

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND

GRADE 2 T.S. = 74,000 PSI to ¾” DIA PROOF STRENGTH = 55,000 PSI T.S. = 60,000 PSI 7/8” to 1-1/2” DIA PROOF STRENGTH = 33,000 PSI COARSE THREAD SERIES - UNC Max. Clamp Dia-Threads Min. Torque Torque Force Per Inch (ft-lbf) (ft-lbf) (lb) 1/4 – 20 3.9 4.3 1,312 5/16 – 18 8.1 8.9 2,162 3/8 – 16 14.4 15.8 3,197 7/16 – 14 23.0 25.3 4,385 1/2 – 13 35 39 5,853 9/16 – 12 51 56 7,508 5/8 – 11 70 77 9,323 3/4 – 10 124 136 13,778 7/8 – 9 120 132 11,435 1–8 180 198 14,999 1 1/8 – 7 255 280 18,884 1 1/4 – 7 360 396 23,983 1 3/8 – 6 470 517 28,463 1 1/2 – 6 626 689 34,774 FINE THREAD SERIES – UNF 1/4 – 28 4.5 5.0 5/16 – 24 9.0 9.9 3/8 – 24 16.3 17.9 7/16 – 20 26 28 1/2 – 20 40 44 9/16 – 18 57 62 5/8 – 18 79 87 3/4 – 16 138 152 7/8 – 14 132 146 1 – 14 (UNS) 202 222 1 1/8 – 12 286 315 1 1/4 – 12 398 438 1 3/8 – 12 537 591 1 1/2 – 12 704 775

1,502 2,393 3,622 4,896 6,596 8,374 10,560 15,386 12,598 16,805 21,186 26,557 32,546 39,130

SIZE

GRADE 5 T.S. = 120,000 PSI to 1” DIA PROOF STRENGTH = 85,00 PSI T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA PROOF STRENGTH = 74,000 PSI Min. Torque (ft-lbf) 6.1 12.5 22.2 36 54 78 108 192 309 464 572 807 1,053 1,404

Max. Torque (ft-lbf) 6.7 13.8 24.5 39 60 86 119 211 340 510 629 887 1,158 1,544

7.0 13.9 25.2 40 61 87 122 214 341 519 641 893 1,204 1,579

7.7 15.3 27.7 44 67 96 135 235 375 571 705 983 1,325 1,737

2,321 3,698 5,597 7,567 10,194 12,941 16,320 23,779 32,449 43,286 47,508 59,552 72,983 87,746

DWG NO

DS00008 NONE

7 7 7 7

REV

A SCALE

Clamp Force (lb) 2,027 3,341 4,941 6,777 9,046 11,603 14,408 21,293 29,453 38,633 42,347 53,780 7 63,825 7 77,978 7

WT LBS

SHEET

G 6

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND

GRADE 8 TENSILE STRENGTH = 150,000 PSI PROOF STRENGTH = 120,000 PSI

COARSE THREAD SERIES - UNC Max. Clamp Dia-Threads Min. Torque Torque Force Per Inch (ft-lbf) (ft-lbf) (lb) 1/4 – 20 8.6 9.5 2,860 5/16 – 18 17.8 19.7 3,720 3/8 – 16 32 35 7,000 7/16 – 14 50 55 9,550 1/2 – 13 78 87 12,750 9/16 – 12 107 118 16,100 5/8 – 11 157 173 20,350 3/4 – 10 271 299 30,100 7/8 – 9 428 473 41,600 1–8 641 709 54,500 1 1/8 – 7 912 1,008 68,700 1 1/4 – 7 1,297 1,433 87,200 1 3/8 – 6 1,696 1,874 104,000 1 1/2 – 6 2,252 2,489 126,500 FINE THREAD SERIES – UNF 1/4 – 28 10 11 3,280 5/16 – 24 17.8 19.7 5,220 3/8 – 24 36 39 7,900 7/16 – 20 57 63 10,700 1/2 – 20 86 95 14,400 9/16 – 18 121 134 18,250 5/8 – 18 171 189 23,000 3/4 – 16 299 331 33,600 7/8 – 14 470 520 45,800 1 – 14 (UNS) 713 788 59,700 1 1/8 – 12 1,026 1,134 77,000 1 1/4 – 12 1,425 1,575 96,600 1 3/8 – 12 1,938 2,142 11,840 1 1/2 – 12 2,537 2,804 142,200

SIZE

HOLO-KROME TENSILE STRENGTH = 170,000 PSI PROOF STRENGTH = 136,000 PSI

7 7 7 7 7

Min. Torque (ft-lbf) 9.7 20.0 36 57 87 125 173 307 495 742 1,051 1,483 1,935 2,580

Max. Torque (ft-lbf) 10.7 22.0 39 63 96 138 190 337 544 816 1,156 1,631 2,129 2,838

Clamp Force (lb) 3,240 5,340 7,920 10,850 14,450 18,500 23,000 34,000 47,000 61,700 77,800 98,700 117,800 143,200

7 7 7 7 7 7

7 7 7 7 7 7

11.1 22.2 40 64 98 140 196 342 545 831 1,179 1,642 2,213 2,903

12.3 24.4 44 70 108 154 215 377 600 914 1,297 1,806 2,434 3,193

3,713 5,916 8,956 12,107 16,310 20,706 26,112 38,046 51,918 69,258 87,312 109,446 134,130 161,262

7 7 7 7 7 7

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 7

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND

300 SERIES / 18-8 STAINLESS TENSILE STRENGTH = 70,000 PSI PROOF STRENGTH = 27,600 PSI (YIELD = 30,000 PSI) COARSE THREAD SERIES - UNC Max. Dia-Threads Min. Torque Torque Per Inch (ft-lbf) (ft-lbf) 1/4 – 20 10.5 11.6 5/16 – 18 17.4 19.1 3/8 – 16 25.7 28.2 7/16 – 14 35 39 1/2 – 13 47 52 9/16 – 12 60 66 5/8 – 11 75 82 3/4 – 10 111 122 7/8 – 9 153 168 1–8 201 221 1 1/8 – 7 253 278 1 1/4 – 7 321 353 1 3/8 – 6 381 419 1 1/2 – 6 465 512

Clamp Force (lb) 658 1,085 1,604 2,200 2,937 3,767 4,678 6,914 9,563 12,544 15,794 20,058 23,805 29,084

FINE THREAD SERIES – UNF 1/4 – 28 12.1 13.3 5/16 – 24 19.2 21.1 3/8 – 24 29.1 32.0 7/16 – 20 39 43 1/2 – 20 53 58 9/16 – 18 67 74 5/8 – 18 85 93 3/4 – 16 124 136 7/8 – 14 169 185 1 – 14 (UNS) 225 247 1 1/8 – 12 284 312 1 1/4 – 12 355 391 1 3/8 – 12 436 479 1 1/2 – 12 524 576

753 1,201 1,817 2,457 3,310 4,202 5,299 7,721 10,536 14,055 17,719 22,211 27,221 32,727 7

STAINLESS ASTM F593U TENSILE STRENGTH = 135,000 PSI PROOF STRENGTH = 95,000 PSI

Min. Torque (ft-lbf) 6.8 14.0 24.8 40 61 88 121 214 346 518 734 1,036 1,352 1,802

Max. Torque (ft-lbf) 7.5 15.4 27.3 44 67 96 133 236 380 570 807 1,139 1,487 1,982

Clamp Force (lb) 2,266 3,734 5,522 7,574 10,110 12,968 16,103 23,798 32,918 43,178 54,364 69,041 81,938 100,106

7 7 7 7

7.8 15.7 28 44 68 97 135 237 377 561 815 1,135 1,530 2,006

8.7 17.3 31 49 75 107 150 261 417 620 901 1,254 1,691 2,218

2,594 4,133 6,256 8,457 11,393 14,464 18,240 26,576 36,266 48,379 60,990 76,451 93,694 112,646

7 7 7 7 7

F593 U

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 8

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS

CLASS 4.6 T.S. = 400 MPa PROOF STRENGTH = 225 MPa T.S. is for all dia.

CLASS 8.8 T.S. = 830 MPa PROOF STRENGTH = 600 MPa T.S. is for all dia *Metric socket head screws*

METRIC SERIES Diameter - pitch

Min. Torque (ft-Ibf)

M3 - .5 M3.5 - .6 M4 - .7 M5 - .8 M6 - 1 M8 - 1.25 M10 - 1.5 M12 - 1.75 M14 - 2 M16 - 2 M18 – 2.5 M20 – 2.5 M22 – 2.5 M24 - 3 M27 – 3 M30 - 3.5 M33 – 3.5 M36 – 3.5 M39 - 4 M42 - 4.5 M48 - 5 M56 - 5.5

0.4 0.6 0.8 1.7 2.9 7.0 13.9 24.2 38 60 83 117 159 202 296 402 547 703 910 1,124 1,678 2,663

Max. Torque (ft-Ibf) 0.4 0.6 0.9 1.9 3.2 7.7 15.2 26.6 42 66 91 129 175 223 326 442 602 773 1,001 1,237 1,846 2,929

Clamp Force (Ib) 191 257 333 539 763 1,388 2,200 3,198 4,363 5,956 7,284 9,294 11,495 13,392 17,413 21,282 26,328 30,994 37,026 42,489 55,510 7 75,494 7

Min. Torque (ft-Ibf) 1.0 1.5 2.2 4.5 7.7 18.7 37 64 103 160 220 312 425 540 790 1,072 1,459 1,874 2,426 2,998 4,475 7,102

4.6

Max. Torque (ft-Ibf) 1.1 1.7 2.5 5.0 8.5 20.5 41 71 113 176 242 343 467 594 869 1,180 1,605 2,062 2,668 3,297 4,923 7,812

Clamp Force (lb) 509 686 888 1,437 2,033 3,703 5,868 8,528 11,634 15,883 19,423 24,785 30,653 35,711 46,434 56,753 70,208 82,651 98,736 113,304 148,003 201,316

7 7 7 7 7 7 7

8.8

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 9

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS

CLASS 10.9 T.S. = 1040 MPa PROOF STRENGTH = 830 MPa T.S. is for all dia

Diameter - pitch

Min. Torque (ft-Ibf)

M3 - .5 M3.5 - .6 M4 - .7 M5 - .8 M6 - 1 M8 - 1.25 M10 - 1.5 M12 - 1.75 M14 - 2 M16 - 2 M18 – 2.5 M20 – 2.5 M22 – 2.5 M24 – 3 M27 – 3 M30 - 3.5 M33 – 3.5 M36 – 4 M39 – 4 M42 - 4.5 M48 - 5 M56 – 5.5

1.3 2.1 3.1 6.3 10.6 26 51 89 142 221 305 432 588 747 1,092 1,484 2,019 2,593 3,355 4,147 6,190 9,824

Max. Torque (ft-Ibf) 1.5 2.3 3.4 6.9 11.7 28 56 98 156 244 335 475 646 822 1,202 1,632 2,221 2,852 3,691 4,561 6,810 10,806

Clamp Force (Ib) 704 949 1,229 1,987 2,813 5,122 8,117 11,797 16,094 21,971 26,869 34,286 42,403 49,400 64,234 78,508 97,121 114,334 136,585 156,737 204,737 278,488

7 7 7 7 7 7 7 7 7

CLASS 12.9 T.S. = 1220 MPa PROOF STRENGTH = 970 MPa T.S. is for all dia. * Metric socket head screws* Min. Max. Clamp Torque Torque Force (ft-Ibf) (ft-Ibf) (lb) 1.6 1.7 823 2.4 2.7 1,109 3.6 4.0 1,436 7.3 8.0 2,322 12.4 13.7 3,287 30 33 5,986 60 66 9,486 104 115 13,787 166 182 18,808 259 285 25,677 356 392 31,401 505 555 40,069 687 755 49,555 873 960 57,733 1,277 1,404 75,069 1,734 1,907 91,751 2,359 2,595 113,503 3,030 3,333 133,619 3,921 4,314 159,623 4,846 5,331 183,174 7,235 7,958 239,271 11,481 12,629 325,461

10.9

7 7 7 7 7 7 7 7 7 7

12.9

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 10

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND

CLASS 4.6 T.S. = 400 MPa PROOF STRENGTH = 225 MPa T.S. is for all dia.

CLASS 8.8 T.S. = 830 MPa PROOF STRENGTH = 600 MPa T.S. is for all dia *Metric socket head screws*

METRIC SERIES Diameter - pitch

Min. Torque (ft-Ibf)

M3 - .5 M3.5 - .6 M4 - .7 M5 - .8 M6 - 1 M8 - 1.25 M10 - 1.5 M12 - 1.75 M14 - 2 M16 - 2 M18 – 2.5 M20 – 2.5 M22 – 2.5 M24 - 3 M27 – 3 M30 - 3.5 M33 – 3.5 M36 – 3.5 M39 - 4 M42 - 4.5 M48 - 5 M56 - 5.5

0.3 0.4 0.6 1.3 2.2 5.2 10.4 18.1 29 45 62 88 119 152 222 302 410 527 682 843 1,259 1,997

Max. Torque (ft-Ibf) 0.3 0.5 0.7 1.4 2.4 5.8 11.4 19.9 32 50 68 97 131 167 244 332 452 580 750 927 1,384 2,197

Clamp Force (Ib) 191 257 333 539 763 1,388 2,200 3,198 4,363 5,956 7,284 9,294 11,495 13,392 17,413 21,282 26,328 30,994 37,026 42,489 55,510 7 75,494 7

Min. Torque (ft-Ibf) 0.7 1.1 1.7 3.4 5.8 14.0 28 48 77 120 165 234 319 405 592 804 1,095 1,406 1,819 2,248 3,356 5,326

4.6

Max. Torque (ft-Ibf) 0.8 1.2 1.8 3.7 6.3 15.4 30 53 85 132 182 258 350 445 652 885 1,204 1,546 2,001 2,473 3,692 5,859

Clamp Force (lb) 509 686 888 1,437 2,033 3,703 5,868 8,528 11,634 15,883 19,423 24,785 30,653 35,711 46,434 56,753 70,208 82,651 98,736 113,304 148,003 201,316

7 7 7 7 7 7 7

8.8

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 11

OF

16

DCF0045 (REV B)

TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND

CLASS 10.9 T.S. = 1040 MPa PROOF STRENGTH = 830 MPa T.S. is for all dia

Diameter - pitch

Min. Torque (ft-Ibf)

M3 - .5 M3.5 - .6 M4 - .7 M5 - .8 M6 - 1 M8 - 1.25 M10 - 1.5 M12 - 1.75 M14 - 2 M16 - 2 M18 – 2.5 M20 – 2.5 M22 – 2.5 M24 – 3 M27 – 3 M30 - 3.5 M33 – 3.5 M36 – 4 M39 – 4 M42 - 4.5 M48 - 5 M56 – 5.5

1.0 1.6 2.3 4.7 8.0 19.4 38 67 106 166 228 324 441 560 819 1,113 1,514 1,945 2,517 3,110 4,643 7,368

Max. Torque (ft-Ibf) 1.1 1.7 2.6 5.2 8.8 21.3 42 74 117 183 251 356 485 616 901 1,224 1,666 2,139 2,768 3,421 5,107 8,105

Clamp Force (Ib) 704 949 1,229 1,987 2,813 5,122 8,117 11,797 16,094 21,971 26,869 34,286 42,403 49,400 64,234 78,508 97,121 114,334 136,585 156,737 204,737 278,488

7 7 7 7 7 7 7 7 7

CLASS 12.9 T.S. = 1220 MPa PROOF STRENGTH = 970 MPa T.S. is for all dia. * Metric socket head screws* Min. Max. Clamp Torque Torque Force (ft-Ibf) (ft-Ibf) (lb) 1.2 1.3 823 1.8 2.0 1,109 2.7 3.0 1,436 5.5 6.0 2,322 9.3 10.3 3,287 22.6 24.9 5,986 45 49 9,486 78 86 13,787 124 137 18,808 194 214 25,677 267 294 31,401 379 416 40,069 515 567 49,555 655 720 57,733 958 1,053 75,069 1,300 1,430 91,751 1,770 1,947 113,503 2,273 2,500 133,619 2,941 3,235 159,623 3,635 3,998 183,174 5,426 5,969 239,271 8,611 9,472 325,461

10.9

7 7 7 7 7 7 7 7 7 7

12.9

The following tables specify torque values for fasteners used with Nord-Lock washers.

SIZE

DWG NO

REV

A SCALE

DS00008 NONE

WT LBS

SHEET

G 12

OF

16

DCF0045 (REV B)

NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 8.8 Oil Washer Size

Bolt Size

Pitch (mm)

Torque (ft-lbf)

Clamp (lb)

NL3 NL4 NL5 NL6 NL8 NL10 NL12 NL14 NL16 NL18 NL20 NL22 NL24 NL27 NL30 NL33 NL36 NL39 NL42

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 M42

.5 .7 .8 1.0 1.25 1.5 1.75 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.5 3.5 4.0 4.0 4.5

1.2 3.0 5.8 10 24 47 82 129 197 276 385 525 664 968 1,322 1,779 2,295 2,960 3,663

540 944 1,529 2,181 4,047 6,295 8,992 12,364 16,861 20,682 26,527 32,822 37,993 49,683 60,474 74,861 88,125 105,211 120,947

Graphite Torque Clamp (ft-lbf) (lb)

1.2 2.7 5.2 9.1 22 43 74 117 177 249 348 474 599 873 1,192 1,600 2,067 2,663 3,297

540 944 1,529 2,181 4,047 6,295 8,992 12,364 16,861 20,682 26,527 32,822 37,993 49,683 60,474 74,861 88,125 105,211 120,947

NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 10.9 Oil Washer Size

Bolt Size

Pitch (mm)

Torque (ft-lbf)

Clamp (lb)

NL3 NL4 NL5 NL6 NL8 NL10 NL12 NL14 NL16 NL18 NL20 NL22 NL24 NL27 NL30 NL33 NL36 NL39 NL42

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 M42

.5 .7 .8 1.0 1.25 1.5 1.75 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.5 3.5 4.0 4.0 4.5

1.7 3.9 7.8 14 33 64 110 175 268 375 524 714 903 1,318 1,798 2,422 3,125 4,030 4,988

719 1,259 2,046 2,900 5,171 8,318 12,140 16,636 22,481 27,651 35,070 43,613 50,582 66,094 80,482 99,590 117,350 140,281 160,963

SIZE

1.5 3.5 6.7 12 29 56 95 151 230 323 451 613 776 1,128 1,542 2,068 2,673 3,440 4,262

764 1,326 2,158 3,057 5,620 8,768 12,814 17,535 23,830 29,225 37,093 46,086 53,505 69,691 84,978 105,211 123,870 148,149 170,180

DWG NO

REV

A SCALE

Graphite Torque Clamp (ft-lbf) (lb)

DS00008 NONE

WT LBS

SHEET

G 13

OF

16

DCF0045 (REV B)

NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 12.9 Oil Washer Size

NL3 NL4 NL5 NL6 NL8 NL10 NL12 NL14 NL16 NL18 NL20 NL22 NL24 NL27 NL30 NL33 NL36 NL39 NL42

Bolt Size

Pitch (mm)

Torque (ft-lbf)

Clamp (lb)

Torque (ft-lbf)

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 M42

.5 .7 .8 1.0 1.25 1.5 1.75 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.5 3.5 4.0 4.0 4.5

1.9 4.4 8.7 15 36 72 123 196 298 419 585 797 1,009 1,470 2,005 2,699 3,483 4,490 5,560

877 1,506 2,450 3,462 6,295 9,892 14,613 20,008 26,977 33,272 42,264 52,380 60,698 79,133 96,668 119,598 140,730 168,157 193,336

1.6 3.8 7.4 13 31 61 105 167 252 355 494 670 850 1,235 1,688 2,265 2,927 3,763 4,666

Graphite Clamp (lb)

922 1,596 2,585 3,664 6,744 10,566 15,287 21,132 28,551 35,070 44,512 55,303 64,295 83,629 102,063 126,343 148,823 177,599 204,126

NORD-LOCK Stainless Steel with Stainless Steel Bolt A4 Washer Size

Bolt Size

Pitch (mm)

NL3 NL4 NL5 NL6 NL8 NL10 NL12 NL14 NL16 NL18 NL20 NL22 NL24 NL27 NL30 NL33 NL36 NL39 NL42

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36 M39 M42

.5 .7 .8 1.0 1.25 1.5 1.75 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.5 3.5 4.0 4.0 4.5

A4-70 w/ Graphite Lube Torque Clamp (ft-lbf) (lb)

0.9 1.9 3.7 7 16 32 54 85 130 183 256 349 441 643 877 1,182 1,525 1,968 2,435 SIZE

337 585 922 1,326 2,473 3,822 5,620 7,644 10,341 12,589 16,186 20,008 23,155 30,124 36,869 45,636 53,729 64,071 73,737

1.2 2.6 5.1 9 21 41 72 114 174 244 341 465 588 858 1,170 1,576 2,034 2,624 3,247

450 764 1,236 1,754 3,147 5,171 7,419 10,116 13,713 16,861 21,357 26,527 30,799 40,241 49,233 60,698 71,714 85,652 98,241

DWG NO

REV

A SCALE

A4-80 w/ Graphite Lube Torque Clamp (ft-lbf) (lb)

DS00008 NONE

WT LBS

SHEET

G 14

OF

16

DCF0045 (REV B)

NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 5 Oil

Graphite

Washer Size

Bolt Size

Pitch (TPI)

Torque (ft-lbf)

Clamp (lb)

Torque (ft-lbf)

Clamp (lb)

NL3 NL3.5 NL4 NL5 NL1/4” NL8 NL3/8” NL11 NL1/2” NL14 NL16 NL3/4” NL22 NL 1” NL30 NL33 NL36 NL39

#5 #6 #8 #10 ¼ 5/16 3/8 7/16 ½ 9/16 5/8 ¾ 7/8 1 1 1/8 1¼ 1 3/8 1½

40 32 32 24 20 18 16 14 13 12 11 10 9 8 7 7 6 6

1.1 1.4 2.7 3.9 9.1 18 30 47 73 104 145 254 408 617 771 1075 1410 1860

550 630 970 1,200 2,200 3,600 5,400 7,300 9,800 12,600 15,600 23,100 31,900 41,800 46,400 58,900 70,200 85,500

1.0 1.3 2.4 3.5 8.3 16 28 42 66 94 131 230 369 557 697 969 1,270 1,670

550 630 970 1,200 2,200 3,600 5,400 7,300 9,800 12,600 15,600 23,100 31,900 41,800 46,400 58,900 70,200 85,500

NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 8 Oil Washer Size

Bolt Size

Pitch (TPI)

Torque (ft-lbf)

Clamp (lb)

NL3 NL3.5 NL4 NL5 NL1/4” NL8 NL3/8” NL11 NL1/2” NL14 NL16 NL3/4” NL22 NL 1” NL30 NL33 NL36 NL39

#5 #6 #8 #10 ¼ 5/16 3/8 7/16 ½ 9/16 5/8 ¾ 7/8 1 1 1/8 1¼ 1 3/8 1½

40 32 32 24 20 18 16 14 13 12 11 10 9 8 7 7 6 6

1.5 1.9 3.5 5.1 12 24 41 64 99 138 197 346 556 840 1,190 1,660 2,180 2,870

740 840 1,300 1,600 2,900 4,900 7,200 9,800 13,100 16,800 20,900 30,900 42,700 56,000 70,600 89,600 107,000 130,000

SIZE

1.3 1.7 3.1 4.6 11 21 36 56 86 122 171 299 479 724 1,030 1,430 1,880 2,470

780 890 1,400 1,700 3,100 5,100 7,600 10,400 13,900 17,800 22,100 32,700 45,100 59,200 74,500 94,600 113,000 137,000

DWG NO

REV

A SCALE

Graphite Torque Clamp (ft-lbf) (lb)

DS00008 NONE

WT LBS

SHEET

G 15

OF

16

DCF0045 (REV B)

NORD-LOCK Stainless Steel with ASTM A574 Bolt Oil Washer Size

Bolt Size

Pitch (TPI)

NL3 NL3.5 NL4 NL5 NL1/4” NL8 NL3/8” NL11 NL1/2” NL14 NL16 NL3/4” NL22 NL 1” NL30 NL33 NL36 NL39

#5 #6 #8 #10 ¼ 5/16 3/8 7/16 ½ 9/16 5/8 ¾ 7/8 1 1 1/8 1¼ 1 3/8 1½

40 32 32 24 20 18 16 14 13 12 11 10 9 8 7 7 6 6

Torque (ft-lbf)

Clamp (lb)

1.7 2.2 3.8 5.8 13 26 45 70 109 148 216 378 607 916 1,300 1,810 2,380 3,140

870 990 1,500 1,900 3,400 5,700 8,400 11,500 15,400 19,800 24,600 36,400 50,200 65,900 83,000 105,000 126,000 153,000

Graphite Torque Clamp (ft-lbf) (lb)

1.6 2.0 3.7 5.5 12 23 39 60 93 141 184 321 514 776 1100 1530 2020 2640

910 1,050 1,600 2,000 3,700 6,000 8,900 12,200 16,300 20,900 26,000 38,400 53,000 69,600 87,700 111,000 133,000 161,000

NORD-LOCK Stainless Steel with ASTM F593 Bolt Oil Washer Size

Bolt Size

Pitch (TPI)

NL3 NL3.5 NL4 NL5 NL1/4” NL8 NL3/8” NL11 NL1/2” NL14 NL16 NL3/4” NL22 NL 1” NL30 NL33 NL36 NL39

#5 #6 #8 #10 ¼ 5/16 3/8 7/16 ½ 9/16 5/8 ¾ 7/8 1 1 1/8 1¼ 1 3/8 1½

40 32 32 24 20 18 16 14 13 12 11 10 9 8 7 7 6 6

Torque (ftlb)

Clamp (lb)

5.2 10.3 18 28 43 61 85 104 166 251 356 497 653 859

1,300 2,200 3,300 4,500 6,000 7,700 9,500 9,800 13,500 17,700 22,300 28,300 33,800 41,100

SIZE

5.2 10.3 18 28 43 61 85 104 166 251 356 497 653 859

1,300 2,200 3,300 4,500 6,000 7,700 9,500 9,800 13,500 17,700 22,300 28,300 33,800 41,100

DWG NO

REV

A SCALE

Graphite Torque Clamp (ftlb) (lb)

DS00008 NONE

WT LBS

SHEET

G 16

OF

16

DCF0045 (REV B)

Hydraulic Fluid Cleanliness

Supplement SM00081 Rev. C

October 26, 2000

Copyright 2000, Varco International, Inc. All rights reserved. This publication is the property of and contains information proprietary to Varco International, Inc. No part of this publication may be reproduced or copied in any form or by any means, including electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Varco International, Inc. Product names mentioned in this publication may be trademarks or registered trademarks of their respective holders and are hereby acknowledged.

ii

Hydraulic Fluid Cleanliness

SM00081-C

Contents Supplement Hydraulic Fluid Cleanliness Scope .................................................................................................................... 5 Hydraulic Fluid Cleanliness ................................................................................. 6 Hydraulic fluid ............................................................................................... 6 Hydraulic Fluid Contamination ............................................................................ 7 Solid contamination ....................................................................................... 7 Classes of contamination ......................................................................... 7 Measuring the contamination of a system ............................................... 9 Taking samples .................................................................................. 9 Analyzing the samples .......................................................................... 10 Cleanliness during installation ........................................................................... 11 Service loops ................................................................................................ 11 Hydraulic pipe cleaning ............................................................................... 11 Reference documents: ........................................................................... 11 Pipe cleaning (carbon steel): ................................................................. 11 Pipe cleaning (stainless steel) ................................................................ 13

SM00081-C

Contents

iii

October 26, 2000

iv

Hydraulic Fluid Cleanliness

SM00081-C

Supplement Hydraulic Fluid Cleanliness

Scope The purpose of this document is to provide guidance to the installers and users of Varco’s hydraulically powered equipment and to ensure that each piece of equipment performs as intended. Prior to connecting Varco equipment to a hydraulic system, the piping/plumbing/hoses/service loops must be cleaned and the hydraulic fluid filtered to minimize hydraulic fluid contamination. The following paragraph defines the hydraulic fluid cleanliness levels required for operating Varco equipment. Failure to maintain these cleanliness levels could result in premature equipment damage and nullification of the equipment warranty. This document outlines fluid cleanliness measurement and analysis criteria and also describes procedures for filtering and cleaning a hydraulic system. Each final assembly item from Varco will be function tested with clean hydraulic fluid maintained at ISO 4406 18/15 (was 9) or better (See Table 1). The hydraulic fluid cleanliness levels will be recorded on Test Specification document (TS00419) for each piece of equipment prior to shipment.

SM00081-C

Hydraulic Fluid Cleanliness

5

October 26, 2000

Hydraulic Fluid Cleanliness Hydraulic fluid Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO 4406 18/15 (was 9) or better prior to the initial connection, startup, and commissioning of Varco equipment. After initial system operation, Varco recommends that the hydraulic supply system be capable of continuously maintaining this level of cleanliness or better to assure that fluid contamination is not a factor in any component failure during the desired useful life of the hydraulic powered equipment. The final level of acceptable cleanliness prior to equipment hook up must be determined by a hydraulic fluid sample and should be analyzed by a qualified laboratory.

6

Hydraulic Fluid Cleanliness

SM00081-C

Hydraulic Fluid Contamination

Hydraulic Fluid Contamination Solid contamination When determining contamination of hydraulic fluids, you must consider the size and quantity of the solid particle contamination within a representative fluid sample. The contamination of hydraulic fluids by solid particles is covered by a number of different classification systems: ❏ ISO DIS 4406 ❏ MIL STD 1246 A ❏ NAS 1638 ❏ SAE 749 D ❏ CETOP RP 70 H

CLASSES OF CONTAMINATION The various classes of contamination define the quantity of particles of a certain size in a 100 ml sample of fluid. A classification is determined by counting and sizing the contaminating solid particles. The classification is performed either under a microscope, or by using an electronic particle counter. The electronic counter method is more objective than using the microscope. Above a dirt concentration of about 20 mg per liter, or if the fluid is very turbid, the contamination can only be ascertained by weight, i.e., by gravimetric analysis. However, with this method, the individual dirt particles cannot be classified.

SM00081-C

Hydraulic Fluid Cleanliness

7

NAS 1638 (1967)

SAE 749 D (1963)

Particles per ml >10 µm

ACFTD solids content mg/L

26/23

140000

1000

25/23

85000

23/20

14000

21/18

4500

20/18

2400

20/17

2300

20/16

1400

19/16

1200

10

18/15

580

9

6

17/14

280

8

5

16/13

140

7

4

15/12

70

6

3

14/12

40

14/11

35

5

2

13/10

14

4

1

12/9

9

3

0

18/8

5

2

10/8

3

10/7

2.3

10/6

1.4

9/6

1.2

0

8/5

0.6

00

7/5

0.3

6/3

0.14

5/2

0.04

Figure 1.

8

Mil STD 1246 A (1967)

ISO DIS 4406 or Cetop RP 70 H

Hydraulic Fluid Cleanliness

1000 100

700 12 500 11

10

300 1

200

0.1

100 1 0.01

Acceptable range for Varco equipment

Acceptable range for Varco equipment

October 26, 2000

50 0.001

Comparison of contamination classifications

SM00081-C

Comparison of contamination classifications

MEASURING THE CONTAMINATION OF A SYSTEM Solid particle contamination is measured by taking a sample of fluid from the output of the hydraulic supply system at a location just prior to the Varco equipment and analyzing it. The analysis can reveal the following: ❏ Solid particle contamination of fluid delivered by suppliers ❏ Effectiveness of the system filters ❏ Flushing time when commissioning a system ❏ State of the system and any possible damage to components when making regular checks

Taking samples Take a sample from a moving fluid (known as dynamic sampling) Sampling point: Take the sample within a system that is operating and which contains turbulent flow. (See ISO 4021.) Since obtaining a fluid sample can be an input for contamination the following general measures should be utilized when taking a fluid sample. ❏ Utilize continuous flow monitoring equipment that records a cleanliness level over a period of time whenever possible. ❏ Take a sample of the circulating fluid of a system that is at operating conditions and temperature. All fluid samples shall be taken from a system test-port fitting using a on/off flow sampling device. Never loosen or break a hydraulic fitting to establish a leak point as a fluid source for fluid contamination sampling. ❏ Before attaching the sampling device, carefully flush out the device and clean the system test-port fitting. ❏ Open sampling device and allow approximately 2 liters of fluid to flow through the test port prior to sampling the fluid. ❏ Without shutting the test port, open and fill the sterile sampling bottle by holding it in the continuous fluid stream. Cap and seal the test bottle. ❏ Label and date the sample bottle to identify the tool and sample hydraulic circuit location.

e

SM00081-C

Only properly trained personnel should be allowed to take the fluid samples. Errors in sampling procedures can greatly affect contamination classes below ISO 18/IS.

Hydraulic Fluid Cleanliness

9

October 26, 2000

ANALYZING THE SAMPLES Analyzing the fluid samples involves using a microscope to make a quick estimate of the amount of solid particle contamination. From this assessment, you can roughly assess the state of the system. To avoid errors in sampling, conduct particle counting off site. Do not allow rig personnel to attempt to check the samples at the time of sampling. Send the samples to an appropriate institute for testing. Usually, samples are analyzed by means of an electronic particle counter. These particle counters are employed by major users of hydraulics, manufacturers of hydraulic filters, and by various institutions. Since testing by an outside source may not be easily accessible from a rig, you can make a quick assessment of the fluid samples on the spot by using the assessment test charts in this document.

z

10

Mobile laboratory services can also perform the measurements for customers.

Hydraulic Fluid Cleanliness

SM00081-C

Cleanliness during installation

Cleanliness during installation Service loops Varco service loops are blown clean in the factory and capped prior to shipment. They are not flushed. All service loops and hoses should be flushed as part of the overall hydraulic system prior to connecting Varco equipment.

Hydraulic pipe cleaning

z

Clean hydraulic piping is critical to the cleanliness of the overall hydraulic system. The following processes are examples of pickling, cleaning, and flushing procedures for cleaning carbon steel and stainless steel pipes prior to hydraulic system installation and are provided for information and reference only. Varco is typically not responsible for any part of the pickling, cleaning, or flushing process of derrick and rig floor piping. The process for cleaning and preparing hydraulic pipes is dependent on the type of pipe (carbon or stainless), the condition of the pipe (pickled or not pickled), the types and levels of contamination, the types and temperatures of the pickling and flushing solutions in use, and the type of flushing equipment.

REFERENCE DOCUMENTS: ❏ ASTM Standard 5.02 D-4174, standard practice for cleaning, flushing, and purification of petroleum fluid hydraulic system.

PIPE CLEANING (CARBON STEEL): Obtain the following chemicals: Hydrochloric acid - 35% commercial grade Alkaline cleaner, KD-500 Potable water - Unless otherwise specified Passivator - iron phosphate, KO-30 Inhibitor - Rodine 214 for HCL

SM00081-C

Hydraulic Fluid Cleanliness

11

October 26, 2000

Degrease Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends on the nature of any contaminants present. Pipes and fittings with heavy rust, varnish or other tough soils should be sandblasted prior to pickling. Rinse Rinse carbon steel pipe with potable water until all alkaline cleaner is removed. Acid pickle Immerse or spray the pipe with a 10-15% inhibited hydrochloric acid solution at ambient temperature (for at least one hour) until all scale, slag, rust, etc. Is removed. Rinse with potable water until all alkaline cleaner is removed. Rinse Rinse the pipe with potable water until the water reaches a neutral PH (7.0). Flush Begin flushing the piping with the hydraulic power unit until the desired state of cleanliness is met.

12

Hydraulic Fluid Cleanliness

SM00081-C

Cleanliness during installation

PIPE CLEANING (STAINLESS STEEL) Use the following recommended procedure for cleaning stainless steel pipe: Obtain the following chemicals: Nitric acid - 42% technical grade Hydrofluoric acid - 35% technical grade Alkaline cleaner, KD-500 Potable water - unless otherwise specified Degrease Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends on the nature of any contaminants present. Rinse Rinse pipe with portable water until all alkaline cleaner is removed. Acid pickle Immerse or spray the pipe with a 15-17% nitric acid/3-5% hydrofluoric acid mixture at ambient temperature (for at least two hours) until all scale, slag, rust, etc. is removed. Rinse Rinse the pipe with potable water until the water reaches a neutral PH. Passivate Use a 10 - 15% nitric acid/75-80% potable water mixture at ambient temperature for approximately one-half the time used in acid pickling. Rinse Rinse with potable water until the PH of the effluent equals the pH of the influent. Dry Dry with oil-free air until all visible traces of moisture are removed. Final inspection Use a white light to inspect all pipe and/or fittings for visible contamination. Prior to hooking up equipment pump clean hydraulic fluid through the plumbing and measure the contamination of the system per this specification. Additional flushing and cleaning may be required if contamination levels do not meet the requirements of this specification.

SM00081-C

Hydraulic Fluid Cleanliness

13

TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

2.2

Spare Parts List

www.nov.com

Document Number:

10862028-MAN TOC 2.2

Revision:

01

Page:

1

Document Number

Rev.

Spares List-Kit, Electrical

10896370-SPL

02

Mechanical Spares Kit ST-120 (UL)

M361005930-SPL-001

02

ST-120 CENTRAL PANUCO UXPANAPA SPARES LIST/KIT, ELECTRICAL

NOTES:

RIG/PLANT

ADDITIONAL CODE

SDRL CODE

TOTAL PGS

REMARKS

MAIN TAG NUMBER

DISCIPLINE

CLIENT PO NUMBER

1.

10896370-1 Recommended Commissioning Spares

2.

10896370-2 Recommended Operational Spares

3.

10896370-3 Recommended Insurance Spares

NEXT ASSY

PRODUCT

10861989-GEN

ST-120

This document contains proprietary and confidential information which belongs to 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 and in any event 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

National Oilwell Varco 11000 Corporate Centre Drive Houston, Texas 77041 (USA) Phone + 281-854-0400 Fax + 281-854-0607

CLIENT DOCUMENT NUMBER

DOCUMENT NUMBER

REV

Client Document Number

10896370-SPL

02

www.nov.com

Document number Revision Page Template Name

10896370-SPL 02 2 ORA_SPL_TPL.doc

REVISION HISTORY

02

02/05/2015

Removed Profibus DP Coupler

B. MALEK

01

03/18/2014

Initial Release

R. MOENCH T. GONZALEZ R. MOENCH

Rev

Date (mm.dd.yyyy)

Reason for issue

CHANGE DESCRIPTION Revision 01 02

Change Description First issue Revision to remove Profibus DP Coupler

D7440000254-TPL-001/01

www.nov.com

Prepared

R. MOENCH R. MOENCH Checked

Approved

Document number Revision Page Template Name

Part No.

Description

-1 -2 Recom. Recom. Commission Operational Spare Spare

-3 Recom. Insurance Spare

10896370-SPL 02 3 ORA_SPL_TPL.doc

Where Used

10066792-001

POWER SUPPLY, 24VDC, 10A, SOLA

2

-

2

10541141-001

10042793-001

PROFIBUS CONNECTOR

-

-

1

10541141-001

1

1

1

10541141-001

1

-

1

10541141-001

-

-

1

10541141-001

-

-

1

10541141-001

-

-

1

10541141-001

10044937-001 10066482-001 10482149-001 10068370-001 10044012-001

RELAY 24VDC, DPDT, ZONE 2 RELAY 24VDC, 5NO, 2NC CONTACTS ATOS PROPORTIONAL SOLENOID DRIVER ELECTRONIC SOLENOID DRIVER OLM-OPTICAL LINK MODULE, EEC

10064194-029

FUSE, 6A

-

-

2

10541141-001

10541475-001

FUSE, 0.5A

-

-

2

10541141-001

1

-

2

10541141-001

2

-

2

10541141-001

1

-

1

10541141-001

1

-

1

10541141-001

2

-

2

10541141-001

1

-

1

10541141-001

1

-

1

10541141-001

1

-

1

10541141-001

10064178-086 10064178-040 10064178-053 10064178-008 10064178-096 10064178-104 10064178-103 10064178-072

PROFIBUS DP COUPLER, 12MB MODULE, DIGITAL INPUT, 4CH MODULE, DIGITAL OUTPUT, 2-CH MODULE, ANALOG INPUT, 2PT, 12 BIT MODULE, POWER SUPPLY/FUSE MODULE, FILTER, 24VDC MODULE, POWER SUPPLY, FILTER, 24VDC MODULE, FIELD SIDE POWER

Description Where Used ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/O J-BOX ST-120 REMOTE I/OJ-BOX

10064178-070

END MODULE

2

-

2

10541141-001

10513206-001

HEATER STRIP, 110-230VAC

-

-

1

10541141-001

10043521-001

PLS-SIE, RS-485 REPEATER

-

-

1

10541141-001

10055036-001

ISOLATOR SWITCH

-

-

1

10541141-001

10508604-001

ISOLATOR, 4 CH AMPLIFIER

1

-

1

10786264-001

CARRIAGE J-BOX

10044537-001

E-STOP PUSHBUTTON

-

-

1

10786264-001

CARRIAGE J-BOX

D7440000254-TPL-001/01

www.nov.com

Mechanical Spares Kit ST-120 (UL) Mechanical and Hydraulic Spares Kit ST-120 Auto (UL)

NOTES: 1. M361005930-1 2. M361005930-2 3. M361005930-3

RIG/PLANT

ADDITIONAL CODE

REFERENCE

SDRL CODE

TOTAL PGS

REMARKS

MAIN TAG NUMBER

Recommended Commissioning Spares Recommended Operational Spares Recommended Insurance Spares

DISCIPLINE

CLIENT PO NUMBER

REFERENCE DESCRIPTION

This document contains proprietary and confidential information which belongs to 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 and in any event 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

National Oilwell Varco, Inc. Rig Solutions 743 N Eckhoff Street Orange, CA 92868 Phone +1 (714) 978-1900

CLIENT DOCUMENT NUMBER

DOCUMENT NUMBER

REV

Client Document Number

M361005930-SPL-001

02

www.nov.com

Document number Revision Page

M361005930-SPL-001 02 2

REVISION HISTORY

02

14-Oct-2014

CORRECTED P/Ns

01

25.03.2013

INITIAL RELEASE

Rev

Date (dd.mm.yyyy)

Reason for issue

M.TEEL Prepared

Change Description First issue Page 5: Base P/Ns are M364001228, were M364001288

www.nov.com

A.JONES

A.HASTINGS J. WALKER J. WALKER

CHANGE DESCRIPTION Revision 01 02

A.JONES Checked

Approved

Document number Revision Page

Part Number

Description

M361005930-SPL-001 02 3

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used

1

Description Where Used

ST-120 ASSEMBLY (M361005910) M364000305

MAIN HYD. LIFT CYLINDER

M361005910

ST-120 ASSEMBLY

108894-G17

ROD SEALS/BRONZE GLAND

1

M364000305

MAIN HYD. LIFT CYL

108894-L40

PISTON SEAL KIT

1

M364000305

MAIN HYD. LIFT CYL

108894-Z677

SPANNER WRENCH

1

M364000305

MAIN HYD. LIFT CYL

108894-Y3

GLAND WRENCH

1

MAIN HYD. LIFT CYL

30184836

CHAIN, ENERGY

M364000305 M361005910

M364001340

HOSE KIT

M361005910

ST-120 ASSEMBLY

30172054-M1

M1 MAGNET

1

M361005910

ST-120 ASSEMBLY

30183688

C’BAL MANIFOLD ASSEMBLY

1

M361005910

ST-120 ASSEMBLY

M364001001

TUBING KIT

M361005910

ST-120 ASSEMBLY

56541-32

KIT, SPLIT FLANGE

1

M361005910

ST-120 ASSEMBLY

1

M361005910

ST-120 ASSEMBLY

1 1

1

ST-120 ASSEMBLY

56541-40

KIT, SPLIT FLANGE

30184446-C3E

ELEMENT, FILTER

1

M361005910

ST-120 ASSEMBLY

92537-E-216

ELEMENT, FILTER

1

M361005910

ST-120 ASSEMBLY

107634-13ANB

VALVE ASSY, MOTION CONTROL

1

M361005908

ARM ASSEMBLY

30172054-M1

M1 MAGNET

1

M361005908

ARM ASSEMBLY

M364000010

CYL, HYD, ARM EXTEND

2

M364000943

EXTEND CYLINDER ASSY

108894-R17

ROD SEALS/BRONZE GLAND

2

M364000010

CYL, HYD, ARM EXTEND

108894-L40

PISTON SEAL KIT

2

30180821-2

MANIFOLD, LOAD HOLDING

2

M364000010 M364000943

EXTEND CYLINDER ASSY

30181558-2

MANIFOLD, LOAD HOLDING

2

M364000943

EXTEND CYLINDER ASSY

94518-13HN

VALVE, C’BAL VENTED

2

M364000943

EXTEND CYLINDER ASSY

98005-13

VALVE, C’BALANCE, INT DRAINED

2

M364000943

EXTEND CYLINDER ASSY

M854000243-HVVH

VALVE, SECTION, MODIFIED

1

VALVE, SECTION, MODIFIED

1

M851003997 M851003997

ARM FUNCTNS MANIFOLD

M854000243-HPPHP M854000243-HGGH

VALVE, SECTION, MODIFIED

1

M851003997

ARM FUNCTNS MANIFOLD

92537-216-A

FILTER, ASSY, NON-BYPASS

1

M851003997

ARM FUNCTNS MANIFOLD

92537-E-216

ELEMENT, FILTER REPLCMNT BALL VALVE, MANIFOLD MOUNT

1

92537-216-A M851003997

FILTER, ASSY, NON-BYPASS

93545-25N 93545-H1401

HANDLE, STRAIGHT, 14mm

1

M851003997

ARM FUNCTNS MANIFOLD

117851-4KHN

LOGIC CARTRIDGE

M851003997

ARM FUNCTNS MANIFOLD

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1 1

3

1

CYL, HYD, ARM EXTEND

ARM FUNCTNS MANIFOLD

ARM FUNCTNS MANIFOLD

Document number Revision Page

Part Number

94817-4AN

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

VALVE REDUCING 100-3000 PSI

M361005930-SPL-001 02 4

Where Used

Description Where Used

1

M851003997

ARM FUNCTNS MANIFOLD ARM FUNCTNS MANIFOLD

93548-4S30N

VALVE, CHECK 2:1

1

M851003997

93548-IS4N

VALVE, CHECK 4 PSI

1

M851003997

ARM FUNCTNS MANIFOLD

14783

GAUGE, 0-3000 PSI

M851003997

ARM FUNCTNS MANIFOLD

30181600-102

KIT, SEAL, HAWE

M854000263-2

MANIFOLD, SANDWICH

P851002660

VALVE, REDUCE/RELIEVE PILOT

94521-ZZN

VALVE, SHUTTLE

P851002750-RV1

VALVE, PROPORTIONAL RELIEF

127908-D2

SOLENOID VALVE, D03, UL

110538-5M

1

M851003997

ARM FUNCTNS MANIFOLD

1

10655517 10655517

ELECTRO-HYD PILOT MANIFOLD

1

10655517

ELECTRO-HYD PILOT MANIFOLD

1

10654007

ENABLE MANIFOLD ASSEMBLY

1

10654007

ENABLE MANIFOLD ASSEMBLY

1

10654007

ENABLE MANIFOLD ASSEMBLY ENABLE MANIFOLD ASSEMBLY

3 1

VALVE, DIRECTIONAL CONTROL

ELECTRO-HYD PILOT MANIFOLD

109858-IEN

PRESSURE REDUCING VALVE

1

10654007

30176410-IWN

VALVE, DIRECTIONAL 3-POSITION

1

10654007

ENABLE MANIFOLD ASSEMBLY

94521-IAN

VALVE, SHUTTLE

1

10654007

ENABLE MANIFOLD ASSEMBLY

M364000287

PIN, WRENCH INTERFACE

1

M361005909

HEAD ASSEMBLY

M364000821

TELESCOPIC CYLINDER

M361005909

HEAD ASSEMBLY

M364000821-01

SEAL KIT

1

M364000821

TELESCOPIC CYLINDER

M364000821-02

REBUILD KIT

1

TELESCOPIC CYLINDER

30184685

CHAIN, ENERGY

1

M364000821 M361005909

30184446-C3B

FILTER, HI-P INLINE, NON-BYPASS

1

M361005909

HEAD ASSEMBLY

30184446-C3E

HI-P FILTER ELEMENT

96276-6

BALL VALVE

1

M361005909

HEAD ASSEMBLY

30181542

INTENSIFIER, HYDRAULIC

1

M361005909

HEAD ASSEMBLY

110563-7CE

ACCUMULATOR, 4” DIA

1

M361005909

HEAD ASSEMBLY

30183995

FLOW DIVIDER

2

M361005909

HEAD ASSEMBLY

M364000685

TARGET, PROXIMITY SENSOR

2

M361005909

HEAD ASSEMBLY

1

M361005909

HEAD ASSEMBLY

M361005909

HEAD ASSEMBLY

M361005909

HEAD ASSEMBLY

1

1

HEAD ASSEMBLY

30184446-C3B FILTER, HI-P IN, NON-BYPASS

3

109270-ECH

LINE BODY, TIIA CAVITY

94521-IBN

SHUTTLE VALVE

M854000244

VALVE BODY

94537-130N

CHECK VALVE, PILOT TO CLOSE

1

M361005909

HEAD ASSEMBLY

M364000744

RETAINER, SPRING, ST-120

1

M361005909

HEAD ASSEMBLY

M364000747

SPRING, COMPRESSION

1

M361005909

HEAD ASSEMBLY

1

M361005909

HEAD ASSEMBLY

M361005909

HEAD ASSEMBLY

1 1

M364000745

PERCH, SPRING

30183554-02

MAIN ROLLER

109270-MAI

LINE BODY SINGLE CAVITY, 90 DEG

1

M361005909

HEAD ASSEMBLY

109655-13

VALVE, C’BAL

1

M361005909

HEAD ASSEMBLY

117068-IREN

VALVE, SEQ. DIRECT ACTING

1

M361005909

HEAD ASSEMBLY

1

M361005909

HEAD ASSEMBLY

M364001243 M364001243

LOWER JAW ASSY

M364001243

LOWER JAW ASSY

M364001243

LOWER JAW ASSY

M364001051

HYDRAULIC CYLINDER

M364001119

HOSE KIT, CENTRALIZER

30181411

GUIDE, DIE, CENTER

30181412

GUIDE, DIE, SIDE

16401-2

DIE, TONG

M364001051

HYDRAULIC CYLINDER 5X10

108894-G20

ROD SEALS AND BRONZE GLAND

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2

1 2 30 1 1

LOWER JAW ASSY

Document number Revision Page

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

108894-P50

SEAL KIT

M364001051-100

HYDRAULIC CYLINDER 5X10

1

108894-G20

ROD SEALS AND BRONZE GLAND

1

M364001072

SEAL KIT

1

M364001228

CLAMP CYLINDER

M364001228-02

SEAL KIT

M364001228-03

REBUILD KIT

M364001228-06

CARTRIDGE KIT

30182552

PLATE, RETAINING

118836-28-46

BUSHING, THRUST-FIBREGLIDE

1

M361005930-SPL-001 02 5

Where Used

Description Where Used

M364001051

HYDRAULIC CYLINDER

M364001243

LOWER JAW ASSY

M364001051

HYDRAULIC CYLINDER

M364001051

HYDRAULIC CYLINDER

M364001243

LOWER JAW ASSY

3

M364001228

CLAMP CYLINDER

3

M364001228

CLAMP CYLINDER

3

M364001228 M364001243

LOWER JAW ASSY

2

M364001243

LOWER JAW ASSY LOWER JAW ASSY

3

1

CLAMP CYLINDER

30172475-28-16

BUSHING, GARLOCK

2

M364001243

30172475-28-20

BUSHING, GARLOCK

2

M364001243

LOWER JAW ASSY

30172475-36-24

BUSHING, GARLOCK

2

M364001243

LOWER JAW ASSY

M361000211

MANIFOLD, CLAMP CYL

1

M364001243

LOWER JAW ASSY

M361000212

MANIFOLD, CLAMP CYL

1

M364001243

LOWER JAW ASSY

M364000345

2

M364001243

LOWER JAW ASSY

59347P17A033

PLATE, GUIDE RING, CENTER ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59343P170042

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59344P230029

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59347P230030

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59344P170043

ASSEMBLY, HOSE

M364001243

LOWER JAW ASSY

59343O230028

ASSEMBLY, HOSE

1 1

M364001243

LOWER JAW ASSY

59324P230044

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59343P170028

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59324P230011

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59343P170013

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

59324P170008

ASSEMBLY, HOSE

1

M364001243

LOWER JAW ASSY

30181411

GUIDE, DIE, CENTER

1

M364001244

30181412

GUIDE, DIE, SIDE

2

UPPER JAW ASSY UPPER JAW ASSY

16401-2

DIE, TONG

M364001244 M364001244

M364001051

HYDRAULIC CYLINDER 5X10

1

M364001244

UPPER JAW ASSY

108894-G20

ROD SEALS AND BRONZE GLAND

1

M364001051

HYDRAULIC CYLINDER

108894-P50

SEAL KIT

1

M364001051

HYDRAULIC CYLINDER

M364001051-100

HYDRAULIC CYLINDER 5X10

108894-G20

ROD SEALS AND BRONZE GLAND

1

M364000064 M364001051

HYDRAULIC CYLINDER

108894-P50

SEAL KIT

1

M364001051

HYDRAULIC CYLINDER

M364001228

CLAMP CYLINDER

M364001244

UPPER JAW ASSY

M364001228-02

SEAL KIT

3

REBUILD KIT

3

M364001228 M364001228

CLAMP CYLINDER

M364001228-03 M364001228-06

CARTRIDGE KIT

3

M364001228

30182552

PLATE, RETAINING

M364001244

CLAMP CYLINDER UPPER JAW ASSY

118836-28-46

BUSHING, THRUST-FIBREGLIDE

M364001244

UPPER JAW ASSY

M361000211

MANIFOLD, CLAMP CYL

M364001244

UPPER JAW ASSY

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30

1

3

1 2 1

UPPER JAW ASSY

UPPER JAW ASSY

CLAMP CYLINDER

Document number Revision Page

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

M361005930-SPL-001 02 6

Where Used

Description Where Used

M364001244

UPPER JAW ASSY

1

M364001244

UPPER JAW ASSY

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

59347P230030

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

59344P170043

ASSEMBLY, HOSE

UPPER JAW ASSY

59343O230028

ASSEMBLY, HOSE

1 1

M364001244 M364001244

UPPER JAW ASSY

59324P230044

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

59343P170028

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

59324P230011

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

59343P170013

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

59324P170008

ASSEMBLY, HOSE

1

M364001244

UPPER JAW ASSY

M364000624

CLYINDER, SPIN WRENCH

M364000464

SPIN WRENCH ASSY

M364000730

BEARING, SPHERICAL

1

M364000464

M364000761

STRUT, COMPRESSION SPRING

1

SPIN WRENCH ASSY SPIN WRENCH ASSY

59324P290015C

1

59324P290023

HOSE ASSEMBLY HOSE ASSEMBLY

M364000464 M364000464

1

M364000464

SPIN WRENCH ASSY

59324P290024

HOSE ASSEMBLY

1

M364000464

SPIN WRENCH ASSY

59344P230022

HOSE ASSEMBLY

1

M364000464

SPIN WRENCH ASSY

59344P230025

HOSE ASSEMBLY

1

M364000464

SPIN WRENCH ASSY

59344P230027

HOSE ASSEMBLY

1

M364000464

SPIN WRENCH ASSY

59344P230034

HOSE ASSEMBLY

1

M364000464

SPIN WRENCH ASSY

M364000935

TUBING KIT

1

M364000464

SPIN WRENCH ASSY

M364000484

ROLLER, GROOVED

2

M364000465

M364000499

MOTOR, HYDRAULIC

2

M364000465

S.W. ROLLR CARRIER LT S.W. ROLLR CARRIER LT

P364000026

BEARING, BALL

6

M364000465

S.W. ROLLR CARRIER LT

P364000027

BEARING, BALL

4

M364000465

S.W. ROLLR CARRIER LT

P364000028

SEAL, V TYPE RING

4

M364000465

S.W. ROLLR CARRIER LT

M364000484

ROLLER, GROOVED

2

M364000465

M364000499

MOTOR, HYDRAULIC

2

M364000465

S.W. ROLLR CARRIER RT S.W. ROLLR CARRIER RT

P364000026

BEARING, BALL

6

M364000465

S.W. ROLLR CARRIER RT

P364000027

BEARING, BALL

4

M364000465

S.W. ROLLR CARRIER RT

P364000028

SEAL, V TYPE RING

4

M364000465

S.W. ROLLR CARRIER RT

93548-IS30N

VALVE, CHECK, 30 PSI

1

94522-ICN

VALVE, CART. PRESS RELIEF

1

M364000513 M364000513

SPIN WRENCH MANIFOLD SPIN WRENCH MANIFOLD

M854000243-HPPH

VALVE, SECTION, MODIFIED

1

VALVE, SECTION, MODIFIED

4

M851003996 M851003996

HD FUNCTNS MANIFOLD

M854000243-HXXH

1

M851003996

HD FUNCTNS MANIFOLD

M851003996

HD FUNCTNS MANIFOLD

M851003996

HD FUNCTNS MANIFOLD

M361000212 59347P17A033

MANIFOLD, CLAMP CYL ASSEMBLY, HOSE

59343P170042 59344P230029

1

1

SPIN WRENCH ASSY

HD FUNCTNS MANIFOLD

M854000243-HXXHN

VALVE, SECTION, MODIFIED

30181600-102

KIT, SEAL, HAWE

125556-25-4

LOGIC INSERT, PRESSURE REDUCING

93548-1S30N

VLV, CHECK 30 PSI

1

M851003996

HD FUNCTNS MANIFOLD

94518-13AN

COUNTERBAL VLV CATRIDGE

1

M851003996

HD FUNCTNS MANIFOLD

1

M851003996

HD FUNCTNS MANIFOLD

30107236-IDN

CARTRIDGE, SEQUENCE VLV

www.nov.com

6 1

Document number Revision Page

Part Number

Description

M361005930-SPL-001 02 7

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used

Description Where Used

94536-230N

VLV, CHECK FLOW 1>2 30 PSI

2

M851003996

HD FUNCTNS MANIFOLD

94537-230N

VLV, CHECK PILOT TO CLOSE

1

M851003996

96079-A

COVER PLATE, DO3

1

M851003996

HD FUNCTNS MANIFOLD HD FUNCTNS MANIFOLD

P85400025-25-210

COVER, LOGIC PRESSURE REGULATING

1

M851003996

HD FUNCTNS MANIFOLD

131733-2N

CARTRIDGE, FILTER

M851003996

1

ELECTRO-HYD PILOT MANIFOLD

M854000240-2

MANIFOLD, SANDWICH

P851002660

VALVE, REDUCE/RELIEVE PILOT

1

M851004192

ELECTRO-HYD PILOT MANIFOLD

94521-ZZN

VALVE, SHUTTLE

1

M851004192

ELECTRO-HYD PILOT MANIFOLD

30181781-3EN

VALVE, SHUTTLE

1

M854000200

WRENCH CTR MANIFOLD

M364000611

VALVE, 3-WAY

1

M854000200

WRENCH CTR MANIFOLD

30154047-A4N

SEQUENCE VLV, 3-WAY

1

M854000200

WRENCH CTR MANIFOLD

94521-IDN

VALVE, SHUTTLE

1

M854000200

WRENCH CTR MANIFOLD

94537-130N

CHECK VLV, PILOT TO CLOSE

2

M854000195

CLAMP CYL MANIFOLD

112802-10

CHECK VALVE, PILOT TO CLOSE

1

M854000197

CLAMP CYL MANIFOLD

117851-1KHN

LOGIC CARTRIDGE, N.C

1

M854000197

CLAMP CYL MANIFOLD

94537-130N

CHECK VLV, PILOT TO CLOSE

2

M854000199

CLAMP CYL MANIFOLD

117851-1KHN

LOGIC CARTRIDGE, N.C.

1

M854000199

CLAMP CYL MANIFOLD

P854000031-19XN

VALVE, COUNTERBALANCE

1

M854000199

CLAMP CYL MANIFOLD

94522-1SN

VALVE, CART, PRES RELIEF

1

M854000199

CLAMP CYL MANIFOLD

30184401-P30N

VALVE, CHECK

1

M854000199

CLAMP CYL MANIFOLD

94521-PMN

VALVE, SHUTTLE

1

M854000199

CLAMP CYL MANIFOLD

30154047-A4N

SEQUENCE VLV, 3-WAY

1

M854000199

CLAMP CYL MANIFOLD

P854000031-19XN

VALVE, COUNTERBALANCE

1

M854000280

CENTRALIZER MANIFOLD

30176410-1YN

VALVE, DIRECTIONAL

1

M854000280

CENTRALIZER MANIFOLD

93548-1S30N

VALVE, CHECK, 30 PSI

1

M854000280

CENTRALIZER MANIFOLD

94518-13HN

VALVE, C’BAL 1000-4000 PSI

1

30183688

C’BAL MANIFOLD ASSY

M364000422-6-60-75

VLV, CNTRL MODULAR HYD

1

M364000360

VALVE CONTROL ASSY

30183734

TORQUE GAGE

1

M364000360

VALVE CONTROL ASSY

30158739-3

VLV, PILOT RELIEF

M364000360

VALVE CONTROL ASSY

M364000422-3-60-75

VLV, CNTRL MODULAR HYD

M364000360

VALVE CONTROL ASSY

M364001332-2

VALVE BODY, HYDRAULIC ENABLE

1

M364000360

VALVE CONTROL ASSY

P854000079-10N

VALVE, HYDRAULIC ENABLE

1

M364000360

VALVE CONTROL ASSY

M364000929-100

TUBING KIT

1

M364000360

VALVE CONTROL ASSY

M36400982

ASSY, CYLINDER, 2.5X3.31

1

M364000704

PIPE CENTRALIZER ASSY

84882-V2

PROX. SWITCH, 8mm

1

M364000704

PIPE CENTRALIZER ASSY

30181290

BEARING, TURNTABLE, INT. GEAR

1

M364000032

COLUMN BASE ASSY

P364000002

REDUCER, PLANETARY GEAR

1

M364000032

COLUMN BASE ASSY

30172146

GASKET, UNIVERSAL INPUT

1

M364000032

COLUMN BASE ASSY

118461-3

LIP SEAL

M364000032

COLUMN BASE ASSY

128944-1

BRAKE UNIVERSAL INPUT

1

M364000032

COLUMN BASE ASSY

30172144

SAE-A MOTOR ADAPTER KIT W / UNIVERSAL INPUT

1

M364000032

COLUMN BASE ASSY

71033

GASKET, MOTOR

M364000032

COLUMN BASE ASSY

30156326-36E

MOTOR, HYDRAULIC

M364000032

COLUMN BASE ASSY

www.nov.com

1

HD FUNCTNS MANIFOLD

M851004192

1 1

1

1 1

Document number Revision Page

Part Number

Description

M361005930-SPL-001 02 8

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

Where Used

Description Where Used

1

M364000032

COLUMN BASE ASSY

M364000032

COLUMN BASE ASSY

M364000032

COLUMN BASE ASSY

M364000058

GEAR, PINION

P364000004

LIP SEAL

M364000061

GEAR, IDLER

P364000005

BEARING, ROLLER

2

M364000032

COLUMN BASE ASSY

P364000006

LIP SEAL

2

M364000032

COLUMN BASE ASSY

55909-4-4-S

VALVE, NIPPLE QD

1

M364000032

COLUMN BASE ASSY

55908-4-4-S

VALVE, COUPLER, QD

1

M364000032

COLUMN BASE ASSY

55909-6-6-S

VALVE, NIPPLE QD

1

M364000032

COLUMN BASE ASSY

55908-6-6-S

VALVE, COUPLER, QD

1

M364000032

COLUMN BASE ASSY

113036-2

COUPLING, QD

1

M364000032

COLUMN BASE ASSY

112987-2

NIPPLE, QD

1

M364000032

COLUMN BASE ASSY

59344P170011

1

M364000032

COLUMN BASE ASSY

59344P080014

HOSE ASSEMBLY HOSE ASSEMBLY

1

M364000032

COLUMN BASE ASSY

59344P080010

HOSE ASSEMBLY

1

M364000032

COLUMN BASE ASSY

59344P080012

HOSE ASSEMBLY

1

M364000032

COLUMN BASE ASSY

P364000046-1070

PROFIBUS LINEAR TRANSDUCER

1

M361005916

ELECTRICAL CNTRLS

P364000046-0420

PROFIBUS LINEAR TRANSDUCER

1

M361005916

ELECTRICAL CNTRLS

30173169-4-8

FLEXIBLE COUPLING

1

M361005916

ELECTRICAL CNTRLS

10053242-001

ELBOW, STREET

1

M361005916

ELECTRICAL CNTRLS

83444-03

ARMOURED GLAND

3

M361005916

ELECTRICAL CNTRLS

30156220

CABLE, PROFIBUS

100 FT

M361005916

ELECTRICAL CNTRLS

84882-V3

SENSOR, INDUCTIVE PROXIMITY

1

M361005916

ELECTRICAL CNTRLS

10654734-001

E-STOP ASSY, LH

1

M361005916

ELECTRICAL CNTRLS

10654734-002

E-STOP ASSY, RH

1

M361005916

ELECTRICAL CNTRLS

10044207-001

CABLE, SHIPBOARD MULTICORE

50 FT

M361005916

ELECTRICAL CNTRLS

56625-1.5-03

CABLE, SHIPBOARD MULTICORE

30 FT

M361005916

ELECTRICAL CNTRLS

10660910-001

SENSOR

1

M361005916

ELECTRICAL CNTRLS

P801000094-2

REFLECTOR

2

M361005916

ELECTRICAL CNTRLS

M614001556-2

BEACON/STROBE LIGHT

M361005916

ELECTRICAL CNTRLS

84882-V1-7

CORDSET, PROX SWITCH

1

M361005916

ELECTRICAL CNTRLS

P364000046-M1

M1 MAGNET

1

M361005916

ELECTRICAL CNTRLS

P764000046-M6

M6 MAGNET

1

M361005916

ELECTRICAL CNTRLS

P364000043

SENSI

2

M361005916

92056-40RM

VLV, LOGIC CARTRIDGE INSERT

1

M854000277

ELECTRICAL CNTRLS FLOW SWITCH ASSEMBLY

98390

COVER, LOGIC CARTRIDGE

1

M854000277

FLOW SWITCH ASSEMBLY

98391

PROXIMITY SENSOR

1

M854000277

FLOW SWITCH ASSEMBLY

98392

TARGET, SENSOR

1

M854000277

FLOW SWITCH ASSEMBLY

53601-21

RING, RETAINING – EXTERNAL

1

M854000277

FLOW SWITCH ASSEMBLY

98393

SPRING, COMPRESSION

1

M854000277

FLOW SWITCH ASSEMBLY

108465-20

PLUG, SHIPPING, SAE O-RING

1

M854000277

FLOW SWITCH ASSEMBLY

www.nov.com

2 2

1

Document number Revision Page

Part Number

Description

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

BULK PARTS 53201 53203 30172008 30176240 30176284 30177379 30182757 30183076 30183108 30183254 30183449 30183469 30183470 30183654 30183995 30184083 30184109 108465-20 108894-G20 108894-R17 113036-2 114320-6 114320-7 114320-8 116920-175 116920-215 116920-237 118836-28-46 118836-36-54 118844-28-16 30157107-20 30172475-12-08 30172475-18-12 30172475-28-16 30172475-28-20

GREASE FITTING FITTING, GREASE ADAPTER, ENCODER PIN SCREW, SK-HD, MODIFIED PIN, RETAINER PIN, ARM ASSY FLANGED BUSHING PIN, TIMING LINK KEEPER, PIN PIN, GUIDE ASSY PIN, CLEVIS PIN, KEEPER PIN, CLEVIS FLOW DIVIDER SCREW, SK-HD, MODIFIED PIN PLUG, SHIPPING, SAE O-RING ROD SEALS AND BRONZE GLAND ROD SEALS/BRONZE GLAND COUPLING, QD COTTER, HAIRPIN, 2 3/8L COTTER, HAIRPIN,2-3/8L COTTER, HAIRPIN RING, SPIRAL RETAINING RING, RETAINING RING, RETAINING BUSHING, THRUST-FIBREGLIDE WASHER, THRUST-FIBREGLIDE BUSHING, SLEAVE PLUG, STOPPING, EEX dc, IP66 BUSHING, GARLOCK BUSHING, GARLOCK BUSHING, GARLOCK BUSHING, GARLOCK

www.nov.com

26 1 1 2 4 1 3 11 1 4 1 1 3 1 2 2 1 1 4 2 1 1 1 2 2 4 4 7 8 2 1 2 1 6 5

M361005930-SPL-001 02 9

Where Used

Description Where Used

Document number Revision Page

Part Number

30172475-28-8 30172475-36-16 30172475-36-20 30172475-36-24 30172475-40-16 30173169-4-8 30176178-1 30176178-2 30176796-218 51204-8-S 51222-10-8 51300-011-B 51300-014-B 51300-020-B 51300-037-B 51300-127-B 51300-210-B 51300-225-B 51300-231-B 51300-339-B 51402-14-S 51402-6-S 51402-8-S 51403-12-S 51403-24 51404-32 51433-10-S 53001-02-C 53008-4-4-S 53008-6-8-S 53601-21 53602-112 53602-75 56405-12-C 56405-16-C 56406-13-C 56500-8-8-S 56501-2-4-S 56501-4-4-S 56501-6-6-S 56502-2-4-S 56502-2-4-S 56504-6-6-S

Description

BUSHING, GARLOCK BUSHING, GARLOCK TYPE DP4 BUSHING, GARLOCK BUSHING, GARLOCK BUSHING, GARLOCK FLEXIBLE COUPLING PIN, PIVOT 1.75 DIA PIN, PIVOT 2.25 DIA

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

1 2 2 4 1 1 2 2 50

PLUG, SEALING, EXPANSION TYPE

PIN, DOWEL PIN, SPIRAL O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING PIN, COTTER PIN, COTTER PIN, COTTER COTTER PIN PIN, COTTER PIN, COTTER PIN, COTTER PLUG, PIPE HEX HEAD ADAPTER, 37 MALE / BSPP MALE ADAPTER, 37O M / BSPP M RING, RETAINING – EXTERNAL RING, RETAINING, 1.125 SHAFT RING, RETAINING, .75 SHAFT PIN, CLEVIS PIN, CLEVIS PIN, CLEVIS TEE, INT PIPE/37/37 CONNECTOR, EXT PIPE 37 CONNECTOR, EXT PIPE / EXT 37 CONNECTOR, EXT PIPE / EXT 37 CONNECTOR, EXT PIPE/EXT 37 CONNECTOR, EXT PIPE/EXT 37 TEE, BULKHEAD UNION

www.nov.com

1 1 2 1 1 1 1 5 1 1 4 1 1 1 2 1 4 1 1 2 1 1 1 1 1 1 2 1 2 1 1 1 1

M361005930-SPL-001 02 10

Where Used

Description Where Used

Document number Revision Page

Part Number

56506-04-04-S 56512-2-4-S 56513-20-S 56513-8-S 56514-20-S 56515-6-4-S 56516-8-4-S 56517-20-16-S 56517-6-4-S 56517-8-4-S 56517-8-6-S 56518-6-6-S 56519-10-12-S 56519-10-6-C 56519-12-16-S 56519-12-8-S 56519-12-8-S 56519-16-12-S 56519-16-16-S 56519-20-16-S 56519-20-20-S 56519-4-4-S 56519-4-6-S 56519-6-4-S 56519-6-6-S 56519-8-6-S 56519-8-8-S 56522-12-12-S 56522-16-16-S 56522-6-6-S 56525-12-12-S 56525-6-6-S 56525-8-8-S 56529-10-6-S 56529-10-8-S 56529-12-12-S 56529-12-6-S 56529-16-16-S 56529-4-4-S 56529-4-4-S 56529-4-6-S 56529-6-4-S 56529-6-6-S

Description

ELBOW, 90O EXT PIPE 37O ELBOW, 90, EXT PIPE/ 37 X-LONG TEE-BULKHEAD UNION 37O TEE-BULKHEAD UNION 37O TEE, 37/STRAIGHT O-RING/37 REDUCER, INT 37/37 REDUCER, TUBE END REDUCER, INT 37O/37O REDUCER INT 37/37 REDUCER, INT 37/37 REDUCER, INT 37/37 ELBOW, 90O 37 SWIVEL ELBOW, 90, 37/O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90DEG 37 O-RING BOSS ELBOW, 90 BULKHEAD 37/37 ELBOW, 90 DEG BULKHEAD ELBOW, 90 BULKHEAD 37/37 TEE,SWIVEL, INT 37/37/37 TEE, SWIVEL INT. 37/37/37 TEE, SWIVEL INT. 37/37/37 CONNECTOR, O-RING BOSS/37 CONNECTOR, O-RING/37 CONNECTOR, O-RING/37 CONNECTOR, O-RING BOSS CONNECTOR, O-RING BOSS /37 CONNECTOR, O-RING BOSS CONNECTOR, O-RING BOSS /37 CONNECTOR, O-RING BOSS/37 CONNECTOR, O-RING BOSS/37 CONNECTOR, O-RING BOSS/37

www.nov.com

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

1 6 1 1 1 1 1 5 1 2 1 1 3 1 5 2 1 1 1 1 1 3 1 2 16 3 15 1 1 1 2 2 1 11 2 4 2 1 2 6 4 8 13

M361005930-SPL-001 02 11

Where Used

Description Where Used

Document number Revision Page

Part Number

56529-8-4-S 56529-8-6-S 56529-8-8-S 56530-4-4-S 56530-6-6-S 56538-12-12-S 56538-4-4-S 56538-6-6-S 56538-8-8-S 56546-12-12-S 56546-16-16-S 56546-6-6-S 56547-06-S 56547-08-S 56547-12-S 56547-16-S 56547-20-S 56547-4-S 56547-6-S 56547-8-S 56551-4-4-S 56552-4-S 56553-2-S 56555-4-S 56555-6-S 56556-8-6-S 56557-12-12-S 56557-4-4-S 56557-6-6-S 56557-8-8-S 56561-6-6-S 56562-6-8-S 56571-4-12 56609-25 78317-20 81072-6-6-S 87196-10-S 87196-12-S 87196-16-S 87196-24-S 87196-2-S 87196-4-6-S

Description

CONNECTOR, O-RING BOSS CONNECTOR, O-RING/37 CONNECTOR, O-RING BOSS TEE, 37, 37, O-RING TEE, 37/ 37/ O-RING UNION, BULKHEAD, -12 37 DEG UNION BULKHEAD UNION BULKHEAD UNION, BULKHEAD, -8 37 DEG ELBOW, 90, 37 O-RING, LONG ELBOW 90, 37 O-RING ELBOW, 90, 37 O-RING, LONG LOCKNUT, BULKHEAD, -4 LOCKNUT, BULKHEAD LOCKNUT, BULKHEAD LOCKNUT, BULKHEAD LOCKNUT, BULKHEAD LOCKNUT BULKHEAD LOCKNUT, BULKHEAD LOCKNUT, BULKHEAD CONNECTOR, O-RING BOSS ADAPTER, BULKHEAD, INT PIPE PLUG, PIPE HEX HEAD TEE, O-RING TEE, O-RING REDUCER, O-RING BOSS ELBOW, 45, 37/O-RING ELBOW, 45 DEG ELBOW, 45, 37 O-RING ELBOW, 45, 37/O-RING CONNECTOR, LONG O-RING BOSS CONNECTOR, O-RING BOSS /37 ADAPTER, 37 MALE / BSPP MALE LUG, CONNECTOR LOCKNUT, 20MM TEE, BULKHEAD UNION PLUG, STRAIGHT THD PLUG, STRAIGHT THD PLUG, STRAIGHT THD PLUG, STRAIGHT THD PLUG, STRAIGHT THD PLUG, STRAIGHT THD, HEX W/ ORING

www.nov.com

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

3 8 7 1 1 1 8 2 1 1 1 1 1 1 2 1 1 8 2 1 1 4 1 1 1 1 2 1 1 1 1 1 1 4 1 1 5 3 1 1 27 1

M361005930-SPL-001 02 12

Where Used

Description Where Used

Document number Revision Page

Part Number

87196-4-S 87196-6-S 87196-8-S 93018-15 93019-13 93024-4JIC 93024-4SAE 93024-6JIC 93024-6SAE 93204-6JIC 93204-6SAE 93204-8JIC 93667-M11 93667-M22 93667-X11 94041-10 94872-72 98399-200PS M364000157 M364000268 M364000287 M364000291 M364000308 M364000348 M364000393 M364000394 M364000451 M364000473 M364000474 M364000475 M364000476 M364000478 M364000489 M364000501 M364000581 M364000617 M364000665 M364000728-28 M364000740 M364000821 M364000931 M364000950-01 M364000950-02

Description

PLUG, STRAIGHT THD PLUG, STRAIGHT THD PLUG, STRAIGHT THD PLUG, ORIFICE - #10-32 X .059 PLUG, ORFICE FITTING, TEST, ¼ NPT FITTING, TEST, SAE-4 FITTING, TEST, JIC-6 FITTING, TEST, SAE-6 FITTING TEST, 3/8 NPT FITTING, TEST SAE -6 FITTING, TEST,1/2 NPT PLUG, CAVITY PLUG, CAVITY PLUG, CAVITY PLUG, ORIFICE LUG, CONNECTOR, COPPER RING, RETAINING BUSHING, ARM PIN, RETAINING, 1.75 DIA PIN, WRENCH INTERFACE PIN, COLUMN PIN, STORAGE PIN, GUARD PIN, PIVOT PIN, PIVOT CASTLE NUT - METRIC BUSHING, FLANGED BUSHING, FLANGED PIN, ARM HINGE PIN, ARM HINGE PIN, GUIDE BUSHING, GUIDE PIN PIN, CLEVIS BUSHING, PASSIVE GUIDE SCREW, MODIFIED PIN, LOCKING ARM RING, RETAINING PIN, LINK, SPIN WRENCH TELESCOPIC CYLINDER PIN, PIVOT, 1.75 PIN, PIVOT, 1.13X2.1 PIN, PIVOT, 1.13X2.57

www.nov.com

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

9 10 11 1 1 1 17 2 7 1 2 2 1 1 2 1 1 1 1 1 1 4 1 1 2 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 1

M361005930-SPL-001 02 13

Where Used

Description Where Used

Document number Revision Page

Part Number

M364001247 M854000284 M854000286 P364000002 P364000007 P364000009-12-12 P364000009-16-16 P364000009-20-20 P364000009-6-6 P364000009-8-6 P364000009-8-8 P364000031-6-6 P764000019-06-06 P764000020-06-06 P764000105-01

Description

BUSHING, FLANGED CAP. CONNECTOR, 4 PIN 15-24 MALE CONNECTOR, 4 PIN 15-24 FEMALE REDUCER, PLANETARY GEAR RING, INTERNAL, SPIRAL ELBOW, 90, O-RING X 37 ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90, O-RING X 37 ELBOW, 90, 37 O-RING ELBOW, 90, 37 O-RING ELBOW, 90 DEG O-RING X 37 DEG CONNECTOR, FEMALE, 37 DEG/BSPP

BULKHEAD, BSPP THUMB SCREW

P764000125-M12-020-B SCREW, SHOULDER-SOCKET HEAD P764000125-M6-010-B

SCREW, SHOULDER-SOCKET HEAD

www.nov.com

-1

-2

-3

Commission Spare

Operational Spare

Insurance Spare

4 3 1 1 1 2 2 2 1 1 3 2 1 1 1 1 1

M361005930-SPL-001 02 14

Where Used

Description Where Used

TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

3

Technical Documents & Drawings

1

3.1

General/Mechanical Drawings

1

3.2

System/Process Diagrams

1

3.3

Electrical/Instrument

1

3.4

Performance Data Remarks: Section Not Applicable

www.nov.com

Document Number:

10862028-MAN TOC 3

Revision:

01

Page:

1

TABLE OF CONTENTS

Vol.

1

Chapter/ Section

Title

3.1

General/Mechanical Drawings

www.nov.com

Document Number:

10862028-MAN TOC 3.1

Revision:

01

Page:

1

Document Number

Rev.

Customer Configuration

10861989-GEN

02

General Arrangement, Auto, ST-120

D364000122-GAD-001

09

Manifold Assembly, Hydraulic Enable, ST-120 (UL)

10654007-ASM

01

Assembly, Manifold Electro - Hyd, Pilot

10655517-ASM

03

Roller Carrier Assembly, Left, Spin Wrench

10664344-ASM

03

Roller Carrier Assembly, Right, Spin Wrench

10664345-ASM

03

Assembly, Spin Wrench

10676154-ASM

05

Assembly, ST-120 Carriage Junction Box (UL)

10786264-ASM

01

Kit, Console Caps & Plugs, ST-120

10794593-KIT

02

Assembly, Spin Wrench

10887378-ASM

05

Hose Kit, ST-160

11384087-KIT

04

Assembly, ST-120, Manifold, Counterbalance

30183688

B

Service Loop, ST-120

30184501

B

Derrick Termination Assembly, ST-120 Remote I/O J-Box

M361003091-ASM-001

04

Arm Assembly, ST-120 (UL)

M361005908-ASM-001

05

Assembly, Head, ST-120 (UL)

M361005909-ASM-001

05

ST-120 Assembly (UL)

M361005910-ASM-001

04

Electr Components, ST-120 (UL)

M361005916-ASM-001

05

Kit, Floor Socket, ST-120

M364000002-ASM-001

03

Assembly, Column Base

M364000032-ASM-001

09

Assembly, Front Lower Arm

M364000299-ASM-001

02

Assembly, Valve Control, Man. ST-120

M364000360-ASM-001

08

Assembly, Socket Base

M364000364-ASM-001

02

Die, Kit ST-120

M364000403-KIT-001

01

Vlv, Cont, Modular, Hyd, Mod, Handle, ST-120

M364000422-ASM-001

02

Skid, Shipping, Assembly Kit Gen-2, ST-120

M364000496-ASM-001

06

Assembly, Hyd. Manifold, SW-10

M364000513-ASM-001

03

Cylinder, Spin Wrench, Assembly, ST-120

M364000624-ASM-001

02

Kit, Slew Stop ST-120

M364000669-KIT-001

04

TABLE OF CONTENTS

Vol.

Chapter/ Section

Document Number:

10862028-MAN TOC 3.1

Revision:

01

Page:

2

Title

Document Number

Rev.

Assembly, Pipe Centralizer

M364000704-ASM-001

13

Kit, Bracket, Service Loop

M364000758-KIT-001

06

Strut, Compression Spring

M364000761-ASM-001

01

Cylinder Assembly Extend, ST-120

M364000943-ASM-001

02

Assembly, Cylinder, 2.0 ” Bore, 3.313 “ Stroke

M364000982-ASM-001

05

Kit, Cinch, Strap

M364001017-KIT-001

04

Hose Kit, Centralizer, ST120

M364001119-KIT-001

02

Enclosure, Remote Control

M364001150-ASM-001

04

Assembly, Jaw, Lower, ST-120

M364001243-ASM-001

02

Assembly, Jaw, Upper, ST-120

M364001244-ASM-001

03

Assembly, Wrench, ST-120

M364001245-ASM-001

09

Hose Kit, ST-120

M364001340-KIT-001

02

Assembly, ST-120 Carriage Junction Box

M801001373-ASM-001

06

Assembly, Service Loop, ST-120 Assembly, Service Loops

M801001885-DAD-001

04

Head Function Manifold, ST-120 (UL)

M851003996-ASM-001

02

Arm Funct Manifold, ST-120 (UL)

M851003997-ASM-001

02

Assembly, Manifold Electro - Hyd, Pilot

M851004192-ASM-001

03

Manifold Assembly ST-120 Clamp – CCC

M854000195-ASM-001

02

Manifold Assembly ST-120 Clamp, HUZ

M854000197-ASM-001

05

Manifold Assembly, ST-120

M854000199-ASM-001

04

Manifold, Assembly, Wrench, Centering, ST-120

M854000200-ASM-001

06

Manifold Assembly, Hydraulic Enable, ST-120

M854000256-ASM-001

03

Assembly, Flow Switch

M854000277-ASM-001

04

Assembly, Manifold, Centralizer, ST-120

M854000280-ASM-001

03

www.natoil.com

This document contains proprietary information, and such information may not be disclosed to others for any purpose, nor used for manufacturing purposes without written permission from National Oilwell Varco, LLC.

REVISIONS

REV 01 02

DESCRIPTION Initial Release Added Serial #

PREPARED / DATE A.Hastings C.HABEL

CHECKED/ DATE APVD / DATE 14-Dec-13 A.Jones 14-Dec-13 J.Walker 03-Jun-15 S.KARAJAGI 03-Jun-15 S.KARAJAGI

STANDARD ORDER INFORMATION

QUALITY REQUIREMENTS

SHIPMENT DATE:

October 10, 2014

CERTIFICATION:

ABS/MODU

PRE-SHIP:

NONE

DATA BOOK:

STANDARD

RIG TYPE:

JACK UP

INSTALLATION LOCATION:

UNITED STATES

OPERATION LOCATION:

N/A

CONTACT NOTES

RELATED CONFIGS:

N/A

PROJECT MANAGER:

SALES ORDER # (ORA / RIG):

194415 / 190787

SYSTEM INTEGRATION:

QUOTE # & REV:

187184 REV 3

CONTRACT ADMINISTRATOR:

SPRING BAILEY

SPARES QUOTE #:

TBD

RESPONSIBLE ENGINEER:

JOHN WALKER

UNIT #:

N/A

ELECTRICAL ENGINEER:

SERIAL #:

ST120J20X123

SOFTWARE ENGINEER:

ITEM ID #:

TBD

APPLICATION ENGINEER:

DELIVERED PRODUCT ID #:

M000033056

14-Dec-13 03-Jun-15

APPLICATION NOTES: 1) Tong Die Kit QTY 6 - An extra set of tong dies is included with the ST-120

Sheet

CUSTOMER CONFIGURATION FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 3:14 PM 6/3/2015

1 of 3

REVISION

DOCUMENT NUMBER

10861989-GEN

02

Customer: Rig: Equipment:

CENTRAL PANUCO UXPANAPA ST-120 AUTO (USA)

PART NUMBER

QTY S/O

-001

DESCRIPTION

(Legacy Number)

-002

IRON ROUGHNECK SYSTEM 1 10861989-001 10659153-001 10071528-001 10071537-001 10474873-002 10071570-001 10655528-001

1 7 1 1 1 2

ST-120 AUTO SYSTEM IRON ROUGHNECK UNIT, AUTO UNIT (USA) KIT, TONG DIE SHIPPING SKID, ST-120 PIPE CENTRALIZER ASSEMBLY SERVICE LOOP BRACKET ASSEMBLY, ST-120 ST-120 PLACARD

M361005910 M364000403 M364000496 M364000704-100 M364000758 D811000247-PRO-001

RIG FLOOR 10071509-001 10071522-001 10071561-001

1 1 1

KIT, FLOOR SOCKET, ST-120 SOCKET BASE ASSEMBLY SLEW STOP KIT

M364000002 M364000364-501 M364000669

SERVICE LOOP & CONTROL SYSTEM 1 10031208-001 1 10475775-001 REF SUPPLIED BY NOV

KIT, SERVICE LOOP, ST-120 SERVICE LOOP, ELECTRICAL MTC CONTROL CABINET ASSEMBLY

30184501 M801001885-025-25-20-1

DERRICK TERMINATION 10472618-007 10088854-001

ASSY, DERRICK J-BOX, USA, W/ BACKUP TRANSMITTER WIRELESS REMOTE DOCKING STATION

M361003091-006 M364001150

1 1

MANUALS, CERTIFICATION, AND DOCUMENTATION 4 10862028-001 USER MANUAL, ST-120 (E-COPY INCLUDED) 1 10861989-997 ABS/MODUCERTIFICATION 2 10861989-998 DATA BOOK, STANDARD (E-COPY INCLUDED) 1 10860820-001 ST-120 OPERATION VIDEO REF D811000557-MAN-001 SERVICE MANUAL, ST-120 REF D364000163-SPC-001 FACTORY ACCEPTANCE TEST REF M000033576 SUPPLIER MASTER DOCUMENT LIST Sheet

CUSTOMER CONFIGURATION FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 3:14 PM 6/3/2015

2 of 3

REVISION

DOCUMENT NUMBER

10861989-GEN

02

D392004474-MMD-001

Customer: Rig: Equipment:

CENTRAL PANUCO UXPANAPA ST-120 AUTO (USA)

PART NUMBER

QTY S/O

REFERENCE DRAWINGS D364000122-GAD-001 D364000049-SPC-001 D851002163-SCH-001 D364000170-PRO-001 D364000171-PRO-001 M361005930-SPL-001 10896364-DIA 10896365-DIA 10896366-IDX 10896367-IDX 10896368-IDX 10896369-DIA 10896370-SPL

-001

DESCRIPTION

REF REF REF REF REF REF REF REF REF REF REF REF REF

GENERAL ARRANGEMENT, ST-120 FUNCTIONAL DESIGN SPECIFICATION, ST-120 HYDRAULIC SCHEMATIC, ST-120 FIELD INSTALLATION PROCEDURE COMMISSIONING PROCEDURE KIT, MECHANICAL SPARES, ST-120 BLOCK DIAGRAM, ST-120 INTERCONNECT DIAGRAM, ST-120 CABLE SCHEDULE, ST-120 I/O MAP, ST-120 HAZARDOUS AREA INDEX, ST-120 NETWORK TOPOLOGY, ST-120 SPARES LIST, ELECTRICAL CONTROLS, ST-120

Sheet

CUSTOMER CONFIGURATION FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 3:14 PM 6/3/2015

(Legacy Number)

-002

3 of 3

REVISION

DOCUMENT NUMBER

10861989-GEN

02

Customer: Rig: Equipment:

CENTRAL PANUCO UXPANAPA ST-120 AUTO (USA)





PART NO.: 10786264−001 ST−120 CARRIAGE JUNCTION BOX ST−NSJB100

SUITABLE FOR CLASS I DIV 2, GROUPS C,D HAZARDOUS LOCATIONS WHEN INSTALLED IN ACCORDANCE WITH DRAWING: 10629441−man

WARNING: DO NOT OPEN WHEN ENGERGIZED





PART NO.: 10786264−001 ST−120 CARRIAGE JUNCTION BOX ST−NSJB100

SUITABLE FOR CLASS I DIV 2, GROUPS C,D HAZARDOUS LOCATIONS WHEN INSTALLED IN ACCORDANCE WITH DRAWING:10629441−man

WARNING: DO NOT OPEN WHEN ENGERGIZED





TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

3.2

System/Process Diagrams

Schematic, Hydraulic ST-120

www.nov.com

Document Number:

10862028-MAN TOC 3.2

Revision:

01

Page:

1

Document Number

Rev.

10902576-SCH

02

TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

3.3

Electrical/Instrument

www.nov.com

Document Number:

10862028-MAN TOC 3.3

Revision:

01

Page:

1

Document Number

Rev.

Block Diagram, ST-120, Central Panuco Uxpanapa

10896364-DIA

02

Interconnect Diagram, ST-120, Central Panuco Uxpanapa

10896365-DIA

03

Cable Schedule, ST-120 Central Panuco Uxpanapa

10896366-IDX

02

I/O Map, ST-120 Central Panuco Uxpanapa

10896367-IDX

01

Hazardous Equipment, ST-120 Central Panuco Uxpanapa

10896368-IDX

01

Network Diagram, ST-120, Central Panuco Uxpanapa

10896369-DIA

03

10861989-GEN

ST-120

NEXT ASSY

USED ON

APPLICATION

This document contains proprietary and confidential information which belongs to 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 and in any event upon completion of the use for which it was loaned. This document and the information contained TITLE and represented herein is the copyrighted property of NOV. © National Oilwell Varco

DRAWN CHECKED APPVD DATE

R. MOENCH

R. MOENCH

B. MALEK

T. GONZALEZ

SIZE

R. MOENCH

R. MOENCH

B

4/7/2015

6/9/2014

SCALE

CABLE SCHEDULE, ST-120 CENTRAL PANUCO UXPANAPA DWG NO

REV

10896366-IDX 02 NONE

WT LBS

SHEET

1

OF

2

D74DCF0049-TPL-001 (REV B)

CABLE SCHEDULE, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

CABLE ID

CABLE

NOV

GLAND

GLAND

CABLE

TAG NO.

CONSTRUCTION

PART NO.

SIZE

P/N

TYPE

DATE

FROM TAG NO.

TO LOCATION

TAG NO.

BLOCK DIAG. LOCATION

INTERCONNECT

DWG. NO.

SHT.

DWG. NO.

SHT.

4/7/2015 10:58:17 AM

REMARKS

CABLE SUPPLIED BY

ST-N01

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-01-H

SPIN WRENCH IN/OUT PROPORTIONAL SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

2

NOV

ST-N02

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-02-H

SPIN WRENCH CLAMP/UNCLAMP SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

2

NOV

ST-N03

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-03-H

TORQUE WRENCH CLAMP/UNCLAMP SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

2

NOV

ST-N04

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-04-H

MODE SPIN WRENCH BACKUP/TORQUE WRENCH CENTER SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

2

NOV

ST-N05

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-05-H

TORQUE WRENCH MAKE/BREAK SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

2

NOV

ST-N06

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-06-H

SPIN WRENCH DOWN/UP SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

2

NOV

ST-N07

3C x 1.5mm

56625-1.5-03

-

-

N.I.S.

PV-01

TORQUE CONTROL INCREASE/DECREASE PROPORTIONAL SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

2

NOV

ST-N08

4C x 18 AWG

10044207-001

-

-

N.I.S.

SW-02

ST-120 HEAD LEFTSIDE TOOL SHUTDOWN

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

4

NOV

ST-N09

4C x 18 AWG

10044207-001

-

-

N.I.S.

SW-03

ST-120 HEAD RIGHTSIDE TOOL SHUTDOWN

ST-NJB100

ST-120 HEAD LEFTSIDE TOOL SHUTDOWN

10896364-DIA

2

10896365-DIA

4

NOV

ST-N10

4C x 2.5mm²

56625-2.5-04

-

-

N.I.S.

HOR-01

BEACON/STROBE LIGHT

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

7

NOV

ST-N20

3C x 1.5mm²

56625-1.5-03

-

-

N.I.S.

SV-01-C

HYDRAULIC ENABLE ON/OFF SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

3

NOV

ST-N21

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-02-C

CARRIAGE DOWN/UP PROPORTIONAL SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

3

NOV

ST-N22

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-03-C

DEPLOY EXTEND/RETRACT PROPORTIONAL SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

3

NOV

ST-N23

5C x 18 AWG

PIGTAIL

-

-

N.I.S.

SV-05-C

CARRIAGE SLEW CW/CCW PROPORTIONAL SOLENOID VALVE

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

3

NOV

ST-D01

PROFIBUS + 3C x 0.75mm²

30156220

-

-

DATA

LT-01

SPIN WRENCH UP/DOWN LINEAR TRANSDUCER

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

2

10896365-DIA

6&8

NOV

ST-D02

PROFIBUS + 3C x 0.75mm²

30156220

-

-

DATA

LT-02

DEPLOY EXTEND/RETRACT LINEAR TRANSDUCER

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

8

NOV

ST-D03

PROFIBUS + 3C x 0.75mm²

30156220

-

-

DATA

LT-03

CARRIAGE UP/DOWN LINEAR TRANSDUCER

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

8

NOV

ST-D04

PROFIBUS + 3C x 0.75mm²

30156220

-

-

DATA

ENC-04

SLEW POSITION PROFIBUS DP ABSOLUTE ENCODER

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

8

NOV

ST-S01

2C x 0.34mm²

84882-V1-7

-

-

I.S.

ZS-01

TOOL JOINT DETECT PROXIMITY SWITCH

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

5

NOV

ST-S02

2C x 0.34mm²

84882-V1-7

-

-

I.S.

ZS-02

MAKE END OF STROKE BREAKOUT PROXIMITY SWITCH

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

5

NOV

ST-S03

2C x 0.34mm²

84882-V1-7

-

-

I.S.

ZS-03

BREAK END OF STROKE MAKEUP PROXIMITY SWITCH

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

5

NOV

ST-S04

2C x 0.34mm²

84882-V1-7

-

-

I.S.

ST-S04

IN-LINE CONNECTOR

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

5

NOV

ST-S05

2C x 0.34mm²

84882-V1-7

-

-

I.S.

ST-S05

OBJECT DETECT LEFT SIDE BOTTOM RETRO-REFLECTIVE SENSOR

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

5

NOV

ST-S06

2C x 0.34mm²

84882-V1-7

-

-

I.S.

ST-S06

OBJECT DETECT RIGHT SIDE BOTTOM RETRO-REFLECTIVE SENSOR

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

5

NOV

ST-S07

2C x 0.34mm²

84882-V1-7

-

-

I.S.

ST-S07

IN-LINE CONNECTOR

ST-NJB100

ST-120 CARRIAGE J-BOX

10896364-DIA

3

10896365-DIA

5

NOV

ST-S04A

2C x 23 AWG

PIGTAIL

-

-

I.S.

ZS-04

HYDRAULIC FLOW DETECT PROXIMITY SWITCH

ST-S04A

IN-LINE CONNECTOR

10896364-DIA

3

10896365-DIA

5

NOV

ST-S07A

2C x 20 AWG

PIGTAIL

-

-

I.S.

ZS-07

SENSI-SWITCH

ST-S07A

IN-LINE CONNECTOR

10896364-DIA

3

10896365-DIA

5

NOV

ST-120 DERRICK REMOTE I/O J-BOX

10896364-DIA

4

10896365-DIA

13

NOV

PLUG PANEL

10896364-DIA

2&4

10896365-DIA

2, 9

NOV

ST-120 DERRICK REMOTE I/O J-BOX

10896364-DIA

4

10896365-DIA

9, 19

CUSTOMER

ST-N100

COAXIAL

ANTENNA

-

-

N.I.S.

ANTENNA

SAFE AREA LOCATION

ST-N101

37C x 14 AWG

P801000054

-

-

N.I.S.

ST-NJB100

ST-120 CARRIAGE J-BOX

ST-N101A

37C x 14 AWG

-

-

-

N.I.S.

-

ST-N102

24 TSP x 16 AWG

7828635

-

-

N.I.S.

ST-NJB100

ST-N102A

24 TSP x 16 AWG

-

-

-

N.I.S.

-

ST-PNJB101 -

PLUG PANEL

ST-PNJB101

ST-120 CARRIAGE J-BOX

-

PLUG PANEL

ST-D101

PROFIBUS + 3C x 0.75mm²

30156220

-

-

DATA

ST-NJB100

ST-D101A

PROFIBUS + 3C x 0.75mm²

-

-

-

DATA

-

PLUG PANEL

ST-PE01

1C x 70mm²

30156341-70

FIELD INSTALL

-

POWER

-

ST-120 GROUND

ST-N1005

7C x 1.5mm²

-

FIELD INSTALL

-

N.I.S.

ST-PNJB101

ST-120 DERRICK REMOTE I/O J-BOX

ST-P1001

3C x 2.5mm²

-

FIELD INSTALL

-

POWER

ST-PNJB101

ST-P1002

3C x 2.5mm²

-

FIELD INSTALL

-

POWER

ST-PNJB101

ST-P1003

3C x 2.5mm²

-

FIELD INSTALL

-

POWER

ST-F1001

62.5-125um x 4C

-

FIELD INSTALL

-

ST-F1002

62.5-125um x 4C

-

FIELD INSTALL

-

ST-PNJB101

ST-120 CARRIAGE J-BOX

-

PLUG PANEL

10896364-DIA

2&4

10896365-DIA

4, 10

NOV

ST-120 DERRICK REMOTE I/O J-BOX

10896364-DIA

4

10896365-DIA

10, 14

CUSTOMER

PLUG PANEL

10896364-DIA

2&4

10896365-DIA

8, 9

NOV

ST-120 DERRICK REMOTE I/O J-BOX

10896364-DIA

4

10896365-DIA

9, 11

CUSTOMER

DERRICK GROUND

10896364-DIA

2&4

10896365-DIA

3 & 24

NOV

DFT-NJB100

DRILL FLOOR REMOTE I/O CABINET

10896364-DIA

4

10896365-DIA

14 & 25

CUSTOMER

ST-120 DERRICK REMOTE I/O J-BOX

MTC #1

MULTI TOOL CONTROL CABINET #1

10896364-DIA

4

10896365-DIA

12 & 25

CUSTOMER

ST-120 DERRICK REMOTE I/O J-BOX

MTC #1

MULTI TOOL CONTROL CABINET #1

10896364-DIA

4

10896365-DIA

12 & 25

CUSTOMER

ST-PNJB101

ST-120 DERRICK REMOTE I/O J-BOX

MTC #1

MULTI TOOL CONTROL CABINET #1

10896364-DIA

4

10896365-DIA

13 & 25

CUSTOMER

FIBER

ST-PNJB101

ST-120 DERRICK REMOTE I/O J-BOX

MTC #1

MULTI TOOL CONTROL CABINET #1

10896364-DIA

4

10896365-DIA

11 & 25

CUSTOMER

FIBER

ST-PNJB101

ST-120 DERRICK REMOTE I/O J-BOX

MTC #1

MULTI TOOL CONTROL CABINET #1

10896364-DIA

4

10896365-DIA

11 & 25

CUSTOMER

ST-PNJB101 -

SHEET

2

OF

2

DWG NO

10896366-IDX

REV

02

10861989-GEN

ST-120

NEXT ASSY

USED ON

APPLICATION

This document contains proprietary and confidential information which belongs to 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 and in any event 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

CURRENT DRAWN CHECKED APPVD DATE

TITLE

I/O MAP, ST-120 CENTRAL PANUCO UXPANAPA

INITIAL R. MOENCH T. GONZALEZ

SIZE

R. MOENCH

B

3/17/2014

SCALE

DWG NO

REV

10896367-IDX 01 NONE

WT LBS

SHEET

1

OF

5

D74DCF0051-TPL-001 (REV B)

I/O MAP, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

I/O ADDRESS

SIGNAL TYPE

NETWORK ID

NODE No.

DATE

I/O DESCRIPTION

I/O LOCATION

1 FUNCTION

0 FUNCTION

POS 3 (1) POS 3 (5) POS 3 (4) POS 3 (8) POS 4 (1) POS 4 (5) POS 4 (4) POS 4 (8) POS 8 (1) POS 8 (5) POS 8 (4) POS 8 (8) POS 11 (1) POS 11 (5) POS 11 (4) POS 11 (8) POS 12 (1) POS 12 (5) POS 12 (4) POS 12 (8) POS 13 (1) POS 13 (5) POS 13 (4) POS 13 (8)

POWER SUPPLY 1 OK

POWER SUPPLY 1 FAULT

-

-

-

POWER SUPPLY 2 OK

POWER SUPPLY 2 FAULT

-

-

-

POWER SUPPLY 3 OK

POWER SUPPLY 3 FAULT

-

-

-

-

-

-

-

-

OLM OK

OLM FAULT

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

E-STOP NOT ACTIVATED

E-STOP ACTIVATED

-

-

-

E-STOP NOT ACTIVATED

E-STOP ACTIVATED

-

-

-

E-STOP NOT ACTIVATED

E-STOP ACTIVATED

-

-

-

-

-

-

-

-

10DI0.0

24VDC

DP1

10

POWER SUPPLY 1 STATUS

10DI0.1

24VDC

DP1

10

POWER SUPPLY 2 STATUS

10DI0.2

24VDC

DP1

10

POWER SUPPLY 3 STATUS

10DI0.3

24VDC

DP1

10

SPARE

10DI0.4

24VDC

DP1

10

OLM STATUS

10DI0.5

24VDC

DP1

10

SPARE

10DI0.6

24VDC

DP1

10

SPARE

10DI0.7

24VDC

DP1

10

SPARE

10DI1.0

24VDC

DP1

10

MASTER E-STOP FROM DFSD (CAT 0)

10DI1.1

24VDC

DP1

10

TOOL E-STOP PUSHBUTTON

10DI1.2

24VDC

DP1

10

WIRELESS OPERATOR E-STOP

10DI1.3

24VDC

DP1

10

SPARE

10DI1.4

24VDC

DP1

10

TOOL JOINT PROXIMITY SWITCH

10DI1.5

24VDC

DP1

10

TORQUE WRENCH END OF STROKE BREAKOUT PROXIMITY SWITCH

10DI1.6

24VDC

DP1

10

TORQUE WRENCH END OF STROKE MAKEUP PROXIMITY SWITCH

10DI1.7

24VDC

DP1

10

HYDRAULIC FLOW DETECT

10DI2.0

24VDC

DP1

10

LEFT SIDE BOTTOM OBJECT DETECT

10DI2.1

24VDC

DP1

10

RIGHT SIDE BOTTOM OBJECT DETECT

10DI2.2

24VDC

DP1

10

SENSI-SWITCH

10DI2.3

24VDC

DP1

10

WIRED SPARE

10DI2.4

24VDC

DP1

10

PROXIMITY SWITCH FAULT 1

10DI2.5

24VDC

DP1

10

PROXIMITY SWITCH FAULT 2

10DI2.6

24VDC

DP1

10

SPARE

10DI2.7

24VDC

DP1

10

SPARE

10AI3

4-20mA

DP1

10

TORQUE CONTROL PRESSURE

10AI5

4-20mA

DP1

10

TORQUE WRENCH CLAMP PRESSURE

10AI7

4-20mA

DP1

10

HYDRAULIC SYSTEM PRESSURE

10AI9

4-20mA

DP1

10

MANUAL HYDRAULIC OVERRIDE PRESSURE

10AI11

4-20mA

DP1

10

TORQUE WRENCH END OF STROKE BREAKOUT PRESSURE

10AI13

4-20mA

DP1

10

TORQUE WRENCH END OF STROKE MAKEUP PRESSURE

10AI15

4-20mA

DP1

10

DERRICK J-BOX TERMPERATURE TRANSMITTER

10AI17

4-20mA

DP1

10

SPARE

10DQ0.0

24VDC

DP1

10

ALARM-STROBE LIGHT

10DQ0.1

24VDC

DP1

10

ALARM-AUDIBLE HORN

10DQ0.2

24VDC

DP1

10

WIRELESS OPERATOR STOP BYPASS

10DQ0.3

24VDC

DP1

10

SPARE

10DQ0.4

24VDC

DP1

10

SPIN WRENCH CLAMP SOLENOID

10DQ0.5

24VDC

DP1

10

SPIN WRENCH UNCLAMP SOLENOID

10DQ0.6

24VDC

DP1

10

TORQUE WRENCH CLAMP SOLENOID

10DQ0.7

24VDC

DP1

10

TORQUE WRENCH UNCLAMP SOLENOID

10DQ1.0

24VDC

DP1

10

MODE SPIN WRENCH BACKUP SOLENOID

10DQ1.1

24VDC

DP1

10

MODE TORQUE WRENCH CENTER SOLENOID

10DQ1.2

24VDC

DP1

10

TORQUE WRENCH MAKE SOLENOID

10DQ1.3

24VDC

DP1

10

TORQUE WRENCH BREAK SOLENOID

10DQ1.4

24VDC

DP1

10

SPARE

10DQ1.5

24VDC

DP1

10

SPARE

10DQ1.6

24VDC

DP1

10

SPARE

10DQ1.7

24VDC

DP1

10

SPARE

10DQ2.0

24VDC

DP1

10

SPARE

10DQ2.1

24VDC

DP1

10

HYDRAULIC ENABLE ON/OFF SOLENOID

10DQ2.2

24VDC

DP1

10

SPARE

10DQ2.3

24VDC

DP1

10

SPARE

ENG. MIN ENG. UNITS UNITS

MAX ENG. UNITS

TOOL JOINT PRESENT

TOOL JOINT NOT PRESENT

-

-

-

END OF STROKE BREAKOUT

END OF STROKE NOT BREAKOUT

-

-

-

END OF STROKE MAKEUP

END OF STROKE NOT MAKEUP

-

-

-

HYDRALIC FLOW

NO HYDRALIC FLOW

-

-

-

OBJECT PRESENT

OBJECT NOT PRESENT

-

-

-

OBJECT PRESENT

OBJECT NOT PRESENT

-

-

-

OBJECT PRESENT

OBJECT NOT PRESENT

-

-

-

-

-

-

-

-

PROXIMITY SWITCH OK

PROXIMITY SWITCH FAULT

-

-

-

PROXIMITY SWITCH OK

PROXIMITY SWITCH FAULT

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

°C

0

100

-

-

-

-

-

POS 14 (1) POS 14 (5) POS 15 (1) POS 15 (5) POS 16 (1) POS 16 (5) POS 17 (1) POS 17 (5) POS 20 (1) POS 20 (5) POS 21 (1) POS 21 (5) POS 24 (1) POS 24 (5) POS 25 (1) POS 25 (5) POS 26 (1) POS 26 (5) POS 27 (1) POS 27 (5) POS 30 (1) POS 30 (5) POS 31 (1) POS 31 (5) POS 32 (1) POS 32 (5) POS 33 (1) POS 33 (5)

SHEET

ALARM-STROBE LIGHT ON

ALARM-STROBE LIGHT OFF

-

-

-

ALARM-AUDIBLE HORN ON

ALARM-AUDIBLE HORN OFF

-

-

-

ESTOP BYPASS ON

ESTOP BYPASS OFF

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

HYDRAULIC ENABLE ON

HYDRAULIC ENABLE OFF

-

-

-

-

-

-

-

-

-

-

-

-

-

2

OF

5

SETPOINTS

3/17/2014 1:54:02 PM

INTERCONNECT DIAGRAM

DWG NO

REMARKS

10896367-IDX

REV

01

I/O MAP, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

I/O ADDRESS

SIGNAL TYPE

NETWORK ID

NODE No.

11DI1.0

Data

DP1

11DI1.1

Data

DP1

11DI1.2

Data

11DI1.3 11DI1.4

DATE

I/O DESCRIPTION

I/O LOCATION

1 FUNCTION

0 FUNCTION

ENG. MIN ENG. UNITS UNITS

MAX ENG. UNITS

11

OVERRIDE

-

OVERRIDE ON OR TURN THE TOOL ON

-

-

-

11

DESTINATION

-

TOGGLE DESTINATION

-

-

-

-

DP1

11

TRIP

-

TOGGLE TRIP MODE

-

-

-

-

Data

DP1

11

SLOW

-

SELECT SLOW MODE

-

-

-

-

Data

DP1

11

TEACH DESTINATION

-

START OR STEP THROUGH TEACH SEQ.

-

-

-

-

11DI1.5

Data

DP1

11

AUTO

-

START OR STEP THROUGH AUTO SEQ.

-

-

-

-

11DI1.6

Data

DP1

11

POWER SLIPS MODE

-

SELECT POWER SLIPS MODE

-

-

-

-

11DI1.7

Data

DP1

11

WRENCH

-

TOGGLE WRENCH SELECTION

-

-

-

-

11DI2.0

Data

DP1

11

MODE

-

TOGGLE TOOL MODE

-

-

-

-

11DI2.1

Data

DP1

11

ADJUST TORQUE

-

SET TORQUE

-

-

-

-

11DI2.2

Data

DP1

11

TOOL JOINT

-

SET TOOL JOINT LENGTH

-

-

-

-

11DI2.3

Data

DP1

11

INCREASE

-

INCREASE TORQUE OR TOOL JOINT LENGTH

-

-

-

-

11DI2.4

Data

DP1

11

DECREASE

-

DECREASE TORQUE OR TOOL JOINT LENGTH

-

-

-

-

11DI4.0

Data

DP1

11

TW MAKE

-

TORQUE WRENCH MAKE UP

-

-

-

-

11DI4.1

Data

DP1

11

TW BREAK

-

TORQUE WRENCH BREAK OUT

-

-

-

-

11DI6.0

Data

DP1

11

SW IN

-

SPIN WRENCH SPIN IN

-

-

-

-

11DI6.1

Data

DP1

11

SW OUT

-

SPIN WRENCH SPIN OUT

-

-

-

-

11DI8.0

Data

DP1

11

SW/TW CLAMP

-

CLOSE TORQUE WRENCH OR SPIN WRENCH

-

-

-

-

11DI8.1

Data

DP1

11

SW/TW UNCLAMP

-

OPEN TORQUE WRENCH OR SPIN WRENCH

-

-

-

-

11IW9

Data

DP1

11

SW/TW CARRIAGE

-

RAISE OR LOWER TW OR SW CARRIAGE

-

-

-

-

11IW11

Data

DP1

11

DEPLOY

-

EXTEND OR RETRACT ARM

-

-

-

-

11IW13

Data

DP1

11

SLEW

-

SLEW CW OR CCW

-

-

-

-

Data

DP1

11

WELL CENTER

-

DESTINATION IS WELL CENTER

-

-

-

-

11DQ0.1

Data

DP1

11

FOXHOLE 1

-

DESTINATION IS FOXHOLE 1

-

-

-

-

11DQ0.2

Data

DP1

11

FOXHOLE 2

-

DESTINATION IS FOXHOLE 2

-

-

-

-

11DQ0.3

Data

DP1

11

IN

-

TRIP MODE IS TRIP IN

-

-

-

-

11DQ0.4

Data

DP1

11

OUT

-

TRIP MODE IS TRIP OUT

-

-

-

-

11DQ0.5

Data

DP1

11

SLOW

-

SLOW MODE IS ON

-

-

-

-

11DQ0.6

Data

DP1

11

TEACH

-

TEACH SEQUENCE IS ON

-

-

-

-

11DQ0.7

Data

DP1

11

AUTO

-

AUTO SEQUENE IS ON

-

-

-

-

11DQ1.0

Data

DP1

11

POWER SLIPS

-

POWER SLIPS MODE IS ON

-

-

-

-

11DQ1.1

Data

DP1

11

TW

-

TORQUE WRENCH IS SELECTED

-

-

-

-

11DQ1.2

Data

DP1

11

SW

-

SPIN WRENCH IS SELECTED

-

-

-

-

11DQ1.3

Data

DP1

11

NORMAL

-

TOOL MODE IS NORMAL

-

-

-

-

11DQ1.4

Data

DP1

11

TDS BACKUP

-

TOOL MODE IS TDS BACKUP

-

-

-

-

11DQ1.5

Data

DP1

11

SW BACKUP

-

TOOL MODE IS SPIN WRENCH BACKUP

-

-

-

-

11DQ1.6

Data

DP1

11

INTERLOCKED

-

TOOL IS INTERLOCKED

-

-

-

-

11DQ1.7

Data

DP1

11

MESSAGE

-

MESSAGE IS BEING DISPLAYED

-

-

-

-

11QW3

Data

DP1

11

MESSAGE LINE

-

OPERATOR MESSAGE

-

-

-

-

11QW5

Data

DP1

11

ACTUAL TORQUE

-

ACTUAL TORQUE

-

-

-

-

11QW7

Data

DP1

11

SETPOINT TORQUE

-

SETPOINT TORQUE

-

-

-

-

11QW9

Data

DP1

11

TOOL JOINT LENGTH

-

-

-

-

-

11QW11

Data

DP1

11

INFORMATION

-

TOOL JOINT LENGTH DISPLAY ACT. TORQUE, SET POINT. TORQUE, OR TOOL JOINT LENGTH

-

-

-

-

12IW0

DATA

DP1

12

SW.Spin.dma.in.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

12IW2

DATA

DP1

12

SW.Spin.dma.in.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

12IW4

DATA

DP1

12

SW.Spin.dma.in.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

12IW6

DATA

DP1

12

SW.Spin.dma.in.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

12IW8

DATA

DP1

12

SW.Spin.dma.in.raw.byte8byte9.ioIdentifier

-

-

-

-

-

-

12IW10

DATA

DP1

12

SW.Spin.dma.in.raw.byte10byte11.ioIdentifier

-

-

-

-

-

-

12IW12

DATA

DP1

12

SW.Spin.dma.in.raw.byte12byte13.ioIdentifier

-

-

-

-

-

-

12IW14

DATA

DP1

12

SW.Spin.dma.in.raw.byte14byte15.ioIdentifier

-

-

-

-

-

-

12IW16

DATA

DP1

12

SW.Spin.dma.in.raw.byte16byte17.ioIdentifier

-

-

-

-

-

-

12IW18

DATA

DP1

12

SW.Spin.dma.in.raw.byte18byte19.ioIdentifier

-

-

-

-

-

-

12QW0

DATA

DP1

12

SW.Spin.dma.out.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

3

OF

5

INTERCONNECT DIAGRAM

REMARKS

-

11DQ0.0

SHEET

SETPOINTS

3/17/2014 1:54:02 PM

DWG NO

10896367-IDX

REV

01

I/O MAP, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

DATE

I/O ADDRESS

SIGNAL TYPE

NETWORK ID

NODE No.

I/O DESCRIPTION

I/O LOCATION

1 FUNCTION

0 FUNCTION

ENG. MIN ENG. UNITS UNITS

MAX ENG. UNITS

12QW2

DATA

DP1

12

SW.Spin.dma.out.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

12QW4

DATA

DP1

12

SW.Spin.dma.out.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

12QW6

DATA

DP1

12

SW.Spin.dma.out.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

SETPOINTS

3/17/2014 1:54:02 PM

INTERCONNECT DIAGRAM

REMARKS

13IW0

DATA

DP1

13

SW.Carriage.dma.in.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

13IW2

DATA

DP1

13

SW.Carriage.dma.in.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

13IW4

DATA

DP1

13

SW.Carriage.dma.in.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

13IW6

DATA

DP1

13

SW.Carriage.dma.in.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

13IW8

DATA

DP1

13

SW.Carriage.dma.in.raw.byte8byte9.ioIdentifier

-

-

-

-

-

-

13IW10

DATA

DP1

13

SW.Carriage.dma.in.raw.byte10byte11.ioIdentifier

-

-

-

-

-

-

13IW12

DATA

DP1

13

SW.Carriage.dma.in.raw.byte12byte13.ioIdentifier

-

-

-

-

-

-

13IW14

DATA

DP1

13

SW.Carriage.dma.in.raw.byte14byte15.ioIdentifier

-

-

-

-

-

-

13IW16

DATA

DP1

13

SW.Carriage.dma.in.raw.byte16byte17.ioIdentifier

-

-

-

-

-

-

13IW18

DATA

DP1

13

SW.Carriage.dma.in.raw.byte18byte19.ioIdentifier

-

-

-

-

-

-

13QW0

DATA

DP1

13

SW.Carriage.dma.out.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

13QW2

DATA

DP1

13

SW.Carriage.dma.out.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

13QW4

DATA

DP1

13

SW.Carriage.dma.out.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

13QW6

DATA

DP1

13

SW.Carriage.dma.out.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

14IW0

DATA

DP1

14

TW.Carriage.dma.in.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

14IW2

DATA

DP1

14

TW.Carriage.dma.in.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

14IW4

DATA

DP1

14

TW.Carriage.dma.in.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

14IW6

DATA

DP1

14

TW.Carriage.dma.in.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

14IW8

DATA

DP1

14

TW.Carriage.dma.in.raw.byte8byte9.ioIdentifier

-

-

-

-

-

-

14IW10

DATA

DP1

14

TW.Carriage.dma.in.raw.byte10byte11.ioIdentifier

-

-

-

-

-

-

14IW12

DATA

DP1

14

TW.Carriage.dma.in.raw.byte12byte13.ioIdentifier

-

-

-

-

-

-

14IW14

DATA

DP1

14

TW.Carriage.dma.in.raw.byte14byte15.ioIdentifier

-

-

-

-

-

-

14IW16

DATA

DP1

14

TW.Carriage.dma.in.raw.byte16byte17.ioIdentifier

-

-

-

-

-

-

14IW18

DATA

DP1

14

TW.Carriage.dma.in.raw.byte18byte19.ioIdentifier

-

-

-

-

-

-

14QW0

DATA

DP1

14

TW.Carriage.dma.out.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

14QW2

DATA

DP1

14

TW.Carriage.dma.out.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

14QW4

DATA

DP1

14

TW.Carriage.dma.out.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

14QW6

DATA

DP1

14

TW.Carriage.dma.out.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

15IW0

DATA

DP1

15

Traverse.dma.in.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

15IW2

DATA

DP1

15

Traverse.dma.in.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

15IW4

DATA

DP1

15

Traverse.dma.in.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

15IW6

DATA

DP1

15

Traverse.dma.in.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

15IW8

DATA

DP1

15

Traverse.dma.in.raw.byte8byte9.ioIdentifier

-

-

-

-

-

-

15IW10

DATA

DP1

15

Traverse.dma.in.raw.byte10byte11.ioIdentifier

-

-

-

-

-

-

15IW12

DATA

DP1

15

Traverse.dma.in.raw.byte12byte13.ioIdentifier

-

-

-

-

-

-

15IW14

DATA

DP1

15

Traverse.dma.in.raw.byte14byte15.ioIdentifier

-

-

-

-

-

-

15IW16

DATA

DP1

15

Traverse.dma.in.raw.byte16byte17.ioIdentifier

-

-

-

-

-

-

15IW18

DATA

DP1

15

Traverse.dma.in.raw.byte18byte19.ioIdentifier

-

-

-

-

-

-

15QW0

DATA

DP1

15

Traverse.dma.out.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

15QW2

DATA

DP1

15

Traverse.dma.out.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

15QW4

DATA

DP1

15

Traverse.dma.out.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

15QW6

DATA

DP1

15

Traverse.dma.out.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

16IW0

DATA

DP1

16

Slew.dma.in.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

16IW2

DATA

DP1

16

Slew.dma.in.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

16IW4

DATA

DP1

16

Slew.dma.in.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

16IW6

DATA

DP1

16

Slew.dma.in.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

16IW8

DATA

DP1

16

Slew.dma.in.raw.byte8byte9.ioIdentifier

-

-

-

-

-

-

16IW10

DATA

DP1

16

Slew.dma.in.raw.byte10byte11.ioIdentifier

-

-

-

-

-

-

16IW12

DATA

DP1

16

Slew.dma.in.raw.byte12byte13.ioIdentifier

-

-

-

-

-

-

SHEET

4

OF

5

DWG NO

10896367-IDX

REV

01

I/O MAP, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

DATE

I/O ADDRESS

SIGNAL TYPE

NETWORK ID

NODE No.

I/O DESCRIPTION

I/O LOCATION

1 FUNCTION

0 FUNCTION

ENG. MIN ENG. UNITS UNITS

MAX ENG. UNITS

16IW14

DATA

DP1

16

Slew.dma.in.raw.byte14byte15.ioIdentifier

-

-

-

-

-

-

16IW16

DATA

DP1

16

Slew.dma.in.raw.byte16byte17.ioIdentifier

-

-

-

-

-

-

16IW18

DATA

DP1

16

Slew.dma.in.raw.byte18byte19.ioIdentifier

-

-

-

-

-

-

16QW0

DATA

DP1

16

Slew.dma.out.raw.byte0byte1.ioIdentifier

-

-

-

-

-

-

16QW2

DATA

DP1

16

Slew.dma.out.raw.byte2byte3.ioIdentifier

-

-

-

-

-

-

16QW4

DATA

DP1

16

Slew.dma.out.raw.byte4byte5.ioIdentifier

-

-

-

-

-

-

16QW6

DATA

DP1

16

Slew.dma.out.raw.byte6byte7.ioIdentifier

-

-

-

-

-

-

17IW0

DATA

DP1

17

TW.Torque.atos.wi.id.ioIdentifier

-

-

-

-

-

-

17IW6

DATA

DP1

17

TW.Torque.atos.wi.pValue.ioIdentifier

-

-

-

-

-

-

17IW8

DATA

DP1

17

TW.Torque.atos.wi.status.ioIdentifier

-

-

-

-

-

-

17QW0

DATA

DP1

17

TW.Torque.atos.wq.id.ioIdentifier

-

-

-

-

-

-

17QW6

DATA

DP1

17

TW.Torque.atos.wq.pValue.ioIdentifier

-

-

-

-

-

-

SHEET

5

OF

5

SETPOINTS

3/17/2014 1:54:02 PM

INTERCONNECT DIAGRAM

DWG NO

REMARKS

10896367-IDX

REV

01

NOTES: UNLESS OTHERWISE SPECIFIED 1. THIS DOCUMENT BEST VIEWED THROUGH MS EXCEL. 2. THE STATUS COLUMN AND REVISION LETTER CORRESPONDS TO THE MOST CURRENT CHANGE TO RESPECTIVE LINE (ROW).

10861989-GEN

ST-120

NEXT ASSY

USED ON

APPLICATION

This document contains proprietary and confidential information which belongs to 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 and in any event 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

CURRENT DRAWN CHECKED APPVD DATE

TITLE

HAZARDOUS EQUIPMENT, ST-120 CENTRAL PANUCO UXPANAPA

INITIAL R. MOENCH T. GONZALEZ

SIZE

R. MOENCH

B

3/17/2014

SCALE

DWG NO

REV

10896368-IDX NONE

WT LBS

SHEET

1

OF

01

4

D74DCF0050-TPL-001 (REV B)

HAZARDOUS EQUIPMENT, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

NOV

NOV

TAG NO.

P/N:

DESCRIPTION

LOCATION

MANUFACTURER

DATE

MANUFACTURER

HAZARDOUS

HAZARDOUS

LOCATION

CERTIFICATION

CERTIFICATE

TEMP.

ENVIRONMENTAL

P/N:

RATING

AREA RATING

ON RIG

AGENCY

No.

RATING

RATING

MATERIAL

BLOCK DIAG. DWG. NO.

INTERCONNECT SHT.

DWG. NO.

ASSOCIATED SHT.

3/17/2014 4:32:13 PM

REMARKS

COMPONENT

ST-120 SV-01-H

10487704-002

SPIN WRENCH IN/OUT PROPORTIONAL SOLENOID VALVE

ST-120 HEAD

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS I DIV 1

CLASS I DIV 1

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

2

10896365-DIA

2

SV-02-H

10487704-002

SPIN WRENCH CLAMP/UNCLAMP SOLENOID VALVE

ST-120 HEAD

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS I DIV 1

CLASS I DIV 1

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

2

10896365-DIA

2 2

SV-03-H

10487704-002

TORQUE WRENCH MODE/CENTER SOLENOID VALVE

ST-120 HEAD

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS I DIV 1

CLASS I DIV 1

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

2

10896365-DIA

SV-04-H

10487704-002

MODE SPIN WRENCH BACKUP/TORQUE WRENCH CENTER SOLENOID VALVE

ST-120 HEAD

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS I DIV 1

CLASS I DIV 1

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

2

10896365-DIA

2

SV-05-H

10487704-002

TORQUE WRENCH MAKE/BREAK SOLENOID VALVE

ST-120 HEAD

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS I DIV 1

CLASS I DIV 1

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

2

10896365-DIA

2

SV-06-H

10487704-002

SPIN WRENCH DOWN/UP PROPORTIONAL SOLENOID VALVE

ST-120 HEAD

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS I DIV 1

CLASS I DIV 1

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

2

10896365-DIA

2

PV-01

10487703-002

TORQUE CONTROL INCREASE/DECREASE PROPORTIONAL SOLENOID VALVE

ST-120 HEAD

ATOS SYSTEMS, INC

RZMA-UL-A-010/180/-NPT/**/*

CLASS I GROUP C,D

GROUPS IIA,IIB

CLASS I DIV 1

UL

VAPTE192514

-20ºC to +70ºC

IP67

CAST IRON

10896364-DIA

2

10896365-DIA

2

SW-01

10044537-001

CARRIAGE TOOL E-STOP

BARTEC

05-0003-000800BN

THERMOPLASTIC

10896364-DIA

2

10896365-DIA

8

ALUMINUM

10896364-DIA

2

10896365-DIA

4

ALUMINUM

10896364-DIA

2

10896365-DIA

4

316L STAINLESS STEEL

10896364-DIA

3

10896365-DIA

5

316L STAINLESS STEEL

10896364-DIA

3

10896365-DIA

5

316L STAINLESS STEEL

10896364-DIA

3

10896365-DIA

5

316L STAINLESS STEEL

10896364-DIA

3

10896365-DIA

5

THERMOPLASTIC POLY

10896364-DIA

3

10896365-DIA

5

THERMOPLASTIC POLY

10896364-DIA

3

10896365-DIA

5

5

ZONE 1

II 2GE Ex e II ST-120 CARRIAGE

CLASS I ZONE 1

CLASS I ZONE 1 AEx de IIC

ZONE 1

Ex e II

SW-02

SW-03

10654603-001

10654603-002

LEFT SIDE TOOL E-STOP

RIGHT SIDE TOOL E-STOP

ST-120 HEAD

ST-120 HEAD

EGS ELECTRICAL GROUP

EGS ELECTRICAL GROUP

CLASS I GROUP B, C, D

CLASS I DIV 1

CLASS I GROUP C, D

CLASS I DIV 1

10460068-004

TOOL JOINT DETECT PROXIMITY SWITCH

ST-120 HEAD

PEPPERL & FUCHS

CLASS I GROUP B, C, D

CLASS I DIV 1

CLASS I GROUP C, D

CLASS I DIV 1 ZONE 1

MAKE END OF STROKE BREAK OUT PROXIMITY SWITCH

ST-120 HEAD

PEPPERL & FUCHS

CLASS I DIV 1 ZONE 1 CLASS I DIV 1 ZONE 1

II 1G Ex ia IIC T6 10460068-011

BREAK END OF STROKE MAKEUP PROXIMITY SWITCH

ST-120 HEAD

PEPPERL & FUCHS

CLASS I DIV 1 ZONE 1

II 2G Ex ia IIC T6

PZS-05

PZS-06

10465056-001

10660910-001

10660910-001

HYDRAULIC FLOW DETECT PROXIMITY SWITCH

LEFT SIDE BOTTOM RETRO-REFLECTIVE SENSOR

RIGHT SIDE BOTTOM RETRO-REFLECTIVE SENSOR

ST-120 CARRIAGE

ST-120 CARRIAGE

ST-120 CARRIAGE

PEPPERL & FUCHS

BANNER ENGINEERING

BANNER ENGINEERING

Q45AD9LPQ

E10449 E81751

7CD NEMA 3

UL

E10449

UL

E81751

9EFG 7CD NEMA 3

PTB

00ATEX2048X

FM

116-0165F

PTB

00ATEX2048X

FM

116-0165F

PTB

00ATEX2048X

FM

116-0165F

PTB

00ATEX2048X

FM

116-0165F

9EFG -25ºC to +100ºC

IP67

-

-

-25ºC to +100ºC

IP67

-

-

-25ºC to +100ºC

IP67

-

-

-25ºC to +85ºC

IP66/IP68

-

-

-40ºC to +70ºC

IP67

CLASS I DIV 2

NJ1.5-18GM-N-D

Q45AD9LPQ

UL UL

IP67

CLASS I DIV 1

NCB15-30GM40-N0-V1 CLASS I DIV 1 GROUP A, B, C, D

ZS-04

PTB 08.0037U

CLASS I DIV 1

NCB15-30GM40-N0-V1 CLASS I DIV 1 GROUP A, B, C, D

ZS-03

IP66/67 -20ºC to +70ºC

CLASS I DIV 1

NCB8-18GM40-N0-V1

II 1G Ex ia IIC T6 10460068-011

IECEx

00ATEX3114U E184198

CLASS I DIV 1

EDS1192UM1-SA

CLASS I DIV 1 GROUP A, B, C, D

ZS-02

UL

CLASS I DIV 1

EDSC1192UM1-SA

II 1G Ex ia IIC T6 ZS-01

PTB CLASS I DIV 2

CLASS I DIV 1 GROUP A, B, C, D

CLASS I DIV 1

CLASS I, II, III, DIV1 GROUPS A-G , DIV 2 GROUPS A-D & G

CLASS 1 DIV1 ZONE 0

II 1G EEx ia IIC T6 CLASS I DIV 2 GROUP A, B, C, D

CLASS 1 DIV1

CLASS I, II, III, DIV1 GROUPS A-G , DIV 2 GROUPS A-D & G

CLASS 1 DIV1 ZONE 0

II 1G EEx ia IIC T6

CLASS I DIV 2

J.I. 5Y3A4.AX 03ATEX1441X

CSA

CLASS I DIV 2

CLASS 1 DIV1

CLASS I DIV 2 GROUP A, B, C, D

FM KEMA

LR 41887

FM

J.I. 5Y3A4.AX

KEMA

03ATEX1441X

CSA

-

-40ºC to +70ºC

LR 41887

IP67 -

ZS-07

10474197-001

SENSI-SWITCH

RECORA

P364000043

SIMPLE APPARATUS (INTRINSICALLY SAFE)

ZONE 1

CLASS I DIV 2

NONE

SV-01-C

10359384-002

HYDRAULIC ENABLE ON/OFF SOLENOID VALVE

ST-120 CARRIAGE

ATOS SYSTEMS, INC

DHA/UL/0631/2/NPT 24DC20

II 2G EEx d IIC T6, T4, T3

ZONE 1

CLASS I DIV 2

CESI

SV-02-C

10487704-002

CARRIAGE DOWN/UP PROPORTIONAL SOLENOID VALVE

ST-120 CARRIAGE

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS1 DIV2

CLASS I DIV 2

FM

SV-03-C

10487704-002

DEPLOY EXTEND/RETRACT PROPORTIONAL SOLENOID VALVE

ST-120 CARRIAGE

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS1 DIV2

CLASS I DIV 2

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

3

10896365-DIA

3

SV-05-C

10487704-002

CARRIAGE SLEW LEFT/RIGHT PROPORTIONAL SOLENOID VALVE

ST-120 CARRIAGE

HAWE HYDRAULICS

PMZ-1-30-G24 TEx70-FM-10M

CLASS 1 DIV1 GROUP C,D

CLASS1 DIV2

CLASS I DIV 2

FM

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

3

10896365-DIA

3

LT-01

10656373-003

SPIN WRENCH UP/DOWN DPLINEAR TRANSDUCER

ST-120 HEAD

MTS SYSTEMS CORP.

1070

CLASS 1 GROUP A,B,C,D

CLASS1 DIV1

CLASS I DIV 1

UL

FTRV.E234045

-40ºC to +60ºC

IP68

316L STAINLESS STEEL

10896364-DIA

2

10896365-DIA

6

LT-02

10656373-002

DEPLOY EXTEND/RETRACT PROFIBUS LINEAR TRANSDUCER

ST-120 CARRIAGE

MTS SYSTEMS CORP.

420

CLASS 1 GROUP A,B,C,D

CLASS1 DIV1

CLASS I DIV 2

UL

FTRV.E234045

-40ºC to +60ºC

IP68

316L STAINLESS STEEL

10896364-DIA

3

10896365-DIA

8

LT-03

10656373-003

CARRIAGE UP/DOWN PROFIBUS LINEAR TRANSDUCER

ST-120 CARRIAGE

MTS SYSTEMS CORP.

1070

CLASS 1 GROUP A,B,C,D

CLASS1 DIV1

CLASS I DIV 2

UL

FTRV.E234045

-40ºC to +60ºC

IP68

316L STAINLESS STEEL

10896364-DIA

3

10896365-DIA

8

PTB

10ATEX1036X

-40ºC to +60ºC

IP64/65 316L STAINLESS STEEL

10896364-DIA

3

10896365-DIA

8

ETL 4007103

-20ºC to +40ºC

-

-35ºC to +60ºC

IP66 ALUMINUM

10896364-DIA

2

10896365-DIA

7

-

316L STAINLESS STEEL

10896364-DIA

2

10896365-DIA

6

316L STAINLESS STEEL

10896364-DIA

2

10896365-DIA

6

316L STAINLESS STEEL

10896364-DIA

2

10896365-DIA

6

ST-120 HEAD CARRIAGE

ZONE 1

II 2 G EEx d II C T4 Gb, Ex d IIC T6 Gb ENC-04

10562846-001

SLEW POSITION PROFIBUS ABSOLUTE ENCODER

ST-120 CARRIAGE

HENGSTLER

NONE

-29ºC to +65ºC

IP67

MOLDED URETHANE

10896364-DIA

3

10896365-DIA

02ATEX014

-20ºC to +70ºC

IP66

CAST IRON

10896364-DIA

3

10896365-DIA

3

3044176

-40ºC to +80ºC

IP67

STEEL

10896364-DIA

3

10896365-DIA

3

CLASS I DIV 2

AX71/1214EK.42DPX-FO:5604 CLASS I DIV 2

AEx d IIC T4 Gb

INTERTECK

II2 GD EEx d IIB T4

BASEEFA

02ATEX0212X

IECEx

BAS 05.0086X

UL

UGKZ.E161818

-

10ATEX0100 X

-40ºC to +120ºC

ZONE 1 HOR-01

10659217-001

BEACON/ STROBE LIGHT

ST-120 CARRIAGE

CLIFFORD & SNELL

YL60-B-D50-Y-IN

CLASS I DIV 1

Ex d IIB T4 CLASS I DIV 1

CLASS I DIV 1 GROUP B,C,D

ZONE 1

II 2G EEx d IIC T6.T5 PT-01

10548969-008

TORQUE CONTROL PRESSURE TRANSMITTER, 0-3000 PSI

ST-120 CARRIAGE J-BOX

HYDAC TECHNOLOGY

2095471 (0-3000PSI)

CLASS I DIV 1

CLASS I GROUP A,B,C,D

KEMA CLASS I DIV 2

CSA

2032612

IP66 TYPE 4

-40ºC to +60ºC ZONE 1

Ex d IIC T6, T5 Gb

ZONE 1

II 2G EEx d IIC T6.T5 PT-02

10548969-010

TORQUE WRENCH CLAMP PRESSURE TRANSMITTER, 0-6000 PSI

ST-120 CARRIAGE J-BOX

HYDAC TECHNOLOGY

2095473 (0-6000PSI)

IECEx

CLASS I DIV 1

CLASS I GROUP A,B,C,D

KEMA CLASS I DIV 2

CSA

KEM 10.0053X 10ATEX0100 X

-40ºC to +120ºC

2032612

IP66 TYPE 4

-40ºC to +60ºC ZONE 1

Ex d IIC T6, T5 Gb

ZONE 1

II 2G EEx d IIC T6.T5 PT-03

10548969-008

HYDRAULIC SYSTEM PRESSURE TRANSMITTER, 0-3000 PSI

ST-120 CARRIAGE J-BOX

HYDAC TECHNOLOGY

2095471 (0-3000PSI)

IECEx

CLASS I DIV 1

CLASS I GROUP A,B,C,D

KEMA CLASS I DIV 2

CSA

KEM 10.0053X 10ATEX0100 X

-40ºC to +120ºC

2032612

IP66 TYPE 4

-40ºC to +60ºC ZONE 1

Ex d IIC T6, T5 Gb

SHEET

2

OF

4

IECEx

KEM 10.0053X

-

DWG NO

10896368-IDX

REV

01

HAZARDOUS EQUIPMENT, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

NOV

NOV

TAG NO.

P/N:

DESCRIPTION

LOCATION

MANUFACTURER

MANUFACTURER

HAZARDOUS

HAZARDOUS

LOCATION

CERTIFICATION

CERTIFICATE

TEMP.

ENVIRONMENTAL

P/N:

RATING

AREA RATING

ON RIG

AGENCY

No.

RATING

RATING

ZONE 1

II 2G EEx d IIC T6.T5 PT-04

10548969-008

MANUAL HYDRAULIC OVERRIDE PRESSURE TRANSMITTER, 0-3000 PSI

ST-120 CARRIAGE J-BOX

HYDAC TECHNOLOGY

DATE

2095471 (0-3000PSI)

CLASS I DIV 1

CLASS I GROUP A,B,C,D

KEMA CLASS I DIV 2

CSA

10ATEX0100 X

-40ºC to +120ºC

2032612

MATERIAL

BLOCK DIAG.

INTERCONNECT

ASSOCIATED

DWG. NO.

SHT.

DWG. NO.

SHT.

316L STAINLESS STEEL

10896364-DIA

2

10896365-DIA

6

316L STAINLESS STEEL

10896364-DIA

2

10896365-DIA

6

316L STAINLESS STEEL

10896364-DIA

2

10896365-DIA

6

POLYAMID 6

10896364-DIA

4

10896365-DIA

3

316L STAINLESS STEEL

10896364-DIA

2,3

10896365-DIA

2-8

316L STAINLESS STEEL

10896364-DIA

2,3

10896365-DIA

2-8

THERMOPLASTIC

10896364-DIA

2,3

10896365-DIA

2-8

THERMOPLASTIC

10896364-DIA

2,3

10896365-DIA

2-8

THERMOPLASTIC

10896364-DIA

2,3

10896365-DIA

5

THERMOPLASTIC

10896364-DIA

2,3

10896365-DIA

8

BRASS

10896364-DIA

2,3

10896365-DIA

2-8

BRASS

10896364-DIA

2,3

10896365-DIA

2-8

BRASS

10896364-DIA

2,3

10896365-DIA

2-8

BRASS

10896364-DIA

2,3

10896365-DIA

2-8

BRASS

10896364-DIA

2,3

10896365-DIA

2-8

STAINLESS STEEL

10896364-DIA

2,3

10896365-DIA

2-8

STAINLESS STEEL

10896364-DIA

2,3

10896365-DIA

2-8

3/17/2014 4:32:13 PM

REMARKS

COMPONENT

IP66 TYPE 4

-40ºC to +60ºC ZONE 1

Ex d IIC T6, T5 Gb

ZONE 1

II 2G EEx d IIC T6.T5 PT-05

10548969-010

TEST PRESSURE TRANSMITTER, 0-6000 PSI

ST-120 CARRIAGE J-BOX

HYDAC TECHNOLOGY

2095473 (0-6000PSI)

IECEx

CLASS I DIV 1

CLASS I GROUP A,B,C,D

KEMA CLASS I DIV 2

CSA

KEM 10.0053X 10ATEX0100 X

-40ºC to +120ºC

2032612

IP66 TYPE 4

-40ºC to +60ºC ZONE 1

Ex d IIC T6, T5 Gb

ZONE 1

II 2G EEx d IIC T6.T5 PT-06

10548969-008

TORQUE WRENCH END OF STROKE-MAKEUP PRESSURE TRANSMITTER, 0-3000 PSI

ST-120 CARRIAGE J-BOX

HYDAC TECHNOLOGY

2095471 (0-3000PSI)

CLASS I DIV 1

CLASS I GROUP A,B,C,D

II 2G Eex ib IIB T4 10072746-001

ST-120 WIRELESS TRANSMITTER

DRILL FLOOR

HBC

KEMA CLASS I DIV 2

ZONE 1

Ex d IIC T6, T5 Gb

WT-101-M

IECEx

CSA

10ATEX0100 X

-40ºC to +120ºC

2032612

IP66 TYPE 4

-40ºC to +60ºC IECEx

ZONE 1

KEM 10.0053X

IBExU

KEM 10.0053X 06ATEX1056

-20ºC to +60ºC

IP65

-

-

-20ºC to +55ºC

IP66

-

-

-40ºC to +60ºC

IP66

-

-

-50ºC to +110ºC

IP20

-

-

-50ºC to +110ºC

IP20

-

-

CLASS I DIV 1

FSS726-1110909 CLASS I DIV 1

CLASS I DIV 1

TBD

TBD

ST-120 CARRIAGE ST-SNJB100 ZONE 2

II 2 (1) G Ex de [ia Ga] IIB T3 Gb ST-NJB100

10786264-001

ST-120 CARRIAGE JUNCTION BOX

ST-120 CARRIAGE J-BOX

NOV-M/D TOTCO

CLASS I DIV 2

CLASS I DIV 2 GROUP C, D

ZONE 1

II 2G, Ex e II ST-NJB100

10531330-001

ENCL,EXE,36" X 24" X 6"

ST-120 CARRIAGE J-BOX

NOV-M/D TOTCO

ITS

11ATEX37460X

TBD

TBD

CLASS I DIV 2

10786264-001

DEMKO

07ATEX0649571U

CLASS I DIV 2

40224461-0014 CLASS I DIV 2

CLASS I DIV 2 GROUP C, D

TBD

Ex e II

TBD

KEMA

04ATEX2048U

IECEx

KEM 06.0027U

UL

XCIB2.E192998

KEMA

04ATEX2048U

IECEx

KEM 06.0027U

UL

XCIB2.E192998

ZONE 1 ST-NJB100

10066985-001

TB-5.2MM, GRAY, UT 2.5

ST-120 CARRIAGE J-BOX

PHOENIX

3044076

CLASS I DIV 2

Ex e II CLASS I ZONE 1

CLASS I ZONE 1 AEx e II Ex e II

ZONE 1 ST-NJB100

10066965-001

TB-5.2MM, GRN/YEL, UT 2.5-PE

ST-120 CARRIAGE J-BOX

PHOENIX

3044092

CLASS I DIV 2

Ex e II CLASS I ZONE 1

CLASS I ZONE 1 AEx e II II 2(1)G Ex de [ia] IIC

PTB

97ATEX1068U

-20ºC to +50ºC

IP66

IECEx

TUN 11.0027X

-20ºC to +75ºC

IP20

2484303

-40ºC to +40ºC

-

ZONE 1 ST-NJB100

10508604-001

ISOLATOR-4 CH AMPLIFIER

ST-120 CARRIAGE J-BOX

BARTEC

07-7311-97MT/BA12

CLASS I DIV 2

[Ex ia Ga] IIC CLASS I ZONE 1

CLASS I ZONE I IIC

ZONE 1

II 2G Ex de IIC ST-NJB100

10055037-001

BUS MOD, EExd PROFIBUS DP COUPLER, 4 OUTPUTS

ST-120 CARRIAGE J-BOX

BARTEC

CSA PTB

97ATEX1068U

-20ºC to +60ºC

IP66

CLASS I ZONE 1

CSA

2484303

-40ºC to +60ºC

-

SIRA

06ATEX1097X

ZONE 1

SIRA

07ATEX4326X

IECEx

SIR 06.0039X

CLASS I DIV 2

07-7311-97WP/K4NO CLASS I ZONE 1 IIC II 2 GD Ex d IIC, Ex e II, Ex nR II, Ex tD A21

IP66 II 3G Ex nR II ST-NJB100

10505841-001

CABLE GLAND, M20, UNARMORED

ST-120 CARRIAGE J-BOX

CMP PRODUCTS

-60ºC to +130ºC

CLASS I DIV 2

20S16A2F1RA Ex d IIC/Ex e II/Ex nRII CLASS I ZONE 1

Ex d IIC I M2 Ex d I Ex e I

CSA

1211841

SIRA

06ATEX1283X

SIRA

07ATEX4328X

IECEx

SIR 07.0005X

-

NEMA 4X

IP66 ZONE 1

II 3G Ex nR II ST-NJB100

10064218-001

CABLE GLAND, M20, ARMORED

ST-120 CARRIAGE J-BOX

CMP PRODUCTS

-60ºC to +130ºC

CLASS I DIV 2

20T3CDS1RA7 Ex d IIC/Ex e II/Ex nRII CLASS I DIV 1

CLASS I DIV 2 GROUP A, B, C, D I M2 Ex d I Ex e I

CSA

1310517

SIRA

06ATEX1283X

SIRA

07ATEX4328X

IECEx

SIR 07.0005X

-

TYPE 4

IP66 ZONE 1

II 3G Ex nR II ST-NJB100

10512557-001

CABLE GLAND, M40, ARMORED

ST-120 CARRIAGE J-BOX

CMP PRODUCTS

-60ºC to +130ºC

CLASS I DIV 2

40/T3/CDS/M40 Ex d IIC/Ex e II/Ex nRII CLASS I DIV 1

CLASS I DIV 2 GROUP A, B, C, D I M2 Ex d I Ex e I

CSA

1310517

SIRA

06ATEX1283X

SIRA

07ATEX4328X

IECEx

SIR 07.0005X

-

TYPE 4

IP66 ZONE 1

II 3G Ex nR II ST-NJB100

10512555-001

CABLE GLAND, M50, ARMORED

ST-120 CARRIAGE J-BOX

CMP PRODUCTS

-60ºC to +130ºC

CLASS I DIV 2

50/T3/CDS/M50 Ex d IIC/Ex e II/Ex nRII CLASS I DIV 1

CLASS I DIV 2 GROUP A, B, C, D I M2 Ex d I Ex e I

CSA

1310517

SIRA

06ATEX1283X

SIRA

07ATEX4328X

IECEx

SIR 07.0005X

-

TYPE 4

IP66 ZONE 1

II 3G Ex nR II ST-NJB100

10044109-001

CABLE GLAND, M20, ARMORED

ST-120 CARRIAGE J-BOX

CMP PRODUCTS

Ex d IIC/Ex e II/Ex nRII CLASS I DIV 1

CLASS I DIV 2 GROUP A, B, C, D ATEX Ex II 2 GD Ex e II

CSA

1310517

SIRA

10ATEX1037U

IECEx

SIR 10.0149U

ZONE 1 ST-NJB100

10066383-001

BREATHER DRAIN, (EEx ell), IP66, M20, 316SS

ST-120 CARRIAGE J-BOX

CMP PRODUCTS

781EM24

CLASS I DIV 2

Ex e II/ Ex tD A21 CLASS I ZONE 1

CLASS I ZONE 1 AEx e II ATEX Ex II 2 GD Ex e II

ZONE 1

I M2 Ex d I Ex e I ST-NJB100

10052314-001

STOPPER PLUG, (EEx ell), IP66, M20, 316SS

ST-120 CARRIAGE J-BOX

CMP PRODUCTS

-60ºC to +130ºC

CLASS I DIV 2

20ST3CDS1RA5

CSA

1055233

SIRA

01ATEX1284U

SIRA

02ATEX1003X

IECEx

SIR 07.0056X

CLASS I DIV 2

757-D-M-2-4 Ex d I/Ex e I/Ex d IIC/Ex e II/Ex tD A21 CLASS I ZONE 1

CLASS I ZONE 1 AEx e II

SHEET

3

OF

4

-

TYPE 4

-20ºC to +130ºC

IP66

-

TYPE 4X

-60ºC to +200ºC IP66 -20ºC to +60ºC

CSA

1055233

-

TYPE 4X

DWG NO

10896368-IDX

REV

01

HAZARDOUS EQUIPMENT, ST-120 CENTRAL PANUCO UXPANAPA

NATIONAL OILWELL VARCO

NOV

NOV

TAG NO.

P/N:

DESCRIPTION

LOCATION

MANUFACTURER

MANUFACTURER

HAZARDOUS

HAZARDOUS

LOCATION

CERTIFICATION

CERTIFICATE

TEMP.

ENVIRONMENTAL

P/N:

RATING

AREA RATING

ON RIG

AGENCY

No.

RATING

RATING

-55ºC to +60ºC

IP67

-

-

-20ºC to +55ºC

IP66

ZONE 1

II 2G Ex d IIC T6 ST-NJB100

10044713-001

SWITCH MODULE, PNL MTD, W/ CABLE PIGTAIL, 2NC

ST-120 CARRIAGE J-BOX

BARTEC

DATE

PTB

00ATEX1092X

CLASS I DIV 2

07-3323-3103 CLASS I ZONE 1 AEx de IIC

CLASS I ZONE 1

UL

NONE

NONE

NWFN.E184198

MATERIAL

BLOCK DIAG.

INTERCONNECT

ASSOCIATED

DWG. NO.

SHT.

DWG. NO.

SHT.

THERMOPLASTIC

10896364-DIA

2,3

10896365-DIA

4

316L STAINLESS STEEL

10896364-DIA

4

3/17/2014 4:32:13 PM

REMARKS

COMPONENT

SAFE AREA ST-PNJB101

10541141-001

ST-120 REMOTE I/O JUNCTION BOX

ST-120 REMOTE I/O J-BOX NOV

10541141-001

NONE, SAFE AREA ONLY

SHEET

4

OF

4

NONE

10896365-DIA 11-24

DWG NO

10896368-IDX

REV

01

TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

3.4

Performance Data Remarks: Section Not Applicable

www.nov.com

Document Number:

10862028-MAN TOC 3.4

Revision:

01

Page:

1

Document Number

Rev.

TABLE OF CONTENTS

Vol.

Chapter/ Section

Title

1

4

Vendor Documentation Remarks: Chapter Not Applicable

www.nov.com

Document Number:

10862028-MAN TOC 4

Revision:

01

Page:

1

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