ST-80

Roughneck
Service Manual

SM00995
General Information 1

Specifications 2

Maintenance 3

Troubleshooting 4
1 General Information

2 Specifications

3 Maintenance

4 Troubleshooting
 General Information
General Information

Preface ................................................................ 1-3

Manual conventions ...................................................... 1-3 1
Note ................................................................................... 1-3
Caution .............................................................................. 1-3
Warning ............................................................................. 1-3
Product bulletins ............................................................ 1-3
Overall equipment safety requirements ......................... 1-3 2
Personnel training .............................................................. 1-4
Systems safety practices ................................................... 1-4
Hydraulic systems and components ............................ 1-4
General safety ................................................................... 1-5
Equipment motion hazards 1-5
3
Proper use of equipment .............................................. 1-6
Tool orientation .................................................. 1-7
ST-80 general information .................................. 1-8
4
ST-80 carriage assembly .............................................. 1-9
Pedestal assembly ........................................................ 1-10
ST-80 wrench assembly ................................................ 1-11
Control System .............................................................. 1-12

Operating the ST-80............................................ 1-14

Making and breaking connections ................................. 1-14
Adjusting the makeup torque ......................................... 1-16
Adjusting the stabbing guide ......................................... 1-17
Adjusting torque gauge responsiveness........................ 1-18

Storing the ST-80 ................................................ 1-19

1-1
 General Information
General Information

1
1

1-2
 General Information

Preface
Manual conventions
This Preface contains the conventions used throughout this manual. 1
Avoid injury to personnel and/or equipment damage by reading this
manual and related documents before operating, inspecting, or
servicing the equipment.

Notes, cautions, and warnings

The following examples explain the symbols for notes, cautions, and
warnings. Please pay close attention to these important advisories.

Note

i Provides additional information on procedures involving little or no

risk of injury to personnel or equipment damage.

Caution

! Alerts the reader to procedures involving a risk of equipment

damage.

Warning

Warns the reader of procedures involving a definite

risk of injury to rig personnel.

Product bulletins
The Product Bulletin tab, if included in your manual, defines a
section of the manual in which you can store Product and Safety
bulletins that may be issued by Varco.
Overall equipment safety requirements
Varco drilling equipment is installed and operated in a controlled
drilling rig environment that involves hazardous operations and
situations.

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

the following safety requirements.

1-3
 General Information

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

i During installation, operation, maintenance, or repair of this

equipment, personnel should wear protective equipment.

Contact the Varco Service Department to arrange for training for

equipment operation and maintenance.

Systems safety practices

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

i Before installing or performing maintenance or repairs on the

equipment, read the following instructions to avoid endangering
exposed persons or damaging equipment.

❏ Isolate all energy sources before beginning work.

❏ Avoid performing maintenance and repairs while the

equipment is in operation.

❏ Wear proper protective equipment during the installation,

maintenance, or repair of this equipment.

Hydraulic systems and components

Hydraulic systems and components are designed for specific use in

the drilling industry. The hydraulic pressure for this equipment can
be as high as 3,000 psi.

❏ Before beginning work on any portion of the hydraulic system,

familiarize yourself with the hydraulic and electrical
schematics.

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

❏ Take precautions when bleeding down residual system

pressure, using bleed valves or equivalent techniques.

1-4
 General Information

Hydraulic fluids can be extremely hot and under high

pressure.
1
❏ Properly discharge all system accumulators.

❏ Collect all residual hydraulic fluid in a container to prevent rig or

environmental contamination.

❏ Take precautions to prevent hydraulic oil from leaking into other

open electrical or mechanical components, such as junction
boxes.

Pneumatic systems and components

Pneumatic systems and components are designed for specific use

in the drilling industry. The pneumatic pressure for this equipment
can be as high as 150 psi.

❏ Prior to beginning work on any portion of the pneumatic system,

familiarize yourself with the pneumatic and electrical
schematics.

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

❏ Take precautions when bleeding down residual system pressure

using bleed valves or equivalent techniques.

❏ Properly discharge all system accumulators.

General safety
Equipment motion hazards

Some of the Varco equipment travels either horizontally, vertically on

rails, or both.

i Avoid placing objects in or near the path of motion for this

equipment. Such interference could cause personnel to be trapped
or crushed by equipment.

i Keep the working envelope/zone of the equipment free from

personnel.

1-5
 General Information

When replacing components

❏ During disassembly and reassembly of any equipment, verify

all components such as cables, hoses, etc. are tagged and
1 labeled to ensure reinstalling the components correctly.

❏ Replace failed or damaged components with Varco certified

parts. Failure to do so could result in a hazard, equipment
damage, or personal injury.

During routine maintenance

Equipment must be maintained on a regular basis. See the body of

the service manual for maintenance recommendations.

i Failure to conduct regular maintenance can result in a hazard,

equipment damage, or injury to personnel.

Visibility of equipment operation

Clear, unobstructed visibility of all equipment functions is critical to

safe operation. Do not block or impair the equipment operator’s
field of view. In cases where this is not possible, the customer must
install video cameras to ensure adequate visibility.

Proper use of equipment

Varco equipment is designed for specific functions and applications

and should be used only for the intended purpose.

i Do not hoist personnel using this equipment.

Contact the Varco service center for questions regarding equipment

operation, maintenance, hazards, and designed function.

1-6
 General Information

Tool orientation

Rear Right

Left Front

1-7
 General Information

ST-80 general information

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

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

❏ ST-80 carriage assembly

❏ Pedestal assembly

❏ ST-80 wrench assembly

❏ ST-80 controls

❏ Upper and lower motion control

Pedestal
Assembly

Upper Motion ST-80 Carriage

Control Assembly

Wrench
Assembly

ST80 Controls

Lower Motion
Control
Not Visible

1-8
 General Information

ST-80 general information

ST-80 carriage assembly
The carriage assembly can move vertically to position the ST-80 1
properly at the tool joint.

Hydraulic
Stabbing Manifold
Guide

Controls

Wrench
Assembly
Carriage

1-9
 General Information

ST-80 general information

Pedestal assembly
1

Lift Cylinder

Extend/Retract
Duplex Cylinder

Transport
Pin
Stowed Position

Transport
Lock
Insert Transport
Pin Prior to Transport

Socket
Flange

Turntable
Bearing

1-10
 General Information

ST-80 general information

ST-80 wrench assembly
The ST-80 uses a combination spinning and torque wrench. The 1
dies of the upper jaws are located in between the spinner rollers.
The spinner rollers grip the pipe and spin in connections with a
torque of 1,750 ft lb.

After spinning, the torque wrench can torque the connection with a
maximum torque of 60,000 ft lb. The wrench can break out
connections with a maximum torque of 80,000 ft lb.

Upper Jaw
Dies
1 each side

Spin Rollers
2 each side

Lower Die
and Die Holder
1 each side

1-11
 General Information

ST-80 general information

Control System
1 The ST-80 controls are mounted on the carriage. They include the
following:

❏ JAWS: UN-CLAMP, CLAMP. Clamps or unclamps the wrench

on a tubular.

❏ MODE: SPIN, TORQUE. Determines whether the wrench

spins or torques connections. The operator must hold this
control in the desired postion while performing these
operations.

❏ TORQUE: MAKE, BREAK. Determines whether the wrench

makes or breaks connections.

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

out.

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

❏ ADJUST: EXTEND, RETRACT. Adjusts the travel distance of

the ST-80 when extending or retracting the tool.

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

or retracts.

1-12
 General Information

ST-80 general information

Torque
Gage

Jaws
Clamp, Unclamp

Mode
Spin, Torque

Torque
Make, Break

Spin
In, Out

ST-80
Up, Down

Adjust
Extend, Retract

ST-80
Extend, Retract

1-13
 General Information

Operating the ST-80

Making and breaking connections
1

Before operating the ST-80

! for the first time, be sure to
remove the transport pin.

1. Completely extend the tool using

ST-80 the ST-80 EXTEND/ RETRACT control.
Up, Down
2. Adjust the vertical position of the
Adjust wrench on the connection using
Extend, Retract ST-80 UP/DOWN control.

ST-80 3. Use the ADJUST control to precisely

Extend, Retract position the ST-80 horizontally.
The correct position is when the lower
guide plate contacts the tubular.
This is typically adjusted only
once per trip.

Vertical Adjustment
Tubular
Pin
Rollers
4 places

Tubular
Box

1-14
 General Information

Operating the ST-80

Making and breaking connections
1
Making Connections
Hold
1 Clamp the jaws on the tubular. 6 2 5 3
2 Hold the MODE control in
the SPIN position.

3 SPIN the connection IN.

4 Hold the MODE control in

the TORQUE position.

5 Hold the TORQUE control in the MAKE

1 4
position until the desired torque is achieved.
Hold
If the wrench does not reach the desired
i value in one stroke, recycle the torque
wrench and repeat steps 4 and 5.
UN-CLAMP SPIN MAKE IN

JAWS MODE TORQUE SPIN

6 UN-CLAMP the jaws and recycle the
torque wrench to prepare for the
CLAMP TORQUE BREAK OUT
next connection.

Breaking Connections
Hold
1 Clamp the jaws on the tubular. 6 4

2 Hold the MODE control in

the TORQUE position.

3 Hold the TORQUE control in the BREAK

position until the connection is broken.

4 Hold the MODE control in

the SPIN position.
1 2 3 5
5 SPIN the connection OUT.
Hold
6 UN-CLAMP the jaws and recycle the
UN-CLAMP SPIN MAKE IN
torque wrench to prepare for the
next break.
JAWS MODE TORQUE SPIN

CLAMP TORQUE BREAK OUT

1-15
 General Information

Operating the ST-80

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

i
Turning the PRV adjustment knob counter
Reference Indicator clockwise decreases torque. Turning the
PRV adjustment knob clockwise increases
the torque.

2. Clamp onto a tubular.

3. Spin the connection in.
4. Torque the connection.
5. While holding the torque, turn the PRV
adjustment knob clockwise while
watching the torque gauge until the
desired torque is achieved.

!
Do not adjust the torque if one of the
torque cylinders is at its end of stroke.

6. Position the reference indicator (red

needle) on the torque gauge at the
desired torque value.

PRV Adjustment Knob

1-16
 General Information

Operating the ST-80

Adjusting the stabbing guide
Use the following procedure to adjust the stabbing guide: 1
1. Use the horizontal travel and vertical travel controls to position
the torque wrench on the tool joint box.

2. Clamp onto the tubular.

3. Stab the next stand.

4. Loosen two adjusting nuts and align the inside edge of the
stabbing guide with the outer circumference of the pipe. Tighten
the nuts.

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

Adjusting Nuts

Stabbing Guide

1-17
 General Information

Operating the ST-80

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

Needle Valve
Torque Gauge

1-18
 General Information

Storing the ST-80

Palletize the ST-80 for indoor storage. A cargo container is
appropriate for indoor or outdoor storage. 1
Avoid wide temperature and humidity variations. The ideal
environment for storing the ST-80 is clean and dry with an ambient
temperature of 60°F (16°C). If high humidity is unavoidable, Varco
recommends storing the ST-80 at 70°F (21°C).

All exposed, unpainted metal surfaces are coated with rust

preventive at the factory prior to shipment. Coat all unpainted metal
surfaces with rust preventive prior to storage or transport.

Cover all openings to prevent water or dust from entering. Varco

does not recommend using silica or dehydrating agents.

When the ST-80 is not being used for more than 3 months, perform
the following:

1. Clean the ST-80.

2. Grease the ST-80 as described in the Maintenance section of

this manual.

3. Clean and cap all hydraulic quick disconnects (QDs).

i Varco recommends Kendall Grade 5 (GE-D6C6A1) rust preventive,

or an equivalent.

! Replace the shipping pin prior to storage and/or moving the

ST-80.

1-19
 General Information

1-20
 Specifications
Specifications

General specifications ....................................... 2-3

Hydraulic requirements ................................................. 2-4 1
Wrench assembly .......................................................... 2-4
Shipping data (approx., allowing for crate/palette) ........ 2-4

2-1
 Specifications
Specifications

2
2

2-2
 Specifications

General specifications

59.0 62.8

95.6 80.0

33.2 51.3

2-3
 Specifications

General specifications
Hydraulic requirements
Hydraulic operating pressure (max.) 2,600 psi

Hydraulic operating pressure (min.) 2,000 psi

Hydraulic flow rate required (min.) 28 gpm @ 1000 psi

Hydraulic flow rate required (max.) 40 gpm (150 l/min)

2
Supply connections (min.) 1" JIC

Return connections 1 1/4" JIC

Wrench assembly
Motor spinning roller ratio 2:1

Spin speed (rollers) 190 rpm

Spin speed (8 1/2" pipe) 90 rpm

Make up torque 60,000 ft lb max.

Break out torque 80,000 ft lb max.

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

Height 88"

Width 60"

Depth 65"

Weight 6,800 lb

2-4
 Maintenance
Maintenance

Lubricant specifications..................................... 3-3

Selecting a lubricant ...................................................... 3-3 1
Recommended general lubricants ..................................... 3-3
Recommended hydraulic fluids ......................................... 3-3
Inspection and lubrication ................................. 3-4
Inspecting hardware and fittings .................................... 3-4 2
Lubricating the ST-80 .................................................... 3-4

Disassembly and assembly ................................ 3-6

Precautions ................................................................... 3-6
Changing dies ............................................................... 3-7 33

3-1
 Maintenance
Maintenance

3-2
 Maintenance

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

Recommended general lubricants

Ambient Temperature Range

Below -20˚ C Above -20˚ C
(Below -4˚ F) (Above -4˚ F)

Manufacturer
Castrol N/R MP Grease
Chevron Avi-Motive W Avi-Motive
Exxon Lidok EP1 Lidok EP2
3
Gulf Gulf Crown EP31 Gulf Crown EP32
Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Statoil Uniway EP1N Uniway EP2N
Texaco Multifak EP1 Multifak EP2
Total Multis EP1 Multis EP2
Union Unoba EP1 Unoba EP2

Viscosity Index
NGLI 1 2

Recommended hydraulic fluids

Oil Temperature Range

-15˚ to 75˚ C -10˚ to 85˚ C
(5˚ to 167˚ F) (14˚ to 185˚ F)

Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46

Viscosity Index
ISO Viscosity Grade 32 46

3-3
 Maintenance

Inspection and lubrication

Inspecting hardware and fittings
Visually inspect the ST-80 for loose or missing hardware and
fittings daily. Make sure all safety wire is undamaged.

Check the inline pressure filter daily. Replace as necessary if the

indicator is red.

Lubricating the ST-80

The lubrication intervals described in this manual are based on
lubricant supplier recommendations. Severe conditions such as
extreme loads or temperature, corrosive atmosphere, etc., may
require more frequent lubrication.
3
Worn bushings, binding parts, rust accumulations, and other
abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example, too
much grease forced into a fitting can pop out a bearing seal. Over
lubrication can also affect safety since over lubricated parts can
drip, creating a potential slipping hazard for personnel.

Apply grease daily to all grease fittings as shown on the following

page.

3-4
 Maintenance

Inspection and lubrication

Inline Pressure
Filter
Replace if indictor is red
Daily

Grease
Fitting
Motion Control 1 each side
Brush mating surfaces
with grease Daily
Daily
Grease
Fitting
1 each side
Daily
3

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

Daily
Grease
Fitting Daily
1 each side Grease
Fitting

3-5
 Maintenance

Disassembly and assembly

Precautions

! Only authorized Varco repair technicians should perform the

following major disassembly and assembly procedures.

! Transport hydraulic components to a clean, dust-free service

area before disassembling for service.

3 i Disassemblypr ocedur esar eusuallyper for medwhenr eplacing

damagedcomponentsthatar ecausingatoolfunctiontofail.
Wheneverper for mingadisassembly ,practicepr eventive
maintenanceby:

❏ Cleaning and inspecting all disassembled parts.

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

❏ Installing thread protectors on exposed threads.

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

Release all hydraulic oil pressure before

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

Before opening the hydraulic system, thoroughly clean

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

3-6
 Maintenance

Disassembly and assembly

Changing dies

Carriage Use the following procedure to replace upper and lower

Assembly dies:

Replacing upper dies

1. Remove the 2 screws holding each die.

Replacing lower dies

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

!
Caution the die can slip out of the die holder once its
free of the housing. 3

Upper
Die
1 each side

Screw
2 each side

Set Screw
2 each side

Die Holder
1 each side

Lower
Die Screw
1 each side 2 each side

3-7
 Maintenance

3-8
 Troubleshooting
Troubleshooting

Troubleshooting the ST-80 ................................. 4-3

Theory of operation ....................................................... 4-4 1

4-1
 Troubleshooting
Troubleshooting

4 4

4-2
 Troubleshooting

Troubleshooting the ST-80

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

Make sure all hydraulic lines are isolated and the ball
valve is closed before ANY work is carried out on the
ST-80.

When troubleshooting the ST-80, make sure the hydrualic pressure

is between 2,000 and 2,600 psi at the inlet of the manifold. Check
the back pressure of the tank line (make sure the pressure does not
exceed 30 psi).

Make sure that all hoses and QDs are properly connected.

Check to see if oil leakage is visible at the manifold, QDs or hoses.

Make sure the tool is lubricated per the Maintenance section of this 4
manual.

Refer to the theory of operation and schematic when

troubleshooting specific ST-80 components or functions.

4-3
 Troubleshooting

Troubleshooting the ST-80

Theory of operation
(((TBD Engineering will supply when Hydraulic Schematic is
released)))

4-4
 Troubleshooting

Troubleshooting the ST-80

(((TBD Hydraulic Schematic in revision)))

4-5
 Troubleshooting

4-6