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.
TITLE
CURRENT INITIAL ST-120 AUTO
DRAWN Functional Design Specification
A. ODUNFA B. WINTER
CHECKED
J. WALKER J. WALKER SIZE DWG NO REV
APPVD
J. WALKER B. WINTER A D364000049-SPC-001 03
DATE
6/21/2010 3/5/2008 SCALE NONE WT LBS SHEET 1 OF 24
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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................................................................................................................................................................................................... 11

Service Loop ............................................................................................................................................................................................... 11

OPERATION .......................................................................................................................................... 12

Configuration Setup ................................................................................................................................................................................... 13

General Operation ..................................................................................................................................................................................... 13

Manual vs. Maintenance Mode ................................................................................................................................................................. 13

Interlocks .................................................................................................................................................................................................... 14

ELECTRICAL COMPONENTS .............................................................................................................. 16

Feedback Devices ....................................................................................................................................................................................... 16

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E-STOP ....................................................................................................................................................................................................... 16

PERFORMANCE ................................................................................................................................... 17

Arm Travel ................................................................................................................................................................................................. 17

Slewing ........................................................................................................................................................................................................ 17

Required User Defined Input .................................................................................................................................................................... 17

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

INITIAL SETUP ...................................................................................................................................... 18

Rig Floor Setup........................................................................................................................................................................................... 18

Arm Extend Adjust Procedure (Auto) ..................................................................................................................................................... 18

Torque Set Procedure (Auto): ................................................................................................................................................................... 18

Torque Set Procedure (Manual Procedure): ........................................................................................................................................... 19

OPERATING PROCEDURES ................................................................................................................ 19

Makeup Sequence (Manual-Electric) ....................................................................................................................................................... 19

Break Out Sequence (Manual-Electric) ................................................................................................................................................... 20

Auto Sequence Matrices ............................................................................................................................................................................ 22

ST-120 FUNCTIONS .............................................................................................................................. 24

Multi-Valve Section Mounted on Head Unit............................................................................................................................................ 24

Multi-Valve Section Mounted on Carriage .............................................................................................................................................. 24

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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. ST-120 Hydraulic Service Loop Interface ................................................................................................ 12
Figure 7. ST-120 torque adjustment knob ................................................................................................................ 19

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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 ft-
lbs and 120,000 ft-lbs, respectively, and handles tubulars ranging from 3-1/2” 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

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SPECIFICATIONS
Performance
Tubular Diameter
Tubular Types
Max. Torque Wrench Height
Max Spin Wrench Height
Travel
Cycle Time
Service Loops
Variable Clamp Force
Instrumentation
Torque Readout
Vertical Position
Deploy Position
Position Accuracy
Physical Specification As Shipped
Maximum Height:
Width:
Depth:
ST-120 Weight:
Service Loop Kit Weight:
Floor Socket Weight:
Service Requirements
Hydraulic operating pressure
min:
Hydraulic operating pressure
max:
Hydraulic flow rate min:
Hydraulic flow rate max:
Pneumatic Utilities required:
Electrical Utilities required:
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):
3-1/2” to 10” OD.
Tools to be defined specifically by Customer to
ensure performance of ST-120 to Customer’s
desires
73.4” [1,864 mm] min from top of rotary
144.9” [3,679 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)
Required length to rear of column
Varies the clamp force proportionally to torque
setting
Ft-lbs
Torque wrench relative to datum position
Position relative to datum
Positive position to +/-10mm at datum
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]
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
3-1/2" (drill pipe)
10" (drill collar)
10.3" [262 mm] roller to roller
4
80 rpm nominal on 5” drill pipe
4
60 rpm
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 Spin-out speed max (6-5/8" 60 rpm
DP):
Spin-in torque at stall: 3,000 ft lb [4,067 Nm] nominal on 5" drill pipe
Spin-out torque at stall: 3,000 ft lb [4,067 Nm] nominal on 5" drill pipe

Torque Wrench
Minimum pipe size capacity: 3-1/2" (drill pipe) – 4” tool joint
Maximum pipe size capacity: 10" (drill collar)
Makeup torque (maximum): 100,000 Ft-lb [135,582 Nm]
Breakout torque (fixed): 120,000 Ft-lb [162,698 Nm]
Torque range adjustable: Yes
Clamp force adjustable: A function of Torque setting
Degrees of rotation: 60°
Length of stroke (torque): 10" [254 mm]
Length of stroke (clamp): 4.5" [114 mm]
Cylinder bore (torque): 5" [127 mm]
Cylinder bore (clamp): 7" [178 mm]

Horizontal Movement
Deploy type: Hydraulic
Number of deploy cylinders: 2
Speed: 12”/sec [0.30 m/sec.], nominal

Vertical Movement
Drive type: Hydraulic
Number of cylinders: 1
Vertical movement: 42" [1,067 mm]
Speed: 5"/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: ASTM A36 Steel
Piston: ASTM A36 Steel
Rod: 17-4 PH, chrome plated
Seals: BUNA-N
Hydraulic tube: Stainless steel
Hydraulic tube/hose fittings: 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.

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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.

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 controls with capabilities of interfacing
with a PLC. The wireless remote controls will be the standard auto controls for the ST-
120. The wireless control box 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).

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 ST-
120 is raised at 4.7 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.

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 ST-
120 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 ST-
120 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 right 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 and a stranded pair cable, and one single conductor
ground cable) bundled together in a protective wrap.

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 Drain

Supply
Return

Figure 6. 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
 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 use a bit breaker. The ST-120 can rotate a tubular or sub
immediately above a drill bit with the torque wrench while the drill bit is held stationary
in a holding fixture (bit breaker box).

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  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.
 Selecting destination, setting trip mode, setting torque, selecting normal or slow mode.

Configuration Setup

The following Amphion 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 - well center deploy, Spin Wrench and Torque Wrench
heights are adjustable
 Setup Foxhole®/Mousehole Positions - Foxhole®/Mouseholes can be selected and
deploy
 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
use of an HMI screen and / or other controls. 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.

Manual vs. Maintenance Mode

Manual control of the ST-120 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 a keyed switch in the derrick mounted junction box. No interlocks are enforced in
this mode as this type of operation is intended to be used for maintenance and emergencies
only.

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 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).
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 torquing
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
a 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.
4. Spin Wrench Clamp Interlock – The up/down adjustment of the spin wrench is
disabled while the spin wrench is clamped.
5. Torque Sequence Interlock – This interlock does not allow the torque sequence to
begin until the clamp pressure has reached a steady state. 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.
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. See bullets about non-driven 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.

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 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)

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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 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

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.

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
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 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 0-
3000 psi
6. Makeup/Breakout Pressure Transducer – Provides pressure feedback to determine
full make up or breakout position, 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 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.
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 when spin wrench or torque wrench
shoulders a pipe connection during any sequence.

E-STOP

Three E-STOP buttons are located on 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.

The wireless remote is also equipped with an e-stop.

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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. 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 inch per second.

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. Slewing speed will be set at 1 rpm when fully
retracted, but is reduced to a slower speed (less than 1 rpm) when 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)

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 5. Home Position (requires set value from arm extend/retract linear transducer and
slewing encoder)
6. Tool Joint Length (for tool joint sensing)
7. Drill Pipe / Drill Collar 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.

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 ST-
120 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
preformed:

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 setting which will be displayed on the digital
display.

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 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
3. Actuate the TW function in the break position until it stops. While holding the TW
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 7. 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.

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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.
4. Raise the spin wrench six inches to allow for thread compensation.
5. Activate the spin wrench to clamp on the drill pipe using the SW-CLAMP function.
While the SW-CLAMP 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
SW-CLAMP functions and activate the SW-UNCLAMP function to unclamp the spin
wrench from the drill pipe.
6. The upper torque wrench is indexed 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.
7. Activate the torque wrench to clamp on the tubular using the TW-CLAMP function and
hold. This clamps both the upper and lower clamp cylinders at proper clamping
pressure.
8. 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 6 thru 8.
9. Activate the TW-UNCLAMP, to retract the upper and lower jaws away from the drill
pipe.
10. Once the torque wrench and spin wrench are unclamped and the torque wrench has
been returned to its “home” 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.
11. 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 Iron Roughneck is fully retracted and 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.
4. The upper torque wrench is indexed to the BREAK-OUT position by using the TW-
MAKE 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.

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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).
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.
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 its “home” 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.

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 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 Action Required by tool to move to next step

X Maintained from start or previous step
X Spin wrench raised to certain elevation (refer to thread compensation section)
X 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

Auto Makeup Sequence, Assuming all user info is Preset
1 2 3 4 5 6 7 8 9
Extend X
Retract X X
TW Clamp X X
TW Unclamp X X 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
Wrench
Center X X X X
SW Clamp X X
SW Unclamp X X X X X X X

Table 2. Auto Breakout Sequence

Auto Breakout Sequence, Assuming all user info is Preset
1 2 3 4 5 6 7 8 9
Extend X
Retract X X
TW Clamp X X
TW Unclamp X X X X X X X
Raise X
Lower X
SW Raise X
SW Lower
Make X X
Break X
Spin Out X X
Wrench
Center X X X X
SW Clamp X X X X
SW Unclamp X X X X X

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Table 3. Auto Power Slips Mode Sequence
Auto Power Slips Mode Sequence, Assuming all user info is Preset
1 2 3 4 5 6 7 8 9
Extend X
Retract X
TW Clamp X X
TW Unclamp X 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 X
SW Clamp X X X X
SW Unclamp X X X X X

Table 4. Auto TDS Backup Sequence

Auto TDS Backup Sequence, Assuming all user info is Preset
1 2 3 4 5 6 7 8 9
Extend X
Retract X X X
TW Clamp X X
TW Unclamp X X X X X X X
Raise X
Lower
SW Raise
SW Lower
Make
Break
Spin Out
Wrench
Center X X X X
SW Clamp
SW Unclamp

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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.

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