Varco HT-Tong HT14 User manual

Revision -, October 2003
Rev A, December 2004
HT-Tong
User's Manual
HT-Tong
User's Manual
pn 50006190

© Copyright 2004 Varco LP. All rights reserved.
Varco is a registered trademark of Varco I/P reg. U.S. Patent & Trademark Office. 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 IP®.
All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective
owners. Information in this manual is subject to change without notice.

Table of Contents
Chapter 1: General information
How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Special information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Caution: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Warning: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Warning plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
HT-Tong restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Design standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Chapter 2: General specifications
Specifications, requirements & sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Part numbers, ratings & weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Chapter 3: Lubrication and maintenance
Recommended General Purpose EP grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Daily inspection schedule (when HT-Tong is in use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
6 Monthly inspection schedule (when HT-Tong is in use) . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Magnetic Particle Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Acceptance criteria for MPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Torque test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Maximum allowable wear to maintain 100% torque rating . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Shop repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Changing dies/inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Chapter 4: Installation and commissioning
General procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Table of Contents
Chapter 5: Operations
Changing size components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Changing dies/inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Lug jaw removal for changing sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Applying make up torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Direction of pulling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Chapter 6: Assembly and dis-assembly
Head assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Disassembly of the hanger and lever assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Chapter 7: Trouble shooting
Overview possible problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Chapter 8: Appendixes
Summary of risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
General conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Torque values (US) for bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
Torque values (metric) for bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Chapter 9: Drawings and Parts Break Down
Added parts jaw assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-31
HT-14 additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
HT-35 additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
HT-55 additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
HT-65 additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-32
HT-100 additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
HT-200 additional parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33
Parts lists and exploded views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Parts list HT 14 manual tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34
Exploded view HT-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-35
Parts list HT 35 manual tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-36
Exploded view HT-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-37
Parts list HT 55 manual tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-38
Part list HT 65 manual tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-40
Exploded view HT-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-41
Parts list HT100 manual tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-42
Exploded view HT-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-43
Parts list HT 200 manual tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-44
Exploded view HT-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
Parts list HT 50 casing head assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-46
Casing head assemblies overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-48
Critical area drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49

General information
1
HT-Tong 1-5
General information
How to use this manual
This manual is divided into 9 sections. Each page within each section is marked with a
black tab that lines up with the thumb nail index tabs for each section. You can quickly find
each section without looking through a full table of contents. Use the symbols printed at
the top corner of each page as a quick reference system. Each section uses a different
symbol.
When applicable, each section includes:
1. A table of contents, or an illustrated view index showing:
RMajor assemblies, system or operations
RPage references to descriptions in text
2. Disassembly / assembly information and tools
3. Inspection information
4. Testing / trouble shooting information
5. Repair information
6. Adjustment information
7. Torque values
Special information
Detailed descriptions of standard workshop procedures, safety principles and service
operations are not included. Please note that this manual may contain warnings about
procedures which could damage equipment, make it unsafe, or cause PERSONAL
INJURY. Please understand that these warnings cannot cover all conceivable ways in
which service (whether or not recommended by Varco) might be done, or the possible
hazardous consequences of each conceivable ways. Anyone using service procedures or
tools, whether or not recommended by Varco Systems, must be thoroughly satisfied that
neither personal safety nor equipment safety will be jeopardized.
All information contained in this manual is based upon the latest product information
available at any time of printing. We reserve the right to make changes at any time without
notice.
Intended audience
This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information
contained herein. Varco®2004, Varco LP, will not be held liable for errors in this material,
or for consequences arising from misuse of this material.
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings provide readers with additional information, and to advise
the reader to take specific action to protect personnel from potential injury or lethal
conditions. They may also inform the reader of actions necessary to prevent equipment
damage. Please pay close attention to these advisories.

General Information
1
1-6 HT-Tong
Note:
Caution:
Warning:
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or
screen snapshots for use in identifying parts or establishing nomenclature, and may or
may not be drawn to scale.
For component information specific to your rig configuration, see the technical drawings
included with your Varco documentation.
Safety Requirements
Varco equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in Varco manuals are the recommended methods of performing
operations and maintenance.
i
The note symbol indicates that additional information is
provided about the current topics.
!
The caution symbol indicates that potential damage to
equipment or injury to personnel exists. Follow instructions
explicitly. Extreme care should be taken when performing
operations or procedures preceded by this caution symbol.
The warning symbol indicates a definite risk of
equipment damage or danger to personnel. Failure
to observe and follow proper procedures could
result in serious or fatal injury to personnel,
significant property loss, or significant equipment
damage.
!
CAUTION: To avoid injury to personnel or equipment
damage, carefully observe requirements outlined in this
section.

General information
1
HT-Tong 1-7
General System Safety Practices
The equipment discussed in this manual may require or contain one or more utilities, such
as electrical, hydraulic, pneumatic, or cooling water.
RIsolate energy sources prior to beginning work.
RAvoid performing maintenance or repairs while the equipment is in operation.
RWear proper protective equipment during equipment installation, maintenance or
repair.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.
Contact the Varco Drilling Equipment training department for more information about
equipment operation and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
described. Varco recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures or using tools not specifically recommended by Varco.
Replacing Components
RVerify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installation.
RReplace failed or damaged components with Varco certified parts. Failure to do so
could result in equipment damage or injury to personnel.
!
CAUTION: Read and follow the guidelines below before
installing equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.
!
CAUTION: Personnel should wear protective gear during
installation, maintenance, and certain operations.

General Information
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1-8 HT-Tong
Routine Maintenance
Equipment must be maintained on a routine basis. See this manual for maintenance
recommendations.
Proper Use of Equipment
Varco equipment is designed for specific functions and applications, and should be used
only for its intended purpose.
Identification numbers
You will find the serial number of the tool stamped into the lever.
Warning plates
Warning plate p/n # 52319
Warning plate p/n # 201350
!
CAUTION: Failure to conduct routine maintenance could
result in equipment damage or injury to personnel.
WARNING: Warning plates must be present on the HT-
Tong. Do not remove the labels. When a label or
warning plate has disappeared, it must be replaced.
WARNING
Dies and inserts could be hazardous if improperly handled, installed or removed.
Such misuse could cause serious injury to personnel. Wear eye protection at all
times when installing or removing. Wear gloves when handling.
CAUTION: Manual tongs are critically loaded tools when used to torque tubular goods.
Line pull on lever should be at 90 degrees (a right angle) to axis of lever. The full length of
the tong die must be engaged with tool joint when making up or breaking out connections.
Running tong dies on irregular surfaces of tool joints, such as hard banding, must be
avoided. Torque on tongs should not exceed manufacturer’s rating at any time.
WARNING: Only Varco BJ parts should be used. Manual tongs are cast alloy heat
treated steel and should not be welded in the field. Improper welding can cause cracks and
brittleness in heat affected areas which can result in drastic weakening of the part and
possible failure. Repairs involving welding and/or machining should be performed only by
an authorized Varco BJ repair facility. Using a manual tong that has been improperly welded
or repaired can cause failure which may result in serious bodily injury or property damage.

General information
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HT-Tong 1-9
Lifting
The lifting procedures should carefully be observed and carried out according to the
manual.
HT-Tong restrictions
The HT-Tong is designed to be used as a tong for making up and breaking out tubular
connections, and must not be used for any other purpose.
Limited warranty
The warranty will be void if the HT-Tong or parts were either:
Runauthorized modified, repaired or serviced
Rreplacement parts not manufactured by Varco were utilized
Rnot properly stored or maintained
Design standard
The HT-Tong complies with API-7K and with the Directive 98/37/EC (Machinery Directive)

General Information
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