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Automated Rig Equipment
• Mechanized rig systems - All-in-one technology - Control systems - Iron roughnecks & drillpipe tongs - Pipe-handling equipment - Positioning systems - Power tongs - Rig equipment packages
Well constructionCompletion
Production
Intervention
Drilling
Evaluation
Engineered efficiency
Safe, efficient, well construction through engineered technology
© 2010 Weatherford. All rights reserved. 1
Contents
Introduction Offering More Innovative Rig-Mechanization Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Why Weatherford? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Product Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Research and Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Our Enterprise Excellence Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rig-Equipment PackagesOptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pipe-Handling EquipmentIron Derrickman RG Pipe-Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Iron Derrickman S3 Pipe-Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Stabberless® Single-Joint Elevator for Drillpipe and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Iron Roughnecks and Drillpipe TongsTorkWrench™ 10-100 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24TorkWrench 10-100 Mobile Bucking Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26SpeedTork™ Hydraulic Drillpipe Tong 8.0-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Positioning SystemsMiniScope Tong-Positioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32PowerScope® Tong-Positioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34PowerFrame® II Tong-Positioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36PowerFrame III Tong-Positioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control Systems HiPer™ Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power Tongs5.5-15 Hydraulic Tubing Tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447.6-30 Hydraulic Tubing Tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4614-50 High-Torque Casing Tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4816-25 Hydraulic Casing Tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5024-50 High-Torque Casing Tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
All-in-One TechnologyTorkWrench™ 10-100 All-in-One System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56UniTong™ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Contents
2 © 2010 Weatherford. All rights reserved.
Monitoring and Testing ETG® Electronic Torque Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62ExTG™ Electronic Explosion-Proof Torque Gauge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Bucking UnitsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Torque Process Control (TPC) for Bucking Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Oilfield Bucking Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Power UnitsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Electric Power Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Diesel Power Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Mud PumpsEllis-Williams™ Mud Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Ironman™ Mud Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Pump Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Mud Pump Expendables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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© 2010 Weatherford. All rights reserved. 3
4 © 2010 Weatherford. All rights reserved.
Introduction
Offering More Innovative Rig-Mechanization Solutions
Weatherford’s rig systems offer a combination of experience and innovation.
Nearly 50 years of experience building casing and tubing tongs, including 25 years building drillpipe tongs, combine with the innovation of our Iron Derrickman® pipe-handling and offline makeup systems plus the creativity of the recently introduced UniTong™ All-in-One solution. These add up to a game-changing offering of package options for advanced rig equipment that surpasses anything available in today’s market.
Choose from a multitude of options for ultimate flexibility.Weatherford offers a mechanized option for any rig environment. Our packages provide solutions for making up any kind of tubulars—from drillpipe to drilling tools, heavy-wall casing—down to small diameter and chrome tubing. The majority of our rig equipment is designed to fit into a modular system, and our innovative technologies are customizable to all types of rigs—from land rigs to jackups and from semisubmersibles to drill ships.
Our modular, plug-and-play approach to rig mechanization provides various combinations of positioning devices and power tongs, depending on the rig environment. This approach provides a specific tool for each individual task. Our fully integrated control systems not only provide operation of our equipment, but are completely compatible with the rig’s drilling controls and zone management system to enhance safety and improve critical path efficiency.
Weatherford also offers the UniTong system, the world’s first field-proven, all-in-one tong that concentrically parks around the drillstring, covering the entire area from connection to disconnection of the tubular. Three clamp-housing models accommodate all pipe dimensions, ranging in size from 2-7/8 to 20 in. (7 to 51 cm) and a torque capability of 0 to 150,000 ft/lb (0 to 205,000 N•m).
What are Mechanized Rig Systems?
Mechanized rig systems improve rig floor operations by helping operators run tubing, casing, and drillpipe more safely and efficiently during demanding drilling operations. Weatherford’s mechanized rig systems are available in different levels of complexities, from a simple installation of a MiniScope positioning arm with no need for a major retrofit to a fully automated system with the PowerFrame® II positioning system and integration into a driller’s console.
© 2010 Weatherford. All rights reserved. 5
Offering More Innovative Rig-Mechanization Solutions
Introduction
No matter which approach you choose, our mechanized rig systems are specifically designed to be a powerful and compact solution for your rig.With rig floor space at a premium, we have engineered equipment that is space- saving and functional. All our solutions can be run by a single operator. Once a task is completed, the specific modules are easily removed from the well center and away from drilling operations. This feature enables the majority of necessary maintenance work to be done offline, saving valuable rig time.
A safer, more efficient rig environment.More than 30 percent of production time is spent tripping drillpipe or running casing and tubing. As rig costs rise, speed becomes even more critical—at the same time torque requirements are higher. Especially as operations move into ultradeepwater, operators are seeking new techniques and technologies that save time. Plus, manual tubular running operations pose a significant safety risk to personnel. Stabbing operations in particular are often the hardest and most difficult tasks to perform while casing is being run.
Weatherford’s innovative rig-mechanization systems• Providing a safer work
environment by removing personnel from the derrick and rig floor
• Increasing operational efficiency and achieving reduced rig operating times that were once thought to be impossible
• Requiring only a single person to operate equipment, minimizing overall personnel needs
6 © 2010 Weatherford. All rights reserved.
More experience than any other global provider of rig systems technology. We have been designing and manufacturing iron roughnecks and drillpipe tongs for more than 25 years, and tubing and casing tongs for almost 50 years. We have led the way in the development of mechanized technology since 1994. Over the past 15 years, we have introduced mechanization to operators around the globe, increasing operational efficiency and improving personnel safety.
Innovative technology that is unmatched in the industry. We have developed many of the most game-changing technologies available on the market today, including dozens of unique solutions that were custom-designed for specific operator requirements. Our technologies are field-proven and reliable.
Robust global resources. Weatherford’s existing infrastructure spans more than 100 countries, including 125 manufacturing locations, supporting more than 800 service bases, and 16 state-of-the-art training facilities. With manufacturing and engineering facilities in Houston (USA), Calgary (Canada), Kristiansand (Norway) and Langenhagen (Germany), the global infrastructure of our Tubular Running Services group fully supports our Mechanized Rig Equipment business. Our R&D budget for tubular running services alone was more than US$15 million in 2007. Our highly trained engineers have the expertise to partner with our clients to develop customized solutions for any need.
Full service on-site to support our equipment. Almost anywhere around the globe you get the well-known Weatherford service. It doesn’t stop with the equipment. We offer 24/7, decentralized technical and engineering support for all our installations in all regions. Our global training program ensures local expertise whether the equipment is run in Singapore or the Gulf of Mexico. Local technical support personnel are vigorously trained before the release of new equipment. And our global training and competency standards ensure that we provide the same level of service quality in every location.
Why Weatherford?
Introduction
© 2010 Weatherford. All rights reserved. 7
Product Quality
Introduction
Tubular running systems are part of Weatherford’s wide range of well construction offerings; and these systems facilitate safe and efficient running of tubulars—minimizing wellsite risk and reducing nonproductive time (NPT). As the largest casing/tubing running company in the world, Weatherford offers an extensive selection of advanced mechanized tubular running equipment. Our many safety- and efficiency-enhancing innovations include modular rig mechanization systems that adapt to any rig environment, from land rigs to fifth-generation semisubmersibles for deepwater service. Our Stabberless® system—a remotely controlled pipe alignment system—eliminates one of the most dangerous jobs on a rig.
Weatherford maintains three dedicated tubular running manufacturing facilities, located in Langenhagen, Germany; Kristiansand, Norway; and Calgary, Canada. Working in close coordination with one another and additional Weatherford locations, these facilities design, fabricate and test tubular running systems and accessories, and engage in research and development (R&D) related to the products they make.
Product portfolioBacked by its strong patent portfolio, Weatherford is committed to the ongoing development of technology that helps clients maximize the value of their oil and gas assets. Weatherford conducts extensive R&D on tubular running equipment at its Langenhagen, Kristiansand and Calgary facilities. Major areas of focus include:
• computer-based, remote- controlled applications designed to enhance efficiency
• more cost-effective equipment
• specialized monitoring systems
• Web-based maintenance and trouble-shooting applications
• workspace safety
Quality controlIn accord with the company-wide Enterprise Excellence Process (EEP)—guidelines that help maximize performance in all critical aspects of Weatherford’s business—Weatherford’s tubular running manufacturing plants maintain the highest industry quality, health, safety, security and environmental (QHSSE) standards. All four have ISO- and API-certified quality management systems, as well as on-site QHSSE professionals, to help them achieve QHSSE objectives. Extensive training and competence assurance further assist efforts to produce high-quality tubular running products and to ensure the safety of manufacturing personnel.
Weatherford dedicates more than US$200 milion to research and development.
8 © 2010 Weatherford. All rights reserved.
Research and Development
Introduction
Tubular running R&D effortsWeatherford manufactures and assembles a full line of tubular running systems and accessories at its Langenhagen, Kristiansand and Calgary facilities. Specific products include:
• bucking units• casing running and drilling systems• chrome-handling systems• handling tools• Iron Derrickman® pipe-handling solutions• monitoring and testing equipment• pipe-handling equipment• positioning systems• power tongs• power units• top drives
2000 2001 2002 2003 2004 2005 2006 2007 2008 projected
R&D Investment
Additions 2008-200917 Service Locations
3 R&D Facilities5 Training Facilities
Additions 2008-200917 Service Locations
3 R&D Facilities5 Training Facilities
International303 Service Locations
64 Manufacturing Facilities
International303 Service Locations
64 Manufacturing Facilities
GENEVA
© 2010 Weatherford. All rights reserved. 9
Introduction
Our Enterprise Excellence Policy
Weatherford International Ltd. is committed to pursuing the highest standards of excellence in all our business processes. It is the policy of the company to:
• comply with all applicable laws and regulations of the areas within which we operate or exceed compliance where our stated expectations require;
• conduct all operations in a manner that promotes safe work practices and minimizes risk to our employees, our communities and the environment;
• implement the programs, training and internal controls necessary to achieve our goals.
ObjectiveTo achieve complete internal and external client satisfaction and to conform to mutually agreed requirements the first time, every time, while protecting the well-being of all personnel, assets and the environment.
This objective is achieved through a commitment to understanding and applying defined business processes, complying with established standards and implementing continual improvements. Paramount attention will be given to achieving error-free processes, products and services and maintaining a safe environment.
CommitmentWe empower each employee to take the appropriate action to ensure compliance with this policy and objective.
This policy and the associated objective and commitment statement describe the targets we have set ourselves in achieving excellence. The principles described in this document define the corporation’s expectations that must be incorporated into the culture of the enterprise in order to achieve excellence.
The structure of the basic competency system model is known as the “Triple 5,” which refers to the five levels of personnel the system addresses, the five components of assessment and the five methods of assessment.
Rig-EquipmentPackages
12 © 2010 Weatherford. All rights reserved.
Option 1• TorkWrench™ iron roughneck
• MiniScope tong-positioning system
• Control: pneumatic from the roughneck or safe location
Implementation of standard casing, tubing, and riser tongs is possible (with free-floating backup).
Equipment Packages
The MiniScope tong-positioning system is used to reach one location on the rig floor. This system is not used to serve multiple stations simultaneously, such as the well center and mouse hole. The MiniScope system is manually adjusted to change direction. This option is ideal for land rigs and is not applicable to semi-submersible rigs or drill ships.
Option 2• TorkWrench iron
roughneck
• PowerScope® system
• Control: pneumatic from the roughneck or safe location
Implementation of casing, tubing, and riser tongs is possible (with free-floating backup).
The PowerScope system’s rotational angle capability enables this equipment package to simultaneously serve more than one station, such as the well center and mouse hole. This package is available in a fully mechanized version. This option is ideal for rigs of any type or size. The PowerScope system has proven to be successful in high-motion (rough sea) environments.
Option 3• TorkWrench iron roughneck
• PowerFrame® III
• Control: pneumatic from the roughneck or safe location
Implementation of casing and tubing tongs is possible (with free-floating backup).
The PowerFrame III tong-positioning system runs on tracks and can be adapted to an existing tracking system. The system can be used with mechanized tong modules. This package eliminates any suspension line and is ideal for semisubmersible rigs and drill ships with a more spacious rig layout.
Options
Rig-Equipment Packages
© 2010 Weatherford. All rights reserved. 13
Option 4• TorkWrench™ iron roughneck mechanized
• PowerFrame® III system
• Control: remote controlled with HiPer™ control system
Implementation of mechanized casing and tubing tongs is possible (with free-floating backup).
The PowerFrame III tong-positioning system runs on tracks, and can be adapted to an existing tracking system. This package eliminates any suspension line and is ideal for semisubmersible rigs and drill ships with a more spacious rig layout.
Option 5• TorkWrench iron roughneck
mechanized
• PowerFrame II mechanized
• Control: remote controlled with HiPer control system
Implementation of mechanized casing and tubing tongs is possible (with free-floating backup).
Implementation of riser tong possible with special adapter.
The PowerFrame III tong positioning system runs on tracks and can be adapted to an existing tracking system. This package eliminates any suspension line and is ideal for semi-submersible rigs and drill ships with a more spacious rig layout.
Option 6• TorkWrench
iron roughneck mechanized
• PowerScope mechanized
• Control: remote controlled with HiPer control system
Implementation of mechanized casing, tubing and riser tongs is possible (with free-floating backup).
The PowerScope system’s rotational-angle capability allows this equipment package to simultaneously serve more than one station, such as the well center and mouse hole. This option is ideal for rigs of any type or size.
Rig-Equipment Packages
Options
Pipe-Handling
Equipment
16 © 2010 Weatherford. All rights reserved.
Weatherford’s Iron Derrickman model RG pipe-handling system marks a major advancement in hands-free handling of tubulars on double and triple rigs. This patent-pending, racking-board-mounted system lifts up to 10,000 lb (4,536 kg) at a 7-ft (2-m) radius and eliminates the need for personnel on the derrick when tripping or making connections.
Designed to mount with little or no modification to standard double and triple masts, the system vertically lifts and racks double and triple stands of drillpipe, heavyweight drillpipe, and drill collars. The design combines innovative mechanical engineering, positive control of hydraulic closed-loop proportional circuitry, electrical remote-motion controls, and a human-machine interface screen for ease of operation.
Applications• Double and triple masts of onshore and offshore rigs
• Small jackup rigs with pyramid-style derricks
Features, Advantages and Benefits• The Iron Derrickman RG system operates from the rig floor by portable or wired
remote control, significantly enhancing safety by removing personnel from the mast and floor when racking or unracking pipe during tripping operations.
• Rig-up and rig-down of this compact, lightweight system is simple; the system is attached to, or is built as part of, the racking board.
• The unique rotating gate design of the Iron Derrickman RG system offers simplicity of operation, low-mast loading characteristics, and smooth control of all pipe movements. The system lifts the stand, moves it into the rotating gate, captures and holds the stand while the pipe handler rotates from well center toward the setback area, and automatically racks the stand in the fingerboard.
• Wind walls may be omitted from the fingerboard area, as the pipe-tripping operations are remotely controlled without derrick personnel.
Iron Derrickman® RG Pipe-Handling System
Pipe-Handling Equipment
© 2010 Weatherford. All rights reserved. 17
Iron Derrickman® RG Pipe-Handling System
Specifications
Length (ft/m) 30 9.1
Weight (lb/kg) 7,000 3,175
Lifting capacity (lb/kg)a 10,000 4,536
Tubular handlingDrillpipe (in.) ≤ 5-7/8
Heavyweight drillpipe (in.) ≤ 5-1/2
Collars (in.)b ≤ 8
HydraulicsHydraulic power unit (HP) 35
Flow (gpm/lpm) 20 76
Pressure (psi/bar) 3,000 207
aAt 7-ft (2-m) radiusbThe system can lift drill collars up to 7 in.
Pipe-Handling Equipment
18 © 2010 Weatherford. All rights reserved.
Iron Derrickman® S3 Pipe-Handling System
Weatherford’s Iron Derrickman model S3 is a racking board and pipe-handling system that is designed to enhance safety and efficiency by eliminating the need for personnel on the racking board and drill floor during tripping operations. The Iron Derrickman S3 system lifts and smoothly racks triple stands of drillpipe, heavyweight collars, and drill collars with programmed sequential movements. The system can use existing racking-board mounts and rigs up and/or down quickly with the optional racking-board winch after initial installation.
When paired with Weatherford’s offline stand-building solutions, the Iron Derrickman S3 provides substantial time savings by building stands away from the critical path without interrupting drilling operations.
Applications• Medium to large triple land rigs
• Jackups, platforms and barges
Features, Advantages and Benefits• The Iron Derrickman S3 system operates from the driller’s cabin or rig floor with
both portable and wired controls, significantly enhancing safety by removing per-sonnel from the mast and floor when handling tubulars during tripping operations.
• The system’s smooth, repetitive movements improve tripping efficiency.
• Easy integration with zone management systems enhances operational efficiency and flexibility.
Pipe-Handling Equipment
© 2010 Weatherford. All rights reserved. 19
Iron Derrickman® S3 Pipe-Handling System
Specifications
Lifting capacity (lb/kg) 7 ft (2 m) 14 ft (4 m)
15,000 6,804
6,000 2,722
Drillpipe, weights and collars (in.) 2-7/8 to 8-1/4
Total weight* (lb/kg) 9,500 4,309
Hydraulic requirements 35 gpm at 3,000 psi constant pressure
Maximum reach (ft/m) 14 4.27
Options• Racking-board camera system
• Remote log-in diagnostic service
• Offline stand-building options
*Without racking board
Pipe-Handling Equipment
20 © 2010 Weatherford. All rights reserved.
Pipe-Handling Equipment
Stabberless® Single-Joint Elevator for Drillpipe and Tubing
Weatherford’s Stabberless single-joint elevator (SSJE) is designed to lift single joints of drillpipe or tubing without the potential safety incidents associated with variable-sized-body elevators. Several key features enhance safety by addressing such issues as incorrect latching, safety-pin problems, incorrect selection of blocks, and hinge-pin failures. In addition, the SSJE enhances efficiency in time-critical operations.
The Stabberless single-joint elevator is manufactured and tested to API 8C specifications.
Applications• Lifting single joints of 3 1/2- to 6 5/8-in. drillpipe with 18° beveled tool-joint
contact shoulder
• Lifting single joints of 3 1/2-in. tubing with 12° beveled tool-joint contact shoulder
Features, Advantages and Benefits• The Stabberless single-joint elevator is double-hinged for easy installation and
removal from joints.
• For operational efficiency, the SSJE is substantially lighter than variable-sized elevators.
• The elevator’s design eliminates variable-sized inserts. This feature removes the potential of incorrectly sized inserts being used for lifting and the resultant safety hazards.
• The size of the elevator is hard-stamped on the tool body, simplifying identification and reducing potential for errors which may result in dropped objects.
• The tapered contact shoulder optimizes alignment for lifting standard drillpipe and tubing, minimizing the potential of damage to pipe during lifting operations.
• The locking pins and related design elements are designed to provide several advantages and benefits:
– a pin on each side enables left- or right-handed use and it can always be unlatched from the topside of horizontal pipe.
– pins cannot be removed, so there is no requirement for secondary retention devices such as chains.
– the positive latch mechanism confirms the pins are locked, ensuring safety.
© 2010 Weatherford. All rights reserved. 21
Pipe-Handling Equipment
Stabberless® Single-Joint Elevator for Drillpipe and Tubing
Size (in.)
Tubing/Drillpipe
Part Number
Contact Shoulder
Load Rating (ton/kg)
Weight (lb/kg)
3-1/2 EU Tubing 1227212 12°
5 5,080
30.4 13.8
3-1/2 EU
Drillpipe
1204918
18°
31 14.1
4 IU 1204919 32.1 14.6
4 EU
1250108 33.7 15.34-1/2 IU
4-1/2 IEU
4-1/2 EU1204920 35.5
16.15 IEU
5-1/2 IEU 1203868 36.5 16.6
5-7/8 IEU 1204921 37.917.2
6-5/8 IEU 1204922 40.2 18.2
Specifications
Iron Roughnecks
and Drillpipe
Tongs
24 © 2010 Weatherford. All rights reserved.
Iron Roughnecks and Drillpipe Tongs
Features, Advantages and Benefits• High-torque wrenching and spinning units combine to
provide faster makeup and breakout operations.
• Three-jaw gripping system enables equal load distribution and easy jaw and die exchange, eliminating shear forces on tool joints and reducing backup clamping pressure while spinning.
• Pneumatic “intelligent” control box can be disconnected from tong unit and relocated into safe area.
• Free-floating spinning system follows the movement of pipe, protecting the tool joint and minimizing drillpipe damage caused by conventional systems.
Applications• Running drillpipe, tripping standard- or premium-
connection drillpipe, offline stand building, and bit breaking
• Bottomhole assembly makeup and installation
Weatherford’s patented TorkWrench 10-100 iron roughneck is the performance-leading hydraulic iron roughneck in its class, providing up to 100,000 lbf-ft of torque for the toughest makeup and breakout operations. The TorkWrench 10-100 has a compact design with fewer moving parts that increase overall reliability and provide outstanding high-speed breakout performance.
The TorkWrench 10-100 can be used for most oilfield connections including drillstring components, tools, packers, couplings, and
valves.
Ancillary features include the PowerFrame®, PowerScope®, and MiniScope automated tong-positioning systems, which greatly increase productivity
by providing the means to work offline to make up and break out drill bits and bottomhole assemblies clear of the rotary table and out of
the critical path.
TorkWrench™ 10-100 Iron Roughneck
© 2010 Weatherford. All rights reserved. 25
Iron Roughnecks and Drillpipe Tongs
Options• PowerFrame® tong positioning system
• PowerScope® system
• MiniScope system
• HiPer™ remote-control system
• Electric and hydraulic power units
• Electronic torque gauge (ExTG™)
• Stabbing guide and tool joint finder (for remote-controlled, all-in-one version)
• Automated thread cleaning and doping (for remote-controlled, all-in-one version)
• Automated mud bucket (for remote-controlled. all-in-one version)
Specifications
Applicable rig floor size Small to large
Maximum pressure 3,000 psi 21 MPa
Maximum oil flow 40 to 79 gpm 151 to 299 Lpm
Wrenching cylinders 2
Clamping range 2-7/8 to 10 in. 73 to 254 mm
Maximum makeup torque 100,000 lbf-ft 135.56 kN•mMaximum breakout torque
Vertical travel lifting capacity 39.3 in. 1,000 mm
Horizontal travel lifting capacity 78.7 in. 2,000 mm
Wrenching angle per stroke 40°
Power supply Open/close center
Controls Onboard or various remote
Independent spinner BHA and thread travel compensation
API 7K
TorkWrench™ 10-100 Iron Roughneck
26 © 2010 Weatherford. All rights reserved.
Iron Roughnecks and Drillpipe Tongs
Weatherford’s TorkWrench 10-100 mobile bucking unit is a variation of the TorkWrench iron roughneck designed for making and breaking joints of drillpipe that have diameters ranging from 2-7/8 to 10 in. The mobile bucking unit enables offline makeup of drilling tools, drillpipe and bottomhole assemblies (BHAs), providing significant time savings.
The mobile bucking unit provides up to 100,000 lbf-ft of torque for the toughest makeup and breakout operations. A robust, compact design with fewer moving parts increases overall reliability and provides outstanding high-speed breakout performance in the workshop or on the rig for most oilfield connections including drillstring components, tools, packers, couplings, and valves.
Applications• Offline makeup of drillpipe, drill collars, BHAs, and drilling tools
Features, Advantages and Benefits• High-torque wrenching and spinning units combine to provide faster makeup and
breakout operations.
• Three-jaw gripping system enables equal load distribution and easy jaw and die exchange, eliminating shear forces on tool joints and reducing backup clamping pressure while spinning.
• Top-loading capability does not require pipe-feeding transport, conserving valuable space and enhancing operational efficiency.
• Electronic control system enables remote operation for enhanced rig safety.
• Free-floating spinning system follows the movement of pipe, protecting the tool joint and minimizing drillpipe damage caused by conventional systems.
• Compact design can be used on pipe deck, enabling fast and easy rig up and rig down, enhancing operational efficiency.
TorkWrench™ 10-100 Mobile Bucking Unit
© 2010 Weatherford. All rights reserved. 27
Iron Roughnecks and Drillpipe Tongs
TorkWrench™ 10-100 Mobile Bucking Unit
System Components• TorkWrench mobile bucking unit
• Control cabinet
• Support jacks
• Power unit
All components are installed on a transportation platform.
Specifications
Weight (approximately)
(lb/kg)
DimensionsLength
(extension frames in) (in./mm)
Length (extension frames out)
(in./mm)Width
(in./mm)Height
(in./mm)
Pipe Center Height
(in./mm)33,070 15,000
479.2 12,171.7
614.7 15,613.4
95.2 2,418.1
81.9 2,080.3
66.3 1,684.0
28 © 2010 Weatherford. All rights reserved.
Iron Roughnecks and Drillpipe Tongs
Weatherford’s patented SpeedTork 8.0-70 is a hydraulic-powered drillpipe tong that safely and efficiently makes up and breaks out standard API drillpipe connections and special connections that
require continuous rotation for proper makeup. The SpeedTork tong provides 70,000 lbf-ft torque capacity for drillpipe and drillstring accessories with diameters ranging from 3-1/2 to 8 in. The small footprint and low height add to the overall operational efficiency.
The SpeedTork drillpipe tong is compatible with Weatherford’s PowerFrame® III, PowerScope®, and MiniScope tong-positioning systems and is the ideal solution for nonautomated operation. A smaller 6.6-30 version of the SpeedTork tong is also available.
Applications• Running and pulling 3-1/2 to 8 in. drillpipe
• Performing offline drillpipe makeup and breakout operations
Features, Advantages and Benefits• Special clamping arrangement provides protection for the
operator under high-load conditions for maximum safety.
• Torsion-bar reaction system eliminates shear and bending loads across the tool joint, reducing casing deformation that can affect long-term wellbore integrity.
SpeedTork™ Hydraulic Drillpipe Tong 8.0-70
© 2010 Weatherford. All rights reserved. 29
Iron Roughnecks and Drillpipe Tongs
Options• PowerFrame® III tong positioning system
• PowerScope® system
• MiniScope system
• Electric and hydraulic power units
• Electronic torque gauge
Technical Data
Tool joint range (in./mm) 3-1/2 to 8 88.9 to 203.2
Maximum makeup torque (lbf-ft, N•m) 70,000 94,907
Maximum rotary speed (low gear/high gear) (rpm) 6/60
Torque arm length (in./mm) 40 1,016
Weight (tong and backup) (lb/kg) 5,071 2,300
Length × width × height (tong and backup) (in./mm)
56 × 45 × 59 1,420 × 1,140 × 1,500
Maximum clamping force at backup (lb/kN)
77,175 350
Maximum clamping pressure at backup (psi/bar)
2,030 140
DP 6.6-30 - Tong and BackupPipe size range (drillpipe mode) (in./mm)
3-3/4 to 6-5/8 92.25 to 168.28
Maximum makeup torque (drillpipe mode) (lbf-ft, N•m)
30,000 40,000
Maximum rotary speed–low/high gear at 78 gpm (rpm) 10/45
Torque arm length (in./mm) 30 762
Weight-tong and backup (lb/kg) 3,528 1,600
Length × width × height - tong and backup (in./mm)
60 × 51 × 53 1,532 × 1,306 × 1,342
Maximum clamping pressure at backup (psi/bar)
2,103 145
SpeedTork™ Hydraulic Drillpipe Tong 8.0-70
Hydraulic Oil Specifications
Hydraulic flow (gpm/Lpm) 70 265
Maximum hydraulic pressure (psi/bar) 3,045 210
Recommended hydraulic pressure (psi/bar)
2,500 175
Viscosity at 104°F (40°C) ISO - 32
Operating oil temperature (°F/°C) 122° to 158° 50° to 70°
Filtration 10 μm; SAE class 5 (17/14 - ISO 4406)
Positioning Systems
32 © 2010 Weatherford. All rights reserved.
MiniScope Tong-Positioning System
As torque requirements increase, power tongs are being built stronger and heavier than before. The larger mass of these tongs requires more manpower to maneuver. Alternatively, the larger mass can be efficiently handled by a powered manipulating device, such as the MiniScope tong-positioning system.
The MiniScope tong-positioning system accelerates total makeup time by efficient tong manipulation, saves rig time and enhances safety. Its simple design allows easy transport and fast installation with only minor rig modifications. Then a single operator uses the system to easily—and more safely—maneuver power tongs to and from the well center.
The MiniScope tong-positioning system is designed for small- to medium-size drilling and workover rigs. The system can handle a wide range of tubing, casing and drillpipe tongs, including Weatherford’s 21-300 riser tong, producing up to 300,000 lbf-ft of continuous rotational torque, and offers the following benefits:
One operator, all control. The MiniScope tong-positioning system is lightweight and highly maneuverable because the power tongs are on a suspension line that bears their weight. A single operator easily manipulates the system to push and pull the tongs to and from the well center.
Drilling flat-time reduced. The agility and speed of the MiniScope system facilitate efficient makeup and breakout operations.
Safety, safety and more safety. Single-operator capability reduces risk exposure on the rig floor. And the extra controllability and maneuverability of the MiniScope system help avoid accidents and ensure the precise placement of tongs.
Simple and fast installation. The MiniScope system can be installed quickly, with only minor modifications to the rig. The simple system design makes for easy transport to the site and fast rig-up.
Low maintenance through simplicity. The MiniScope system is very simple and lightweight. Reliability is enhanced because the MiniScope system is powered by the tong power unit and does not absorb the weight of the tongs, which are on a suspension line.
Offline service. The MiniScope system can be easily disconnected from the rig so all service work can be done away from the rig.
The MiniScope tong-positioning system is designed to be used with any of Weatherford’s power tongs:
The compact MiniScope system saves valuable rig floor space and enhances safety with single-operator maneuverability. Here it is working with Weatherford’s compact TorkWrench power tongs, which fit within the rig floor envelopes of small- to medium-size drilling and workover rigs.
Positioning Systems
*First number represents maximum casing, drillpipe or riser size; second number represents maximum torque capability.
Drillpipe tongs• TorkWrench™ iron roughneck• 6.6-30 tong• 8.5-80 tong
Riser tongs• 14-100 hydraulic tong• 21-300 tong
Tubing and casing tongs• 5.5-15* hydraulic tong• 7.6-30 hydraulic tong• 13-100 hydraulic tong• 14-50 high-torque tong• 14-100 hydraulic tong• 16-25 hydraulic tong• 24-50 high-torque tong
© 2010 Weatherford. All rights reserved. 33
MiniScope Tong-Positioning System
Positioning Systems
Specifications
General Temperature Range Comments
Min. Design Temperature °F°C
–4–20
Operational Temperature °F°C
+14 to +122–10 to +50
Miniscope System Comments
Displacement in.mm
131.93.350
Max. Pulling Force kN 20.1
Max. Pushing Force kN 31.4
Weight approx. lbkg
650295
Dimensions(see also Fig. 3.2)
Min. Length
inmm
59.11 500 Without
adapter and bracketMax.
Lengthin.
mm189.04 800
Min. Mounting Height above Rig Floor
in.mm
189.04 800
Max. Mounting Height above Rig Floor
in.mm
142.13 610
Min. Mounting Distance from Well Center
in.mm
155.93 960
Max. Mounting Distance from Well Center
in.mm
196.95 000
Max. Hydraulic Pressure psibar
2 466170
Min. Hydraulic Flow gpmlpm
2.210
Via tong valve section
Filtration µm 25
Technical specifications are subject to change without prior notice.
34 © 2010 Weatherford. All rights reserved.
Positioning Systems
PowerScope® Tong-Positioning System
Weatherford’s PowerScope tong-positioning system is a patented* telescoping device used to enable precise positioning of power tongs. The system allows one-man operation of both remote-control power tongs and semi-mechanized, manually operated power tongs. Position memory is used to ensure accuracy, efficiency, and repeatability when positioning and operating the tongs remotely. For manual operations, the PowerScope system provides sufficient stabilization and force for a single tong operator to manipulate the tongs without assistance from other rig crew members. In most cases the PowerScope system can be installed without obstructing other rig floor operations, and it is easily assembled or disassembled from the pedestal or rig structure without the loss of effective rig time. The PowerScope system enables simple, fast transport and rig-up.
Applications• Manipulation of remotely operated and manual power tongs for casing, tubing,
drillpipe, and production risers
• Use on land rigs, semi-submersibles, drill ships, platforms, and jackups
Features, Advantages and Benefits• Positioning memory enables fast, accurate, and repeatable operation when used
with remote control, increasing efficiency.
• Rotating mounting base provides safe, simple, and precise movement of power equipment by a single operator, increasing efficiency and saving costs.
• Hydraulic operation eliminates personnel risks associated with tong handling, including back strains and pinch points.
• System uses power from existing equipment, such as a hydraulic tong power unit, thereby requiring minimal rig space and conserving costs.
• Smooth, efficient positioning of hydraulic tongs onto the pipe ensures safe operations in adverse weather conditions on semi-submersibles and drill ships.
* U.S. Patent No. 6412553
© 2010 Weatherford. All rights reserved. 35
Positioning Systems
PowerScope® Tong-Positioning System
SpecificationsWeight without tongs
Length (in./cm) Weight
(lb/kg)Width
(in./cm)
Pushing Force (lbf/N)
Stroke (Maximum Extension)
(in./cm)Retracted Extended98 249
256 650
2,000 907
44.3 113
2,000 8,896
157 399
PowerScope™ system with tong modules
Description
PowerScope withTong Weight
(lb/kg)
Maximum Torque
(ft-lb/N•m)
Dimensions L × W × H (in./cm)
Tubular Size Range
(in./mm)
TorkWinder™ drillpipe tong with spinner 9,640 4,373
145,000 196,594
65 × 58 × 48 165 × 147 × 122
2-1/4 to 10 57.2 to 254.0
8.5-80 drillpipe tong 7,056 3,201
80,000 108,466
85 × 48 × 67 216 × 122 × 170
4 to 8-1/2 101.6 to 215.9
7.6-30 tubing tong with backup 2,352 1,067
30,000 40,675
55 × 43 × 76.7 140 × 109 × 195
2-3/8 to 7-5/8 60.3 to 193.7
14-50 casing tong with backup 4,100 1,860
50,000 67,791
64 × 42 × 82.7 163 × 107 × 210
7 to 14 177.8 to 355.6
24-50 casing tong with backup 4,400 1,996
50,000 67,791
75.6 × 64.3 × 82.7 192 × 163 × 210
10-3/4 to 24 273.1 to 609.6
Additional tongs available for manual and/or semi-mechanized operations including 6.5-30 drillpipe tong, 8.0-70 drillpipe tong, 5.5-15 tubing tong, 16-25 casing tong, and 14-100 casing/riser tong.
36 © 2010 Weatherford. All rights reserved.
Positioning Systems
Features, Advantages and Benefits• Remote operation requires fewer rig floor personnel, improving safety and
reducing operating costs.
• Plug-and-play technology enables quick tong change-out, saving time during operations.
• BHA makeup capability reduces required onboard storage.
• Use with Weatherford’s patented TorkWinder® drillpipe tong (photo) provides the most efficient available premium-connection (XT, XTM, WT) drillpipe makeup.
• Compatibility with the entire family of Weatherford mechanized power tongs reduces capital investment, making the system very cost-effective.
• Design incorporates multiple safety cutoffs and interlocks, decreasing the risk of accidents and injuries.
• Memory feature positions the tong horizontally and the connection finder automatically positions the tong vertically for extremely efficient tong positioning.
• Customizable for specific rig requirements, the system also fits existing roughneck rails, minimizing costly rig modifications.
• System allows offline makeup, improving operational efficiency.
• Design enables advanced integration with rig safety systems, including the Varco V-ICIS system.
Applications• Running drillpipe, casing, tubing, and production risers
• Offline stand building and bottomhole assembly (BHA) makeup and installation
• Drillbit makeup and breakout
• New-build rigs and refurbishment applications
Weatherford’s track-mounted PowerFrame II tong-positioning system is designed to house and position the entire family of Weatherford mechanized power tongs, including casing, tubing, drillpipe, and production riser tongs. The PowerFrame II system can be remotely operated for safety and employs programmable logic control (PLC) technology for efficiency and reliability. This patent-pending PowerFrame system is rugged and reliable and has a small footprint, which makes it ideally suited for new-build rigs and refurbishment applications.
PowerFrame® II Tong-Positioning System
© 2010 Weatherford. All rights reserved. 37
Positioning Systems
PowerFrame® II Tong-Positioning System
SpecificationsGeneral Temperature Range Comments
Min. Design Temperature °F°C
–4–20
Operational Temperature °F°C
+32 till +1580 till +70
PowerFrame PF2 System Comments
Weight without tooling lbskg
7,9373,600
without tong module
with TorkWinder System
lbskg
16,8657,650
with TorkWinder and Spinner
with DP 8.5 - 80
lbskg
14,9916,800
with CT 24 - 50
lbskg
14,3306,500
with CT 14 - 50
lbskg
12,7875,800
with TT 7.6 - 30
lbskg
11,1335,050
Dimensions Max. height inchmm
1704,312
Frame fully extended
Min. height inchmm
932,362
when retracting to home position
Lifting stroke inchmm
771,950
35.4 inch telescope device + 41.3 inch carrier device
Lifting stroke telescope
inchmm
35.4900
Max. stroke of TorkWinder
Lifting stroke carrier
inchmm
41.31,050
including thread compensation
Width inchmm
681,730
Width between chassis legs
inchmm
491,250
Length inchmm
932,350
Rail width inchmm
59/751,499/1,905
Part no.: 949 1400/949 1401
Wheel width inchmm
721,825
Width between chassis legs
inchmm
491,250
Space in operating area of the spider tool
Max. Load (for tong carrier)
tons 3.25 (tong with backup)
(for frame chassis)
tons 4.1 (TorkWinder and Spinner)
Speed, horizontal inch/secmm/sec
12300
Hydraulic Pressure psibar
3,046210
180 for PowerFrame only
Hydraulic Flow gpmlpm
40150
Max. Inclination of Rig Floor degree 3° (only with attached safety brackets)
Electric Control Cabinet (ECR-Version)
Weight lbskg
529240
Dimensions Height inchmm
832,100
Width inchmm
32800
Depth inchmm
24600
Power Supply
Voltage VAC 115 or 230
Frequency Hz 50/60
Current/ Fuse rating
Amps 10
Electric Control Cabinet (MCSU EEx d-Housing)
Weight lbskg
760300
Dimensions Height inchmm
421,048
Width inchmm
30743
Depth inchmm
15366
Power Supply
Voltage VAC 115 or 230
Frequency Hz 50/60
Current/ Fuse rating
Amps 10
38 © 2010 Weatherford. All rights reserved.
PowerFrame® III Tong-Positioning System
Positioning Systems
Weatherford’s PowerFrame III system offers a first and simple step toward mechanizing tubular-handling operations. This cost-effective tong manipulation frame is designed to position power tongs on the rig floor from a standby position to well center and/or mouse hole. The lightweight frame is adaptable to most rig floor designs. One person can set up the entire system, which is compatible with Weatherford’s tubing, casing, and drillpipe tongs.
The tong, with backup, is installed to and suspended from the PowerFrame III. The frame is controlled by the valve section of the tong, eliminating the need for an additional control system or power unit. Depending on tong configuration and project requirements, remote control of the system can be manual, pneumatic, or by programmable logic controller (PLC). Any experienced power tong operator can run the PowerFrame III system.
Applications• Running drillpipe, casing, tubing,
and production risers using tongs weighing up to 3.7 tons
• Running tubular goods from a rig floor that can incorporate a rail-mounted device
• Building stands offline, in conjunction with corresponding tong unit
• Making up and breaking out bottomhole assemblies (BHAs), in conjunction with the corresponding tong unit
Features, Advantages and Benefits• The PowerFrame III system serves as a single tong-positioning device to cover
all tubing, casing, and drillpipe operations requiring Weatherford tongs with up to 3.7-ton capacity. This versatility eliminates the need for additional positioning devices in this capacity range.
• One-person tubular handling and running enhances safety and increases rig efficiency. Fewer rig floor personnel reduces risk exposure and operating costs.
• Plug-and-play technology enables quick tong changeout, saving time during operations.
• Compatibility with most Weatherford mechanized power tongs reduces capital investment, making the PowerFrame III system a cost-effective tong handling solution.
• BHA makeup capability (in conjunction with corresponding tong unit) reduces onboard storage requirement.
• Frame is controlled by the valve section of the tong, eliminating the need for an additional control system, which reduces costs while enhancing ease of operation.
• System is operated by one hydraulic cylinder for horizontal movement on the rails and two hydraulic lift cylinders for vertical lifting of the gantry, for a maximum lifting stroke of 39.4 in. (1,000 mm) to accelerate operations.
• Customizable for specific rig requirements, the PowerFrame III fits existing roughneck rails, minimizing the need for costly rig modifications.
• Frame system design incorporates multiple safety cutoffs and interlocks, decreasing the risk of accidents and injuries. Other safety features:
– frame features a special lifting arrangement to provide maximum protection for the operator under high-load conditions;
– two burst-pipe safety valves in the lift cylinders section prevent unexpected downward movement in the event of hydraulic tube or hose failure;
– slip-through/safety sensor shuts off mechanized tong when it detects backup slipping;
– protective cover on back of the frame prevents manual access to the movable parts.
• System allows offline makeup, improving operational efficiency.
© 2010 Weatherford. All rights reserved. 39
Positioning Systems
PowerFrame® III Tong-Positioning System
Options• Tail-in guide is a gantry-mounted hydraulic cylinder with a roller head to align the pipe and a separate control panel for easier
thread alignment. The stroke of the tail-in cylinder is 55 in. (1,400 mm).
• A lifting frame can be specifically constructed to allow lifting of the PowerFrame III structure, including the installed tong.
• Tong gantry frame is available in a standard version and in heavy-duty configuration to accommodate heavier tongs (maximum 8,100 lb [3,700 kg]).
• A positioning cylinder, with 78.7-in. (2,000 mm) stroke, is available for moving the PowerFrame III system between well center and park position.
Specifications
Minimum design temperature (°F/°C) –4 –20
Operational temperature (°F/°C) 32 to 158 0 to 70
Approximate weighta (lb/kg)
Without tooling 3,500 1,600
With CT 24 - 50b 9,700 4,400
With CT 14 - 100b
11,500 5,200
With CT 14 - 80b
With CT 14 - 50 8,200 3,700
With TT 7.6 - 30c 6,100 2,780
With TT 5.5 - 15c 5,343 2,440
With DPT 8.5 - 80b 10,600 4,800
Maximum heightd (in./mm) 126.0 3,190
Minimum heighte (in./mm) 87.2 2,214
Lifting stroke (in./mm) 39.4 1,000
Chassis length (in./mm) 100.6 2,554
Chassis widthf (in./mm) 63.0 1,600
Rail gaugeg (in./mm) 59.0 to 90.6 1,498 to 2,300
Chassis width, including wheels (in./mm) Rail gauge + 3.5 Rail gauge + 90
Working load limith (lb/kg) 8,157 3,700
Maximum speed, horizontal (in./sec, mm/sec) 6.3 160
Minimum hydraulic pressure, frame onlyh (PSI/bar) 2,466 170
Hydraulic flow, frame onlyh (GPM/LPM) 18.570
aWithout tongbWith heavy-duty gantry onlycTong with backupdFrame fully extended; without accessorieseFrame fully retracted; without accessoriesfWithout wheelsgDepending on wheel sethFrame flow/pressure, tong might require more
ControlSystems
42 © 2010 Weatherford. All rights reserved.
HiPer™ Control System
The HiPer control system is used for the remote control of Weatherford’s suite of mechanized power tongs and tong-positioning systems. The system consists of certified explosion-proof rig-floor components, Weatherford’s universal remote-control system (URCS), and a main control cabinet that can be installed in a safe area.The URCS is an intrinsically safe, portable control panel that provides a practical, user-friendly interface that enables remote operation from a safe distance. Using modern computer technology and data mapping, the HiPer control system integrates with all major drilling control systems and can be used to communicate with the rig’s anti-collision system to avoid contact between Weatherford equipment and other rig-floor machinery. The HiPer control system is also available in a portable version certified for use in hazardous areas.
Applications• Control of mechanized tong-positioning systems such as the PowerFrame® tong
frame and PowerScope® tong positioning systems
• Control of mechanized casing, tubing, riser, and drillpipe tongs
• Control of optional equipment for the patented TorkWinder® and TorkWrench™ drillpipe wrenching tongs (integral mud bucket, stabbing guide, and cleaning/doping device)
• Control of the StabMaster® vertical positioning system
Features, Advantages and Benefits• System incorporates a high-speed industrial computer that emulates a
programmable logic controller (PLC) and features an open system configuration for versatility.
• Fully remote capability from driller’s control cabin enables operation from a safe distance.
• Integration of rig safety and zone-management systems enhances safety and efficiency.
• Network TCP/IP connection provides off-site remote support capability, ensuring quick response for troubleshooting,software installation and upgrades.
Control Systems
Power Tongs
44 © 2010 Weatherford. All rights reserved.
5.5-15 Hydraulic Tubing Tong
Weatherford’s 5.5-15 hydraulic tubing tong provides 15,000 ft-lb (20,340 N•m) of torque capability for running and pulling 2 3/8- to 5 1/2-in. tubing and casing. The ergonomic and lightweight design of the tong enables safe and efficient makeup of premium connections on both standard and corrosion-resistant alloy (CRA) tubulars. Features such as the integrated thread-compensation system, the optional patented Micro-Grip® slips gripping system, and the free-floating hydraulic backup help to ensure proper connection makeup and long-term wellbore integrity. Operation can be fully or semi-mechanized, and the tong is fully compatible with Weatherford’s patent-pending, remote-control PowerFrame® and patented PowerScope® tong-positioning systems.
Applications• Running and pulling 2 3/8- to 5 1/2-in. tubing and casing
• Making premium connections on CRA tubular strings
• Making connections on standard tubular strings
• Running work strings
Features, Advantages and Benefits• Patented free-floating backup design virtually eliminates bending and shearing
when making up or breaking out connections. This design avoids loss of production by reducing casing deformation, which can affect long-term wellbore integrity.
• Tong design provides integrated thread-compensation system to prevent thread damage, saving repair costs.
• Optional Micro-Grip system grips the casing fully, minimizing marking of the tubular surface which can lead to expensive repairs associated with stress corrosion cracking and sulfide stress cracking.
• Extra-length jaw design maximizes the gripping contact area, allowing instant change from connection makeup to breakout, increasing efficiency.
• Patented safety interlock system prevents tong operation when the gate is ajar, reducing the risk of personal injury.
Power Tongs
© 2010 Weatherford. All rights reserved. 45
Power Tongs
General Temperature Range Comments
Min. Design Temperature °F°C
- 4- 20
Operational Temperature °F°C
+32 till +1580 till +70
5.5 – 15 Tubing Tong System Comments
Pipe size range inchmm
1.66 to 5 1/242 to 140
Max. make-up/break-out torque ft-lbsNm
15,00020,340
Max. rotor speed Commercial rpmUpm 88 high gear
Dinamic/Piston rpmUpm 60 high gear
Danfoss rpmUpm 40 high gear
Tong arm length inchmm
30/25762/635 with/without backup
Weight lbskg
1,843/1,080840/490 with/without backup
Dimensions Length inchmm
37.9962 with backup
Width inchmm
41.31,050 with backup
Height inchmm
65.51,665 with backup
Environmental temperature °F°C
22 to 122-10 to +50
Backup only Comments
Weight lbskg
763350
Dimensions Length inchmm
20.5520
Width inchmm
37.9962
Height inchmm
43.31,100
Max. clamping pressure at backup psibar
5,875400
Pressure booster on backup 1 : 4 input/output ratio
Specifications Dimensions
5.5-15 Hydraulic Tubing Tong
46 © 2010 Weatherford. All rights reserved.
Power Tongs
7.6-30 Hydraulic Tubing Tong
Weatherford’s 7.6-30 hydraulic tubing tong provides 30,000 lbf-ft (40,670 N•m) of torque capability for running and pulling 2 3/8- to 7 5/8-in. tubing and casing. The ergonomic and lightweight design of the tong allows safe and efficient makeup of premium connections on both standard and corrosion-resistant alloy (CRA) tubulars. Features such as the integrated thread-compensation system, the optional patented Micro-Grip® slips gripping system, and the free-floating hydraulic backup help to ensure proper connection makeup and long-term wellbore integrity. Operation can be fully or semi-mechanized, and the tong is fully compatible with Weatherford’s remote-control tong-positioning systems, including the patent-pending PowerFrame® and patented PowerScope® systems.
Applications• Running or pulling 2 3/8- to 7 5/8-in. tubing and casing
• Making premium connections on CRA tubular strings
• Making connections on standard tubular strings
• Running work strings
Features, Advantages and Benefits• Patented, free-floating backup design virtually eliminates bending and shearing
when making up or breaking out connections. This design avoids loss of production by reducing casing deformation, which can affect long-term wellbore integrity.
• Integrated thread-compensation system adjusts tubular travel to prevent thread damage, saving repair costs.
• Optional Micro-Grip system grips the casing fully, minimizing marking of the tubular surface, which can lead to costly repairs associated with stress corrosion cracking and sulfide stress cracking.
• Extra-length jaw design maximizes the gripping contact area, allowing instant change from connection makeup to breakout for greater operational efficiency.
• Patented safety interlock system prevents tong operation when the gate is ajar, reducing the risk of personal injury.
© 2010 Weatherford. All rights reserved. 47
Power Tongs
General Temperature Range Comments
Min. Design Temperature °F°C
- 4- 20
Operational Temperature °F°C
+32 till +1580 till +70
7.6 – 15/30 Tubing Tong System Comments
Pipe size range inchmm
2-3/8 to 7-5/860 to 193
Max. make-up/break-out torque7.6 – 15
ft-lbsNm
15,00020,340 Commercial single
Max. make-up/break-out torque7.6 – 30
ft-lbsNm 30,000
40,680
Commercial Tandem (in low-
speed mode only), Dinamic, Danfoss
Max. rotor speed
Commercial Tandem motor
(refer to Sec.4.2.1.)
CommercialSingle motor
rpmUpm 19/88 Low gear/
high gear
High-speed mode
rpmUpm 20/90 Low gear/
high gear
Low-speed mode
rpmUpm 10/45 Low gear/
high gear
Dinamic/Piston rpmUpm 12/60 Low gear/
high gear
Danfoss rpmUpm 9/40 Low gear/
high gear
Tong arm length inchmm
36914
Weight approx. lbskg
2,6001,180 with backup
Dimensions Length inchmm
531,346 with backup
Width inchmm
35889 with backup
Height inchmm
812,050 with backup
7.6 Backup Comments
Weight lbskg
992450
Dimensions Length inchmm
32.2/21.3820/540
with/without support legs
Width inchmm
43.91,114
Height inchmm
481,220
Max. clamping pressure at backup psibar
5,875400
Pressure booster on backup 1 : 4 input/output ratio
Specifications Dimensions
7.6-30 Hydraulic Tubing Tong
48 © 2010 Weatherford. All rights reserved.
Power Tongs
14-50 High-Torque Casing Tong
Weatherford’s 14-50 high-torque casing tong provides 50,000 lbf-ft (67,791 N•m) of torque capacity for running and pulling 6 5/8- to 14-in. casing. At the heart of the tong is a unique gated rotary that completely encircles the casing, distributing gripping forces over a greater area and ensuring a positive grip without pipe deformation and pipe marking problems. For added safety, the hydraulic door interlock prevents tong operation while the doors are open or unlatched.
The 14-50 casing tong is capable of fully mechanized, remote operation or semi-mechanized operation. The tong is completely compatible with all of Weatherford’s automated tong-positioning systems, including the patent-pending PowerFrame® and patented PowerScope® systems.
Applications• Running and pulling 6 5/8- to 14-in. casing
• Making up and breaking out connections that require high torque
• Performing offline or moonpool casing makeup operations
Features, Advantages and Benefits• Tong with hydraulic backup eliminates the need to use large manual rig tongs as
backup when running casing, thereby enhancing safety.
• Integral hydraulic backup grips pipe and couplings without crushing, saving equipment repair costs.
• Patented free-floating backup design virtually eliminates shearing and bending when making up or breaking out connections, minimizing production loss by reducing casing deformation, which can affect long-term wellbore integrity.
• Compatible with Weatherford’s JAMPro™ torque control systems.
• Hydraulic door interlock prevents tong operation while the doors are open or unlatched for improved safety.
• Versatile tong design allows running of casing in the moonpool or offline on rigs that accommodate these activities.
• Optional patented Micro-Grip® gripping system grips the casing fully, minimizing damage to the tubular surface, which can lead to stress corrosion and sulfide stress cracking and associated repair costs.
© 2010 Weatherford. All rights reserved. 49
Specifications
Pipe size range 6-5/8 to 14 in.
Tong dimensions 42 × 64 × 38 in. 1,067 × 1,626 × 965 mm
Tong weight 2,000 lb 909 kg
Maximum torque, continuous 50,000 lbf-ft 67,791 N•m
Operating pressure 3,000 psi 207 bar
Flow 44 gpm 166 lpm
Low speed 6 rpm
High speed 30 rpm
Torque arm length 42 in. 1,067 mm
Dimensions
14-50 High-Torque Casing Tong
Power Tongs
50 © 2010 Weatherford. All rights reserved.
Power Tongs
16-25 Hydraulic Casing Tong
Weatherford’s 16-25 hydraulic casing tong provides 25,000 lbf-ft (33,900 N•m) of torque capacity for running and pulling 6 5/8- to 16-in. casing. At the heart of this versatile and lightweight tong is a unique gated rotary that completely encircles the casing. This design provides as many as seven contact points which distribute gripping forces over a greater area than conventional tong designs, ensuring a positive grip without damaging the casing. The optional integral free-floating backup (lower photo) helps to ensure proper connection makeup and long-term wellbore integrity.
Applications• Running and pulling 6 5/8- to 16-in. tubulars
Features, Advantages and Benefits• Tong design handles high-torque requirements without the case body distortion
problems that plague many other tongs, saving equipment repair costs and increasing efficiency.
• Versatile and lightweight tong is easy to operate, saving time and enhancing personal safety.
• Tong design allows the operator to switch between makeup and breakout modes by moving a single pin, saving time and increasing operational efficiency.
• Optional hydraulic free-floating backup virtually eliminates shearing and bending when making or breaking out connections, reducing casing deformation, which can affect long-term wellbore integrity.
• Hydraulic door interlock prevents tong operation while the doors are open or unlatched, providing additional safety.
• Optional lift cylinder quickly adjusts to varying connection heights, making this versatile tong easily adaptable for out-of-tolerance contoured pipe.
• Multiple contact points distribute gripping forces, preventing damage to casing and the need for costly repairs.
© 2010 Weatherford. All rights reserved. 51
Power Tongs
16-25 Hydraulic Casing Tong
Specifications
Pipe size range 6-5/8 to 13-3/8 in.a 16 in.b
Rated torque in low gearc 25,000 lbf-ft 33,900 N•m
Rated speed in high geard 93 rpm
Tong dimensions 34×54×31 in. 864×1,356×782 mm
Torque arm length 32 in. 813 mm
Weight 1,075 lb 488 kg
Nominal power requirement flowe 60 to 80 gpm 227 to 303 lpm
Nominal power requirement flowf 30 to 40 gpm 114 to 152 lpm
a13 3/8-in. rotary and jawsb16-in. rotary and jawscAt 2,000 psi (138 bar)dAt 70 gpm (265 lpm)eAt 1,000 psi (69 bar)fAt 2,000 psi (138 bar)
Dimensions
52 © 2010 Weatherford. All rights reserved.
Power Tongs
24-50 High-Torque Casing Tong
Weatherford’s 24-50 high-torque casing tong provides 50,000 lbf-ft (67,791 N•m) of torque capacity for running and pulling 10 3/4- to 24-in. casing. At the heart of the tong is a unique gated rotary that completely encircles the casing, providing greater circumferential coverage, a smaller footprint, and lighter overall weight than conventional tong designs. For added safety, the hydraulic door interlock prevents tong operation while the doors are open or unlatched. The 24-50 tong is capable of fully mechanized remote operation or semi-mechanized operation and is completely compatible with all of Weatherford’s automated tong-positioning systems, including the patent-pending PowerFrame® (lower photo) and patented PowerScope® systems.
Applications• Running and pulling 10 3/4- to 24-in. casing
• Making up and breaking out connections with high-torque requirements
• Performing offline or moonpool casing makeup operations
Features, Advantages and Benefits• Gated rotary completely encloses the casing, distributing gripping forces over
a greater area and ensuring a positive grip without pipe deformation or pipe marking problems, avoiding the risk of incurring costly repairs.
• Integral hydraulic backup grips pipe and couplings without crushing, saving repair costs.
• Tong design eliminates need for large manual rig tongs as backup when running casing, thereby enhancing personal safety.
• Patented, free-floating, backup design virtually eliminates shearing and bending when making or breaking out connections, reducing casing deformation and promoting long-term wellbore integrity.
• Compatible with Weatherford’s JAMPro™ torque control systems.
• Versatile tong design enables running of casing in the moonpool or offline on rigs requiring these activities.
© 2010 Weatherford. All rights reserved. 53
Power Tongs
24-50 High-Torque Casing Tong
Specifications
Pipe size range 10-3/4 to 20 in.a 24 in.b
Rated torque in low gearc 50,000 lbf-ft 67,791 N•m
Rated speed in high geard 38 rpm
Torque arm length 48 in. 1,219 mm
Tong weight 2,300 lb 1,045 kg
Tong dimensions 53×77×28 in. 1,346×1,948×711 mm
Nominal power requirement flowe 60 to 80 gpm 227 to 303 lpm
Nominal power requirement flowf 30 to 40 gpm 114 to 152 lpm
a20-in. rotary and jawsb24-in. rotary and jawscAt 2,500 psi (172 bar)dAt 70 gpm (265 lpm)eAt 1,000 psiI (69 bar)fAt 2,500 psi (172 bar)
Dimensions
All-in-OneTechnology
56 © 2010 Weatherford. All rights reserved.
All-in-One Technology
Features, Advantages and Benefits• Remote control enables running of drillpipe, tubing, casing, and riser pipe by a
single operator for safer operations.
• Automatic tool joint finder determines the correct positioning height for the TorkWrench wrenching tong, increasing operational efficiency of the makeup/breakout process.
• Automated stabbing guides guide pipe into the correct position during the makeup process and enable easier lifting of the pipe during breakout operations, reducing thread wear.
• Automated mud bucket positioned between spinner and wrench allows pipe rotation while closed, optimizing mud capture.
• Cleaning and doping system performs thread cleaning with air and box doping automatically, enhancing safety by removing personnel from drop zone.
• Integration with JAMPro™ and JAMPro net systems enables optimal makeup monitoring, testing, and control for increased operational efficiency.
Applications• Tripping standard- or premium-connection drillpipe, offline stand building,
and bit breaking
• Running drillpipe, casing, tubing, and production risers
• Bottomhole assembly makeup and installation
• Controlling mechanized tong-positioning systems and casing, tubing, riser, and drillpipe tongs
The TorkWrench 10-100 all-in-one modular iron roughneck system facilitates hands-off tubular makeup and breakout operations and includes an automated stabbing guide, tool joint finder, thread cleaning and doping system, and automated mud bucket.
Weatherford’s TorkWrench drillpipe tong module and the ancillary all-in-one components are operated inside the PowerFrame® II tong-positioning system, a rail-mounted tong carrier. The tong carrier enables the easy exchange of tong modules when required to run casing, tubing, and/or threaded riser connections. A single operator controls the system from the drill floor through the HiPer™ control system panel or through the driller’s cabin when integrated into the rig control system.
The ability to interchange tong modules and/or working mechanisms offline on the rig or in the workshop makes it the perfect all-in-one solution for safe and efficient operations.
TorkWrench™ 10-100 All-in-One System
© 2010 Weatherford. All rights reserved. 57
All-in-One Technology
TorkWrench™ 10-100 All-in-One System
Options• Mud bucket, thread cleaning and doping systems
• Stab-in guide
• 7.6-30 casing tong
• 14-50 casing tong
• 24-50 casing tong
• 21-300 riser tong
Specifications
Approximate weight 6.5 ton
Maximum pressure 3,000 psi 20.7 MPa
Maximum oil flow 40 to 79 gpm 151 to 299 Lpm
Wrenching cylinders 2
Clamping range 2-7/8 to 10 in. 73 to 254 mm
Maximum makeup torque 100,000 lbf-ft 135.56 kN•mMaximum breakout torque
Wrenching angle per stroke 40°
Power supply Open/close center
Controls Onboard or various remote
Independent spinner BHA and thread travel compensation
58 © 2010 Weatherford. All rights reserved.
All-in-One Technology
Weatherford offers the UniTong system, the all-in-one tong from V-Tech AS, designed to improve drill floor operational safety and drilling efficiency. The world’s first field-proven, all-in-one tong concentrically parks around the drillstring, covering the entire area from connection to disconnection of the tubular. Three clamp-housing models accommodate all pipe dimensions ranging in size from 2-7/8 to 20 in. (7 to 51 cm) and a torque capability of 0 to 150,000 lbf-ft (0 to 205,000 N•m).
The UniTong system improves the security of pipe-handling operations on the drill floor with fully automated makeup and breakout. No crew member is needed in the hazardous area around the well center. A single operator can monitor and control the operation from anywhere on the drill floor, including the driller’s chair.
The UniTong system is also the first field-tested power tong capable of handling drillpipe, tubing, and casing in all sizes. The system requires fewer personnel and equipment, decreasing the overall cost of tubular running services operations.
The clamp housing is the heart of this outstanding concept. It consists of one split housing with four double-acting hydraulic cylinders. This design increases the radial stroke of the cylinders, permitting a range of diameters to be covered. A specially designed jib crane with an L-profile is used to change out the clamp housing simply and safely.
The UniTong system remains concentric to the drillstring during operations, unlike conventional tongs which must move backward and forward for each connection. The jaws form a closed ring when clamping on the pipe, unlike conventional tongs with their U-shaped jaws, so UniTong systems are less likely to suffer from catastrophic fatigue as a result of high-bursting forces.
Applications• Onshore and offshore tubular, casing and drillpipe running and pulling
• Makeup and breakout connections with high-torque requirements
• Makeup and breakout of specialty tubulars, such as high-chrome content and wedge-thread connections
Features, Advantages and Benefits• This system allows all tubular connections to be performed by one machine (pipe
UniTong™ System
© 2010 Weatherford. All rights reserved. 59
All-in-One Technology
UniTong™ System
range 2-7/8 to 20 in. [7 to 51 cm]), reducing the chances of pipe deformations while promoting long-term performance integrity.
• This power tong’s remote, automated makeup and breakout system improves safety since all monitoring and operations can be controlled from within the driller’s cabin, eliminating the need for a crew member on the drill floor during operations.
• The UniTong multi-power tong’s capabilities provide additional health, safety and environmental (HSE) enhancements with
– no tugger line needed when handling power slips, slips segments, master bushing, and bottom hole assembly (BHA) and so this tong doesn’t tie up a tugger.
– certification as lifting device, so it is capable of lifting power slips from rotary; again, no tugger line required.
– no machines moving backward and forward during operations.
– concentrical parking to rotary table during operations for no retraction between connections, no exposure to personnel from rotating and clamping devices, simple and fast disassembly of tongs, plus the system is easy to operate and maintain because of the system’s all-in-one design.
• Includes automatic pipe doping, washing and mud bucket functions; safety and time savings.
Specifications
Maximum spinning speed (rpm) 50
Torque range (lbf-ft/N•m) 0 to 150,000 0 to 205,000
Work diameter area (in./mm) 2-3/8 to 20 60.3 to 508.0
Hydraulic supply 3,046 psi and 63 gal/min. 210 bar and 240 l/min.
Control system Electrical PLC with auto sequence and remote control
Approximate weight (lb/kg) 18,739 8,500
Lower park connection (in./mm) 23.62 600
Maximum connection height (in./mm)
120.08 3,050
Width (in./mm) 101.85 2,587
Length (in./mm) 122.05 3,100
Monitoring and Testing
62 © 2010 Weatherford. All rights reserved.
Monitoring and Testing
ETG® Electronic Torque Gauge
Weatherford’s ETG electronic torque gauge is a self-contained, battery-operated unit that accurately and reliably controls the makeup of tubing, casing, drillpipe, and work strings. The gauge provides the tong operator with complete connection makeup control and is completely programmable to specific job requirements. The system displays a real-time digital torque reading and a horizontal bar graph, which allow the tong operator to visually monitor the makeup progress. Selectable codes for each makeup enable the operator to identify bottomhole assemblies, nipples, pup joints, and other string accessories while running pipe. The gauge comes with a dump valve, a load cell and cable, hoses, a computer serial cable for downloading data, a battery charger with power cable, and a mounting kit. Battery replacement takes only three minutes, and the battery charger quickly recharges the discharged battery.
Applications• Makeup or breakout of tubing, casing, drillpipe, or work strings
• String makeup operations requiring portable torque control system
Features, Advantages and Benefits• Unit stores more than 5,000 connection makeups or breakouts in memory,
enabling export of job data to a simple spreadsheet or ASCII file for manipulation on a personal computer.
• System provides a real-time digital torque reading and bar graph display with digital readouts, allowing the tong operator to monitor the makeup progress visually.
• Selectable makeup codes enable the operator to identify string accessories while running pipe, providing greater efficiency.
• System provides more than 12 hours of battery operation for operational compatibility with rig crew changes.
Specifications• System supports tong-handle lengths from 12 to 99 in. (305 to 2,515 mm).
• Unit operating temperature range is 0° to 120°F (–18° to +49°C).
• System supports torque range of 0 to 99,999 ft-lb. (135,581 N•m).
© 2010 Weatherford. All rights reserved. 63
Monitoring and Testing
ExTG™ Electronic Explosion-Proof Torque Gauge System
Applications• Running and pulling tubing, casing, and drillpipe strings
• Pre-assembly of bottomhole assemblies and downhole tools (when used with bucking units)
• Measurement and control of all power tongs for casing, tubing, and drillpipe installation
• Permanent electronic recording of critical makeup data
• Data export to external software
Features, Advantages and Benefits• More than 5,000 makeups or breakouts can be stored on the removable memory
card, using a standard file system readable by a CF-card interface.
• Soft-selectable acceptance codes accelerate entry of special identification markers for specific downhole components or accessories.
• Two power supply options make the ExTG system compatible with virtually all power systems found on the rig: an external 115/230 V, 50/60 Hz AC power supply and battery charger; or an optional battery power system which provides a minimum of 12 hr of continuous operation while using the dump valve.
• Software-driven power status indication provides early warning of low battery to help avoid interruption to running and pulling operations.
• The ExTG system is equipped with an internal real-time clock so that each makeup or breakout is time and date stamped to help analyze job performance and efficiency.
• The wide operating temperature range makes the ExTG system suitable for most global climates where remote drilling and workover operations occur.
• Two-millisecond dump valve reaction and 16-bit processor provide very accurate torque control, helping to achieve the best possible connection integrity.
• The ExTG system can be tong mounted for operator convenience and safety.
• The ExTG unit is protected by a shock-proof mounting.
• The high-contrast LCD screen provides excellent readability.
• Built-in software features an intuitive user interface.
Weatherford’s ExTG electronic explosion-proof torque gauge system provides precise measurement and control of torque applied by a power tong. It can also be used for measurement of pressure, using a 4- to 20-mA pressure transducer in place of the load cell. Programmable values can be set to automatically terminate hydraulic supply to the tong with the included dump valve.
The ExTG system can record and display 0 to 999,000 ft-lb (0 to 1,355 kNm) of torque or pressure at 16-bit resolution, depending on the load cell or pressure transducer measuring range. The gauge accepts all 4- to 20-mA load cells and pressure transducers and can be programmed for any arm length between 7.0 and 99.9 in. (178 and 2,537 mm).
This easy-to-use system is designed to operate with all existing Weatherford power tongs as well as other manufacturers’ tongs that use standard load cells; other load cells are available on request. The system is ATEX certified for worldwide use in hazardous locations and is accepted by the USCG for operation in the United States.
64 © 2010 Weatherford. All rights reserved.
Monitoring and Testing
ExTG™ Electronic Explosion-Proof Torque Gauge System
Options• Non-standard load cells are available on request.
• Required power supply (AC and/or battery pack complete with charger) must be specified when order is placed.
• A pressure transducer for measurement of fluid or air pressure is available.
Feature Imperial Metric
Torque measurement range(depending on load cell) 0 to 999,999 ft-lb 0 to 1,355 N•m
Data resolution 16 bit, 1 ms
Handle length (software) 7.0 to 99.9 in. 178 to 2,537 mm
Minimum display refresh rate 20 Hz
Load cell, Intrinsically Safe (IS) 4 to 20 mA
Servo (dump) valve (IS) 50 mA
Maximum dump valve reaction time 2 ms
Battery packMinimum battery (IS) operating time(status by software)
Hooked onto back wall of ExTG system, changeable
12 hr
AC power operation 115/230 V AC, 50/60 Hz, maximum 80 W
Battery chargingWith AC supply, possible while running
"ExTG system can run directly from AC supply without battery"
Storage capacity Compact flash card (16 MB), minimum 5,000 jt
Real-time clock yes
Operating temperature(humidity non-condensing) 0 to 150°F –17 to +65°C
Dimensions
ExTG system 12.6 x 9.0 x 6.3 in. 340 x 235 x 170 mm
Battery pack Adds 3.1 in. at the back of the ExTG system
Adds 80 mm at the back of the ExTG system
AC power supply 10.4 x 7.8 x 10.4 in. 263 x 218 x 302 mm
Load cell
length Load-cell specific
diameter Load-cell specific
pad eyes spacing Load-cell specific
Protection
ExTG system IIB T4 (ATEX) IP64, EEx ia
Load cell IIC T4 (ATEX) IP65, EEx ia
AC supply IP40, non-hazardous area, output EEx ia IIB (ATEX)
Cable length
Load cell to ExTG system 6.5 ft 2.0 m
Dump valve to ExTG system 3.2 ft 1.0 m
Mains cable AC supply 8.2 ft 2.5 m
AC supply to ExTG system 82.0 ft 25.0 m
Specifications
Bucking Units
The requirements for horizontal makeup and breakout operations continue to expand with the introduction of new thread types into the oil field and the further implementation of optimized drilling-rig operation.
An OCTG manufacturing plant demands a challenging productivity rate with perfect traceability and high repeatability of precise makeup operations; workshops alternatively require machines that can handle a wide and comfortable pipe-size range in combination with a sufficient torque capacity to cope with the different requirements of the day-to-day business.
A bottomhole assembly (BHA) and stand-building make/break unit in the bypass of a drilling rig could need sheer but controlled force to break and make various pipe connections and/or could require top-loading capabilities. However, the two latter ones often need to be approved to run in a zone 2 environment.
Weatherford’s custom-designed bucking systems address all these challenges. These coupling application machine (CAM) systems set new standards for the oil and gas industry. They can be used for make and break operation in pipe mills, threading facilities, pipe yards, repair shops, and workshops. CAM systems can be used for shoe-track, completion and BHA pre-assembly, and to support running drilling rigs.
The range of applications for CAM systems varies from completely automated systems that control every aspect of pipe and coupling handling in a pipe mill to semiautomated units for threading shops. These systems are also used as manually controlled workshop machines and climax in flexible rig support machines, including pipe-feeding and discharge features.
Weatherford’s CAM systems offer an extensive variety of services, including:
• Hardware and software delivery
• Regular calibration and maintenance services
• Equipment running services provided by Weatherford’s trained and experienced operator crews
• Workshop services for downhole equipment repair
• Engineering support to create client-tailored, system-makeup packages for pipe manufacturing lines or complex rig solutions
Contact your local Weatherford representative for more information.
66 © 2010 Weatherford. All rights reserved.
Bucking Units
Introduction
© 2010 Weatherford. All rights reserved. 67
Bucking Units
Torque Process Control (TPC) for Bucking Units
Weatherford´s Torque Process Control (TPC) is designed exclusively for the operation of Weatherford bucking units. The TPC analyzes and documents all makeup or breakout parameters. The TPC is an advanced system that measures, displays, records, controls and evaluates both applied torque/turn and pin advancement during makeup or breakout. The system detects shoulder contact and controls the applied final torque to ensure optimum connections.
Applications• On-line control of the entire makeup process
• Data storage of makeup diagrams and connection data
• -Statistical functions
Features, Advantages and Benefits• The PLC of the TPC system controls the makeup speed and decreases it at
preset torque values which are vital for premium connections.
• Anomalies are easily and immediately identified with a high-resolution monitor.
• Graphs can be printed to document each single connection and store all data on a hard disk for use in subsequent statistical applications.
• Immediate input of technicians’ comments for each connection, thus improving production report data for future reference
• High-resolution printouts of makeup diagrams for each single connection and the connection data.
• With the TPC system monitoring, pipe manufacturers’ criteria are exactly and safely met.
68 © 2010 Weatherford. All rights reserved.
Bucking Units
Oilfield Bucking Units
Weatherford’s coupling application machines (CAM) field product line has been developed for standard applications, as well as for the challenging problems encountered during the makeup and breakout of oilfield tubular goods in threading and repair shops, pipe yards, and for completion applications.
The development of these machines contains all the experience we have gained in the course of long-term, worldwide activities in the field of vertical makeup of oilfield pipes. Modular customization of machines and powerful accessories enable our clients to skillfully make up and break out the various tubular connections in oilfield equipment. For rotational makeups/breakouts (ComCAM unit), TPCPro—an advanced computer analysis system—monitors the torque curves.
Applications• A rotational makeup system, such as ComCAM, is perfect for repair shops,
completion services, and smaller pipe-threading facilities. Connections include tubings, casings, and completions.
• The TorkWizard™ unit and the TorkWrench™ mobile-bucking unit (HMBU) are wrenching units (nonrotational makeup) that specialize in high-torque achieve-ment (TorkWizard unit) and operations as a mobile workstation (HMBU) on onshore and offshore rigs. Connections include drillpipes, bottomhole assemblies (BHAs), drill collars, downhole motors, and drilling tools.
Features, Advantages and Benefits• These units provide the latest state-of-the-art design and optimum technical solutions
for economical operation for clients worldwide.
• Easy and simple handling of technical equipment saves time.
• The units offer safe, reliable, and fast operations.
• Easy jaw changes keep job preparation time to a minimum.
• Automated control of power tightening ensures highly accurate makeup and instant reversal from makeup to breakout.
• Modular machine design and helpful accessories enable these units to be configured for special purposes, such as subassembly makeup of downhole equipment (Com-CAM) or top-loading capabilities (TorkWizard™ unit).
• The ComCAM units feature precise torque measuring, controlling, and recording with TPCPro computer; control stick operation providing ease of handling; and a long-operation, live-clamping cylinder design.
• The TorkWizard units make or break most oilfield connections in shop or rig environ-ments. Also these units transmit torque and accurate measurements on drillstring.
• The TorkWizard TL (top loader) enables top-loading of drillstring components.
• The TorkWrench™ HBMU features high-torque wrenching and spinning unit, providing a faster makeup and breakout operation; top-loading capability does not require pipe-feeding transport; free-floating spinning system follows the movement of pipe, protect-ing the tool joint and minimizing drillpipe damage caused by conventional systems; and the compact design can be used on pipe deck, enabling fast and easy rig-up and rig-down—enhancing operational efficiency.
TorkWizard 15-210
TorkWrench 10-100 HMBU
ComCAM 15-160: view from free-floating backup side with mounted centering jack, and hydraulic power unit (HPU), as well as a control panel with stick control, integrated TPCPro, and air condition
TorkWizard 15-150TL with combined HPU and operator cabin
© 2010 Weatherford. All rights reserved. 69
Bucking Units
Oilfield Bucking Units
Specifications
Unit Size (in.)
Maximum Passing OD (in.)
Maximum Torque (ft-lb, N·m)
ComCAM 15-160 15 15-1/8 160,000a
216,931ComCAM 20-160 20 21-1/2
TorkWizard 15-21015 15-1/8
210,000b
284,722
TorkWizard 15-150TL 150,000c
203,370
TorkWrench 10-100 HMBU 10 100,000 135,582
a Optional 80,000 ft-lb (108,464 N·m) fully rotatingbMaximum breakout torque. Maximum makeup torque is 190,000 ft-lb (257,602 N·m).cMaximum makeup/breakout torque.
Options• The ComCAM offers optional modules to tailor suit the unit for various
applications.
• The TorkWizard 15-210 provides an optional split-type backup for top-loading capability.
Features, Advantages and Benefits (continued)
• For special applications, the appropriate NANOGrip/TC dies eliminate the need for conventional metal-tong dies, replacing them with unique reinforced nonferrous inserts. These special dies prevent excessive markings that could cause stress-corro-sion cracking in expensive corrosion-resistant alloy (CRA) tubulars.
• Weatherford’s worldwide network provides optimum support.
Hydraulic Power Units
72 © 2010 Weatherford. All rights reserved.
Hydraulic Power Units
Introduction
Electric- or diesel-power units are available to provide a reliable power source for a wide range of hydraulic requirements, including all onshore and offshore applications. Our power units can be used to power everything from a single piece of equipment to a complete rig-system solution.
Weatherford’s power units are available in standard or custom-designed configurations and are generally skid-mounted. Most units include provisions for DNV certifications for marine handling.
Applications• Rig equipment
• Mechanized and remotely operated tongs
• Tubing tongs
• Casing tongs
• Drillpipe tongs
• Iron roughneck systems
• Rig-skidding systems
• Pipe-handling systems
• Hydraulic top drives
• Cranes
• Jacking systems
• Other rig-related equipment
Model 37 kW E-PU
© 2010 Weatherford. All rights reserved. 73
Hydraulic Power Units
Electric Power Units
Weatherford’s electric power units are equipped with 30 hp (22 kW) to more than 500 hp (373 kW) motors (explosion proof available), starter/circuit breakers and start/stop controls. Standard features include a hydraulic reservoir, suction and return filters; heavy-duty pumps; hydraulic coolers; pressure-control valves; and pressure gauges.
We also offer low temperature 5 EW power units that can handle temperatures down to –40°F (–40°C). Also we have units for both open- and closed-center operation. Many of our power units are explosion proof for zone 1 and are ATEX certified. (ATEX product certification—or EC Type Examination—involves a detailed examination, testing and assessment of equipment and confirms that the product is safe to use—within certain parameters—within potentially explosive atmospheres.1)
1Source: siracertification.com/atex
Model ID-HPU-200-135-5000 (offshore application, rig floor equipment)
Model Engine Type
Horsepower Rating (hp/kW)
Maximum OutputReservoir
Size WeightDimension
(in./mm)
(gpm/lpm) (psi/bar) (gal/l) (lb/kg) Width Length Height
37kW E-PU1 Electric2 50 37
67 252
3,046 210
35 132
2,600 1,179
71 1,803
55 1,397
71 1,803
2 EW-P1 Electric2 30 22
20 76
3,046 210
79 300
3,310 1,501
67 1,702
35 889
70 1,778
3 EW-P Electric2 48 36
90 340
2,755 1,250
69 1,753
46 1,168
44 1,118
4 EW-PU Electric2 70 52
68 257
3,046 210
85 320
2,810 1,275
75 1,905
50 1,270
65 1,651
5 EW-PU Electric2 86 64
79 300
3,046 210
119 450
5,027 2,280
99 2,515
57 1,448
61 1,549
ID-HPU-500160-4000 Electric – Soft Starters3
500 373
162 615
4,500 310
203 770
13,000 5,897
90 2,286
130 3,302
90 2,286
ID-HPU-200-135-5000 Electric3 200 149
137 520
5,000 345
335 1,270
10,000 4,536
90 2,286
130 3,302
84 2,134
LP 365-2M Electric 75 56
54 204
1,500 103
200 757
6,500 2,948
53 1,346
92 2,337
70 1,778
43 163
2,000 138
36 136
2,500 172
LP-324-A Electric 40 30
28 106
2,000 138
50 189
2,100 953
Data not available.
LP-324-A Electric 33 25
24 91
2,000 138
50 189
2,100 953
Data not available.
LP364-J4 Electric 60 45
62 235
1,200 83 90
3413,000 1,361
46 1,168
90 2,286
46 1,16830
1142,500 172
LP364-J Electric 50 37
52 197
1,200 83 90
3413,000 1,361
46 1,168
90 2,286
46 1,16825
952,500 172
LP364-J50 Electric 50 37
52 197
1,100 76 90
3413,000 1,361
46 1,168
90 2,286
46 1,16825
952,500 172
LP364-J504 Electric 50 37
52 197
1,100 76 90
3412,926 1,327
46 1,168
90 2,286
46 1,16825
952,500 172
1ATEX-certified power units are (atmospheric explosible) Zone 1, DNV on request.2These electric units are available for Class I, Division I, (Zone I) areas and available to Cenelec Standard EN 50014-50018.3 These units are a leak-free system, using SAE 4-bolt flanges or ORFS (O-ring face seals), which are used in the aircraft industry. This plumbing system differentiates our units from those of other designers/manufacturers. NPT or JIC fittings are not used because they will eventually leak. Also when applicable, we hard line the plumbing instead of using hoses.
4Active power units for sale at Weatherford OCM.
74 © 2010 Weatherford. All rights reserved.
Hydraulic Power Units
Electric Power Units
Specifications
© 2010 Weatherford. All rights reserved. 75
Hydraulic Power Units
Diesel Power Units
Weatherford’s standard diesel power units are equipped with four- or six-cylinder Deutz engines. All are constructed with large hydraulic-oil reservoirs which effectively helps with heat dissipation.
All models are equipped with automatic and manual engine shutoffs, and an emergency shutdown system. An optional air-intake engine shutoff for additional safety is available. The exhaust system has a built-in spark arrestor.
Air- or water-cooled engines with air, electric or spring starters are standard. All units are installed on an oilfield skid with pickup provisions, power-tong mountings and storage baskets.
Weatherford offers low-noise units to meet the stringent environmental regulations; stainless steel units for use in corrosive environments; and models designed for low-temperature operations. Zone II units are also available.
Model LS6914
76 © 2010 Weatherford. All rights reserved.
Hydraulic Power Units
Diesel Power Units
Model
Horsepower Rating (hp/kW)
Maximum OutputReservoir
Size WeightDimension
(in./mm) Standards
(gpm/lpm) (psi/bar) (gal/l) (lb/kg) Width Length Height Systems Powered
LS 6912 Model II G 6 Cylinder1
88 66
71 270
1,300 90
24 91
3,660 1,660
96 2,438
48 1,219
61 1,549
6DW-V 6 Cylinder1
91 68
71 270
1,300 90
24 91
3,638 1,650
87 2,210
51 1,295
56 1,422
Exhaust Emission Standard EPA II / COM II
LS6914 113 84
65 246
1,200 83 90
3414,000 1,814
48 1,219
96 2,438
66 1,676
All standard tongs; air cooling; electric starter44
1672,500 172
LS6914 113 84
65 246
1,200 83 90
3414,000 1,814
48 1,219
96 2,438
66 1,676
All standard tongs; air cooling; air starter44
1672,500 172
LS6914 113 84 Data not available Air cooling; inertia starter;
other data not available
LS6914 113 84 Data not available Air cooling; electric starter;
other data not available
LS6914 113 84 Data not available Air cooling; air starter;
other data not available
1These units are available with special exhaust systems for Class I, Division II, Zone II areas.
Specifications
Mud Pumps
78 © 2010 Weatherford. All rights reserved.
Mud Pumps
Mud Pumps and Packages, Expendable Parts, and Service
Mud pumps are a critical part of any drilling rig, and no matter if you are land based or offshore, insuring you have a reliable source of high pressure drilling mud is an important concern for any driller. Weatherford provides a full range of products and services designed to minimize expensive downtime and maximize the capabilities of the rig.
We offer a variety of pumps specifically designed for land based, offshore, and other specialty drilling conditions as well as the ability to provide complete, ready to run pump packages. In addition, we now offer a full line of premium mud pump components and expendables for Weatherford’s own pumps but also any almost any other brand pump you may have operating in your rig fleet.
Ellis-Williams™ Mud PumpsWeatherford’s Ellis-Williams™ mud pumps represent our flagship product line and are designed to offer unmatched performance under the most demanding drilling conditions. Since 1942, the name Ellis Williams has been associated with efficient, durable, and innovative mud pumps and that tradition is proudly extended today under Weatherford with the acquisition of the Ellis Williams Engineering Company in 2008.
Ellis-Williams mud pumps are available in three different series covering 19 unique pump modes rated at up to 3000 HP. Designed and manufactured in the USA, the Ellis-Williams pumps are the pump of choice for the toughest drilling assignments.
Applications:• Offshore drilling
• Extreme condition land drilling
• Helicopter drilling packages
• Artic drilling package
• Riser boost service
Features, Advantages, and Benefits:• Fully balanced, forged steel crankshafts
• Premium valves, pistons, and liners offered as standard equipment
• Revolutionary smooth, low pulsation EQ series quintuplex pump
• Ultra lightweight EH series designs
• Best warranty in the industry
Specifications• Use the quick reference table from page 5 of the new Ellis-Williams catalog.
© 2010 Weatherford. All rights reserved. 79
Mud Pumps
Mud Pumps and Packages, Expendable Parts, and Service
Ironman™ Mud PumpsThe Ironman™ mud pump line represents great value in a proven, simple to maintain mud pump design that is perfectly suited for most traditional, land based drilling applications. The Ironman pumps are based on the industry recognized, proven and trusted F series mud pump design. This offers peace of mind knowing that parts and services are readily available almost anywhere in the world and compatibility with many of the pumps already in service with most rig fleets.
The Ironman pumps are available in 5 models rated up to 1600 HP. When you factor in our competitive pricing, off the shelf availability of pumps and parts, plus the true global support that only a company like Weatherford can provide, it’s clear that the bar for mud pumps has been raised.
Applications:• Traditional land based drilling
Features, Advantages, and Benefits:• Single piece, alloy steel crankshaft
• Full roller bearing construction
• Extra value accessories like pulsation dampeners, discharge strainers, and liner wash systems provided as standard equipment
Specifications• Make a similar quick reference table like the one on page 5 of the new Ellis-
Williams catalog.
80 © 2010 Weatherford. All rights reserved.
Mud Pumps
Pump PackagesBoth the Ironman and Ellis-Williams mud pumps can be supplied fully packaged directly from Weatherford. We have over 130 years of pump packaging experience at our disposal and we have over 100 different pump an drive train configurations to choose from. Packages are available with a variety of different power and drive components to meet the needs of the operating condition. We can supply standard packages engineered by Weatherford at competitive prices and with quick deliveries, or the ability to build a custom system that is designed specifically around the needs and requirements of the customer.
All Weatherford mud pump packages are designed and built by Weatherford to insure the best quality, performance, and durability. Our extensive experience building pump systems insures that your pump well as the package are designed to work together properly.
Features, Advantages, and Benefits:• AC or DC electric motor drivers
• Diesel or natural gas engine drives
• Belt, Chain, or gear drives
• Transmissions, clutches, and torque converters
• Electric or full mechanical accessory options
• Lightweight, narrow, or multi-piece package options for easy transport to drilling locations by highway, water, or air
• Full in-house engineering support
Mud Pumps and Packages, Expendable Parts, and Service
© 2010 Weatherford. All rights reserved. 81
Mud Pumps
Mud Pump ExpendablesWhile all drillers carefully evaluate mud pump, many underestimate the importance of using quality expendables in these pump. These expendables are relatively low in cost compared to the pumps themselves and may even look good sitting in the box. It’s tempting to consider using locally available parts because of low cost or convenience, but the fact is that the real costs to the driller using low cost products may be many times more that the savings realized on the parts when a failure results in unplanned downtime.
Weatherford offers a full line of expendables designed to work with all major brands of mud pumps in operation today. These are premium components that are designed and manufactured fully in the USA to strict quality standards. They provide reliable, repeatable performance that drillers can count on when needed.
Weatherford can provide OEM quality parts for Continental-Emsco, Gardner-Denver, LEWCO, Oilwell, National, and other leading mud pumps.
Products:• Valves
• Seats
• Pistons
• Chrome Iron Liners
• Zirconia Ceramic Liners
• Piston Rods
• Fluid End Modules
• Crankshafts
• Gear Sets
Mud Pumps and Packages, Expendable Parts, and Service
weatherford.comWeatherford products and services are subject to the Company’s standard terms and conditions, available on request or at weatherford.com. For more information contact an authorized Weatherford representative. Unless noted otherwise, trademarks and service marks herein are the property of Weatherford. Specifications are subject to change without notice. Weatherford sells its products and services in accordance with the terms and conditions set forth in the applicable contract between Weatherford and the client.
© 2009 Weatherford. All rights reserved. 6017.01
Automated Rig Equipment
Engineered efficiency
Weatherford provides worldwide service and support from approximately 800 locations in more than 100 countries. To find out more about our automated rig equipment, contact an authorized Weatherford representative at [email protected], or visit weatherford.com/MechanizedRigSystems.