DRILL PIPE TONGS

OPERATING PROCEDURE MANUAL

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Drill Pipe Tongs Operating Procedure Manual
 TABLE OF CONTENTS

Section Page

1 - Introduction 2

2 - Operation 3

3 - Non Destructive Examination 4

5 - Maintenance 5-6

6 - Repairs 7

7 - Warnings and Cautions 8

Certificate of Warranty and Guarantee to Quality 9

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1 - INTRODUCTION

All Access Manual Tongs are manufactured in accordance with API Specifications 7K and
AOT Quality Control Procedures. Torque capacity ranges from 35,000 to 100,000 Ft-lbs over
a variation of 5 different types covering size ranges from 2-3/8” to 25”. Each tong is
manufactured from heat-treated alloy steel. Lug jaws are designed for safe and convenient
interchangeability for different pipe sizes. Installing additional hinge jaws, with hinge pins
manufactured from special heat-treated alloy steel, allows for bigger pipe handling.

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2. OPERATION

To install the tong, connect the tong support line to the suspension ring and install the right
lug and/or hinge jaw to cover the appropriate size range. You must also verify that the tong is
capable of handling the torque required. To reduce the arc of swing and distance that the
tong must travel, suspend the tong up by the support line as close to the center of the rotary
table as possible. Tong balance is required and can be adjusted by the hanger adjustment
bolts/screw and/or balancing screw. Open the jaws and balance the tong from lever to latch
and from side to side without making contact with the pipe. For best operation the long jaw
should be about 1” lower than the short jaw. Connect the pull line to the end of the lever and
a back-up line, sized safely to withstand the tong torque rating, to secure safe operation.

With the tong positioned and balanced properly, the operation of the tong is as follows:

• Grasp the lug jaw and hanger safety handles then move the tong into position about
the pipe.
• Press the short jaw firmly around and against the pipe.
• While simultaneously pushing both safety handles, the manual tong will latch
automatically.
• Pull both safety handles to break-over the tong and grip the pipe.

CAUTION:
Because manual tongs are critically loaded tools, line pull on the lever should be 90˚ from
axis of lever, see figure 1. Torque should never exceed the manufacture’s rating at any time.
Injury can be avoided should the tong slip, release, or fall by having all rig personnel out of
the tong lever travel area of the rig floor when making up or breaking out tubulars.

MAKE-UP TORQUE

Torque is the measurement of how much force acting on an object, which causes that object
to rotate.
Multiplying the tong arm length (L) and the line pull (F) is the measurement of torque, when
the arm tong (axis of lever) and the pulling line are at right (90˚) angles.

When making up connections, it is recommended that a line pull gauge is used and that the
line to be pulled is at a right angle (90˚) to the tong handle. Be sure to apply a long steady
pull rather than jerking the line.

AXIS OF LEVER

LINE PULL

Figure 1

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3 - NON-DESTRUCTIVE EXAMINATION

AOT Tongs should be MPI examined on a regular basis and conducted as outlined in the
latest revision of the recommended practice of API spec 7K. The magnetic particle
examination should be conducted every 3 months for existing manual tongs, HT tongs or HT
upgraded tongs. The magnetic particle examinations consist of magnetizing the area to be
inspected and then applying magnetic particles to the surface of the test area. The test area
shall be cleaned prior to beginning the inspection process. The part shall be clean, dry, and
free of contaminants such as oil, grease, and loose rust or scale.

The part shall be inspected using the continuous (active) magnetization technique and
examinations must be performed with sufficient overlap to assure 100% coverage of the area
or part under inspection. Wet continuous method must be done in accordance with ASTM
E709 and defects compared to ASTM E125 reference photographs and AOT critical area
drawings.

ACCEPTANCE CRITERIA
ASTM shall be applied as a reference standard for evaluation of magnetic particle indications
on castings and AOT critical area drawings. The acceptance criteria shall be as specified in
the following tables.

MAXIMUM PERMITTED DEGREE

TYPE DISCONTINUITY DESCRIPTIONS CRITICAL AREAS NON-CRITICAL AREAS
I HOT TEARS, CRACKS NONE DEGREE 1
II SHRINKAGE DEGREE 2 DEGREE 2
III INCLUSIONS DEGREE 2 DEGREE 2
IV INTERNAL CHILLS, CHAPTERS DEGREE 1 DEGREE 1
V POROSITY DEGREE 1 DEGREE 2

Critical Areas
Non-Critical Areas

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5 - ROUTINE MAINTENANCE

Functional testing should be performed prior to use of the manual tongs or on a regular basis.
AOT recommends checking the following list of items when performing functional test.

• Visual inspections for loose, worn, and missing parts.

• Check for worn hinge pin and hinge pin holes by trying to vertically move the jaws from
the lever.
• Make sure all pins are properly locked,
• Verify proper latch engagement with the steps of the lug jaw. When latched and under
torque, the latch must not touch any other part of the tong except on the step of the lug
jaw.
• Clean dies thoroughly and check for wear.

Lubrication plays a key role in the functionality of the tong and should be performed prior to
use and on a regular basis. Hinge pins should be greased through grease nipples.
Lubrication during regular usage and storage will prevent corrosion to the tong’s operating
mechanism. Extreme pressure lithium based multi-purpose grease of no. 1 or 2 consistency
should be used along with 10W 30 or 10W 40 motor oil to lubricate the manual tongs.

Torque testing on all AOT Manual Tongs manufactured or repaired is performed at 1-1/2
times the torque rating for a duration of 5 minutes.

WEAR CRITERIA

Manual tongs found to have excessive wear or cracks should be replaced or repaired by AOT
or an AOT authorized service center. Failure to do so can result in serious bodily harm or
property damage.

Please reference the following table and illustration for the maximum allowable wear to
maintain 100% torque rating.

Tong Type Dim A Max. Clearance Dim B Max Clearance

HT 100 .035 .035
B
HT 65 .035 .035
TYPE B .025 .035
A TYPE C .030 .035

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 WEAR GROOVES

Pin wear is measured by the three wear grooves along the shaft. If any of the grooves are
unseen, this means that the pin has some wear and must be replaced immediately.

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6 - REPAIRS

Caution: Always wear Personal Protective Equipment during repair of manual tongs.

CHANGING DIES:

Worn dies must be replaced as needed according to the following steps.

• Take out cotter pins by removing the die retaining pins.

• Using tong die driver, drive the dies out and replace with new ones.
• Re-install die retaining pins with cotter pins.

REMOVING LUG JAW FOR SIZE CHANGES:

Please use the following steps when removing lug jaws for size changes.

• Unscrew hinge pin nut and unlock pin to remove hinge pin.
• Remove existing lug jaw and replace with appropriate size lug jaw needed to perform
the work.
• Re-install hinge pin with pin nut and relock pin.

DISASSEMBLING HEAD:

Please use the following procedures to disassemble the head assembly.

• Remove the hinge pin and lock for the lever and disconnect the head assembly.
• Disconnect the latch by removing the hinge pin. Then remove latch and latch spring
plunger.
• For Type B tongs remove the latch jaw by removing the hinge pin. This will allow
removal of the adjustable stop assembly and booster plunger assembly.
• All other lug, hinge, short, and long jaws are to be removed by taking the various hinge
pins out.
• Removing all nuts and bolts of various jaws will allow for complete disassembly.
• Remove the hanger bolt and nut to disconnect the hanger assembly from the lever.
• Removing all nuts and bolts will completely disassemble the hanger and lever
assembly.

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7 - WARNINGS AND CAUTIONS

WARNING - The inspection and maximum wear allowances which are contained in this
document are only valid when the equipment is in good condition, has not been misused, and
does not have excessive wear, cracks, or other defects or previous weld repair. These
inspection criteria and maximum wear allowances apply only to certain components and as
such cannot, on their own, determine the overall condition of the equipment and it’s suitability
for continued use.

WARNING - Only AOT parts should be used for repair or replacement. Because of their cast
alloy heat-treated steel, manual tongs should not be welded in the field. Heat affected areas
containing cracks and brittleness due to improper welding can cause drastic weakening of the
part and possible failure. Repairs involving machining and/or welding should be performed
only by AOT or an authorized AOT repair facility. Using a manual tong that has been
improperly welded or repaired can cause failure, which may result in serious bodily injury of
property damage.

WARNING – To avoid injury do not place hands or any part of your body between pinch point
areas like jaws and pipe, between jaws, between latch and latch jaw, and between lever and
jaws. Also, be aware of sharp corners, which may cause cuts.

CAUTION – Practice safety at all times during operation and maintenance and used
approved safety methods, tools, and equipment. Do not place hands in undesignated areas
and used provided handles for operating manual tongs.

CAUTION – Improper machining could result in increased stress or improper alignment of

component parts, which could be hazardous to personnel and equipment. Only an AOT or
an AOT authorized facility may re-machine or re-heat treat parts. Field welding is not
recommended due to specialized metallurgy.

CAUTION – Always wear eye protection when grinding and striking parts.

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 CERTIFICATE OF WARRANTY AND GUARANTEE TO QUALITY

Seller warrants all materials, products and supplies manufactured or furnished by it to be free
from defects in material and workmanship, under normal use and service, when installed,
used and serviced in the manner provided and intended by seller for a period of twelve (12)
months after installation or delivery, whichever shall occur first. Seller’s obligations under this
warranty are expressly limited to repair or replacement, at its option, of any materials,
products or supplies returned to seller’s plant, Broussard, Louisiana, and which are
determined by seller to be defective. All freight charges for return and reshipment shall be
paid by customer. A new warranty period shall not be established for repaired or replaced
materials, products or supplies; such items shall remain under warranty only for the
remainder of the warranty period on the original materials, products or supplies. This is the
sole warranty of seller and no other warranty is applicable, either express or implied, in fact or
by law, including any warranty as to merchantability or fitness for a particular use or purpose.

In case of goods or parts not wholly of seller’s manufacture, seller shall make available to the
customer whatever warranty or guaranty is extended to seller for such goods or parts by the
supplier or manufacturer thereof.

Seller will not assume responsibility or liability for any repairs, rebuilding, welding or heat
treating done to its material, products or supplies outside of seller’s plants, such work shall
void any all warranties. All parts used in the manufacture and/or final assembly of seller’s
materials, products and supplies are necessary for both safety and operational performance.
Omission of any part or failure to replace any part may result in a malfunction and a
consequent safety hazard for which seller disclaims any responsibility or liability for injuries or
damage as a result thereof.

Buyer’s sole and only remedy in regard to any defective materials, products or supplies shall
be the repair or replacement thereof as herein provided, and seller shall not be liable for any
consequential, special, incidental or punitive damages resulting from or caused by any
defective materials, products or supplies.

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