Summary Rig automation projects can benefit from the experiences developed during the successful automation of rig pipe-handling equipment. The data provided were derived from the operation and development of iron roughnecks and pipe-handling systems in the field. This paper includes a study of failure mechanisms and how they affect reliability, presents maintenance experiences to show the impact of automation on crew capability and training, and describes many operational and design pitfalls. Introduction Four years ago, Varco Intl. Inc. installed fully integrated, automated pipe-handling machines (PHM's) on two jackup rigs and one semisubmersible rig. The PHM unit on the semisubmersible was removed in 1989 primarily because the operator was not satisfied with its reliability. The PHM's on the jackups operate in the North Sea and have undergone extensive modifications as a result of the information learned during their operation. These modifications include major changes to the control hardware, hydraulic systems, and many of the control components. Many of the changes resulted from activities and operations not anticipated during the original design of the system. Today, these two PHM's are considered successful state-of-the-art automated pipe-handling systems, and seven additional units have been ordered. One of these new units is operational and two more have been installed. The PHM's trip drillpipe and drill collars up to 9% in. [248 mm] in diameter without floor hands or a derrickman. PHM Description The PHM trips drillpipe and drill collar stands in and out of the well by remote control. This machine has spinning, torquing, lifting, and rack stand positioning. Each stand has fingerboard locking. Many operations, such as stand makeup and breakout, are performed automatically. The PHM (Fig. 1) consists of a column assembly that runs from the drill floor to the racking board, upon which two extending arms and an iron roughneck assembly are mounted. The columns move between well center and setback and can rotate 90° to the left or right. The arms are pivot-mounted and mechanically interconnected to operate in parallel. Hydraulic clamping jaws at the ends of the arms hold drillpipe and drill collars from 3½ to 9 ¾ in. [88.9 to 248 mm] in diameter.