radial cutting torch_operating_manual_ver_g.pdf
TRANSCRIPT
THIS OPERATING MANUAL MUST BE READ AND UNDERSTOOD BY THE OPERATOR PRIOR TO USING THE RADIAL CUTTING TORCH SYSTEM.
ONLY TRAINED OPERATORS LICENSED BY MCR OIL TOOLS CORP. ARE PERMITTED TO USE OR RUN THE RADIAL CUTTING TORCH SYSTEM. MCR ISSUES A CERTIFICATE OF LICENSE TO ALL TRAINED PERSONNEL.
Operating Manual RADIAL CUTTING TORCH
www.mcroiltools.com
Revision G August, 2002
MCR Oil Tools P.O. Box 684 Burleson, TX 76097 Sales: 817 447-8878 1-800-538-2338
WARNING
Contents
I. BRIEF DESCRIPTION: PAGE
1. RADIAL CUTTING TORCH.............................................................................. A) Assembly Cutaway Drawing..................................................................... B) Complete Assembly Cutaway Drawing.................................................... 2. EXTENSION ADAPTER.................................................................................. A) Assembly Drawing................................................................................... 3. PRESSURE BALANCE ANCHOR................................................................. A) Assembly of Aluminum Anchor.................................................................. B) Assembly of Steel Anchor....................................................................... 4. THERMAL GENERATOR................................................................................ A) Assembly Drawing................................................................................... B) Radio Silence Testing Summary............................................................... 5. ASSEMBLY...................................................................................................... A) Assembly Drawing.................................................................................... B) Dimensional Data....................................................................................
II. THEORY AND OPERATION...................................................................................
III. SAFETY PRECAUTIONS.......................................................................................
IV. ASSEMBLY PROCEDURES...................................................................................
V. DISASSEMBLY AND CLEANING...........................................................................
VI. SPECIFICATIONS..................................................................................................
VII. APPLICATIONS......................................................................................................
VIII. ADVANTAGES........................................................................................................
IX. RETURN POLICY...................................................................................................
X. TRAINING..............................................................................................................
XII. MSDS SHEET........................................................................................................
XI. FIELD REPORT FORM..........................................................................................
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Radial Cutting Torch
The Radial Cutting Torch ( RCT) is a patented cutting device used to sever tubing, casing and drill pipe and coil tubing. The RCT performs this task without the use of highexplosives or dangerous chemicals. The RCT utilizes a new technology which consists of a proprietary mixture of various powdered metals, a torch body, and a nozzle section. There is no detonation with the actuation of the RCT. The reaction can best be described as a burn with the effect being similar to that of an oxyacetylene cutting torch.
The nozzle section, located at the lower end of the torch, consists of carbon elements that act as a heat barrier for the steel nozzle, the threaded nozzle, the diverter, the cap andsleeve. The nozzle section is protected from well bore fluids by means of a sleeve that slides out of the way upon ignition exposing the nozzle to the well bore for cutting.
The powdered metal mix is pressed into solid donut -shaped pellets that are then stacked into the elongated part of the torch body. The pellets are held in place in the body of the torch with an aluminum "Buffington" disc and a snap ring. The new "Buffington "disc is an aluminum disc that allows the Thermal Generator to effectively penetrate the disc during initiation. The "Buffington" disc does not need to be removed prior to assembly. No field assembly of the torch is required as the torch comes completely assembled.
MCR has developed a new Isolation Sub to protect the tools located above the RCT system from being damaged by the molten plasma generated during the cutting process. In practice certain well conditions can cause the molten plasma in the torch to move upward into the tool string and cause a great deal of damage to subs, sinker bars, collar locators and other tools attached to the RCT. The Isolation Sub acts as a check valve to prevent this plasma from entering into the tool string above the RCT.
A new patented design has allowed MCR to develop new small diameter torches to cut coil tubing. This new design will allow MCR to develop and expand the capabilities of the new smaller torches as well as our larger torches into higher pressure ranges (15 ksi - 20 ksi).
Operating Manual 1 ______________________________________________________________________________
Radial Cutting Torch (RCT)
Snap Ring w/Disk
Fuel Pellets
Nozzle SectionSliding Sleeve
Anchor Connects here
Operating Manual 2
Rad
ial C
uttin
g To
rch
_____________________________________________________________________________________________
Radial Cutting Torch Assembly (with/out Anchor)
Isolation Sub
Thermal Generator SubThermal Generator
RCT Extension
Fuel Pellets
Radial Cutting Torch (RCT)
RCT--Nozzle EndSliding Sleeve
Anchor Connects Here
Operating Manual 3
Electrical Contact
Snap Rings w/ Disk
Radi
al Cu
tting
Torc
h Ass
embl
y
_______________________________________________________________________________
Extension Adapters
The Extension Adapter (EXT) is a small section of machined tubing loaded with thesame pellets as the main section of the RCT. The adapter has a male thread section on the lower end and female thread section on the upper end. The male threaded section of the extension is mated into the female thread section located at the top of the RCT. Both ends of the Extension Adapter are sealed with an aluminum "Buffington" disc and a snap ring. O'rings are provided with the adapter.
The Extension Adapter is used to increase the load capacity of the basic RCT. The standard RCT (without Extension Adapters) is used when the hydrostatic pressure is below 4,000 psi. The extension adapter is added when the hydrostatic pressure is above 4,000 psi. or when a higher degree of cutting is needed such as in uncentralized cutting conditions or cutting tail pipe. Please reference the specification sheet for actual pressure ratings. Higher pressure RCT's may be available for certain pipe sizes.Check with manufacturer for high-pressure applications above 10,000 psi.
Use of the Extension Adapter gives the field engineer flexibility because it allows him to increase the basic torch load at the job site with a minimum of effort. Inventoryand storage costs can be greatly reduced and kept to a minimum especially when usedin remote areas.
Operating Manual 4 _______________________________________________________________________________________________
RCT Extension
Fuel Pellets
O'Rings
Snap Rings w/ Disks
Operating Manual 5
RC
T EX
TEN
SIO
N
______________________________________________________________________________
Pressure Balance Anchor
The Pressure Balance Anchor (PBA) is a patented anchor system that uses state of the art dynamics to stabilize the RCT during the cutting operation. Extreme forcescaused by rapid pressure increases and flow velocities will cause the RCT to develop a thrust element and move up hole when fired. The PBA harnesses these forces so so that movement of the RCT during the cutting operation is prevented.
The Pressure Balance Anchor consists of a cylindrical body approximately the same diameter as the RCT. The PBA cylinder is connected to the bottom of the RCT by meansof a socket that slides over the end of the RCT cap and is held in place with setscrews. Smaller versions (1-11/16", 1-1/2", 1-3/8") of the PBA come with two port holes on thebottom end of the anchor that house rubber fingers used for centralizers. Larger versions(2" and above) should be centralized with conventional mechanical bow spring typecentralizers.
The Pressure Balance Anchor has no moving parts such as slips or buttons that can cause the cutter to malfunction or slip during the cutting operation or become stuck in certain tubulars.
Pressure Balance Anchors for the 1-3/8" and 1-1/2" RCT's are made of aluminum and come in two sections; the upper section is called the Pressure Balance Extension (PBE) and the lower section is called the Pressure Balance Anchor. Under most cutting conditions both sections are required for successful operation. All the other Pressure Balance Anchors are made of steel. Some assembly is required with these anchors. The steel anchors come with tube sections packaged separately from the three sub connections and are connected as follows:
1. Socket sub - mates to end cap of RCT 2. Tube section 3. Dual pin connector - mates between two tube sections 4. Tube section 5. Bull plug ( has a 15/16"-10 UN thread in the bottom, 5/8" sucker rod connection) 6. Centralizer sub (comes separately) - Larger torches require centralizers that will thread to the bottom of the anchor bull plug.
Operating Manual 6 ___________________________________________________________________
Pressure Balance Anchor - (Aluminum)
Anchor Extension (PBE)
Anchor (PBA)
Rubber Centralizer
Operating Manual 7_____________________________________________________________________________
Pres
sure
Bal
ance
Anc
hor
Pressure Balance Anchor (Steel)
Socket Sub
Dual Pin Connector
Bull Plug
Body Sections
Operating Manual 8
Pres
sure
Bal
ance
Anc
hor
_______________________________________________________________________________
Thermal Generator
Prior to 1999, the Radial Cutting Torch System relied upon the use of settingtool igniters as the primary means for initiating the RCT. Setting tool igniters, alsoreferred to as flame caps, are igniters that contain black powder, a Class C explosive. These are igniters that produce a variety of outputs ranging from a flame to an explosion. It is this wide range of output possibilities that cause severe problems when used with the RCT. SETTING TOOL IGNITERS OR FLAME CAPS ARE NO LONGER APPROVED FOR USE WITH THE RADIAL CUTTING TORCH SYSTEM.
MCR Oil Tools Corp. has developed a new "Thermal Generator" system for initiating the RCT. The Thermal Generator is a resistorized device requiring a firing current of one(1) Amp. for 10 to 30 seconds (depending on well temperature and wireline condition)to initiate. The MCR Thermal Generator contains a flammable solid composition; it cantherefore be shipped with the RCT as a Flammable Solid, UN 1325, Section 4.1Classification.
The Thermal Generator mates directly into the new Thermal Generator Sub12 UN thread. It is held in place with a snap ring thus insuring positive grounding. Initiation may be accom-plished with either AC current or DC+ current. The proper procedure to insure a positive initiation is to slowly ramp the variac to amp and hold for15 seconds. If the Thermal Generator has not fired after 15 seconds, very slowly rampthe current upwards at 0.1 amp increments until a break is achieved. DO NOT USE DC-CURRENT.
When performing a functionality check on the Thermal Generator a resistance reading of 45 to 55 ohms must be read on the galvanometer. If the resistance reading is outside this range do not attempt to use it; return the Thermal Generator to thefactory for replacement. If the Thermal Generator checks within the acceptable range,install it in the Thermal Generator sub and attach the Isolations Sub. Check the thermal generator again for the proper resistance reading. If the resistance is outside the acceptable range check perform a continuity check on the subs and replace the subs if necessary.
The MCR Thermal Generator has undergone an extensive series of Radio Sensitivity tests to provide MCR with data qualifying it for use in Radio Sensitive areas. The ThermalGenerator passed all tests performed by an independent third party laboratory; a copyof the results page is provided on page 10. All Radial Cutting Torch Systems are now qualified for use in Radio Silence / Radio Sensitive conditions.
Operating Manual 9____________________________________________________________________
Thermal Generator - Sub Assembly with Isolation Sub
Isolation Sub
Snap Ring Secures THG to SUB
Banana Pin
Thermal Generator (THG)O'Ring
Thermal Generator--Sub
O'RINGS
Snap Ring Groove
__________________________________________________________________Operating Manual 10
Th
erm
al G
ener
ato
r
Radio Silence Testing Summary
Report 20498 February 11, 2002
6. Conclusions
These are very insensitive devices. For a DC stimulus, it takes more than 30 voltsfire a Thermal Generator. Since the input resistance is 50 ohms, this corresponds to 18 watts.
For RF stimulus, it takes more than 54 rms volts (58 watts) to fire a Thermal Generator. That was a frequency of 2 MHz, close to the AM broadcast band. There is noreason to think that the Thermal Generators would be more sensitive at any otherfrequency.
The long-term RF exposures were performed with 42 rms volts on a 50-ohm load. That corresponds to approximately 35 watts The Thermal Generators did not fire during a 15-minute exposure. That is such a long time the Thermal Generator must have come tothermal equilibrium with its surroundings so it could withstand this kind of exposureindefinitely. It did not affect the Thermal Generators' performance; they fired normally inresponse to a high level stimulus later on. When wires are attached to these Thermal Generators, they will naturally pick up some amount of radio frequency (RF) power from nearby radio transmitters. But theamount of RF power pickup will be much lower than 18 watts or 35 watts or 58 watts.That will be true no matter what kind of transmitter is nearby. This judgment is based onthe experience of staff scientists at Franklin Applied Physics, Inc.
These Thermal Generators are safe to use near all kinds of radio-frequency transmitters.It is not necessary to turn the transmitters off. This includes transmitters used for broad-casting, communications, and radar of all kinds. This includes hand- held walkie-talkies, VHF, HF, SSB, AM, microwave links, and maritime radar.
Franklin Applied Physics, Inc. - Page 10
___________________________________________________________________Operating Manual 11
Radial Cutting Torch Assembly
The Radial Cutting Torch assembly consists of the Thermal Generator, Isoaltion SubThermal Generator Sub, the Extension Adapter(s) (as needed), the Radial Cutting Torch,and the Pressure Balance Anchor with centralizer.
For best results, both the upper and lower end of the assembly should always becentralization. If this is not possible, an increased load may be required to compensatefor the lack of centralization (contact manufacturer for recommendation).
A common run configuration will consist of:
1. The cable head assembly attached to; 2. A centralizer sub with electrical feed through (Applied Electronics P/N AS5-0023) attached to; 3. A CCL assembly attached to; 4. A 5' sinker bar (Optional) with electrical feed through attached to; 5. An electrical GO type dual pin sub (Applied Electronics P/N AS60070) attached to; 6. The Isolation Sub attached to; 7. The Thermal Generator sub with the Thermal Generator installed attached to; 8. The Extension Adapter(s) (As needed) attached to; 9. The Radial Cutting Torch followed by; 10. The Pressure Balance Anchor Assembly 11. Centralizer fingers (rubber) or a bottom centralizer or centralizer sub
Note: . An optional mechanical or pneumatic set of jars may also be used with the assembly.
Operating Manual 12 __________________________________________________________________
Typical Assembly
Cable Head Assembly
Centralizer Sub
Collar Locator (CCL)
Sinker Bar
Isolation Sub
Thermal Generator and Sub
Radial Cutting Torch (RCT)
Anchor (PBA)
Operating Manual 13
Typi
cal A
ssem
bly
______________________________________________________________________________
Dimensional Table For RCT Systems
P/N Torch Length* Add Extension Anchor
RCT-0750-200 52.75" 8.5" each 47"
RCT-0875-200 52.75" 8.5" each 47" RCT-1000-200 52.75" 8.5" each 47"
RCT-1375-200 34.75" 8" each 56"
RCT-1500-200 36.25" 8" each 56"
RCT-1688-200 31.25" 8" each 52.5"
RCT-2000-200 31.25" 8" each 52.5"
RCT-2437-500 36.75" 10" each 52.5"
RCT-2500-200 31.25" 10" each 52.5"
RCT-2937-100 29.25" 10" each 71"
RCT-2937-500 38.75" 10" each 71"
RCT-3375-200 37.75" 14" each 71" RCT-4000-200 55.75" 14" each 71" RCT-5000-100 55.75" 14" each 71"
*Measurements with/ Isolation Sub and Thermal Generator Sub attached
___________________________________________________________Operating Manual 14
Theory and Operation
The Radial Cutting Torch assembly is lowered into the well on an electric wire line to the desired depth. Current is passed through the wire line to the Thermal Generator (see page 9). The resistor in the Thermal Generator is heated to ignition temperature. The generator creates heat to ignite the main load. Ignition of the main load is fueled by the release of oxygen in the mixture. The by-product of this process is heat in the form of highly energized molten plasma. It is this heat generated in the torch that also causes an increase in internal pressure. Once the pressure in the torch exceeds that of the well bore, the sleeve covering the nozzle slides down exposing the nozzle to the well bore. The molten, highly energized plasma escapes the torch body through the nozzles and is diverted 90 degrees toward the inside diameter of the tubing. At this point, the molten plasma has the consistency and cutting action of a 6,000 degree sand blaster. The highly energized by products act as atomic sand blast beads that impart heat and erosion to the cut area. It is this erosion property that permits the RCT to cut effectively even under high stand off conditions. The cutting process is accomp-lished in approximately 25 milliseconds.
Once the cut is made, the RCT assembly is removed from the well by picking up on the wireline. Disassemble the RCT assembly and discard the optional Extension Adapter(s) and the expended RCT and the Thermal Generator. The Pressure Balance Anchor and the Thermal Generator Sub can be cleaned for future use.
________________________________________________________________ Operating Manual 15
HANDLING - The Radial Cutting Torch system (RCT) should be handled with the same care and precautions as those used in the handling of explosive devices and chemical cutters, as spelled out in the American Petroleum Institutes recommended practice-67 (api rp67) and should be strictly adhered to.
NEVER DROP - or mishandle the RCT as damage will occur to the nozzle which will cause the RCT to malfunction during the cutting operation and may cause the torch assembly to leak.
DO NOT DAMAGE NOZZLE -The Radial Cutting Torch assembly, consisting of the torch or torch and extension adapters, must be attached to the tool string in the vertical position. Care must be taken not to twist, bend, or bind the nozzle section as damage may occur to the nozzle section causing the RCT to fail by filling the RCT with well-bore fluids or by premature o'ring failure at pressure causing a sudden ingress of fluid.
NO SPUDDING -The practice of spudding (lowering the wireline at ever increasing free fall speeds in an attempt to pass through or move an obstruction or restriction in the well) should "never" be attempted. Spudding can cause damage to the torch and a sudden ingress of well bore fluid and pressure to the main load that can result in premature ignition. Reference the applications section of this manual for further information on spudding.
MUST BE CENTRALIZED -The RCT system must always be centralized to insure proper cutting action of the RCT assembly. If this is not possible, you must call the manufacturer for recommendations; in some cases an extra extension adapter may be required to accomplish the cut. Extreme care must be taken not to over-load the RCT system as casing damage may occur.
STORAGE - The RCT system must be stored in a clean, dry and protected place. Never exceed the pressure rating of the RCT as defined in the Specifications section of this manual. Specifications may change so be sure the current specifications are being used. Call the manufacturer at 817-447-8878 for the current specifications sheet.
Operating Manual 16
SAFETY PRECAUTIONS
________________________________________________
SAFETY PRECAUTIONS
PLUGGED TUBING - Do not use the Radial Cutting Torch (RCT) in tubing that is plugged or that is collapsed or restricted in any way. When fired in these cutting situations the RCT will become unbalanced and will be lifted upward by the escaping plasma. Not only will the RCT not cut the tubing, but severe damage will occur to the tool string and the tools above the RCT will be thermally gutted (the isolation sub may prevent most of this). The RCT will also sustain damage and can weld itself to the tubing. For further information on how to use the RCT properly in these situations, refer to the Applications section of this manual.
NO PUMPING WHILE RUNNING- The RCT should not be run when pumping into a well that is taking fluid. Fluid moving past the RCT may destabilize the RCT and cause it to move during the cutting operation.
RUN GAGES PRIOR TO RUNNING RCT - A drift gage must always be run prior to running the RCT to insure that there are no obstructions or restrictions in the wellbore that would prevent the tool string from getting to depth. A dummy run without the live RCT must be run whenever a no-go gage is used. This will insure that the RCT will pass through any restriction or obstruction in the well.
NEVER MODIFY - Do not modify the RCT system by attaching externalcentralizers or no-go gages to the RCT system or anchor system.
NEVER REMOVE SLIDING SLEEVE - Do not remove the sliding sleeve from the torch, as damage may occur to the o'rings when repositioning the sleeve onto the RCT. This will cause the damage to the RCT and will cause the RCT to malfunction.
MAXIMUM RUNNING SPEED - The maximum running speed for the RCT system in clean unrestricted and unobstructed tubing, casing or drill pipe is three hundred feet per minute provided a dummy gage run has been made prior to running the live RCT.
________________________________________________ Operating Manual 17
Assembly Procedures
1. Unwrap the Thermal Generator, screw the banana plug into the top button and insert the generator into the generator sub so that the banana pin on the generator is looking up toward the female threaded end of the sub. Install the snap ring provided. Check the resistance of the generator with an approved meter prior to further assembly.
NOTE: Resistance should read between 45 and 55 ohms for the Thermal Generator. Attach a blast shield over the generator sub similar to Halliburton Explosive Products Center P/N 40528.
2. Attach the electrical contact sub to the top of the isolation and the isolation sub to the top of the generator sub. Tighten prior to running down hole. (A) Use Applied Electronics, GO type dual pin sub P/N AS6-0070 for 1-1/2" RCT's and larger. (B) Use Applied Electronics, GO type dual pin sub P/N AS3-0005 for the 1" & 1-3/8" RCT's. (C) Use Applied Electronics, GO type dual pin sub P/N ASO-0014 for the 7/8" & 3/4" RCT's.
3. Check the resistance again with an approved meter. Place one lead of the meter of the con- tact socket of the electrical contact sub and the other against the side of the sub.
NOTE: Resistance should read the same as Noted.NOTE: Make sure the wireline shooting panel has been tested and shunted prior to connect- ing the generator sub.
4. Attach the Electrical Contact Sub/Isolation Sub/Thermal Generator Sub assembly to the cable head assembly and tighten.
5. Remove the Radial Cutting Torch from its package. Take care not to drop the RCT as damage could occur to the box end of the torch or nozzle.
6. Attach the Extension Adapter(s) (EXT), as required, to the top end of the RCT. Tighten all threaded connections. The torch assembly is now ready to connect to the vertically hanging tool string. (See step #10 before mating torch assembly to the Thermal Generator Sub).
NOTE: THE METHOD OF ATTACHING THE RCT ASSEMBLY TO THE TOOL STRING IS TO FIRST RAISE THE WIRELINE ASSEMBLY, WHILE SUSPENDED VERTICALLY THREAD THE RCT TO THE THERMAL GENERATOR SUB FOLLOWED BY THE ANCHOR ASSEMBLY.
___________________________________________________________________Operating Manual 18
7. Assemble the anchor. The 1-3/8" and 1-1/2" systems have an aluminum anchor system. The anchor extension must be used with the anchor. They are attached with a socket connection and four 1/4" socket set screws. All larger anchor systems are made of steel and must be assembled by connecting the two tubular bodies with the three sub connections, See page 6, Pressure Balance Anchor section. The smaller size torches have a one piece steel anchor.
8. Insert the rubber centralizers in the anchor or anchor bull plug as required or attach the appropriate centralizer as required. Refer to page 6, Pressure Balance Anchor section.
9. The anchor assembly is now ready to be attached to the bottom end of the RCT assembly.
NOTE: WHEN ATTACHING THE ANCHOR ASSEMBLY TO THE VERTICALLY HANGING RCT ASSEMBLY ALWAYS SUPPORT THE NOZZLE SECTION BY HOLDING ONTO THE RCT BODY. DO NOT PUT THE NOZZLE IN A BIND, AS THIS CAN CAUSE DAMAGE TO THE NOZZLE.
10. Attach the Pressure Balance Anchor to the bottom end of the RCT and tighten the setscrews on the anchor. For torch systems using the steel sectioned anchor system, the socket sub that attaches to the top of the anchor should first attached to the grooved cap at the bottom of the torch and the rest of the anchor attached. This may also be performed with the RCT in a vertical position.
NOTE: Care should be taken not to twist or bind the nozzle end of the RCT, as this may damage the nozzle. Make sure the set screws on the anchor sub are aligned with the groove on the RCT cap. To insure proper alignment, remove one setscrew & put the allen wrench through the hole vacated by the removed set screw and slide the anchor over the end cap of the torch until the wrench seats in the groove. Once the groove is located by the end of the wrench, tighten the remaining three screws and replace and tighten the removed screw. To be sure that the set screws are located in the groove untorque the set screws and try to slide the anchor. The set screws will prevent the anchor from moving more than 1/8th of an inch, if more move- ment is experienced, the anchor is not seated properly.
11. The Thermal Generator is initiated by ramping the current to one (1) amp and holding it for fifteen (15) seconds if the circuit has not broken after 15 seconds, then slowly ramp up the current until the Thermal Generator ignites. The increase in current may be necessary due to current leakage in the wire line. One amp must be applied to the Thermal Generator resistor before proper heating can occur. ___________________________________________________________________ Operating Manual 19
Disassembly and Cleaning
1. After firing and removal of the tool from the well, check the tool for signs of a possible malfunction. Always fill out a copy of the Field Report and send it to the manufacturer.
1. Check for holes in the body of the RCT. 2. Check for wash out places in the o'ring area of the nozzle. 3. Check for cracks in the diverter. 4. Check to make sure the sleeve has slid all the way clear of the nozzle.
2. Disassemble the RCT system from the cable head assembly.
3. Unscrew the setscrews on the anchor from the nozzle end of the RCT.
4. Unscrew the electrical contact sub from the Isolation Sub; rebuild if necessary.
5. Unscrew the Isolation Sub from the Generator Sub & rebuild if necessary.
6. Unscrew the Thermal Generator sub from the RCT or Extension Adapter as the case may be. Remove the spent Thermal Generator case from the sub.
7. Thoroughly steam clean the Thermal Generator sub, the anchor & centralizer.
8. The RCT and the Extension Adapter(s) may be discarded and disposed of as scrap iron.
9. After cleaning, all parts should be coated with a suitable rust inhibiter to prevent corrosion during storage.
___________________________________________________________________ Operating Manual 20
0-4,0004,000-10,000
0-4,0004,000-10,0000-4,0004,000-10,000
0-4,0004,000-10,000
0-4,0004,000-10,0000-4,0004,000-10,000
0-4,0004,000-10,000
0-4,0000-4,0004,000-10,0004,000-10,000
PART NUMBER DESCRIPTION RECOMMENDED USE PRESSURE PSI
SPECIFICATIONS
RADIAL CUTTING TORCH
Operating Manual 21_______________________________________________________________________________
RCT-1500-200RCT-1500-300
RCT-1688-200RCT-1688-300
RCT-1688-400
RCT-2500-200RCT-2500-300
RCT-2937-100RCT-2937-200*
RCT-2937-300
RCT-4000-200RCT-4000-300
RCT-5000-100RCT-5000-200*
RCT-5000-300
1 1/2" O.D.1 1/2" O.D.
1 11/16" O.D.1 11/16" O.D.
1 11/16" O.D.
2 1/2" O.D.2 1/2" O.D.
2 15/16" O.D.2 15/16" O.D.
2 15/16" O.D.
4" O.D.4" O.D.
5" O.D5" O.D.
5" O.D..
2 1/16" - 2 3/8" Tubing2 2/16" - 2 3/8" Tubing
2 7/8" Tubing 6.4# - 8.7#2 7/8" Tubing 6.4# - 8.7#2 7/8" Tubing 8.9# - 11/7#2 7/8" Tubing 8.9# - 11.7#
3 1/2" Tubing all weights3 1/2" Tubing all weights
4" Tubing, Casing & D.P.4" Tubing, Casing & D.P4 1/2" & 5" D.P.4 1/2" & 5" D.P.
5 1/2" Casing5 1/2" Casing
6 5/8" Casing7" - 7 5/8" Casing6-5/8" Casing7" - 7 5/8" Casing
Note: A -300 RCT is made by adding the -100 Extension Adapter to the basic -200 RCT. A -400 RCT is made by adding two -100 Extension Adapters to the basic -200 RCT. *These -200 RCT's are made by adding the -100 Extension Adapter to the basic -100 RCT.
RCT-0750-200RCT-0750-300
RCT-0875-200RCT-0875-300
RCT-1000-200RCT-1000-300
RCT-1375-200RCT*1375-300
RCT-2000-200RCT-2000-300RCT-2000-400
RCT-2437-500*RCT-2437-600*
RCT-2937-600*
RCT-3375-200
RCT-3375-300RCT-3375-550
3/4" O.D.3/4" O.D.
7/8" O.D.7/8" O.D.
1" O.D.1" O.D.
1 3/8" O.D.1 3/8" O.D.
2" O.D.2" O.D.2" O.D.
2 7/16" O.D. H.P.2 7/16" O.D. H.P.
2 15/16" O.D HP.
3 3/8" O.D.
3 3/8" O.D.3 3/8" O.D.
Coil Tubing to 1.5"Coil Tubing to 1.5"
Coil Tubing to 1.75" OD.Coil Tubing to 1.75" O.D.
Coil Tubing 1.5"-1.75" O.D.Coil Tubing 1.5" 1.75" O.D.
2 3/8" Tubing all weights2 3/8" Tubing all weights
3 1/2" Tubing 7.5#-10.3#3 1/2" Tubing 7.5#-10.3#3 1/2" Tubing 10.3#-16#
3 1/2" Tubing & DP3 1/2" Tubing & DP
4"- 4 1/2" TubingCasing & DP all weights
5" Casing 11/5# - 24#5 1/2" Casing 14# - 23#
5 1/2" Casing 14# - 23#5 1/2" Casing 24# - 26#
0-4,0004,000-10,000
0-4,0004,000-10,000
0-4,0004,000-10,000
0-4,0004,000-10,000
0-4,0004,000-10,0004,000-10,000
10,000-14,00014,000-20,000
10,000-15,000
0-4,000
4,000-10,0004,000-10,000
PART NUMBER DESCRIPTION RECOMMENDED USE PRESSURE PSI
SPECIFICATIONS
RADIAL CUTTING TORCH - SPECIAL ORDER
A -600 RCT is made by adding the -500 high pressure Extension Adapter to the 500 RCT.
*Denotes a high pressure tool (HP).
Operating Manual 22 ______________________________________________________________________________
SPUDDING: The RCT MUST NEVER be used as a ram (spudding) or forced by or through a restriction or obstruction in the well bore by means of repeated passes at high speeds with the wireline. Impact on the nozzle of the RCT created by the excessive force generated during "SPUDDING' can dislodge the o'rings in the nozzle and/or critically damage the nozzle parts. If the o'rings become dislodged or unseated during "SPUDDING", the o'ring will fail due to excessive loading and allow wellbore fluid to enter the RCT. The RCT will, under low pressure and temperature (4000 psi & 100 degrees F), flood and become inert. The torch may be able to be repaired and reloaded. At a combination of pressure above 4000 psi and temperature above 100 degrees F, the RCT can auto ignite. During auto ignition, usually no damage will be experienced to the tubing or casing, however, damage can occur to the internal elements of the tool string; damage to the torch will come in the form of the loss of the nozzle and anchor assembly. Auto Ignition can produce a complete cut of the tubing, a partial cut of the tubing ,no cut at all or damage to the RCT and sticking of the tool.
CUTTING PLUGGED, RESTRICTED OR COLLAPSED TUBING: When trying to cut tubing that is plugged or tubing that has a restriction such as a flapper valve or an obstruction such as a stuck tool string or collapsed tubing, the tubing MUST be perforated at some point between the bottom of the torch and the top of the plug, restriction, obstruction or collapse point. Perforating is MANDATORY even though the operator may be able to pump through the valve / plug or past the restriction or obstruction. The RCT requires a minimum amount of unrestricted flow area below the torch for proper operation. The only way to insure that the proper amount of flow area is available to stabilize the RCT is to perforate according to the attached perforating table (page 24).
If the operator does not follow the above requirements, the following scenarios will occur:1. The torch and the tool string will hydraulic upward causing the flow in the torch to stagnate.2. Stagnation causes excessive heat and pressure to be generated in the torch.3. Excessive heat and pressure in the torch could cause the torch body to burn out, the nozzle section to wash out and even lose the nozzle and anchor down hole.4. Excessive heat and pressure in the torch will cause the stagnated molten plasma in the torch to migrate upward through the tool string and melt the internals of every tool in the string.5. Upward movement of the torch will cause the torch to weld to the tubing at the point of stagnation.6. The RCT will not be able to remain stationary long enough to cut. No cut will be possible.7. The distance between the RCT and any plug, restriction, obstruction or collapse point is irrelevant. The RCT "WILL NOT CUT" in any of the above conditions without first perforating the tubing below the cutter.
Operating Manual 23_____________________________________________________________________________
Applications
PERFORATING TABLE
RCT-1375 must perforate with a minimum of 6 shots RCT-1500 must perforate with a minimum of 8 shots RCT-1688 must perforate with a minimum of 8 shots RCT-2000 must perforate with a minimum of 8 shots RCT-2500 must perforate with a minimum of 12 shots RCT-2937 must perforate with a minimum of 12 shots RCT-2937 must perforate with a minimum of 12 shots RCT-3375 must perforate with a minimum of 12 shots RCT-4000 must perforate with a minimum of 12 shots RCT-5000 must perforate with a minimum of 12 shots RCT-6750 must perforate with a minimum of 12 shots
CUTTING IN DRY PIPE AND LOW FLUID LEVEL PIPE:
These are difficult conditions to operate under. Dry pipe allows the flame from the torch to flow unrestricted causing high temperatures in the nozzle due to higher velocities of the flame. Some nozzle washing will occur, but this is normal under these conditions. The lack of a hydrostatic head will allow the flame to expand and a loss of velocity concentration will be evident. To overcome this condition a RCT rated at 4,000-10,000 psi is recommended for use in dry pipe.
In wells where there is only a small amount of fluid head above the cutter (less than 2,000 ft.), is beneficial to remove enough fluid from the well so that a minimum of 100 feet of dry pipe is below the cutter. Use the appropriate cutter for the dry pipe to be cut. If pumping the well down is not possible it will be necessary to run the RCT on tubing with the tubing being anchored at surface. The RCT can now be pressure fired with a pressure activated firing head using a CP initiator.
Operating Manual 24 ____________________________________________________________________________
ADVANTAGES OF THE RCT OVER JET & CHEMICAL CUTTERS
1. Not an explosive or dangerous chemical.
2. Classified as a Flammable Solid, Organic, NOS., UN1325 Section 4.1.
3. No special storage, handling, or disposal problems.
4. Causes no flaring or swelling of the pipe to be cut.
5. Cuts all stainless steels, Hastalloy, Monel, Inconel and plastic coated pipe.
6. Can be run thru restrictions to cut larger diameter pipe.
7. Can be used in close contact pipe conditions.
8. Can cut in dry pipe conditions.
9. Can operate to temperatures to 500 degrees F.
10. Can cut in exotic fluids or drilling mud without problems.
11. Cuts heavy wall pipe.
12. New patented Pressure Balance Anchor system eliminates movement, slipping, or sticking problems associated with other anchors.
13. Pressure Balance Anchor also eliminates the problems associated with going thru restrictions and operating in larger diameters below the restriction, because it has no moving parts.
14. The complete system is safe to use in Radio Sensitive areas such as offshore platforms or drill ships without going into Radio Silence resulting in significant savings in rig time.
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RETURN POLICY
MCR's return policy allows our customers, who do not wish to carry an inventory, to purchase our products and then return the unused products for credit. The following is the required procedure for return of items.
All returned goods must be returned in the original crating. Packaged tools must not be opened and must be returned in original undisturbed packaging. A 30% restocking fee will be assessed to all unopened shipments returned for credit. An additional 40% fee will be assessed to shipments where the torches and other tools have been unpackaged. All unpackaged tools must be disassembled and reloaded prior to returning them to stock.
MCR "KITS" are a set of two complete cutting tool systems. The crates containing the Kits may be opened for inspection and inventory purposes. However, the individual tubes may not be opened without incurring a rebuild fee of 40%.
If tools are unpackaged and returned for credit and found to be damaged, then no credit will be given for the damaged tool or kit. This policy applies to all licensed customers of MCR Oil Tools Corp.
CWP.Manual-RCT-RevG.doc
Operating Manual 26 _____________________________________________________________________________
TRAINING
MCR Oil Tools Corp. requires all users of the Radial Cutting Torch System to be Licensed by MCR. A License is simply a standard legal document (Agreement) from MCR and signed by the user agreeing to conditions of payment of invoices, confidentiality of patented and proprietary information and trade secrets, and conscientious use of the RCT System. There is no charge for the first license. A reinstatement fee may be required if the user Licensee has been revoked for the reasons stated in the License. Contact MCR Oil Tools for additional information on how to obtain a License.
Once Licensed, the Licensee MUST have its service technicians / engineers, who are slated to run the RCT system, trained at MCR's facility in Burleson, Texas. MCR also provides training at the Licensee's facility. Training consists of a one day session on the use and application of the RCT system, the design and function of the RCT system, and the assembly of the RCT system. When training is complete, MCR provides a Certificate of Completion signed by the licensed Instructor and embossed with MCR's official seal.
A Licensed trainee can become a Licensed Instructor by receiving training at the MCR facility and showing proficiency in the field with the RCT system substantiated with the submission of at least 20 field reports reflecting their proficiency. Once the Licensed Instructor receives his Instructors Certificate he is then allowed to train other technicians/engineers within his company on the use of the RCT system. The Instructor submits the proof of training and MCR will issue a Certificate of Completion.
After one hundred jobs using the RCT system, an Instructor may submit the job reports substantiating his proficiency with the RCT. The Instructor is then eligible to receive his Masters Certificate. Also, the instructor will receive a hat and jacket with the RCT emblem.
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MATERIAL SAFETY DATA SHEET RADIAL CUTTING TORCH
1. IDENTIFICATION OF THE PREPARATION AND THE COMPANY: PRODUCT NAME: RADIAL CUTTING TORCH SYNONYMS: RCT SUPPLIER: MCR OIL TOOLS CORP., 417 N. RUDD ST., BURLESON, TEXAS, USA 76028 BUSINESS TELEPHONE: (817)447-8878-8877 BUSINESS FAX: (817)447-566 EMERGENCY TELEPHONE: Continental U.S. (800)424-9300 & Outside Cont. U.S. (703)527-3887
2. COMPOSITION / INFORMATION ON INGREDIENTS: INGREDIENT NAME GAS NO. CONTENTS IRON OXIDE 1309-37-1 >50% ALUMINUM 7429-90-5 <35% POLYTETRAFLUOROETHYLENE 9002-84-0 >15%
3. HAZARDOUS IDENTIFICATION: FLAMMABLE SOLID
4. FIRST AID MEASURES: 4.1 INGESTION: If swallowed, immediately give large amounts of water. Get medical attention. 4.2 INHALATION: Remove to fresh air. 4.3 EYES: Flush with water for 15 minutes. Consult a physician. 4.4 SKIN: Wash with water and plenty of soap for at least 15 minutes.
5. FIRE FIGHTING MEASURES: EXTINGUISHER MEDIA: FOAM, DRY CHEMICALS, CO2. FIRE FIGHTING INSTRUCTIONS: Wear self-contained breathing apparatus. Wear full protective equipment. Hydrogen fluoride fumes emitted during a fire can react with water to form hydrofluoric acid. Wear neoprene gloves when handling refuse from fire. UNUSUAL FIRE & EXPLOSION HAZARDS: Molten aluminum may react violently with water, rust, certain metal oxides (e.g. oxides of copper, iron, and lead), and nitrates (e.g. ammonium nitrate, and fertilizers containing ammonium nitrate).
6. ACCIDENTAL RELEASE MEASURES: SPILL CLEANUP METHODS: Avoid all ignition sources around spill area. Prohibit smoking. do not use water for spill cleanup. Avoid dusting of powder to the greatest extent possible. Sweep spilled powder with natural bristle broom. Pick up material with non-sparking shovel. Place in dry, watertight containers. Seal containers after complete cleanup by sweeping, area may be washed down with copious quantities of water if necessary.
7. HANDLING AND STORAGE: USAGE PRECAUTIONS: Keep away from heat, sparks, and open flame. See Operation Manual for further handling procedures. STORAGE PRECAUTIONS: Keep container tightly sealed and store in dry area. Storage rooms must be of fire-resistant construction. Smoking is prohibited.
8. EXPOSURE CONTROLS/ PERSONAL PROTECTION: PROTECTIVE EQUIPMENT: Wear eye and face protection. A respirator is not required if used in ventilated area. If there is potential contact with hot/molten material, wear heat resistant clothing, footwear, gloves, eye & face protection, and respirators. VENTILATION: Use general or local exhaust ventilation to meet TLV requirements. EYE/SKIN PROTECTION: Safety goggles & Neoprene gloves are recommended.
Operating Manual 28 ___________________________________________________________________
9. PHYSICAL AND CHEMICAL PROPERTIES: COLOR: Light red to orange ODOR: None: None FORM: Hard pressed powder and loose powder. FLAMMABILITY: Flammable metal. BOILING POINT: Not applicable. DENSITY: 2.5 g/cm3
10. STABILITY AND REACTIVITY: STABILITY: Stable at normal temperatures and storage conditions. Avoid open flame, sparks, heat and ignition sources. REACTIVITY: Incompatible with hydrazine, calcium hypochlorite, acids, & halogenated hydocarbons.
11. TOXICOLOGICAL INFORMATION: TOXIC DOSE 1-LD50, OR LC50 Found for oral, dermal, or inhalation routes of administration.
12. ECOLOGICAL INFORMATION: Not toxic.
13. DISPOSAL CONSIDERATIONS: DISPOSAL METHODS: Preferred options for disposal are (1) recycling of unused tools, (2) landfill or scrap recycling of reacted tools.
14. TRANSPORT INFORMATION: PROPER SHIPPING NAME: Flammable Solid, Organic, N.O.S., Contains: Iron Oxide & Aluminum. UN NUMBER: UN 1325 CLASS OF DIVISION 4.1 PACKING GROUP: iii
15. REGULATORY INFORMATION: U.S. FEDERAL REGULATIONS: OSHA STATUS: Components listed. TSCA STATUS: Components listed. CERCLA REPORTABLE QUANTITY: None SARA TITLE iii: Section 302 Extremely Hazardous Substances: None Section 311/312 Hazardous Categories: Reactive: Sudden release of pressure. Section 313 Toxic Chemicals: Aluminum (fumes), TFE ( hydrogen fluoride gas). RCRA STATUS: Not federally regulated. INTERNATIONAL REGULATIONS: Canadian Domestic Substances: All components listed. European Community: All components listed on European Core Inventory (ECOIN)
16. OTHER INFORMATION: MSDS STATUS; New format. PRODUCT USE: Pipe recovery for the petroleum industry. INFORMATION SOURCES: Aluminum Association Bulletin TR-2, @ Recommendations for storage & handling of aluminum pigments & powder@. DUPONT CHEMICAL CORPORATION Bureau of Mines #6516, Explosibility of Metal Powders.
DATE: March 11, 1998___________________________________________________________________ Operating Manual 29
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