11320 FM 529 • Bldg I • Houston, TX 77041

Phone 713.856.8777 • Fax 713.856.8738

General e-mail [email protected]
www.chammascutters.com

The Chammas Chemical Cutters Manual is

produced by Chammas Cutters Inc. as a general guide
and reference for its customers.

12/2009
 Table of Contents

1- CCI Chemical Cutters

1-1 Chemical Cutter General Layout (Direct Action)
1-2 Chemical Cutter General Layout (Wedge Type)
1-3 How Chemical Cutters Work

2- Safety
2-1 Safety Guidelines and Recommendation
2-4 Safety Equipment
2-5 Chemical Cylinder Recommendations
2-6 Chemical Cutter Emergency Response Procedure

3- First Aid
3-1 First Aid Suggestions and Recommendations

4- Advantages of Chemical Cutters

4-1Chemical Cutters Advantage over Conventional Cutters

5- Chemical Cutters Rating

5-1CCI Chemical Cutters Rating and Chart

6- Operating Recommendations
6-1 CCI Chemical Cutter Operating Recommendations

7- CCI Chemical Cutter Selection Guide

7-1 Coiled Tubing
7-2 Tubing, Casing and Drill Pipe
7-3 Extended Reach Tools

8- Gas Generator Grain/ Chemical Cylinder Chart

8-1 Coiled Tubing
8-2 Tubing, Casing and Drill Pipe
8-3 L-80 and Chrome/ Nickel Pipe
8-4 Extended Reach Tools
8-5 Non-Standard Sizes

9- Physical Measurements
9-1 Weights and measurements of CCI Chemical Cutters
9-3 Week points on Chemical Cutter Tool Assemblies

i
10- Repair Kits and Anchor Packets
10-1 Repair Kits and Anchor Packets

11- Expendable Parts

11-1 Expendable Parts Packet List

12- Extreme Weather Operations

12-1 Extreme Weather Operations Chart

13- O-Ring Size Chart

13-1 O-Ring Size/ Number Chart

14- Cable Head/ Sinker Bar

14-1 Cable Head/ Sinker Bar Schematic

15- Slack Joint Assembly

15-1 Slack Joint Assembly Schematic
15-2 Slack Joint Assembly Instructions

16- Firing Systems

16-1 Firing Systems
16-2 Halliburton Red Igniter Assembly Schematic

17- Assembly Schematics

17-1 11/16” O.D. Tool
17-2 3/4”, 13/16”, 7/8” and 15/16” O.D. Tools
17-3 15/16” Extended Reach Tool
17-4 1”, 1 1/16”, 1 1/8”, 1 3/16” and 1 1/4” O.D. Tools

18- Assembly Schematics

18-1 1 3/8”, 1 1/2” and 1 9/16” O.D. Tools
18-2 1 3/8” O.D. Extended Reach Tool
18-3 1 1/2” and 1 9/16” O.D. Extended Reach Tool

19- Assembly Schematics

19-1 1 11/16”, 2” and 21/8” O.D. Tools
19-2 1 3/4” and 1 7/8” O.D. Tools
19-3 1 3/4” and 1 7/8” O.D. Extended Reach Tools
19-4 1 3/4” Extended Reach tool for 3 1/2” Drill Pipe
19-5 2”, 2 1/8”, 2 3/16”, 2 1/4” and 2 3/8” O.D.
Extended Reach for 3 1/2” Tubing

ii
20- Assembly Schematics
20-1 2 3/8” O.D. Tool
20-2 2 5/8” O.D. Tool
20-3 2 7/8” and 3 1/8” O.D. Tools
20-4 2 7/8” O.D. Extended Reach for 4 1/2” and
5” Drill Pipe
20-5 3 1/8” O.D. Extended Reach Tool For 4 1/2” Tubing
20-6 3 1/4”, 3 3/8” and 3 1/2” O.D. Tool
20-7 3 1/4” and 3 3/8” O.D. Extended Reach Tools for
5” Tubing

21- Assembly Schematics

21-1 3 1/2” and 3 5/8” O.D. Extended Reach Tools For
5” Tubing
21-2 3 5/8”, 3 7/8” and 4” O.D. Tools
21-3 3 7/8”, 4” and 4 1/8” O.D Extended Reach Tools for
5 1/2” Tubing
21-4 4 3/16”, 4 7/16” and 4 9/16” O.D. tools
21-5 5 1/2”, 5 3/4” and 6 3/8” O.D. Tools
21-6 7 1/2” O.D. Tool For 8 5/8” Casing

22- Tool Preparation

22-1 Tool Preparation Procedure

23- T-Shape Go/ Nogo and Plug Gage Set

23-1 T-Shape Go/ Nogo gage and Instructions
23-2 T-Shape and Plug Gage Set Size Chart

24- Gas Generator Sub Assembly

24-1 11/16” – 1 1/4” O.D. Wedge Type
24-2 1 3/8” – 7 1/2” O.D. Direct Action Type

25- Anchor Body Assembly

25-1 11/16”- 1 1/4” O.D. Wedge Type
25-3 1 3/8” – 2 5/8” O.D. Direct Action Type
25-5 2 7/8” – 7 1/2” O.D. Direct Action Type

26- Tandem Anchor Body Assembly

26-1 11/16” – 1 1/4” O.D Wedge Type
26-2 1 3/8” – 7 1/2” O.D. Direct Action
26-3 Tandem Anchor Body Assembly Schematic

iii
27- Pressure Test Procedure
27-1 Hydraulic Pressure Test Procedure

28- Severing Head Assembly

28-1 Integral Severing Head (11/16” – 2 3/8” O.D)
28-3 Non-Integral Severing Heads (2 5/8” – 4” O.D)
28-5 Non-Integral Severing Heads (4 3/16” – 4 9/16” O.D.)
28-7 Non-Integral Severing Heads (5 1/2” – 7 1/2” O.D.)

29- Centralizer Assembly

29-1 Rubber Centralizer
29-2 Adjustable Bottom Centralizer
29-4 Cage Centralizer
29-6 Adjustable Top Centralizer
29-8 Adjustable Cylinder/ Mandrel Centralizer (1 11/16”)
29-9 Adjustable Cylinder/ Mandrel Centralizer (2”)

30- Chemical Cylinder Assembly

30-1 Safety Check
30-2 11/16” – 1 1/4” Wedge Type
30-3 1 3/8” – 7 1/2” Direct Action Type
30-4 Cylinder Tandem

31- Tool Assembly at Wellhead

31-1 Final Tool Assembly at Wellhead

32- Retrieval and Disassembly

32-1 Tool Retrieval and Disassembly

33- Retrieval of Stuck Tools

33-1 Retrieval of Stuck tools

34- Proper Disposal of Spent Cylinders

34-1 Proper Disposal of Spent Cylinders

35- Post-Operation Tool Cleaning

35-1 Post-Op Tool Cleaning Procedure

36- Conversion Chart

36-1 Conversion Chart

iv
37- Hazardous Material Data Sheet, MSDS and DOT
Special Permit
37-1 Hazardous Material Data
37-2 Igniter MSDS
37-4 Gas Generator Grain MSDS for UN 0481, 1.4S
37-9 Chemical Cylinder MSDS
37-11 DOT Special Permit

v
 Background and History
Chammas Cutters Inc. was founded in the summer
of 2009 by Mr. Michel Chammas, the nephew of
the great Mr. Eddie Chammas.

Michel has spent the last twenty five years of

service at Pipe Recovery Systems, where he was
trained and coached on chemical cutters and pipe
retrieval systems by his now late uncle Mr. Eddie
Chammas.

Chammas Cutters is now taking the responsibility

of carrying on the Chammas family tradition of
providing the highest quality equipment, service
and technical support.

The knowledge and experience that the team at

Chammas Cutters has are far superior to any
company in the chemical cutter industry.

vi
vii
 08/2009

1-1
 08/2009

1-2
 HOW THE CCI CHEMICAL CUTTER WORKS

The CHEMICAL CUTTER is a mechanical/chemical pipe cutting/

puncturing device that is based on the oxidation/reduction process.

1. An igniter is initiated electrically or mechanically that in turn

initiates the Gas Generator Grain. The Grain burns at a controlled
rate increasing the pressure and temperature in the system.

2. Gas pressure forces the anchor out to anchor the tool inside the
pipe and prevent the tool from moving.

3. Gas pressure continues to increase inside the tool, forcing the seal
discs in the Cylinder to rupture.

4. The chemical (Bromine Trifluoride) is then forced through an

oil/steel wool mixture, placed at the top of the severing head. The
BF3 chemical reacts with the oil and ignites the steel wool.

5. The combination of the chemical and reactant causes the

temperature and pressure in the chamber to increase. When the
pressure exceeds the hydrostatic well pressure and the strength of
the piston support washer, the Severing Head Piston moves down to
expose the severing orifices. Through these orifices the activated
chemical is forced at high pressure and temperature to preheat and
cut the wall of the tubing at the desired position.

6. After the chemical has been expelled, pressure in the CHEMICAL

CUTTER equalizes with the hydrostatic pressure allowing the
anchors to retract under the action of their respective springs, and
releasing the tool from the tubing, so that it can be retrieved from the
well.

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1-3
 SAFETY GUIDELINES AND RECOMMENDATIONS

CCI CHEMICAL CUTTER are safe tools when used according to procedure. However, like any
oilfield pipe cutting device, when safety procedures and precautions are not followed the
CHEMICAL CUTTER CAN BECOME DANGEROUS. Assembly and disassembly procedures are
outlined in this manual. The instructions must be followed WITHOUT EXCEPTION.

1. It is compulsory to all personnel to be trained and certified in the safe use and handling of
the CHEMICAL CUTTER prior to running the service. CCI qualified and experienced
personnel provide the training for field operators through training classes given at training
centers or the CCI facility.

2. Only CCI approved and tested safety equipment should be used when handling Chemical
Cylinders and when the Cylinder(s) is/are part of the tool assembly while on the surface.
This applies to the assembly and disassembly of the CUTTER. For every chemical cutter
job, a minimum of two safety kits is required.

3. Standard explosives operating procedure must be followed (see field explosives control
manual.)

4. Chemical cylinders should be inspected for leakage upon receiving from CCI and removal
from shipping crate.

5. To prevent chemical cylinders from expiring, always use older cylinders before the newer
ones.

6. Chemical cylinders and gas generator grain have an effective shelf life of five years from
the date of manufacturing (refer to label on product for important dates).

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2-1
7. Cylinders should be stored in a safe and secured area at least 25 feet from any explosive

material.

8. Chemical cutters should not be initiated when the chemical temperature is at or below 32º F
(which is close to the freezing point temperature of Bromine Trifluoride). At that
temperature, please refer to chart “Extreme Weather Conditions Operation.”

9. Cylinders must be inspected for leakage annually.

10. Do not mix loaded cylinders with empty cylinders. Shipping plugs must be removed
from empty cylinders prior to discarding.

11. Chemical Cylinders must be handled with care. They should never be dropped, dragged,
rolled, or slid even for a short distance. The Chemical Cylinders must be securely
fastened during shipment so that they are not subjected to hard blows or jars that may
damage the seals and allow chemical leakage.

12. Chemical cutters must never be transported completely assembled. The igniter, gas
grain and chemical cylinder(s) must be assembled at well site only.

13. Shipping Plugs must not be removed from the Chemical Cylinder until immediately before
final assembly at the well site.

14. A first aid kit must be readily available at the well site and must include at least burn
ointment and eye wash. An ample supply of clean fresh water must also be available for
flushing in case of emergency.

15. An aluminum Protective Sleeve must be used around the Severing Head for as long as
the chemical cylinder is attached to it. The sleeve acts as a deflection shield for the
chemical away from field personnel.

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2-2
16. An aluminum protective sleeves must always be used over the Anchor Assembly when the
tool is fully assembled to the line while on surface and when retrieving it from the well.
The sleeve must remain on until the pressure is bled from the tool.

17. Bromine Trifluoride is not flammable but it can support combustion. Small fires may be
controlled by carbon dioxide, dry chemical extinguisher or dry sand.

18. In case of a chemical spill, dry clean sand, soda ash (sodium carbonate) or activated
carbon may be used over the spill to contain and neutralize the chemical.

29. NEVER FIRE OR DISCHARGE THE CHEMICAL CUTTER ON SURFACE!

20. Surface pressure can be applied while running chemical cutters, as long as the pressure is
within the safe limit of the chemical cylinder rupture disc. A safety factor of 3 is used to
determine the maximum surface pressure. NOTE: No Personnel should stand near the
pressure control equipment when tool is being run in hole or coming back to
surface.

11/16” - 15/16” OD tools_______________ Maximum surface pressure is 1700 PSI

1” - 1 1/4” OD tools/__________________ Maximum surface pressure is 2000 PSI
1 3/8” - 1 9/16” OD tools _______________Maximum surface pressure is 2500 PSI
1 11/16” – 7 1/2” OD tools ______________Maximum surface pressure is 3000 PSI

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2-3
 SAFETY EQUIPMENT
SAFETY KIT w/ FABRIC COVERALL (CCI 168230) - NEW

o FABRIC SAFETY COVERALL

o CCI 168215 FULL FACE RESPIRATOR W/Filters
o CCI 168218 SET SPARE FILTERS
o CCI 168220 LENS COVER FOR 3M RESPIRATOR W/ WIPES
o CCI 168212 SAFETY GLOVES
o CCI 168108 BURN OINTMENT
o CCI 168211 EYE WASH
o CCI 168232 LITMUS PAPER
o CCI 168210-550 TOOL PROTECTOR CASE

SAFETY KIT w/SAFETY SUIT (CCI 168206)

o SAFETY SUIT (Jacket & Overall)

o CCI 168215 FULL FACE RESPIRATOR W/Filters
o CCI 168218 SET SPARE FILTERS
o CCI 168220 LENS COVER FOR 3M RESPIRATOR W/ WIPES
o CCI 168212 SAFETY GLOVES
o CCI 168108 BURN OINTMENT
o CCI 168211 EYE WASH
o CCI 168232 LITMUS PAPER
o CCI 168210-550 TOOL PROTECTOR CASE

SAFETY KIT w/COVERALL (CCI 168208)

o SAFETY COVERALL
o CCI 168215 FULL FACE RESPIRATOR W/Filters
o CCI 168218 SET SPARE FILTERS
o CCI 168220 LENS COVER FOR 3M RESPIRATOR W/ WIPES
o CCI 168212 SAFETY GLOVES
o CCI 168108 BURN OINTMENT
o CCI 168211 EYE WASH
o CCI 168232 LITMUS PAPER
o CCI 168210-550 TOOL PROTECTOR CASE

SAFETY SLEEVE F/SEVERING HEAD

o CCI 168201 SAFETY SLEEVE f/11/16 THRU 2 1/8 O.D. CUTTERS

o CCI 168202 SAFETY SLEEVE f/2 1/4 THRU 4 9/16 O.D. CUTTERS
o CCI 168205 SAFETY SLEEVE f/5 1/2 THRU 6 3/8 O.D. CUTTERS

SAFETY SLEEVE F/ANCHOR SYSTEM ASSEMBLY

o CCI 168203SAFETY SLEEVE f/ TOOLS UP TO 3 1/8 OD CUTTERS

o CCI 168204 SAFETY SLEEVE f/ TOOLS 3 1/4 THRU 6 3/8 - OD CUTTERS

11/09
2-4
 CHEMICAL CYLINDERS RECOMMENDATIONS

STORAGE

- The chemical cylinders must be stored in a safe and secured area in their
original shipping containers (wooden crates with labels intact.)
- They can also be stored on metal racks horizontally or stood up vertically.
- They need to be at least 25 ft away from any explosive material.
- Always rotate stock to use older cylinders before the newer ones.
- Cylinders must be inspected for leaks upon arrival at base.
- Annual inspection is required if cylinders stay in storage longer than one year.
- Proper safety gear is required when opening/inspecting cylinders.
- Chemical cylinders have an effective shelf life of five years.

TRANSPORTATION
CCI has Special Permit DOT- SP 14796 from the US DOT (dept. of
transportation) to ship the chemical cylinders by the following modes of transport:
Motor vehicle, cargo aircraft only, cargo vessel, and rail freight.
All CCI customers are covered by this special permit to re-transport the chemical
cylinders providing no modifications or changes are made to the package or label.
CCI also has a Competent Authority Approval (CA# 2009060001) to transport
cylinders internationally on cargo aircraft.

CONTINGENCY PLANNING

- For contingency planning, a stainless steel tray filled with dry clean sand can be
placed below the chemical cylinders to absorb and contain chemical spills.
- Incase a spill occurs; the contaminated sand can be neutralized with water.

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2-5
 Chemical Cutter Emergency Response Procedure

Recommended first aid treatment

 Prompt medical attention is required in all cases of overexposure to Bromine Trifluoride

 Rescue Personnel should be equipped with appropriate protective equipment (Self Contained Breathing
Apparatus, etc.) to prevent unnecessary exposure.

Inhalation:

 Move exposed Personnel to an uncontaminated area. If not breathing, give artificial respiration, preferably
mouth-to-mouth. If breathing is difficult, give oxygen. Keep victim warm and quiet.
 Assure that mucus or vomited material does not obstruct the airway by use of positional drainage.
 Delayed pulmonary edema may occur. Keep patient under medical observation for at least 24 hours.

Eye Contact:

PERSONS WITH POTENTIAL EXPOSURE TO BROMINE TRIFUORIDE SHOULD NOT WEAR CONTACT
LENSES.

 Flush contaminated eye(s) with large quantities of water. Hold eyelids open with fingers to assure
complete flushing. Continue for minimum of 30 minutes
 Apply eye wash (CCI 168211)

Skin Contact:

 Flush affected area with large quantities of water.

 Remove affected clothing as rapidly as possible.
 Skin burns may be treated with calcium gluconate gel (CCI 168108) or slurry in water or glycerin. This
compound binds the active fluorides in an insoluble form and limits burn extension and relieves pain.

Fire & Explosion Procedures:

SPECIAL FIRE FIGHTING PROCEDURES

Fires with Bromine Trifluoride as the oxidizer can only be extinguished by shutting off the source of Bromine
Trifluoride. Do not use water, chemicals, carbon dioxide or other extinguishing media, as these will only add more
fuel to the fire.

UNUSUAL FIRE AND EXPLOSION HAZARDS

Bromine Trifluoride reacts violently or explodes on contact with water or organic material. Combustion products,
including hydrogen fluoride, are toxic and reactive.

Spill or Leak Procedures:

Evacuate all personnel from affected area. Use proper protective equipment.

To contain the spill, the following is recommended:

 Activated Carbon (CCI 168217)
 Sodium Carbonate
 Dry clean sand

Precaution While in Storage

Place a stainless steal tray (1/8” thick) filled with dry clean sand below the cylinders to contain any chemical spill
that may take place while in storage. The contaminated sand should be neutralized with water before discarding.

11/09
2-6
 FIRST AID SUGGESTIONS
The chemical, Bromine trifluoride, is a highly toxic, colorless to gray/yellow liquid and It reacts
violently with most organic compounds. Since Bromine Trifluoride is extremely corrosive to
human tissue and the eyes, personnel working with this material must wear acid resistant
gloves, respirator, and protective clothing.

SUMMON A PHYSICIAN IMMEDIATELY FOR ANY PERSON WHO HAS BEEN BURNED
OR OVERCOME BY BROMINE TRIFLUORIDE.

Listed below are first aid measures, based on common practice in the industry, that are to be
taken prior to the physician’s arrival. Their adoption in any specific case should be subject to
prior endorsement by a competent medical advisor.

1. Remove exposed individual from the area.

2. For exposure due to inhalation, oxygen should be administered by trained personnel only.
Artificial respiration should be given only if breathing has ceased.

3. For external exposure wash with a large amount of water and apply Glycerol
Paste*.

4. If the burn is severe enough to cause blisters DO NOT BREAK THEM DURING FIRST
AID TREATMENT.

5. In the event chemical gets into the eye(s), wash the eye(s) thoroughly with
clean, running water for at least 15 minutes. If needed, have someone hold the
eyelids open.

*If Glycerol Paste is not available, a paste mixture of bicarbonate of soda and
water may be used. A burn can also be neutralized with Zephirine solution that
must be prepared by a physician.

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3-1
 ADVANTAGES OF THE CHEMICAL CUTTER

™ NO DAMAGE TO ADJACENT PIPE OR CASING

™ NO FLARE OR ENLARGEMENT TO CUT PIPE

™ NO DEBRIS OR JUNK IS LEFT IN THE HOLE

™ UNDERSIZED CUTTERS FOR SMALL RESTRICTIONS

™ ALL THREAD CONNECTIONS HAVE BUILT-IN PRESSURE RELEASE

SYSTEM (Note: While the O-Rings are exposed, the threads are still engaged)

™ CAN BE USED AS A PUNCHER, JUST BY CHANGING THE

SEVERING HEAD

™ PUNCHERS ARE AVAILABLE FOR ALL SIZES OF CHEMICAL CUTTERS

™ NUMBER OF HOLE PER PUNCHER CAN BE SET BY CUSTOMER

NEEDS, BETWEEN 2 AND 8 HOLES

™ THE SIZE OF HOLES INTO THE PIPE MAY RANGE AS FOLLOWS:

ƒ FOR COILED TUBING: 3/16” – 1/4”

ƒ FOR TUBING/CASING: 1/4 – 7/16”

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4-1
 CCI CHEMICAL CUTTER RATINGS

The success rate of CCI chemical cutters is more a factor of temperature than hydrostatic
pressure. Refer to table below for guidance.

Example: if downhole temperature is 200˚ F and the hydrostatic pressure is 9000 PSI, the
tool will operate at 91% efficiency.

RECOMMENDED OPERATIONAL RATINGS

Operational Ratings for Pressure and Temp

100

200 F
90

225 F
80
250 F

70

60 275 F
Efficiency %

50 300 F

40

30

20

10

0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Hydrostatic Pressure (PSI)

08/2009

5-1
 OPERATING RECOMMENDATIONS

NOTE: All parts of the chemical cutter should be assembled by hand to facilitate the break
down after firing the tool.

1. All the formal EXPLOSIVE SAFETY procedures must be followed before the Gas Generator
grain and Anchor Assembly are attached to the cable.

2. A Safety Ohmmeter must be used to check the electrical continuity of the Igniter. It requires a
minimum of 750 milliamps to initiate.

3. Make a gage run (dummy run) to determine the smallest restriction and its depth. The effi-
ciency of the CUTTER is drastically reduced if it is fired in tubing or pipe with a larger I.D. than
recommended. Always use the largest tool size recommended by the selection guide for opti-
mum results.

4. It is important to centralize the CHC on every job. However, it is very critical to centralize the
anchor and severing head when using the undersize tools, and also in deviated wells.

5. Make sure of the fluid level and weight in the tubing. This is needed to calculate hydrostatic
pressure for selecting the proper Gas Generator Grain Length.

6. Never run the CUTTER at excessive speeds. 6000 ft/hr is recommended if no gage run was
made.

7. NEVER SPUD WITH THE CHEMICAL CUTTER. The seals in the chemical cylinder may
become damaged, and the severing head piston might drop prematurely.

8. It is recommended to fire the chemical cutter in fluid to prevent the inside of the severing head
from overheating. In the absence of fluid, attach a swab cup to the bottom of the tool and
pump fluid from surface.

9. When cutting above a plug or solid obstruction, allow 15 ft. of fluid cushion below the Severing
Head. Tandem anchors if cutting closer than 15 FT.

10. Do not set the Anchor Assembly or Severing Head inside collars.

11. If the tubing is scaly, a clean out shot is recommended where the cut is to be made. The
shot should cover the cutting and anchoring points. Use the same number of strands as pre-
scribed for backoff operation in the pipe type.

12. If the tubing is plastic or ceramic coated, run a clean out shot covering the anchors to the
severing head and increase the chemical by a minimum length of 12”.

13. If the pressure differential between the tubing and the annulus is greater than 200 PSI, it is
recommended to equalize pressure by punching holes into the tubing or by pressuring up the
tubing from surface before firing the chemical cutter.
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 OPERATING RECOMMENDATIONS

14. When tandeming Anchors, always increase the grain length by 1 inch.

15. When using the Adjustable Top Centralizer, the grain length must be increased by 1 inch.

16. When cutting tailpipe, additional chemical is required. Always use the next longer size cylin-
der or tandem two cylinders if necessary. If a complete severance is not achieved, a clean
out shot should be fired in the same area of the chemical cut to help separate the tubing.
Centralization would be extremely critical.

17. Cutting Chrome/Hi-Nickel (13% or higher) and L-80 tubing requires changes in the Gas
Generator Grain and the Chemical Cylinder (Refer to special chart for Chrome/ High Nickel).

18. If the CHEMICAL CUTTER is fired in H2S fluid (0.2% or higher), the tool should not be re-
used due to Hydrogen embrittlement.

19. The CHEMICAL CUTTER works in most types of fluids: oil, diesel and mud. However
water is the preferred fluid. The Severing Head should always be filled with silicone (using
the injection kit) to prevent solids from plugging the orifices.

20. Chemical Cutters can cut tubing in compression, tension or neutral. However, over-pull of
10% over the neutral weight of the pipe is recommended during or after the cut is attempted.

21. When cutting shallow (250 ft or less), safety precautions are required on surface; the tubing
and the cable must be secured and a pack-off should be used to prevent over spray.

22. It is not recommended to use chemical cutters in Zinc Bromide when the weights are above
12 lb/gal

23. In the event of an unsuccessful cut, do not try to cut in the same place. Ferric Fluoride de-
posits inhibit further reaction. You should allow at least 6 inches from the previous cut
for a second attempt.

24. When operating on floating vessel, the line movement should be minimized by securing the
line with a cable clamp to the top of the tubing. Activate rig wave compensation before at-
tempting the cut.

25. When cutting in heavy mud, it is recommended to run a “slack-joint” or bumper jar above the
CUTTER to help release the Slips if needed..

26. Never-Seez Lubricant should be applied to all threads and O-Rings when assembling the
CUTTER.

27. To prevent galling NEVER apply silicone to any thread. Silicone should only be used on
anchor slips and severing head piston and orifices.
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 OPERATING RECOMMENDATIONS

28. When the CHEMICAL CUTTER is in the hole and you are preparing to make a cut,
PRECAUTIONS ON THE RIG FLOOR HAVE TO BE TAKEN. The pipe may jump and fluid
may get blown out of it. Follow the same precautions as for a back-off, clear the floor, tie the
slips, ensure the cable does not jump a sheave, etc.

29. Do not begin retrieving the CUTTER immediately after firing. Allow two to three minutes for
pressure equalization. Always move the CUTTER DOWN one to two feet before moving UP.
This will allow the Slips to release from the tubing.

30. After the Severing Head has been attached to the Chemical Cylinder, install the Protective
Sleeve over it. The Sleeve must NOT BE REMOVED UNTIL THE CUTTER IS RUN IN THE
HOLE.
31. If the Gas Generator Grain has to be cut, then use a razor blade on a block of wood.
32. Release of possible trapped pressure MUST be done as soon as the CHEMICAL CUTTER
reaches surface. Place Safety Sleeve around the Anchor Body and bleed pressure by un-
screwing the bleed-off stem.
33. If for any reason a CUTTER gets stuck in the tubing after firing, CCI must be notified for rec-
ommendations. (Refer to retrieval of stuck tools section)
34. Only Silicone should be used inside the severing head for filling the orifices and lubricating
the piston O-rings.

35. It may be necessary to use extension spacer to space out the Severing Head from the
Anchor System Assembly in the tubing to be cut. The standard length of extension
spacer for all size CUTTERS is 36”. One Inch (1”) of grain must be added for every
spacer used.

36. The Igniter, Gas Generator Grain, Chemical Cylinder, Severing Head, Pressure Relief
Kit, Wedges/Anchor Slips Grain Spacer and Expendable Part Packet are expendable
and must be replaced after each firing.

08/2009

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 SELECTION GUIDE F/ COILED TUBING CHEMICAL CUTTER

TOOL SPECIFICATIONS (IN) COILED TUBING SPECIFICATIONS

TOOL SIZE MAX. EXTENSION O.D. I.D. WEIGHT

(ANCHOR & SEV WEDGES / SLIPS (INCH) (INCH) POUND/FOOT
HEAD)
*11/16" 0.92 1" .782 - .810 .918 - 1.037
*3/4" 1.05 1" .826 - .866 .688 - .848
*13/16" 1.09 1 1/4 .938 - 1.076 1.081 - 1.823
*7/8" 1.11 1 1/4 1.032 - 1.076 1.081 - 1.328
*15/16" 1.15 1 1/4 1.100 - 1.116 .840 - .941
*15/16" EXT.
1.35 1 1/2 1.188 - 1.334 1.256 - 2.239
REACH
*1" 1.33 1 1/2 1.188 - 1.282 1.619 - 2.239
*1 1/16" 1.35 1 1/2 1.188 - 1.282 1.619 - 2.239
*1 1/8" 1.42 1 1/2 1.282 - 1.334 1.256 - 1.619
*1 3/16 1.51 1 3/4 1.374 - 1.500 2.169 - 3.136
*1 1/4" 1.61 1 3/4 1.400 - 1.532 1.910 - 2.944
1 3/8" 1.80 2" 1.594 - 1.688 3.072 - 3.896
1 1/2" 2.04 2" 1.732 - 1.782 2.201 - 2.671
1 11/16" 2.20 2 3/8 1.969 - 2.025 4.112 - 4.709
1 7/8" 2.55 2 3/8 2.063 - 2.157 2.638 - 4.709
2 1/8" 2.60 2 7/8 2.469 - 2.563 4.530 - 5.793
2 5/8" 3.35 3 1/2 3.094 - 3.150 6.215 - 7.148

SELECTION GUIDE F/ CS HYDRIL TUBING 1.050 - 1.660 OD

TOOL SPECIFICATIONS (IN) TUBING SPECIFICATIONS

TOOL SIZE O.D.

MAX. EXTENSION OF WEIGHT
(AMCHOR & SEV (INCH) I.D. (INCH)
WEDGES POUND/FOOT
HEAD)
*11/16" 0.92 1.05 0.824 1.200
*3/4" 1.05 1.315 0.957 2.250
*13/16" 1.09 1.315 1.049 1.800
*1 1/16" 1.35 1.660 1.278 3.020
*1 3/16" 1.51 1.660 1.380-1.410 2.100-2.400
* DENOTES WEDGE TYPE ANCHOR 08/09

7-1
 Selection Guide F/ Tubing, Casing & Drill Pipe Chemical Cutter

TOOL SPECIFICATIONS (IN) TUBING SPECIFICATIONS

TOOL SIZE MAX. EXTENSION
(ANCHOR OF ANCHOR SLIPS OD
ID (INCH) WEIGHT POUND/FOOT
& SEV (INCH)
HEAD)
1 3/8 1.80 1.90 1.500 - 1.650 2.40 - 3.64
2 1/16 1.670 - 1.751 3.25 - 3.40
1 1/2 2.04
2 3/8 1.703 - 1.995 4.70 - 7.70
1 9/16 2.10 2 3/8 1.853 - 1.995 4.70 - 6.20
1 11/16 2.20 2 3/8 1.939 - 1.995 4.70 - 5.30
1 3/4 2.50 2 7/8 2.059 - 2.441 6.50 - 10.70
1 7/8 2.55 2 7/8 2.059 - 2.441 6.50 - 10.70
2" 2.58 2 7/8 2.195 - 2.441 6.50 - 9.50
2 1/8 2.60 2 7/8 2.323 - 2.441 6.50 - 7.90
2 3/8 3.25 3 1/2 2.602 - 3.068 7.70 - 15.50
*2 5/8 3.35 3 1/2 2.922 - 3.068 7.70 - 10.30
*2 7/8 3.65 4 3.240 - 3.476 11.00 - 15.70
*3 1/8 3.92 4 3.340 - 3.548 9.50 - 14.00
*3 1/4 4.04 4 1/2 3.640 - 3.958 12.60 - 20.00
*3 3/8 4.16 4 1/2 3.697 - 4.000 11.60 - 17.70
*3 1/2 4.28 4 1/2 3.826 - 4.090 9.50 - 15.50
*3 5/8 4.40 4 1/2 3.920 - 4.090 9.50 - 13.50
*3 7/8 4.68 5 4.154 - 4.408 15.00 - 21.00
*4 " 4.80 5 4.276 - 4.560 11.50 - 19.50
*4 3/16 4.92 5 1/2 4.548 - 4.778 20.00 - 26.00
*4 7/16 5.14 5 1/2 4.670 - 4.950 15.50 - 23.00
*4 9/16 5.14 5 1/2 4.892 - 5.044 13.00 - 17.00
5 1/2 6.50 7 6.004 - 6.214 28.00 - 35.00
5 3/4 6.50 7 6.276 - 6.456 20.00 - 26.00
6 3/8 7.37 7 5/8 6.765 - 7.125 20.00 - 33.70
7 1/2 8.5 8 5/8 7.725 - 8.017 24.00 - 40.00

08/09

7-2
 Selection Guide F/ 1 3/8 – 4 1/8 OD Extended Reach Chemical
Cutter

Item Tool Specifications (IN) Tubing Specifications

MAX.
TOOL SIZE
EXTENSION WEIGHT
(ANCHOR & OD (INCH) ID (INCH)
OF ANCHOR POUND/FOOT
SEV HEAD)
SLIPS
1 1 3/8 ER 2.1 2 3/8 1.703 - 1.995 4.70 - 7.70
2 1 1/2 ER 2.2 2 1/16 1.670 - 1.751 3.25 - 3.40
2 3/8 1.703 - 1.995 4.70 - 7.70
3 1 9/16 ER 2.26 2 3/8 1.703 - 1.995 4.70 - 7.70
4 1 3/4 ER 2.75 2 7/8 2.059 - 2.441 6.50 -10.70
5 1 7/8 ER 2.81 2 7/8 2.059 - 2.441 6.50 -10.70
*6 1 3/4 ER SPC 2.9 3 1/2 2.480 - 2.750 12.95 - 16.70
*7 2" ER 2.85 3 1/2 2.480 - 2.750 12.95 - 16.70
*8 2 1/8 ER 3.1 3 1/2 2.480 - 2.992 9.30 -16.70
9 2 3/16 ER 3.1 3 1/2 2.480 - 2.992 9.30 -16.70
10 2 1/4 ER 3.22 3 1/2 2.602 - 2.992 9.30 -15.50
11 2 3/8 ER 3.37 3 1/2 2.602 - 3.068 7.70 -15.50
12 2 7/8 ER 4 4 1/2 3.640 - 3.958 12.60 - 20.00
**13 2 7/8 ER SPC 4.45 4 1/2 DP 3.500 - 3.958 13.75 - 22.82
14 3 1/8 ER 4.5 4 1/2 3.640 - 3.958 12.60 - 20.00
15 3 1/4 ER 4.62 5 4.154 - 4.560 11.50 - 21.00
16 3 3/8 ER 4.75 5 4.154 - 4.560 11.50 - 21.00
17 3 1/2 ER 4.87 5 4.154 - 4.560 11.50 - 21.00
***18 3 5/8 ER 5 5 4.154 - 4.560 11.50 - 21.00
19 3 7/8 ER 5.12 5 1/2 4.548 - 4.892 17.00 - 26.00
20 4 " ER 5.25 5 1/2 4.548 - 5.044 13.00 - 26.00
21 4 1/8 ER 5.37 5 1/2 4.548 - 5.044 13.00 - 26.00

*ITEMS 6, 7 & 8 CAN ALSO BE USED FOR CUTTING 2 7/8 TBG 08/09

**ITEM 13 CAN ALSO BE USED FOR CUTTING 5" DP

*** ITEM 18 CAN ALSO BE USED FOR CUTTING 5 1/2 CSG

7-3
 GAS GENERATOR GRAIN/ CHEMICAL CYLINDER CHART

F/ COILED TUBING CHEMICAL CUTTER 11/16 - 2 5/8 OD TOOLS

TOOL SIZE GRAIN LENGTH (INCH) X GRAIN OD (INCH)

TUBING
CYLINDER VS BHP (KPSI) CATALYST
(ANCHOR & SEV
QTY. & SIZE SIZE
HD OD) OD WT. #/FT 0-2.5 KPSI 2.5-5 KPSI 5-7.5 KPSI 7.5-10 KPSI

* 11/16 1" .918-1.037 1 - 11/16 x 72 8 X 1/4 9 X 1/4 10 X 1/4 N/A #2

* 3/4 1" .688-.848 1 - 3/4 x 72 8 X 1/4 9 X 1/4 10 X 1/4 N/A #2

* 13/16 1 1/4 1.081-1.823 1 - 3/4 x 72 8 X 1/4 9 X 1/4 10 X 1/4 N/A #2

* 7/8 1 1/4 1.081-1.328 1 - 3/4 x 72 8 X 1/4 9 X 1/4 10 X 1/4 N/A #2

* 15/16 1 1/4 .840-.941 1 - 3/4 x 72 8 X 1/4 9 X 1/4 10 X 1/4 N/A #2

15/16" EXT. 1 1/2 1.256-2.239 2- 3/4 x 72 11 X 1/4 11 X 1/4 11 X 1/4 N/A #3

REACH

* 1" 1 1/2 1.619-2.239 1 - 1 x 72 6.5 X 3/8 7.5 X 3/8 9 X 3/8 N/A #3

* 1 1/16 1 1/2 1.619-2.239 1 - 1 x 72 6.5 X 3/8 7.5 X 3/8 9 X 3/8 N/A #3

* 1 1/8 1 1/2 1.256-1.619 1 - 1 x 72 6.5 X 3/8 7.5 X 3/8 9 X 3/8 N/A #3

* 1 3/16 1 3/4 2.169-3.136 1 - 1 x 72 7 X 3/8 8 X 3/8 9 X 3/8 N/A #3

* 1 1/4 1 3/4 1.910-2.944 1 - 1 x 72 7 X 3/8 8 X 3/8 9 X 3/8 N/A #3

1 3/8 2" 3.072-3.896 1 - 1 3/8 x 72 8 X 9/16 8 X 9/16 9 X 9/16 9 X 9/16 #5

1 1/2 2" 2.201-2.671 1 - 1 3/8 x 72 8.5 X 9/16 8.5 X 9/16 9.5 X 9/16 9.5 X 9/16 #6

1 11/16 2 3/8 4.112-4.709 1 - 1 11/16 x 48 8.5 X 9/16 8.5 X 9/16 9.5 X 9/16 9.5 X 9/16 #6

1 7/8 2 3/8 2.638-4.709 1 - 1 11/16 x 48 8.5 X 9/16 8.5 X 9/16 9.5 X 9/16 9.5 X 9/16 #6

2 1/8 2 7/8 4.530-5.793 1 - 1 11/16 x 48 8.5 X 9/16 8.5 X 9/16 9.5 X 9/16 9.5 X 9/16 #6

2 5/8 3 1/2 6.215-7.148 1 - 1 11/16 x 72 10 X 9/16 10 X 9/16 11 X 9/16 11 X 9/16 #10

* DENOTES WEDGE TYPE TOOL 08/09

8-1
 GAS GENERATOR GRAIN / CHEMICAL CYLINDER CHART
F/ 1 3/8 - 7 1/2 OD TOOLS

TOOL SIZE TUBING CYLINDER GRAIN LENGTH (INCH) X GRAIN OD (INCH) CATALYST
(ANCHOR & QTY & SIZE VS BHP (KPSI) SIZE
SEV HEAD) OD WT: #/FT 0-5 KPSI 5-10 KPSI
1 3/8 1.9 2.40-3.64 1 - 1 3/8 x 72 8 X 9/16 9 X 9/16 #5
1 1/2 2 1/16 3.25-3.40 1 - 1 3/8 x 72 8.5 X 9/16 9.5 X 9/16 #6
2 3/8 4.70-7.70 1 - 1 3/8 x 72 8.5 X 9/16 9.5 X 9/16 #6
1 9/16 2 3/8 4.70-6.20 1 - 1 3/8 x 72 8.5 X 9/16 9.5 X 9/16 #6
1 11/16 2 3/8 4.70-5.30 1 - 1 11/16 x 48 8.5 X 9/16 9.5 X 9/16 #6
1 - 1 11/16 x 60 9 X 9/16 10 X 9/16 #6
1 3/4 2 7/8 6.50-10.70 1 - 1 11/16 x 72 9.5 X 9/16 10.5 X 9/16 #6
1 7/8 2 7/8 6.50-10.70 1 - 1 11/16 x 72 9.5 X 9/16 10.5 X 9/16 #6
2 2 7/8 6.50-9.50 1 - 1 11/16 x 72 9.5 X 9/16 10.5 X 9/16 #6
2 1/8 2 7/8 6.50-7.90 1 - 1 11/16 x 48 8.5 X 9/16 9.5 X 9/16 #6
1 - 1 11/16 x 60 9 X 9/16 10 X 9/16 #6

2 3/8 3 1/2 7.70-10.30 1 - 2 x 60 11 X 9/16 12 X 9/16 #10

12.95-15.50 1 - 2 x 72 12 X 9/16 13 X 9/16 #10

2 5/8 3 1/2 7.70-10.30 1 - 1 11/16 x 72 10 X 9/16 11 X 9/16 #10

2 7/8 4 11.00-15.70 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

3 1/8 4 9.50-14.00 1 - 2 x 72 12 X 9/16 13 X 9/16 #10

3 1/4 4 1/2 12.60-20.00 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

3 3/8 4 1/2 11.60-17.70 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

3 1/2 4 1/2 9.50-15.50 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

3 5/8 4 1/2 9.50-13.50 1 - 2 x 72 12 X 9/16 13 X 9/16 #10

3 7/8 5 15.00-21.00 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

4 5 11.50-15.00 1 - 2 x 72 12 X 9/16 13 X 9/16 #10

16.25-19.50 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

4 3/16 5 1/2 20.00-26.00 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

4 7/16 5 1/2 15.50-23.00 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

4 9/16 5 1/2 13.00-15.00 1 - 2 x 72 12 X 9/16 13 X 9/16 #10

15.50-17.00 2 - 2 x 48 OR 1 - 2 x 80 14 X 9/16 15 X 9/16 #10

USE THIS CHART FOR 3/4" OD GRAIN

5 1/2 7 28.00-35.00 2 - 2 x 72 12.5 X 3/4 13.5 X 3/4 #12

5 3/4 7 20.00-26.00 2 - 2 x 60 OR 1 - 2 x 84 11.5 X 3/4 12.5 X 3/4 #12

6 3/8 7 5/8 20.00-33.70 2 - 2 x 72 12.5 X 3/4 13.5 X 3/4 #12

7 1/2 8 5/8 24.00-40.00 2 - 2 x 72 12.5 X 3/4 13.5 X 3/4 #12
USE THIS CHART FOR 9/16" OD GRAIN
5 1/2 7 28.00-35.00 2 - 2 x 72 19 X 9/16 20 X 9/16 #12

5 3/4 7 20.00-26.00 2 - 2 x 60 OR 1 - 2 x 84 17 X 9/16 18 X 9/16 #12

6 3/8 7 5/8 20.00-33.70 2 - 2 x 72 19 X 9/16 20 X 9/16 #12

7 1/2 8 5/8 24.00-40.00 2 - 2 x 72 19 X 9/16 20 X 9/16 #12

NOTE: THE GRAIN LENGTH MUST BE INCREASED BY 1" WHEN ANY OF THE FOLLOWING 08/09
CONFIGURATIONS ARE USED:
TANDEM ANCHORS, ADJUSTABLE TOP CENTRALIZER, EXTENSION SPACER

8-2
 SPECIAL CHART FOR L-80 & CHROME/NICKEL PIPE 13% AND UP
GAS GENERATOR GRAIN / CHEMICAL CYLINDER CHART
F/ 1 3/8 - 7 1/2 OD TOOLS
TOOL SIZE TUBING CYLINDER GRAIN LENGTH (INCH) X GRAIN OD (INCH) CATALYST
(ANCHOR & QTY & SIZE VS BHP (KPSI) SIZE
SEV HEAD) OD WT: #/FT 0-5 KPSI 5-10 KPSI
1 3/8 1.9 2.40-3.64 1 - 1 3/8 x 72 8 X 9/16 9 X 9/16 #5
1 1/2 2 1/16 3.25-3.40 1 - 1 3/8 x 72 8.5 X 9/16 9.5 X 9/16 #6
2 3/8 4.70-7.70 2 - 1 3/8 x 72 11 X 9/16 12 X 9/16 #6

1 9/16 2 3/8 4.70-6.20 2 - 1 3/8 x 72 11 X 9/16 12 X 9/16 #6

1 11/16 2 3/8 4.70-5.30 1 - 1 11/16 x 72 9.5 X 9/16 10.5 X 9/16 #6

2 - 1 11/16 x 48 OR
1 3/4 2 7/8 6.50-10.70 11 X 9/16 12 X 9/16 #6
1- 1 11/16 X 80

2 - 1 11/16 x 48 OR
1 7/8 2 7/8 6.50-10.70 11 X 9/16 12 X 9/16 #6
1- 1 11/16 X 80

2 - 1 11/16 x 48 OR
2 2 7/8 6.50-9.50 11 X 9/16 12 X 9/16 #6
1- 1 11/16 X 80

2 1/8 2 7/8 6.50-7.90 1 - 1 11/16 x 72 9.5 X 9/16 10.5 X 9/16 #6

2 3/8 3 1/2 7.70-10.30 1 - 2 x72 12 X 9/16 13 X 9/16 #10

12.95-15.50 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

2 - 1 11/16 x 48 OR
2 5/8 3 1/2 7.70-10.30 10.5 X 9/16 11.5 X 9/16 #10
1- 1 11/16 X 80

2 7/8 4 11.00-15.70 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

3 1/8 4 9.50-14.00 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

3 1/4 4 1/2 12.60-20.00 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

3 3/8 4 1/2 11.60-17.70 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

3 1/2 4 1/2 9.50-15.50 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

3 5/8 4 1/2 9.50-13.50 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

3 7/8 5 15.00-21.00 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

4 5 11.50-19.50 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

4 3/16 5 1/2 20.00-26.00 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

4 7/16 5 1/2 15.50-23.00 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

4 9/16 5 1/2 13.00-17.00 2 - 2 x 48 OR 1- 2 X 80 14 X 9/16 15 X 9/16 #10

USE THIS CHART FOR 3/4" OD GRAIN

5 1/2 7 28.00-35.00 2 - 2 x 72 12.5 X 3/4 13.5 X 3/4 #12

5 3/4 7 20.00-26.00 2 - 2 x 60 OR 1 - 2 X 84 11.5 X 3/4 12.5 X 3/4

#12
6 3/8 7 5/8 20.00-33.70 2 - 2 x 72 12.5 X 3/4 13.5 X 3/4 #12
7 1/2 8 5/8 24.00-40.00 2 - 2 x 72 12.5 X 3/4 13.5 X 3/4 #12

USE THIS CHART FOR 9/16" OD GRAIN

5 1/2 7 28.00-35.00 2 - 2 x 72 19 X 9/16 20 X 9/16 #12

5 3/4 7 20.00-26.00 2 - 2 x 60 OR 1 - 2 X 84 17 X 9/16 18 X 9/16

#12
6 3/8 7 5/8 20.00-33.70 2 - 2 x 72 19 X 9/16 20 X 9/16 #12
7 1/2 8 5/8 24.00-40.00 2 - 2 x 72 19 X 9/16 20 X 9/16 #12

NOTE: THE GRAIN LENGTH MUST BE INCREASED BY 1" WHEN ANY OF THE FOLLOWING 08/09
CONFIGURATIONS ARE USED:
TANDEM ANCHORS, ADJUSTABLE TOP CENTRALIZER, EXTENSION SPACER

8-3
 GAS GENERATOR GRAIN / CHEMICAL CYLINDER CHART
F/ 1 3/8 - 4 1/8 OD EXTENDED REACH CHEMICAL CUTTER

TOOL SIZE CYLINDER GRAIN (LENGTH X OD) CYL. (QTY. AND SIZE) GRAIN (LENGTH X OD) CATALYST
TUBING
(ANCHOR & QTY & SIZE F/ REGULAR PIPE F/ L-80 AND CR/NI F/L-80, CR/NI 13% AND UP SIZE
SEV HEAD) OD WT: #/FT F/ REG. PIPE 0-5 KPSI BHP 5-10 KPSI BHP 13% AND UP 0-5 KPSI BHP 5-10 KPSI BHP
1 3/8 ER 2 3/8 4.70 - 7.70 2 - 1 3/8 X 48 9 X 9/16 10 X 9/16 2 - 1 3/8 X 48 9 X 9/16 10 X 9/16 #6
2 1/16 3.25 - 3.40 1 - 1 3/8 X 72 8.5 X 9/16 9.5 X 9/16 2 - 1 3/8 X 72 11 X 9/16 12 X 9/16 #6
1 1/2 ER
2 3/8 4.70 - 7.70 1 - 1 3/8 X 72 8.5 X 9/16 9.5 X 9/16 2 - 1 3/8 X 72 11 X 9/16 12 X 9/16 #6
1 9/16 ER 2 3/8 4.70 - 7.70 1 - 1 3/8 X 72 8.5 X 9/16 9.5 X 9/16 2 - 1 3/8 X 72 11 X 9/16 12 X 9/16 #6
2 - 1 11/16 X 48 OR
1 3/4 ER 2 7/8 6.50 - 10.70 1 - 1 11/16 X 72 9.5 X 9/16 10.5 X 9/16 11 X 9/16 12 X 9/16 #6
1 - 1 11/16 X 80

2 - 1 11/16 X 48 OR
1 7/8 ER 2 7/8 6.50 - 10.70 1- 1 11/16 X 72 9.5 X 9/16 10.5 X 9/16 11 X 9/16 12 X 9/16 #6
1 - 1 11/16 X 80

1 3/4 ER SPC 3 1/2 12.95 - 16.70 2 - 1 11/16 X 72 15 X 9/16 16 X 9/16 2 - 1 11/16 X 72 15 X 9/16 16 X 9/16 #10

2 - 2 X 48 OR 2 - 2 X 48 OR
2" ER 3 1/2 12.95 - 16.70 14 X 9/16 15 X 9/16 14 X 9/16 15 X 9/16 #10
1 - 2 X 80 1 - 2 X 80

2 - 2 X 48 OR 2 - 2 X 48 OR
2 1/8 ER 3 1/2 9.30 - 16.70 14 X 9/16 15 X 9/16 14 X 9/16 15 X 9/16 #10
1 - 2 X 80 1 - 2 X 80

2 - 2 X 48 OR 2 - 2 X 48 OR
2 3/16 ER 3 1/2 9.30 - 16.70 14 X 9/16 15 X 9/16 14 X 9/16 15 X 9/16 #10
1 - 2 X 80 1 - 2 X 80

2 - 2 X 48 OR 2 - 2 X 48 OR
2 1/4 ER 3 1/2 9.30 - 15.50 14 X 9/16 15 X 9/16 14 X 9/16 15 X 9/16 #10
1 - 2 X 80 1 - 2 X 80

2 - 2 X 48 OR
2 3/8 ER 3 1/2 7.70 - 15.50 1 - 2 X 72 12 X 9/16 13 X 9/16 14 X 9/16 15 X 9/16 #10
1 - 2 X 80

2 - 2 X 60 OR 2 - 2 X 60 OR
2 7/8 ER 4 1/2 12.60 - 20.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 7/8 ER SPC 4 1/2 DP 13.75 - 22.82 2 - 2 X 72 19 X 9/16 20 X 9/16 2 - 2 X 72 19 X 9/16 20 X 9/16 #10

2 - 2 X 60 OR 2 - 2 X 60 OR
3 1/8 ER 4 1/2 12.60 - 20.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
2 7/8 ER SPC 5 DP 19.50 - 25.60 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
3 1/4 ER 5 11.50 - 21.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
3 3/8 ER 5 11.50 - 21.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
3 1/2 ER 5 11.50 - 21.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
3 5/8 ER 5 11.50 - 21.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
3 7/8 ER 5 1/2 17.00 - 26.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
4 " ER 5 1/2 13.00 - 26.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84

2 - 2 X 60 OR 2 - 2 X 60 OR
4 1/8 ER 5 1/2 13.00 - 26.00 17 X 9/16 18 X 9/16 17 X 9/16 18 X 9/16 #10
1 - 2 X 84 1 - 2 X 84
NOTE: THE GRAIN LENGTH MUST BE INCREASED BY 1" WHEN ANY OF THE FOLLOWING CONFIGURATIONS ARE USED : 08/09
TANDEM ANCHORS, ADJUSTABLE TOP CENTRALIZER, EXTENSION SPACER

8-4
 GRAIN CHART FOR NON-STANDARD CYLINDER COMBINATIONS

11/16 X 72" OD CYLINDER F/ 11/16" OD TOOL

3/4" X 72" OD CYLINDER F/ 3/4" - 15/16" OD TOOLS
GRAIN LENGTH (IN.) X GRAIN OD (IN.)
CYLINDER QTY & SIZE VS BHP (KPSI)
0 - 2.5 KPSI 2.5 - 5 KPSI
2 - 11/16 X 72 10 X 1/4 11 X 1/4
2 - 3/4 X 72 10 X 1/4 11 X 1/4

1" OD CYLINDERS F/ 1" - 1 1/4" OD TOOLS

GRAIN LENGTH (IN.) X GRAIN OD (IN.)
CYLINDER QTY & SIZE VS BHP (KPSI)
0 - 2.5 KPSI 2.5 - 5 KPSI 5 - 7.5 KPSI
2 - 1 X 48 8 X 3/8 9 X 3/8 10 X 3/8
2 - 1 X 72 9 X 3/8 10 X 3/8 11 X 3/8
1 - 1 X 48, 1 - 1 X 72 8.5 X 3/8 9.5 X 3/8 10.5 X 3/8

1 3/8" OD CYLINDERS F/ 1 3/8" - 1 9/16" OD TOOLS

GRAIN LENGTH (IN.) X GRAIN OD (IN.)
CYLINDER QTY & SIZE VS BHP (KPSI)
0 - 5 KPSI 5 - 10 KPSI
2 - 1 3/8 X 48 9 X 9/16 10 X 9/16
2 - 1 3/8 X 72 11 X 9/16 12 X 9/16
1 - 1 3/8 X 48, 1 - 1 3/8 X 72 10 X 9/16 11 X 9/16

1 11/16" OD CYLINDERS F/ 1 11/16" - 2 5/8" OD TOOLS

GRAIN LENGTH (IN.) X GRAIN OD (IN.)
CYLINDER QTY & SIZE VS BHP (KPSI)
0 - 5 KPSI 5 - 10 KPSI
2 - 1 11/16 X 48 11 X 9/16 12 X 9/16
1 - 1 11/16 X 48, 1 - 1 11/16 X 60 12 X 9/16 13 X 9/16
1 - 1 11/16 X 48, 1 - 1 11/16 X 72 12.5 X 9/16 13.5 X 9/16
2 - 1 11/16 X 60 12.5 X 9/16 13.5 X 9/16
1 - 1 11/16 X 60, 1 - 1 11/16 X 72 13 X 9/16 14 X 9/16
2 - 1 11/16 X 72 14 X 9/16 15 X 9/16

2" OD CYLINDERS F/ 2" ER - 4 9/16" OD TOOLS

GRAIN LENGTH (IN.) X GRAIN OD (IN.)
CYLINDER QTY & SIZE VS BHP (KPSI)
0 - 5 KPSI 5 - 10 KPSI
1 - 2 X 48, 1 - 2 X 60 16 X 9/16 17 X 9/16
1 - 2 X 48, 1 - 2 X 72 17 X 9/16 18 X 9/16
1 - 2 X 60, 1 - 2 X 72 18 X 9/16 19 X 9/16

2" OD CYLINDERS F/ 5 1/2" - 7 1/2" OD TOOLS

GRAIN LENGTH (IN.) X GRAIN OD (IN.)
CYLINDER QTY & SIZE VS BHP (KPSI)
0 - 5 KPSI 5 - 10 KPSI
1 - 2 X 60, 1 - 2 X 72 12 X 3/4 13 X 3/4 08/09

8-5
 Estimation of the Total Lengths and Weights of CHC Assemblies

CHC Assemblies Total Lengths(in.) Total Weights(lb.)

11/16" OD tool 74 6
3/4" OD tool 100 11
13/16" OD tool 100 11
7/8" OD tool 100 12
15/16 OD tool 100 12
1" OD tool 105 21
1 1/16" OD tool 105 22
1 1/8" OD tool 105 22
1 3/16" OD tool 105 22
1 1/4" OD tool 105 23
1 3/8" OD tool 41 15
1 1/2" OD tool 80 30
1 9/16" OD tool 80 31
1 11/16"OD tool 62 31
1 3/4"OD tool 82 41
1 7/8"OD tool 82 43
2" OD tool 62 37
2 1/8" OD tool 62 38
2 3/8" OD tool 65 47
2 5/8" OD tool 69 58
2 7/8" OD tool 67 73
3 1/8" OD tool 66 76
3 1/4" OD tool 67 83
3 3/8" OD tool 67 87
3 1/2" OD tool 67 91
3 5/8" OD tool 66 92
3 7/8" OD tool 67 103
4" OD tool 67 108
4 3/16" OD tool 69 128
4 7/16" OD tool 69 130
4 9/16"OD tool 69 133
5 1/2"OD tool 65 149
5 3/4" OD tool 65 154
6 3/8" OD tool 65 175
7 1/2" OD tool 65 233
08/09

*Chemical Cylinders are not included in the chart (refer to Chapter 42-1 in the CHC review for lengths and weights).
*11/16" - 1 1/4" OD tools include cablehead assembly with one sinker bar.
*1 1/2" - 7 1/2" OD tools include adjustable bottom centralizer.
*1 1/2", 1 9/16", 1 3/4", 1 7/8" OD tools include adjustable in-line top centralizer.
*To obtain the lengths and weights in m and kg respectively, use the following formulas: 1 in. = 0.0254 m 1 lb. = 0.4536 kg

9-1
 Estimation of the Total Lengths and Weights of CHC Assemblies (Continued)

Total Lengths(in.) Total Weights(lb.)

15/16 OD E.R tool 115 15
1 3/8" OD E.R tool 59 20
1 1/2" OD E.R tool 80 30
1 9/16" OD E.R tool 80 31
1 3/4"OD E.R tool 85 42
1 3/4"OD E.R SPC. tool 90 46
1 7/8"OD E.R tool 82 43
2" OD E.R tool 88 53
2 1/8 OD E.R tool 88 54
2 3/16" OD E.R tool 88 55
2 1/4" OD E.R tool 88 54
2 3/8" OD E.R tool 65 47
2 7/8" OD E.R tool 67 73
2 7/8" OD E.R SPC. tool 79 85
3 1/8" OD E.R tool 76 91
3 1/4" OD E.R tool 76 94
3 3/8" OD E.R tool 76 98
3 1/2" OD E.R tool 76 103
3 5/8" OD E.R tool 76 107
3 7/8" OD E.R tool 76 115
4" OD E.R tool 76 120
4 1/8" OD E.R tool 76 125

08/09

*15/16" OD E.R tool includes cablehead assembly with one sinker bar.
1 3/8" E.R - 2 7/8" E.R SPC OD tools include adjustable in-line top centralizer.
*1 3/4" - 4 1/8" OD E.R tools include adjustable bottom centralizer.
*Chemical Cylinders are not included in the chart (refer to Chapter 42-1 in the CHC review for lengths and
weights).
*To obtain the lengths and weights in m and kg respectively, use the following formulas: 1 in. = 0.0254 m 1 lb. = 0.4536 kg
*Information on individual parts of the tool assemblies can be obtained upon request from CCI.

9-2
 WEAKPOINTS ON CHC TOOL ASSEMBLIES
TOOL SIZE UPPER ASSEMBLY (ABOVE CYLINDER) LOWER ASSEMBLY (BELOW CYLINDER)
11/16" 8000 LB. (SS & UAB CONNECTION) 2000 LB. (CYL. & SH CONNECTION)
3/4" 13,000 LB.(SS & UAB CONNECTION) 3500 LB.(CYL & SH CONNECTION)
13/16" 13,000 LB.(GGS & SS CONNECTION) 3500 LB.(CYL. AND SH CONNECTION)
7/8" 13,000 LB.(GGS & SS CONNECTION) 3500 LB.(CYL. AND SH CONNECTION)
15/16" 13,000 LB.(GGS & SS CONNECTION) 3500 LB.(CYL. AND SH CONNECTION)
1" 25,000 LB. (UAB WEDGE WINDOWS) 8500 LB. (SH AND BP CONNECTION)
1 1/16" 30,000 LB.(GGS & SS CONNECTION) 10,000 LB.(CYL. AND SH CONNECTION)
1 1/8" 30,000 LB. (FSA & GGS CONNECTION) 10,000 LB.(CYL. AND SH CONNECTION)
1 3/16" 30,000 LB. (FSA & GGS CONNECTION) 10,000 LB.(CYL. AND SH CONNECTION)
1 1/4" 30,000 LB. (FSA & GGS CONNECTION) 10,000 LB.(CYL. AND SH CONNECTION)
1 3/8" 44,000 LB. (UAB & LAB CONNECTION) 17,000 LB. (SH & BP CONNECTION)
1 1/2" 75,000 LB. (LAB & CYL CONNECTION) 20,000 LB. (CYL & SH CONNECTION)
1 9/16" 75,000 LB. (LAB & CYL CONNECTION) 20,000 LB. (CYL & SH CONNECTION)
1 11/16" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 25,000 LB. (CYL. & SH CONNECTION)
1 3/4" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 25,000 LB. (CYL. & SH CONNECTION)
1 7/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 25,000 LB. (CYL. & SH CONNECTION)
2" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 25,000 LB. (CYL. & SH CONNECTION)
2 1/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 25,000 LB. (CYL. & SH CONNECTION)
2 3/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 38,000 LB. (CYL. & SH CONNECTION)
2 5/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 20,000 LB. (CYL & CS{COPPER} CONNECTION)
2 7/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
3 1/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
3 1/4" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
3 3/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
3 1/2" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
3 5/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
3 7/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
4" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
4 3/16" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
4 7/16" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
4 9/16" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
5 1/2" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
5 3/4" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
6 3/8" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)
7 1/2" 105,000 LB. (ELECT. X-OVER & FSA CONN.) 35,000 LB. (CYL & CS{COPPER} CONNECTION)

08/09

BP: BULL PLUG GGS: GAS GENERATOR SUB UAB: UPPER ANCHOR BODY
CS: CATALYST SUB LAB: LOWER ANCHOR BODY
CYL: CHEMICAL CYLINDER SH: SEVERING HEAD
FSA: FIRING SUB ADABTER SS: SAFETY SUB

9-3
 REPAIR KITS
CCI 075001-KIT-1 F/ ¾ - 15/16 CABLEHEAD ASS’Y (7/32 LINE)
CCI 075001-KIT-2 F/ ¾ - 15/16 CABLEHEAD ASS’Y (5/16 LINE)
CCI 075002 F/ ¾ - 15/16 SINKER BAR ASS’Y
CCI 100001-KIT-1 F/ 1” – 1 ¼ CABLEHEAD ASS’Y (7/32 LINE)
CCI 100001-KIT-2 F/ 1” – 1 ¼ CABLEHEAD ASS’Y (5/16 LINE)
CCI 100002-KIT F/ 1” – 1 ¼ SINKER BAR ASS’Y
CCI 137044 PRESSURE RELIEF REPAIR KIT F/ 1 11/16 – 7 1/2
ANCHOR PACKETS
CCI 137008 F/ 1 3/8 – 1 9/16 OD TOOL
CCI 137108 F/ 1 3/8 OD TOOL EXTENDED REACH
CCI 150108 F/ 1 ½ - 1 9/16 OD TOOL EXTENDED REACH
CCI 168008 F/ 1 11/16, 2, 2 1/8 OD TOOL
CCI 175008 F/ 1 3/4 OD TOOL
CCI 175054 F/ 1 ¾ OD TOOL EXT. REACH SPECIAL
CCI 175108 F/ 1 ¾ - 1 7/8 OD TOOL EXTENDED REACH
CCI 187008 F/ 1 7/8 OD TOOL
CCI 200108 F/ 2” OD TOOL EXTENDED REACH
CCI 212108 F/ 2 1/8 – 2 3/8 OD TOOL EXTENDED REACH
CCI 237008 F/ 2 3/8 – 2 5/8 OD TOOL
CCI 287008 F/ 2 7/8 OD TOOL
CCI 287208 F/ 2 7/8 OD TOOL EXTENDED REACH
CCI 287108 F/ 2 7/8 OD TOOL EXT. REACH SPECIAL
CCI 312008 F/ 3 1/8 – 4 9/16 OD TOOL
CCI 312108 F/ 3 1/8 – 4 1/8 OD TOOL EXTENDED REACH
CCI 550008 F/ 5 ½ - 7 1/2 OD TOOL

08/09

10-1
 EXPENDABLE PARTS PACKET LIST
PACKET NUMBER TOOL SIZE
CCI 068013 11/16"
CCI 075013 3/4", 13/16", 7/8 and 15/16"
CCI 093113 15/16" ER
CCI 100013 1", 1 1/16", 1 1/8", 1 3/16" and 1 1/4"
CCI 137013 1 3/8", 1 1/2" and 1 9/16"
CCI 137113 1 3/8" ER , 1 1/2" ER and 1 9/16" ER
CCI 168013 1 11/16", 1 3/4", 1 3/4" ER , 1 7/8", 1 7/8" ER , 2" and 2 1/8"
CCI 175213 1 3/4" ER (F/ 3 1/2" DRILL PIPE)
CCI 200113 2" ER , 2 1/8" ER , 2 3/16" ER , 2 1/4" ER and 2 3/8" ER
CCI 237013 2 3/8"
CCI 262013 2 5/8" (F/ 3 1/2" TUBING W/ 1 11/16" CYLINDER)
CCI 287013 2 7/8", 3 1/8", 3 1/4", 3 3/8", 3 1/2", 3 5/8", 3 7/8" and 4"
CCI 287113 2 7/8" ER
CCI 312113 3 1/8" ER , 3 1/4" ER , 3 3/8" ER , 3 1/2" ER , 3 5/8" ER , 3 7/8 ER and 4" ER
CCI 412113 4 1/8" ER
CCI 418013 4 3/16", 4 7/16" and 4 9/16"
CCI 550013 5 1/2", 5 3/4" and 6 3/8"
CCI 750013 7 1/2"

12/2009

11-1
 08/09

12-1
13-1
14-1
14-2
14-3
14-4
14-5
15-1
 SLACK JOINT ASSEMBLY INSTRUCTIONS
- Refer to assembly drawing while assembling.
- Gather all parts needed and verify their part numbers using the assembly drawing

MANDREL ASSEMBLY:
a. Screw the Feed Thru Connector (item 12) into the Contact Rod Mandrel (item 11). (Note : There
should be a small gap, about 1/8” between the shoulder of the Feed Thru Connector and the end of
the Contact Rod Mandrel after they are fully engaged)

b. Lubricate the o-rings on the Feed Thru Connector (item 12) with silicone and slide the Contact Rod
Mandrel (item 11) into the Mandrel (item 6) until the o-rings of the Feed Thru Connector are
pushed into the recess of the Mandrel. (Caution : End of Feed Thru Connector is fragile)

c. Slide the Cone Insulator (item 3) into the other end of the Contact Rod Mandrel and gently secure
it by screwing in the Contact Rod Sleeve (item 1)

d. Assemble the O-rings (item 4) onto the Mandrel (item 6).

e. This assembly is now ready.

TEAR DROP ASSEMBLY:

a. Lubricate o-rings on the Feed Thru Connector (item 12) and insert it into the recess of the Tear Drop
(item 18) (Caution : End of Feed Thru Connector is fragile)

b. Slide in the Insulating Washer (item 19) onto the threaded end of Feed Thru Connector in the Tear Drop
and gently secure it by screwing the Connector Rod Sleeve (item 20)

c. Insert the Insulating Sleeve (item 21) (pre-cut length = 1.60”) over the Connector Rod Sleeve and then
install the Contact Spring (item 22) (pre-cut length = 1.40”)

d. Slide Insulating Washer (item 24) over the Contact Pin (item 26) and push down on the Contact Spring
while securing the Retainer Ring (item 25) on the groove of the Tear Drop.

e. Install O-rings (item 23) onto the Tear Drop.

f. This assembly is now ready

08/2009

15-2
CONDUCTOR WIRE ASSEMBLY:
a. Slide the Retaining Sleeve (item 14), (the non-threaded end first) onto one end of the Conductor Wire-Curly
Q (item 16) (See diagram below)

b. Assemble the Boot Assembly (item 15) to that end by first inserting the boot with the liner and then crimping
the contact to the conductor with a crimping tool. (See diagrams below)

c. Assemble the other end of the Conductor Wire-Curly Q using steps a. and b.

d. This assembly is now ready.

08/2009

15-3
FINAL ASSEMBLY:

a. Gently screw one end of the Conductor Wire Assembly into Feed Thru Connector of Mandrel
Assembly. (Caution : End of Feed Thru Connector is fragile)

b. Screw the Feed Thru Connector of the Tear Drop Assembly to the other end of the Conductor Wire
Assembly. (Caution : End of Feed Thru Connector is fragile)

c. Now, the Conductor Wire Assembly, Tear Drop Assembly and Mandrel Assembly are called, Contact
Assembly.

d. Slide the Contact Assembly into the Housing (item 10) and screw Tear Drop Assembly to the end of the
Housing while turning the Mandrel Assembly from the other end of Housing in the same direction
simultaneously to prevent kinking the Conductor Wire.

e. Insert the Slack Joint Key (item 7) into the slot on the Mandrel Assembly with the bevels up (see
diagram below) and align the two tapped holes of the Housing to the ones on the key. Secure the key
down with the Button Head

f. Screw Top Sub (item 2) to the end of the Mandrel Assembly and secure it with Lock Screws (item 5)

g. Keeping the Top Sub flush with the Housing (closed position), screw the Shear Screws (item 9) into the
Housing.

h. Screw Lock Screws (item 17) into the Housing.

i. Slack Joint is now assembled. Check for continuity or shortage by using a multi-meter.

08/2009

15-4
 FIRING SYSTEMS

FOR CCI CHEMICAL CUTTERS

THE FOLLOWING METHODS CAN BE USED TO INITIATE CHEMICAL CUTTERS:

ELECTRICAL (WIRELINE)

1. SMALL IGNITER P/N CCI 068017 FOR TOOLS 11/16” - 1 1/4” AVAILABLE

ONLY FROM CCI

2. REGULAR BP-3/BP-4 IGNITER P/N CCI 137017 FOR TOOLS 1 3/8” - 7 1/2” OD

3. OWEN IGNITER DET-5306-074 (REQUIRES SPECIAL ADAPTER P/N

CCI 168109)

4. JRC - HALLIBURTON RED IGNITER (RED 3), GO STYLE, PART NUMBER

101272602 (REQUIRES SPECIAL ADAPTER P/N CCI 168104-HES)

PRESSURE (COILED TUBING / DRILL PIPE)

1– SEVERAL COMPANIES PROVIDE PRESSURE FIRING HEADS USING

PERCUSSION IGNITERS.

SLICKLINE

1– REQUIRE SLICKLINE FIRING HEADS TO INITIATE CUTTER

08/2009

16-1
16-2
16-3
17-1
17-2
17-3
17-4
18-1
18-2
18-3
19-1
19-2
19-3
19-4
19-5
20-1
20-2
20-3
20-4
20-5
20-6
20-7
21-1
21-2
21-3
21-4
21-5
21-6
 HINTS FOR TOOL PREPARATION BEFORE ASSY

A - NEW PARTS:
If using new parts, remove oil residue with a degreaser

B - USED PARTS:
1 - Inspect all parts for any defect and/or cracks.

2 - Brush and clean all threads and sealing surfaces using the proper size wire
brushes supplied by CCI.

3 - Make sure the gas generator sub is clean on the inside and free from any rust
that could obstruct the flow of gas down into the tool.

4 - The anchor slip cavities in the upper anchor body should be extremely polished
and free from any rust deposit that could interfere in the retraction of the anchor
slips and retrieval of the tool.

5 - The narrow gas orifices in the upper anchor body must be clean and open to
allow uniform distribution of gas pressure against the anchor slips.

6 - Anchor slip cavities should be inspected after every job with “T” go/ nogo gages
for tolerances (see details/instructions on next page).

7 - All parts should be degreased before assembly.

08/09

22-1
 “T” SHAPE NOGO GAGE SET
08/09

The “T” shape NOGO gage set is designed to check the anchor slip cavities in the upper anchor body
for any out of tolerance parts which may not be detected by using the standard GO/NOGO plug gage
set p/n CCI 168111.

GAGE PART DIMENSION AND TOLERANCE SIZE OF UPPER DIMENSION AND TOLERANCE
NUMBER NUMBER OF MEASURE BARS ANCHOR BODIES OF ANCHOR SLIP CAVITIES

1 137081 0.509" (+0.001, -0.000) 1 3/8" - 1 9/16" 0.503" ID (+0.002, -0.000)

2 168081 0.573" (+0.001, -0.000) 1 11/16" - 2 1/8" 0.563" ID (+0.002, -0.000)

3 237081 0.761" (+0.001, -0.000) 2 3/8" - 4 9/16" 0.753" ID (+0.002, -0.000)

4 200081 0.821" (+0.001, -0.000) 2" - 2 3/8" (EXT. REACH) 0.813" ID (+0.002, -0.000)

5 550081 1.010" (+0.002, -0.000) 5 1/2" – 7 1/2" 1.003" ID (+0.002, -0.000)

Checking instructions:

Insert “T” shape NOGO gage into anchor slip cavity slightly tilted, when at bottom of cavity, the
operator should gently try to place the gage handle into the chamber axis of the slip cavity. If it is
possible as drawing in position “A” below, the part should be immediately junked. If it is not as drawing
in position “B” is showing, the same procedure should be applied mid-way and at the cavity top. Note:
Avoid checking bottom cavity at pressure channel because this will give false impression of out of
tolerance.

23-1
 "T" & PLUG GAGE SET

GAGE REFERENCE # BORE LOCATION

"T" GAGE #1 1 3/8" - 1 9/16" UPPER ANCHOR BODY (SLIP CAVITY)

"T" GAGE #2 1 11/16" - 2 1/8" UPPER ANCHOR BODY (SLIP CAVITY)

"T" GAGE #3 2 1/4" - 4 7/16" UPPER AMCHOR BODY (SLIP CAVITY)

"T" GAGE #5 2" - 2 1/4" EXTENDED REACH UPPER ANCHOR BODY (SLIP CAVITY)

2 5/8" - 4 9/16" (4-SLIP) UPPER ANCHOR BODY (SLIP CAVITY)

"T" GAGE #4
5 1/2" - 7 1/2" (9-SLIP) UPPER ANCHOR BODY (SLIP CAVITY)

23-2
1 3/8" - 1 9/16" OD PARTS:
PLUG GAGE #4 FIRING SUB ADAPTER (BOTTOM), PRESSURE RELIEF SUB,
TOP CENTRALIZER MANDREL, UPPER ANCHOR BODY (TOP)

1 3/8" - 1 9/16" UPPER ANCHOR BODY (BOTTOM)

PLUG GAGE #6
1 3/8" - 7 1/2" FIRING SUB ADAPTER (TOP)

1 11/16" - 4 9/16" OD PARTS:

PLUG GAGE #7 FIRING SUB ADABTER (BOTTOM), PRESSURE RELIEF SUB,
TOP CENTRALIZER MANDREL, UPPER ANCHOR BODY (TOP)

PLUG GAGE #8 1 11/16" - 2 1/8 UPPER ANCHOR BODY (BOTTOM)

2" - 2 1/4 EXTENDED REACH UPPER ANCHOR BODY (BOTTOM)

PLUG GAGE #9

08/09
2 3/8" - 7 1/2" UPPER ANCHOR BODY (BOTTOM)
 GAS GENERATOR SUB

11/16 - 1 1/4 OD WEDGE TYPE

FIRING SUB ADAPTER IGNITER O-RING

O-RING GAS GENERATOR SUB O-RING

1. Place one O-Ring over the Igniter barrel.

2. Place two O-Rings on each end of the Gas Generator Sub.

3. Place the Igniter, barrel first, in the upper end of the Gas Generator Sub, which has a
counter bore.

4. The Firing Sub Adapter has two ends, a shallow end and a deep end. Place the end with
the deepest thread over the upper end of the Gas Generator Sub and screw together.

NOTE: THERE WILL BE A SMALL GAP BETWEEN THE GAS GENERATOR SUB
AND FIRING SUB ADAPTER. DO NOT ATTEMPT TO CLOSE GAP, THE IGNITER
MAY BE CRUSHED.

5. Check continuity with Safety Ohmmeter.

NOTE: ALL PARTS OF THE CHEMICAL CUTTER

WHICH MUST BE SCREWED TOGETHER SHOULD BE DONE BY HAND
WITHOUT ANY FORCE.

DO NOT INSERT THE GAS GENERATOR GRAIN INTO THE SUB AT THIS TIME. THIS
MUST BE DONE AT THE WELLHEAD AFTER THE SUB ASSEMBLY, WITH THE IGNITER IN
PLACE, HAS BEEN ATTACHED TO THE CABLE/CCL.

24-1
 GAS GENERATOR SUB

1 3/8 - 7 1/2 DIRECT ACTION

CROSSOVER ASSY FIRING SUB ADAPTER IGNITER

O-RING O-RING O-RING

O-RING GAS GENERATOR SUB O-RING

1. Place O-Rings on both ends of the Cross Over Sub and screw the end with the contact
pin into the Firing Sub Adapter.

2. Place O-Rings on both ends of the Gas Generator Sub and an O-Ring in the face seal.

NOTE: THERE WILL BE A SMALL GAP BETWEEN THE GAS GENERATOR SUB AND
FIRING SUB ADAPTER. DO NOT ATTEMPT TO CLOSE GAP, THE IGNITER MAY BE
CRUSHED.

3. Insert the Igniter, barrel end first, in the Gas Generator Sub at the face seal and screw
to the Firing Sub Adapter.

4. Check continuity with Safety Ohmmeter.

NOTE: ALL PARTS OF THE CHEMICAL CUTTER THAT MUST BE SCREWED

TOGETHER SHOULD BE DONE BY HAND WITHOUT ANY FORCE.

DO NOT INSERT THE GAS GENERATOR GRAIN INTO THE SUB AT THIS TIME. THIS MUST
BE DONE AT THE WELLHEAD AFTER THE SUB ASSEMBLY WITH THE IGNITER IN PLACE
HAVE BEEN ATTACHED TO THE CABLE/CCL.

24-2
 ANCHOR BODY ASSEMBLY
11/16 - 1 1/4 WEDGE TYPE

WEDGE

ORING ORING
SAFETY SUB ORING "WEDGE RETAINER"
2-012

ORING

ANCHOR PISTON

UPPER LOWER

RETURN SPRING ANCHOR BODY ASSEMBLY ORING T-WRENCH

032601

NOTICE:
The anchor piston has been modified to include an O-Ring (2-012) behind the
wedges to help retain and prevent them from falling out.

1. Place two O-Rings on the Safety Sub.

2. Place two O-Rings on each end of the Anchor Piston.

3. Slip the Piston Return Spring over the shaft. Apply a small amount of Lubriplate grease
to the Piston shaft between the coils of the spring. This will help prevent well particles
from entering the lower Anchor Body and inhibiting free movement of the spring.

NOTE: The free length of the spring MUST be at least 2 1/2” for the 11/16 - 15/16
CUTTERS and 2 3/4” for the 1” - 1 1/4”; IF IT IS NOT, DISCARD THE SPRING.

4. Screw the Wrench into the large end of the Anchor Piston. Place the three Wedges in
the milled slots of the Piston and engage the ears in place.

5. Insert the Anchor Piston, with Wedges attached, into the upper Anchor Body and align the
Wedges with the openings in the Upper Body. Some pressure must be applied to the
Wrench in order to position the Piston and Spring in the Anchor Body. The Wedges MUST
be protruding out of the openings.

25-1
 ANCHOR BODY ASSEMBLY
WEDGE TYPE (Continued)

6. Unscrew and remove the Wrench.

7. Take the assembled upper Body and snug to the lower.

8. With one hand gripping the Wedges, screw the Anchor Body Assembly to the Safety
Sub and snug.

NOTE: THE WEDGES MUST REMAIN OUT.

Using 1/32” copper or steel wire, wrap once around the Anchor Body in the grooves
provided and twist. This prevents the Wedges from extending prematurely and catching
or rubbing against the tubing ID as the CUTTER is being lowered into the well.

The newer version of anchor bodies provides wider and shallower groove that uses the
polyimide tape instead of the copper wire for retaining the wedges inside the ancho
body.

See Selection Guide for the Maximum extension of the Wedges. Never actuate the
Tool where the pipe I.D. at the anchors is greater than the value given for the maximum
extension of the Wedges/Slips. The result could be a failure to cut and difficulty pulling
the Tool from the well.

9. Place two O-Rings on the pin end of the Anchor Body.

Proceed to Severing Head Assembly.

25-2
 1 3/8 - 2 5/8 DIRECT ACTION

1. Place O-Rings on pin end of pressure relief sub.

2. Place one O-Ring on pressure relief stem.

3. Screw pressure relief stem into pressure relief nut.

4. Place one O-Ring in the side opening of the pressure relief sub. Place the seat on the O-Ring and
screw stem and nut into it and tighten.

Proceed to step 6 if not using adjustable top centralizer 227300-000

5. Place O-Rings on the adjustable top centralizer and screw into pin end of the pressure relief sub
and box end of upper anchor body.

6. Screw pressure relief sub into the top end of the upper anchor body.

NOTE: The pressure relief nut has a left hand thread.

7. Place O-Rings on each of the Anchor Slips and apply a small amount of Silicone to the O-Rings.

8. Insert each Anchor Slip into the Anchor Body with the Wrench. Align the Orientation Pin into the
groove of the counter bore so that the teeth are facing the top end. The slot should be parallel to
the body.

NOTE: Anchor Slip should assemble flush with the OD of the Anchor
Body. If it is protruding out or recessed into the Slip cavity then
the Slip should not be used.

9. Place the Anchor Spring in each Anchor Slip and compress.

10. Secure each Anchor Spring in place with a Retainer Bar and flat head screws. (These Springs
are expendable and must be replaced after each run).

11. Repeat steps 7, 8, 9 and 10 until all the Slips have been properly positioned in the Anchor Body.

NOTE: See Selection Guide for the maximum extension of the Slips.
Never actuate the Tool where the pipe I.D. at the anchors is
greater than the value given for the maximum extension of the
Wedges/Slips. The result could be a failure to cut and difficulty
pulling the Tool from the well.

Proceed to Final Assembly at the wellhead.

25-3
25-4
 ANCHOR BODY ASSEMBLY
2 7/8 - 7 1/2 DIRECT ACTION

1. Place O-Rings on pin end of pressure relief sub.

2. Place one O-Ring on pressure relief stem.

3. Screw pressure relief stem into pressure relief nut.

4. Place one O-Ring in the side opening of the pressure relief sub. Place the seat on the O-Ring and screw stem
and nut into it and tighten.

5. Screw pressure relief sub into the top end of the upper anchor body.

NOTE: The pressure relief nut has a left hand thread.

6. Place O-Rings on each of the Anchor Slips and apply a small amount of Silicone to the O-Rings.

7. Insert each Anchor Slip into the Anchor Body with the Wrench. Rotate the Slip so that the orientation notch and
the Retainer Bar align properly in the Anchor Body. The teeth in the Slip should point upward.

NOTE: Anchor Slip should assemble flush with the OD of the Anchor
Body. If it is protruding out or recessed into the Slip cavity then
the Slip should not be used.

8. Place the Anchor Spring in each Anchor Slip and compress.

9. Secure each Anchor Spring in place with a Retainer Bar and flat head screws. (These Springs are expendable
and must be replaced after each run).

10. Repeat steps 6, 7, 8 and 9 until all the Slips have been properly positioned in the Anchor Body.

NOTE: See Selection Guide for the maximum extension of the Slips.
Never actuate the Tool where the pipe I.D. at the anchors is
greater than the value given for the maximum extension of the
Wedges/Slips. The result could be a failure to cut and difficulty
pulling the Tool from the well.

Proceed to Final Assembly at the wellhead.

25-5
25-6
 TANDEM ANCHOR BODY ASSEMBLY
11/16 - 1 1/4 WEDGE TYPE

WEDGE
SAFETY SUB ORING ORING

ANCHOR BODY ASSEMBLY

ORING ANCHOR PISTON RETURN SPRING ORING

WEDGE
ORING ORING
TANDEM SUB ANCHOR BODY ASSEMBLY

ORING ANCHOR PISTON RETURN SPRING ORING

Two Anchor Bodies must run in tandem when cutting in deviated holes
and/or tough tubing material such as stainless or high chrome.

Join two Anchor Body Assemblies (Upper, Lower, Anchor Piston

w/Wedges and Piston Return Spring) with the appropriate
Anchor Body Tandem. Treat the Assembly as one unit and
proceed to the next step.

Available Anchor Body Tandems:

CCI 068022 f/11/16 O.D. Cutter

CCI 075022 f/3/4 thru 15/16 O.D. Cutter
CCI 100022 f/1” thru 1 1/4 O.D. Cutter

26-1
 TANDEM ANCHOR BODY ASSEMBLY
1 3/8 - 7 1/2 DIRECT ACTION

Two Anchor Bodies must run in tandem when cutting close to the bottom (plug or
obstruction), plastic or ceramic coated pipe, deviated holes, chrome/nickel or
stainless steel tubing.

Join two Anchor Body Assemblies with the appropriate Tandem Sub and treat them
as one unit. Proceed to the next step.

Available Anchor Body Tandems:

CCI 137022 f/1 3/8 thru 1 9/16 O.D. Cutter

CCI 168022 f/1 11/16 thru 2 1/8 O.D. Cutter
CCI 168022 f/2 5/8 - 4 9/16 4-Slip Anchor O.D. Cutter
CCI 200022 f/2” - 2 3/16 E.R., 2 1/4 - 4 9/16 O.D. Cutter
CCI 550022 f/5 1/2 thru 7 1/2 O.D. Cutter

NOTE: ADD ONE EXTRA INCH OF GAS GRAIN FOR TANDEM ANCHORS.

26-2
26-3
 HYDRAULIC PRESSURE TEST PROCEDURE FOR CCI
CHEMICAL CUTTER PARTS ABOVE THE CHEMICAL
CYLINDER

THE PURPOSE OF THE TEST IS TO ENSURE THAT ALL PARTS ABOVE THE CHEMICAL
CYLINDER (FIRING SUB ADAPTER, GAS GENERATOR SUB, PRESSURE RELIEF ASSY,
ADJUSTABLE TOP CENTRALIZER & ANCHOR ASSY) ARE:

1. CORRECTLY ASSEMBLED

2. THE O-RING SEALS ARE NOT LEAKING

3. THE ANCHOR SLIPS ARE OPENING TO THE CORRECT INTERNAL DIAMETER AND
RETRACTING PROPERLY

IMPORTANT REMINDERS

WARNING: NO HAZARDOUS MATERIAL (IGNITER AND/OR GAS GENERATOR GRAIN)

SHOULD BE PRESENT IN THE TOOL DURING THIS PROCEDURE!!!

• ALWAYS ASSEMBLE THE RIGHT SIZE SECTION OF PIPE OVER THE ANCHOR ASSY
WHEN PRESSURE TESTING
08/2009

27-1
 REQUIRED EQUIPMENT FOR THE HYDRAULIC PRESSURE TEST

1. PRESSURE TEST SUB P/N CCI 168083 WITH 1/4" NPT FITTING FOR TOOLS
1 3/8” – 6 3/8” OD (see fig. 1)

fig. 1

1. PRESSURE TEST PLUG (SOLID) FOR LOWER ANCHOR BODY (see fig. 2):

A. FOR LOWER ANCHOR BODY CCI 150007, USE TEST PLUG CCI 137082

B. FOR LOWER ANCHOR BODY CCI 168007, USE TEST PLUG CCI 168082

C. FOR LOWER ANCHOR BODY CCI 200007, USE TEST PLUG CCI 200082

fig.2
08/2009

27-2
3. CHEMICAL CUTTER UPPER ASSY:

- FIRING SUB ADAPTER

- GAS GENERATOR SUB
- PRESSURE RELIEF ASSY
- ADJUSTABLE TOP CENTRALIZER
- ANCHOR ASSY

4. TEST SLEEVE WITH SET SCREWS ON BOTH ENDS TO BE SECURED OVER THE
ANCHOR ASSY (see fig. 3).

fig.3

08/2009

27-3
 PRESSURE TEST PROCEDURE F/ 1 3/8 – 6 3/8” OD TOOLS

1. ASSEMBLE THE UPPER ASSY OF THE CHEMICAL CUTTER (FIRING SUB

ADAPTER, GAS GENERATOR SUB, PRESSURE RELIEF ASSY, ADJ. TOP
CENTRALIZER & ANCHOR ASSY) WITH ALL ORINGS AND LUBRICANT AS
INSTRUCTED IN THE CCI CHEMICAL CUTTER MANUAL

2. SCREW THE PROPER PRESSURE TEST PLUG (SOLID) TO THE BOTTOM OF THE
LOWER ANCHOR BODY

3. RUN THE TEST SLEEVE OVER THE ANCHOR ASSY AND SECURE IT IN PLACE
WITH SET SCREWS ON BOTH ENDS.

NOTE: THE TEST SLEEVE MUST BE OF THE SAME SIZE PIPE FOR THE
ANCHOR ASSY BEING TESTED. (REFER TO SELECTION GUIDE FOR
REFERENCE ON PIPE AND TOOL SIZES)

4. CONNECT THE PRESSURE TEST SUB P/N CCI 168083 TO THE HYDRAULIC HOSE
OF THE PRESSURE PUMP (see figs. 4&5) (USE TEFLON TAPE TO INSURE GOOD
SEAL)

fig.4 fig.5

5. SCREW PRESSURE TEST SUB P/N CCI 168083 INTO THE FIRING SUB ADAPTER
AND THE TOOL IS NOW READY FOR TESTING

08/2009

27-4
LOW PRESSURE TESTING:

1. FULLY SUBMERGE TEST FIXTURE IN A WATER CONTAINER. APPLY PRESSURE

SLOWLY UNTIL THE SLIPS ARE FULLY OPEN AND ANCHORED INSIDE THE TEST
SLEEVE. APPROXIMATELY 100 - 300 PSI IS REQUIRED FOR THE ANCHORS TO BE SET

2. WAIT THREE MINUTES AND CHECK FOR LEAKS BY OBSERVING THE PRESENCE OR
LACK OF BUBBLES IN THE WATER. IF LEAKING, TROUBLE SHOOT, RESOLVE
PROBLEMS & RETEST

HIGH PRESSURE TEST:

IF THERE ARE NO LEAKS, INCREASE PRESSURE GRADUALLY UP TO A RANGE OF
1500 - 3000 PSI AND HOLD FOR 3 MINUTES

IF NO LEAK IS DETECTED, BLEED THE PRESSURE AND THE ANCHOR SLIPS

SHOULD FULLY RETRACT

IF LEAKING IS DISCOVERED, TROUBLE SHOOT, RESOLVE PROBLEMS & RETEST

IF SLIPS DO NOT RETRACT AFTER PRESSURE IS BLED OFF, INSPECT THE ANCHOR SLIP
CAVITIES FOR ROUGH SURFACES/DAMAGED ORINGS/SHORT ANCHOR SPRING
LENGTHS/ ETC…AND REPEAT THE TEST

MAINTENANCE:
DISASSEMBLE THE CUTTER PARTS AND DEGREASE TO REMOVE OIL AND/OR WATER
RESIDUE. IF THE PARTS ARE NOT IMMEDIATELY NEEDED FOR A JOB, APPLY ANTI
CORROSION LUBRICANT TO KEEP RUST AWAY. IF THEY ARE NEEDED FOR A JOB, THEN
PROCEED WITH THE ASSEMBLY AFTER DEGREASING AS REQUIRED.

NOTE:
IF YOU PRESSURE TEST WITH NITROGEN (N2), THE SAME PROCEDURE MAY BE APPLIED

08/2009

27-5
 INTEGRAL SEVERING HEAD ASSEMBLY
11/16 Through 2 3/8 CUTTERS

1. Insert the Orifice Cleaner through each orifice of the Severing Head to be sure all the orifices are open.

2. Place O-Rings on the pin end of the Severing Head.

3. Using the Silicone Injection Kit, insert the Silicone Injection Piston into the Piston cavity and fill the
orifices with Silicone. Otherwise, wrap the orifices with Mylar tape.

4. Place O-Rings on each end of the Severing Head Piston and lubricate with Silicone DC 111.

Insert piston until it is flush with the bore shoulder

NOTE: No grease other than Silicone is to be used inside the Severing Head.

6. Remove the Catalyst from its container and gently roll between the hands to form a cylinder. Insert it

into the pin end of the Integral Severing Head until it is recessed 1/8” from the bore end.

WARNING: The catalyst must assemble loosely by hand. Do not use tools for this operation.

DO NOT ADD ANY EXTRA OIL!!!!!

7. Drop the thin copper Piston Support in the bottom end of the Severing Head.

8. Make sure that the Bull Plug recess is free from grease, dirt, and mud.

9. Place O-Rings on Bull Plug seal nut and screw into bottom of Bull Plug using Hex wrench CCI 150041

10. Place O-Rings on the pin end of the Bull Plug and snug into the Severing Head.

NOTE: Severing head must remain vertical while assembling bull plug to keep piston support washer flat.

11. Screw bottom centralizer into bull plug. Line up the set screws with the flats on centralizer and tighten.

28-1
28-2
 NON-INTEGRAL SEVERING HEAD
2 5/8 THROUGH 4” CUTTERS

1. Insert the Orifice Cleaner through each orifice of the Severing Head to be sure all the orifices are open.

2. Place O-Rings on both ends of the Catalyst Sub.

3. Place a Teflon Thread Protector in the Severing Head making sure it rests flat on the shoulder.

4. Screw the Catalyst Sub into this end and snug.

5. Using the Silicone Injection Kit, insert the Silicone Injection Piston into the Piston cavity and fill the

orifices with Silicone. Otherwise, wrap the orifices with Mylar tape

6. Place O-Rings on each end of the Severing Head Piston and lubricate with Silicone DC 111. Insert the

Piston until it is flush with the bore shoulder.

NOTE: No grease other than Silicone is to be used inside the severing head.

7. Remove the Catalyst from its container and gently roll between the hands to form a cylinder. Insert it
into the top end of the Catalyst Sub until it is recessed 1/8” from the bore end.

WARNING: The catalyst must assemble loosely by hand. Do not use tools for this operation.

DO NOT ADD ANY EXTRA OIL!!!

8. Drop the thin copper Piston Support in the bottom end of the Severing Head.

9. Make sure that the Bull Plug recess is free from grease, dirt, and mud.

10. Place O-Rings on Bull Plug seal nut and screw into bottom of Bull Plug using

Hex wrench CCI 150041.

11. Place O-Rings on the pin end of the Bull Plug and snug into the Severing Head.

NOTE: Severing head must remain vertical while assembling bull plug to keep piston support washer flat.

12. Screw bottom centralizer into bull plug. Line up the set screws with the flats on centralizer and tighten

28-3
28-4
 NON-INTEGRAL SEVERING HEAD ASSEMBLY
4 3/16 THROUGH 4 9/16 CUTTERS
1. Insert the Orifice Cleaner through each orifice of the Severing Head to be sure all the orifices are open.

2. Using the Silicone Injection Kit, insert the Silicone Injection Piston into the Piston cavity and fill the

orifices with Silicone. Otherwise, wrap the orifices with Mylar Tape.

3. Place O-Rings on each end of the Severing Head Piston and lubricate with Silicone DC 111. Insert the

Piston until it is flush with the bore shoulder.

NOTE: No grease other than Silicone is to be used inside the Severing Head.

4. Place O-Rings on both ends of the Catalyst Sub.

5. Place a Teflon Thread Protector in the smaller bore opening of the Severing Head making sure it rests

flat on the shoulder.

6. Screw the Catalyst Sub into this end and snug.

7. Remove the Catalyst from its container and gently roll between the hands to form a cylinder. Insert it

into the top end of the Catalyst Sub until it is recessed 1/8” from the bore end.

WARNING: The catalyst must assemble loosely by hand. Do not use tools for this operation.

DO NOT ADD ANY EXTRA OIL!!!

8. Drop the thin copper Piston Support in the bottom end of the Severing Head.

9. Make sure that the Bull Plug recess is free from grease, dirt and mud.

10. Place O-Rings on Bull Plug seal nut and screw into bottom of Bull Plug using

Hex wrench CCI 150041.

11. Place O-Rings on the pin end of the Bull Plug and snug into the Severing Head.

NOTE: Severing head must remain vertical while assembling bull plug to keep piston support washer flat.

12. Screw bottom centralizer into bull plug. Line up the set screws with the flats on centralizer and tighten.

28-5
28-6
 NON-INTEGRAL SEVERING HEAD ASSEMBLY
5 1/2 - 7 1/2 CUTTERS
1. Insert the Orifice Cleaner through each orifice of the Severing Head to be sure all the orifices are open.

2. Place O-Rings on both ends of Catalyst Sub.

3. Screw Catalyst Sub into Severing Head.

4. Using the Silicone Injection Kit, insert the Silicone Injection Piston into Piston cavity and fill the

orifices. Otherwise, wrap the orifices with Mylar tape.

5. Place O-Rings on the Severing Head Piston and lubricate with Silicone DC 111. Insert the Piston into

Severing Head until flush with bore shoulder.

NOTE: No grease other than Silicone is to be used inside the Severing Head.

6. Drop the thin copper Piston Support into the bottom end of Severing Head.

7. Place O-Rings on Bull Plug Seal Nut and screw into bottom of Bull Plug using

Hex wrench CCI 150041.

Place O-Rings on the pin end of the Bull Plug and snug into the Severing Head.
8.
NOTE: Severing head must remain vertical while assembling bull plug to keep piston support
washer flat.

Gently roll the Catalyst between the hands to form a cylinder and insert into top end of Catalyst Sub
9. until it is recessed 1/8” from the bore end.

WARNING: The catalyst must assemble loosely by hand. Do not use tools for this operation.

DO NOT ADD ANY EXTRA OIL!!!

10. Screw bottom centralizer into bull plug. Line up the set screws with the flats on centralizer and tighten.

28-7
28-8
 RUBBER CENTRALIZER
CCI 137042 F/ 1 3/8 O.D. CUTTER
CCI 150042 F/ 1 1/2 - 2 1/8 CUTTERS

1. Insert the rubber Centralizer Arms through each of the bottom oppenings of the Centralizer
Body and pull until they snap in place.

2. Screw the Centralizer Assembly into the bottom of the Bull Plug and Tighten the cone
point set screw.

11/09

29-1
 ADJUSTABLE BOTTOM CENTRALIZER

1 1/2 - 7 1/2 OD CUTTERS

1. Screw the Centralizer into the bottom of the Bull Plug.

2. To set the drag, tighten the Retainer Nut until the outside diameter of the
springs is about 1/2 inch greater than the I.D. of the tubing.

11/09

29-2
 ADJUSTABLE BOTTOM CENTRALIZER

Overall Upper Collar, Centra Mandrel, Lower Collar, Compression Sprinc, Centralizer Spring, Retainer Nut, Overall SET SCREW
Adj. Bottom Cent. Length, B C D E F G Centralizer SIZE,
A P/N O.D. Length P/N O.D. Length P/N O.D Length P/N O.D Length P/N Height P/N O.D. Length OD, H I

CCI 150016
1/4-20 x 1/4
F/ 1 1/2" - 2 1/8" OD 21.50 168151 1.50 1.62 168152 1.12 21.5 168154 1.50 1.38 168155 1.46 2.50 168153 1.00 168156 1.50 1.00 3.12
(P/N 137126)
Tools
CCI 200016
1/4-20 x 1/4
F/ 2" E.R. - 2 5/8" OD 21.50 262151 1.69 1.62 168152 1.12 21.5 262154 1.69 1.38 168155 1.46 2.50 262153 0.94 168156 1.50 1.00 3.00

29-3
(P/N 137126)
Tools
CCI 312016
1/4-20 x 1/4
F/ 2 7/8" - 3 1/8" OD 21.50 312151 2.50 1.50 312152 2.00 21.5 312154 2.50 1.38 312155 2.53 2.50 312153 0.85 312156 2.50 1.00 3.70
(P/N 137126)
Tools
CCI 362016
1/4-20 x 1/4
F/ 3 1/4" - 3 5/8" OD 21.50 312151 2.50 1.50 312152 2.00 21.5 312154 2.50 1.38 312155 2.53 2.50 362153 1.10 312156 2.50 1.00 4.20
(P/N 137126)
Tools

CCI 400016 1/4-20 x 1/4

21.50 312151 2.50 1.50 312152 2.00 21.5 312154 2.50 1.38 312155 2.53 2.50 400153 1.25 312156 2.50 1.00 4.50
F/ 3 3/4" - 4" OD Tools (P/N 137126)

CCI 418016
1/4-20 x 1/4
F/ 4 3/16" - 4 9/16" OD 21.50 312151 2.50 1.50 312152 2.00 21.5 312154 2.50 1.38 312155 2.53 2.50 418153 1.55 312156 2.50 1.00 5.00
(P/N 137126)
Tools
CCI 550016
1/4-20 x 1/4
F/ 5 1/2" - 5 3/4" OD 21.50 312151 2.50 1.50 312152 2.00 21.5 312154 2.50 1.38 312155 2.53 2.50 550153 2.12 312156 2.50 1.00 6.20
(P/N 137126)
Tools

CCI 575016 1/4-20 x 1/4

21.50 312151 2.50 1.50 312152 2.00 21.5 312154 2.50 1.38 312155 2.53 2.50 637153 2.50 312156 2.50 1.00 7.00
F/ 6 3/8" OD Tool (P/N 137126)

CCI 725016 1/4-20 x 1/4

21.50 312151 2.50 1.50 312152 2.00 21.5 312154 2.50 1.38 312155 2.53 2.50 725153 3.00 312156 2.50 1.00 8.00
F/ 7 1/2" OD Tool (P/N 137126)

THE ADJUSTABLE BOTTOM CENTRALIZER ASSEMBLES ONTO THE BOTTOM OF THE BULL PLUG AND THEN IT SECURES IN PLACE BY THE SET SCREWS. THE CENTRALIZER PROVIDES FLEXIBILITY TO 11/09
SQUEEZE THROUGH RESTRICTIONS, AND THEN RE-OPEN TO HELP CENTRALIZE IN THE BIGGER TUBING.

* All measurements are in Inches.

 CAGE CENTRALIZER

For 2 1/8 O.D. CUTTER through 7 1/2 O.D. CUTTER

NOTE: These Centralizers now have locking screws. They are not kept
floating anymore.

Two Centralizers are recommended per tool assembly at the Severing

Head and the Anchor System Assembly.

11/09

29-4
 CAGE CENTRALIZER ASSY F/ 2 1/8 - 7 1/2 OD TOOL

Centralizer Colar, B Centralizer Spring, C

CAGE CENT. Overall Length, Centralizer SET SCREW
TOOL O.D. Tubing/ Casing Cylinder O.D.

29-5
P/N A O.D., D SIZE, E
O.D. Max Weld O.D. I.D. Length Qty. & Dims. Height
4 1/4-20 X 3/16
2 1/8" CCI 212018 2 7/8 1 11/16 21.00 2.00 2.00 - 2.10 1.73 3.00 0.40 2.38 - 2.50
.125(t) x .50(w) P/N: 137125
6 3/8-16 X 1/4
2 3/8" CCI 237018 3 1/2 2 21.00 2.37 2.40 - 2.50 2.04 3.00 0.45 2.87 - 3.00
.125(t) x .50(w) P/N: 137137
6 3/8-16 X 3/8
2 5/8" CCI 262018 3 1/2 1 11/16 21.00 2.37 2.38 - 2.50 1.73 3.00 0.45 2.87 - 3.00
.125(t) x .50(w) P/N: 137130
6 3/8-16 X 1/4
3 1/8" CCI 312018 4 2 21.00 2.37 2.60 - 2.70 2.04 3.00 0.50 3.33 - 3.50
.125(t) x .50(w) P/N: 137137
6 3/8-16 X 1/4
3 5/8" CCI 362018 4 1/2 2 21.00 2.37 2.60 - 2.70 2.04 3.00 0.85 3.83 - 4.00
.125(t) x .50(w) P/N: 137137
6 3/8-16 X 1/4
4" CCI 400018 5 2 21.00 2.37 2.60 - 2.70 2.04 3.00 1.10 4.33 - 4.50
.125(t) x .50(w) P/N: 137137
6 3/8-16 X 1/4
4 9/16" CCI 418018 5 1/2 2 21.00 2.37 2.60 - 2.70 2.04 3.00 1.35 4.85 - 5.00
.125(t) x .50(w) P/N: 137137
8 3/8-16 X 1/4
5 1/2" CCI 550018 7 2 21.00 2.50 2.50 - 2.60 2.04 3.00 2.00 6.06 - 6.25
.125(t) x .50(w) P/N: 137137
8 1/2-13 X 1
6 3/8" CCI 637018 7 5/8 2 21.00 4.00 4.10 - 4.20 2.04 3.00 1.62 6.75 - 7.00
.125(t) x .50(w) P/N: 137133
11/09
8 1/2-13 X 1
7 1/2" CCI 725018 8 5/8 2 21.00 4.00 4.10 - 4.20 2.04 3.00 2.12 7.75 - 8.00
.125(t) x .50(w) P/N: 137133
 THE ADJUSTABLE TOP CENTRALIZER ASSEMBLES BETWEEN THE GAS GENERATOR SUB/ PRESSURE RELIEF SUB AND THE UPPER ANCHOR BODY TO PROVIDE CENTRALIZATION TO THE UPPER PART OF THE TOOL, AND TO THE ANCHOR BODY ASSEMBLY IN
PARTICULAR. THE ADJUSTABLE TOP CENTRALIZER IS FLEXIBLE TO ALLOW IT TO GO THROUGH SMALLER RESTRICTIONS, AND STILL BE ABLE TO CENTRALIZE THE TOOL IN A LARGER I.D. TUBING/ CASING.

NOTE:
THE GAS GENERATOR GRAIN MUST BE INCREASED BY ONE INCH WHEN THE ADJUSTABLE TOP CENTRALIZER IS USED.

Adjustable Top Centralizer F/ 1 3/8" OD E.R. Tool

29-6
Centralizer Spring, Set Screw, O-Ring,
Fixed Centralizer Colar, B Centralizer Mandrel, C Centralizer Colar, D Top Sub Adj Top Cent, F Compression Spring, H
ADJUSTABLE G (6-PKG) Overall J, (QTY. 2) K
Overall
TOP CENT. Centralizer
length Quantity
P/N P/N O.D. Length P/N O.D. Length P/N O.D. Length P/N O.D. Length P/N & Dims Height P/N Length O.D., I Size & P/N
& Size

CCI CCI CCI 137092 1/4-20 x 3/16 2

CCI 137010 17.75 CCI 137091 1.38 1.50 1.38 17.75 1.38 1.38 CCI 137095 1.38 4.75 0.75 CCI 137094 2.00 2.30 - 2.50
137096 137093 .063(t) x .38(w) CCI 137125 2-115

*All measurements are in inches.

11/09
 THE ADJUSTABLE TOP CENTRALIZER ASSEMBLES BETWEEN THE GAS GENERATOR SUB/ PRESSURE RELIEF SUB AND THE UPPER ANCHOR BODY TO PROVIDE CENTRALIZATION TO THE UPPER PART OF THE TOOL, AND TO
THE ANCHOR BODY ASSEMBLY IN PARTICULAR. THE ADJUSTABLE TOP CENTRALIZER IS FLEXIBLE TO ALLOW IT TO GO THROUGH SMALLER RESTRICTIONS, AND STILL BE ABLE TO CENTRALIZE THE TOOL IN A LARGER I.D.
TUBING/ CASING.

NOTE:
THE GAS GENERATOR GRAIN MUST BE INCREASED BY ONE INCH WHEN THE ADJUSTABLE TOP CENTRALIZER IS USED.

ADJUSTABLE TOP CENTRALIZER F/ 1 1/2" - 2 1/4" OD TOOLS

29-7
Centralizer Adjustable Centralizer Fixed Retainer, Centralizer Spring, Compression Spring, Overall Set Screw,
Adj. Top Cent. Overall Fixed Centralizer Collar, B Centralizer Mandrel, C Centralizer Collar, D
Retainer Nut, E F G (QTY. 6) H Centralizer J, (QTY. 12)
P/N Length, A
P/N O.D. Length P/N O.D. Length P/N O.D. Length P/N O.D. Length P/N O.D. Length P/N & DIM. Height P/N Length O.D., I P/N & Size

CCI 150015 CCI CCI 150092 CCI 137125

22.50 CCI 150091 1.50 1.50 1.50 22.50 CCI 150093 1.50 1.38 CCI 150096 1.50 1.50 CCI 150095 1.50 0.80 0.75 CCI 150094 2.50 2.50 - 2.80
1 1/2" - 1 9/16" 150097 .063(t) x .38(w) 1/4-20 x 3/16

CCI 168015
CCI CCI 168092 CCI 137125
1 3/4" - 1 7/8" 22.50 CCI 168091 1.68 1.50 1.68 22.50 CCI 168093 1.68 1.38 CCI 168096 1.68 1.50 CCI 168095 1.68 0.80 1.00 CCI 168094 2.10 3.00- 3.30
168097 .063(t) x .38(w) 1/4-20 x 3/16
2" - 2 1/4" E.R.

*All measurements are in inche

11/09
 THE ADJUSTABLE CENTRALIZER ASSEMBLES OVER ANY 1 11/16" O.D. MANDREL (WEIGHT BAR, CHEMICAL CYLINDER, ETC.). IT IS MOST EFFECTIVE WHEN USED OVER 1 11/16"
WEIGHT BARS IN DEVIATED WELLS.

ADJUSTABLE CENTRALIZER

Fixed Centralizer Centralizer Collar, Adjustable Nut, Fixed Retainer Nut, Compression Set Screw Size,
Overall

29-8
ADJ. CYL. Centralizer Spring,
Collar, B C D E Spring, G I
Overall F Centralizer
CENT. P/N: CCI 200167 P/N: CCI 200166 P/N: CCI 200164 P/N: CCI 200165 P/N: CCI 200168 P/N: CCI 137137
Length, A O.D.,
P/N
H
O.D. Length O.D. Length O.D. Length O.D. Length P/N Qty & Size Height Length Qty & Size

6 12
CCI 312170 22.94 2.38 1.88 2.38 1.60 2.38 2.67 2.38 3.00 CCI 312171 1.00 3.00 3.70
.093(t) x .50(w) 3/8-16 x 1/4
6 12
CCI 362170 22.88 2.38 1.88 2.38 1.60 2.38 2.67 2.38 3.00 CCI 362171 1.25 3.00 4.20
.093(t) x .50(w) 3/8-16 x 1/4
6 12
CCI 400170 22.81 2.38 1.88 2.38 1.60 2.38 2.67 2.38 3.00 CCI 400171 1.40 3.00 4.50
.093(t) x .50(w) 3/8-16 x 1/4
6 12
CCI 418170 22.63 2.38 1.88 2.38 1.60 2.38 2.67 2.38 3.00 CCI 418171 1.65 3.00 5.00
.093(t) x .50(w) 3/8-16 x 1/4
6 12
CCI 550170 23.19 2.38 1.88 2.38 1.60 2.38 2.67 2.38 3.00 CCI 550171 2.25 3.00 6.20
.093(t) x .50(w) 3/8-16 x 1/4
6 12
CCI 637170 22.75 2.38 1.88 2.38 1.60 2.38 2.67 2.38 3.00 CCI 637171 2.65 3.00 7.00
.093(t) x .50(w) 3/8-16 x 1/4
6 12
CCI 850170 22.75 2.38 1.88 2.38 1.60 2.38 2.67 2.38 3.00 CCI 850171 3.15 3.00 8.00
.093(t) x .50(w) 3/8-16 x 1/4

*All measurements are in inches 11/09

 THE ADJUSTABLE CYLINDER CENTRALIZER ASSEMBLES OVER 2" O.D. CYLINDERS TO OFFER SUPPORT TO THE ANCHOR BODY ASSEMBLY AND SEVERING HEAD. TWO SETS OF
CENTRALIZERS ARE RECOMMENDED FOR EACH CHEMICAL CUTTER JOB. THIS TYPE OF CENTRALIZER OFFERS FLEXIBILITY PASSING THROUGH RESTRICTIONS AND CENTRALIZING
THE TOOL INSIDE A LARGE I.D. PIPE/ CASING.

Adjustable centralizer

Fixed Centralizer Centralizer Collar, Adjustable Nut, Fixed Retainer Nut, Centralizer Spring, Compression Set Screw Size,
Collar, B C D E F Spring, G Overall I
ADJ. CYL. CENT, Overall
(P/N: CCI 200064) (P/N: CCI 312154) (P/N: CCI 200061) (P/N: CCI 200062) (QTY. 6) (P/N: CCI 312155) Centralizer (P/N: CCI 137137)
P/N Length, A
O.D., H

29-9
O.D. Length O.D. Length O.D. Length O.D. Length P/N & Size Height Length Qty & Size

CCI 312150 CCI 312153 12

21.81 2.50 1.38 2.50 1.38 2.50 2.67 2.50 1.00 0.85 2.50 3.70
F/ 2 5/8 - 3 1/8 OD TOOL .093(t) x .50(w) 3/8-16 x 1/4

CCI 362150 CCI 362153 12

21.68 2.50 1.38 2.50 1.38 2.50 2.67 2.50 1.00 1.10 2.50 4.20
F/ 3 1/4 - 3 5/8 OD TOOL .093(t) x .50(w) 3/8-16 x 1/4

CCI 400150 CCI 400153 12

21.62 2.50 1.38 2.50 1.38 2.50 2.67 2.50 1.00 1.25 2.50 4.50
F/ 3 3/4 - 4 OD TOOL .093(t) x .50(w) 3/8-16 x 1/4

CCI 418150 CCI 418153 12

21.43 2.50 1.38 2.50 1.38 2.50 2.67 2.50 1.00 1.55 2.50 5.00
F/ 4 3/16 - 4 9/16 OD TOOL .093(t) x .50(w) 3/8-16 x 1/4

CCI 550150 CCI 550153 12

22.09 2.50 1.38 2.50 1.38 2.50 2.67 2.50 1.00 2.12 2.50 6.20
F/ 5 1/2 - 5 3/4 OD TOOL .093(t) x .50(w) 3/8-16 x 1/4

CCI 637150 CCI 637153 12

21.74 2.50 1.38 2.50 1.38 2.50 2.67 2.50 1.00 2.50 2.50 7.00
F/ 6 3/8 OD TOOL .093(t) x .50(w) 3/8-16 x 1/4

CCI 725150 CCI 725153 12

21.74 2.50 1.38 2.50 1.38 2.50 2.67 2.50 1.00 3.00 2.50 8.00
F/ 7 1/2 OD TOOL .093(t) x .50(w) 3/8-16 x 1/4

*All measurements are in inches 11/09

 CHEMICAL CYLINDER
PRE-ASSEMBLY SAFETY CHECK

Safety equipment must be worn at all times when assembling or disassembling the
Chemical Cylinder.

Prior to final assembly, check the end seals of the Cylinder for possible leaks that may
have occurred during shipping. To check properly, the temperature of the Cylinder must be
above the freezing point of the chemical (+32F in pure form). During inclement weather,
the Cylinder must be warmed to 60°F.

Place the Cylinder with one end on the ground and the other end elevated.

CAUTION: FOR THE FOLLOWING STEPS, THE CYLINDER MUST BE KEPT IN A

VERTICAL OR ELEVATED POSITION.

NOTE: THE USE OF A TOOL STAND (MINIMUM 12” HIGH) IS RECOMMENDED

TO POSITION THE ELEVATED END OF THE TOOL ON.

CAUTION: MAKE SURE THE VENT HOLE IS POINTED AWAY FROM OPERATOR’S
FACE.

Remove one strip of Litmus paper and place it on the vent hole on the side of the Shipping
Plug on the raised end of the Cylinder. Unscrew the Allen screw 1-2 turns. Wait 1-2
seconds, then note if the Litmus paper changes to red or remains blue. If the Litmus turns
red, this indicates the Cylinder is leaking at that end. Label the end “LEAKING” and tighten
the vent screw.

CAUTION: DO NOT USE THIS LEAKING CYLINDER.

If the Litmus paper remains blue, repeat the same test for the other end. If the Cylinder
has no leaks, then proceed with the final assembly.

CHEMICAL CYLINDER RUPTURE DISCS RATING

11/16 – 3/4” OD Cylinders……………………5,000 PSI

1” OD Cylinders……………………….………6,500 PSI
1 3/8” OD Cylinders…………………………..7,500 PSI
1 11/16” OD Cylinders………………………..9,000 PSI
2” OD Cylinder………………………………12,500 PSI

08/2009

30-1
 CHEMICAL CYLINDER ASSEMBLY
11/16 - 1 1/4 WEDGE TYPE

CAUTION: FOR THE FOLLOWING STEPS, THE CYLINDER MUST BE

KEPT IN A VERTICAL OR ELEVATED POSITION

NOTE: THE USE OF A TOOL STAND (MINIMUM 12” HIGH) IS

RECOMMENDED TO POSITION THE ELEVATED END OF
THE TOOL ON.

The Pre-Assembly Safety check should be completed prior to removing Shipping Plugs.

1. Remove one Shipping plug from one end of the Cylinder and place a Teflon Thread
Protector making sure it rests flat on the Jam Insert.
2. Screw the Severing Head Assembly into this end and snug all individual subs.

NOTE: THERE WILL BE A SMALL GAP BETWEEN THE CYLINDER AND THE
SEVERING HEAD. DO NOT ATTEMPT TO CLOSE IT; THE TEFLON WASHER MAY
GET CRUSHED.

3. Slide the aluminum Protective Sleeve over the Integral Severing Head.

The three sub assemblies of the CHEMICAL CUTTER are ready to be carried to the
wellhead to complete the assembly.

08/2009

30-2
 CHEMICAL CYLINDER ASSEMBLY
1 3/8 - 7 1/2 DIRECT ACTION

CAUTION: FOR THE FOLLOWING STEPS, THE CYLINDER MUST BE

KEPT IN A VERTICAL OR ELEVATED POSITION

NOTE: THE USE OF A TOOL STAND (Minimum 12” High) IS HIGHLY

RECOMMENDED TO POSITION THE ELEVATED END OF CYLINDER ON.

1. The Pre-Assembly Safety check should be completed prior to removing Shipping Plugs.

Remove one Shipping Plug from one end of the Cylinder. Place first a Teflon Thread Protector and
2. then a copper Thread Protector on top of the Teflon. Both should rest flat on the Jam Insert.

Screw the Severing Head Assembly with Catalyst Sub into this end and snug all individual subs.

NOTE: THERE WILL BE A SMALL GAP BETWEEN THE CYLINDER AND SEVERING HEAD. DO
NOT ATTEMPT TO CLOSE IT; THE TEFLON WASHER MAY BE CRUSHED.

3. Slide the aluminum Protective Sleeve over the Severing Head and lock in place.

4. NOTE: Skip step 4 if not using centralizers over the cylinder.

Reverse the cylinder and assemble the cage or adjustable centralizers over it.
5.
Repeat Step 1.
6.
Place O-Rings on both ends of the Lower Anchor Sub.
7.
Screw the Lower Anchor Body into the Cylinder and snug with Friction Tongs (Optional). The sub
assemblies of the CHEMICAL CUTTER are ready to be carried to the well head for final assembly.

NOTE: THERE WILL BE A SMALL GAP BETWEEN THE CYLINDER AND LOWER ANCHOR
BODY. DO NOT ATTEMPT TO CLOSE IT; THE TEFLON WASHER MAY GET CRUSHED.
08/2009

30-3
 CYLINDER TANDEM

Cylinder Tandems are available for all sizes of cylinders:

F/ 11/16 O.D. Cylinder………………............................P/N CCI 068021

F/ 3/4 O.D. Cylinder………………………………………P/N CCI 075021
F/ 1 O.D. Cylinder………………………………………...P/N CCI 100021
F/ 1 3/8 O.D. Cylinder…………………………………….P/N CCI 137021
F/ 1 11/16 O.D. Cylinder………………………………….P/N CCI 168021
F/ 2 O.D. Cylinder………………………………………....P/N CCI 200021

The Pre-Assembly Safety check should be completed prior to removing Shipping Plugs.
1.
Place two O-Rings on each end of the Tandem Sub.
2.
Remove a Shipping Plug from each Cylinder to be run in tandem. Place a Teflon Thread
Protector first and then a copper Thread Protector on top of the Teflon. Both should rest flat
on the Jam Insert.
3.
Screw one end of the Tandem Sub into the Cylinder and snug.

NOTE: THERE WILL BE A SMALL GAP BETWEEN THE CYLINDER AND TANDEM SUB.
DO NOT ATTEMPT TO CLOSE IT; THE TEFLON WASHER MAY GET CRUSHED.

NOTE: DO NOT PLACE CATALYST MATERIAL IN THIS SUB.

4.
Repeat Step 2 with the second cylinder.
5.
Screw the other end of the Tandem Sub into the second Cylinder and snug.
6.
You may treat the tandem Cylinder as one and continue with further assembly.
08/2009

30-4
 FINAL ASSEMBLY AT WELLHEAD

1. With the line, cable head, and CCL laying down from the sheave, screw the Gas Generator Sub
Assembly and snug. This assembly should only include the igniter (NO GAS GENERATOR
GRAIN).

2. Determine the length of the Gas Generator Grain by referring to the Grain Chart.

CAUTION: the Gas Generator Grain package is thermally sealed at both ends.

3. Using a razor blade and a block of wood, cut the Grain to the required length and insert into the
large bore end of the Gas Generator Sub. Then fill the void with the grain spacer, crimped end
first. The make up length of the gas generator grain and grain spacer after they are inserted into
the gas generator sub should be flush with the bottom end of the gas generator sub.

4. Screw the Adjustable Top Centralizer/upper Anchor Body Assembly to the Gas Generator Sub and
snug.

5. Slide the Anchor System Safety Sleeve over the upper Anchor Body Assembly and secure on Gas
Generator Sub/Adjustable Top Centralizer.

6. With the top end of the cylinder resting on a tool stand, screw the upper anchor body and snug into
it.

NOTE:

For wedge type (coiled tubing) CUTTERS, remove the second Shipping Plug from the Cylinder and
place a Teflon Thread Protector and screw into the Anchor Body Assembly.

Take Measurements between the CCL/ Anchors and CCL/ Severing Head Orifices. Now Cutter
is ready to be picked up. Loosen the thumb screws and remove the Severing Head Protective
Sleeve and lower the CUTTER into the tubing. As soon as the Anchor Assembly is eye level,
loosen the thumb screws and remove the Anchor System Safety Sleeve and precede
downhole.

08/09

31-1
RETRIEVAL AND DISASSEMBLY OF THE CHEMICAL CUTTER

Upon retrieving the CUTTER, allow two to three minutes for pressure equalization. Always
move the CUTTER DOWN one to two feet before moving UP. This will allow the Slips to
release from the tubing.

It is important to disassemble the CHEMICAL CUTTER AS SOON AS POSSIBLE. The

residue from the chemical is strongly acidic and will cause corrosion and thread galling.
Recommended safety equipment must be worn when retrieving and disassembling the
CUTTER.

1. On retrieving the CHEMICAL CUTTER, treat it with the same caution as though it had
malfunctioned.

a. As soon as the Cable head is out of the tubing, slide the Anchor System Safety Sleeve
over the Anchor Assembly and tighten the thumb screws to the Adjustable Top
Centralizer.

b. Place a Protective Sleeve over the Severing Head Assembly.

NOTE: WHEN USING LUBRICATOR, COVER THE SEVERING HEAD WITH

PROTECTIVE SLEEVE FIRST FOLLOWED BY THE ANCHOR ASSY.

c. Open the Stem of the Pressure Relief Assembly to release trapped pressure that might
still be inside.

d. Keep the CUTTER Vertical or Elevated with the Cylinder upper end at least one foot
higher than the lower end.

e. Disconnect the assembly from the cable head or directly at the Lower Anchor Body /
Cylinder connection, whichever is more convenient.

NOTE: THE USE OF A TOOL STAND (Minimum 12” High) IS HIGHLY RECOMMENDED
TO POSITION THE ELEVATED END OF THE TOOL ON.
CAUTION: THE CUTTER SHOULD NEVER BE PLACED IN A HORIZONTAL POSITION
AS LONG AS THE CHEMICAL CYLINDER IS STILL ATTACHED TO IT.

2. Once the Lower Anchor Body is disconnected from the cylinder, visually inspect the
cylinder rupture disc for rupture.

3. Place one of the Shipping Plugs in the open end of the Chemical Cylinder and tighten
it.
08/09

32-1
 (Continued)

RETRIEVAL AND DISASSEMBLY OF THE CHEMICAL CUTTER

4. Reverse the CUTTER so that the Bull Plug end is elevated.

5. Remove Protective Sleeve from Severing Head Assembly and unscrew Severing Head
Assembly from Chemical Cylinder. And visually inspect the cylinder rupture disc for rupture.

6. Place the other Shipping Plug in the open end of the Chemical Cylinder and tighten it.

CAUTION: KEEP FACE AND EYES AWAY FROM DIRECT LINE OF ORIFICES.

WARNING: IF AT LEAST ONE OF THE RUPTURE DISCS DID NOT RUPTURE, THE
SHIPPING PLUGS MUST REMAIN ON TIGHT AND SHIP CYLINDER BACK
TO CCI. IF BOTH DISCS ARE OPEN, THEN PROCEED TO DISPOSAL
SECTION.

WARNING: BEFORE UNSCREWING SEVERING HEAD FROM BULL PLUG FOR TOOLS
1 1/2” - 7 1/2” OD, ALWAYS REMOVE SEAL NUT (P/N CCI 168140) FROM
BOTTOM OF BULL PLUG TO RELEASE ANY POSSIBLE TRAPPED
PRESSURE.

08/09

32-2
 Retrieval of stuck Chemical Cutter inside a pipe

All personnel handling the chemical cutter upon retrieval must have all their safety equip-
ment on (acid resistant suit, respirator, and gloves). The tool must remain elevated (never
horizontal) with the anchor assembly higher than the severing head by at least 12”.

When a stuck chemical cutter is retrieved at surface, three possible situations exist for tool
position inside the pipe:

A) Top of tool exposed at any point above the anchors.

B) The bottom of the tool exposed at any point below the anchors.

C) The tool completely covered inside the pipe.

NOTE: THE TOOL HAS TO BE ENGAGED WITH A FISHING TOOL OR CLAMPED

BEFORE PRESSURE IS BLED OF TO PREVENT TOOL FROM DROPPING DOWN AT
SPEED.

The main objective is to gain access to the firing sub adapter/gas generator sub connection
to bleed the pressure from the tool.

Two critical dimensions are needed to locate the F.S.A. /G.G.S. connection: 1- CCL to the
anchor assembly 2- CCL to severing head orifices

If “A” is the case, follow this procedure:

Loosen the F.S.A/G.G.S connection slowly, the igniter will be pushed up against the firing
sub adapter and losing its seal with the gas generator sub. As soon as the two o-ring seals
of the gas generator sub are exposed, the pressure starts to escape while the threads are
still engaged and the tool becomes free. Proceed with the disassembly as recommended in
the manual.

If “B” is the case, follow this procedure:

Place safety sleeve around severing head. Using measurements taken prior to running
the tool in the hole, locate the top of the anchor assembly from the severing head
orifices. Measure at least six inches above the top of the anchor assembly and mark it.
Using a mechanical tubing cutter, or an air driven disc grinder, cut the pipe at the
marked area above the anchor assy.
08/2009

33-1
Loosen the F.S.A/G.G.S connection slowly, the igniter will be pushed up against the
firing sub adapter and loses its seal with the gas generator sub. As soon as the two o-
ring seals of the gas generator sub are exposed, the pressure starts to escape while
the threads are still engaged and the tool becomes free. Proceed with the disassembly
as recommended in the CHC review.

If “C” is the case, follow this procedure:

Locate the top of the anchor assembly from the severing head orifices or from the CCL
whichever is more reliable. Measure at least six inches above the top of the anchor
assembly and mark it. Using a mechanical tubing cutter, cut the pipe at the marked area
above the anchor assy. Loosen the F.S.A./G.G.S. connection slowly, the igniter will be
pushed up against the firing sub adapter and loses its seal with the gas generator sub. As
soon as the two o-ring seals of the gas generator sub are exposed, the pressure starts to
escape while the threads are still engaged and the tool becomes free. Proceed with the
disassembly as recommended in the CHC review.

Note: In all of the above cases, the tool should be kept in an elevated position
(severing head at least 12” lower than anchor assembly) until the
chemical cylinder is removed from the assembly.

08/2009

33-2
 08/09

33-3
 DISPOSAL OF SPENT CYLINDERS

Spent Cylinders may be disposed of as follows:

1. All safety gear must be put on

2. Position cylinder vertical

3. Remove top shipping plug

4. Check for rupture disc burst

5. Place shipping plug back

6. Reverse cylinder

7. Remove top shipping plug

8. Check for rupture disc burst

9. If both rupture discs are burst, remove second shipping plug and flush with water or
steam clean

10. Check that water can flow through the cylinder

11. Do not place back shipping plug

12. Dispose of cylinder as scrap iron

Note: If one or two rupture discs are not burst, follow this procedure:

1. Place back shipping plugs

2. Label cylinder as “Leaking”

3. Store in a safe place

4. Contact Chammas Cutters Inc. for recommendations

08/09

34-1
 TOOL CLEANING AND MAINTENANCE

1. After each firing all expendable parts, the Igniter, Gas Generator Grain, Anchors/
Wedges, pressure relief kit, Severing Head, Chemical Cylinder and expendable Part
Packet must be replaced. Also, parts such as the Bull Plug and Anchor Body Assembly
must be visually inspected to be sure they are free from cracks or defects that will
prevent proper functioning of the CHEMICAL CUTTER.

2. Thoroughly wash or, preferably, steam clean all disassembled parts.

3. Use wire brushes to polish all sealing surfaces and internal threads.

4. For further cleaning, place all disassembled nonexpendable components in a tank

containing a commercial cleaner.

5. Blow dry and spray with anti-rust fluid such as WD-40 and store on shelf or in tool
boxes. For better prevention against rust, wrap parts in paper after cleaning.

08/09

35-1
CONVERSION CHART FROM ENGLISH TO INTERNATIONAL SYSTEM

- LENGTH: ONE INCH = 2.54 cm

- PRESSURE: ONE PSI = 6894.8 PASCALS

- TEMPERATURE: TO CONVERT DEG “F” TO DEG “C”: T(c)= (T(f) - 32)/1.8

08/2009

36-1
 HAZARDOUS MATERIAL TABLE
CHEMICAL CYLINDER DATA

BROMINE TRIFLUORIDE UN 1746 CLASS 5.1 PG1 DOT-SP 14796

OXIDIZER CORROSIVE POISON BY INHALATION
LOADED
CHEMICAL
CYLINDER SIZE CYLINDER CHEMICAL WEIGHT
PART NUMBER VOLUME
OD X LENGTH (IN) WEIGHT (KG)
(CC)
(LB)
211500-72 11/16 X 72 7 90 0.25
212500-72 3/4 X 72 7 124 0.35
216500-48 1 X 48 8 155 0.43
216500-72 1 X 72 12 247 0.69
222500-48 1 3/8 X 48 17 225 0.63
222500-72 1 3/8 X 72 25 354 1.00
227500-24 1 11/16 X 24 12 161 0.45
227500-36 1 11/16 X 36 18 277 0.77
227500-48 1 11/16 X 48 24 392 1.12
227500-60 1 11/16 X 60 30 506 1.43
227500-72 1 11/16 X 72 36 621 1.75
227500-80 1 11/16 X 80 48 784 2.24
240500-48 2 X 48 33 608 1.70
240500-60 2 X 60 41 790 2.20
240500-72 2 X 72 49 970 2.70
240500-80 2 X 80 66 1216 3.40
240500-84 2 X 84 74 1398 3.90

GAS GENERATOR GRAIN DATA

SUBSTANCES, EXPLOSIVE N.O.S.
GRAIN SIZE
GRAIN NET
PART NUMBER OD X LENGTH UN No. CLASS EX No.
WEIGHT (KG)
(IN)
068014 1/4 X 10 0481 1.4 S EX2006110337 0.013
100014 3/8 X 12 0481 1.4 S EX2006110337 0.036
137016-8 9/16 X 8 0481 1.4 S EX2004020073 0.0537
137014 9/16 X 14 0481 1.4 S EX2006110337 0.094
137016 9/16 X 16 0481 1.4 S EX2004020073 0.1075

IGNITER DATA
IGNITER UN 0325 CLASS 1.4G PG2 EX 8509015
PART NUMBER EXPLOSIVE NET WEIGHT (KG)
068017 0.00075
137017 0.001

09/09

37-1
 0$7(5,$/6$)(7<'$7$6+((7
352'8&7,*1,7(5
81*3*,,(;

SUPPLIER: EMERGENCY NUMBER:

CHAMMAS CUTTERS, INC. 
11320 FM 529, Bldg.,
Houston, Texas 77041
Tel: 713-856-8777

PRODUCT IDENTIFICATION:

Trade Name: Igniter, UN0325, Class 1.4G, Packing Group II, EX#8509015 - Mfg. No. 240448
Chammas Cutters Inc Part Numbers:
#068017 - 11/16-1 1/4 IGNITER UN0325 (Mfg. No. 240448-001)
#137017 - 1 3/8-7 1/2 IGNITER UN0325 (Mfg. No. 240448-000)

PRODUCT INFORMATION:

CAS NO PEL/OSHA TLV/ACGHI % by VOLUME

INGREDIENT HAZARD STATEMENT: BLACK POWDER. The specific ingredients of this product
have been classified as a trade secret. Inquiries concerning the toxicity or hazardous nature of this
product should be directed to the department engineer in charge at (713) 461-7770. All inquiries
must adhere to the provisions set out in 29CFR 1910.1200.

PHYSICAL / CHEMICAL CHARACTERISTICS and DATA

BOILING POINT: N/A SPECIFIC GRAVITY (H2O = 1) 1.70 - 1.82
MELTING POINT: N/A VAPOR PRESSURE (mm hg): N/A VAPOR DENSITY (AIR=1): N/A
EVAPORATION RATE (Butyl Acetate=1): N/A SOLUBILITY/WATER: High
APPEARANCE AND ODOR: Black - No Odor

FIRE and EXPLOSION DATA

FLASH POINT: N/A AUTO IGNITION: > 464ºF LEL: N/A UEL: N/A
NFPA HAZARD CLASSIFICATION: Flammable 1 HEALTH: 0 REACTIVITY: 0
SPECIAL: N/A FIRE FIGHTING: Do not fight fires. Evacuate area.

UNUSUAL FIRE/EXPLOSION HAZARDS: Powder may deflagrate or explode in a fire due to heat
and/or confinement. Evacuate area.

CHAMMAS CUTTERS, INC. Page 1 MSDS 09/09

37-2
REACTIVITY DATA

STABILITY: Product is stable, HANDLE CAREFULLY and keep away from flame or excessive heat.
DECOMPOSITION / BY-PRODUCTS: Polymerization will not occur

HEALTH DATA

INHALATION: No SKIN: No INGESTION: No EYES: No

ADDITIONAL: Handle with gloves.
CARCINOGENICITY ---
NTP: N/A IARC: N/A OSHA: N/A ACUTE/CHRONIC HEALTH HAZARDS: None Known
SIGNS/SYMPTOM OF EXPOSURE: N/A MEDICAL CONDITIONS FROM EXPOSURE: N/A

SAFE HANDLING & USE DATA

SPILLS/RELEASE: Packets may be picked up carefully and returned to carton.

HANDLING/STORAGE: Avoid rough handling and dropping, NO SMOKING, store in a cool dry place.
Do not open containers in bulk storage area.

CONTROL MEASURES

RESPIRATORY PROTECTION: N/A LOCAL EXHAUST: N/A SPECIAL EXHAUST: N/A

EYE PROTECTION: Safety Glasses CLOTHING: Use static free clothing
WORK/HYGIENE: No smoking around containers. Wash hands after handling.

SARA HAZARD CATEGORIES

FIRE HAZARD: X SUDDEN PRESSURE RELEASE: REACTIVITY :
ACUTE (IMMEDIATE) HEALTH HAZARD: DELAYED (CHRONIC) HAZARD:
CONVERSION VALUE TO POUNDS: 50. CHEMICAL DESCRIPTOR: CLASS C EXPLOSIVE

CHAMMAS CUTTERS, INC. Page 2 MSDS 09/09

37-3
 Pg 1 of 3

MATERIAL SAFETY DATA SHEET

PRODUCT: PROPELLANT – GAS GENERATOR GRAIN

Supplier Information:

CHAMMAS CUTTERS, INC.

11320 FM 529, Bldg. I
Houston, TX 77041
EMERGENCY TEL: 1-800-255-3924

Product Identification:

Trade Name and Synonyms: Propellant, TP-J-3006

DOT description and shipping classification: Propellant, solid, UN0499, 1.3C, EX8707073A
Alternate DOT description and shipping classification: UN0481, Substances, explosive, n.o.s., 1.4S

EX2006110337 for TP-J-3006 Propelling Sticks –

Part No. 068014 - Propellant F/11/16-15/16, D: ¼”, L: 10”, Wt per Stick: 13.0 grams

Part No. 100014 - Propellant F/1-1 ¼, D: 3/8”, L: 12”, Wt per Stick: 36.0 grams

Part No. 137014 - Propellant 14" 1 3/8-4 9/16, D: 9/16, L: 14”, Wt per Stick: 94.0 grams

EX2004020073 for TP-J-3006 Propelling Stick

Part No. 137016 - Propellant 16" 1 3/8-4 9/16, D: 9/16”, L: 16”, Wt per Stick: 107.50 grams

Note: This classification is only valid when the explosive substance is packaged as follows:
Inner Packaging – Bags, static-shielded or velostat, each containing one extruded cylindrical grain.
Intermediate Packaging – Divider, fiberboard, 5x5 array with not more than six (6) non-adjacent inner packagings.
Outer Packaging – UN 4G fiberboard box, each containing one intermediate packaging.

Physical Data:

Appearance and Odor: Propellant is a rubber/solid material, dark gray in color. Aromatic in odor.
Volatiles: None.

Composition:

Hazardous Ingredients % OSHA PEL ACGIH TLV

1. Ammonium 70.0 15mg/m³(total) 10mg/m³(total)

Perchlorate 5mg/m³(resp.) 3mg/m³(resp.)
2. PVC Plastisol 25.0 NE NE
3. Oxamide 4.8 15mg/m³(total) 10 mg/m³(total)
5mg/m³(resp.) 3mg/m³(resp.)
4. Carbon (Thermax) 0.2 3.5mg/m³ 3.5mg/m³

MSDS 07/09

37-4
 Pg 2 of 3

Health Hazard Data:

Threshold Limit Value: See Composition Section . Note: TLV’s or PEL’s only pertain to materials when in raw form.
Materials are contained within the propellant by a binder system.

Effects of Overexposure:

Respiratory: None known. Decomposition products are known to cause breathing difficulty and respiratory
damage.

Eyes: No known hazard unless burned. Decomposition products are extremely irritating.

Skin: Fired propellant residue contains hydrochloric acid and other corrosive compounds which can cause skin
irritation.

Skin Absorption: No known hazard.

Ingestion: No known hazard.

Other: N/A

Emergency and First-Aid Procedures:

Inhalation: If decomposition products are inhaled, remove victim to fresh air. Call a physician and/or emergency facility
immediately.

Eyes: If irritated, flush with water and contact physician.

Skin: Thermal burns and/or exposure to decomposition products: call physician and/or emergency facility
immediately.

Other: N/A

Fire and Explosion Hazard Data:

Flash Point: N/A

Explosive Limits: DOT Class 1.3 explosive.

Extinguishing Media: Do not attempt to fight burning propellant. Water, CO₂, or foam may be used to restrict spreading
fire after bulk of propellant has burned.

Special Fire Fighting Procedures: Propellant ingredients contain oxidizer and fuel. Do no fight fires involving these
materials. If ignited, thrust created while burning may give this propellant uncontrollable ballistic properties. Fire fighting
should be limited to preventing the spread of other fires.

Explosion Hazards: Static discharge, impact, friction, and pinch points between hard surfaces can initiate propellant fires
and should be avoided. See Reactivity Data Section.

MSDS 07/09

37-5
 Pg 3 of 3

Reactivity Data:

Stability: Unstable. Conditions to avoid (stability): Temperatures above 200°F. Propellant becomes unstable when
exposed to temperatures above 200°F. Avoid shock, impact, friction, and static charge buildup.

Incompatibility (Materials to Avoid): Water. Water-soaked propellant may liberate hydrogen gas, creating an explosive
hazard.

Hazardous Decomposition Products: CH₄, CO, CO₂, HCI, NOｘ, H₂, and N₂ are theoretical exhaust products.

Hazardous Polymerization: Will not occur.

Special Precautions:

Protective Measures:

Ventilation: For ignited propellant, provide sufficient mechanical (general and/or local exhaust) ventilation. Firing
area should be cleared of exhaust gases prior to personnel exposure.

Respiratory Protection: None for cured propellant. If exposed to exhaust gases, use HIOSH/MSHA approved
respirator with organic vapor/acid gas cartridges or positive-pressure airline.

Protective Clothing: Acid-resistant gloves should be worn when handling decomposition products. Flame-
resistant lab coats or coveralls, safety glasses, and safety shoes are recommended when handling explosives.

Handling and Storage Precautions:

Protect propellant from ignition sources, static charge buildup, mechanical shock or friction, and elevated
temperatures (above 200°F).
Approved quantity/distance requirements for storage of explosives should be observed.
DoD Storage Compatibility Group C.
DoD Hazard Class 1.3.

Other Precautions: This propellant is a DOT Class 1.3 explosive. Access to this propellant should be limited to
authorized personnel properly trained in the handling of pyrotechnics.

Environmental Protection:

Propellant must be protected from sources of ignition. If ignition occurs, unpredictable ballistic properties may be
exhibited releasing pressure and spreading burning material over a wide area. Contact appropriate authorities.

Waste Disposal Method: Dispose of in accordance with federal, state and local regulations.

“To the best of our knowledge the information contained herein is correct. All Chemicals may present unknown health
hazards and should be used with caution. Although certain hazards are described herein, we cannot guarantee that these
are the only hazards which exist. Final determination of suitability of the chemical is the sole responsibility of the user.
Users of any chemical should satisfy themselves that the conditions and methods of use assure that the chemical is used
safely.

NO REPRESENTATIONS OR WARRANTIES, EITHER EXPRESSED OR IMPLIED, OF MECHANTABILITY, FITNESS

FOR A PARTICULAR PURPOSE OR ANY OTHER NATURE ARE MADE HEREUNDER WITH RESPECT TO THE
INFORMATION CONTAINED HEREIN OR THE CHEMICAL TO WHICH THE INFORMATION REFERS.”

MSDS 07/09

37-6
U.S. Department 400 Seventh Street, S.W.
of Transportation Washington, D.C. 20590

Pipeline and Hazardous The US Department of Transportation

Materials Safety Administration Competent Authority for the United States

CLASSIFICATION OF EXPLOSIVES

Based upon a request by Alliant Techsystems, Inc. Elkton Operations, 55 Thiokol Road,
Elkton, MD, the following items are classed in accordance with Section 173.56, Title 49,
Code of Federal Regulations (49 CFR). A copy of your application, all supporting
documentation and a copy of this approval must be retained and made available to DOT
upon request.

U.N. PROPER SHIPPING NAME AND NUMBER:

Substances, explosive, n.o.s., UN0481

U.N. CLASSIFICATION CODE: 1.4S

REFERENCE NUMBER PRODUCT DESIGNATION/PART NUMBER

EX2006110337 TP-J-3006 Propelling Stick (D: 9/16, L: 14", Wt.
per Stick: 94.0 grams), TP-J-3006 Propelling Stick
(D: 3/8", L: 12", Wt. per Stick: 36.0 grams),
TP-J-3006 Propelling Stick (D: 3/8", L: 11", Wt.
per Stick: 33.0 grams), TP-J-3006 Propelling Stick
(D: 1/4", L: 11", Wt. per Stick: 15.0 grams),
TP-J-3006 Propelling Stick (D: 1/4", L: 10",
Wt. per Stick: 13.0 grams)

NOTES:
This classification is only valid when the explosive substance is packaged as follows:
Inner Packaging - Bags, static-shielded or velostat, each containing one extruded
cylindrical grain. Intermediate Packaging - Divider, fiberboard, 5x5 array with not more
than six (6) non-adjacent inner packagings. Outer Packaging - UN 4G fiberboard box,
each containing one intermediate packaging.

DATED: December 1, 2006

Tracking No: 2006114273 Page 1 of 1

37-7
37-8
 MATERIAL SAFETY DATA SHEET
PRODUCT - BROMINE TRIFLUORIDE
SUPPLIER:
CHAMMAS CUTTERS, INC. CAS #7787-71-5
11320 FM 529, Bldg. I
Houston, Texas, USA EMERGENCY PHONE:
713-856-8777 1-800-255-3924

PRODUCT IDENTIFICATION
TRADE NAME AND SYNONYMS: Bromine Trifluoride, Chemical cylinder, UN1746 Class 5.1, Packing Group I
CHEMICAL NAME AND SYNONYMS: Bromine Trifluoride
FORMULA: BrF3 CHEMICAL FAMILY: Halogen Fluoride
TIME WEIGHTED AVERAGE EXPOSURE LIMIT: See last page

HEALTH HAZARD DATA

SYMPTOMS OF EXPOSURE:
Corrosive and extremely irritating to the upper and lower respiratory tracts, skin, and eyes. BrF3 hydrolyzes to form hydrofluoric acid, therefore
skin burns and mucous membrane irritation are similar to those caused by the acid. Symptoms include tearing of the eyes, cough, difficult
breathing, abnormal fluids formation in the nose, mouth and throat. Inhalation of BrF3 may cause pneumonitis ( deep lung inflammation) and
pulmonary edema (abnormal fluid buildup in the lungs) which can be fatal. Symptoms of hydrofluoric acid burns are severe pain, redness,
possible swelling and tissue destruction.
TOXICOLOGICAL PROPERTIES:
Bromine Trifluoride is irritating and corrosive to all living tissues. Toxic level exposure to skin tissue causes hydrofluoric acid burns and skin lesions
resulting in tissue destruction and eventual scarring. Burn activity continues while any residual active fluorides remain. Chemical pneumonitis and
pulmonary edema result from exposure to the lower respiratory tract and deep lung. Residual pulmonary malfunction might also occur. Burns
of the eye result in lesions and possible loss of vision. Extended low level systemic absorption of fluorides may cause fluorosis, an abnormal
calcium accumulation in the bone structure.
RECOMMENDED FIRST AID TREATMENT:
PROMPT MEDICAL ATTENTION IS REQUIRED IN ALL CASES OF OVEREXPOSURE. BROMINE TRIFLUORIDE RESCUE PERSONNEL
SHOULD BE EQUIPPED WITH APPROPRIATE PROTECTIVE EQUIPMENT (SELF-CONTAINED BREATHING APPARATUS, ETC.) TO
PREVENT UNNECESSARY EXPOSURE.
Inhalation: Move exposed personnel to an uncontaminated area. If not breathing, give artificial respiration. If breathing is difficult,
give oxygen. Keep victim warm and quiet. Assure that mucus or vomited material does not obstruct the airway by use of positional
drainage. Delayed pulmonary edema may occur. Keep patient under medical observation for at least 24 hours.
Eye Contact: PERSONS WITH POTENTIAL EXPOSURE TO BROMINE TRIFLUORIDE SHOULD NOT WEAR CONTACT LENSES.
Flush contaminated eye(s) with large quantities of water. Hold eyelids open with fingers to assure complete flushing. Continue for minimum of
30 minutes.
Skin Contact: Flush affected area with large quantities of water. Remove affected clothing as rapidly as possible. Skin burns may be treated
with a calcium gluconate gel or slurry in water or glycerin. This compound binds the active fluorides in an insoluble form and limits burn
extension and relieves pain.
HAZARDOUS MIXTURES OF OTHER LIQUIDS, SOLIDS, OR GASES:
Bromine Trifluoride is a very reactive halogen fluoride. It reacts with virtually all organic and most inorganic substances. Some of the
perfluorinated organic substances in their pure form will not be oxidized by Bromine Trifluoride. It reacts violently with water or fuels.
PHYSICAL DATA
3 3)
BOILING POINT: 258.4°F (125.8°C) LIQUID DENSITY AT BOILING: 157.2 lb/ft (2513KG/M
VAPOR PRESSURE: @70°F (21.1°C) 0.145psia (1.0 kPa) GAS DENSITY AT 79°F 1 atm : Liquid
SOLUBILITY IN WATER: Reacts violently FREEZING POINT: 47.8°F (8.8°C)
APPEARANCE AND ODOR: Colorless, fuming liquid with a choking, pungent odor.

Chammas Cutters Inc. 37-9 Page 1 Bromine MSDS 0709

BROMINE MSDS Cont'd.

FIRE AND EXPLOSION HAZARD DATA

FLASH POINT (Method used): N/A AUTO IGNITION TEMPERATURE: N/A
FLAMMABLE LIMITS % BY VOLUME: LEL UEL N/A
EXTINGUISHING MEDIA: Nonflammable
ELECTRICAL CLASSIFICATION: Nonhazardous
SPECIAL FIRE FIGHTING PROCEDURES: Fires with bromine Trifluoride as the oxidizer can only be extinguished by shutting off the
source of bromine trifluoride. Do not use water, chemical, carbon dioxide or other extinguishing media as these will only add more fuel to the fire.
UNUSUAL FIRE AND EXPLOSION HAZARDS: Reacts violently or explodes on contact with water or organic materials. Combustion
products, including hydrogen fluoride, are toxic and reactive.
STABILITY: Stable X Unstable
CONDITIONS TO AVOID:
Reacts violently or explodes on contact with water and organic materials.
INCOMPATIBILITY (Material to avoid):
Water, plastics, hydrocarbons, other organic materials.
HAZARDOUS DECOMPOSITION PRODUCTS:
Bromine, fluorine, bromine monofluoride; hydrogen fluoride in reactions
HAZARDOUS POLYMERIZATION: CONDITIONS TO AVOID:
May Occur Will Not Occur X
SPILL OR LEAK PROCEDURES
STEPS TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED:
Evacuate all personnel from affected area. Use appropriate protective equipment.
Call company technical supervisor or Chammas Cutters Inc. phone number 713-856-8777.
WASTE DISPOSAL METHOD:
All Federal, State and Local Regulations regarding health and pollution should be followed in waste disposal. Contact
Chammas Cutters Inc. for specific recommendations. Do not dispose of unused quantities. Contact Tech Manager
or Chammas Cutters Inc. for instructions.
SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (Specify type):
Full face piece cartridge respirator, positive pressure air line or self breathing apparatus.
VENTILATION: INDOOR - Hood with forced ventilation OUTDOOR - Open area, none required
PROTECTIVE GLOVES: Neoprene Rubber EYE PROTECTION: Full face piece respirator
OTHER PROTECTIVE EQUIPMENT:
Safety shoes, eyewash and acid resistant over garments.
SPECIAL PRECAUTIONS*
SPECIAL LABELING INFORMATION:
D.O.T. Shipping Name: Bromine Trifluoride D.O.T. Shipping Class: Oxidizer I.D. No.: UN 1746
D.O.T. Shipping Labels: Oxidizer, corrosive, poison, inhalation hazard
SPECIAL HANDLING RECOMMENDATIONS:
Use in only well-ventilated areas. Do not drag, slide or roll cylinder.
SPECIAL STORAGE RECOMMENDATIONS:
Protect cylinders from physical damage. Store in cool, dry, well-ventilated area away from heavily trafficked areas and
emergency exits. Do not allow the temperature where cylinders are stored to exceed 130°F (54°C). Full and empty cylinders
should be segregated. Use a "first-in-first-out" inventory system.
TIME WEIGHTED AVERAGE EXPOSURE LIMIT:
None established (ACGIH 1984-85). Observation of the exposure limits for hydrogen fluoride, which forms when BrF3 is
hydrolyzed, is recommended.
The TWA for HF is 3 molar ppm; the STEL is 6 molar ppm (ACGIH 1984-85)
Note: ACGIH (1984-85) has proposed adoption of a ceiling value of 3 molar for HF.
Local Exhaust: To prevent accumulation above the TWA for hydrogen fluoride

*Various Government agencies (I.e., Department of Transportation, Occupational Safety and Health Administration, Food and Drug
Administration and others) may have specific regulations concerning the transportation, handling, storage or use of this product which
will not be reflected in this data sheet. The customer should review these regulations to ensure that he is in full compliance.

Chammas Cutters Inc. 37-10 Page 2 Bromine MSDS 0709

 August 27, 2009

East Building, PHH-30

U.S. Department 1200 New Jersey Avenue S.E.
of Transportation Washington, D.C. 20590

Pipeline and Hazardous

Materials Safety Administration
DOT-SP 14796
(SECOND REVISION)

EXPIRATION DATE: December 31, 2010

(FOR RENEWAL SEE 49 CFR § 107.109)

1. GRANTEE: Chammas Cutters Inc.

Houston, TX

2. PURPOSE AND LIMITATION:

a. This special permit authorizes the transportation in

commerce of non-DOT specification cylinders containing
bromine trifluoride. The cylinders will be integrated into
a tool to form a chemical cutter. This special permit
provides no relief from the Hazardous Materials Regulations
(HMR) other than as specifically stated herein.

b. The safety analyses performed in the development of this

special permit only considered the hazards and risks
associated with the transportation in commerce.

c. No party status will be granted to this special permit.

3. REGULATORY SYSTEM AFFECTED: 49 CFR Parts 106, 107 and 171-

180.

4. REGULATIONS FROM WHICH EXEMPTED: 49 CFR § 172.101 Column

(9B) in that bromine trifluoride is forbidden by cargo-only
aircraft, § 172.301(c) in that marking the special permit
number on each cylinder is required, and §§ 173.228(a).

5. BASIS: This special permit is based on the application of

Chammas Cutters Inc. dated December 14, 2008 submitted in
accordance with § 107.105 and the public proceeding thereon
and additional correspondence dated March 13, 2009.

37-11
Continuation of DOT-SP 14796 (2nd Rev.) Page 2
August 27, 2009
6. HAZARDOUS MATERIALS (49 CFR § 172.101):

Hazardous Materials Description

Proper Shipping Name Hazard Identi- Packing

Class/ fication Group
Division Number

Bromine trifluoride 5.1* UN1746 I,

Hazard
Zone B
* In addition to the oxidizer label, Division 6.1 and Class
8 labels are required.

7. SAFETY CONTROL MEASURES:

a. PACKAGING -

(1) Packagings prescribed are non-DOT specification,

non-refillable, seamless cylinders manufactured from
cold drawn SAE 4130, 4135, or 4140 alloy steel tubing,
with threaded plug closures (transport plugs) at each
end. The transport plugs render the rupture discs on
each cylinder inoperable during transportation. Each
cylinder must conform with Chammas Cutters,
Incorporated (CCI) drawings on file with the Office of
Hazardous Materials Special Permits and Approvals
(OHMSPA). The cylinders range from: 4.8 to 85.3 cubic
inches chemical volume; 11/16 inch to 2.0 inches
outside diameter; and, 24 to 84 inches in length.

(2) The maximum charge pressure of the cylinder must

be 700 psig at 130°F. The ratio of design burst
pressure to charge pressure at 130°F must be at least
40:1.

(3) The maximum filling density must be such that the

liquid content must not completely fill the cylinder at
54°C (130°F).

b. TESTING - At the time of manufacture, each cylinder

must be pressure tested to a minimum of 5,000 psig without
evidence of failure.

37-12
Continuation of DOT-SP 14796 (2nd Rev.) Page 3
August 27, 2009

c. OPERATIONAL CONTROLS –

(1) Emergency response information provided with the

shipment and available via an emergency response
telephone number must indicate that the pressure relief
devices fitted on the cylinder have been rendered non-
functional and provide appropriate guidance for
exposure to fire.

(2) Cylinders must be overpacked in a strong wooden

crate with a maximum capacity of six cylinders per box.
The wooden box must be as shown on the CCI drawing
entitled “Chemical Cylinder Shipping Box” dated
November 2, 2008 on file with OHMSPA.

(3) Advance Notice of FAA Regional Dangerous Goods

Manager. The operator of the aircraft must notify the
regional Dangerous Goods Manager in the region where
the flight will originate of their intent to transport
this material. This notification must be given at
least 72 hours in advance of plans to operate under the
special permit, unless prior arrangements have been
made with the cognizant Regional Dangerous Goods
Manager. The notification must include the point of
departure, intermediate stops, destination(s), and a
loading and departure schedule. Alternate notification
procedures may be established subject to the written
approval of the cognizant Regional Dangerous Goods
Manager.

(4) Advance Notice to the Air Carrier. The shipper

must notify the air carrier to be used of the hazardous
materials being transported under the terms of this
special permit and receive a written authorization from
the air carrier prior to the hazardous materials being
offered for transportation. This notification must be
given at least 72 hours in advance of plans to operate
under the special permit. All air carriers must have
Operations Specifications permitting them to transport
hazardous materials and notify their POI of the use of
this Approval.

37-13
Continuation of DOT-SP 14796 (2nd Rev.) Page 4
August 27, 2009
8. SPECIAL PROVISIONS:

a. A person who is not a holder of this special permit who

receives a package covered by this special permit may
reoffer it for transportation provided no modification or
change is made to the package or its contents and it is
reoffered for transportation in conformance with this
special permit and the HMR.

b. A current copy of this special permit must be maintained

at each facility where the package is offered or reoffered
for transportation.

c. MARKING – The marking requirements of § 172.301(c) are

waived. Each wooden crate must be marked “INSIDE CONTAINERS
COMPLY WITH DOT-SP 14796”.

9. MODES OF TRANSPORTATION AUTHORIZED: Motor vehicle, rail

freight, cargo vessel, and cargo aircraft only.

10. MODAL REQUIREMENTS: A current copy of this special permit

must be carried aboard each cargo vessel, aircraft, or motor
vehicle used to transport packages covered by this special
permit. The shipper must furnish a copy of this special
permit to the air carrier before or at the time the shipment
is tendered.

11. COMPLIANCE: Failure by a person to comply with any of the

following may result in suspension or revocation of this
special permit and penalties prescribed by the Federal
hazardous materials transportation law, 49 U.S.C. 5101 et
seq:

o All terms and conditions prescribed in this special

permit and the Hazardous Materials Regulations, 49 CFR
Parts 171-180.

o Persons operating under the terms of this special

permit must comply with the security plan requirement
in Subpart I of Part 172 of the HMR, when applicable.

o Registration required by § 107.601 et seq., when

applicable.

Each "Hazmat employee", as defined in § 171.8, who performs

a function subject to this special permit must receive
training on the requirements and conditions of this special

37-14
Continuation of DOT-SP 14796 (2nd Rev.) Page 5
August 27, 2009
permit in addition to the training required by §§ 172.700
through 172.704.

No person may use or apply this special permit, including

display of its number, when this special permit has expired
or is otherwise no longer in effect.

Under Title VII of the Safe, Accountable, Flexible,

Efficient Transportation Equity Act: A Legacy for Users
(SAFETEA-LU)—“The Hazardous Materials Safety and Security
Reauthorization Act of 2005” (Pub. L. 109-59), 119 Stat.
1144 (August 10, 2005), amended the Federal hazardous
materials transportation law by changing the term
“exemption” to “special permit” and authorizes a special
permit to be granted up to two years for new special permits
and up to four years for renewals.

12. REPORTING REQUIREMENTS: Shipments or operations conducted

under this special permit are subject to the Hazardous
Materials Incident Reporting requirements specified in 49
CFR '' 171.15 B Immediate notice of certain hazardous
materials incidents, and 171.16 B Detailed hazardous
materials incident reports. In addition, the grantee(s) of
this special permit must notify the Associate Administrator
for Hazardous Materials Safety, in writing, of any incident
involving a package, shipment or operation conducted under
terms of this special permit.

Issued in Washington, D.C.:

for Theodore L. Willke

Associate Administrator for Hazardous Materials Safety

Address all inquiries to: Associate Administrator for Hazardous

Materials Safety, Pipeline and Hazardous Material Safety
Administration, U.S. Department of Transportation, East Building
PHH-30, 1200 New Jersey Avenue, Southeast, Washington, D.C.
20590.

37-15
Continuation of DOT-SP 14796 (2nd Rev.) Page 6
August 27, 2009
Copies of this special permit may be obtained by accessing the
Hazardous Materials Safety Homepage at
http://hazmat.dot.gov/sp_app/special_permits/spec_perm_index.htm.
Photo reproductions and legible reductions of this special permit
are permitted. Any alteration of this special permit is
prohibited.

PO: CWF/AM

37-16
 CHC JOB PLANNING / DATA SHEET
COMPANY:
WELL : RIG : UNIT :
CUTTER SPECIALIST :
COMPANY REPRESENTATIVE :
DATE :

1) TUBING DETAILS: SIZE(OD) : WEIGHT (LB/FT) : L-80 (Y,N):

GRADE : CHROME / NICKEL (Yes, No)
ID (in) : DRIFT (in) : RESTRICTION:

2) DOWNHOLE CONDITIONS:
TVD AT CUT (FT): FLUID TYPE:

FLUID WEIGHT: HYDROSTATIC PRESSURE (PSI):

TEMP. AT CUT (DEG F): DEVIATION (DEG):

3) SAFETY EQUIPMENT: SAFETY KITS-PPE (Yes, No):

SAFETY SLEEVE-ANCHOR (YES, NO) : SAFETY SLEEVE-SEV. HD (YES, NO):

4) "DUMMY" and STRING SHOT Run (Yes,No) : DUMMY/String Shot Combo(Y,N):

Distance from CCL to shot : Gauge OD: Shot length: Prima cord:

Tool Sketch attached (Y, N): Pressure Test Lubricator (Y, N) : Test press:

Depth of STRING SHOT : Total Depth Gauged : Feed-Thru JAR (Y, N) :

5) CHEMICAL CUTTER SELECTION :

ANCHOR ASSY SIZE: SEVERING HEAD SIZE:

CHEMICAL CYLINDER OD/LENGTH: QTY. CATALYST:

NOTE: MORE CHEMICAL IS REQUIRED WHEN CUTTING:

CHROME/NICKEL, L-80, PLASTIC COATED, TAIL PIPE (REFER TO CHART IN CHC REVIEW)

GAS GRAIN SIZE IN. (OD & LENGTH):

NOTE: ADD ONE INCH OF GAS GRAIN FOR EACH OF THE FOLLOWING:
TANDEMING ANCHORS, EXTENSION SPACERS, ADJ. TOP CENTRALIZER
IGNITER TYPE (BP-3, RED, OTHER):
CENTRALIZERS TYPES: QTY.

6) CUT RESULTS:
SUCCESSFUL? (YES NO):
OVERPULL APPLIED?(HOW MUCH):
TOOL CONDITION AFTER RETRIEVAL: