MCR Training Manual
MCR Training Manual
MCR Training Manual
Training Manual
Rev. F
ii
Disclaimer
This operating Manual covers MCR Oil Tools, LLC products presently offered for sale including
radial cutting torch systems and perforating torch systems that utilize our thermite and or solid fuel
technologies.
MCRs other species of tools, tools in research and development and tools under investigation may not
be covered in this manual.
The information in this operating manual does not attempt to address all possible downhole issues,
well configurations, or well conditions. When specific issues, well configurations or well conditions are
not covered in this manual, the licensee is required to call MCR Oil Tools, LLC to discuss the relevant
downhole issues, well configurations, or well conditions and receive proper instruction, guidance and
recommendations in the use of MCR products.
For assistance call:
MCR Oil Tools
Bill Boelte
Mike Robertson
817.701.5100
337.519.5081
817.291.0544
Training Manual
Rev. F
iii
Return Policy
MCR Oil Tools, LLC does not allow the return of tools that have been purchased and shipped. Once
the tools leave the custody of the MCR dock, the sale is complete and the tools cannot be returned to
MCR for any reason. MCR strives to provide to our customers an extremely high level of confidence
in our products. Our Licensees are guaranteed to receive new tools with every order. You can be
assured that the tools you receive have never left the MCR dock for delivery to another customer,
been in another customer's possession, stored in a non-MCR warehouse, or have been transported to
a competitors well site.
Training Manual
Rev. F
iv
Training Manual
Rev. F
Table of Contents
Disclaimer.......................................................................................................................................................................................iii
Return Policy...................................................................................................................................................................................iv
Research and Development Services...........................................................................................................................................v
Section 1
Training............................................................................................................................................................................................1
Safety Precautions......................................................................................................................................................................2-3
Restricted Applications ..............................................................................................................................................................4-5
Theory and Operation......................................................................................................................................................................6
Section 2
Section 3
Section 4
Training Manual
Rev. F
Table of Contents
Appendix
A
Training Manual
Rev. F
Section 1
Training
MCR Oil Tools, LLC requires all users of Radial Cutting Torch Technology Systems (RCT, PTC,
etc.) and other MCR products to be Licensed by MCR. A License is simply a standard legal
document (Agreement) from MCR and signed by the user agreeing to conditions of payment of
invoices, confidentiality of patented and proprietary information and trade secrets, and conscientious
use of the RCT System. A reinstatement fee may be required if the Licensed company has its License
revoked for the reasons stated in the License. Contact MCR Oil Tools for additional information on
how to obtain a License.
Once Licensed, the Licensed company MUST have its service technicians / engineers, who are slated
to run any MCR system, trained at MCR's facility in Arlington, Texas. MCR may also provide
training at the Licensee's facility. Training consists of a one day session on the use and application of
the RCT system, the design and function of the RCT/PTC system, and the assembly of the RCT/
PTC system. When training is complete and a qualification test has been passed, MCR provides a
Certificate of Completion signed by MCR and embossed with MCR's official seal.
A Licensed trainee can become a Licensed Instructor by receiving training at the MCR facility and
showing proficiency in the field with the RCT system substantiated with the submission of at least
20 field reports reflecting their proficiency. Once the Licensed Instructor receives his Instructors
Certificate he is then allowed to train other technicians/engineers within his company on the use of
the RCT system. The Instructor submits the proof of training and MCR will issue a Certificate of
Completion.
Training Manual
Rev. F
Section 1
Safety Precautions
HANDLING - Radial Cutting Torch systems (RCT, PTC, etc.) should be handled with the same care
and precautions as recommended in the American Petroleum Institutes Recommended Practice-67
(API RP67).
NEVER DROP - or mishandle RCT systems as damage will occur to the nozzle which may cause the
system to malfunction during the cutting operation and may cause the torch assembly to leak.
DO NOT DAMAGE NOZZLE - Torch assemblies, consisting of the torch or torch and extensions,
must be attached to the tool string in the vertical position. Care must be taken not to twist, bend or
bind the nozzle section as damage may occur to the nozzle section causing the Torch to fail by filling
the system with wellbore fluids or by premature o-ring failure at pressure, causing a sudden ingress of
fluid.
NO SPUDDING -The practice of spudding (lowering the wireline at ever increasing free fall speeds
in an attempt to pass through or move an obstruction or restriction in the well) should NEVER
be attempted. Spudding can cause damage to the torch and a sudden ingress of wellbore fluid and
pressure to the main load that can result in premature ignition. Reference the Applications section of
this manual for further information on spudding.
MUST BE CENTRALIZED - RCT Torch systems must always be centralized to insure proper cutting
action of the assembly. If this is not possible, you must call the manufacturer for recommendations; in
some cases, an extra extension may be required to accomplish the cut. Extreme care must be taken not
to overload the tool system as casing and/or toolstring damage may occur.
STORAGE - RCT/PTC Systems systems must be stored in a clean, dry and protected place.
Specifications may change: be sure that the current specifications are being used. Call the manufacturer
at 817-701-5100 or visit online at www.mcroiltools.com for the current specifications sheet applicable
to your well conditions and torch system.
PRESSURE RATING - Never exceed the pressure rating of the RCT/PTC system as defined in the
Specifications section of this manual.
PLUGGED TUBING - Do not use the RCT in tubing that is plugged or that is collapsed or restricted
in any way. When fired in these cutting situations, the RCT will become unbalanced and will be lifted
upward by the escaping plasma. Not only will the RCT not cut the tubing, but severe damage will
occur to the tool string and the tools above the RCT may be thermally gutted (the isolation sub may
prevent most of this). The RCT will likely sustain damage and can weld itself to the tubing. For further
information on how to use the RCT properly in these situations, refer to the Applications section of
this manual. Perforating Torch Cutters (PTC), are intended to be run in plugged pipe.
NO PUMPING WHILE RUNNING - RCT systems should not be activated when pumping into a
well that is taking fluid. Fluid moving past RCT systems may destabilize the tool, causing it to move
during the cutting operation.
Training Manual
Rev. F
Section 1
Safety Precautions
RUN GAGES PRIOR TO RUNNING RCT/PTC SYSTEMS - A drift gage must always be run
prior to deploying the toolstring in order to insure that there are no obstructions or restrictions in
the wellbore that would prevent the tool string from getting to depth. A dummy run without the live
RCT/PTC must be run whenever a no-go gage is used. This will insure that the toolstring will pass
through any restriction or obstruction while running into the well.
NEVER MODIFY - Do not modify RCT/PTC systems by attaching external centralizers or no-go
gages to the tool or anchor system.
NEVER REMOVE SLIDING SLEEVE - Do not remove the sliding sleeve from the torch, as damage
may occur to the o-rings when repositioning the sleeve onto the RCT. This will result in damage to the
RCT and will cause the RCT to malfunction.
MAXIMUM RUNNING SPEED - The maximum running speed for RCT/PTC systems in clean,
unrestricted and unobstructed tubing, casing or drill pipe is three hundred feet per minute provided a
dummy gage run has been made prior to running the live tool system.
Training Manual
Rev. F
Section 1
Restricted Applications
Spudding
The RCT MUST NEVER be used as a ram or forced by or through a restriction or obstruction in
the wellbore by means of repeated passes at high speeds with the wireline (SPUDDING). Impact on
the nozzle of the RCT created by the excessive force generated during "SPUDDING can dislodge
the o-rings in the nozzle and/or critically damage the nozzle parts. If the o-rings become dislodged or
unseated during "SPUDDING", the o-ring will fail due to excessive loading, allowing wellbore fluid
to enter the RCT. The RCT will, under low pressure and temperature (<4000 psi & 100 F), flood and
become inert. If this occurs, the torch will not be able to be repaired or reloaded. At a combination of
pressure above 4000 psi and temperature above 100 F, the RCT can auto ignite. During auto ignition,
damage to the tubing or casing may not be experienced; however, damage can occur to the internal
elements of the tool string; damage to the torch will come in the form of the loss of the nozzle and
anchor assembly. Auto ignition can produce a complete cut of the tubing, a partial cut of the tubing,
no cut at all or damage to the RCT and sticking of the tool in the pipe.
When trying to cut tubing that is plugged or tubing that has a restriction such as a flapper valve
or an obstruction such as a stuck tool string or collapsed tubing, the tubing MUST be perforated
at some point between the bottom of the torch and the top of the plug, restriction, obstruction
or collapse point. Perforating is MANDATORY even though the operator may be able to pump
through the valve / plug or past the restriction or obstruction. The RCT requires a minimum
amount of unrestricted flow area below the torch for proper operation. The only way to insure
that the proper amount of flow area is available to stabilize the RCT is to perforate using MCRs
Perforating Torch Systems (see PTC/PTS; Sec. 2, Pg. 7) or according to the attached perforating
table (Table 7; Sec. 4, Pg. 5). If the operator does not follow the above requirements, the following
scenarios will occur:
1. The torch and the tool string will hydraulic upward causing the flow in the torch to stagnate.
2. Stagnation causes excessive heat and pressure to be generated in the torch.
3. Excessive heat and pressure in the torch could cause the torch body to burn out, the nozzle section
to wash out and even lose the nozzle and anchor down hole.
4. Excessive heat and pressure in the torch will cause the stagnated molten plasma in the torch to
migrate upward through the tool string and melt the internals of every tool in the string.
5. Upward movement of the torch will cause the torch to weld to the tubing at the point of stagnation.
6. The RCT will not be able to remain stationary long enough to cut. No cut will be possible.
7. The distance between the RCT and any plug, restriction, obstruction or collapse point is irrelevant.
The RCT WILL NOT CUT in any of the above conditions without first perforating the tubing
below the cutter.
*Operator may use the ElectroMechanical Anchor in lieu of the above procedure.
Training Manual
Rev. F
Section 1
Restricted Applications
Cutting in Dry Pipe and Low Fluid Level Pipe
Dry pipe and low fluid level are difficult conditions to operate under. Dry pipe allows the flame from
the torch to flow unrestricted causing high temperatures in the nozzle. Some nozzle washing will
occur, but this is normal under these conditions. The lack of a hydrostatic head will allow the flame to
expand and a loss of velocity concentration will be evident. To overcome this condition an RCT rated
at 4,000-10,000 psi for the desired pipe weight is recommended for use in dry pipe.
In wells where there is only a small amount of fluid head above the cutter (less than 2,000 ft.), it is
beneficial to remove enough fluid from the well so that a minimum of 100 feet of dry pipe is below the
cutter. Use the appropriate cutter for the dry pipe to be cut. If pumping the well down is not possible,
it will be necessary to run the RCT on tubing with the tubing being anchored at the surface. The RCT
can be pressure fired with a pressure activated firing head. The best option is to use MCRs ElectroMechanical Anchor.
Training Manual
Rev. F
Section 1
Training Manual
Rev. F
Section 2
The Radial Cutting Torch (RCT), (Fig. 1) is a patented, non-explosive tool developed to cut wellbore
tubular components. Ranging in O.D. size from 3/4" to 7", the RCT is a highly versatile pipe recovery
tool. The systems utilize a 4.1 flammable solid fuel source with all components radio safe. The flammable
solid active component of the MCR line of products allows for the tool to be shipped via passenger
aircraft for delivery time best measured in hours instead of days.
RCT's can be initiated on e-line, on slickline with a downhole power unit/trigger, as well as on coil
or pipe with a pressure firing system. Simple to handle and modular in construction, the RCT line of
tools require minimal material handling.
Tested and proven in some of the harshest well conditions on the planet, the RCT offers solutions for
cuts up to 20,000 psi and 500 F (Table 1). Inconel, Monel, Hastelloy, High Chrome and other
tough materials offer no challenge to superior MCR technology. Once activated, the RCT erodes the
target material with a stream of ceramic integrated plasma, removing away the target material with no
damage to adjacent pipe. By removing the material at the cut zone, as opposed to displacing it, a clean,
non-flared and fracture-free section remains simplifying recovery efforts. The target material can be
cut in any orientation: compression, tension, neutral or in torque.
An additional benefit of the RCT line of tools is the versatility it offers personnel in the field. The
trained and certified operators running RCT's have the ability to tailor the power generated by the
cutters by varying the number and length of extensions. When challenging downhole conditions
demand unique solutions: heavy wall pipe, high deviation, slotted liners, mandrel cuts, sand screens,
etc., MCR has the product line necessary to solve your pipe recovery dilemma.
MCR Oil Tools has several families of radial cutting tools for use with a variety of pipe cutting needs.
Dimensional toolstring data is included on the following page (Table 2, Fig. 2).
Table 1. Pressure Range Descriptors
Torch
Pressure (psi)
SP - Standard Pressure
0 - 10,000
XP - Extra Power
0 - 10,000
0 - 10,000
HP - High Pressure
10,001 - 15,000
15,001 - 20,000
NOZZLE SECTION
RCT BODY
SLIDING SLEEVE
ANCHOR CONNECTION
Training Manual
Rev. F
Section 2
ADD EXTENSION
ANCHOR
part number
A*
B (each)
RCT-0750-200
43.50"
8.5"
48"
RCT-0875-200
43.50"
8.5"
48"
RCT-1000-200
43.50"
8.5"
48"
RCT-1125 -200
37.25"
8.5"
48"
RCT-1375-200
31.75"
8"
56"
RCT-1500-999XP
56.00"
6"
56"
RCT-1688-200
26.75"
6"
52"
RCT-1750-999XP
43.00"
12"
52"
RCT-2000-200
30.75"
6"
52.25"
RCT-2500-200
31.25"
8"
52.25"
RCT-2937-200
29.50"
8"
70.25"
RCT-3375-200
38.00"
10"
70.25"
RCT-4000-200
44.00"
14"
70.25"
RCT-5000-200
RCT-7000-300
TRCTSPL092010
BASIC TORCH
EXTENSION
RCT DIMENSIONAL
Figure D-1 FIGURES
Figure 2
ANCHOR ASSEMBLY
Training Manual
Rev. F
Section 2
New developments in MCR fuel technology have made it possible to produce an enhanced, increased
power line of radial cutting torches. Identified as XP torches and currently produced in 1-1/2
and 1-3/4 diameters, these systems serve two pressure ranges when built to varying fuel loading
orientations. The very small diameter, with respect to the target diameter, makes it possible to cut
heavy wall pipe while passing through substantially reduced ID restrictions. The XP torches are a
sliding sleeve design and are limited to pressures below10,000 psi.
Training Manual
Rev. F
Section 2
MCRs new XRT Torches build on the reliability of the sliding sleeve system while overcoming the
efficiency limitations inherent in the sliding sleeve design. The new XRT design mirrors the successful
high pressure nozzle design. This new cutting torch is a superior performer while offering the greatest
offset to cut distances in the industry.
A new integrated Thermal Generator Sub / Isolation Sub accompanies the XRT line of torches which
drastically improves torch performance and reliability. When coupled with our improved Thermal
Generator design, the XRT promises to be the best choice for any and all cutting jobs.
Training Manual
Rev. F
Section 2
MCR has developed, tested and patented a high pressure Radial Cutting Torch system of tools. This
family of torches is capable of cutting pipe at pressures to 15,000 psi. Reference the Specifications
section for High Pressure torch capabilities.
MCRs high pressure torches are defined much in the same way that the standard tools are denoted. The
basic high pressure torch is an RCT-XXXX-1000* that will cut the noted pipe at pressures referenced
in the Torch Specifications section. The 3/4, 7/8, 1-1/8, 1-3/8, 1-1/2, 1-11/16, 2", 2-1/2",
2-15/16", 3-3/8" and 4"will cut pipe from 10,001 to 15,000 psi. By using high pressure extensions,
the load of the torch can be adjusted to produce a more precise cutting load for various pipe sizes and
weights. The result is a family of torches with load ranges from a -1000 load to a -5000 load depending
on the torch size and the pipe to be cut. The -1000, -2000, -3000, -4000, -5000 are dimensionless
numbers that indicate increasing energy levels corresponding to the correct number of extensions that
provide the operator a means of building a torch to make the prescribed cut.
* The center four digit numerals, "XXXX," denotes maximum tool O.D.
Training Manual
Rev. F
Section 2
MCR has developed, tested and patented an ultra high pressure Radial Cutting Torch system of tools.
This family of torches is capable of cutting pipe at pressures to 20,000 psi. Reference the Specifications
section for Ultra High Pressure torch capabilities.
MCRs ultra high pressure torches are defined much in the same way that the high pressure tools are
denoted. The basic ultra high pressure torch is an RCT-XXXX-10000 that will cut the noted pipe at
pressures referenced in the Specification section. The 1-11/16 & 2 will cut pipe from 15,001 to
20,000 psi. By using ultra high pressure extensions, the load of the torch can be adjusted to produce a
more precise cutting load for various pipe sizes and weights. The result is a family of torches with load
ranges from a -10000 load to a -50000 load depending on the torch size and the pipe to be cut. The
-10000, -20000, -30000, -40000, -50000 are dimensionless numbers that indicate increasing energy
levels corresponding to the correct number of extensions that provide the operator a means of building
a torch to make the prescribed cut.
Training Manual
Rev. F
Section 2
When running a Radial Cutting Torch job that requires adequate flow into the annulus, explosive
perforators and punchers are unreliable at producing a consistent and sufficient hole in pipe. The
short comings of these devices have a dramatic effect on the success or failure of an RCT cut. Because
of this, MCR has developed a line of punchers to perforate coil tubing, tubing, casing and drill pipe.
MCR's non-explosive circulation perforators / punchers utilize the same basic principles as the Radial
Cutting Torch. The subs, anchors and extensions used with the RCT are the same parts used on the
perforators. MCR sells Perforating Torch Cutters (PTC) individually (Perforator only) (Fig. 3). By
doing this, Licensees can utilize unused subs, anchors, extension adaptors and thermal generators with
a single PTC purchase. MCR also offers a complete Perforating Torch System (PTS) that includes the
Isolation Sub, Thermal Generator Sub, Thermal Generator, Extension Adapter/Adapters, Anchor and
a PTC. The PTS is a complete system that will make one perforating run.
The nozzles on the perforators / punchers are oriented in a vertical plane and cut in a single direction.
The axial thrust force produced by the perforators nozzle is greater than the vertical thrust force. It is
this phenomenon that allows MCRs perforators to function properly in plugged pipe situations and
not move. The cutting jet forces the tool against the wall of the pipe with a tremendous force. This
force creates high frictional forces between the perforator and the wall of the pipe. These high frictional
forces are greater than the thrust forces from the pressure bubble and thus the perforator remains in
place long enough to make the cut. Even if the perforator were to thrust upward it would only serve
to create a longer cut in the pipe with an action similar to that of an oxy-acetylene cutting torch.
MCR offers the following sizes of perforators: 3/4", 7/8", 1", 1-3/8, 1-11/16, 2-1/2 and 2-15/16"
diameter perforators. All of the perforators with the exception of the 2-15/16 cut a single slot that
varies in size and dimension depending on the size of perforator used. The Specifications for Perforating
Torches table (Table 6; Sec. 4, Pg. 4) provides the specifications for each torch and the approximate
hole size. Our 2-15/16" PTS cuts two opposing slots that are 2" long x 1" wide in 5.5" pipe. This
same perforator can be run eccentrically to cut slots in pipe diameters to 9-7/8.
PTC BODY
ANCHOR CONNECTION
NOZZLE SECTION
Training Manual
Rev. F
Section 2
Extensions (EXT)
The Extension (EXT) (Fig. 4) is a small section of machined tubing loaded with the same pellets as the
main body of the RCT. The Extension has a male thread section on the lower end and a female thread
section on the upper end. The male threaded section of the extension is mated into the top of the RCT.
Both ends of the Extension are sealed with an aluminum "Buffington" disc and a snap ring. O-rings
are provided on the male (pin) end of the Extension.
The Extension is used to increase the load capacity of the basic RCT. One or more Extensions may be
added to the basic torch depending on the weight of the pipe, well conditions or pressure in the well.
Reference the Specifications section of this manual for the appropriate size and number of Extensions
needed for the proposed cut. The standard RCT (without Extensions) may be used to cut a specific size
of pipe when the hydrostatic pressure is below 4,000 psi. The extension is added when the hydrostatic
pressure is above 4,000 psi or when a higher degree of cutting is needed such as in un-centralized
cutting conditions or cutting tail pipe, or when cutting heavier weight pipe. Extensions are used with
low pressure RCTs, XP torches, XRTs, PTS perforators, High Pressure (HP) torches and Ultra-High
Pressure (UHP) torches.
Use of the Extension gives the field engineer flexibility as it allows the basic torch load to be increased
at the job site with minimal effort. Inventory and storage costs can be greatly reduced and kept to a
minimum, especially beneficial when stocking in remote areas.
EXT
Training Manual
Rev. F
Section 2
The Pressure Balance Anchor (PBA) is a patented anchor system that uses fluid dynamics to stabilize
the RCT during the cutting operation. Extreme forces caused by rapid pressure increases and flow
velocities will cause the RCT to develop a thrust element and move up hole when fired. The PBA
harnesses these forces so that movement of the RCT during the cutting operation is prevented.
The Pressure Balance Anchor consists of a cylindrical body approximately the same diameter as the
RCT. The PBA cylinder is connected to the bottom of the RCT by means of a socket that slides over
the end of the RCT cap and is held in place with setscrews. Small versions (3/4, 7/8, 1 and 1-1/8)
(Fig. 5) are made of steel and are a single length tube with roller centralizers machined into both
ends of the anchor. These centralizers may be easily removed if desired. Larger versions (1-11/16"
and above) (Fig. 6) have a sucker rod female threaded connection machined into the bull plug of the
anchor and should be centralized with conventional mechanical bow spring type centralizers.
The Pressure Balance Anchor has no moving parts such as slips or buttons that can cause the cutter
to malfunction or slip during the cutting operation or become stuck in certain tubulars. This feature
allows the operator to run the tool string with the PBA through a restriction and still anchor the RCT.
Pressure Balance Anchors for the 1-3/8" and 1-1/2" RCT's are made of aluminum (Fig. 7) and come
in two sections. The upper section is called the Pressure Balance Extension (PBE) and the lower section
is called the Pressure Balance Anchor Body (PBA). Under most cutting conditions both sections are
required for successful operation. All the other Pressure Balance Anchors are made of steel. Some
assembly is required with these anchors. The steel anchors come with tube sections packaged separately
from the two or three sub connections (Fig. 6) and are connected as follows:
1. Socket sub
Mates to end cap of the RCT (sliding sleeve design only).
The socket sub is not used with the perforators (PTS), the XRT line, the High Pressure RCT
line, or the UHP RCT line.
2.
Tube section
Connects to socket sub (sliding sleeve design only)
Connects directly to the end cap of the perforators (PTS) or the line, the High Pressure RCT,
or the UHP RCT line.
Training Manual
Rev. F
ROLLER WHEEL
ROLL PIN
PBA
Training Manual
Rev. F
10
Section 2
1-11/16" OPTIONAL
RUBBER FINGER
SUB
(-220)
PBA BODY
(-221)
PBA CONNECTOR
(-219)
PBA BODY
(-221)
Training Manual
Rev. F
PBA SOCKET
(-218)
11
Section 2
RUBBER FINGERS
Training Manual
Rev. F
12
Section 2
Figure 8L-4
Figure
RCT
GREASE HERE
RCT
Training Manual
Rev. F
13
Section 2
Section 2
The EMA (Fig. 9) is an Electric Line deployed anchoring device intended for use with MCR Radial
Cutting Torches. With an outside diameter (arms retracted) of 1 1/2, the EMA-1500-100 can be
deployed with RCT's from 1.500 to 3.375*. This wide range of capabilities allows for cuts in 2 3/8
to 5 1/2 tubulars, all weights. *Arms for cutting 5 and 5 1/2 in conjunction with a 3.375 RCT are
available as separate components from the standard Arm Kit.
Anchor arm material and design allow for fixation within ALL commonly used tubular material for
which the RCT is rated, e.g. Monel, Hastelloy, Inconel, Chrome, etc. Features have been designed
into the arm segments that assist in toolstring removal under stuck tool scenarios:
Predictable excess pull yield strength: resulting in tip fracture & arm geartooth collapse.
Jarring force arm yield: folded arms will predictably dislodge from the EMA when tight
restrictions are encountered following an excess pull yield event.
Arm material 6063 Aluminum will dissolve in concentrated acids or bases, accelerated by the
geometry of the arms.
Operator & well safety: arms actuate on DC (+) positive; thru fire on DC (-) negative.
See Appendix B for the EMATechnical Operation Manual for all use and safety requirements.
Training Manual
Rev. F
14
Section 2
The CheckFire Panel (CFP) (Fig. 10) is a tool designed to test the competency of the power supply
and wireline system to successfully activate the ElectroMechanical Anchor (EMA) and Thermal
Generator product line. The CheckFire Panel (CFP) displays RED and Green LED's that correspond
to the wireline and tool strings' ability to effectively energize. The GREEN LED will illuminate when
POSITIVE (+) DC polarity, voltage and amperage threshold is achieved for deployment/stowage of the
EMA arms. The RED LED will Illuminate when NEGATIVE (-) DC polarity, voltage and amperage
threshold is adequate to activate the selected Thermal Generator. The CFP has a large dial indicating
various ohm selections that simulates the resistance of the wireline's armor when dispensed downhole.
If the cut depth and the e-line armor resistance is known, dial in the matching resistance and test. The
CheckFire Panel is a first line test device to adequately confirm your system's competency, allowing
you to avoid the embarrassment of deploying with an inadequate power source for the EMA and
Thermal Generator downhole expectations.
MCRs CheckFire Panel system is both a firing system competency tool and an effective training aid
for service providers which allows wireline personnel to train to precisely control a deployed EMA and
simulate the firing of any one of MCRs types of thermal generators. MCRs CheckFire Panel, as well
as the EMA, is for use with power supply systems having the ability to produce clean D.C. voltage.
In the event that inadequate D.C. voltage is produced by a power supply system, a Firing Panel Filter*
may be required.
The CheckFire Panel is capable of simulating the firing thresholds for the following THGs:
THG-1000-200/-300, Standard Voltage THGs
THG-1000-600, Low Voltage THGs
THG-1000-700, High Voltage Heater series THGs
EMA operation is simulated with all qualities of the tool exhibited:
Power application time for anchor arm deployment
Power application time for next cycle command
Polarity response for arm actuation vs. THG firing
Wireline unspooled armor resistance can be dialed-in
to ensure that the firing panel sees the actual unspooled
downhole deployed, increased line resistance. This
eliminates needless surface actuations of the anchor
while having the ability to verify full anchor
command competency.
*Firing Panel Filter FPF-0000-100
CHECKFIRE PANEL
CFP-1500-100
Figure 10
Training Manual
Rev. F
15
Section 2
The development of MCRs ElectroMechanical Anchor and new ceramic core Thermal Generators
made MCR acutely aware of the need to have CLEAN D.C. power in order to be able to operate
these devices as well as to overcome the shortcomings of market-available power units. We learned
that most power panels simply rectify the A.C. power to give a "DIRTY" D.C power output. The
MCR Fire Panel Filter (Fig. 11) was developed to be used in conjunction with industry accepted power
panels and clean the D.C. for use when deploying the EMA. If you are uncertain of the quality of the
D.C. power output of your power panel, place a Fire Panel Filter (FPF) in line. It never hurts to be safe.
The FPF-0000-100 can filter up to 600V D.C., positive or negative, and includes a quick discharge
button for those of us who cannot wait the full minute necessary to fully self-discharge.
Training Manual
Rev. F
16
Section 2
Prior to 1999, the Radial Cutting Torch System relied upon the use of setting tool igniters as the
primary means for initiating the RCT. Setting tool igniters, also referred to as flame caps, are igniters
that contain black powder, a Class 1.4 explosive. These type igniters produce a variety of outputs
ranging from a flame to an explosion. It is this wide range of output possibilities that cause severe
problems when used with the RCT.
NOTE: SETTING TOOL IGNITERS OR FLAME CAPS ARE NO LONGER APPROVED FOR
USE WITH THE RADIAL CUTTING TORCH SYSTEM AND MUST NEVER BE USED.
MCR Oil Tools, LLC uses the patented "Thermal Generator" system (Fig. 12) for initiating the RCT/
PTC system. There are several variations of The Thermal Generator. One variation is a 50 ohm
resistorized device requiring a firing current of 1.5 amperes at the wireline shooting panel for 10 to
30 seconds (depending on well temperature and wireline condition) to initiate. Another version is a
ceramic heater and yet another design is a low voltage coil version.
The resistorized Thermal Generators contain a solid fuel composition making it possible to be shipped
with the RCT as a Flammable Solid, UN 1325, Section 4.1 Classification.
There are several sizes of Thermal Generators that utilize 50 ohm resistors. The THG-1000-200
(Fig. 12) is the small body version and is used in the 1-3/8, 1-1/2, 1-1/11. 1-3/4 and 2 torches
both standard sliding sleeve torches and XP torches. The THG-1000-300 (Fig. 12) is the large body
version and is used in sliding sleeve torches 2-1/2 and larger. The resistorized Thermal Generator
inserts into the top of the Thermal Generator sub and is held in place with a snap ring thus insuring
positive grounding. Initiation may be accomplished with either AC current or DC current. The proper
procedure to insure a positive initiation is to rapidly ramp the Variac to 1.5 amps and hold for up to
25 seconds. If the Thermal Generator has not fired after 25 seconds the resistor may be damaged and
the tool must be removed from the well.
The Thermal Generator should be checked electrically before each use. A Blaster's Galvanometer or
Safety Meter is used to measure the resistance between the banana pin and the case of the Thermal
Generator. The resistance should read 45 to 55. If the resistance is different from these values,
return the Thermal Generator for replacement. Do not disassemble or attempt any repairs.
If the Thermal Generator checks within the acceptable range, install it in the Thermal Generator sub,
insert the snap ring and attach the Isolations Sub. Check the Thermal Generator again for the proper
resistance reading. If the resistance is outside the acceptable range check perform a continuity check
on the subs and replace the subs if necessary.
The resistorized Thermal Generator has undergone an extensive series of Radio Sensitivity tests to
provide MCR with data qualifying it for use in Radio Sensitive areas. The Thermal Generator passed
all tests performed by an independent third party laboratory; a copy of the results page is provided
in Appendix A. All Radial Cutting Torch Systems are now qualified for use in Radio Silence / Radio
Sensitive conditions.
Training Manual
Rev. F
17
Section 2
Other versions of the Thermal Generator that utilize resistors are the small Thermal Generators used in
our 3/4 (THG-0750-100), 7/8 (THG-0875-100), 1 (THG-1000-100) and 1-1/8 (THG-1125100) torches. These Thermal Generators, due to their small size, have the thermal generator built into
the thermal generator sub. (Fig. 12)
A phenomenon inherent in the resistorized Thermal Generator design is the resistor itself. Testing has
shown that the resistor will fail when exposed to a current range of 0.6 0.8 amps. Testing has shown
that below 0.6 amps the resistor suffers no damage and can be re-energized for ignition. Above 0.8
amps and the resistor will heat up to ignition temperature. Dirty tool strings, poor wireline condition,
wireline kinks and poor grounding will have a dramatic effect on the ability of the wireline string to
supply the required one (1) amp of current to the resistor.
These new Thermal Generators (Fig. 12) were developed to replace the resistor versions. Small heaters
have been reliably used for years by industry and are designed to function repeatedly with hundreds
of cycles of heating and cooling. This ability makes them the perfect candidate to replace the resistor.
The Ceramic Heater Thermal Generator produces a higher intensity initiation and longer burning
time. It is designated the THG-1000-700; it replaces both the THG-1000-200, THG-1000-300 and
the Thermal Generators in the 3/4", 7/8", and 1-1/8" tools.
The new Thermal Generator requires a different Thermal Generator sub from the previous Thermal
Generators. The new subs are as follows:
Table 3. Generator Sub crossover for THG-1000-700
SUB
TORCH APPLICATION
SUB-1375-700
RCT-1375, PTC-1375
SUB-1500-700
SUB-1688-700
SUB-2000-700
RCT-2000, HP-2000
SUB-2500-700
SUB-2975-700
SUB-3375-700
SUB-4500-700
RCT-7000
Existing stocks of the THG-1000-200 and THG-1000-300 may continue to be used. New production
of the THG-1000-700 will begin July 2010.
The THG-1000-700 is the primary initiation device for the Radial Cutting Torch system, Perforating
Torch system and Gas Generators. It is an electric device which consists of a resistance heating element
inside a steel case filled with a proprietary non-hazmat rated fuel mixture.
The Thermal Generator should be checked electrically before each use. A Blaster's Galvanometer or
Safety Meter is used to measure the resistance between the banana pin and the case of the Thermal
Generator. The resistance should read 130 to 160. If the resistance is different from these values,
return the Thermal Generator for replacement. Do not disassemble or attempt any repairs.
2010 MCR Oil Tools, LLC. All rights reserved
Training Manual
Rev. F
18
Section 2
The low voltage Thermal Generator (Fig. 12) was developed to provide a non-explosive RF safe means
of initiating Radial Cutting Torches, Perforators and related tools utilizing a battery pack. In an effort
to support the industry with conveyance choices, the Low-Voltage Thermal Generator was developed.
The Low-Voltage Thermal Generator (P/N THG-1000-600) is the primary device used to run RCT
Torch systems and PTS perforating systems in combination with a competent Remote Triggering
Device (RTD). This allows RCTs and PTSs and other MCR devices and tools to be initiated with
competent devices that utilize a battery pack.
CAUTION: LOW VOLTAGE THERMAL GENERATORS ARE FOR USE WITH MCR REMOTE
TRIGGER DEVICES ONLY!
The resistance reading for our Low-Voltage Thermal Generator should be between 9 and 12 ohms.
THIS MUST ONLY BE MEASURED USING A BLASTERS GALVANOMETER!
* See Appendix A for Radio Silence Testing Summary for Resistorized, Ceramic Heater and Low Voltage
Thermal Generators.
THG-1000-200
Figure H-1
THG-1000-700
THG-1000-300
Figure H-2
Figure H-5
THG-0875-100
Figure H-3
THG-1000-600
Figure H-4
Training Manual
Rev. F
19
Section 2
The High Voltage and Low Voltage series Thermal Generators is pushed into the bottom or torch end of the
Thermal Generator Sub (Fig. 13); a "garter spring" around the middle of the Thermal Generator holds it in
place and provides for a competent ground. The Isolation Sub, SUB-1500-500 (shown), is screwed into the
top of the Thermal Generator Sub. Make another resistance measurement between the center contact of the
Isolation Sub and the body of the Thermal Generator Sub: the resistance should be the same as measured
previously. The Isolation Sub may now be attached to the safe electric wireline.
Operation
The Thermal Generator is fired by applying AC or DC power to the wireline. Either Positive or Negative DC
polarity may be used. In operation, ramp up the firing current by rotating the Variac of the firing panel until
1.5 amperes is indicated. Hold for 15 seconds. Continue to ramp up the firing current in 0.1 Amp increments
if the Thermal Generator has not fired after 15 seconds. This high- voltage system requires 1 amperes; typical
175 VAC or 175 VDC at the Thermal Generator.
ISOLATION SUB
GENERATOR SUB
THG-1000-600 / 700
TYPICAL
ASSEMBLY
TYPICALIGNITION
IGNITION ASSEMBLY
THG-1000-600&& THG-1000-700
THG-1000-700
THG-1000-600
Figure 13
L-1
Figure
ISOLATION SUB
THG-1000-200 / 300
GENERATOR SUB
SNAP RING
Training Manual
Rev. F
20
Section 2
When operations require "electric before ballistic" tool string handing, MCR Oil Tools' Generator
Safety Sleeve (Fig. 15) is required equipment; designed to safely dissipate all THG energy, the GSS is
a valuable tool for field specialists.
MCR's Generator Safety Sleeve is developed for use with the following MCR Thermal Generators only:
THG-1000-200, tool sizes 1-3/8", 1-1/2", 1-11/16" & 2"
THG-1000-300, tool sizes 2-1/2", 2-15/16", 3-3/8", 4" & 5"
THG-1000-700, all tool sizes with compatible Generator Subs
All MCR 3/4", 7/8", 1" & 1-1/8" Cutters and Perforators
All MCR setting tool Generator Subs
This tool is designed for one SINGLE Thermal Generator DISCHARGE ONLY! In the event of a
THG discharge into the GSS, the entire GSS must be discarded and replaced with a new system.
Note: "XXXX" in GSS part number corresponds to actual MCR Generator Sub utilized
Training Manual
Rev. F
21
Section 2
MCRs new Remote Trigger Device (RTD) is a culmination of over six years of development. MCR
has developed a family of small RTDs being produced in 7/8, 1-1/2 and a 2-1/2 outside diameters:
all under 36 in length and capable of being powered by select off-the-shelf power cells.
The RTD contains up to nine pre-programmed parameter that are selectable from a rotary switch. This
feature allows the RTD to be used in nine combinations without reprogramming. The RTD is also
programmable at the well site to accommodate well conditions outside the pre-programmed selections.
The RTD senses accelerations, temperature, pressure and elapsed time.
Training Manual
Rev. F
22
Section 3
Training Manual
Rev. F
Section 3
WHEN ATTACHING THE ANCHOR ASSEMBLY TO THE VERTICALLY HANGING RCT / PBE
ASSEMBLY ALWAYS SUPPORT THE NOZZLE SECTION BY HOLDING ONTO THE RCT BODY.
DO NOT PUT THE NOZZLE IN A BIND, AS THIS CAN CAUSE DAMAGE TO THE NOZZLE.
Training Manual
Rev. F
Section 3
NOTE 4:
Make sure the set screws on the anchor sub are aligned with the groove on the RCT cap (Fig. 8). To
insure proper alignment, remove one set screw & put the Allen wrench through the hole vacated by
the removed set screw and slide the anchor over the end cap of the torch until the wrench seats in the
groove. Once the groove is located by the end of the wrench, tighten the remaining three screws and
replace and tighten the removed screw. To be sure that the set screws are located in the groove untorque
the set screws and try to slide the anchor. The set screws will prevent the anchor from moving more
than 1/8th of an inch, if more movement is experienced; the anchor is not seated properly. Re-torque
the set screws following correct insertion verification process.
9. Attach the Bull Plug (-220) to one end of one of a body (-221) and fully tighten the set screws.
10. Attach the Connector (-219) to the other end of the body (-221) with the Bull Plug (-220) and
fully tighten the set screws.
11. Attach the other Body (-221) to the other end of the Connector (-219) and fully tighten the set
screws. The completed anchor assembly is now ready to attach to the vertically hanging torch assembly.
Set this assembly aside until the torch assembly is completely assembled and hanging vertically to the
tool string.
NOTE 5:
The bow spring centralizer should be mated to the Bull Plug (-220) and wrench tightened. The Bull
Plug has a 1" Sucker Rod Thread (15/16"-10 UN)
Training Manual
Rev. F
Section 3
NOTE 7:
Care should be taken not to twist or bind the nozzle end of the RCT, as this may damage the nozzle.
6. First remove the Generator Safety Sleeve from the Thermal Generator Sub; then thread the RCT
/ PTS assembly (Fig. 16, Fig. 17 & Fig. 18) onto the Thermal Generator and tighten with wrenches.
7. Attach the anchor assembly (with centralizer sub) to the end of the RCT / PTS and tighten the set
screws on the anchor body.
Figure 16 is a typical toolstring for the Radial Cutting Torch and Pressure Balance Anchor with upper
and lower centralizers. MCR recommends using a competent set of impact selector jars above the
RCT especially when the RCT is used in deviated electric wireline wells.
Figure 17 is a typical toolstring for the Radial Cutting Torch, Pressure Balance Anchor with upper and
lower centralizers for the Electro-Mechanical Anchor and a lower centralizer for the truncated PBA
system. MCR recommends using a competent set of impact selector jars above the RCT especially
when the RCT is used in deviated electric wireline wells.
Figure 18 is a typical toolstring for the Perforating Torch Cutter (PTC) and Pressure Balance Anchor.
MCR recommends using a competent set of impact selector jars above the RCT especially when the
RCT is used in deviated electric wireline wells.
Training Manual
Rev. F
GO BULL PLUG
CENTRALIZER
ADAPTER MAY BE
REQUIRED TO CONNECT
CENTRALIZER WITH PBA
BULL PLUG SUCKER
ROD THREAD
PRESSURE BALANCE
ANCHOR ASSEMBLY
SINKER BAR
Figure
L-5
Figure 16
THERMAL
GENERATOR
SUB
ISOLATION SUB
Training Manual
Rev. F
EXTENSION (EXT),
IF NECESSARY
THG
RADIAL CUTTING
TORCH (RCT)
CENTRALIZER SUB
Section 3
CENTRALIZER
GO BULL PLUG
CENTRALIZER
Training Manual
Rev. F
SINKER BAR
EXTENSION (EXT),
IF NECESSARY
THG
ISOLATION SUB
RADIAL CUTTING
TORCH (RCT)
PRESSURE BALANCE
ANCHOR ASSEMBLY WITH
ONE PBA BODY ONLY
CENTRALIZER
Section 3
SINKER BAR
Figure
Figure L-7
18
EXTENSION (EXT),
IF NECESSARY
THG
SUB
GO TYPE DUAL PIN
CABLE
HEAD
ASSEMBLY
Training Manual
Rev. F
THERMAL
GENERATOR
SUB
ISOLATION SUB
Section 3
PERFORATING
TORCH CUTTER (PTC)
Figure
Figure L-8
19
RCT/PTS ASSEMBLY
RADIAL CUTTING
TORCH (RCT)
EXTENSION (EXT),
IF NECESSARY
Training Manual
Rev. F
EXTENSION (EXT),
IF NECESSARY
Section 3
GENERATOR
SAFETY SLEEVE
Figure
L-3
Figure 20
GENERATOR
SAFETY SLEEVE
GENERATOR
SUB WITH THG
Section 3
Training Manual
Rev. F
ISOLATION SUB
CABLE HEAD
GENERATOR
SUB WITH THG
ISOLATION SUB
GO TYPE
DUAL PIN SUB
Do not remove the security cable or brass tag; removal voids product
qualification. Do not disassemble the GSS; internal components must
remain sealed and properly oriented. Stow the GSS in its shipping
container when not in use to avoid damaging the relief filter component
& threads. Grease the o-ring surface prior to making up the GSS to the
Generator Sub pin end. Avoid using pipe wrenches: strap wrenches or
hand application is preferred to avoid marring damage to the Aluminum
housing. Each toolstring requires a specific Safety Sleeve - DO NOT
alter threaded ends to accommodate other tools.
Section 4
Qty
Part Number(s)
Tool Build
Description
Pressure (psi)
Recommended Use
RCT-0750-200
RCT-0750-200
3/4" O.D.
(19.05 mm)
0-4000
1
1
RCT-0750-200
EXT-0750-100
RCT-0750-300
3/4" O.D.
(19.05 mm)
4001-10,000
RCT-0875-200
RCT-0875-200
7/8" O.D.
(22.23 mm)
0-4000
1
1
RCT-0875-200
EXT-0875-100
RCT-0875-300
7/8" O.D.
(22.23 mm)
4001-10,000
RCT-1000-200
RCT-1000-200
1" O.D.
(25.4 mm)
0-4000
1
1
RCT-1000-200
EXT-1000-100
RCT-1000-300
1" O.D.
(25.4 mm)
4001-10,000
RCT-1375-200
RCT-1375-200
1.375" O.D.
(34.93 mm)
0-4000
1
1
RCT-1375-200
EXT-1375-100
RCT-1375-300
1.375" O.D.
(34.93 mm)
4001-10,000
1
2
RCT-1375-200
EXT-1375-100
RCT-1375-400
1.375" O.D.
(34.93 mm)
4001-10,000
RCT-1500-200
RCT-1500-200
1.500" O.D.
(38.1 mm)
0-4000
1
1
RCT-1500-200
EXT-1500-100
RCT-1500-300
1.500" O.D.
(38.1 mm)
4001-10,000
1
1
RCT-1500-200
EXT-1500-100
RCT-1500-400
1.500" O.D.
(38.1 mm)
4001-10,000
RCT-1500-999XP
RCT-1500-999XP
(No EXT added)
1.500" O.D.
(38.1 mm)
0-4000
1
1
RCT-1500-999XP
EXT-1500-100
RCT-1500-999XP
(EXT added)
1.500" O.D.
(38.1 mm)
4001-10,000
RCT-1688-200
RCT-1688-200
1.688" O.D.
(42.86 mm)
0-4000
1
1
RCT-1688-200
EXT-1688-100
RCT-1688-300
1.688" O.D.
(42.86 mm)
4001-10,000
0-4000
1
2
RCT-1688-200
EXT-1688-100
RCT-1688-400
1.688" O.D.
(42.86 mm)
4001-10,000
RCT-1750-999XP
RCT-1750-999XP
(No EXT added)
1.750" O.D.
(44.45 mm)
0-4000
3-1/2" Pipe
1
1
RCT-1750-999XP
RCT-1750-100
RCT-1750-999XP
(With EXT)
1.750" O.D.
(44.45 mm)
4001-10,000
3-1/2" Pipe
RCT-2000-200
RCT-2000-200
2" O.D.
(50.8 mm)
0-4,000
1
1
RCT-2000-200
EXT-2000-100
RCT-2000-300
2" O.D.
(50.8 mm)
0-4000
4001-10,000
1
2
RCT-2000-200
EXT-2000-100
RCT-2000-400
2" O.D.
(50.8 mm)
4001-10,000
Training Manual
Rev. F
Section 4
Qty
Part Number(s)
Tool Build
Description
Pressure (psi)
Recommended Use
RCT-2500-200
RCT-2500-200
2.500" O.D.
(63.5 mm)
0-4000
3-1/2" Tubing
1
1
RCT-2500-200
EXT-2500-100
4001-10,000
3-1/2" Tubing
RCT-2500-300
2.500" O.D.
(63.5 mm)
0-4000
2.500" O.D.
(63.5 mm)
0-4000
4001-10,000
4001-10,000
0-4000
1
2
RCT-2500-200
EXT-2500-100
RCT-2500-400
1
1
RCT-2937-100
EXT-2937-100
RCT-2937-200
2.937" O.D.
(74.6 mm)
0-4000
4-1/2" Pipe
1
2
RCT-2937-100
EXT-2937-100
RCT-2937-300
2.937" O.D.
(74.6 mm)
4001-10,000
RCT-3375-200
RCT-3375-200
3.375" O.D.
(85.7 mm)
0-4000
1
1
RCT-3375-200
EXT-3375-100
RCT-3375-300
3.375" O.D.
(85.7 mm)
4001-10,000
1
2
RCT-3375-200
EXT-3375-100
RCT-3375-400
3.375" O.D.
(85.7 mm)
4001-10,000
1
1
RCT-4000-100
EXT-3375-100
RCT-4000-200
4" O.D.
(101.6 mm)
0-4000
5-1/2" Pipe
1
1
1
RCT-4000-100
EXT-3375-100
EXT-4000-100
RCT-4000-300
4" O.D.
(101.6 mm)
4001-10,000
1
1
2
RCT-4000-100
EXT-3375-100
EXT-4000-100
RCT-4000-400
4" O.D.
(101.6mm)
4001-10,000
1
1
1
RCT-5000-050
EXT-3375-100
EXT-4000-100
4001-10,000
6-5/8" Pipe
RCT-5000-200
5" O.D.
(127 mm)
0-4000
4001-10,000
6-5/8" Pipe
1
1
2
RCT-5000-050
EXT-3375-100
EXT-4000-100
RCT-5000-300
5" O.D.
(127 mm)
4001-10,000
1
1
3
RCT-5000-050
EXT3375-100
EXT-4000-100
RCT-5000-400
5" O.D.
(127 mm)
4001-10,000
1
2
RCT-7000-100
EXT-7000-075
RCT-7000-200
7" O.D.
(177.8 mm)
0-4000
1
2
2
RCT-7000-100
EXT-7000-025
EXT-7000-075
RCT-7000-300
7" O.D.
(177.8 mm)
0-4000
Training Manual
Rev. F
Section 4
Qty
Part Number(s)
Tool Build
Description
Pressure (psi)
Recommended Use
HPT-0750-1000
HPT-0750-1000
3/4" O.D.
(19.05 mm)
10,001 - 15,000
HPT-0875-1000
HPT-0875-1000
7/8" O.D.
(22.23 mm)
10,001 - 15,000
HPT-1125-1000
HPT-1125-1000
1.125" O.D.
(28.58 mm)
10,001 - 15,000
HPT-1375-1000
HPT-1375-1000
1.375" O.D.
(34.93 mm)
10,001 - 15,000
HPT-1500-1000
HPT-1500-1000
1.500" O.D.
(38.1 mm)
10,001 - 15,000
HPT-1688-1000
HPT-1688-1000
1.688" O.D.
(44.45 mm)
10,001 - 15,000
HPT-2000-1000
HPT-2000-1000
2" O.D.
(50.8 mm)
10,001 - 12,000
1
1
HPT-2000-1000
HPE-2000-1000
HPT-2000-2000
2" O.D.
(50.8 mm)
12,001 - 15,000
1
1
HPT-2500-1000
HPE-2500-1000
HPT-2500-2000
2.500" O.D.
(63.5 mm)
10,001 - 12,000
4" Pipe
4-1/2" Pipe 15.5#
1
1
HPT-2500-1000
HPE-2500-2000
HPT-2500-3000
2.500" O.D.
(63.5 mm)
10,001 - 12,000
1
1
1
HPT-2500-1000
HPE-2500-1000
HPE-2500-2000
HPT-2500-4000
2.500" O.D.
(63.5 mm)
12,001 - 15,000
1
2
1
HPT-2500-1000
HPE-2500-1000
HPE-2500-2000
HPT-2500-5000
2.500" O.D.
(63.5 mm)
12,001 - 15,000
HPT-2937-1000
HPT-2937-1000
2.937" O.D.
(74.6 mm)
10,001 - 15,000
1
1
HPT-3375-1000
HPE-3375-1000
HPT-3375-2000
3.375" O.D.
(85.7 mm)
10,001 - 12,000
1
1
HPT-3375-1000
HPE-3375-2000
HPT-3375-3000
3.375" O.D.
(85.7 mm)
1
1
1
HPT-3375-1000
HPE-3375-1000
HPE-3375-2000
HPT-3375-4000
1
1
HPT-4000-1000
HPE-4000-2000
1
1
1
HPT-4000-1000
HPE-4000-1000
HPE-4000-2000
4" Pipe
4-1/2" Pipe 15.5#
5" Pipe 18#
4-1/2" Pipe 15.5#
5" Pipe 18#
5" Pipe 18#
12,001 - 15,000
10,001 - 12,000
3.375" O.D.
(85.7 mm)
12,001 - 15,000
HPT-4000-3000
4" O.D.
(101.6 mm)
10,001 - 12,000
HPT-4000-4000
4" O.D.
(101.6 mm)
12,001 - 15,000
Training Manual
Rev. F
Section 4
Qty
Part
Number(s)
Tool Build
Description
Pressure
(psi)
Recommended
Use
Approximate
Hole Size
(in)
PTS-0750-200
PTC-0750-200
3/4" O.D.
(19.05 mm)
0-4000
0.38
1
1
PTC-0750-200
EXT-0750-100
PTC-0750-300
3/4" O.D.
(19.05 mm)
4001-10,000
0.38
PTC-0750-1000
PTC-0750-1000
3/4" O.D.
(19.05 mm)
10,001 15,000
0.42
PTC-0875-200
PTC-0875-200
7/8" O.D.
(22.23 mm)
0-4000
0.42
1
1
PTC-0875-200
EXT-0875-100
PTC-0875-300
7/8" O.D.
(22.23 mm)
4001-10,000
0.42
PTC-0875-1000
PTC-0875-1000
7/8" O.D.
(22.23 mm)
10,001 15,000
0.47
PTC-1000-200
PTC-1000-200
1" O.D.
(25.4 mm)
0-4000
0.6
1
1
PTC-1000-200
EXT-1000-100
PTC-1000-300
1" O.D.
(25.4 mm)
4001-10,000
0.6
PTC-1000-1000
PTC-1000-1000
1" O.D.
(25.4 mm)
10,001 15,000
0.6
PTC-1375-200
PTC-1375-200
1-3/8" O.D.
(34.93 mm)
0 - 4000
2-3/8" Tubing
1.05
1
1
PTC-1375-200
EXT-1375-100
PTC-1375-300
1-3/8" O.D.
(34.93 mm)
4001 - 10,000
2-3/8" Tubing
1.05
0 - 4000
2-7/8" Tubing
1.05
PTC-1375-400
1-3/8" O.D.
(34.93 mm)
0 - 4000
2-7/8" Tubing
1.1
4001 - 10,000
2-7/8" Tubing
1.1
0 - 4000
3-1/2" Tubing
1.3
4001 - 10,000
3-1/2" Tubing
1.3
4001-10,000
4" Pipe
2.2
1
2
PTC-1375-200
EXT-1375-100
PTC-1688-200
PTC-1688-200
1-11/16" O.D.
(42.86 mm)
1
1
PTC-1688-200
EXT-1688-100
PTC-1688-300
1-11/16" O.D
(42.86 mm)
PTC-2500-200
PTC-2500-200
2-1/2" O.D.
(63.5 mm)
0 - 4000
4-1/2" Pipe
2.2
1
1
PTC-2500-200
EXT-2500-100
PTC-2500-300
2-1/2" O.D.
(63.5 mm)
4001 - 10,000
4-1/2" Pipe
2.2
*PTC-2937-200
*PTC-2937-200
2.937" O.D.
(74.6 mm)
0-4000
5-1/2" Pipe
7.5
1
1
*PTC-2937-200
EXT-2937-100
*PTC-2937-300
2.937" O.D.
(74.6 mm)
4001 - 10,000
5-1/2" Pipe
7.5
TRCTPTS092010
Training Manual
Rev. F
Section 4
MCR Torch
RCT -1375
RCT -1500
RCT -1688
RCT -2000
RCT -2500
RCT -2937
RCT -3375
RCT -4000
RCT -5000
RCT -6750
NOTE: Perforations are based on 0.3 inch diameter individual shot holes. If the hole size
is smaller, then more holes are required to produce the required flow area.
The above perforation count has been doubled with respect to the table shown in the
previous Operation Manual (rev. H). Since the expectation that the 0.3 holes produced
are 100% efficient, shot diameters falling short are often encountered. As such, MCR has
doubled the number of shots required in order to compensate for efficiency shortfalls.
Training Manual
Rev. F
Pressure Balance Anchor does not contain moving parts, eliminating the
problems associated with going through restrictions and operating in larger
diameters below the restriction.
The complete system is safe to use in Radio Sensitive areas such as offshore platforms
or drill ships without going into Radio Silence, resulting in significant savings in rig time.
Training Manual
Rev. F
Appendix A
Radio Silence Testing Summary
Appendix A
Appendix A
Radio Silence Testing Summary
Appendix A
Appendix A
Radio Silence Testing Summary
Appendix A
Appendix B
Appendix B
EMA-1500-100
Manual Revision D
10/2010
Table of Contents
GENERAL TERMS & CONDITIONS .......................................... i
TOOL SPECIFICATIONS .......................................................... 2
ASSEMBLY & DISASSEMBLY ................................................. 3
MAINTANENCE ........................................................................ 4
OPERATION ............................................................................. 8
TROUBLESHOOTING PROCEDURES .................................. 12
ADDITIONAL EQUIPMENT .................................................... 12
ARM SELECTION CHART ...................................................... 13
EMA ACTUATION & DEPLOYMENT LOG ............................. 13
INDEX ..................................................................................... 13
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
TOOL SPECIFICATIONS
Description:
Length:
46 (116.8 cm)
Weight:
1 (3.8 cm)
Pressure Rating
Temperature Rating
250 F (121 C)
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
MAINTANENCE
Proper maintenance of the EMA is necessary in order to ensure continued safe
tool operation. Maintenance is limited to cleaning, grease injection at the anchor
arm housing grease ports, arm removal & replacement and o-ring replacement on
the pin end of the bottom sub (MCR Product # HOR-90-211). Removal of all
contaminated grease, slag or other debris from within the arm slots should be
conducted with cotton swabs prior to fresh grease injection. (This operation follows
an alignment cycle to properly orient the arms for removal/replacement).
Do not clean the tool with a high pressure high velocity power washer.
Use non-solvent cleaning products followed by a light coat of Marvel Mystery Oil
after use and prior to long term storage of the EMA. Always store the EMA with
fresh driveshaft grease and new arms!
To prepare the tool for a downhole run, arm replacement, or for storage, orient the
arms as indicated in Step #2 of the Arm Replacement instructions.
Once the arms have been removed and all slot grease and debris has been
cleaned-out, remove the grease port set screws (Fig. 2).
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
ARM REPLACEMENT:
Note: New EMA kits ship from the MCR facility with ARM #7 series
installed in the arms closed (parallel to drive shaft) position and on the
open sequence processor cycle.
All arm actuation cycles must be performed utilizing DC (+) positive
polarity. Arm actuation cycles that are stopped by removing power to the
EMA prior to processor time-out will remain on that cycle, and begin at time
= 0s.
Step 1:
Begin this sequence with the currently installed arms in the armsCLOSED position. The arms-CLOSED cycle can be confirmed by the
arms closing or by visualizing the arm driveshaft traveling towards the
bottom of the EMA (knurled end) in the event that no arms or yielded arms
are encountered. A distinct clicking will be felt and heard once the travel
limit of the shaft or arm impingement on shaft has occurred. This is normal
and will stop upon processor time-out. Power can be removed from the tool
following processor time-out, with the next power application cycle being
the opposite arm travel.
In the event that a cycle has placed the shaft in a position where arm
installation is prevented, conduct an arms open cycle until the shaft gear
section is approximately centered with the arm shoulder screws. Removal
of power prior to processor time-out may be necessary in order to
adequately line-up the shaft gear section.
Step 2:
Apply DC+ for approximately 7 to 8 seconds (2 to 3 seconds following
processor start of the motor, which begins 3 to 5 seconds after power
application to the tool), just enough to elevate the arms off of the driveshaft.
This position is for ease of arm removal & replacement. This step is
particularly necessary when switching from shorter arms to longer arms.
Step 3:
Remove the used or improperly sized arms and replace with new arms. All
arms must be installed in the same orientation as those being replaced.
Ensure that the shoulder screws that retain the arms are tightly fastened.
Step 4:
Apply DC+ power again to reach full arms-OPEN orientation (~90 to
body) until cycle stop** (fig. 3). Please note that an excessive number of
2010 MCR OIL Tools, LLC
5
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
open cycles on a single set of arms may result in a flattening of the last arm
tooth. This may hinder functionality due to side wall rubbing.
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
Electrical check:
1) Through resistance
4M to ____
2)
4M to 64M__
3)
64M to ___
4)
5)
CheckFire
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
OPERATION
ORDER #
KIT-ARM-340
KIT-ARM-341
KIT-ARM-342
KIT-ARM-343
KIT-ARM-344
KIT-ARM-345
KIT-ARM-346
KIT-ARM-347
KIT-ARM-348
KIT-ARM-349
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
3)
j)
k)
4)
5)
Perform an open / fire / close / fire sequence on the EMA (NO RCT,
PTC or THG ATTACHED!) For Functionality Check
d)
e)
f)
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
Apply power. Verify both the end of line voltage and pin polarity* (Only
DC (-) NEGATIVE voltage passage allowed!). If positive voltage
conduction is indicated, detach the EMA and label INOPERATIVE.
*Insure lead polarity selection is correct for polarity check.
Power to zero, Shooting key to SAFE and depress Fire Panel Filter
Discharge button (if attached between firing panel and wireline) for 5
seconds.
Select DC (+) Positive.
Ramp-up to CheckFire Panel UPHOLE Arm Actuation Threshold
voltage, Apply Power, (amperage will begin low, then after a 5 second
delay, arms CLOSED sequence begins, indicated by a raise in
amperage draw 17 second duration). Increase voltage to obtain one
(1) Ampere of panel indicated current. Hold until amperage drops
back to initial power application range. Verify that no voltage is sensed
at the bottom pin.
Power to zero, Shooting key to SAFE and depress Fire Panel Filter
Discharge button (if attached between firing panel and wireline) for 5
seconds.
Select DC (-) Negative.
Ramp up to the CheckFire Panel UPHOLE Fire Threshold voltage.
Apply power. Verify both end of line voltage and pin polarity (Only DC
(-) NEGATIVE voltage passage allowed! If positive voltage conduction
is indicated, detach the EMA and label INOPERATIVE. *Insure lead
polarity selection is correct for polarity check.
Power to zero, Shooting key to SAFE and depress Fire Panel Filter
Discharge button (if attached between firing panel and wireline) for 5
seconds.
Select DC (+) Positive.
Power off & secure firing panel.
7)
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
c)
d)
e)
Verify that no movement is indicated on the CCL and that the over pull
weight is maintained.
Power to zero, Shooting key to SAFE and depress Fire Panel Filter
Discharge button (if attached between firing panel and wireline) for 5
seconds.
Switch to DC (-) Negative.
9)
10)
11)
POOH
a)
Ensure release with a slow pull and watch for initial increase then
reduction in wireline weight pick up.
b)
Slow toolstring speed prior to entering any significant casing or tubing
internal restrictions or profiles.
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
TROUBLESHOOTING PROCEDURES
The EMA has numerous built-in recovery features should the arm stowage process fail
following a cut or perforate sequence. There are multiple failure zones on the arms as
well as an internal driveshaft shear pin. When used in conjunction with recommended
jars, recovery of the toolstring is very likely.
The 1 EMA arms are designed to successfully anchor and hold all cutter sizes up to
and including 2 RCTs while within 2 3/8 to 4 pipe species (up to 5 with
optional arms).
The following operations should be considered in the event of a held-up toolstring.
Always attempt to verify the root cause of the stuck component do not assume that
an immovable toolstring containing an EMA is always due to stuck arms!
Yield sequence:
Carbide inserts begin to fracture at ~750lbs. This begins the process of reducing their
profile.
At between 900 lbs to 1100 lbs, depending on the impinging angle, the gear teeth of
the arms fail, allowing the arms, sequentially, to fold forward or backwards
depending on their contact with the pipe wall or a constriction feature inside the well.
Once folded backwards, the next shear will tend to separate the arm from the anchor.
This is advantageous should the arms become bent and not nest within a slot. This
yield can occur in conjunction with the above gear yield or slightly above it. The arms
can then be flowed to surface, allowed to settle, or dissolved.
In the event that there is a constriction feature precluding the arm gear from shearing
at the driveshaft, the next yield will occur within the EMA housing. A 1500 lb shear pin
will release the driveshaft, allowing the arms to fold. This action will be assisted by the
use of competent jars.
A final option to recover the toolstring from the well is the use of acid to dissolve the
arms. They are constructed of 6063 Aluminum for that reason.
ADDITIONAL EQUIPMENT
Applied Filter Panel (FP-AES)
CheckFire Panel (CFS)
Generator Safety Sleeve (GSS)
2010 MCR OIL Tools, LLC
12
M A N U A L :
E M A - 1 5 0 0 - 1 0 0
EMA ACTUATION
& DEPLOYMENT LOG
INDEX