SPE/IADC 52824

Pyro Technology for Cutting Drill Pipe and Bottomhole Assemblies

James F. Cole/Baker Atlas
IADC Member
Copyright 1999, SPE/IADC Drilling Conference
This paper was prepared for presentation at the 1999 SPE/IADC Drilling Conference held in
Amsterdam, Holland, 911 March 1999.
This paper was selected for presentation by an SPE/IADC Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the Society of Petroleum Engineers or the
International Association of Drilling Contractors and are subject to correction by the author(s).
The material, as presented, does not necessarily reflect any position of the SPE or IADC, their
officers, or members. Papers presented at the SPE/IADC meetings are subject to publication
review by Editorial Committees of the SPE and IADC. Electronic reproduction, distribution, or
storage of any part of this paper for commercial purposes without the written consent of the
Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to
an abstract of not more than 300 words; illustrations may not be copied. The abstract must
contain conspicuous acknowledgment of where and by whom the paper was presented. Write
Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

Abstract
In recent years, limited advances have been made in drill
pipe recovery services technology. Depending on the size,
weight per foot, and type of pipe stuck in the well, the options
available to separate the pipe string, have remained the same
for over a decade. These include:
1.
2.
3.
4.

String shot/back off

Chemical Cutter
Jet Cutter
Metal Severing Tool

The most commonly used tool is the string shot/back off,

which involves applying left hand torque to the pipe string at
the neutral weight. The explosive produces and intense
hammer blow and allows the joint to be unscrewed at the
desired connection. The most difficult part of this procedure
is determining the neutral weight at the depth of the back off
attempt and the amount of torque required at that point.
The back-off is a preferred method because it leaves a
clean top on the down hole fish. This saves time in the fishing
operation, which is critical to a successful fishing job.
However, as wells become more deviated or well conditions
become more severe, the back-off method can become less
effective.
This paper introduces new technology for disengaging pipe
located above the point where the drill string assembly is
stuck. The system uses a solid combustible mixture which
produces sufficient heat to separate drill pipe, leaving a clean
top on the remaining down hole fish. The sytstem is safe to
store, transport and handle at temperatures up to 660C. Its

solid combustible mixture does not ignite due to pressure,

shock or impact, under normal conditions.
Introduction
During drilling operations the drill-string can become stuck
due to a variety of mechanical failures, well conditions and
human error. The vast majority of stuck pipe occurrences are
in deviated or directional wells having greater than a 42
angle. In the North Sea 65% of stuck pipe incidents occurred
in wells with an angle greater that 421. In the Gulf of Mexico
directional wells accounted for 91% of the stuck pipe
incidents2. As the hole angle increases so does the difficulty
for successfully backing off pipe. It is more complicated to
work the appropriate amount of torque downhole.
Determining neutral weight, one key to a successful back off,
is more difficult to determine.
Hole angle, hole size and mud weight were all found to
affect the probability of freeing stuck pipe. In this paper
fishing in considered an attempt to free stuck pipe with fishing
jars. Shivers and Domangue2 have shown that fishing
operations have only a 33% success rate. For fishing attempts
the relationship of success versus time shows it is most critical
within the first 72 hours. There were no successful fishing
operations after 96 hours.
Time is a critical factor for a successful fishing operation.
The quicker the fishing jar assembly can be employed the
greater the chances of a successful fishing operation. The drill
pipe assembly must be disengaged above the stuck point so
the fishing assembly can be attached. To improve the
efficiency in employing the fishing assembly, a clean top
down hole is needed. Leaving a clean top is a major
advantage of the string shot/back off.
There can be many reasons why a string shot/back off
cannot be performed or is not successful. However, in the
interest of time a clean fish is still important. Having a viable
second option is important for pipe recovery. This paper
details a pyrotechnic device that can be used to sever drill pipe
and bottom hole assemblies. This device will produce a
flare-free cut which, unlike high-explosive devices, will
eliminate the need for an extra pipe trip to dress the top of
the fish..

SPE/IADC 52824

PYRO TECHNOLOGY FOR CUTTING DRILL PIPE AND BOTTOMHOLE ASSEMBLIES

Historical Background
The field of pyrotechnics is very broad. It encompasses
the field of chemistry, thermodynamics, and the art of
pyrotechnics. For the purpose of this paper discussion will be
limited to the reaction of aluminum and iron-oxide and a
radial cutting tool design.
When powdered aluminum and iron-oxide are mixed and
ignited a vigorous and highly exothermic reaction occurs;
2 A1 + Fe203 1Fe + A1203 + H .
This is known as the thermite or Goldschmidt reaction. The
temperature of the reaction can raise the mixture to about
1,649C which iron and aluminum become liquid.
The Goldschmidt3 reaction;
8 A1( soldi ) + 3Fe204( soid ) 4 A1203(solid ) + 9 Fe(liquid ) ,
is the oldest gasless heating mixture. Patented in 1895, it
was used for repairing cast iron equipment, butt welding and
general railway repairs.
The classical work of Spice and Staveley4 established the
connection between pyrotechnics and solid-state chemistry,
when two materials are placed in intimate contact, something
must cross the boundary for a reaction to occur. Spice and
Staveley proved that two reactions were occurring during a
self-propagating reaction: ignition and pre-ignition. The preignition is necessary for the bulk, self-propagating reaction
rate. If one can control the pre-ignition rate and the slope of
its self-heating curve, then one can control the bulk reaction.
The Pyronol torch was developed in the 1970s for use at
sea by salvage crews. A 1971 study5 of the Pyronol torch
showed it could cut through 4 inches of stainless steel in 0.025
seconds at a depth of 2000 feet. The overall reaction is;
2 A1 + Ni + Fe203 A1203 + Ni 0 + 2 Fe .
The report concluded that an alloying reaction,
Ni 2 A1 A12 Ni ,served a dual role to preheat the reactants
and to control the burning rate and subsequent heat output.
Discussion - Thermite Mixture
The radial torch contains a heat generating source of
thermite material. This thermite material is a powdered
mixture of aluminum, iron oxide and fluorocarbon. This
powdered mixture is pressed into solid donut-shaped pellets,
which are then stacked into the torch body. The centered
holes in the pellets are then filled with the loose powdered
mixture of the same thermite mix. Upon initiation, a
deflagration reaction occurs within the elongated torch
housing. The resulting liquid iron and aluminum oxide are
forced through the nozzle system at high velocities by
internally generated gas pressure. This gas pressure is
generated by the decomposition of the fluorocarbon.

The exact composition of the mixture is proprietary and

not available for public disclosure. However, the bulk of the
mixture can be reviewed. The reaction taking place1:

4 A + Fe203 4Fe + A1203H = 205kcal / mol 1 .

This reaction is self sustaining and produces products that
raise the temperature to approximately 2600C. However,
there is no gaseous products being produced.
To produce internal gas pressure in the torch body, to expel
the reaction products, polytetrafluoren (Teflon) is added to the
mixture. This polymer dissociates at temperatures above
450C, producing gaseous products according to the reaction;

450oC
700oC
C 2 F 4)n gas (CF 3) 2C = CF 2
CF 3CF = CFCF 3
CF 3CF = CF 2
This decomposition occurs during the thermite reaction and
creates the necessary internal pressure to eject the molten iron
The ignitor initiates thedeflagration system. A temperature
(or heat-flux) boundary first encounters the isothermal surface
of the thermite mixture. When the heat generated raises the
temperature of the aluminum to 660C the phase change
(partial reaction) begins. The phase change is the breakdown
of the thermite mixture as the melting aluminum ignites the
iron oxide. Total reaction (liquid state) finally follows as the
aluminum and iron oxide mixture is converted to iron and
aluminum oxide.
If the heat-flux boundary produces heat faster than heat is
dispatched, the temperature of the solid material rises. The
temperature rises increases the reaction rate, which in turn,
increases the rate of heat generation. The process is
accelerated until total reaction occurs or is slowed down by
the decrease in available reactants.
Figure 1 shows the stages of the deflagrating system.
Figure 2 shows the temperature versus time relationship for
the exothermic reaction of the radial torch.
Discussion - Molten Metal Jet
The igniter initiates a deflagration reaction, between the
aluminum and iron oxide, that is exothermic. This reaction
will take place without external support of oxygen. The only
requirement for initiation of the reaction is that a portion of the
loose powder mixture reached the melting point of aluminum
(660C). Once the aluminum has ignited a phase change
establishes a self-propagating thermochemical reaction. The
temperature of the molten products cause the Teflon powder in
the mixture to decompose. The resultant gaseous product
expands, forcing the molten metals through a nozzle. These
molten metals then form a high velocity liquid jet, traveling in
the order of 200-250 meters/second.

SPE/IADC 52824

PYRO TECHNOLOGY FOR CUTTING DRILL PIPE AND BOTTOMHOLE ASSEMBLIES

When the liquid jet strikes the metallic target at high

velocities, shock waves are introduced into the target and the
stresses generated by the impact may be above the yield
strength of the metallic target. The jet forces itself into the
target, replacing the target material from the region of impact.
At the interface between the front of the jet and the target a
shallow crater is formed which starts to expand rapidly. The
expanding crater follows the shock wave which is attenuated
as the crater size increases. Relief waves move rapidly
towards the jet and causes both the jet and target material to be
injected backwards, in the form of small particles. The
compressive wave is reflected from the back face of the target
as an unloading tensile wave, resulting in particles of the jet
and target assuming high forward speed after penetration of
the target.
The maximum pressure generated during normal impact of
a steady, compressible jet against a rigid surface is given by7;
P=v

(P 0C 0 )(PsCs)
P 0C 0 + PsCs

with v as the impact velocity, P0 as the initial density of the

liquid jet, Ps as the density of the target, C0 as the sound
velocity of the liquid jet and Cs as the sound velocity of the
target. The pressure, P, is applied over the area of contact at
the instant of impact.
In the interaction between the liquid jet and ductile targets
such as steel, nickel and chrome, one is concerned more with
the plastic flow under the action of stresses setup by the
impact. It is expected that plastic flow will occur first on the
central axis, but slightly below the surface of the target7. As
the stress builds, full plastic yielding develops and plastic flow
follows. Theoretical calculations based on the strain energy
yield criterion, indicates that the impact pressure at the
contact point must be greater than 5/3 of the elastic limit of the
target material in order to initiate plastic flow8.
The impingement of the liquid jet erodes the metal target
located within a distance as far as 20cm from the nozzle. The
total time expired from initiation to target penetration is
approximately 25 milliseconds.
Discussion - Nozzle Mechanism
A nozzle is connected internally to the bottom of the torch
housing to direct the molten jet radially against the pipe to be
cut10. The operational performance of the radial torch depends
to a large extent on the nozzle material and design. Nozzle
erosion is detrimental to the tools performance because it
substantially decreased the jet velocity. This reduced jet
velocity drastically affects the crater volume and the depth of
target penetration.
Reducing the flow intensity by increasing the number of
holes in the nozzle effectively reduced the erosion of each
hole and therefore, improved the tools performance. The
deepest penetrations have been achieved with multiple hole
nozzles. The present design uses eight passageways that are
equidistant from one another around the edge10.

Selection of the material for the nozzle was critical for

preventing nozzle erosion. The use of a high density, finegrained graphite proved preferable. This provided a material,
when sufficiently compressed, that is heat resistant and
chemically neutral to the liquid metals.
The complete nozzle mechanism, consisting of a shield,
conical head, nozzle and diverter, are made of graphite
material. An external sliding sleeve is used to seal the nozzle
from the wellbore.
Figure 2(A) shows the nozzle mechanism before the
thermatic reaction is initiated. Once the reaction is initiated
and internal gas pressures are sufficient, to overcome
hydrostatic pressures, the sliding sleeve shifts downward.
Figure 2(B) shows the sleeve shifted downward exposing the
radial exit port. The conical head directs the molten liquid
into the nozzle passage ways and therefore increasing the
liquid jets velocity. As the liquid jets exit the nozzle
passageways the diverter directs the jets outward radially at a
90 angle.
Safety
It is clear that during transport to the well site, assembly,
arming and running cutting tools, the safety of the rig and its
crew must be of paramount importance. For this reason the
cutting tools must be carefully chosen to minimize handling
hazards while providing sufficient output to perform serving
operations.
Explosive materials are by nature sensitive. Explosive
detonation reactions may be initiated by shock, heat and solid
object impacts. Thermite is a combustible material and does
not provide an explosive reaction but rather an ignition
reaction. Ignition can only occur if temperatures reach the
melting point of the aluminum component of the thermite
mixture, which is 660C. The torch is classified as a
Flammable Solid UN1325 Section 4.1. This allows it to be
transported by air, sea and land.
In 1996 and again in 1998 two different operators
experienced premature ignition of the torch in a downhole
environment. In both cases the sliding sleeve was disengaged
when the tool became stuck. This caused an instantaneous
rush of well fluid into the nozzle mechanism at hydrostatic
pressures of 8,000 psi and 10,000 psi, respectively. This lead
to laboratory test to determine if pressure was in fact causing
the thermite mixture to pre-ignite. It was determined that
4,000 psi of fluid pressure instantly passing through the nozzle
passages generated sufficient temperature increases to ignite
the thermite mixture. However, the ignition took 30-60
seconds to occur allowing a portion of the mixture to become
wet.
This has a dramatic slowing of the temperature change
(heat-flux) and therefore stops the phase change. A self
propagating thermochemical reaction can not continue. The
1998 field report states that a caliper log and visual inspection
did not show any internal erosion of the pipe. Laboratory tests
supported these field observations.

SPE/IADC 52824

PYRO TECHNOLOGY FOR CUTTING DRILL PIPE AND BOTTOMHOLE ASSEMBLIES

Discussion - Field use and Efficiencies

Since its introduction into the industry approximately
2,000 tools have been run in down-hole environments. The
well fluids have included oil based drilling fluids, completion
fluids and saltwater. Fluid weights have varied from 17.5
lbs/gal. mud to 8.6 lbs/gal saltwater. Tublers have ranged in
size from 2 3/8 tubing to 5 drillpipe. Tubular material
compositions have consisted of the industry standards,
including N-80, J-55, P-110, Monel, Inconel, Hastiloy and a
variety of nickel/chrome alloys. Hydrostatic pressures have
reached 11,000 psi and minimum pressures of 1,000 psi, with
the median hydrostatic of 7,000 psi.
Since the tool is used by a variety of service companies it
is difficult to obtain a sufficient number of job data sheets.
For 1996 twenty-four job reports were obtained, 47 reports for
1997 and 136 for 1998. Not until 1998 has the tool been
regularly used internationally. North America and South
America use the vast majority of the tools. In 1996 a design
change was made to the O-ring seal on the sliding sleeve. The
design changed from a single O-ring to a double O-ring seal at
top and bottom. This new limited design experienced a 100%
failure rate. This brought the overall 1996 efficiency to 62%,
with the bulk of the tools being used by a single operator. In
1997 the tool began seeing more international use. The tools
efficiency varied from customer to customer, with a low of
33% to a high of 94%. Insufficient training can be attributed to
most of these recorded failures. The overall efficiency for
1997 was 81%. In 1998 the customer base has remained
unchanged and efficiencies are averaging from 94% - 98% for
its customers.
Though the fluid type does not have an effect on the
performance of the tool, the hydrostatic pressure is of primary
concern. As the hydrostatic pressure increases the liquid jet
temperature and velocity decrease. The molten metals needs
to sustain a temperature in the 5,000 - 6,000F range with a
velocity of 800 - 1,000 ft/sec, for an effective cut. The
original torch is rated for 4,000 psi. An extension, with more
thermite mixture, can be added for pressures between 4,000 10,000 psi. A second extension can be added for pressure
above 10,000 psi, but there are limited field reports, so
conclusions to its effectiveness at higher hydrostatics are
premature.
Conclusion
The radial torch employs employing a thermite mixture,
providing another means for separating downhole tubulars
without flaring or swelling at the cutting area (see Figure 3).
1.
2.
3.
4.

It is a non-explosive, using a non-hazardous solidsolid combustible.

It is classified as a Flammable Solid.
Operates at temperatures of 500F (limited by
igniter).
Cuts wall thickness up to 2 inches.

5.
6.
7.
8.

Not affected by wellbore fluids (filtrates).

Not affected by material composition of pipe.
Can be run through restrictions to cut larger pipe.
Design changes are underway to correct the problem
with premature disengagement of the sliding sleeve.
The sliding sleeve will eventually be replaced by a
fixed, protective sleeve. The majority of the job
failures occur because of inadequate or no training on
the tool. The three areas of training that were not
followed:
a. Spudding with the tool and causing it to become
lodged.
b. Mishandling during assembly which caused
stress cracks in the graphite nozzle assembly.
c. Not compensating for increased hydrostatic
pressure.

References
1.

Nimo and Kamp, Explosive Cutting of Struck

Drillpipe and Bottom Assemblies, 1984, SPE13003
2. R. Shivers III. And R. Domangue, Operational
Decision Making for Stuck-Pipe incidents in the Gulf
of Mexico, 1993, SPE 21998.
3. Goldschmidt, H., German Patent 96,317 (1895).
4. Spice, J. E. and Staveley L.A.K., J. Soc. Chem. Ind.
68,313-319 (1949).
5. McLain, J.H. and Hoops, M.T., The chemistry of the
Pyronol Torch, Contract No. N00174-71-C0012,NAVEODFAC, Indian Head, Mode, 1971.
6. Jones, K. Dr. and AI-Hassani, Sr. Dr., The
Application of Pyrotechnic Systems for Cutting 50D
Steel, 1987.
7. Timoshenko, S. and Goodier, J.N., Theory of
Elasticity, 1951.
8. Hill, R., The Mathematical Theory of Plasticity,
1950.
9. Robertson, M., Radial Cutting Torch, Dept. of
Energy Tech. Brief, 1994.
10. Robertson, M. Patent number 4,598,769 (USA),
1986.
Acknowledgment
The author wishes to thank Mr. Mike Robertson for his
help in obtaining field reports and the education he provided
in pyrotechnics. To Dr. William Harvey, David Betancourt
and John Loehr for reviewing the paper. To Dian Schneider
for her typing and graphs.

SPE/IADC 52824

PYRO TECHNOLOGY FOR CUTTING DRILL PIPE AND BOTTOMHOLE ASSEMBLIES

Figure 1

T
e
m
p
e
r
a
t
u
r
e

Propagation

Total Reaction
(liquid State)

Phase
Change

Heat
Flux

Isothermal
Surface

Axial Position
(exaggerated for illustration)
Figure 2

3766

3228

Plastic Flow

2690

(35% of Material)

Cutting Range
4
3

2152
Heat Up
(40% of Material)

Cooling Range
(25% Material Left in Tool)

1614
1076

538

10

15
Time (milliseconds)

20

25

Temperature (C)

Temperature (F) (000'0)

SPE/IADC 52824

PYRO TECHNOLOGY FOR CUTTING DRILL PIPE AND BOTTOMHOLE ASSEMBLIES

Figure 3

Housing
Thermite

Protective
Shield

Conical Head

Nozzle
Nozzle Sleeve
Diverter

Radial Exit
Port (Sealed)

Radial Exit
Port (Exposed)
Nozzle Sleeve
(Shifted)

Before Firing
A

Figure 4

After Firing
B