Chammas Plasma

Chammas Plasma Cutters LLC.
1
BACKGROUND AND HISTORY
Chammas Plasma Cutters LLC. 2

HOW THE CHAMMAS PLASMA CUTTER
WORKS
Thermite is a pyrotechnic composition of metal powder and metal

oxide. When ignited by heat, thermite undergoes an exothermic
reduction-oxidation (redox) reaction and can create brief bursts of
heat and high temperature in a small area.
Elemental aluminum reduces the oxide of another metal, in this

common example iron oxide, because aluminum is stronger and
more stable bonds with oxygen than iron:
Fe2O3 + 2 Al 2 Fe + Al2O3
1. A heating coil is heated by applying current from surface that

ignites the thermite cartridge, which then causes the solid thermite
pellet rods to burn.
2. The burning thermite raises the temperature and the pressure

inside the tool.
3. The mixture of hot plasma is forced through the internal orifices of

the severing head and exits the tool with intense heat and high
pressure.
4. The hot plasma (6,000 F) is directed toward the internal diameter

of the tubing and cuts it instantaneously.

CHAMMAS PLASMA CUTTER SAFETY
GUIDELINES
Chammas Plasma Cutters are safe tools when used according to the procedure. However, like
any oilfield pipe cutting device, this tool can become dangerous when safety procedures and
precautions are not followed. Assembly and disassembly procedures are outlined in this
manual and must be followed without exception.
1. It is compulsory for all personnel to be trained and certified in the safe use and handling
of the Chammas Plasma Cutters prior to running the service. Chammas’ qualified and
experienced technicians provide training for field operators through training classes
given at our training center or at a customer-preferred location
2. Always rotate stock and use older tools before the newer ones
3. Plasma Cutters should be stored in a safe and secured area
4. Plasma Cutters must be handled with care. They should never be dropped, dragged,
rolled, or slid even for a short distance. They must be securely fastened during
shipment so that they are not subjected to hard blows or jars
5. Plasma Cutters must never be transported completely assembled. The thermite
cartridge must be installed at the well site
6. Never fire or discharge the Chammas Plasma Cutter on surface for any reason
7. Never disassemble the Chammas Plasma Cutter. O-ring damage will occur making the
tool unusable
8. Do not free fall the Chammas Plasma Cutter or Perforator. Damage may occur to the
firing head assembly making the tool unusable.
9. Proper PPE must be worn during assembly and disassembly of the plasma cutter

ADVANTAGES OF THE CHAMMAS PLASMA CUTTER
(CPC) / PERFORATOR (CPP)
DOT APPROVED AS A FLAMMABLE SOLID (NON-EXPLOSIVE)
NO LICENSING FEES TO USE OUR TOOLS
RF SAFE TESTED BY FRANKLIN APPLIED PHYSICS
NO MOVING PARTS, MAKING OUR TOOL MORE RELIABLE
CAN CUT AT HIGHER HYDROSTATIC PRESSURES THAN OTHER PIPE

CUTTERS
TUBING & ANNULUS PRESSURE DON’T NEED TO BE BALANCED WHEN

USING THE SELF-ANCHORING TOOL
NO FLARE OR ENLARGEMENT DAMAGE TO THE CUT PIPE,

ELIMINATING THE NEED FOR MILLING
MINIMAL DEBRIS LEFT IN THE HOLE
UNDERSIZED CUTTERS FOR SMALL RESTRICTIONS
RELIABLE UP TO 400 F
CAN CUT ALL GRADES OF PIPE (CHROME, NICKEL, HASTELLOY,

INCONEL, STAINLESS STEEL, ETC..)
CAN CUT IN ALL FLUID TYPES AND WEIGHTS INCLUDING MUD
CUT TAILPIPE BELOW PACKER
CAN CUT CLOSE TO AN OBSTRUCTION
EASY TO SHIP ANYWHERE IN THE WORLD

OPERATING RECOMMENDATIONS
NOTE: All parts of the plasma cutter should be assembled by hand
1. All Chammas safety guidelines (page 7) must be followed before the

Chammas Plasma Cutter (CPC) is attached to the cable.
2. A safety ohmmeter/galvanometer must be used to check the continuity of the
Ignition Assembly. The heating coil requires 1.2 amps of AC or DC current to
initiate the tool. Be careful not to exceed 1.2 amps. A 500-volt firing panel is
recommended to overcome electrical resistance.
3. Make a gauge run (dummy run) to determine the smallest restriction. Always
use the recommended size Plasma Cutter / Perforator for the pipe you are
cutting.
4. It is important to centralize the Plasma Cutter on every job. However, it is
more critical to be centralized when using undersized tools and when in
highly deviated wells.
5. Make sure to know fluid level and weight as they are needed to calculate
hydrostatic pressure for selecting the proper Plasma Cutter / Perforator
length.
6. Never run the Plasma Cutter at excessive speeds. 100 ft/min is
recommended if no gauge run was made. 250 ft/min is recommended if a
gauge run was conducted.
7. Never spud with the Plasma Cutter as damage may occur to the tool.
8. When running a self-anchoring Chammas Plasma Cutter, ensure a minimum
of 2,000 psi of fluid pressure above the tool. No fluid bypass is necessary
below the cut for the tool to function.
9. When using a standard Chammas Plasma Cutter, it is necessary that there is
a fluid bypass below the cut to prevent the tool assembly from jumping up the
hole and resulting in a failed cut. The tool may be run utilizing the Chammas
Electrical Anchor, eliminating the need for a fluid bypass.
10. It is recommended that the fluid in the tubing be greater than or equal to the
fluid level of the annulus.
11. Plasma Cutter can cut tubing in compression, tension, or neutral. However,
10% over-pull over the neutral weight of the pipe is recommended during or
after the cut is attempted.

12. 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.
13. When operating on a 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 attempting the cut.
14. Add one extension to the gun tube when cutting tailpipe.
15. If cutting corroded pipe or plastic/ceramic coated pipe, a back-off shot must
be used to clean the pipe prior to running the plasma cutter.
16. Silicone lubricant should be applied to all O-Rings when assembling the
Chammas Plasma Cutter.
17. To prevent galling, never apply silicone to any thread.
18. When the Plasma Cutter is in the hole and you are preparing to make a cut,
precautions on the rig floor must be taken. The pipe may jump, and fluid may
be 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.
19. In rare situations, the Plasma Cutter may trap some gas pressure between
the GO Button Sub and the Ignition Assembly. Slowly unscrew the button sub
from the ignition assembly. Once the first O-ring from the button sub has
been exposed, pressure can safely escape from the tool. Note: portion of the
button sub threads will still be threaded to the ignition assembly.
20. All parts become expendable after every run except for the GO Button Sub,
Top Stabilizer w/ Tandem, Bottom Stabilizer, Top Centralizer, and Bottom
Centralizer.
21. Self-anchoring tools cannot be used when cutting in dry pipe conditions.
Standard CPCs are required in dry pipe conditions. 100 feet of dry pipe is
required below the cut. No fluid bypass is required.

1.
2.
3.
4.

Note: The thermite pellet rods are shipped in a vacuum sealed antistatic bag. Take
precaution not to cut into the actual pellet rod when removing the outer packaging.
The thermite pellet rods are shrink wrapped with a proprietary material that is not
to be removed. Removal of the film will result in negative effects of the tool’s
cutting ability.
Loading Steps:
1. Load Cutter/Perforator Assembly first by sliding pellet rods into the tool
one at a time and seat with a PVC or wooden dowel rod. Repeat process
until tool body is filled.
2. Add an extension to Cutter/Perforator Assembly if needed (always

lubricate O-rings). Load the extension by sliding pellet rod into the
extension. Repeat process if using additional extensions. Note: Always
load the extension before attaching an additional extension.

1. Clean the button sub’s internal body, threads, and o-ring grooves. Make
sure it is completely dry before assembly.
2. Place o-ring and insulating washer on the contact rod. Make sure the o-
ring is properly seated under the head of the contact rod groove.
3. Install another o-ring to the end of the button sub body, make sure it is
properly seated in the groove. Then insert the contact rod to the button sub
body.
4. Insert the rubber washer first, then insulating washer into the other end of
button sub body over the end of the contact rod.
5. Insert the flat SS washer and SS lock washer over the contact rod. Install
and tighten the SS nut firmly.
6. Put the external o-ring over the body.
7. Check the electrical resistance between the contact rod and the body with
a galvanometer/ohmmeter.

HAZARDOUS MATERIAL TABLE
THERMITE PELLET DATA

UN3178 Flammable Solids, Inorganic, n.o.s., (Thermite), 4.1, PG III
PELLET ROD SIZE NET WEIGHT

PART NUMBER
OD X LENGTH (IN) kg / lb
0875-PLT-5 0.450 X 5 0.032 (0.070)

1500-PLT-5 0.835 X 5 0.115 (0.254)
2000-PLT-5 1.200 X 5 0.240 (0.529)
2500-PLT-5 1.450 X 5 0.355 (0.783)
3000-PLT-5 1.650 X 5 0.451 (0.994)
THERMITE CARTRIDGE DATA

UN3178 Flammable Solids, Inorganic, n.o.s., (Thermite), 4.1, PG III
CARTRIDGE SIZE NET WEIGHT

PART NUMBER
OD X LENGTH (IN)
0875-5 0.50 X 2.18 0.005 (0.011)

1500-5 1.24 X 2.30 0.023 (0.051)
2000-5 1.61 X 2.30 0.023 (0.051)
3000-5 2.12 X 2.30 0.023 (0.051)
* CARTRIDGE OD IS BASED ON THE BOTTOM CAP SIZE

SDS
Date of Issue: Dec. 14, 2020
SECTION 1. IDENTIFICATION
Product Identifier: Thermite
Synonyms: Thermite Pellet(s) or Thermite Powder
Product Form: Mixture
Manufacturer: Chammas Plasma Cutters, LLC.
11320 FM 529 bldg. I
Houston TX 77041
Tel (713) 856-8777
Emergency Number: CHEMTEL 1-800-255-3924 or Int'l +01-813-248-0585, (Contract # MIS0000161)
Recommended Use: Designed to be used exclusively with Chammas Plasma Cutters for cutting/perforating
oilfield tubular downhole
SECTION 2. HAZARDS IDENTIFICATION

Mixture Classification: Flammable Solid (Category 1)
GHS Label Elements
Hazard Pictograms:
Signal Word: Danger

Hazard Statements: Fire hazard. May cause fire. Causes severe skin burns and eye damage. May cause
damage to organs through prolonged or repeated exposure.
Precautionary Statements
General: If medical advice is needed, have product container or label at hand. Keep out of reach
of children. Read label before use.
Prevention: Wear fire resistant clothing. Wear eye/face protection. Wear protective gloves. Wear
protective clothing. Keep away from heat/sparks/open flames/hot surfaces - no
smoking. Keep away from combustible materials. Use in a well-ventilated area. Wash
hands, forearms, and other exposed areas thoroughly after handling. Protect from
moisture. Store in a dry place. Store and dispose of contents/container in accordance
with the provisions of Bureau of Alcohol, Tobacco and Firearms regulations contained
in 27 CFR part 555.

SECTION 3. COMPOSITION/INFORMATION ON INGREDIENTS
COMPONENT % CAS #
Aluminum Proprietary 7429-90-5
Magnalium Proprietary 7439-95-4 / 7429-90-5
Iron Oxide Proprietary 1309-37-1
Polytetrafluoroethylene (PTFE) Proprietary 9002-84-0
SECTION 4. FIRST AID MEASURES

First Aid Measures
Eye Contact: Obtain medical attention. Flush eyes with water for several minutes. Check for and
remove contact lenses. Continue flushing with water.
Skin Contact: Obtain medical attention. Remove contaminated clothing and shoes. Wash skin with
plenty of soap and water. Wash clothing before reuse. Clean shoes before reuse.
Inhalation: When symptoms occur, go into fresh open air. Should symptoms continue, obtain
medical attention.
Ingestion: Obtain medical attention. Rinse mouth with water. Do not induce vomiting. Treat
symptomatically and supportively.
Important Symptoms
Eye Contact: May cause eye damage. Causes severe irritation.
Skin Contact: Causes irritation. Redness, pain, swelling, itching, burning.
Inhalation: Prolonged exposure may cause irritation.
Ingestion: May cause irritation, nausea, and diarrhea.

SECTION 5. FIRE FIGHTING MEASURES
Extinguishing Media
Suitable Extinguishing Media: Dry silica sand, dry chemical.
Unsuitable Extinguishing Media: Water, carbon dioxide, foam, halogenated extinguishers.
Specific Hazards: After ignition, chemical reaction cannot be halted. Material burns
vigorously. May cause fire. Material is sensitive to shock, high
pressure, friction, and temperature.
Advice for Firefighters: Exercise caution when fighting any chemical fire. Apply
extinguishing media carefully to avoid spreading the powder. Fire
fighters should wear appropriate personal protective equipment (PPE)
and self-contained breathing apparatus (SCBA).
SECTION 6. ACCIDENTAL RELEASE MEASURES

General Measures: Keep unnecessary and unprotected personnel from entering danger area.
Keep away from heat, sparks, open flames, hot surfaces. No smoking in
hazard area. Do not breathe in dust or fumes. Evacuate danger area. Avoid all
contact with skin and eyes.
Non-Emergency Personnel: Use appropriate PPE. Evacuate unnecessary personnel. Evacuate danger area.
Emergency Personnel: Use appropriate PPE. Eliminate ignition sources. Ventilate area.
Environmental Precautions: Prevent entry into sewers and public water. Avoid release to the environment.
Notify competent authorities after a spill.
Spill Containment & Cleanup: Isolate area from ignition sources. Clean up spills immediately and dispose of
waste safely. Do not absorb with combustible material. Absorb with an inert
material and place in a suitable container for waste. Use spark-proof tools.
Avoid friction and shock when transferring material.
SECTION 7. HANDLING AND STORAGE

Precautions for Safe Handling: May cause fire. Handling restricted to trained personnel only. Always keep
powder dry. Keep away from sources of ignition – no smoking. Keep away
from heat, sparks, open flames, hot surfaces. Do not breathe in dust or fumes.
Avoid all contact with skin and eyes. Wear fire resistant clothing. Do not
handle until all safety precautions have been read.
Advice on Hygiene: Handle in accordance with good industrial hygiene and safety procedures.
Eating, drinking, and smoking should be prohibited in areas where this
material is handled, stored, and processed. Wash hands thoroughly along with
any other exposed areas with soap and water before eating, drinking, and
smoking. Remove contaminated clothing before entering eating areas.
Conditions for Safe Storage: Store in accordance with local regulations. Store under dry conditions in a
well-ventilated area. Keep away from heat, sparks, open flames, hot surfaces.
Store away from extremely high or low temperatures, direct sunlight, ignition
sources. Keep original container protected sealed until ready for use.

SECTION 8. EXPOSURE CONTROLS / PERSONAL PROTECTION
No permissible exposure limits (PELs) or threshold limit values (TLVs) exist for thermite. The listing below is a
summary of elements used in the chemical mixture. Thermite will contain different combinations of the elements
and/or trace materials. The composition percentage is considered proprietary.
COMPONENT CAS # OSHA PEL ACGIH TLV

15 mg/m3 (total dust)
Aluminum 7429-90-5 5 mg/m3 (respirable fraction) 1 mg/m3
15 mg/m3 (total dust)
Magnalium 7439-95-4 / 7429-90-5 5 mg/m3 (respirable fraction)
Iron Oxide 1309-37-1 10 mg/m3 (fume) 5 mg/m3 (resp.)
Polytetrafluoroethylene (PTFE) 9002-84-0 15 mg/m3 (total dust)
Appropriate Engineering Controls: Ensure adequate ventilation. Ensure all local regulations are observed.
Product to be handled in a closed system under strictly controlled conditions.
Skin & Body Protection: Flame resistant clothing. Appropriate footwear and any additional skin
protection measures should be selected.
Hand Protection: Flame resistant gloves.
Eye Protection: Chemical safety glasses / goggles.
Respiratory Protection: Based on potential exposure or if irritation occurs, select a respirator that
meets appropriate standard. In case of inadequate ventilation, wear approved
respiratory protection.
Other Information: Do not eat, drink, or smoke when using product.
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES
Physical State: Solid

Appearance: Fine metal powder, gray, black, brown, orange, and red in color
Odor: Metallic
Specific Gravity (water =1): >1
Relative Density: Not available
Boiling Point: Not available
Freezing Point: Not available
Viscosity: Not available
Ph @ 25°C: Not available
Vapor Density: Not available
Evaporation Rate: Not available
Vapor Pressure: Not available
% Volatile: Not available
Particle Size: > 1 micron
Decomposition Temp: Not available

Solubility: Not available
SECTION 10. STABILITY & REACTIVITY DATA

Reactivity: Fire hazard.
Chemical Stability: Stable if handled properly.
Possibility of Hazardous Reactions: Hazardous polymerization will not occur.
Conditions to Avoid: Keep away from open flames, hot surfaces, and sources of ignition. Material
is sensitive to shock, high pressure, friction, and temperature.
Incompatible Materials: Acids, halogens, moisture, water, oxidizers.
Hazardous Decomposition: Hazardous decomposition will not occur if handled properly.
SECTION 11. TOXICOLOGICAL INFORMATION

Acute Effects: Not Available
Chronic Effects: Not Available
Target Organs: Not Available
ORL-RAT LD50: Not Available
Acute Health Effects
Eye Contact Symptoms: May cause eye damage. Causes severe irritation.
Skin Contact Symptoms: Causes irritation. Redness, pain, swelling, itching, burning.
Inhalation Symptoms: Prolonged exposure may cause irritation.
Ingestion Symptoms: May cause irritation, nausea and diarrhea.
Chronic Health Effects
Carcinogenicity: No known significant effects.
Mutagenicity: No known significant effects.
Teratogenicity: No known significant effects.
Developmental Effects: No known significant effects.
Fertility Effects: No known significant effects.
SECTION 12. TOXICOLOGICAL INFORMATION

Toxicity: Not Available
Persistence and Degradability: Not Available
Bioaccumulative Potential: Not Available
Mobility in Soil: Not Available
Other Information: Avoid release to the environment.

SECTION 13. DISPOSAL CONSIDERATIONS
Disposal Methods: Review and dispose of contents in accordance with international, federal,
state, and local regulations. Avoid release to the environment. Prevent
entry into sewers and public water.
SECTION 14. TRANSPORT INFORMATION

UN3178 Flammable Solids, Inorganic, n.o.s., (Thermite), 4.1, PGIII
DOT IATA
UN Number UN 3178 UN 3178
Flammable solid, inorganic, Flammable solid, inorganic,
UN Proper Shipping Name
n.o.s., (Thermite) n.o.s., (Thermite)
Transportation Hazard Class(es) 4.1 4.1
Packing Group III III
Passenger and Cargo Aircraft Allowed Allowed
Cargo Aircraft Only Allowed Allowed
SECTION 15. REGULATORY INFORMATION

US FEDERAL REGULATIONS
TSCA (Toxic Substance Control Act): Listed
CERCLA- Hazardous Substances: Not Listed
EPCRA Section 302- Extremely Hazardous Substances: Not Listed
EPCRA Section 313- Toxic Chemicals: Aluminum (fume or dust)
SECTION 16. OTHER INFORMATION

NFPA Hazard Classification: Health: 1 Flammability: 1 Reactivity: 0
HMIS Hazard Classification: Health: 1 Flammability: 1 Reactivity: 0
Disclaimer:
Chammas Plasma Cutters, Inc. believes that to the best of our knowledge, the information contained herein is
accurate in describing the product for purposes of health, safety, and environmental requirements only. However,
neither the above-named supplier, nor any of its subsidiaries, assumes any liability whatsoever for the accuracy or
completeness of the information contained herein. Final determination of suitability of any material is the sole
responsibility of the user. All material may present unknown hazards and should be used with caution. Although
certain hazards are described herein, we cannot guarantee that these are the only hazards that exist.


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Chammas Plasma Cutters LLC.

Chammas Plasma Cutters LLC. 2

Thermite is a pyrotechnic composition of metal powder and metal

Elemental aluminum reduces the oxide of another metal, in this

1. A heating coil is heated by applying current from surface that

2. The burning thermite raises the temperature and the pressure

3. The mixture of hot plasma is forced through the internal orifices of

4. The hot plasma (6,000 F) is directed toward the internal diameter

Chammas Plasma Cutters LLC. 6

Chammas Plasma Cutters LLC. 7

DOT APPROVED AS A FLAMMABLE SOLID (NON-EXPLOSIVE)

NO LICENSING FEES TO USE OUR TOOLS

RF SAFE TESTED BY FRANKLIN APPLIED PHYSICS

NO MOVING PARTS, MAKING OUR TOOL MORE RELIABLE

CAN CUT AT HIGHER HYDROSTATIC PRESSURES THAN OTHER PIPE

TUBING & ANNULUS PRESSURE DON’T NEED TO BE BALANCED WHEN

NO FLARE OR ENLARGEMENT DAMAGE TO THE CUT PIPE,

MINIMAL DEBRIS LEFT IN THE HOLE

UNDERSIZED CUTTERS FOR SMALL RESTRICTIONS

CAN CUT ALL GRADES OF PIPE (CHROME, NICKEL, HASTELLOY,

CAN CUT IN ALL FLUID TYPES AND WEIGHTS INCLUDING MUD

CUT TAILPIPE BELOW PACKER

CAN CUT CLOSE TO AN OBSTRUCTION

EASY TO SHIP ANYWHERE IN THE WORLD

Chammas Plasma Cutters LLC. 8

NOTE: All parts of the plasma cutter should be assembled by hand

1. All Chammas safety guidelines (page 7) must be followed before the

Chammas Plasma Cutters LLC. 9

Chammas Plasma Cutters LLC. 10

Chammas Plasma Cutters LLC. 50

2. Add an extension to Cutter/Perforator Assembly if needed (always

Chammas Plasma Cutters LLC. 51

Chammas Plasma Cutters LLC. 53

THERMITE PELLET DATA

PELLET ROD SIZE NET WEIGHT

0875-PLT-5 0.450 X 5 0.032 (0.070)

THERMITE CARTRIDGE DATA

CARTRIDGE SIZE NET WEIGHT

0875-5 0.50 X 2.18 0.005 (0.011)

Chammas Plasma Cutters LLC. 5

SECTION 2. HAZARDS IDENTIFICATION

Signal Word: Danger

Chammas Plasma Cutters LLC. 57

Aluminum Proprietary 7429-90-5

Magnalium Proprietary 7439-95-4 / 7429-90-5

Iron Oxide Proprietary 1309-37-1

Polytetrafluoroethylene (PTFE) Proprietary 9002-84-0

SECTION 4. FIRST AID MEASURES

Chammas Plasma Cutters LLC. 58

SECTION 6. ACCIDENTAL RELEASE MEASURES

SECTION 7. HANDLING AND STORAGE

Chammas Plasma Cutters LLC. 59

COMPONENT CAS # OSHA PEL ACGIH TLV

SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES

Physical State: Solid

Chammas Plasma Cutters LLC. 60

SECTION 10. STABILITY & REACTIVITY DATA

SECTION 11. TOXICOLOGICAL INFORMATION

SECTION 12. TOXICOLOGICAL INFORMATION

Chammas Plasma Cutters LLC. 61

SECTION 14. TRANSPORT INFORMATION

SECTION 15. REGULATORY INFORMATION

SECTION 16. OTHER INFORMATION