The procedures described in this document apply only to the 2-7/8” / 3-3/8” HST™ System. This system should only be assembled by personnel trained in the safe and proper handling of explosives and explosive components. Failure to follow proper and safe explosive-handling techniques could result in severe injury and / or death.

Note: This assembly procedure references the attached assembly drawing and uses part numbers and item numbers as noted.

1. Layout, inspect, and clean all components prior to beginning assembly. Dry-fit components, where necessary, to ensure proper fit and make-up.
2. Run the 3/8” Stainless Steel Control Line (Item 9) through the Carrier (Item 4), insuring the Control Line is a minimum of 2’ longer the Carrier length.
3. Cut and trim the lower end of the Control Line, using a standard wheel-type cutter. Remove any burrs or sharp edges from the outside of the Control Line with a file. Ream the inside of the Control Line with a drill-operated countersink, or other suitable tool.
4. Install 2-O-rings #230 onto Firing Head X-Over sub (Item 2).
5. Install 1-O-ring #211 (not shown) onto Transfer Insert (qty 2) (Item 10) and then press firmly into HST Top Sub Pin X Box Transfer (Item 5) and Firing Head X-Over sub (Item 2).
   Note: All O-rings and threaded areas should be lightly lubricated prior to installation.
6. Tightly wrap Teflon tape around the threads of the Control Line Fitting (Item 7) and install tightly into the into HST Top Sub Pin X Box Transfer sub-assembly.
7. Remove threaded Swagelok cap and two-piece ferrule from the Control Line Fitting and slide onto the lower end of the Control Line. Insure ferrules are installed properly.
8. Gently slide Control Line into Control Line Fitting until control line “bottoms out” against the Transfer Insert. Mark the Control Line and then gently remove the Control Line 1 ½” from the HST Top Sub Pin X Box Transfer sub-assembly.
9. Tighten cap and ferrules onto Control Line fitting until finger-tight. Using combination wrench, tighten cap 1 ¼ turns.
10. Slide entire HST Bottom Sub sub-assembly with Control Line attached into the carrier and tighten securely.
11. .Install Set Screws (Item 12) and tighten snugly.
12. From the top-end of the Carrier, slide HST Bushing (ITEM 11) over the Control Line and position inside the Carrier at the desired position.
13. Gently slide 2” OD HST Propellant (Item J) over control line, installing desired number of HST Propellant sticks in interlocking fashion.
14. Slide second HST Bushing over Control Line and secure firmly against the top-most section of the Propellant.
    Note: Installation of Bushings and Propellant is most-easily achieved using the appropriate length of ½” threaded conduit or steel pipe, sliding over the Control Line and “pushing” the items.
15. Slide HST Top Sub Grooved Pin x Pin sub-assembly over Control Line and tighten securely into Carrier.
16. .Install Set Screws (Item 12) and tighten snugly.
17. Measure Control Line 1-¾” from the exposed end of the HST Top Sub Grooved Pin x Pin sub-assembly and cut the Control Line using a standard wheel-type cutter. Remove any burrs or sharp edges from the outside of the Control Line with a file. Ream the inside of the Control Line with a drill-operated countersink, or other suitable tool.
18. Tightly wrap Teflon tape around the threads of the Control Line Fitting (Item 9). Remove threaded Swagelok cap and two-piece ferrule from the Control Line Fitting and set them aside.
19. Slide the Control Line Fitting over the exposed end of the Control Line and Install the Control Line Fitting in the top of the HST Top Sub Grooved Pin x Pin sub assembly.
20. Slide the threaded Swagelok cap and two-piece ferrule from the Control Line Fitting onto the exposed end of the Control Line. Insure ferrules are installed properly.
21. Tighten cap and ferrules onto Control Line fitting until finger-tight. Using combination wrench, tighten cap 1 ¼ turns.
22. Working from the bottom of the Carrier assembly, insert detonating cord through HST Bottom Sub and through Control line until the detonating cord appears through the Control Line at the top of the assembly.
23. Cut detonating cord and install booster on bottom end of Carrier assembly.
24. Using great care, gently slide the detonating cord with attached booster until booster is flush or slightly recessed in HST Bottom Sub and Transfer Insert.
25. Slide 1” Crimp Tube (not shown) over the detonating cord at the top end of the Carrier until the Crimp Tube contacts the exposed Control Line. Crimp firmly in-place.
26. Measure 10” from the make-up point below the two O-rings on the HST Top Sub Grooved Pin x Pin and cut and booster the detonating cord.
27. Using great care, install HST Top Sub Box x Pin over exposed booster and secure tightly.
28. Install top and bottom thread protectors (not shown) and secure Carrier Assembly for installation.

Available only to licensees of the Propellant Technology Development Group.

Download Product Spec Sheet (PDF)