I remember the day all too well. The sun was relentless, beating down on us as we wrapped up our cased hole logging operation. It was just another day in the oilfield, another wireline job, another run with perforating guns. We had just retrieved a shot perforating gun, and the team was preparing to break it down when something went terribly wrong.

A non-wireline crew member, eager to lend a hand, stepped in to assist with breaking down the gun assembly. Despite the best intentions, this is where things took a dangerous turn. As he began removing the port plug from the switch sub, a sudden force shot the plug out of the assembly like a bullet. In a split second, it struck him square in the face. The silence that followed was deafening.

The Hidden Danger: Trapped Pressure in Explosive Devices

This incident was a stark reminder of why only trained wireline engineers should handle explosive devices. In wireline well logging, pressure is an ever-present concern, particularly when dealing with perforation services and downhole tools. Trapped pressure in perforating guns and subs can turn a routine task into a life-threatening hazard.

The signs were there—sub connections that were difficult to unscrew, a faint hissing noise, and debris protruding from shot holes. But in the rush to finish the job, they were overlooked. The reality is that every shot gun retrieved from a well must be treated as if it contains trapped pressure, no matter how harmless it appears.

A Change in Procedure for Safer Wireline Operations

Following this incident, we made a critical shift in how we handle perforating guns. No longer do we remove port plugs first. Instead, we break the guns down at the tandem, leaving port plugs untouched until they are safely secured in a vice—facing away from any personnel. Any perforating gun suspected of having trapped pressure is immediately moved away from the work area and left to sit for two hours before rechecking.

If after two hours there are still signs of trapped pressure, management is notified for further instruction. There’s no room for guessing in wireline and perforating work. This isn’t just about following protocol; it’s about keeping every person on site safe.

Lessons for Every Wireline Engineer

Wireline service companies and oilfield service providers operate in an environment where the smallest oversight can have catastrophic consequences. Whether handling perforating guns, wireline pressure control equipment, or conducting cased hole well services, vigilance is key.

Every wireline company must ensure its engineers understand these risks. Investing in proper oilfield safety training and reinforcing best practices in handling wireline tools can prevent incidents like the one we experienced. The wireline services market is evolving, and so must our approach to safety.

At the end of the day, we work in an industry that thrives on precision—whether it’s a caliper log, a cement bond log, or production logging services. That same precision must extend to how we handle explosive devices. A split-second mistake can change lives, and in wireline services, safety is the one thing we can’t afford to compromise.

That day, we learned the hard way. But from that experience came a safer way forward.