In wireline operations, precision and reliability are essential. As a wireline engineer, I’ve experienced my share of challenges, but one particular event stands out as a powerful reminder of why we must always be vigilant with our procedures and equipment. This story begins with a misrun during a pumpdown job that nearly derailed the entire operation.

The Incident: A Misrun Caused by a PSA Insert Short

It started during a routine wireline operation where we were using a PSA insert as part of a pumpdown job. Everything seemed to be running smoothly until the PSA insert began to malfunction once we started running in hole. The signal was weak, and after getting back to surface, we performed a series of tests and discovered a short in the insert. At first, we assumed it was an issue with the PSA tool itself, so we megged it (checked insulation resistance) before removing the black tape. To our surprise, the short remained.

After removing the tape, we found glue residue left behind, and the PSA insert megged perfectly with an insulation resistance of over 200 Mohms. That’s when the root cause became clear: the tape or its residue was causing the short. It was a stark reminder that even the smallest detail—like the adhesive used in electrical tape—can make a big difference in wireline operations.

What Went Wrong?

Our investigation showed that the black tape, likely of a different brand than we usually use, caused the issue. The tape’s glue residue created an electrical short, disrupting the functionality of the PSA insert. In wireline logging operations, components like the PSA insert, which is crucial for tasks like cased hole logging, well perforation, and even fishing wire line, need to be properly insulated and free from contaminants. One small misstep in the preparation of these tools can lead to costly delays and operational failures.

Moreover, this issue wasn’t limited to the PSA insert. We realized that the firing block at the top of the toolstring could also have been affected by this problem. When working with wireline perforating and wireline logging systems, every component, whether it’s a perforating gun or a wireline unit, needs to be correctly prepared, including the insulation and protection from debris.

The Lesson: Best Practices for PSA Inserts and Firing Blocks

Following the misrun, we quickly implemented new best practices to prevent this kind of failure from happening again. Here’s what we did:

1. Proper Taping of PSA Inserts and Firing Blocks:
   We now ensure that all PSA inserts and firing blocks are taped correctly. The first step is to wrap two layers of heat-resistant or glass tape for every 100°F of temperature expected downhole. This tape should cover the section where the teardrop, insulator, and body of the tool come together. Then, we add several layers of electrical tape to hold the wire securely and protect the assembly from debris or damage during the operation.

2. Routine Inspections and Megging:
   We also made it a standard practice to periodically remove the PSA insert from the sub and megging it every 5 runs. This ensures that we catch any potential issues early, preventing any shorts or malfunctions down the line. Additionally, we rebuild the entire double female-PSA assembly, including the PSA insert, every 10 runs to maintain integrity and reliability.

Prevention Modes: Minimizing Risks in Wireline Operations

One of the key takeaways from this incident is the importance of understanding your equipment and its components. Wireline operations involve various downhole tools, such as perforating guns, logging cables, and hole finders, all of which need meticulous care to ensure they perform at their best. Small details like tape and adhesives can cause big problems if not handled correctly. As part of wireline logging best practices, we’ve taken steps to ensure that this doesn’t happen again by adopting more rigorous maintenance and inspection protocols.

It’s also crucial that we stay up-to-date with the latest wireline technologies, from wireline control systems to cased hole solutions, ensuring that all our tools and equipment are operating efficiently. This incident reinforced how easy it is for small issues to turn into big failures if we’re not proactive in our inspections and procedures.

Looking Forward: Continuous Improvement in Wireline Services

At the end of the day, the goal is to ensure that every wireline service we provide is reliable, precise, and performed with the highest level of safety. Whether it’s for cased hole wireline operations, production logging, or perforating services, we understand that our success depends on the quality of our equipment, the expertise of our engineers, and the diligence we apply in maintaining both.

We’re always striving to enhance our understanding of wireline well logging, downhole pipe recovery, and perforation well services. By learning from incidents like the PSA insert short, we’re able to improve our methods, ensure the integrity of our wireline equipment, and better serve our clients in the oil and gas industry.

Wireline services, from wireline logging to well integrity checks, are fundamental to the success of oilfield operations. We continue to build on these lessons learned, refining our practices, training our team, and making sure that the next well we service is as smooth and efficient as the last.

Ultimately, our commitment to excellence in wireline technologies, tools, and services ensures that we can meet the challenges of the wireline business head-on, delivering precise, high-quality results every time.