As a wireline engineer, you never know when you’ll encounter an unexpected challenge that forces you to rethink your approach to a routine procedure. I’ve been through countless jobs, each with its own unique hurdles, but there was one incident that really opened my eyes to the importance of understanding the tools and techniques we use in wireline services. This story centers around a seemingly simple task—setting a kill plug—but what happened on that day made me realize just how crucial the right tools and practices are for the safety and efficiency of the operation.

The Incident: Trouble Setting a Kill Plug

The day began like any other. We were running a wireline job, using the gunstring to set a kill plug. We had performed similar tasks before with no issues. However, this time, something went wrong. After pumping down to the setting depth, we couldn’t set the plug. Initially, we didn’t know what the issue was, but after further inspection, we discovered that the root cause of the failure was an EBTW (Electric Wireline Tool) shorting the contact pin to the body of the switch sub. This was caused by a retainer nut that had backed off while the gunstring was still in the hole.

This was a critical moment. We had used the same live gunstring that had already been used in the hole for previous tasks to set the plug. What we hadn’t considered were the risks involved in running a live gunstring for something as simple as setting a plug. We learned the hard way that this was not only a risky practice but also one that could lead to tool failures and potentially dangerous situations.

Why Running a Live Gunstring Was a Bad Idea

There were multiple reasons why using a live gunstring to set a kill plug was a mistake:

1. Running Live Explosives: Using a live gunstring meant we were handling explosives in the well, which could be risky. If something went wrong, we could have been dealing with active explosives.

2. Fishing for Live Explosives: If the tool became stuck on the plug, we would have left live explosives in the well, which is a safety hazard.

3. Unnecessary Connections: The live gunstring introduced multiple connections that were unnecessary for simply setting a plug. These extra components increased the chances of things loosening and causing a misrun, which is exactly what happened during this operation.

As a wireline engineer, we work with many downhole tools, including perforating guns, logging cable, and hole finders. Each of these tools plays a role in operations such as wireline perforating or cased hole logging, but they need to be used properly to ensure safe and efficient operations. This incident highlighted how small mistakes, like improper tool selection, can lead to much bigger issues down the road.

The Solution: Switching to Weight Bars for Setting Kill Plugs

After realizing the issue, we decided to implement a new procedure going forward—one that would eliminate the risks associated with using a live gunstring. The solution was simple: we would use weight bars to set the kill plugs instead of the gunstring. This change would prevent the possibility of fishing for live explosives and eliminate the unnecessary movement and vibration that came with using a live gunstring.

The new toolstring for setting kill plugs became straightforward and efficient. It included the following components:

• Cablehead

• Casing Collar Locator (CCL)

• Weight Bar(s)

• Quick Change

• Firing Block & Top Sub

• Double Female Sub

• PSA Sub & Insert

• Firing Head & Setting Tool

This streamlined approach reduced unnecessary complexity, and we were able to set kill plugs with greater reliability and safety.

Best Practices for Setting Kill Plugs

Moving forward, we implemented several key best practices to ensure that setting kill plugs became a smooth, error-free process:

1. Calculate the Toolstring Weight: Before beginning, we made sure to calculate the necessary weight for the toolstring to fall properly in the well. This involved selecting the right weight bars for the job, depending on the depth and the kill plug specifications.

2. Plan Ahead: We learned the importance of planning ahead. When kill plugs need to be set, we ensured that the weight bars were on location in advance to avoid any delays. Proper preparation is essential in wireline operations to ensure the smooth flow of the job.

3. Using the Right Tools for the Job: By switching to weight bars, we minimized the risk of tool failure and eliminated the possibility of dangerous situations arising from using live explosives in the well. This was a valuable lesson in selecting the right tools and understanding their capabilities.

The Bigger Picture: Improving Wireline Operations

This incident reinforced a key principle in wireline services—tool selection and preparation matter. Whether you’re using a pipe caliper tool, wireline control systems, or perforating systems, every choice affects the outcome of the operation. In wireline well logging, cased hole services, or downhole pipe recovery, the equipment you use must be appropriate for the task at hand to avoid costly mistakes.

Furthermore, this experience underlined the importance of using modern wireline technologies, such as wireline trucks and wireline tools, to ensure the job is completed safely and efficiently. As a wireline service provider, we constantly strive to improve our methods, training, and procedures to maintain the highest standards of safety and performance.

Conclusion: Continuous Improvement in Wireline Services

This experience was a valuable learning opportunity for all of us involved. By switching from a live gunstring to weight bars, we not only improved the safety and efficiency of our operations but also reinforced the importance of proper tool management and preparation. Moving forward, we’re more committed than ever to ensuring that every wireline job is executed with the highest level of precision, utilizing the right tools for the task.

Wireline companies must continue to adapt, innovate, and refine their practices to stay ahead in the industry. From formation evaluation to well integrity, each component of a wireline operation plays a critical role in ensuring success. By focusing on the right equipment, proper procedures, and comprehensive training, wireline engineers can minimize risks and maximize the effectiveness of their work.

In the end, it’s not just about setting kill plugs—it’s about continuously improving our practices and ensuring that every wireline operation is performed with precision, safety, and the highest standards of quality.