Maximizing Wireline Cable Life Through Proper Care and Use

Posted on by Crissa Fel Tawadan

Wireline cables are one of the most critical and costly components in wireline operations. Proper care and maintenance not only extend the lifespan of cables but also prevent service failures that can lead to costly downtime. Implementing best practices from installation to operation ensures safety, reliability, and long-term performance.

Proper Cable Installation for Longevity

Cable longevity starts at installation. Following recommended tensioning procedures prevents premature failure and ensures proper seasoning of the cable.

  • Spooling Tension Guidelines:
    • Cables should be installed under the correct tension as per manufacturer recommendations. For example, a 3/8” cable should have a first-layer tension of 1,900 lbs., increasing to 5,000 lbs. by the third layer.
    • The third-layer tension should be maintained until the midpoint, then gradually reduced every 1,000 feet until minimum tension is reached.

Seasoning a New Cable

New cables undergo changes in length, diameter, and torque when first used. The goal of seasoning is to stabilize the cable for wellsite conditions, preventing long-term structural issues.

  • Seasoning Best Practices:
    • Run the cable at 250-300 feet per minute (FPM) during its first 20 trips in and out of the well.
    • Allow the cable to rotate freely to avoid torque buildup, which can cause loose outer armor, loss of tensile strength, and insulator damage.
    • Monitor for permanent stretch, armor layer seating, and wellbore fluid accumulation.

Pressure Control Equipment Considerations

Improper use of pressure control equipment can significantly shorten cable life.

  • Avoid Forced Rotation: Grease heads and hydraulic packoffs can cause excessive rotation, leading to armor separation.
  • Packoff Usage: Never use new packoff rubbers on new cables. Packoffs should only be used while moving uphole and should add no more than 50-100 lbs. of additional tension.

Sheave Wheel Selection and Maintenance

Incorrect sheave sizes contribute to premature cable wear and breaking strength reduction.

  • Recommended Sheave Diameters:
    • 3/16” cable – 12-inch sheave
    • 5/16” cable – 17-inch sheave
    • 7/16” cable – 23-inch sheave
    • Slammer cables – 26-inch sheave
  • Sheave Groove Requirements: The groove should support at least 120 degrees of the cable diameter.
  • Routine Maintenance: Regularly grease sheave wheels and ensure they are in proper working condition.

Lubrication for Increased Cable Lifespan

  • A high-quality cable lubricant should be applied during use to reduce wear caused by metal-to-metal contact.
  • Lubricants should contain inhibitors to protect against H₂S, CO₂, and acidic exposure.
  • Apply lubricant at least during the final run of a well.
  • Cables stored for extended periods should be lubricated before storage to prevent corrosion.

Fleet Angle and Horizontal Well Considerations

Fleet angle—the angle at which the cable enters the sheave—affects cable wear. Keeping the angle between 1.5 to 2 degrees reduces wear and extends cable life.

  • Unit Positioning: Spot the wireline unit at the optimal distance from the wellhead to minimize fleet angle stress.
  • Horizontal Well Operations:
    • Run at slow speeds to allow the cable to release torque.
    • Ensure the cable has time to unwind in the vertical section before fully pulling out of the well.
    • After 40 pump-down runs, send the cable for servicing to tighten armor layers.
    • If the cable rotates more than two turns in 100 feet between the bottom sheave and drum, tightening is required.

Cable Over-Tensioning Precautions

If a cable is subjected to over 60% of its breaking strength, it must be inspected by a qualified cable shop to ensure no mechanical damage has occurred.

Final Thoughts

By following these best practices, wireline service providers can extend cable life, reduce maintenance costs, and minimize the risk of unexpected failures. Proper installation, seasoning, lubrication, and regular inspections all contribute to maintaining the highest standards of safety and efficiency in wireline operations. Investing in cable care today means fewer service interruptions and a stronger bottom line for tomorrow.