In wireline, it’s never just the big failures that cause the most damage. Sometimes it’s the small, overlooked steps that turn into a complete operational shutdown. One of the most memorable experiences I had as a wireline engineer came during what was supposed to be a routine pump down perforating job. Everything looked good: the wireline truck was prepped, the downhole tools were assembled, and the client was ready. We were performing a standard cased hole logging service, and the crew was confident.
But just before we started running in hole, we discovered a critical issue: the grease pump was leaking. And not just a minor leak. The packing had failed completely. What followed was a harsh reminder that proper maintenance of surface equipment, particularly the 10K grease pump and its packing, is just as critical to wireline logging success as the condition of the logging cable or the integrity of the perforating gun.
When Grease Goes Wrong
The issue stemmed from a simple but devastating mistake: the previous crew had allowed the grease tank to run low and dry stroked the pump. A couple of dry strokes may not seem like a big deal, but in this case, it was enough to destroy the pump’s packing. The damage wasn’t noticed immediately, but over time, as other crews continued to operate with the already compromised packing, the failure escalated.
When we arrived, it only took a few more strokes to completely wipe out the seals. We now had a grease pump that couldn’t hold pressure and was leaking from the weep hole in the shaft housing. The timing couldn’t have been worse. We were preparing for a critical wireline and perforating run. Everything had to be airtight. The well integrity depended on it. The grease head is the front line of your wireline pressure control equipment. Without it working properly, we couldn’t proceed safely.
In oil field wireline operations, downtime is costly. A failed 10K grease pump can halt a plug and perf job, delay formation evaluation, disrupt cased hole well services, and force a reschedule of the entire crew and frac operation. It’s not just an inconvenience—it’s a logistical and financial nightmare for both the wireline company and the client.
The Cost of Neglect
This wasn’t the first time I had seen a grease pump issue, but it was by far the worst. The failure was traced back to neglect over multiple shifts. Dry stroking had worn out the packing so badly that it began to leak within seconds of each stroke. We had to shut down immediately.
The cost? $5,600 for a replacement pump, not including labor, lost time, or the ripple effects on other operations.
And the lesson? Never let the grease tank run dry. Never.
From then on, our crews adopted strict new protocols:
- Check grease levels after every run, not just at the start of shift
- Wrap the grease tank with glycol hoses in cold conditions to maintain flow
- Train every operator on the risks of dry stroking and how to monitor the pump
- Include grease system checks in the wireline control systems checklist
These best practices became part of our complete wireline solutions and were integrated into our internal wireline courses for new hires and veteran techs alike.
Understanding the Grease Pump System
For those newer to the wireline services oil and gas sector, here’s a brief overview of why this system is so critical.
The grease injection system is part of the pressure control equipment used to safely seal around the wireline cable during operations. When performing tasks like wireline perforating, well perforation, production logging, or cement bond logging (CBL log), the grease head keeps pressure from escaping at surface.
If grease flow is interrupted or the system fails, you risk losing control of the well. In the worst cases, that can mean exposure to high-pressure gas, tool blowouts, or catastrophic equipment damage. That’s why the health of your grease pump isn’t just a mechanical concern—it’s a well integrity and safety issue.
A properly functioning 10K grease pump ensures that the wireline truck can operate safely under pressure. Whether you’re doing a pipe caliper tool run, formation evaluation, or pump down perforating with wireline perforating guns, a reliable grease system keeps the operation sealed and the personnel protected.
Grease System Failures Across Wireline Services
Since that incident, I’ve been on jobs across every part of the wireline services market—from basic wireline logging to advanced horizontal wireline operations—and I’ve seen the same problem repeated in different forms:
- Leaking grease heads due to worn packings
- Grease pumps seized due to dried lubricant in winter
- Surging and pressure fluctuations caused by poor grease flow
- Misfired guns during wireline and perforating jobs due to sudden pressure loss
All of these failures come back to the same core issue: neglect or lack of awareness.
This is why grease pump operation and maintenance now have their own module in our internal training. My wireline courses don’t just cover the sexy stuff like firing systems and wireline tools—they cover the quiet killers like dry stroking, misaligned grease heads, and unmonitored weep holes.
A Checklist for Grease System Reliability
If you’re managing a crew or trying to build a better wireline company, here’s the checklist I recommend:
- Daily Inspection:
- Check grease tank level
- Inspect weep holes for leaks
- Verify glycol circulation in cold weather
- After Every Run:
- Top off grease tank
- Look for pressure fluctuations
- Confirm no dry strokes occurred
- Weekly Maintenance:
- Check packing wear and replace if needed
- Inspect shaft housing and clean grease lines
- Perform dry stroke simulation with tank filled
- Before Mobilizing to Site:
- Op check full wireline pressure control system
- Confirm 10K grease pump output
- Perform systems test with simulated pressure
Integrating this into your wireline services SOP ensures consistency whether you’re servicing perforation wells, performing pipe recovery, running a caliper log, or logging cement bonds.
Final Thoughts
As a wireline engineer, I’ve made it a priority to turn every near-miss into a lesson. That grease pump failure could have cost us a toolstring, a job, or worse. But it became the foundation for improving how we train, prepare, and operate.
In this business, it’s not just about knowing what is wireline in oil and gas—it’s about knowing how to keep every part of the system running, from the firing head downhole to the grease pump on the truck.
To anyone working in the wireline services oil and gas space, especially those newer to the industry: don’t overlook the small systems. Dry stroking a grease pump may seem like a minor slip, but in wireline, the smallest mistake can carry the heaviest cost.