You never forget the sound of silence when you’re expecting a bang.
We were running a standard job in a cased hole wireline setting—deploying a mechanical plug using a familiar setting tool. The gear was prepped, the wireline truck humming, pressure control equipment tight, and all downhole tools configured. I had done this many times before using standard power charges. But this time, it was on a different setting tool, and I didn’t include a secondary igniter.
That oversight taught me more than any wireline course ever could.
The Misfire That Stayed Quiet
The setup was routine: wireline logging completed, logging cable performing well, pressure verified, and toolstring ready. We were in the middle of a well perforation prep sequence, aiming to set the plug prior to perforating services.
As I initiated the plug setting sequence, a brief system short was detected. No movement. No feedback. And, crucially—no plug set. I consulted with the client rep on location, explained the anomaly, and was advised to continue with the perforation run. The assumption was that maybe the plug had set despite the weak signal.
But assumptions don’t count for much in the oil field wireline world.
When we pulled back to surface, the truth was clear: the plug hadn’t set. The firing head had functioned. The primary igniter had gone off. But it didn’t have the spark strength to ignite the power charge. And since no secondary igniter had been included in the assembly, the charge never lit.
What Went Wrong—and Why It Matters
Wireline service companies know there are many types of power charges on the market. Some come with built-in ignition boosters. Others don’t. That distinction matters—a lot.
In this case, we were using a power charge without an integrated secondary. I had previously set plugs on larger setting tools without needing a secondary igniter. But this was a Baker #10, and the combustion characteristics weren’t the same. The plug stayed put. So did our schedule.
If you work in wireline well logging, especially in the context of cased hole well services, you understand that misfires are costly. Not just in time, but in well integrity, tool wear, and client trust.
A New Standard for Ignition Reliability
After that run, our procedure changed. We now mandate a secondary igniter in every power charge that doesn’t come with one pre-installed. It’s now part of our wireline control systems checklist and included in pre-job inspections.
Secondary igniters are now treated as essential in every firing head configuration—just like logging cable checks, torque specs, and pressure control verifications.
This adjustment has been shared across wireline service providers, becoming a standard practice that spans everything from eline services to pump down perforating and even plug and abandon work.
A Lesson for Wireline Techs Everywhere
This wasn’t just about one plug. It was a wake-up call for how even seasoned engineers can overlook a small but vital component. And in the world of wireline services oil and gas, it’s the small stuff that usually comes back to bite.
Whether you’re working in horizontal wireline, managing downhole pipe recovery, or performing production logging services, your downhole tools are only as effective as your ignition reliability.
Final Thought from the Field
So here’s what I tell new techs coming up through wireline courses or oil field safety training: don’t assume. Always check your charge configuration. Always verify your firing head is set up with both primary and secondary igniters when needed. In the wireline oilfield, redundancy isn’t waste—it’s insurance.
The plug that didn’t set is now the story I tell on every new hire orientation. Because I’d rather they learn from my silence—than hear it firsthand in the hole.