Surface Service Equipment

When a wireline crew and the wireline equipment arrive at a well location to perform wireline
service, there are numerous pieces of equipment that must be assembled before wireline
operations begin. A typical wireline rigup is illustrated in Figure 1 .
Figure 1
First, the connection on the wellhead must be adapted to the connections used on the lubricator.
This is accomplished by screwing a tree connection into the tree, or in some cases by flanging to
the tree an adapter that will accept the connection on the lubricator assembly.
The lubricator must be assembled, and both It and the wireline valve must be lifted and placed on
top of the wellhead. This can be accomplished with a crane, a mast truc, an A!frame, or some
other type of winch assembly. If none of these devices is available or practical, a gin pole must
then be used to lift the lubricator stac onto the wellhead. The gin pole usually consists of three
eight!foot sections of telescoping pipe. The gin pole must be chained to the wellhead in a vertical
position and secured to the tree. "ope falls #bloc and tacle$ are hooed to the top section of the
gin pole. The gin pole must be manually e%tended to its full height #about &' feet$ by scoping
each section and pinning it to the ne%t section through aligning holes.
With the gin pole in position, the wireline valve may be lifted and placed in position on top of the
tree connection where it is (made up( to the tree connection. In a situation that requires the well
to be closed at the surface while wireline is in the well, the wireline valve may be closed without
damaging the wireline. The lubricator sections are laid out and assembled ne%t to the wellhead.
The tool string is assembled and slid into the top of the lubricator, leaving about 1 ft #'.) m$
sticing out of the top of the lubricator. The wireline is threaded through the stuffing bo% and
attached to the wireline socet by tying a not in the wireline. The wireline socet is screwed onto
the tool string and the completed tool string is pushed completely into the lubricator. *ow the
stuffing bo% can be attached to the top of the lubricator sections to complete the lubricator
assembly. The stuffing bo% seals off around the wireline to contain the well pressure in the
lubricator stac.
+efore the lubricator can be lifted into position on the well!head, the tool string must be secured in
the lubricator so it cannot fall out while the lubricator is being lifted. The wire is clamped to the
lubricator with a wireline clamp #also called a Chicago clamp). *e%t, the lubricator is lifted into
position above the wellhead with the rope falls. A sheave is attached to the tree and the wireline
is threaded through this sheave. The slac left in the wireline is reeled onto the reel of the wireline
unit and the clamp is removed from the wire. The tool string may now be lowered out of the open
lower end of the lubricator and the proper tool attached to the bottom of the tool string. After
attaching the proper tool, the depth indicator is ,eroed with the tool level with the tubing hanger.
The tool string is then pulled up into the lubricator and the lubricator attached to the wireline
valve.
+efore opening the valve on the tree to begin wireline operations, the entire lubricator stac
should be tested. If an e%ternal pressure source is available, the stac may be tested from that
source. If not, the stac is normally tested as follows- First, the crown valve of the well is slowly
opened and well pressure is allowed to enter the lubricator stac gradually. The person opening
the valve should observe the lubricator stac for leas. If no leas are detected, the valve may be
opened fully. *e%t, the wireline valve is closed. .nce the wireline valve has been closed, the
pressure is bled from the lubricator above the wireline valve. It no leas are detected, the needle
valve on the lubricator is closed and pressure is equali,ed across the wireline valve. This is
accomplished by opening the equali,ing valve built into the wireline valve for this purpose. .nce
the pressure has been equali,ed, the rams of the wireline valve are opened fully, the equali,ing
valve is closed, and wireline operations may begin.
If any lea is detected during the test procedure, wireline operations should not be begun until the
source of the lea is identified and corrected.
Wirelines
Wirelines are available in a variety of si,es and materials. Wireline si,es are commonly stated in
inches in diameter. The most common wire si,es are .'/&, .'0&, .1'1, 1'/, and .1&1. The
diameter of the wireline relates directly to its minimum breaing strength2 the larger the wire si,e,
the greater the strength of the wireline.
The other factor that affects the strength of the wireline is the type of material of which it is
constructed. The most common material from which wireline is made is improved plow steel, a
type of carbon steel. This is also sometimes called bright line. Although the strength of wireline
varies somewhat from manufacturer to manufacturer, the appro%imate minimum breaing
strengths of the various si,es of plow steel line are shown in Figure 1 .
Figure 1
These strengths are the published minimum breaing strengths of the wireline when new from the
manufacturer. 3owever, there are other factors that affect the strength of the wireline. Wireline
must mae a number of bends as it comes off the reel and is run into the well. This bending of the
wireline tends to cause the wireline to become wor hardened over time, so wire that has been
wored is not as strong as wire that is new. Also the well environment has some effect on the
strength of the wire. 4alt water and hydrogen sulfide are particularly damaging. At any point in
time, it is impossible to now the e%act condition of the wireline or e%actly what the line is capable
of pulling. 5ost wireline specialists try to stay well below the published breaing strengths of
wireline when pulling on the wire. As a rule of thumb, /'6 of the minimum breaing strength is
generally considered as the ma%imum woring strength of the wireline. +ut even that safety factor
is no guarantee that the wireline will not brea at a lower pull. Wireline, lie a chain, is only as
strong as its weaest point.
"esearch in this area has focused on developing wirelines that are more resistant to corrosive
fluids. 4tainless and alloy wirelines are now available for use in hostile subsurface environments.
These wirelines are resistant to 3&4 and corrosive fluids, but have a lower breaing strength than
improved plow steel #16 to l16, depending on diameter$ . Improved plow steel may be used with
a chemical inhibitor when high loads must be pulled for a short time in a hostile environment.
5ultistrand #braided$ wireline is used for 7obs requiring very high pulling forces. The most
common )819!in. #'.:;9!cm$ cable is made up of seven inner wires and nine thicer outer wires.
The breaing strength is 1'9& lb #&&,1'' *$, four times the strength of '.'/& single!strand
wireline. <yform cable, a product of +ritish "opes, has a single!strand core surrounded by nine
inner wires, overlain by nine thicer, beveled outer wires. This cable has a breaing strength of
9)'' lb #&/,''' *$.
Reel Systems (Wireline Units)
Wireline units come in a variety of types and si,es and are available from many manufacturers.
They may be mounted on trucs or trailers for land locations, boats for inland waters and shallow
offshore locations, or may be self!contained, compact units for use offshore # Figure 1 and
Figure & $.
Figure 1
4ome may weigh several thousand pounds and require cranes to move them about, whereas
some may be small and lightweight enough for transport by helicopter to offshore or e%tremely
remote locations.
Figure 2
3owever, they are all designed for one purpose- to allow the tools and wireline to be lowered into
and to be retrieved from the wellbore. This is an oversimplification, but basically that is all a
wireline unit does.
The reel systems used on wireline units must have a power supply, which may be a diesel or
gasoline engine, or an electric motor. "egardless of what type of power supply is used, it always
performs the same function in the wireline unit- the power supply provides the torque that either
runs the wireline reel directly through a transmission or runs a hydraulic pump. The pump
supplies hydraulic fluid under pressure to a hydraulic motor on the reel system, which in turn
provides the torque necessary to turn the wireline reel. 4ince most modern wire!line units use
these hydraulically operated reel systems, a quic loo at a typical system is in order.
Figure ) shows a schematic for a typical hydraulic system.
Figure 3
The hydraulic fluid is supplied to the pump from the hydraulic tan. From the pump, the fluid is
pumped through a line to a system relief valve. This valve is set to the ma%imum operating
pressure of the system and acts as a system safety valve. The return line from the relief valve ties
bac into the main return line for the system.
Immediately downstream of the relief valve on the pump output line, another smaller line tees off
and runs to an adjustable bypass valve #a two!way valve$. This valve is mounted on the control
panel of the wireline unit. +y ad7usting this valve, the wireline specialist can control the speed of
the reel and also the amount of pull the reel can put on the wireline. When the bypass is closed,
all the hydraulic fluid is allowed to go to the hydraulic motor for ma%imum speed and pull. When
open, almost all the fluid is bypassed to the return line of the hydraulic system. A hydraulic
pressure gauge is mounted on the panel of the wireline unit so the specialist can see how much
pressure is being delivered to the hydraulic motor to turn the reel.
The handle that controls a four-way valve is also mounted on the control panel of the wireline
unit. This valve is used by the wireline specialist to control the direction that the reel turns. When
the control handle is in the center position, both lines going to the hydraulic motor are closed and
the valve leading to the return line is open. This delivers no hydraulic fluid to the motor and the
reel does not move in either direction. When the handle is pulled bac toward the operator of the
wireline unit, the return line is closed and the line to the motor is opened, causing the reel to turn
toward the operator. This action reels the wireline onto the reel, retrieving the wire and tools from
the well. When the handle is pushed forward, the other valve outlet is opened, which delivers the
hydraulic fluid to the motor in the opposite direction. This causes the reel to turn away from the
operator, dispensing wire off the reel to lower the tools into the wellbore. The result is that the
four!way valve gives the wireline specialist total control of the direction in which the reel is
allowed to turn.
The remainder of the system is less important from a basic functional standpoint. The return line
carries the circulated hydraulic fluid bac to the tan through a filter. There may also be a heat
e%changer, which eeps the hydraulic fluid cool to prevent fluid breadown. .n any hydraulically
operated system, the location of the valves might be slightly different but the operating principle
will be the same. This system gives the wireline specialist the precise control needed to perform
sensitive wireline operations.
There are a few other devices that are normally considered to be part of a wireline unit but that
really have nothing to do with the reel system itself. These devices provide the wire!line specialist
with information about what the tools are doing in the well.
Depth Measuring Devices
The conventional depth measuring device used on the wireline unit is the counter wheel
connected to a =eeder!"oot counter, which measures the wireline as it is run in the wellbore.
This allows the wireline specialist to read the measured depth of the tools attached to the end of
the wireline simply by reading the depth registering on the on the counter. 4ince there are two
separate parts of this device #the counter wheel assembly and the =eeder!"oot counter$ , each
shall be discussed separately.
Immediately after leaving the wireline reel the wireline is looped around the counter wheel. The
wireline wraps completely around the counter wheel, which means that it must mae a complete
loop at this point. This is significant because this is the only location where the wireline must
mae such a bend. +ecause of the fatiguing effect such a bend has on the wire!line, this is the
most common place for the wireline to brea when pulling heavy loads on the wire or woring the
wire continuously in the well at the same depth. The counter wheel is precision machined so that
when the wireline is wrapped around it, the circumference of the circle measured to the center of
the wireline is e%actly two feet. #This dimension is different for metric counters and counters made
for large!diameter wire!lines. +e sure to chec the counter to determine whether measurement is
in feet or meters.$ This is important to remember for two reasons. First, if the counter wheel
becomes worn, then the counter will not measure to the center of the wireline and the wireline
measurements read on the counter will be in error. At greater depths this error can be significant.
This may not be critical when doing most wireline operations, but it can become important when
performing operations that require the best possible accuracy, such as bottomhole pressure
surveys in very deep wells, or tubing caliper surveys. In such situations, a depth inaccuracy could
result in misleading data.
The second Important point about the counter wheel is that because the counter wheel must
measure to the center of the wire, wherever the si,e of wire is changed on the wireline reel, the
counter must also be changed to match the wire. There are counter wheels machined for each
si,e of wire. >are should be taen to ensure that the correct wheel has been installed for the line
si,e in use.
In addition to the counter wheel, there are two pressure wheels on the counter assembly. .ne is
mounted above the counter wheel and one below. These pressure wheels eep the wire in place
around the counter wheel and minimi,e slippage of the wire, which could lead to inaccurate
measurements. They also serve to balance the force e%erted on the bearing of the counter wheel
when e%cessive strains are being pulled on the wireline.
The =eeder!"oot counter is attached to the shaft of the counter wheel either directly or via a
cable that is quite similar to an automobile speedometer cable. #The counter itself is similar to the
odometer of an automobile.$ It is typically geared so that each revolution of the counter wheel
counts off two feet on the counter #also available in ) and : ft circumference2 metric wheels and
counters measure meters.$ The counter has a ey that allows the wireline specialist to ,ero the
counter before lowering the tools in the well. This is normally done with the tools suspended
within the lubricator and the bottom of the tool string even with the tubing hanger of the well. This
means that wireline measurements read directly from the counter will only correspond to pipe
measurements if the elevation from the tubing hanger to the rig floor is added to the wireline
measurement. If a tubing hanger is not in place, the bottom flange, rotary table, or drill floor is
used as a point of reference.
Weight Indicators
The weight indicator tells the wire!line specialist the (weight,( or tensorial force, being pulled on
the wireline. This information is used in many ways by the specialist to now what is happening to
the tools in the well.
This weight indicator consists of a load cell # Figure 1 and Figure & $,
Figure 1
which is secured to the wellhead or some other equally secure location as close as possible to
the tree.
Figure 2
A sheave called a hay pulley is attached to the other end of the load cell. The wireline from the
wireline unit is strung through the hay pulley and continues up the side of the lubricator to the
sheave on the stuffing bo% and on through the stuffing bo% to the wireline socet of the tool string.
Inside the load cell is a fluid!filled diaphragm that communicates through a port on the side of the
load cell with a high!pressure hydraulic hose. When a load is placed on the wireline, the fluid
inside the diaphragm of the load cell is compressed and the fluid is pressuri,ed. The hose, which
is also filled with fluid, transmits the pressure to a gauge which is usually mounted on the panel of
the wireline unit. The gauge consists of a bourdon tube attached to a needle. This gauge
functions as a pressure gauge. When the pressuri,ed fluid is forced into the bourdon tube of the
gauge, it causes the needle to deflect on a dial face, which gives the specialist a reading of the
weight being pulled on the wireline.
?lectronic weight indicators, which offer greater accuracy and precision than mechanical
indicators, are also available. They are generally not as durable, however, and are more difficult
to repair on site.
u!ricators and Stuffing "o#es
In order to perform wireline operations on a well, it is necessary to be able to gain access to the
wellbore and contain the well pressure while the tools are being run in the wellbore. This is the
function of the lubricator sections and the stuffing bo%.
Lubricators
@ubricator sections come in a variety of si,es and pressure ratings. The si,es of lubricators range
from &!in. #1!cm$ sections to ;!in. #1/!cm$ sections. The si,e of the sections used on a given well
is determined by the si,e of the equipment being run in the well and the si,e of the tool string
being used. The tool string must have enough clearance to move freely in and out of the
lubricator. The lubricator must also have a large enough I< to permit the communication of well
pressure around the tools when the valve on the tree is opened. If the clearance is too small, the
pressure entering the lubricator pushes the tools up against the stuffing bo% at the top of the
sections. If this happens, the wireline could be damaged or broen, resulting in a fishing 7ob.
@ubricator sections are about / ft long for ease of handling and transportation. The lower
lubricator section is normally larger than the upper sections to allow space for the larger diameter
equipment that will be attached below the operating tool string. The lower sections of lubricator
must have ports for valves to allow the pressure to be released from the lubricator when the
lubricator stac is to be lifted off the wellhead. This valve port is often used to monitor the well
pressure with a gauge while wireline operations are taing place. The number of lubricator
sections needed is determined by the length of the tool string being run into the well and by the
operation to be performed in the well. The length of the tool string includes the e%tended 7ars, plus
the length of the devices attached or to be retrieved.
@ubricator sections come with pressure ratings of 1''' psi, 1',''' psi, 11,''' psi, and &','''
psi #):.1, 90, 1').1, and 1)/ 5Aa$. @ubricators also are rated for sweet or sour #hydrogen
sulfide$ service. 4pecial lubricator sections are also needed for sub,ero arctic conditions. The
proper pressure rating and service rating must be matched to the well pressure and environment
for safe operation.
Quick Union Connections
The lubricator, stuffing bo%, and wireline valve normally have uick union connections for ease of
assembly. The quic unions are either threaded or welded #in high!pressure lubricators$ onto the
proper si,e pipe to >onstruct a lubricator section, or onto the body of the wire!line valve to adapt
it to the lubricator and tree connection. The stuffing bo% also has a quic union pin and collar for
attaching it to the top section of lubricator. The quic union has three parts- the bo%, the pin, and
the collar. Figure 1 shows the three parts of the quic union assembled as they would be in a
lubricator stac on the well.
Figure 1
There are two basic quic union designs- the .tis and the +owen. The .tis union has a nurled
collar, whereas the +owen has holes for a special spanning wrench. Their internal angles also
differ slightly. To assemble the quic union, the pin with the '!ring seal is slipped into the bo% end
of the quic union until the shoulder of the pin rests against the top of the bo%. Then the collar is
slid down over the pin and threaded onto the bo% end of the quic union. The connection is
designed to be (made up( by hand and should not be tightened with a wrench or hammered
upon. The collar is fully threaded onto the bo% when all threads of the bo% are covered. The collar
is then (baced off( about 18: turn to prevent the collar from sticing and maing removal difficult.
When the pressure is admitted into the lubricator stac, the seal on the pin is forced against the
wall of the bo%, preventing the pressure from escaping. #When stabbing the pin into the wireline
valve, care should be taen to avoid damaging this seal.$ Although the pressure tends to push the
bo% and pin ends apart, the collar threaded onto the bo% prevents the bo% and pin from
separating. The spreading action locs the collar so that as long as there is pressure in the
lubricator stac sufficient to eep the collar loced, the collar cannot be unthreaded from the bo%.
For safety reasons, the collar should never be hammered upon and a wrench should never be put
on the collar if it does not unthread easily. An inspection should be made to be certain that there
is no pressure still trapped inside the lubricator before any further attempt is made to remove the
collar of the quic union.
!tuffing "o#
The stuffing bo% seals around the wireline and allows the tools to be run into the well with no loss
of well fluids. The body of the stuffing bo% has a quic union pin machined on the lower end for
attaching it to the lubricator # Figure & $.
Figure 2
.ver the body is mounted a sheave staff that has bearings mounted between the body and the
staff to allow the staff to swivel around the body. This eeps the sheave mounted to the staff in
line with the hay pulley so the wireline tracs around the sheaves in a straight line on its way to
the stuffing bo%. Inside the stuffing bo%, the pacing is held in place by two glands, one below the
pacing and one above. The gland below the pacing is threaded into the body of the stuffing bo%
and fi%ed. The gland above the pacing is held in place by the pacing nut. The pacing nut is
ad7ustable so that the pacing can be compressed to e%pand it against the wire as the pacing
becomes worn by the wire. The glands also serve to guide the wire through the pacing to
prevent e%cessive wearing of the pacing. The pacing segments are small cylindrical pieces of
rubber or some other elastomer with a hole through the middle. The required number of pacing
segments varies, but is normally about seven. Immediately below the lower gland is a plunger,
which is also made of resilient material. This plunger is held in place by a plunger stop, which is
threaded onto the lower end of the stuffing bo%. If something should happen to the pacing that
would cause a stuffing bo% to lea severely, the flow coming around the plunger pushes it against
the lower gland and seals off on the wireline. The glands, the pacing, and the plunger in a
stuffing bo% are sub7ect to severe wear from the wireline passing through them on its way into and
out of the well. They must be inspected and changed frequently to maintain the stuffing bo% in
good operating condition. 4tainless steel wirelines require glands made from a special material
#ampcoloy or bron,e$ to prevent the glands from damaging the softer stainless wireline.
Wireline $alves
The wireline valve is a very important piece of equipment for performing wireline operations.
There is always a possibility that the well may have to be shut!in while wireline is in the well. The
wireline valve allows the specialist to do this without damage to the wireline. The capability to do
this successfully is especially important when fishing broen pieces of wireline from a well under
pressure.
The wireline valve consists of a body, a set of opposing rams, ram stems, ram caps, and an
equali,ing assembly # Figure 1 $.
Figure 1
The body either has the proper quic union bo% machined on the upper end or is threaded to
accept a quic union bo%. The lower end of the body is also threaded to accept a quic union pin
and collar or some other appropriate connection to allow mounting the wireline valve to the
wellhead. The ram assemblies have rubber seals that seal around the wireline to contain the well
pressure. The rams also seal in the body of the wireline valve to prevent well pressure from
escaping around the ram when the valve is in the closed position. The rams are connected to the
ram stems, which are threaded through the ram caps. The ram caps are threaded into the body of
the wireline valve. The rams can be closed or opened by turning the ram stems. The wireline
valve is designed in such a way that when the valve is closed and pressure is released above the
rams of the valve, the well pressure trapped below the rams holds them in a closed position. To
reopen the valve, pressure must be equali,ed across the rams. This is done by opening the
equali,ing valve and allowing the pressure below the valve into the lubricator above the valve.
.nce the pressure has been equali,ed, the rams may be opened to allow the wireline and tools
to pass through the valve. The ram stems and ram caps all have seals to contain the well
pressure within the body of the wireline valve whether the rams are opened or closed.
Wireline valves are available in a variety of designs. The design described here is a manual
design that is quite commonly used. 3owever, wireline valves that are hydraulically operated are
also available. 4ome designs allow either hydraulic or manual operation. Wireline valves are
available in si,es ranging from &!in. bore to ;!in. bore and pressure ratings from 1''' psi to
&',''' psi, 7ust lie lubricators.
These valves hold pressure in one direction only. It is vitally important that the valve be installed
right!side!up to avoid problems. Wireline valves should be transported and stored with the rams
closed and the stem handles removed. "outine shop testing is necessary to ensure proper
operation.
<ual wireline valves are made primarily for use with braided line. This component has a single
valve body with two sets of rams placed one above the other. Two single valves can be installed,
one above the other, as a less convenient alternative in high!pressure situations.
In very high pressure gas wells, a third +.A may be installed. In this case, the lowest set of rams
are installed upside down to hold pressure from above.