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SLICKLINE CONNECT
Slickline Wire
Testing

The condition of a Slickline wire can be determined in one of two ways, by physical testing or through visual
checks and observations. A test on a sample of wire provides a definitive snap shot of the condition of the
wire and when this is coupled to the visual checks that the Slickline crew should be making throughout the
operation a clear indication of the condition of the wire can be established and can used as an early warning
system that the wire condition is deteriorating.

The method of determining the physical condition of a Slickline wire is to perform a test on a sample of it.
Wire testing should be done as a matter of routine, as part of the pre-job / pre campaign job preparations as
well as during operations at the well site. The wire test should be recorded on the wire history card and the
information transferred to maintenance management system to update the wire’s Quality File.

The objective of wire testing is to: -

Identify wire issues before they can lead to failures in service
Through systematic testing prolong the life of the wire as part of a comprehensive Wire
Management Program

Wire testing will not alleviate the bulk of wire failures but it remains the corner stone of a wire management
system through recognising or identifying when a wire has lost its edge a potential catastrophic failure during
well operations can be avoided.
Wire testing is used to identify potential failures which may be caused by: -
Hydrogen embrittlement of API 9A wires as the result of exposure to H2S & Co2
Age hardening, a temperature affect associated with UHT wires
Fatigue, generally associated with working wire over sheaves and through measuring devices
Corrosion and corrosion fatigue,
Stress corrosion cracking,
Tensile overload and other mechanical damage

Visual Checks and Observations

Visual checks of the wire must be made at all stages of the operation checking for the following

Wire coiling, typically IPS wires exhibit coils, but alloys do as well to a slightly lesser extent. The diameter of
the coils when the wire is laid out on the deck should correspond approximately to the diameter of the wire
on the drum, if it’s clear that the wire does not exhibiting ‘normal’ coils then it is an indication that the wire
has lost its mechanical properties. The wire must be cut back and tested until ‘good’ wire is reached.

If the wire appears ‘limp’ or ‘slack’ and lays out flat and straight and does not exhibit any spring like
characteristics. The wire must be cut back and tested until ‘good’ wire is reached.
When making the rope socket further checks and observations should be made. For instance if a wire has a
rough surface, exhibits flaking, discolouration, or changes in the surface appearance, then cut and re-test the
wire until a proper test is achieved

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Observe the wire for kinks, defects, abrasions, wasting or any surface damage, in all cases cut off a length of
wire and test, keep repeating until a good test is achieved.

Checks should always be made of the associated equipment in use in the operation. The unit measurehead,
the hay pulley, stuffing box, the wire on the winch drum, in all cases check that the equipment is operating as

designed and tension devices are in working order with bellows gaps as required, and there is no evidence of
wire damage, flakes, abrasions, distortions or material loss.

Always carefully note the amount of wire cut off and update the wire record accordingly

Wire Testing
Alloy wires – Ductility / Pull Test
API 9A Carbon Steel Wires – Torsion / Pull Test

As a rule of thumb it is good practice to test two wire samples every time

Testing Objective
In very case the wire test sample is taken from the end of the wire, testing then assumes that the complete
length of wire remaining on the drum is in the same condition. Therefore if the tested sample does not meet
the required test results a length of wire should be cut off the drum and a further wire sample taken and
tested. This should be repeated until a perfect wire test is achieved

Types of Wire Testing

Torsion test – used for IPS (Improved Plough Steel) API 9A wires. A sample length of wire is twisted along its
length and the number of twists are counted. For each wire size there is a prescribed number of torsions, the
wire manufacturers’ data sheet will provide the correct information which in turn is derived from the API
Specification for Wire Rope 9A

Torsion testing – in the all cases manufacturers publish the number of turns or torsions a Slickline wire should
achieve before failure.

Typical wire sizes, number of torsions and minimum breaking loads (lbf) are: -

Wire OD No. Torsions MBL (lbf)

0.092 23 1547
0.108 19 2109
0.125 19 2837
0.140 14 3505
0.160 11 4580

If the wire test piece does not achieve the number of turns it is has failed the test, cut back the wire on the
drum and repeat the test.

Always inspect the wire break, it should be a clean break, if it is ragged break then the wire is substandard and
should be re-tested

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Tensile Test
A sample of wire is pulled to determine the breaking strain of the wire, this type of test is suitable for both API
9A and alloy wires

Tensile testing can be used for any grade or variety of Slickline wire. This method of testing will provide a
definitive and accurate minimum breaking load (MBL) of the wire which can be compared to the
manufacturer’s data sheet.

Note: - if the test piece breaks below the manufacturer’s MBL, then the test must be rejected and wire cut off
and a new test made.

Ductility Test
Also known as a wrap testing involves wrapping a wire around a straight length of itself. Careful inspection
and evaluation of the wraps after the test will indicate if the wire condition is suitable for continued use.

Clearly if there is a failure of the wire during the test then it must be automatically rejected. There are no
absolute guidelines on the number of wraps that have to be achieved, however the rule of thumb should be a
minimum of eight.

The Sandvic Wraptor Evaluation Guide provides a comprehensive guide to the types of wire conditions and
the courses of action to take.

Pass / Fail Criteria

There is a clear rule on a pass or failure, wire is only suitable for service if it passes the test it is subjected to,
all test failures require wire to be cut from the drum and re-test performed and this will be repeated until a
successful test is achieved. If a successful test cannot be achieved then the wire must be scrapped and
replaced.

How Much Wire to Cut Off

Consider in many case that the alloy wires that are in service are expensive and often clients demand a wire is
removed from service if it falls below a defined overall length. Which means that in every case only the
minimum amount of wire should be cut off and the length of the wire cut off should be recorded in the wire
log book. The rule of thumb is cut off a minimum length (25ft) of wire and keep testing and cutting off until a
good test is achieved.

Slickline Wire Working Life

A question that has never been satisfactorily answered. If a wire is of a suitable length for an operation, does
not fail a wire test and visually shows the correct characteristics it can be considered suitable for operations.
The consequences of a wire failure are easily exceeded by the potential cost of an operational failure, which
at best will result in lost time and at worst the loss of a well.

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Suppliers of Wire Testing Equipment

Ductility & Torsion Testers NOV Elmar TorsionTester

Sandvic Wraptor
Hunting Ductility Tester
Danum Linetech Ductility Tester

Pull Testers Hunting Excro RS Tester

NOV Elmar WireTester

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SLICKLINE CONNECT
Slickline Wire
Maintenance

With the significant cost of Slickline wires, alloys and stainless steel lines every effort must be made to
prolong the life of a wire through proper handling and maintenance procedures. Maintenance for a wire
revolves around observations, inspections, testing and handling, primarily avoiding damage to the wire and
ensuring its condition is monitored and preserved.
Storage is a significant area where the conditions that a wire is stored under should be carefully monitored. A
wire’s condition can deteriorate in storage and it should be inspected and checked regularly and in some
cases spooled and re-spooled to verify its status during storage. Often high alloy wires acquired for special
operations are left in storage for long periods of time, due to their cost their condition must not be allowed to
decline.

Maintenance of wire is done before, during and after use. While on the winch for loadout/backload the wire
should be oiled or greased and covered with Densyl tape to protect it from the elements

Residual well fluids not removed from the wire at the end of an operation can impact a wire’s condition. Of
particular importance when working in ‘dry’ gas wells it is necessary to clean and oil the wire when pulling out
of the well after each run. Working in completions fluids, brine and muds with added chemicals can be a
cause of a wire’s condition to deteriorate and again the wire must
be cleaned and oiled as it comes back onto the winch drum.
Typically, a wireline wiper will be used to clean the wire. The
wireline wiper has a split rubber which is fitted around the Slickline Wireline Wiper
wire and held in place by a retractable pin. The assembly is
attached to the lower hay pulley at the start of pulling out of the
well.
Slickline wireline wiper
In addition stuffing box packing must be kept in a good working
condition and changed when required. Stuffing box packing as well as acting as a barrier for well pressure will
control and wipe off any carried well fluids
Annual wire inspections should be part of a wire maintenance process. The annual inspection should include
spooling off the wire to the top bedding layer. A sample of wire should be tested. The length of the wire can
be confirmed, the wire can be checked dimensionally and the wire can be cleaned as it is spooled off and
lubricated as it is spooled back onto the winch drum.

All maintenance events should be recorded in the wire record and the re-spooling report added to the wire
files history folder.

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