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Oil production · well servicing

Well servicing from wellhead dismantling to reassembly

Six linked scenarios in which a well servicing operator works through the full cycle by hand: dismantles the wellhead, pulls and runs rods and tubing, and puts the wellhead assembly back together.

Oil & gas simulator: ETA-60 elevator on the pipe rack, latching the string, making up with the power tong
Scenarios
6 scenarios, about 160 steps
Equipment
ETA-60, rod elevator, spider, power tong
Models
Key equipment modeled in-house
Status
Pilot version (2025 prototype)

Challenge

Well servicing is repetitive but dangerous work: heavy equipment overhead, rotating tongs, pressure in the well. A mistake in the sequence can lead to an injury or an accident.

New operators learn on live wells, during real servicing jobs.

Solution

We recreated the well site with a pumpjack, pipe rack and tools. Every tool is physics-driven: the ETA-60 jaws open with a trigger, the spider lever moves the linkage, the power tong turns the pipe.

Holograms show where each component goes, and on-screen text says what to do next. The steps follow the work instruction, pulling and running are practiced on two rods and one or two tubing joints, and a scenario can be replayed from the start.

Six well servicing scenarios

  1. Wellhead dismantling: hammer at a hammer union, arrows show the strike direction

    01

    Dismantling the wellhead

    20 steps. Dismantling starts only after confirming there is no pressure in the line.

    1. Close the gate valve and open the bleed valve to check for pressure
    2. Make sure no fluid comes out of the bleed valve
    3. Close the second gate valve
    4. Loosen the hammer unions with a sledgehammer
    5. Lift and rotate the wellhead assembly
    6. Fit the rod elevator and close the latch
    7. Break out the connection with rod wrenches
  2. Hands holding the sucker-rod elevator link above the rod rack, next to the hook block

    02

    Pulling rods

    Setup, then a 14-step cycle for each of the two rods.

    1. Take the rod elevator off the hook and secure it on the rod
    2. Close the latch and hang the rod elevator on the hook
    3. Break out the rod with a rod wrench
    4. Take the rod off the hook and move it away from the well center
    5. Repeat the cycle for the second rod
  3. ETA-60 tubing elevator on its links holding a joint above the wellhead

    03

    Pulling tubing

    An 18-step setup, then pulling one joint in 13 steps.

    1. Hang the ETA-60 on the hook and close the latch
    2. Grip the string with the ETA-60 elevator
    3. Set and close the spider
    4. Loosen the cross: 10 sledgehammer blows
    5. Position the power tong and break out the joint
    6. Lay the joint on the pipe rack
  4. Hydraulic power tong with a pressure gauge on the tubing, slip spider below

    04

    Running tubing

    Three parts: the first joint, the make-up cycle, landing the string.

    1. Close the ETA-60 on the joint and bring it to the wellhead
    2. Close the spider and unhook the ETA-60
    3. Make up the connection with the power tong
    4. Open the spider and lower the string
    5. Make up the wellhead, remove the spider and the ETA-60
  5. Making up a sucker rod with a rod wrench at the wellhead, with the on-screen instruction

    05

    Running rods

    Two rods: the first in 8 steps, the second in 13.

    1. Fit the rod elevator on the rod and close the latch
    2. Hang the rod elevator on the hook and bring the rod to the wellhead
    3. Make up the rod with the wrench
    4. Release the latch and take the rod elevator off the hook
  6. Wellhead assembly: the trainee screws the wellhead tee into place by hand

    06

    Reassembling the wellhead

    20 steps: reassembling the wellhead and opening the gate valves.

    1. Lift the stuffing box assembly on the rod elevator
    2. Make up the assembly with rod wrenches
    3. Install the pup joint and tighten the unions with a sledgehammer
    4. Reconnect the flowline
    5. Open the gate valve and close the bleed valve

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What you need to run it

Headset
Meta Quest 3 or 3S
Computer
PC with an RTX 4070-class graphics card: the simulator runs with the headset connected to the PC
Space
A clear area of about 2 × 2 m per station
Internet
Only for the initial headset setup
Languages
Russian; we add Kazakh and English during rollout

Results

  • All six well servicing scenarios can be completed through to the last step: about 160 steps, 114 of them operator actions.
  • During rollout, we add a log, an exam mode, and error and time tracking. In a 4–8 week pilot, we compare your group with a group that had a conventional briefing.
  • The ETA-60, rod elevator, spider and power tong models are suitable for new scenarios: workover and well completion.
Looking up at the workover rig mast and a pumpjack against the sky
Looking up at the workover rig mast and a pumpjack against the sky
Hydraulic power tong on the tubing and the spider on the wellhead
Hydraulic power tong on the tubing and the spider on the wellhead
Running tubing: the cross, highlighted in green, is brought to the wellhead
Running tubing: the cross, highlighted in green, is brought to the wellhead
Assembled wellhead with gate valves
Assembled wellhead with gate valves
The hook and ETA-60 elevator laying a tubing joint on the pipe rack
The hook and ETA-60 elevator laying a tubing joint on the pipe rack

Need a simulator for your crews?

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WhatsApp+7 705 899 76 86+7 705 272 37 52hello@saqtyq.kz

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