Abstract This paper documents a first‑of‑its‑kind electric‑line intervention to segment and recover a straddle assembly lodged above a downhole safety valve within a restricted internal‑diameter (ID) mandrel. Conventional jarring and high‑force retrieval failed due to scale‑induced confinement and persistent slip engagement. A bespoke slim mechanical cutter head (≈1.7‑in. OD) was engineered to operate inside a 1.811‑in. ID, with a tell‑tale/no‑go feature enabling a precise cut 975 mm (≈37.5 in.) from the inner sleeve top while minimizing torque and swarf generation. Full‑scale surface integration tests calibrated cutting pressure and verified reliability before offshore deployment. The downhole cut was executed in ≈5 h with real‑time SRO monitoring. The straddle was then recovered in three stages using an electric‑line hydraulic stroker and actuated grapple: 77 klbf for the upper section, 70 klbf to pass a weak point, and a final 20/70 klbf push/pull sequence to free the lower body. A downhole video camera provided rapid diagnostics and offshore/onshore decision support. The operation eliminated explosives, reduced risk, and restored full well accessibility. Design‑to‑deployment was completed in 4 weeks. The case offers engineering guidance on tool miniaturization, cut positioning, force staging, and debris control for restricted‑ID interventions, and demonstrates how agile custom tooling can displace higher‑risk methods in time‑critical well integrity scenarios.
Bassie et al. (Mon,) studied this question.