SPE-207012-MS

Case Study in Well Integrity Assurance with Enhanced Ultrasonic

Technology for a Highly Attenuative Environment

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Batakrishna Mandal, Xiang Wu, Sadig Huseynov, Adesoji Adedamola, Teles Huanga, and Tahmina Mirzayeva,
Halliburton; Fuad Rahimov and Ofeliya Novruzaliyeva, Umid Babek Operating Company

Copyright 2021, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Annual Caspian Technical Conference scheduled to be held virtually on 5 - 7 Oct 2021.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
While applying acoustics is not a new science, inherent uncertainties with these techniques are still not
addressing challenges that limit confidence in well integrity programs. The Caspian region's significant
challenges for cement evaluations include heavy mud and thick casing, as well as the high-pressure/high-
temperature (HP/HT) nature of gas condensate wells, which reduces the contrast in acoustic impedance.
Accordingly, difficulties have remained in the interpretation of conventional cement bond logs, which has
led many operators to be suspicious of well integrity technologies.
This paper focuses on the application of ultrasonic cement evaluation technology in the Caspian Sea, and
compares results between advanced ultrasonic applications and traditional cement bond logs in heavy mud.
The workflow is presented to integrate the advancement of this technology and to eliminate the uncertainties
in well integrity analysis. Increasing confidence for further drilling of a high-pressure gas reservoir has been
achieved by combining these various measurements that enable a definitive analysis of zonal isolation.
The main objective of this well assurance program was to ensure zonal isolation and shoe integrity in
order to drill ahead to perform formation integrity tests (FITs). However, obtaining high-resolution cement
data in heavy, 2.16-sg, oil-based mud (OBM) was the biggest concern due to the limitations of standard
ultrasonic technology. The wide disparity in acoustic impedance, combined with the low contrast between
heavy mud and the cemented section, makes evaluation of cement quality and zonal isolation doubtful.
Although well conditions challenged the standard measurements, the cement evaluation objective was
achieved with the new technology by ensuring 360° azimuthal coverage in permeable sand zones capable
of unwanted hydrocarbon production – i.e., preventing sustained casing pressure (SCP). Moreover, a strong
and continuous 40-m cement bond prevented crossflow from charging zones through the wellbore and also
acted as a barrier against corrosion. Enhancement of pulse-echo technology has proved that it can be applied
in a highly attenuative environment to achieve high-fidelity data.
Highly acoustic attenuative mud is a major challenge for acoustic ultrasonic technology to achieve a
quality answer product for well integrity. To mitigate this problem, a new tool was developed with a highly
sensitive low-noise transducer, and with special programmable (both voltage and frequency) firing circuitry,
to enhance the transducer signal at the resonance frequency of the casing. The various features of the
processing algorithm are also improved, based on the numerous laboratory and field measurements.
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Introduction
The most challenging part of using ultrasonic scanning tools is heavy oil base mud, with a thick casing,
which poses severe restrictions to integrity analyses due to extreme attenuation throughout the propagation
period. New advanced technology with a high-voltage transducer has enabled a considerable step forward in
overcoming these barriers so that ultrasonic technology can be applied in thick casing and highly attenuative
borehole fluids. This paper describes the use of this technology, with case histories where its use has led to
better cement bond interpretations for highly attenuated borehole fluid for wide ranges of casing sizes.
In the Caspian region, the thick casing is accompanied by heavy mud to counter the pressures found in

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the wells, thus leading to a low contrast between the mud and cement sheaths to the point that it becomes
virtually impossible to distinguish a bonded-pipe section from a free-pipe section. One of the reliable
methods is applying enhanced ultrasonic Circumferential Acoustic Scanning Tool (CAST) technology to
prevent any artifacts in the cement assurance when the temperatures and pressures change during the
production state.
This paper describes the use of this technology in the Caspian region, where its use has led to better
cement bond interpretations in highly attenuative environments. Additionally, this technology has prevented
incorrect interpretations that can often lead to unnecessary remedial cement treatments.
An ultrasonic pulse/echo transducer in a rotating head that emits and receives signals through borehole
fluid, casing, and material behind the casing (Mandal, 2016). The return signals then analyzed in real-time
and produce complete 360° wellbore images such as borehole shape, casing properties and impedance map
behind the casing for high-resolution well integrity assurance. The challenge of obtaining better signal-to-
noise ratios (SNRs) of ultrasonic wave propagation through highly attenuated borehole fluid is critical to
have good answer products. The new enhanced technology (Mandal, 2016) used sensitive transducer and
proprietary tuned firing circuitry to improve SNRs for confidence of the answer product. The signal strength
of the material behind casing is the highest around the casing fundamental resonance frequency. The tool
fires close to the casing resonance frequency to enhance the SNRs of the received signals. The acoustic
impedance behind casing is derived from the received waveform with the trail of casing reverberation
(most information behind the casing) with adaptive inversion method with three layer (fluid-casing-cement)
system. Due to large acoustic impedance contrast between the fluid inside the wellbore and the casing, the
1st reflection signal is almost representing the transducer response. The 1st reflection response is exploited
as a source wavelet for the theoretical forward model for estimating the impedance behind the casing. The
reverberation signal behind the 1st reflection signal is also utilized for calculating accurate casing thickness.
The reverberation trail has special features for casing thickness (dominant frequency), and the decay of the
reverberation signals depicts directly for determination of the bond quality. For example, less decay rate
(higher amplitude) indicates lower impedance (free pipe) and high decay rate (lower amplitude) provides
the high impedance (strong bonding).
All necessary attributes for well integrity assurance are calculated in real-time with full azimuthal
coverage of the wellbore. To achieve this, an advance planner system is developed for best possible
acquisition parameters with prior knowledge of mud system and well information. The planner not only
select the appropriate transducer for the job but also the firing frequency, firing voltage, number of shots
per scan for 100% azimuthal coverage, and optimal acquisition parameters for essential answer products.
The real-time monitoring system with signal time and frequency domain displays further provides more
confidence of the data quality of the acquisition.
The ultrasonic approach depends on annulus replacement by a solid material. Hence, where cement
isolation is required for well integrity purposes, improper mud removal or insufficient slurry volume will
often result in poor zonal isolation and may lead to loss of well integrity during well construction. The
impedance map generated by a pulse-echo tool can differentiate liquid and solid materials by assigning
colors to the range of impedance values, as long as there is a stark contrast in the impedance threshold
SPE-207012-MS 3

between the slurry and the mud. This fact allows for examination of the cement sheath behind the casing by
looking at the color-coded impedance map according to the impedance values. Defined cutoff values enable
the acquisition program to identify liquid/gas-filled or poorly bonded intervals.
Until recently, ultrasonic technology was not sufficiently advanced to use in a highly attenuative
environments. Recent advancements in this technology have led to high-resolution answer products for
these highly attenuative environments, thus allowing well integrity analysis in greater than 0.75-in. casing
thickness and 14-ppg borehole fluid, which was the limitation of preceding generations of Ultrasonic
technologies. The text below illustrates how applying this technology in the Caspian region promoted

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increased confidence in well integrity analysis and prevented unnecessary remedial operations to be carried
out.

Field Examples
An ultrasonic scanner has been deployed with a conventional cement bond logging tool in a single run.
The main objective of running both tools together was operational efficiency and to overcome limitations
provided by a single acoustic log; to "read" a cement-to-formation bond or to inspect a casing-to-cement
bond when the acoustic log response has been affected by outer casing interference when the gap between
casings becomes less than 1 inch – or, in the case of cementing with a lightweight slurry when pulse-echo
tools may misrepresent the material behind the casing.
The borehole fluid was a 2.16 g/cc (17.9 ppg) OBM, and the zone had 13-5/8 inch casing – a challenging
environment for conventional ultrasonic systems. Combining advanced ultrasonic technology with sonic
measurements reduces the impact of the borehole and the deficiencies mentioned above on the acquired
data, and assured confidence in well integrity to prevent crossflows in the upcoming expected high-pressure
zone and SCP anomalies once the well was put in production. Individual measurement approaches do not
provide the most robust analysis for well integrity, unless they are applied together.
Attenuation was measured for the borehole fluid in order to design this service. It was determined that
the 2.16 g/cc (17.9 ppg) OBM had 7.38 dB/inch attenuation @ 200 kHz, which indicated highly attenuative
borehole fluid. Well casing OD was 13 5/8 inch with 0.625 inch casing thickness (the resonance frequency
of the casing is 186 kHz). Based on this information, the planner selected a transducer with appropriate
firing frequency and voltage which could deliver best signal around 186 kHz at the surface of the casing with
considering the attenuation rate of the propagation @ 200 kHz. The planner also picked appropriate head for
mounting the transducer so that there will be the optimal offset between the transducer and the casing wall for
best possible signal for this environment of attenuative mud. The high-fidelity data then processed in real-
time with enhanced impedance algorithm with other calculations for well integrity assurance measurements.

Presentation of data and results

The 13 5/8 inch casing was carefully assessed to insure well integrity during well construction. For good
well integrity the main requirements that needed to be achieved:
➢ Preventing SCP in the C annulus during the well life cycle
➢ Avoiding broaching risks (hydraulic communication between different pressure zones through a
poorly cemented wellbore, and fluids leaking to the environment external to the well through fractured
cap rock)
➢ Mitigating external corrosion of casing due to direct contact with highly pressurized aquifers
➢ Providing zonal isolation to ensure that no crossflow occurs between highly permeable sands
(hydraulic communication between highly permeable zones, resulting in a higher pore pressure
gradient than in-situ pore pressure)
➢ Ensuring shoe strength for safe drilling of the next casing section
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Table 1—Well integrity requirements during well construction, and final status of achievement

Well Integrity Requirements to Be Achieved Final Status

Preventing SCP Achieved

Avoiding broaching risks Achieved

Mitigating external corrosion Achieved

Providing zonal isolation to prevent crossflows Achieved

Ensuring shoe strength for drill of the next casing section Achieved

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Accurate cement evaluation allows well integrity engineers to assess each of these risks simultaneously,
as cement evaluation plays a key role in risk assessment. For instance, to prevent SCP, at least 30-m
bond above the uppermost flowing zone should be verified from the ultrasonic well log. The same cement
evaluation between permeable zones also helps well integrity engineers to assess whether or not fluids can
escape through the poorly bonded wellbore to the environment by fracturing formation cap rock at the
previous casing shoe. Confirmation of above mentioned well integrity objectives were only possible with
high fidelity cement log data.
As confirmed by geologists, there were two major sand zones behind the 13-5/8 inch casing, which were
potential risks for well integrity.
Figure 1 shows a cement bond in the double casing (13-3/8″ casing and 18-5/8″ casing) interval. The
variable density log (VDL) waveforms appear to be affected by the effects of the double casing as some
strong casing response can be seen. However, the impedance measurement shows good azimuthal cement
coverage also clearly seen on the cement map. Some casing centralizer effects are observed on the data as
indicated on the log, but this does not affect the interpretation of the over 100m cement seen. This verified
cement length would act as a barrier preventing annular pressure communication.

Figure 1—A cement bond log from an interval at x000-m MD to x100-m MD. This shows a section of the double casing
interval where over 100m of good cement was observed, despite the strong casing response seen on the CBL.
SPE-207012-MS 5

Figure 2 shows a cement bond of at least a 40-m interval. This good bond is verified by dampening
variable-density log (VDL) waveforms, low cement-behind-casing (CBL) amplitudes, faded "chevron
effects," a high impedance MRayl value, and a qualitative cement image map. This verified cement length
was above the uppermost flowing zone, which would act as a barrier against SCP (Sustained Casing
Pressure) during the well life cycle.

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Figure 2—A cement bond log from an interval at x110-m MD to x210-m MD. The log shows the
presence of at least 40m of good cement above the uppermost flowing zone (Sand A) at X180-m MD.

Figure 3 shows a section of the log from x300m MD to x400m MD. The variable-density log (VDL)
waveforms generally show attenuation, faded chevron patterns with corresponding low pipe amplitude
which are indicative of good cement. However, the impedance measurement, cement map and solid-liquid-
gas (SLG) map all show the presence of clear channels within the cement in this interval. This shows the
value of having an azimuthal measurement which can tell the true quality of the cement behind pipe as
against the averaged measurement of the VDL and pipe amplitude.
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Figure 3—A cement bond log from an interval at x300-m MD to x400-m MD. The log shows the value of the azimuthal
ultrasonic measurement where channels are seen in the cement while CBL generally shows good cement.

For drillability of the next section, a FIT was performed to verify shoe strength. A successful FIT at
the new formation ensured that the section integrity requirement had been met, which was one of the well
integrity testing (WIT) requirements during section drilling.

List of Log Curves.

▪ Track 1: Natural Gamma Ray (GRC), CAST Eccentricity (ECC), Ovality (OVAL) and Average
Impedance (ZAVG).
▪ Track 2: Depth and Relative Bearing (RB)
▪ Track 3: Well Diagram
▪ Track 4: Azimuthal Coverage (BI/FCEMBI) and CBL Pipe Amplitude (AMP).
▪ Track 5: 5ft VDL Waveform (WMSG).
▪ Track 6: CAST pipe amplitude image/Array (ZCVECT).
▪ Track 7: Impedance Derivative Map (DZ)
▪ Track 8: Cement Map (composite of Derivative Map and Acoustic Impedance map - CEMT)
▪ Track 9: Percent of circumference with less than gas cutoff (0.3 Mrayls – ZCGASPER) and percent
less than liquid cutoff (2.6 Mrayls – ZCLIQUIDPER).

Conclusion
Successful cement evaluation in heavy oil-based mud helped the operator to assess its well integrity
risks by employing enhanced ultrasonic cement evaluation technology with a conventional cement bond
logging tool. Subsequently, obtained high resolution cement data enabled well integrity engineers to
SPE-207012-MS 7

understand the need for SCP management action plans, which had to be determined before the well was
put on production. Consequently, ultrasonic cement evaluation enabled the operator to investigate external
corrosion, broaching, and crossflow risks in detail.

Acknowledgments
The authors acknowledge the management staffs of Halliburton and Umid Babek Operating Company for
their support and permission to publish this paper.

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Reference
Mandal, Batakrishna, 2016, Well Integrity Assurance Through Heavy Borehole Fluid and Thick Casing: A Challenge of
Ultrasonic Evaluation, Society of Petrophysicists and Well Log Analysts (SPWLA) 57th Annual Logging Symposium