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Wellbore Instability Monitoring by Using 4D Imaging of Ultrasonic Caliper

Logs in Real Time Drilling
Behzad Elahifar, Abdolali Esmaeili, University of Leoben, Rudolf K. Fruhwirth, TDE Thonhauser Data
Engineering, Gerhard Thonhauser, University of Leoben

Copyright 2013, International Petroleum Technology Conference

This paper was prepared for presentation at the International Petroleum Technology Conference held in Beijing, China, 2628 March 2013.
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Abstract
Drilling programs continue to push into new and more complicated environments. As a result, accurate measurement and
analysis of drilling data in real time are becoming more critical by means of minimizing failure costs.
The measurement of actual wellbore shape in real-time can be considered as one of the key components to detect problems
such as borehole instability. Abnormal wellbore shape will allow drawing conclusions on the stress field. Accurate wellbore
caliper measurements in real-time will also allow determining cement volume requirements with less measurement time.
Measuring flow rate accurately behind the bit with ultrasonic sensor will also help the driller to detect washouts along drill
string in real time.
This paper describes experiments related to the accuracy of ultrasonic sensor measurements for estimation of wellbore
diameter in drilling fluids with different mud weights and additives in real time. A fully automated test robot has been
designed and tests have been performed in different drilling conditions. The test robot allows moving vertical as well as lateral
movement of a sensor head in an artificial wellbore which can be run with different fluids. In addition, bubbles were added to
the mud while measuring borehole diameter by the sensor. Tests have been performed in relation to the radial position of the
caliper tool inside the wellbore, including different objects inside the borehole simulating latches or dog legs. The wellbore
profiles have been measured with different axial and rotational surveying speeds.
Numerical simulation of ultrasonic measurements and comparison of the results to the recorded data gives an estimate on
the measurement accuracy at different RPMs of drill string. It is also shown that gas bubbles can be detected and compensated
with an appropriate accuracy if circle fitting methods like the Kasa method in combination with robust error models are
applied.
Introduction
Recognition of variations in borehole shape in real-time drilling allow the drilling engineer to actuate appropriate
counteractions to avoid costly failures, or to implement alterations in the drilling practices to optimize the shape of the
borehole and thus improve the drilling efficiency. The received data help the driller to make proper decisions such as reaming
a critical zone, changing the flow rate to reduce erosion or modifying the string rotation speed to reduce vibrations.
Real time application of ultrasonic caliper tools also provides a method for calculating borehole volumes. On a final bit run
for instance, the sensor may collect the caliper data during trip-out for the estimation of cement volumes. Other applications of
ultrasonic caliper tools might include real time casing wear and borehole stability detection, evaluation of borehole cleaning
and determination of tight spots or formation ledges (Maranuk et al., 1997).
This paper reviews tests and experiments which have been performed by the ultrasonic sensor in drilling fluids with
different mud weight. Effects of air bubbles on the recorded data by ultrasonic caliper were determined. However, even with
the modern technology improvements, ultrasonic caliper cannot provide absolute reliable information for all drilling
environments and conditions. Several operational factors such as tool centralization, mud density, borehole wall roughness,
tool position, gas bubbles and drillstring vibration in the borehole among others need to be considered in order to optimize the
accuracy of the borehole caliper data. For this reason analysis of circle fitting algorithms based on the Kasa method have been
implemented.

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Ultrasonic Tests Review

Elahifar et al. (2012a) have performed several experiments in various environments; in different drilling fluids as well as under
different drilling conditions and positions of the tool in the borehole (Figure 1). Tests have been performed in three different
drilling fluids: air, water and bentonite mud. However, viscosity of drilling fluid has a great impact on the results. With
increasing viscosity the quality of the recorded data quantified by the number of invalid measurements increases. The most
number of invalid data points were recorded in air, and the least one in bentonite mud.

Figure 1: Test robot with borehole and sensor

In each drilling fluid different experiments were performed with different tool positions inside the borehole and different
tool rotational speeds. The tests were done with the tool centralized, decentralized and moving towards one side of the
wellbore. In addition squeezed formations were simulated by placing artifacts inside the borehole. During all these tests the
wellbore diameters were recorded with different rotational speeds (15, 30, 45, 60, 100 and 180 RPM). Based on all the
experiments performed, it can be concluded that geometry and position of the tool have a great impact on the results. If the
diameter of the caliper tool compared to the wellbore diameter is small or if the tool is strongly decentralized within the
borehole, the accuracy of the results may decrease dramatically. That challenge can be tackled by some constructional
constraints applied to the design of such a tool. The usage of stabilizers of course leads to a rather stable and centralized
position in the borehole; in combination with appropriate tool diameters the geometrical conditions provide short and
comprehensible wave paths and thus acceptable results (Figure 2).

Figure 2: a- Sensor rotates in air with 30 RPM (centralized position), b- Sensor rotates in air with 15 RPM (tool moving towards right side of
wellbore), c- Sensor rotates in water with 60 RPM (decentralized position), and d- Sensor rotates in bentonite mud with 15 RPM (simulating
squeezed formation)

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Ultrasonic Caliper Package

The ultrasonic caliper package mounted at the test robot has a diameter of 16 cm (6.3 inch) (Figure 3). The package consists of
a sender and a receiver, a battery package, a micro controller and a counter switch. During the experiments recorded data were
sent to the computer via a blue-tooth connection.
The sensor which has been used in these experiments has the following specification:
Voltage: 48V to 24V
Ultrasonic Frequency:
40 kHz
Operating Temperature:
40C to 80C

Figure 3: Ultrasonic caliper package

Effect of Mud Weight on Ultrasonic

In this experiment salt water is used as a drilling fluid to perform different tests regarding to the position and geometry of the
tool in the borehole, more precisely
Centralized position of the tool in the wellbore
Decentralized position of the tool in the wellbore
Simulation of squeezed formation
All experiments have been performed at room temperature and pressure. The tests were performed with three different mud
weights 8.65, 9 and 10 ppg. Salt with different concentration was added to the water, so the rheological properties of
saltwater with different concentration are a plastic viscosity of 2 cp and a yield point of 1 lb/100ft2. The speed of sound in salt
water varies with different densities of the liquid.
Drilling Fluid with 8.65 ppg Mud Weight
In this experiment the sensor is placed in the wellbore at different position and geometry. Caliper rotates with different RPM
(30, 60 and 100 RPM) in the wellbore and recorded the diameter of the borehole. The speed of sound in 8.65 ppg salt water is
1565 m/sec. Figures 4, 5 and 6 shows the results of the experiment with different tool position and geometry in 8.65 ppg salt
water. In centralized position (Figure 4) recorded data were fitted to the wellbore and also to the simulated borehole. Some
deviations of some data points from the wellbore profile may be caused by the borehole roughness due to irregular cement
surface.

Figure 4: Sensor rotates in salt water, 8.65ppg, with 60 RPM in 40 cm diameter wellbore (centralized position)

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When the tool is decentralized, by considering the blind zone, recorded data are spread all around the borehole (Figure 5).
There are some points that are out of the wellbore range, the reason for that is due to multiple reflections or cycle skipping
phenomena.

Figure 5: Sensor rotates in salt water, 8.65ppg, with 100 RPM in 40 cm diameter wellbore (decentralized position)

To simulate squeezed formation an artifact is placed in the borehole and the caliper is centralized inside the well (Figure 6).
The artifact was detected with different RPM and the only abnormal parts are the edge of the artifact where scatting or
multiple reflections causes the recorded data does not match the borehole or the artifact.

Figure 6: Sensor rotates in salt water, 8.65ppg, with 30 RPM in 40 cm diameter wellbore (squeezed formation)

Drilling Fluid with 9 ppg Mud Weight

In this experiment all tests were performed in the salt water with a salt concentration of 9 ppg. The same procedure as before
regarding to the geometry and position of the tool was used to perform all the tests. Caliper rotates with different RPM (30, 45,
60 and 100 RPM) in the wellbore and records the diameter of the borehole. 1680 m/sec is the speed of sound that was recorded
in 9 ppg salt water. Figures 7, 8 and 9 show the results of the tests in the borehole with different position and geometry.

Figure 7: Sensor rotates in salt water, 9 ppg, with 30 RPM in 40 cm diameter wellbore (centralized position)

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Figure 8: Sensor rotates in salt water, 9 ppg, with 45 RPM in 40 cm diameter wellbore (decentralized position)

Figure 9: Sensor rotates in salt water, 9 ppg, with 100 RPM in 40 cm diameter wellbore (squeezed formation)

Drilling Fluid with 10 ppg Mud Weight

In this experiment the same procedure as before was performed in 10 ppg salt water. The tool rotates with different RPM (30,
45, 60 and 100 RPM) in the wellbore and records the wellbore diameter. 1920 m/sec is the speed of sound that was recorded in
10 ppg salt water. Figures 10, 11 and 12 show the results of the tests regarding to the tool position and geometry in the
borehole. As the mud weight increases, the accuracy of the recorded data does not change and it does not have any effect on
ultrasonic caliper recorded data. Increasing mud weight by adding salt to the water changes only the chemical properties of the
drilling fluid no solid particles were suspended. In the centralized position recorded data match well to the borehole and the
simulated wellbore.

Figure 10: Sensor rotates in salt water, 10 ppg, with 45 RPM in 40 cm diameter wellbore (centralized position)

When the tool was decentralized in the borehole, more data were recorded at the sides where the sensor has the shortest and
longest distance to the borehole. The reason is due to the sensors aperture and the actual reflection angle between ultrasonic
sensor and the borehole wall (Figure 11).

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Figure 11: Sensor rotates in salt water, 10 ppg, with 30 RPM in 40 cm diameter wellbore (decentralized position)

Figure 12 shows the result of the test with an artifact inside the borehole to simulate squeezed formation. Recorded data fit
well to the wellbore and also the artifact was detected correctly.

Figure 12: Sensor rotates in salt water, 10 ppg, with 60 RPM in 40 cm diameter wellbore (squeezed formation)

Effect of Air Bubbles on Recording Data

In that experiments the ultrasonic caliper records borehole diameter in different drilling fluids with different tool geometry and
position in the wellbore. During previous tests the drilling fluid condition was stable and only one phase liquid was used to
perform the experiments. In this experiments the effect of gas bubbles in the drilling fluid are monitored during recording of
the diameter. The wellbore is filled with water and the caliper submerged in the fluid, it is placed in the wellbore with a
specified distance from the wall. After ultrasonic caliper started sending echoes to the wall for measuring two way traveling
time to determine the distance, air bubbles were injected from the base plate (Figure 13).

Figure 13: Wellbore condition before and after air injection to the water

Before injecting the air the received signal was recorded and monitored by an oscilloscope. When air was injected to the
wellbore, the received signal was recorded and also compared with the time with no bubbles injected (Figure 14). When the air
bubbles crossed the area between the ultrasonic sensor and the wall, the received signals became weak and no distance
measurement could be done. However when the injection was stopped, the received signal was again appropriate.

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Figure 14: Oscilloscope reading, received signal before and after air injection. Receive signal is the yellow line that is monitored on the oscilloscope.

Circle Fitting
Elahifar et al. (2012b) have performed different experiments in various environments; in different drilling fluids as well as
under different drilling conditions and positions of the caliper in the wellbore. Circle fitting has been applied to the recorded
data to find out the out range data and also to determine squeezed formations by applying robust circle fitting method.
Figure 15 shows the result of applying the circle fitting method to the recorded data where an artifact was inside the borehole
and simulating the squeezed formation.

Figure 15: Simulating squeezed formation, salt water 10 ppg, circle fitted (RPM=60, Borehole radius=200 mm)

The circle radius calculated with robust method was 196.2 mm which by comparing to the real borehole radius has 1.9%
error. This method will also be used if three or more ultrasonic sensors are simultaneously used by a single caliper tool.
Discussion and Conclusion
Based on all the experiments performed it can be concluded that increasing mud weight by salt which causes only chemical
changes in the fluid without solid particles inside the fluid does not have any effect on the recorded data. All recorded data
were fitted well to the wellbore when the caliper is positioned centralized and decentralized, and also for squeezed formation
simulation.
When air bubbles were injected into the drilling fluid during recording, the received signals weaken due to the gas and
liquid mixture.
When drilling is in progress, drilled formations with different characteristics are affected by different phenomena like
hydrostatic pressure or effect of mud cake among others. In case of wash out, squeezed formation or other instabilities,
diameter and shape of the wellbore might change. For detecting such anomalies in the wellbore, robust circle fitting seems to
be an appropriate method.
All experiments were performed with a single set of ultrasonic sensors, future work will emphasize in increasing the
number to at least three concurrently operating sensors. With that configuration it is expected to monitor the wellbore shape
with enhanced accuracy in real time and automatically compensate decentralization of the tool in the borehole.
Multiple ultrasonic calipers along the drill string could be used to monitor the wellbore diameter, shape and wellbore
stability in real time drilling (Figure 16). Depending on the sensors density along the drill string, a 4D image of the borehole
with accurate resolution can be created. Such images will reflect the evolution of a borehole in terms of shape and diameter.

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Since the creation of key-seats for instance will be observable during drilling, this method is expected to be a good monitoring
tool for the driller to tackle arising problems in an early stage.

Figure 16: Using multiple ultrasonic calipers along the drill string

Acknowledgment
The authors would like to acknowledge the help of Franz Fasch and Anton Scheibelmasser for their assistance in this project.
We would like to thank Advanced Drilling Solution GmbH (ADS) for their cooperation and the permission to publish this
paper.
References
Elahifar, B., Esmaeili, A., Fruhwirth, R.K., Thonhauser, G., 2012: Determining the Accuracy of Ultrasonic Caliper Measurements for Real
Time Drilling Application. SPE 158160, SPE Asia Pacific Oil and Gas Conference and Exhibition held in Perth, Australia, 2224
October 2012. (a)
Elahifar, B., Esmaeili, A., Fruhwirth, R.K., Thonhauser, G., 2012: Real Time Measurement of Borehole Shape and Diameter by Using
Ultrasonic Caliper In Different Drilling Fluid and Wellbore Conditions For Detecting Instabilities. SPE 162251, Canadian
Unconventional Resources Conference held in Calgary, Alberta, Canada, 30 October1 November 2012 (b)
Maranuk, C. 1997. Development of an MWD Hole Caliper for Drilling and Formation Evaluation Applications. Paper SPE 38585, Presented
at Annual Conference and Exhibition, San Antonio, Texas, 5-8 October.