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Introduction
Ultrasound Production by Leaks. Sound is defined classically as
Well integrity continues to be an issue of critical importance for all a disturbance of mechanical energy that propagates through mat-
forward-thinking operators. When faced with well-integrity pro- ter as a wave. Sound propagates as waves of alternating pressure
blems, the prudent operator understands the value of gaining a causing local regions of compression and decompression. Parti-
complete understanding of the communication source before cles in any medium are displaced by the wave and oscillate. A
embarking on a remediation campaign. Comparing the process to leak is a fluctuation in pressure and can produce a spectrum of
that of a doctor diagnosing a patient, it is difficult to prescribe a sound that may contain elements of both audible and ultrasonic
remedy without understanding fully the root cause of the ailment. frequencies. The properties of the leak determine whether it will
Symptoms of wellbore-integrity issues are usually fairly evident. produce an ultrasonic signature, an audible signature, or both. The
The root cause of these problems, however, can be rather elusive. In factors involved in producing an ultrasonic signature are related to
particular, when leaks are of a nature that precludes the use of leak rate, differential pressure across the leak, leak-path geometry,
conventional logging tools, it is often difficult, if not impossible, to and the corresponding media. The presence of turbulent flow at a
detect their source. leak point has been determined to produce an ultrasonic signature.
Detection of very small tubing leaks (less than 1 gal/min) is
difficult with conventional logging techniques such as spinners
and temperature logs. Small leaks result in velocity and tempera- Attenuation. All sound, regardless of frequency, will attenuate in
ture changes that may be less than the resolution of any logging strength over distance travelled. As the frequency of the sound
tools, or may result in data that are virtually impossible to inter- increases, the attenuation of the sound over distance also increases.
pret (Blount et al. 1991). Conventional noise logs can detect fluid To illustrate this, consider that the attenuation of a sound in air at
room temperature and atmospheric pressure is generally directly
proportional to the square of the frequency of the sound (Fig. 1).
Copyright 2009 Society of Petroleum Engineers
Audible frequencies (<20 kHz) tend to be attenuated less. At first
This paper (SPE 102815) was accepted for presentation at the SPE Annual Technical glance, one may consider attenuation as a negative physical attri-
Conference and Exhibition, San Antonio, Texas, 2427 September 2006, and revised for
publication. Original manuscript received for review 27 June 2006. Revised manuscript
bute. However, this attenuation can be used to an advantage for
received for review 22 October 2008. Paper peer approved 30 October 2008. leak detection. Because ultrasound typically travels approximately
310 ft in a wellbore, any signal detected will be in close proximity unitless measurements of signal strength. A casing-collar locator
to the leak source, resulting in accurate leak detection. (CCL) is also presented for correlation purposes. The leak signa-
ture shown is a tubing-to-Annulus-A leak in a water-injection well.
Tool Development, Description, and Operation The magnitude of the leak is approximately 0.08 gal/min, with a
With a recognized need for a better method of detecting leaks, differential pressure across the leak of 9001,200 psi. Field trials
development of an ultrasonic leak-detection tool for downhole use have shown that the tool is effective in detecting leaks in casing,
was undertaken at the request of a major operator in the North Sea. tubing, gas lift mandrels (GLMs), and other completion equip-
This section will describe the operation of the resulting equipment. ment, regardless of leak direction or media while logging at con-
ventional logging speeds.
Ultrasonic Sensor. Piezoelectric-crystal sensing devices have
been used for a number of years in many applications. Not only Case Histories in Alaska North Slope Wells. Managing well-
have they been used for sensing ultrasonic energy, but also for integrity issues on the North Slope plays an essential role in main-
applications requiring accurate pressure measurement. For devel- taining and sustaining field life, as is typical with maturing fields
opment of this tool, a sensor was used that detects a spectrum of everywhere. Considering the time effects of corrosion and erosion
frequencies, including those typically produced by leaks. The in a mature field combined with the use of miscible injectant (MI)
sensor used had to be capable of detecting the sound generated gas in some wellswhich can act as a solvent for pipe dope
by a leak through various media encountered in a downhole envi- creates a challenging environment for maintaining tubing/casing
ronment. Steel, for example, attenuates sound on the order of 20:1 bubble-tight integrity. The following four subsections will cite
as compared to air at atmospheric pressure. specific case histories involving a number of leak scenarios that
have been addressed on the North Slope.
Digital-Signal Processing. The piezoelectric sensor produces
very small voltage responses proportional to the signal strength
Casing Leak Behind Tubing (Well A). Detecting leaks behind
produced by the sound generated at the leak point. To isolate the
tubing is one of the most difficult scenarios to analyze by use of
frequencies of interest, the small piezoelectric analog signal is
amplified and passed through a digital-signal-processing unit with-
in the logging tool. The digital-signal-processing unit is equipped
with a large amount of flash random-access memory running a
series of modular signal-processing programs. The programs con-
sist of a series of band-pass algorithms that focus on the ultrasonic
frequencies that are produced typically by leaks. The filtering
algorithms filter out unwanted background energies caused by
mechanical noise or other interference. Virtually all audible fre-
quencies are filtered out. The result is a fully digitized signal of the
leak signature, which is then transmitted uphole through a conven-
tional electric-line telemetry system to a surface readout system,
producing a graphical representation of the leak signature. Recent-
ly, the tool has been adapted to work with downhole memory for
conveyance with slickline, coiled tubing, or by other methods.
Tool Specifications. The tool is rated for 15,000 psi and is designed
for hydrogen sulfide (H2S) or carbon dioxide (CO2) environments.
As of this publication, the temperature rating is 302 F, with higher
temperature versions being developed. The 111/16-in.-diameter
tool (Fig. 2) operates on a telemetry that allows it to be used in
conjunction with other logging tools if desired.
at 2-ft intervals above and below the leak to verify the leak loca-
tion. The dramatic change in signal response over these short dis-
tances demonstrates the resolution of the tool.
Fig. 4Schematic of Well A. When the tool is placed precisely at the leak point and the annular
pressures are manipulated (by bleeding or pressuring up the various
conventional logging methods. Well A (Fig. 4) is an active water- annuli and tubing), the change in signal strength can be observed
and-gas-injection well completed with 3.5-in. tubing inside 7-in. associated with the leak magnitude (Fig. 7). This measurement,
casing. Annulus A failed a mechanical-integrity test (MIT) and was along with the tubing- and annuli-pressure-response monitoring, con-
switched from MI gas to water injection as a result. Further pres- firm in which barrier the leak is located. As the pressure is decreased
sure testing, including an MIT on the tubing, indicated that the well in the annulus, it can be seen that the signal strength diminishes. As
had either a casing leak or a one-way packer leak, with a leak rate the pressure is increased, the signal strength increases.
too small to detect with the use of conventional logging methods. Upon further analysis of other well data available, it was de-
During logging operations, an MIT was emulated by maintaining termined that the leak signature was in close proximity to a casing
Annulus A pressure between 3,300 and 2,800 psi. A calculated leak collar behind the tubing. Additionally, the cement bond log for the
rate was established between 0.21 and 0.39 gal/min. A typical ultra- 7-in. casing indicated that the cement bond at this area was less
sonic-leak-detection-tool signature was located at 2,574 ft measured than optimal. The evaluation of other logs showed the presence of
depth (MD) during a dynamic pass of 30 ft/min (see Fig. 5). a sand zone at this location that could have been accepting fluid
To further confirm the leak location, stationary readings are during the pressurization of the annulus.
taken through an interval above and below the leak point (Fig. 6). The ultrasonic-log results, combined with historic data, created
The center scale, as with all stationary logs presented, has units of a clear picture of the leak location and probable leak mechanism.
time in seconds. The depths are annotated. The tool was positioned The well was shut in and will be repaired with a rig workover.
Fig. 6Signal response while taking stationary logs on Well A. Fig. 7Well A stationary log showing response in signal
Maximum signal strength is shown at 2,574 ft. IA: inner annulus. strength as the differential pressure is manipulated.
present during the dynamic pass, let us consider the signal strength Leaking GLMs (Well C). GLMs are used extensively in tubing
of the stationary and dynamic signatures of this log. The stationary completions on the North Slope. These devices can be the source
logs show the maximum signal strength to be approximately 9000. of tubing-to-Annulus-A leaks that are very small in magnitude.
The average of the maximum dynamic signature is approximately Well C (Fig. 13) is an active MI-injection well that had to be
of the same magnitude. These values are very close to the average placed on water injection because of a tubing-to-annulus A leak.
background noise being generated during the dynamic logging The well had been a preproduced injector and the tubing comple-
pass. In other words, the signal/noise ratio is practically 1:1. As a tion has nine GLMs with dummy gas lift valves installed. The
result, only a slight, atypical dynamic leak signature was present. well passed a liquid pressure test on Annulus A but would build
Further, let us consider the logging example for Well A in pressure while on MI gas injection.
which the leak was sustained in a similar fashion by a fluid loss The leak rate was established by maintaining water-injection
into cement/formation. Comparatively, the leaks were roughly the pressure in the tubing and bleeding Annular A pressure as low as
same magnitude but the dynamic logging signature was 10 to 12 possible to maintain an active leak. Initially, the water-injection
times higher in Well A. From the previously mentioned CCL, it pressure was approximately 1,500 psi the Annulus A at approxi-
was suspected that the cement in Well A at the leak point was mately 200 psi. Over the course of the job, it was necessary to
poorer or not present, which served to attenuate the signal much decrease Annulus A pressure and raise the injection pressure to
less than the signal in the Well B example. maintain a constant leak. Final injection pressure was at 2,000 psi
with an Annulus A pressure as low as 20 psi. The pressures were
manipulated at various times to ensure a maximum leak rate. The
leak rate at the above-stated pressures ranged approximately from
0.16 to 0.024 gal/min. A very strong leak signature (Fig. 14)
appeared during the dynamic pass at 10,307-ft MD.
Fig. 13Schematic of Well C. SSSV: Subsurface safety valve. Fig. 14Dynamic log in Well C showing leak at 10,307-ft MD.
Fig. 20Tabular data of Well D stationary logs showing elevated signal levels around PBR and packer depths.