CASING and TUBING INSPECTION BASICS

Casing and tubing placed in well bores may suffer from damage due to corrosion or mechanical
distress. Corrosion is caused by natural electrical currents that flow in the earth, and from man-
made currents from power lines and surface equipment.

Corrosion can be reduced by cathodic protection systems but not always with perfectly
satisfaction. Corrosion inspection logs and cathodic protection evaluation logs are widely used in
areas where corrosion is known to be a problem.

Holes in tubing or casing caused by corrosion can seriously affect production rates and fluid
composition, resulting in economic loss.

Loss of metal may result in strength loss without holes in the pipe, allowing burst or collapse,
again with serious economic consequences. Bent, squashed, or oval pipe can impede or prevent
the passage of equipment or tools into and out of the wellbore. Moving parts, such as pump rods,
an cause wear that eventually will cause problems if not repaired in time.

Although most tubular goods are inspected before running into the hole, bad pipe has been found
in numerous cases after the well completion has proved unsuccessful. Damage may also occur
during testing of the well, drilling of plugs, or well stimulation. Un-cemented or poorly cemented
casing can be damaged easily with excessive pressure. The effect on production can be severe
and remediation will be assisted by an accurate diagnosis of the problem by an adequate
inspection program. So there are lots of potential problems to look for.

The logs offer precise depth correlation when recorded with gamma ray or casing collar locator
logs. The following descriptions are condensed from the 1999 Schlumberger Services Catalog.
Equivalent logging tools are available from all major ,and many smaller, service companies.

CASING INSPECTION with CEMENT MAPPING LOGS

Cement evaluation tools are traditionally used to assess cement quality, cement bond, channels,
and cement fill-up using azimuthal ultrasonic transceivers. These tools also have a corrosion
inspection mode, measuring the thickness of the casing from its resonant frequency.
Simultaneously. the internal dimensions of the casing are determined from the travel time of
sound reflected off the casing walls. An azimuthal image of the casing inside diameter can be
displayed.
 Casing diameter, casing thickness, and ovality logs from CET tool are use for casing inspection.

Ultrasonic imaging tools evaluate the quality of the cement and determines both internal and
external casing corrosion. A single rotating sensor emits ultrasonic pulses and measures the
resulting resonance. The USI echo strength and casing resonance are processed to produce
detailed images of cement quality and distribution that can spot channels as narrow as 1.2 in.
Alternate presentations provide images of casing thickness, internal radius, and internal
corrosion. Casing ovality, kinks, and holes can be observed on the image logs. The size of the
rotating head is chosen appropriately for the size of the tubular to be surveyed.
Typical USI composite presentation with casing cross section and internal radius measurements.

CASING and TUBING INSPECTION with ELECTROMAGNETIC LOGS

Electromagnetic corrosion and protection
evaluation tools measure casing potential
and resistance in cathodically protected wells
to evaluate protection and determine the
extent of any corrosion. Using four
hydraulically activated sets of three
measurement electrodes spaced at 2 foot
intervals. This service provides axial and
radial current density, corrosion rate, and
casing thickness. In wells without protection,
the tool determines the rate and location of
external corrosion.

This log shows current flow in a casing string

with no cathodic protection. Corrosion is
 occurring at the depths shaded red.

Multi-frequency electromagnetic thickness

tools are nondestructive and non-contact
induction devices to determine metal loss
and changes in casing geometry, regardless
of fluid type. Generally used to find large
scale corrosion or casing splits, the tool also
detects metal loss in the outer casing of
multiple casing strings. A coil centered in the
borehole generates an alternating magnetic
field that interacts with the casing; a second
coil measures phase shift.

These electromagnetic measurements. made

at multiple frequencies. are related to casing
wall thickness. inner diameter, and
permeability / conductivity, Each of these
parameters is averaged around the pipe
circumference.

This composite corrosion log run

across a lost circulation zone shows the axial
and radial currents in the casing. The log
shows anodic and cathodic sections along
the casing, Anodes have developed in front of the poorly cemented section resulting in metal
loss, pits, and holes.

Pipe analysis logs monitor casing quality and

discriminate between internal and external
defects. This corrosion-monitoring service is
designed primarily for detecting small holes
and defects. A high frequency eddy current
test detects flaws on the inner casing. and a
magnetic flux Ieakage test inspects the full
casing thickness. With these measurements.
small defects and corroded areas in pipe are
detected. and defects on the inner and outer
walls of a single casing string can he
identified. Twenty-four sensor signals (12 flux
and 12 eddy) are digitally recorded for
complete surface processing. When
combined with other services. severe
corrosion and defects can be detected and
identified on the inner or outer pipe in a double casing string.

PAL log recorded to evaluate casing corrosion. Perforations are at 1145 to 1160 ft, and
perforations that have been squeeze cemented are at 1165 to 1167 and to 1190 fl.

fs

CASING and TUBING INSPECTION with MULTI-FINGER CALIPERS

Tubing geometry logs are multi-finger
calipers, used to precisely measure variations
in the internal diameter of the tubing and to
provide data for collar corrosion analysis. The
spherical lips of the caliper~ exert only 2 kg
of contact force, thereby avoiding damage to
pipe coatings. Interchangeable fingers permit
corrosion monitoring over a wide range of
tubing sizes. Each set of feelers can be
opened and closed downhole for repeat
passes over the zone of interest. Each of the
16 sensors generates an independent signal
recorded versus depth and both well site and
computed products are available.

Multi-finger tubing caliper with grey

scale caliper map - white is 4.0 inches, black
is 4.5 inches.

Multi-finger casing caliper logs are

mechanical casing inspection devices. Using
from 36 to 72 fingers. depending on the
diameter to be measured. The tool gives very
high resolution, radially and vertically, to identify casing corrosion ranging from small pits and
scale to axial splits. The tool can be opened and closed downhole. Radii measurements include
three minimum and three maximum (one each per 120-degree section) or six maximum (one each
per 60-degree section). All raw data and computations are available at the well site.
 CASE HISTORY: CASING INSPECTION
This example combines both cement integrity and casing integrity
issues. The problem is to determine where a water flow behind
casing is coming from. The first thing you need is a a well diagram
to see what plumbing is in place, as shown at the right. The water
flow is coming up between the 9-5/8 and 13-3/8 inch casing
strings. The only water can get there is through poor quality
cement behind the 9-5/8" casing OR through a leak in the 13-3/8"
casing combined with poor cement behind that casing string.

Well diagram showing casing sizes and depths

The cheapest logs to

check for water flow are
noise logs and
temperature logs. In this
well a temperature log was
run. Water inflow might
show a slight low
temperature at the point of
entry, caused by gas
released from solution,
with a small high
temperature anomaly
above geothermal
gradient, as the warm
water moves upward
through cooler horizons.
This water flow is 100
bbl/day, so it is significant
enough to cause such an
anomaly.

Compressed vertical
scale temperature log.
Dark diagonal line is a
constant gradient. Coolest
temperature is at large arrow, with a warm spot above it
(circled) reverting to geothermal gradient above
suspected entry point.

The illustration below is a casing inspection log showing

good casing at this depth. The casing ID and OD are
normal and the map shows no breaks or holes. Since
water is not entering this casing string, the log merely
confirms our understanding of the situation.
Below that is an illustration of the cement integrity log, showing a large cement channel with only
about 50% of the annulus filled with cement. While the cement is well bonded, it does not provide
isolation, and this problem persists throughout the well bore.

A cement squeeze to fill this channel is needed. The interval should be re-logged after the
squeeze to verify isolation and fill up of the annulus.
Casing inspection log over suspect area shows good casing. Ignore the cement quality indicator
on the right edge - it is just plain WRONG - see below.
 Cement integrity log over suspect interval shows a bad cement job. White on cement map is a
channel and black is good cement., giving a Bond Index of only 50%. Water can easily flow up
through such a channel. The cement quality flag at the extreme right is WRONG (black is
supposed to represent good cement but the trigger level is not set correctly - you need at least 80
to 90% bond for isolation to water.

This may not be the end of the story. The integrity of the intermediate casing also needs to be
checked. Fortunately, casing and cement logs were run before the well was drilled to total depth.
Samples are shown below. Lots of corrosion both inside and outside the casing is indicated,
possibly because this was re-used casing. Kinks and dents are also evident on the casing ID map.
The cement fill up is also poor and a remedial squeeze job should have been performed before the
well was deepened. There is one anomaly on the casing that might indicate a split (see below..
There is no easy way to squeeze behind this casing now and the temperature log is too
insensitive to confirm a water leak at this depth. The salinity of the water flowing in the annulus
might provide a clue as to whether the water is coming from a deep or shallow source.
 Casing profile shows corrosion an inside and outside of pipe. Map of inside diameter shows
casing is oval - dark red is large diameter, pale colour is small diameter. Casing thickness shows
possible splits (white diagonal areas with dark blobs- white is thin, black is thick). "Good" cement
flag at far right is not correct - see image below.
 Cement bond and cement map show poor bond with a medium size channel and no bond to the
formation If the casing is split as indicated in the previous image, this cement could allow water
inflow between this casing string and the liner. Note that the apparent "casing splits" on the
casing log are at the same place as the missing cement. The interpretation of a casing split here is
not certain - an electromagnetic pipe evaluation tool would have been needed to confirm.