Methods and means for simultaneous casing integrity evaluation and cement inspection in a multiple-casing wellbore environment

<u>Technical Field</u>

0001The present invention relates generally to methods and means for detecting anomalies in annular materials, and in a particular though non-limiting embodiment to methods and means for detecting anomalies in the annular materials of single and dual casing string environments and measuring the integrity of the casing immediately surrounding the tool.

<u>Background</u>

0002Within the oil and gas industry, it is important to be able to gauge the quality of cement through multiple casings, as is the ability to determine the status of the annuli. The industry currently employs various methods for the verification of the hydraulic seal behind a single casing string. Typically, ultrasonic tools are run within the well in order to determine whether cement is bonded to the outside of the casing, thereby indicating the presence of cement in the annulus between the casing and formation, or between the casing and an outer casing. Ultimately, a pressure test is required to ensure that zonal isolation has been achieved as ultrasonic tools are highly dependent upon quality of the casing, the bond between the casing and the material in the annulus, and the mechanical properties of the material in the annulus to be able to work correctly. In addition, since ultrasonic tools treat the material in the annulus as a single isotropic and homogenous volume, any actual deviation away from this ideal leads to inaccuracies in the measurement.

0003Current tools can offer information regarding the cement bond of the inner-most casing, yet lack the ability to discriminate between and amongst various depths into the cement or annular material. This limitation means that fluid migration paths may exist at the cement-formation boundary, within the cement itself, or between the casing and an outer casing, thereby leading to a loss of zonal isolation. In addition, the ability to resolve the mechanical and structural integrity of the aforementioned casing is currently reliant upon the use of mechanical calipers that are deployed separately to any cement evaluation techniques. The mechanical calipers provide an operator with a geometric measurement of the inner diameter of the innermost casing, and assume that the outer-diameter of the casing remains unaffected by corrosion, remaining consistent with API-standard pipe diameters.

0004No viable technologies are currently available which are able to determine the radial and azimuthal position of anomalies within the annular region (up to the cement-formation boundary) to ensure that no fluid paths exist that may pose a risk to zonal isolation and well integrity, while simultaneously measuring the integrity of the casing.

0005Prior art teaches a variety of techniques that use x-rays or other radiant energy to inspect or obtain information about the structures within or surrounding the borehole of a water, oil or gas well, yet none teach methods or means capable of accurately analyzing the azimuthal and radial position of anomalies in the annular materials surrounding a wellbore in single or multi-string cased well environments. In addition, none teach of a method of accurately analyzing the azimuthal position of anomalies with a means which includes a centralized (non-padded) tool that is concentric with the well casing, rather than being a 'padded' tool that requires the source and detector assemblies to be in contact with said casing, much as with mechanical calipers when attempting to determine the integrity of the casing by assuming the material remaining in the thickness of materials of the casing.

0006<patcit id="pcit0001" dnum="US7675029B2"><text>US 7,675,029 B2</text></patcit> teaches an apparatus that permits the measurement of x-ray backscattered photons from any horizontal surface inside of a borehole that refers to two-dimensional imaging techniques.

0007<patcit id="pcit0002" dnum="US20180180765A1"><text>US 20180180765 A1</text></patcit> teaches an x-ray based cement evaluation tool for measurement of the density of material volumes within single, dual and multiple-casing wellbore environments.

0008<patcit id="pcit0003" dnum="US8481919B2"><text>US 8,481,919 B2</text></patcit> teaches a method of producing Compton-spectrum radiation in a borehole without the use of radioactive isotopes, and further describes rotating collimators around a fixed source installed internally to the apparatus, but does not have solid-state detectors with collimators. It teaches of the use of conical and radially symmetrical anode arrangements to permit the production of panoramic x-ray radiation.

0009<patcit id="pcit0004" dnum="US3564251A"><text>US 3,564,251 A</text></patcit> discloses the use of a azimuthally scanning collimated x-ray beam that is used to produce an attenuated signal at a detector for the purposes of producing a spiral-formed log of the inside of a casing or borehole surface immediately surrounding the tool, effectively embodied as an x-ray caliper.

0010<patcit id="pcit0005" dnum="US7634059B2"><text>US 7,634,059 B2</text></patcit> discloses an apparatus used to measure two-dimensional x-ray images of the inner surface inside of a borehole without the technical possibility to look inside of the borehole in a radial direction.

0011<patcit id="pcit0006" dnum="US20130009049A1"><text>US 2013/0009049 A1</text></patcit> discloses an apparatus that allows measurement of backscattered x-rays from the inner layers of a borehole.

0012<patcit id="pcit0007" dnum="US8138471B1"><text>US 8,138,471 B1</text></patcit> discloses a scanning-beam apparatus based on an x-ray source, a rotatable x-ray beam collimator and solid-state radiation detectors enabling the imaging of only the inner surfaces of borehole casings and pipelines.

0013<patcit id="pcit0008" dnum="US5326970A"><text>US 5,326,970 A</text></patcit> discloses a concept for a tool that aims to measure backscattered x-rays from inner surfaces of a borehole casing with the x-ray source being based on a linear accelerator.

0014<patcit id="pcit0009" dnum="US7705294B2"><text>US 7,705,294 B2</text></patcit> teaches an apparatus that measures backscattered x-rays from the inner layers of a borehole in selected radial directions with the missing segment data being populated through movement of the apparatus through the borehole. The apparatus permits generation of data for a two-dimensional reconstruction of the well or borehole, but the publication does not teach of the necessary geometry for the illuminating x-ray beam to permit discrimination of the depth from which the backscattered photons originated, only their direction.

0015<patcit id="pcit0010" dnum="US5081611A"><text>US 5,081,611</text></patcit> Adiscloses a method of back projection to determine acoustic physical parameters of the earth formation longitudinally along the borehole using a single ultrasonic transducer and a number of receivers distributed along the primary axis of the tool.

0016<patcit id="pcit0011" dnum="US6725161B1"><text>US 6,725,161 B1</text></patcit> discloses a method of placing a transmitter in a borehole, and a receiver on the surface of the earth, or a receiver in a borehole and a transmitter on the surface of the earth, used to determine structural information regarding the geological materials between the transmitter and receiver.

0017<patcit id="pcit0012" dnum="US6876721B"><text>US 6,876,721</text></patcit> discloses a method of correlating information taken from a core-sample with information from a borehole density log. The core-sample information is derived from a CT scan of the core-sample, whereby the x-ray source and detectors are located on the outside of the sample, and thereby configured as an "outside-looking-in" arrangement. Various kinds of information from the CT scan such as its bulk density is compared to and correlated with the log information.

0018<patcit id="pcit0013" dnum="US4464569B2"><text>US 4,464,569 B2</text></patcit> discloses a method of determining the elemental composition of earth formations surrounding a well borehole by processing the detected neutron capture gamma radiation emanating from the earth formation after neutron irradiation of the earth formation by a neutron spectroscopy logging tool.

0019<patcit id="pcit0014" dnum="US4433240A"><text>US 4,433,240 A</text></patcit> discloses a borehole logging tool that detects natural radiation from the rock of the formation and logs said information so that it may be represented in an intensity versus depth plot format.

0020<patcit id="pcit0015" dnum="US3976879A"><text>US 3,976,879 A</text></patcit> discloses a borehole logging tool that detects and records the backscattered radiation from the formation surrounding the borehole by means of a pulsed electromagnetic energy or photon source, so that characteristic information may be represented in an intensity versus depth plot format.

0021<patcit id="pcit0016" dnum="US9012836B2"><text>US 9,012,836 B2</text></patcit> discloses a method and means for creating azimuthal neutron porosity images in a wireline environment. Similar to <patcit id="pcit0017" dnum="US8664587B"><text>US 8,664,587</text></patcit>, this reference discloses an arrangement of azimuthally static detectors which could be implemented in a wireline tool to assist an operator in interpreting logs post-fracking, by subdividing the neutron detectors into a plurality of azimuthally arranged detectors which are shielded within a moderator to infer directionality to incident neutrons and gamma.

0022<patcit id="pcit0018" dnum="US4883956A"><text>US 4,883,956 A</text></patcit> discloses an apparatus and methods for investigation of subsurface earth formations using an apparatus adapted for movement through a borehole. Depending upon the formation characteristic or characteristics to be measured, the apparatus may include a natural or artificial radiation source for irradiating the formations with penetrating radiation such as gamma rays, x-rays or neutrons. The light produced by a scintillator in response to detected radiation is used to generate a signal representative of at least one characteristic of the radiation and this signal is recorded.

0023<patcit id="pcit0019" dnum="US6078867A"><text>US 6,078,867 A</text></patcit> discloses a method of generating a three-dimensional graphical representation of a borehole, including at least the steps of receiving caliper data relating to the borehole, generating a three-dimensional wire mesh model of the borehole from the caliper data, and color mapping the three-dimensional wire mesh model from the caliper data based on either borehole form, rugosity and/or lithology.

0024<patcit id="pcit0020" dnum="US3321627A"><text>US 3,321,627 A</text></patcit> discloses a system of collimated detectors and collimated gamma-ray sources to determine the density of a formation outside of a borehole, optimally represented in a density versus depth plot format. However, the reference fails to teach or suggest any method or means used to achieve such through a steel wall of a single or multiple well casings. <patcit id="pcit0021" dnum="GB2497857A"><text>GB 2497857 A</text></patcit> discloses a device and method that uses a radiation source for inspecting a subterranean annulus and a radiation detector for inspecting a substance or substances in the annulus. <patcit id="pcit0022" dnum="WO2016153523A1"><text>WO 2016/153523 A1</text></patcit> discloses a tool with an X-ray tomography device to evaluate cement in a downhole environment. The X-ray tomography device includes an X-ray beam source configured to transmit an X-ray beam at a first predetermined angle. The beam angle may be set by a capillary device coupled to the X-ray beam source. An energy dispersive, multi-pixel photon detector is configured to count detected backscatter photons received at a second predetermined angle and determine an energy spectrum for the detected photons. A density map of the cement may be generated in response to the number of detected photons. <patcit id="pcit0023" dnum="US2011285398A1"><text>US 2011/285398 A1</text></patcit> relates to the field of logging a borehole. More specifically, the invention relates to determining the appropriate time and/or location to activate a tool conveyed downhole. <patcit id="pcit0024" dnum="US2008061225A1"><text>US 2008/061225 A1</text></patcit> discloses gamma-ray logging tools, which can be used in the density analysis and imaging of the structure of geological formations around a borehole. <patcit id="pcit0025" dnum="WO2012058579A2"><text>WO 2012/058579 A2</text></patcit> discloses an arrangement of X-ray generators, X-ray detectors, and/or X-ray calibration devices for performing X-ray measurements, such as attenuation and/or photo electric factor measurements, on formation core samples in a downhole environment under conditions including limited space and operations at high pressure and temperature. <patcit id="pcit0026" dnum="US8138471B1"><text>US 8 138 471 B1</text></patcit> discloses methods and systems for inspecting gas well integrity, and more specifically to methods and systems for inspecting gas well integrity using a neutron and X-ray based inspection system. <patcit id="pcit0027" dnum="WO2018156949A1"><text>WO 2018/156949 A1</text></patcit> discloses a method and means for improving resolution of detection of an azimuthal distribution of materials, and methods and means for improving resolution of detection of an azimuthal distribution of materials in multi-casing wellbore environments.

<u>Summary</u>

0025An x-ray based cement evaluation tool for measurement of the density of material volumes through x-ray backscatter imaging, wherein the tool is configured to use x-rays to illuminate a formation surrounding a borehole and having a plurality of detectors which are configured to measure the density of the cement annuli and variations in density within is provided, the tool including at least: an internal length comprising a sonde section, wherein said sonde section further comprises an x-ray source; a radiation shield for radiation measuring detectors; sonde-dependent electronics; and a plurality of tool logic electronics and PSUs.

0026A method of x-ray based cement evaluation for measuring the density of material volumes within single, dual and multiple-casing wellbore environment through x-ray backscatter imaging is also provided, the method including at least: illuminating the formation surrounding a borehole using x-rays; using a plurality of detectors to measure the density of the cement annuli and any variations in density within; and illuminating the casing surrounding a borehole using x-rays and then using a plurality of multi-pixel imaging detectors to measure the thickness of the casing.

<u>Brief Description of the Drawings</u>

0027<ul id="ul0001" list-style="none"><li><figref idref="f0001">Fig. 1</figref> illustrates an x-ray-based tool being deployed into a borehole via wireline conveyance. Regions of interest within the materials surrounding the borehole are also indicated.</li><li><figref idref="f0002">Fig. 2</figref> illustrates one example of the azimuthal placement of near-field imaging detector arrays, arranged so as to enable imaging of the inner-most casing.</li><li><figref idref="f0003">Fig. 3</figref> illustrates one example of the axial placement of near-field imaging detector arrays, arranged so as to enable imaging of the inner-most casing while illuminated by a conical beam of x-ray, while an array of longer offset detectors interrogate the materials surrounding the borehole using the same conical x-ray beam.</li><li><figref idref="f0004">Fig. 4</figref> illustrates how manipulation of an arrangement of collimators/shields can be used to select between a fixed plurality of x-ray beams, or a rotating set of x-ray beams, and further illustrates how the casing imaging detectors would be arranged.</li></ul>

<u>Brief Description of Several Example Embodiments</u>

0028The methods and means described herein for simultaneous casing integrity evaluation, through x-ray backscatter imaging combined with x-ray-based cement inspection in a multiple-casing wellbore environment, is deployed in a package that does not require direct physical contact with the well casings (<i>i.e.,</i> non-padded). Furthermore, the method and means employ an actuated combination of collimators, located cylindrically around an X-ray source within a non-padded concentrically-located borehole logging tool, together with a single or plurality of two dimensional per-pixel collimated imaging detector array(s) used in certain embodiments as the primary fluid/offset compensation detectors. The capability of actuation of the collimators permits the operator, the opportunity between a fixed collimator mode, that provides the output of an azimuthal array of a plurality of x-ray beams (from said x-ray source), or to select through actuation, a mode that produces a single or plurality of individual azimuthally arranged x-ray beams that 'scan' azimuthally, through the rotation of one of the collimators. In one example embodiment the tool comprises an actuated combination of collimators are located cylindrically around the x-ray source within a non-padded concentrically-located borehole logging tool, together with a single two dimensional per-pixel collimated imaging detector array which is configured as a fluid/offset compensation detector or a plurality of two dimensional per-pixel collimated imaging detector arrays which are configured as fluid/offset compensation detectors, wherein collimator sleeves of the tool are configured to be actuated to enable the selection of varying x-ray beam output modes. In one example embodiment the method comprises actuating a combination of collimators, located cylindrically around a x-ray source within a non-padded concentrically-located borehole logging tool, together with a single two dimensional per-pixel collimated imaging detector array used as fluid/offset compensation detector or a plurality of two dimensional per-pixel collimated imaging detector arrays used as fluid/offset compensation detectors, wherein collimator sleeves of the tool are actuated to enable the selection of varying x-ray beam output modes.

0029In one example embodiment, an electronic-source-based borehole logging tool 101 is deployed by wireline conveyance 104 into a cased borehole 102, wherein the density of materials surrounding the borehole 103 are measured by the tool. In a further embodiment, the tool is enclosed in a pressure housing, which ensures that well fluids are maintained outside of the housing.

0030<figref idref="f0002">Fig. 2</figref> further illustrates how an azimuthal plurality of per-pixel collimated two-dimensional detectors 201 can be used to create a plurality of two-dimensional images of the well casing 202 as the tool 203 is logged. The output from each pixel can be summated as a function of depth to provide tool offset (eccentricity) data which acts as a key-input into the fluid compensation of the detectors that possess a larger axial offset (cement evaluation detectors), and hence, a deeper depth of investigation into the materials surrounding the borehole.

0031<figref idref="f0003">Fig 3</figref> illustrates that as the x-ray beam 309 (shown as a cone) interacts with the media surrounding the tool 307 within the borehole 301, 302, 303, 304, 305, the counts that are detected at each axially offset group of detectors 310, 311, 312, 313, 314 is a convolution of the various attenuation factor summations of the detected photons as they travelled through and back through each 'layer' of the borehole surroundings 301, 302, 303, 304, 305. The data each detector may be deconvoluted through the use of the data collected by the 1st order detector group 310, to compensate for fluid-thickness and casing variations alone. As the first order detector 310 is a per-pixel collimated imaging detector array, the detectors are also capable of creating backscatter images of the casing 305 itself. When the tool is actuated axially (through wireline logging) the images, collected as a function of axial offset/depth, can be tessellated to produce long two-dimensional x-ray backscatter images of the casing 305. The backscatter images may also contain spectral information, such that a photo-electric or characteristic-energy measurement may be taken, such that the imaged material may be analyzed for scale-build up or corrosion, <i>etc.</i>

0032In one embodiment, cylindrical collimators are used to provide directionality to the output of an x-ray source located within the pressure housing of a borehole logging tool. An x-ray beam or plurality of beams, rotating azimuthally around the major axis of the bore tool, interacts with the annular materials surrounding the wellbore within a single or multi-string cased hole environment to produce both single and multi-scatter responses, depending upon the axial offset of a plurality of fixed detectors that are employed to measure the incoming photons resulting from said scatter. In a further embodiment, an azimuthal plurality of per-pixel collimated two-dimensional detectors can be used to create a plurality of two-dimensional images of the well casing as the tool is logged.

0033<figref idref="f0004">Fig. 4</figref> further illustrates the rotation of the collimator 404, which permits an increase of the discrete resolving power of the azimuthal location of density variations in the annular materials surrounding the wellbore in multi-string cased-hole environments. An axial plurality of fixed collimated detector-sets 401 can be used to measure the multiple-scatter signal resulting from the interaction of the beam with the casings and annular materials. The collimator sleeves 405 may be actuated to enable the selection of varying x-ray beam output modes 402, 403. In one example of such an arrangement, a non-rotating plurality of azimuthally located x-ray beams 402 is provided, wherein each beam is accompanied by an axially-paired two dimensional per-pixel collimated imaging detector array 401. In another example of such an arrangement, the axial actuation of one sleeve 405 and the rotation of another 404 produce a single or multi-element azimuthally rotating beam 403 (similar to a lighthouse). The azimuthal plurality of detectors 401 rotates with the source collimation sleeve, such that the result is a multi-helical ribbon image that can be re-formatted to create a complete image of the 360 degrees of the casing as a function of depth/axial-distance.

0034In yet another embodiment, the collimators are used to provide directionality to the output of an x-ray source are square, formed tubes disposed within a shielding material. In a further embodiment, the collimators are used to give directionality to the output of an x-ray source are rectangular formed tubes within a shielding material.

0035In one embodiment, the output from each pixel is summated as a function of depth to provide tool offset (<i>i.e.,</i> eccentricity) data which acts as a key-input into the fluid compensation of the detectors that possess a larger axial offset (cement evaluation detectors), and hence, a deeper depth of investigation into the materials surrounding the borehole.

0036In another embodiment, the backscatter images may also contain spectral information, such that a photo-electric or characteristic-energy measurement may be taken, such that the imaged material can be analyzed for scale-build up or casing corrosion, <i>etc.</i>

0037In a further embodiment, machine learning would be employed to automatically analyze the spectral (photo electric or characteristic energy) content of the images to identify key features, such as corrosion, holes, cracks, scratches, and/or scale-buildup.

0038In a further embodiment, the per-pixel collimated imaging detector array would be a single 'strip' array (<i>i.e.,</i> one pixel wide) and multiple pixels long - the imaging result is a 'helical' ribbon image, that can be re-formatted to create a complete image of the 360 degrees of the casing as a function of depth/axial-distance.

0039In a further embodiment, the tool is maintained stationary in the well, and the source collimator would be rotated, the per-pixel collimated imaging detector array would be a single 'strip' array (<i>i.e.,</i> one pixel wide) and multiple pixels long - the imaging result would be a 'cylindrical' ribbon image. Further passes of the rotating source/detector collimator could be accumulated such that the statistical accuracy (and therefore resolution) of the image is improved for each pass.

0040In a further embodiment, the tool is maintained stationary in the well, and the source collimator would be rotated, the per-pixel collimated imaging detector array would be a single 'strip' array i.e. one pixel wide, and multiple pixels long - the imaging result is a 'cylindrical' ribbon image. The tool could be moved axially (for example, by either a wireline-winch or with a stroker) and a new image set taken, such that a section of casing could be imaged by stacking cylindrical ribbon images/logs.

0041In a further embodiment still, machine learning is employed to automatically reformat (or re-tesselate) the resulting images as a function of depth and varying logging speeds or logging steps, such that the finalized casing and/or cement image is accurately correlated for azimuthal direction and axial depth, by comparing with CCL, wireline run-in measurements, and/or other pressure/depth data.

0042The foregoing specification is provided only for illustrative purposes, and is not intended to describe all possible aspects of the present invention. While the invention has herein been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the art will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from the spirit or scope thereof.