Halliburton Energy Services
CIRCUMFERENTIAL ACOUSTIC SCANNING TOOL
INSITE OPERATION (CAST-V)
Field Operations Manual
Revision A
January 2007
D00268695
SAP P/N 101551877
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All information contained in this publication is confidential and proprietary property of Halliburton Company. Any reproduction or use of these instructions, drawings, or photographs without the express written permission of an officer of Halliburton Company is forbidden.
© Copyright 2006 Halliburton Company All Rights Reserved.
Printed in the United States of America
The drawings in this manual were the most recent revisions and the best quality available at the time this manual was printed. We recommend that you check your manual for individual drawing clarity and revision level. Should you have equipment with revisions later than the drawings in this manual, or should you require higher quality drawings than the drawings in this manual, order replacements from the Engineering Print Room in Houston.
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Revision Record
CAST-V
Insite Field Operations Manual
Date Description
19-January-2006 Release Document as Revision A
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Table of Contents
Revision Record...i Table of Contents...iii List of Figures ...v List of Tables...viii Preface ...xSection 1 – General Information...1
Introduction ...1
Product Enhancement...1
Tool Specifications CAST-V...2
CAST-V Equipment List………..………..……….4
Tool Description………..………..…………..5
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Equipment Hazards ...7
Section 3 – Calibration Procedure ...9
Section 4 – Well Site Operations ...18
Section 5 – Log Quality ...33
Section 6 – Maintenance ...36
Appendix A – CAST JOB PLANNER USER’S MANUAL...58
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List of Figures
Figure 1. Calibration Phylosophy………Error! Bookmark not defined. Figure 2. CAST-V Calibration Screen………..…….……….……….………. Figure 3. Selecting Transducer Type………..……….……… Figure 4. CAST-V Graphic View for Step 1 (T/A Mode)……….... Figure 5. Step 1 of 2 of Surface Operational Checks………..……….………. Figure 6. Step 2 of 2 of Surface Operational Checks………..………….……... Figure 7. CAST-V Graphic View Step 2 WF Mode………..……….. Figure 8. Calibration Step 2………..…………..……….….. Figure 9. CAST-V Calibration Summary………..………...…….
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Figure 13. Saving the Service……….…………..……….…… Figure 14. CAST-V Parameter Editor Window……….……….….….…… Figure 15. CAST-V Power GUI……….……….… Figure 16. CAST-V View WF Mode……….………. Figure 17. CAST-V View-Cement Evaluation Mode……….……….
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Halliburton Energy Services List of Tables
1-21-33-76-26-86-136-146-156-166-176-18
Table 1. Caption………Error! Bookmark not defined.
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Preface
This Field Operation Manual provides detail theory of operation for the Circumferential Acoustic Scanning tool (CAST-V) in INSITE Software. Study the manual to develop a thorough
understanding of the tool before operating or servicing it for the first time. Observe all notes, cautions, and warnings to minimize the risk of personal injury or damage to the equipment. Section 1: General Information–presents the tool specification, describes the equipment and explains the purpose and its use.
Section 2: Safety–contains safety procedures and references that must be observed in order to reduce the risk of death or injury to personnel and minimize the risk of equipment damage, destruction, or loss of operating effectiveness.
Section 3: Calibration Procedure--contains the tool calibration procedure.
Section 4: Well Site Operation--details tool configuration and operating procedure at the well site.
Section 5: Log Quality Control–explains the real time quality control measures. Section 6: Maintenance–contains information on tool maintenance.
Section 7: Reference--contains a list of reference materials.
Appendix A: CAST Job Planner–New CAST Job Planner User’s Manual. Appendix B: Insert Name–Description.
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Section 1:
General Information
Introduction
This document describes in detail the operation of the Circumferential Acoustic Scanning Tool (CAST-V) using the INSITE software. Read this manual thoroughly to gain deep understanding of this tool before operating it the first time. Observe all safety notes and cautions when
operating the tool to prevent personal injury or equipment damage.
Previous knowledge of the CAST-V tool in CLASS is assumed in preparing this document. Please refer to the Field Operations Manual (P/ N 100009549 and 100009443) for details of the theory of operation of the tool in cased and open hole respectively. The operation of the tool in CLASS is also discussed in detail in these manuals.
The INSITE software is a direct migration of the CLASS software codes for the CAST-V to INSITE with added enhancement especially in the Graphic User Interface (GUI) for waveform display in both open and cased hole applications. As in CLASS, there are two applications for running CAST-V in INSITE Imaging or Open hole mode and Cased hole mode.
Tool Specification; CAST-V SAP Part Number: 100144829
Refer to the link above to view the detailed technical tool specification for CAST-V.
Section
1
DIMENSIONS AND RATINGS
CAST-V Equipment List
Table 1-1 TOOL EQUIPMENT
DESCRIPTION PART NO. DIMENSION WEIGHT
CAST-V Tool 100144829 17.9 ft x 3-5/8 in. OD 5.45 m x 92.1 mm 316 lb 143 kg
CAST-V Electronics Assembly 100144828 10.2 ft x 3-5/8 in. OD 3.1 m x 92.1 mm 190 lb 86 kg
CAST-V Directional Sub 100144803 3.0 ft x 3-5/8 in. OD .91 m x 92.1 mm 38 lb 17 kg
CAST-V Scanner Assembly 100144779 4.7 ft x 3-5/8 in. OD 1.43 m x 92.1 mm 88 lb 40 kg
CAST-V Auxiliary Heads,2, 3
3-5/8-in. Head Assembly 707.55576
4-3/8-in. Head Assembly 707.55553
5-5/8-in. Head Assembly 120037983
7-in. Head Assembly 100144874
Transducers2, 3
250 kHz (White) 100010435
350 kHz (Brown) 100143708
450 kHz (Black) 100143712
2
Refer to Appendix B of this manual for the recommended Head and Transducer selections.
3
Refer to Appendix C of this manual for the procedure to change the Head Assembly in the Scanner Assembly.
Table 1-2 AUXILIARY EQUIPMENT
DESCRIPTION
PART
NO.
DIMENSION
WEIGHT
Centralizer, Standard Over-Body for 3-5/8 in. 100009785 Centralizer, 19-pin DITS Inline Bowspring 100132737 SDDT-A, Optional Navigational Instrument 100143724 Centralizer, 7 in. to 13-3/8 in. Casing 4 101217962
Oil Fill Gauge (used to check the Scanner oil
fill) 100144876
Chassis Insertion/Removal Tool, 3-5/8 in.
DITS 100132254
Thread Protector, Male, Standard DITS 100132237 Thread Protector, Female, Standard DITS 100132239
DITS 19-Pin Break-Out Box 100128380
Spanner, 3-5/8 in. Standard DITS 100128380 CAST-V Service Manual (order through
Records and Supply in Houston)
Fanfold Paper 100004311
Engineering Documentation Package (EDP)
Bracket, Calibration Stand 100144847 Adapter, Calibration Stand 100144846 Calibration Stand Assembly 100145231
DITS 37-Pin Jumper Cable 100010329
DITS 19-Pin Jumper Cable 100135008
Centralizer, Slipover, Gemco, 5-½ in. Casing 100120926 3 ¾ in. ID x 4 5/8 in. OD
Centralizer, Slipover, Gemco, 7 in. Casing
100120927 or
100110238 3 ¾-in ID x 6 ¼-in OD
Centralizer, Slipover, Gemco, 7-5/8 in. Casing
100120928
3 ¾ in. ID x 6 ¾ in. OD
Centralizer, Slipover, Gemco, 9-5/8 in. Casing
100120929 or
100110240 3 ¾ in. ID x 8 15/16 in. OD Centralizer, Slipover, Gemco, 8-5/8 in.
Tool Description and Basic Theory of Operation
Refer to the manual SAP (P/N 100009549 and 100009443) for detailed tool description and basic theory of operation of the CAST-V tool.Tool Operating Modes
There are two service types for the CAST-V tool in INSITE as follows: CAST_VI: Image Mode of Operation (Open Hole).
CAST_VH: Cased Hole Mode of Operation.
Depending on the service type selected, the software will display the GUI specific to the application and also present only the parameters used to set up that particular mode of operation.
Section 2:
Safety
Danger to Personnel
Refer to the Halliburton Management System (HMS) for the Logging and Perforating Service Delivery Linkage of Processes. The HMS processes can be found at the following link:
http://halworld.halnet.com/WRK/WRKhms/wrkhms_content/processes/HES/HES_Logging/NetFi les/LP-GL-HES-LP-000.htm
General safety guidelines are also covered in publication 770.00356, Safety and Health Manual. Detailed information on all associated HSE risks are provided as well as links to all safety related manuals.
High Voltages
When the CAST-V electronics is out of the chassis, high voltages are present at some points in the electronics. Care must be taken when working on the tool to prevent electrical shocks. Only qualified technicians should attempt repairs on the electronics.
The CAST-V is a DITS tool and is powered with 120 VAC for the instrument and up to 250 VDC for the scanner motor. Care must be taken to observe all safety precautions when working with the tool.
Heavy Equipment
CAST-V has three sections which are fairly heavy. Use proper lifting techniques when lifting the tool to avoid back injury. Use lifting aids as much as possible and do not attempt to lift the tool by yourself. Seek help from others.
Section
2
Section 3:
Equipment Hazards
Risk of equipment damage exists if the CAST-V scanner is not handled properly. The scanner shaft must never be subjected to any load as this can permanently bend the shaft resulting in severe damage to the tool. The scanner head must be protected during transportation as well. The scanner head must never be dragged along the catwalk while rigging up at the well site.
• Do not subject the scanner shaft to any loading.
• Protect the scanner head while transporting or rigging up at the wellsite. • Do not drag the scanner head on the cat walk while rigging up.
• Make sure there is enough oil in the tool before running in the hole.
9 Use extreme caution when lifting the Scanner Assembly. The Scanner’s motor shaft can be easily bent or damaged if it is not handled properly. The Scanner Assembly should be lifted and lowered in the well separately from the CAST-V Electronic Assembly.
9 Use extreme care when handling the transducers. These devices are sensitive to shock and vibration. Avoid bumping or hitting these devices.
9 Ensure that the CAST-V pressure-balance system contains oil to the proper level and that the oil is contaminant-free after every logging job. Both contaminated oil or low oil levels can cause severe damage to the tool even if the tool is operating in wells where the temperature and pressure are within normal specifications. Contaminated oil and low oil levels significantly reduce the operating temperature and pressure limits of the tool.
9 Do not exceed CAST-V pressure, temperature, or electrical limits during operation. 9 Do not “spud” with the tool; otherwise, damage to the motor shaft or face seal may
Section 4:
Calibration
Calibration Procedure
The shop calibration must be performed before every job. The calibration standards are shown in the table below. The calibration procedure is the same for open or cased hole service. The following example is for a cased hole service:
Main Transducer
Measurement
Imaging Mode
Cased Hole Mode
Shop Transit Time Calibrator P/N 100071892 100144881Mud Cell Transducer
Measurement
Imaging Mode
Cased Hole Mode
Shop Transit Time Calibrator P/N 100144761 100144761Calibration Procedure
1. Assemble the tool horizontally on stands and rotate the tool until the mud cell cover faces upwards. Remove screws holding the cover in place and take off the cover.
2. Rotate the scanning head until the main transducer faces upwards as well.
Attach the calibrator (P/N 100071892 or 100144881) to the main transducer making
certain that the face of the transducer is clean and calibrator is firmly attached to the
face of the main transducer. Use grease or silicon to help couple the calibrator firmly
to the transducer surface. Fill the mud cell compartment completely with clean water.
3.Section
4
Figure 3. Data Acquisition Window
9 Start the latest release version of the INSITE software and load the appropriate
service (CAST-VI or CAST-VH), apply instrument power and initialize the tool.
Refer to Section 4 -- Well Site Operation for information on how to set up the
service. Make necessary changes on the parameter table.
9 On the Data Acquisition window (Figure 3.), click Configure and select “Tool
Calibration” to open the tool calibration window.
Figure 4. CAST-V Calibration window
9 Under CASTSCAN, select Shop and click Calibrate. Select the transducer type
on the setup window (Figure 5.) . Click Next to go to step 1.
9 Install the calibrator (P/N 100071892 for open hole transducer or 100144881 for
cased hole transducer). Fill the mud cell compartment with water to totally cover
the surface of the mud cell transducer. Wait for the readings to stabilize and click
Calibrate on the CAST-V Shop Calibration window to acquire the data. Click
Next to go to step 2.
9 Insert the mud cell calibration (P/N 100144761) over the target opposite the mud
cell transducer. Wait for the readings to stabilize and click Calibrate to collect the
data.
Click Next to display the result of the calibration. Check to be sure the calibration is
within the set tolerances. Click Finish to end the calibration.
Figure 8. CAST-V Shop Calibration Summary
It may be necessary to perform the shop calibration twice for the system to compare the current with the previous calibration.
When the calibration is finished, it must be loaded and lock in by clicking Load, selecting the calibration and clicking Load again.
A typical calibration report is shown in Table 2.
CALIBRATION REPORT
Circumferential Acoustic-Scanning Tool - SHOP Calibration Tool Name: CASTSCAN - 001 Reference Calibration Date: 06-Dec-06 11:35:56
Engineer: Calibration Date: 06-Dec-06 11:53:47 Software
Version: Calibration Version: 0
Measurement Reference Shop Shop Difference Tolerance Units
Mud Cell Offset 40.60 40.60 0.0000 +/- 5 uS
Mud Cell TT 0.000 0.000 0.0000 .2uS
Mud Cell Gain 14 14 0.0000
Mud Cell AMP 107 108 -1.0000
Transducer Offset -4.35 -3.87 -0.4800 7 +/- 3 uS
Transducer TT 46 46 0.0000 uS
Transducer Deviation 2 2 0.0000 uS
Table 2. CAST-V Calibration Report
Section 5:
Field Verifications
The field verification involves checking the tool to ensure that it is operational at the wellsite. This verification involves powering up the tool and establishing communication with the tool. Apply motor power to rotate the scanner head and check that the tool is sending data to the surface system. The Graphic User interface for open and cased hole operation is shown in the following figures:
Figure 10. CAST-V Imaging Graphic Display
Before Survey Field Verification
There is no before survey calibration routine for the CAST-V tool. Verify that the
tool is functioning properly prior to running in the hole.
After Survey Field Verification
Section 4 – Well Site Operations
Section 6:
Preparation
CAST-V is a Digital Interactive Telemetry System (DITS) tool and can be run using the INSITE surface system (LOGIQ) or CLASS software; however, this manual will discuss how to operate the tool in INSITE only.
Preparing the CAST-V Tool For Logging Operation
Perform the PM-1 checks on the tool. Refer to the Preventive Maintenance (PM-1) for
the tool in the FOM (P/N 100009549 & 1000009443).
Determine the proper head and transducer for the casing size to be logged using the
planner (refer to Appendix A). It is imperative that the appropriate head size and
transducer frequency be used to record quality log data.
Install the appropriate transducer and head onto the Scanner and evacuate and fill the
Scanner with oil (refer to the maintenance section of the service manual P/N
100009548).
Insert the Directional Sub into the tool string. In cased hole applications, the CAST-V
Directional Sub provides hole deviation and relative-bearing information. This sub is
inserted between the CAST-V Electronics Assembly and the Scanner Assembly. The
Stand Alone DITS Directional Tool (SDDT) must be used instead of the directional sub
in all open hole imaging application. The SDDT is inserted above the CAST-V
electronics when used in the tool string. Additionally, if a DITS Casing Collar Locator
(CCL) is used, the CCL is installed above the telemetry cartridge.
Section
4
Section 7:
Ensure the tool string is
centralized properly. Proper centralization is
critical in recording good quality data. In
cased hole wells, sufficient number of
centralizers must be used to maintain
eccentricity to less than 0.2 in.
Section 8:
Configuring the Logging System
This document describes running CAST-V with the LOGIQ system. On the LOGIQ
system, the Digital Interface Model Panel (DIMP) main selector switch should be set to
DITS to run the CAST-V service. On other surface systems, the appropriate switches
must be configured correctly to run the service.
Setting Up the Logging Service
1. Launch the latest version of the Wire Line INSITE (WLI) software.
Figure 11. INSITE System Manager Panel
Click on Data Acquisition under Logging to open the Initial Setup Window.
2.Figure 12. Service Setup
Click Select New Service from the menu list.
From the Service Selection window, select the CAST-V services as follows:
3.For imaging application: SDDT/CAST_VI /CASTNAV/CASTSCAN.
For Cement evaluation or pipe Inspection: CCL_D/CAST_VH/CASTNAV/CASTSCAN.
For Imaging or open hole service, the two axis navigation sub can be replaced with the three axis SDDT tool. The SDDT tool must be installed above the CAST-V electronics in this case. The 2-axis sub can be left in place if desired. For imaging in cased
Figure 13. Service Selection Screen
The service must be saved before it can be loaded. Give the service an appropriate name, save it and proceed to load the
service.
After loading the service, the Parameter Editor Window should open displaying the
parameters for the tools in the string. Important parameters that must be set correctly
are the following:
Logging Interval Cased? Y/N if Y, Casing OD & Weight
Compute CAST Results?
Impedance Cal. Reference
Use Fix FTT
Head Type
Transducer Position
Transducer Type
Refer to the parameter table for the list of parameters and their suggested values.
Figure 15. CAST-V Parameter Editor Window--Open Hole Application
Click the pen icon on the Parameter Editor window to go into edit mode. Make
appropriate changes and click the pen icon again to save the changes. Close the
Parameter Editor window. The power display should open as shown in Figure 16. The
system is now ready to send power to the tool using the power display.
Figure 16. Power Graphic User Interface with No Power
The tool head voltage is 120 VAC and 60 Hz via AC1 power supply. Set an initial value of about 120 VDC and attach tool power. Increase power until null is achieved. Monitor AC1 voltage
at the top of the tool using the tool data monitor menu in DQA panel. Do not apply motor power DC1 until communication is
established with the tool.
Power up the tool by attaching the AC1 Instrument power supply. Adjust the power level
until null Instrument meter is at the middle position (0). Tool should initialized and start
communicating with the surface system.
Once communication is established with the tool, set a starting value for the motor
voltage
(60-200 VDC) and attach DC1 power. The scanner head should start turning at this
time. Confirm that the scanner is not taking excessive current to operate the sequence.
Figure 17. Power Display with Both AC1 & DC1 Power Attached
Verify that the tool is functioning properly and sending data to the surface system. Click
on the CAST icon on the Data Acquisition window to launch the graphic display. The
sequence should be updating regularly and the CAST-VI or CAST-VH data light should
be green on the graphic displays.
Figure 18. Data Acquisition Window
CAST Graphic DisplayData = Green Sequence Updating
Figure 16. CAST-V View--Imaging Mode
Prepare the tool for running in the hole. Install the appropriate centralizers on the tool to
ensure adequate centralization. Eccentricity should be less than 0.2 at all times. If
running in combination with CBL, be sure to have proper centralizers on the CBL tool as
well.
Data = Green Sequence Updating
Logging Operation
Monitor the tool null meter while going into the hole. The meter will drift slightly as the
line is being spooled off the drum.
Monitor the Motor Speed (MSPD) while lowering the toolstring in the hole. The MSPD
may vary with fluid viscosity; however, it should remain fairly constant and will slow
down if it hits an obstruction with the motor current rising considerably.
Display data monitor and the graphic interface. Verify tool is functioning properly by
monitoring data from both screen.
Once the toolstring is lowered to the logging depth, adjust the motor speed to the value
recommended by the planner and start logging by adjusting the DC1 power supply. Use
the CAST-V View and display to ensure the tool is functioning properly and that the
parameters desired are been used.
While logging the main pass, check the log with other repeated sections of the well.
Monitor the amplitude values and select the pallet scale accordingly.
Rig down the toolstring opposite the order which it was rigged up. Make certain to lay
the scanner down separately.
Wash the tools. Make certain that the Scanner Mud Cell and the piston compensation
area is washed thoroughly free of well fluid and debris.
Logging Screen-CAST-V View-Imaging Mode
The graphic interface (CAST-V View ) contains useful information about the operation of
the tool as follows:
Position Reference. This parameter refers to the reference to which the image data is
aligned. It is recommended to align to azimuth of pad1 in open hole and the relative
bearing in cased hole.
CAST-VI Data Light. This light comes on when the tool is sending valid data and off
when no data is being sent. The data here refers to telemetry data.
Motor Speed (MSPD). This is the actual scanner head rotational speed (rps). The
display is green when the value is less than the maximum and red when it is greater
than the maximum allowable value
Motor current. This variable displays the actual motor current. Should be same or
close to value displayed on the Sorensen power supply (amp).
Max. Line Speed. This is the maximum logging speed as recommended by planner.
This parameter is calculated based on the number of shots/scan and scan/ft required for
the application.
the sample point.
Min Radius. This is the smallest measured radius for the sample point.
The operator can change the gate start time, display the waveform and freeze the waveform if desired.
Logging Screen: CAST-V View--Cased Hole Mode
Figure 17. CAST-V Cased Hole Graphic Interface
The Cased Hole Graphic Interface displays the following information:
Number of Waveforms. There is a drop down box that enables the operator to select
the number of waveforms to display (1-20). The waveforms are displayed in a window
with the waveform numbers.
CAST-VH Data. This light is green when the tool is sending data and gray when no data
is being sent.
Sequence. This is a counter that should be increasing when the tool is functioning
properly.
Motor Current. This indicates the motor current downhole. The motor current should be
stable when the motor is rotating at a constant speed.
Max Log Speed. This is the maximum logging speed as determined by the planner.
Position Reference. This is the reference to which the tool position in the borehole is
aligned. In cased hole, the reference should be to the relative bearing.
In Cased Hole Mode, the gate start time is fixed at 30 micro-seconds. The graphic
display also shows the Impedance, radius and thickness as well.
Another window is used to display Bad Shot Indicators (BSI) as shown in Figure 18.:
Figure 18. Bad Shot Indicator Window
Bad Shot Indexes
error is indicated by blue bars across the affected shots.
Thickness Calculation Error. This error occurs when the computed casing thickness
calculated based on the resonance window information is wrong. Bars in cyan show up
across the affected shots.
Impedance Calculation Error. This occurs when the impedance calculation is wrong.
Red bars are shown across the shots affected.
The graphic interface also contains the main transducer’s display window that simulates
the mode the tool is being run. A second window shows the main transducer waveform
with the option to display any of the shots in a scan.
Other outputs that are displayed on the logging graphic interface window are:
Amplitude. This is the peak amplitude of the first arrival waveform as detected by the
software.
Ovality (OVAL). This is = ((maximum/minimum)-1.0). It is a measure of how round the
borehole or casing internal surface is.
Eccentricity (ECTY). This value is computed as the maximum absolute value of 50
possible differences between sets of opposing valid acoustic caliper values. The
eccentricity is an indication of how well centered the tool is in the bore hole. The amount
of shift from the center of the hole is the value of the eccentricity.
The typical range for FTT is between 180 to 220 µsec/ft. Oil-based muds have a
longer FTT (210 to 220), while fresh and salt muds have a shorter FTT (189 to 210).
Many factors (e.g., additives and solids in the mud) will affect the fluid travel time,
but the tool should still measure FTT within the expected range if the tool is working
properly. FTT is used in calculating the casing diameter, so if it appears that the
measurement transducer is operating properly and the mud cell is not, the Flash
Table parameter can be changed to use a “fixed TT” for the mud cell. This may be
the case when the mud-cell transducer fails, or if debris accumulates on the mud-cell
face.
The fluid travel time is used in the acoustic-impedance calculations. If there is a mud-cell failure, the thickness calculation
will be in error. The fixed value for FTT can be estimated from the before-survey calibration.
Average Casing OD (AVOD). The AVOD of the casing is calculated by the addition of
the average ID of the pipe [(calculated from the effective head radius, transit time (TT),
and the fluid travel time (FTT)] and the wall thickness of the casing (calculated in the
tool from the resonance of the reflected signal). The AVOD calculation is as follows:
logged. The AVOD will display the nominal casing OD from the Flash Table in
the “RANG” mode.
Acoustic Impedance (AVZ). This value is calculated from the resonance sum
(Sw), the casing thickness (Ct), and the calibration coefficients (a
0,b
0,c
0,d
0) derived
from all valid waveform of each scan. The algorithm corrects for all environmental
disparity. The equation used for the computation is:
Z = a0 + b0Ct + c0 Log (Sw) + d0Ct Log(Sw)
Where Z is the acoustic Impedance (in MRayls). Ct is the casing wall thickness
(in inches). AVNS is the ratio of the absolute sum of the 64 data points in the
resonance window divided by the peak amplitude of the first arrival. ZREF is the
acoustic Impedance of the material behind casing at the calibration point.
Figure 19. Resonance Window for Casing Thickness and Cement Impedance Calculations
Free pipe with water behind the casing typically has an acoustic impedance of 1.5
MRayls. For other common acoustic-impedance values, refer to the table under heading
2.4, Log.
Section 5 – Log Quality
Log quality control for the CAST-V is critical to ensure accurate data is obtained at the wellsite. The engineers must perform real time log quality control while logging. The CAST-V GUI contains some bad shot indicators that can help monitor tool performance in real time thereby enabling any errors to be captured.
Section
5
These Bad Shot Indicators (BSI) are circled in Figure 18. and are the basic quality control sequences for CAST-V measurements. These error counts must be monitored closely during logging. The detailed explanation of the errors is as follows:
Tool Pick Error. This indicates an error in the down hole firmware picking of the point on the waveform train where to start searching for the first arrival peak amplitude. When this occurs, a counter shows up indicating the number of shots with bad pick time detected by the tool per scan. This error is caused usually by targets too close or too far, highly attenuating medium or highly eccentered tool. Shots with this flag set are not processed.
Transit Time Error. This flag is set when the transit time calculated by either the downhole or uphole software is not consistent. The consistency is measured between the peak of the first reflection and the start time based on the calculated transducer frequency. This is important for the waveform mode (Casing thickness and cement evaluation). A blue dat will appear in the image graphic display when the transit time error occurs.
Casing Thickness Error. This flag is set when the casing thickness calculated from a shot less than 0.1” and more than 0.9” (0.1<Thk>0.9). The number of shots with this flag set is also
displayed.
Impedance Error. This flag is set when the calculated impedance is negative or greater than 60 MRayls. The results are presented but flagged to indicate that they are not reliable.
A bar is displayed across the shots with a particular error. The color of the bar display is the same as that of the error situation detected (Red, Green Cyan and blue).
Eccentricity. This is an indication how centralized the tool is in the bore hole. Adequate
centralization is very important for the CAST-V tool. Eccentricity should be less that
0.25”. Higher value of eccentricity indicates lack of centralization and may jeopardize
the quality of the data.
Ovality. This is an indication of how round the bore hole shape is. The ovality of the
bore hole will affect the angle of reflection of the ultrasonic waves from the transducer
and therefore the amplitude of the arrival signals.
Fluid Travel Time (FTT). The fluid TT should be stable and fairly constant. The fluid
TT may decrease slowly from TD to casing shoe due to solids settling at the bottom of
the bore hole.
Transducer Frequency. Transducer frequency reported by the tool should be close to
calibrated values through the log.
When run in combination with CBL, the impedance, pipe amplitude and the MSG should
correlate well.
Section 6 – Maintenance
General
M
aintenance
The following basic maintenance must be performed on the CAST-V after every job:
Wash the entire tool thoroughly after every job paying particular attention to the mud cell
area. Wash the mud cell slot thoroughly to be clear of any mud or other materials.
Apply lubricant or penetrating oil to the surface of the housing to prevent rust and
corrosion.
Clean the threads and threads protectors at the upper and lower heads. Inspect the
O-rings for defects and replace if necessary. Apply lubricant grease to the threads.
Perform PM-1 on all sections of the tool.
Perform operational check on the tool and ensure tool is functioning properly.
Assemble and calibrate the tool and confirm the transducer frequency has not changed
significantly.
1.
Electronic Assembly
Place new PM-1 pinout here.
Directional Sub
Using a pressure hose, wash the tool until it is free of all dirt and mud.
Remove both thread protectors. Use a rag and contact cleaner to remove all grease
and mud from the inside of the thread protectors. Do not use a pressure hose on the
electrical connectors.
On the upper head, remove and clean the DITS threaded-ring assembly.
Clean the connector housing until all grease and mud is removed. Use a dielectric
cleaner to clean the connector contacts.
2. Reassemble the DITS threaded ring and split-ring assembly. When reassembling,
Section
6
Inspect all pins, sockets, and insulators for signs of damage and replace as needed.
Perform the following PM-1 checks. Use only a Simpson 260 VOM to check the tool.
UPHOLE END OF TOOL
FROM
TO
READ
SCALE ITEMS CHECKED
ACTUAL
(NOTE1)
(NOTE2)
READING
1-5 CHASSIS OPEN RX100
Through
wires
6
CHASSIS SHORT RX100 Chassis ground
7 - 10 CHASSIS OPEN
RX100 Through wires
11
CHASSIS SHORT RX100
Power ground (same as
chassis)
12 - 13
N.C.
14
CHASSIS OPEN
RX100 Through wires
15
CHASSIS OPEN
RX100 Through wires
16
N.C.
17 (+) CHASSIS 10K-12K RX100 +15 VDC power input
17 (-) CHASSIS 600-800 RX100 +15 VDC power input
18 (+/-) CHASSIS
1700-
3300
RX100 -15 VDC power input
19
N.C.
20
CHASSIS OPEN
RX100
21
CHASSIS OPEN
RX100
22
CHASSIS OPEN
RX100
23
N.C.
24 (+/-) CHASSIS 15K-23K RX10K Magnetometer Y axis output
25 (+/-) CHASSIS 15K-23K RX10K Magnetometer X axis output
26 (+/-) CHASSIS
2500-
4100
RX100 Inclinometer X axis output
27 (+/-) CHASSIS
2500-4100
RX100 Inclinometer Y axis output
28
CHASSIS
4600-
5000
RX100
Temperature output of
inclinometer package
29
CHASSIS SHORT RX100 Signal Ground
30 - 34
N.C.
35 - 37 CHASSIS OPEN
RX100 Through wires
NOTE 1: Parenthesis indicates the polarity of the meter lead which connects to the
test point. NOTE 2: All readings are taken with the Simpson 260. Different brands of
meters will read different resistances when checking nonlinear circuits (i.e., circuits
with semiconductors present).
FROM
TO
READ
SCALE ITEMS CHECKED
UPHOLE DOWNHOLE
READING
ACTUAL1 1
SHORT RX1 Through
wires
2
2
SHORT RX1 Through wires
3
3
SHORT RX1 Through wires
4
4
SHORT RX1 Through wires
5
5
SHORT RX1 Through wires
6
6
SHORT RX1 Chassis ground
7
7
SHORT RX1 Through wires
8
8
SHORT RX1 Through wires
9
9
SHORT RX1 Through wires
10
10
SHORT RX1 Through wires
14
14
SHORT RX1 Through wires
15
15
SHORT RX1 Through wires
20
20
SHORT RX1 Through wires
21
21
SHORT RX1 Through wires
22
22
SHORT RX1 Through wires
35
35
SHORT RX1 Through wires
36
36
SHORT RX1 Through wires
37
37
SHORT RX1 Through wires
Directional Sub Check
The Directional Sub requires two types of measurement checks: a
magnetometer-measurement check (the azimuth) and an inclinometer-magnetometer-measurement check (the relative
bearing and deviation). The two-axis magnetometer measures the tool orientation with
respect to the magnetic north, while the two-axis inclinometer measures tool orientation
with respect to the high-side-of-hole, and hole deviation. Thus, the Directional Sub must
be set up on the test stand, powered up by the logging system, and placed in several
positions such that readings from the test stand and the logging system can be taken
and compared. Comparing the readings from the logging system and the test stand will
determine the operating condition of the Directional Sub.
Use the following steps to ensure the Directional Sub is operating properly:
Align the Test Stand (100145231) using a compass and a level (Figure 3.1).
Ensure that the test stand is as far away from all metals that can cause magnetic
disturbance, and then position the stand on a flat, smooth surface.
Using a compass, align the test stand with respect to magnetic north (Figure 3.1).
Adjust the three screws at the base of the test stand until the stand is level. Use a level
to measure offset. Also, use the level to set the cradle vertical, and then set the
adjustable pointer on the semi-circular disk to 0 degree.
Install the adapter (100144846) onto the test stand using three socket-head cap screws
(100112207). Notice that the threads of these screws are metric.
Mount the Directional Sub Chassis in test stand by inserting the lower DITS connector
into the adapter (100144846). Place the upper bracket (100144847) over the top DITS
connector and clamp it to the test stand. Ensure that the chassis can be rotated freely,
and that the top bracket is placed low enough on the tool to allow the jumper cable to be
plugged into the top of the Directional Sub.
Connect the 37-pin jumper cable (100010329) from the top of the Directional Chassis
and to the bottom of the CAST-V Electronics (100144828). Use the standard 19-pin
DITS jumpers to connect the DSTU/D2TS and the cable head to complete the tool
string.
Ensure the EXCELL 2000 logging system is set up properly (refer to Section 2 under
heading 2.1.1.2, Configuring the Logging System,XL2000-B). Next, enter Service
Selection 2330 on the EXCELL 2000, and then select the DGR configuration to display
azimuth, relative bearing and deviation on the standard logging screen.
Use the following to check the Directional Sub Magnetometer:
3.1. Position the Directional Sub Chassis and cradle to vertical, with the pointer
on the semicircular disc set to 0 degree.
2. Rotate the Directional Sub Chassis and cradle until the fixed pointer on
the cradle aligns with 0 degree on the circular disc. The DITS button
should now be aligned with north, and the logging screen should display 0
degree ± 3 degrees for AZIMUTH.
3.
4. If the value for the azimuth is not within ± 3 degrees, refer to the Directional Sub Test Procedure (770.10566) for instructions on adjusting the magnetometer circuitry. If the value of the azimuth is consistently off tolerance in the same direction (e.g., each reading is 3.5 degrees clockwise of the true azimuth), then either the magnetometer is out of position, or the test stand was not oriented correctly. In either case, it may not be necessary to go through the entire Directional Sub Test Procedure.
5. Rotate the Directional Sub Chassis and cradle clockwise at 45-degree
increments, and compare the circular disc readings with the logging
screen AZIMUTH readings. If both readings are within ± 3 degrees at
each increment, then the Directional Sub Magnetometers are functioning
correctly.
Use the following to check the Directional Sub inclinometer:
4.With the Directional Sub chassis and cradle still positioned to vertical (as was done in
step 3.a. of this procedure), verify that the reading for DEVIATION on the logging
screen displays 0 degree ± 2 degrees.
Incline the Directional Sub chassis and cradle to 45 degrees and then 90 degrees
(Figure 3.2). Compare the semi-circular disc reading to the logging screen DEVIATION
reading for each setting. The semi-circular disc readings and the logging screen
DEVIATION readings should be within ± 2 degrees.
Incline the Directional Sub chassis and cradle to 5 degrees on the semi-circular disc
(see Figure 3.3) and rotate the Directional Sub and cradle to 0 degree on the circular
disc. The logging screen should display 0 degree ± 2 degrees for RELATIVE
BEARING.
Accuracy and stability of the relative bearing reading decreases in deviations of less than 2 degrees.
With the Directional Sub and cradle set at a 5-degree deviation, rotate the cradle
circular disk clockwise in 45-degree increments, and monitor the circular disc reading
and the RELATIVE BEARING reading on the logging screen at each increment. The
circular disc readings and the RELATIVE BEARING readings should agree within ± 2
degrees.
Repeat step d. at 45-degree and 90-degree deviations (counterclockwise from 5
degrees). If the circular disc readings and the logging screen RELATIVE BEARING
readings are within ± 2 degrees for each setting, then the Directional Sub inclinometers
are functioning correctly.
Switch to the Processed Telemetry Logging Screen, and verify that the temperature as
indicated on the logging screen is within 9 degrees of the ambient temperature.
3.3.4 Scanner Assembly
• Wash the Scanner Assembly thoroughly to remove all debris, such as shale and
mud. Direct the water stream into the slotted end cap of the pressure-balance
cylinder (under the slots in the cylinder cover) until the water flows out clean.
Wash the area around the rotating shaft, where it exists the lower end of the tool;
this washing cleans the area around the face seal.
• Using the pressure-balance piston gage, verify that the tool contains the proper
oil level. If the piston gage measures low, evacuate and fill the tool using the
procedure under heading 3.3.4.1 of this manual.
• Visibly inspect all exposed O-rings for cuts or nicks, and replace them as
needed. Refer to the CAST-V Service Manual for the seal guidelines.
• Redress the threaded ring. Use the proper lubricant to grease the threaded ring
and the other seals. Refer to Section 3, Disassembly/Assembly, of the CAST-V
Service Manual (100009548) for instructions on how to service the threaded ring
and for the list of approved lubricants.
• Check all pins and insulators at the top of the tool and replace if necessary.
• Perform the following PM-1 checks. Use only the Simpson 260 VOM for these
checks.
UPHOLE END OF CHASSIS
ITEMS CHECKED
FROM (NOTE 1)TO
READ (NOTE 2)SCALE
ACTUALREADING
1 2 OPEN
RX1
Scanner
Transducer
3
4
VARIABLE RX100
Identification Resistor, If
Used
6
CHASSIS SHORT
RX1
Chassis Ground Wire
1-5
6
OPEN
RX100
Circuits Which Should Be
Open To Chassis
7-37
6
OPEN
RX100
Circuits Which Should Be
Open To Chassis
7
9
OPEN
RX100 Mud Transducer
11
N.C.
12
N.C.
13
N.C.
14
21
55-70
RX1
Resolver Output Winding
15
21
55-70
RX1
Resolver Output Winding
16-19
N.C.
20
GND
OPEN
RX100
Shield (Pin 20) For Resolver
Wires
20
21
OPEN
RX100
Shield (Pin 20) For Resolver
Wires
23-34
N.C.
35
37
9-10
RX1
Motor Winding
36
37
9-10
RX1
Motor Winding
36
CHASSIS
OPEN
Motor Winding Insulation
NOTE 1: Parenthesis indicates the polarity of the meter lead which connects to the
test point. NOTE 2: All readings are in ohms and taken with the Simpson 260.
Different brands of meters will read different resistances when checking nonlinear
circuits (i.e., circuits with semiconductors present).
CAST-V Scanner Oil-Fill Procedure
The Scanner Assembly holds approximately 2 quarts (1.75 liters) of oil. The
recommended oil for the CAST-V Scanner is Exxon Turbo Oil 2380 (100124775). This
oil should not be substituted or mixed with any other types of oil either in the tool or in
the vacuum fill system under any circumstances; otherwise, tool contamination will
result. Refer to engineering drawings 100144779 and 100144780, and the procedure
below for evacuating and filling the Scanner’s pressure-balance system. Notice that the
numbers in parentheses represent the location numbers on drawing 100144780, unless
specified otherwise.
Ensure the Scanner Assembly is supported securely on the tool dolly.
Remove the check-valve assembly to evacuate the tool. There are two evacuation ports
on the Scanner body and on the transducer holder. The upper port on the housing is
threaded deep for a removable check valve (47) as shown on drawing 100144780.
Install the three oil-fill tubes (P/N 100144811) and evacuate using Exxon Turbo Oil (P/N
100124775) per Spec 770.00013.
Do not attempt to seal a vacuum leak at the face seal by applying silicon grease around the shaft. The vacuum leak will suck the grease inside the tool and cause damage to the sealing surfaces of the face seal. If a leak persists, remove the fill tube at the bottom of the head and install the oil plug. Stand the tool vertical with the head in a large container filled with turbo oil. The oil in the container must completely cover the face seal area. Secure the tool vertically and continue evacuation.
Once the tool is filled with oil, remove the fill tubes and install the lower scanner plug
(25) and the head plug. Install the check valve (47) in the upper fill port and reinstall a fill
tube.
Install a piece of ¼-inch Tygon tubing (or similar tubing) to a hand-pressure pump filled
with Turbo oil. Stroke the pump several times to bleed any air from the tubing and top
off the fill tube with oil. Secure the tubing to the fill tube with a small hose clamp.
a. Pump the piston back with oil until the score mark on the oil fill gage (100144846)
is aligned with the inside face of the spring cap (45). See Figure 3.4 and drawing
100144779 for the piston set dimension and gage position.
b. Bleed the pressure off the pump. Remove the oil-fill tube and install the fill-port
plug. It is not uncommon for the check valve to leak a small amount of oil. If the
check valve leaks excessively and will not hold pressure, remove the check valve
and clean it by depressing the ball and blowing air or by soaking the it in solvent
to remove any debris between the ball and seat. If the check valve continues to
leak, use a small brass flat tip punch to strike the ball from the washer and spring
side. Striking the ball will increase the seat sealing area. If the check valve
continues to leak excessively, remove the valve and wrap the threads with teflon
tape. Wrap only the thread area--tape across other areas must be trimmed away.
Install the cover (28).
3.4 RELATED MAINTENANCE
Information for this subsection will be supplied at a later date.
CAST-V SPARE PARTS
Spare parts for the CAST-V are categorized by four type of lists. These lists are as
follows:
Accessory List (707.55636). This list includes items that are needed to run the
service, or to perform the master calibration or any other field calibration. Accessory
parts include calibration stands, special makeup jigs, etc. Special lab equipment
needed for the CAST-V, such as assembly/disassembly tools, is also included here.
Parts not included are those that are used in mandatory factory rebuilds.
Primary Spare Parts List (707.55637). This list contains parts that must be aquired
with the tool, even if there is a backup tool. The parts in this list are high failure rate
items that are deemed necessary to provide quick field location repairs.
Optional Spare Parts List (707.55638). This list contains a much more
comprehensive (and expensive) list of parts. The parts in this list are for remote
locations buying two tools, but with difficult logistics for importing spare parts (i.e., no
hand carries, no commuters, weight/cost import limitations for air freight, etc.).
Personnel at these remote locations may have to seriously consider whether parts on
this list are necessary, even if these locations have two tools.
Preventive Maintenance (PM-1) Supplies List (707.55639). This list contains parts
(e.g., O-rings, oil, screws, etc.) that are used only for few runs. Since the items in this
list are replaced more often than other parts in the tool, always make sure that the
proper quantity for each run is maintained.
Accessory List
CAST-V ACCESSORY LIST
LOC.
PART NO.
QTY.
DESCRIPTION
00001
100132254
1
TOOL—CHASSIS INSERTION/REMOVAL
00002
100000710
1
TOOL--CONTACT INSERTION/REMOVAL
00003
100011418
1
SUPPORT TOOL -- 3-5/8 DITS STANDARD
00004
100116010
1
WRENCH--SPANNER 3-1/2 X 11/32 DIA
00005
100144851
1
CYLINDER--SEAL SIZING
300006
100144843
1
TOOL--BEARING INSTALLATION
3
00007
100144808
1
TOOL--INSTALLATION THREADED RING
3
00008
.88774
1
PUMP--HYDRAULIC HAND OPERATED
00009
100144811
3
TUBE--OIL FILL 3/8-16 UNC
300010
10145231
1
CALIBRATION STAND ASSY-- SED-C
00011
100144847
1
BRACKET--CALIBRATION STAND
00012
100144846
1
ADAPTER--CALIBRATION STAND
00013
120040355
1
CALIBRATION STAND ASSY--
DIRECTIONAL
3
