CAST-V FOM Insite.pdf

Halliburton Energy Services

CIRCUMFERENTIAL ACOUSTIC SCANNING TOOL INSITE OPERATION (CAST-V) Field Operations Manual

Revision A January 2007 D00268695 SAP P/N 101551877

Halliburton Energy Services

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

Revision Record CAST-V Insite Field Operations Manual

Date 19-January-2006

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Description Release Document as Revision A

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Contents

Table of Contents

Revision Record...........................................................................................................................i Table of Contents.......................................................................................................................iii List of Figures .............................................................................................................................v List of Tables............................................................................................................................viii Preface .........................................................................................................................................x Section 1 – General Information................................................................................................1 Introduction .................................................................................................................................1 Product Enhancement................................................................................................................1 Tool Specifications CAST-V.......................................................................................................2 CAST-V Equipment List……………………………………………..……………..…………………….4 Tool Description……………………………………………………..………………………..…………..5 Section 2 – Safety .......................................................................................................................6 Danger to Personnel...................................................................................................................6 High Voltages ..............................................................................................................................6 Heavy Equipment........................................................................................................................6 CAST-V FOM

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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 Appendix B – Insert Name .......................................................................................................92

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Figures

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…………………………..……………………………...……. Figure 10. INSITE System Manager……………………………….…………..………………….……. Figure 11. CAST-V Service Setup………………………………….…………………………....……… Figure 12. CAST-V Service Selection Screen…. ………………….………………………………..… CAST-V FOM

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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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List of Tables 1-21-33-76-26-86-136-146-156-166-176-18

Tables

Table 1. Caption……………………………………………………Error! Bookmark not defined.

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Preface

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

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.

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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

Transducers

2, 3

250 kHz (White)

100010435

350 kHz (Brown)

100143708

450 kHz (Black)

100143712

2 3

Refer to Appendix B of this manual for the recommended Head and Transducer selections. Refer to Appendix C of this manual for the procedure to change the Head Assembly in the Scanner Assembly.

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Table 1-2 AUXILIARY EQUIPMENT

DESCRIPTION

PART NO.

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) Chassis Insertion/Removal Tool, 3-5/8 in. DITS

DIMENSION

WEIGHT

100144876 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

Centralizer, Slipover, Gemco, 7 in. Casing

100120927 or 100110238

3 ¾ in. ID x 4 5/8 in. OD 3 ¾-in ID x 6 ¼-in OD

100120928 Centralizer, Slipover, Gemco, 7-5/8 in. Casing Centralizer, Slipover, Gemco, 9-5/8 in. Casing Centralizer, Slipover, Gemco, 8-5/8 in. Casing

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3 ¾ in. ID x 6 ¾ in. OD 100120929 or 100110240 100110239

3

3 ¾ in. ID x 8 15/16 in. OD 3 ¾ in. ID x 7 ¾ in. OD

CAST-V FOM

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.

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Section 2

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.

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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 occur.

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Section 4

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 Shop

Shop

Transit Time

Imaging Mode

Calibrator P/N 100071892

Cased Hole Mode 100144881

Mud Cell Transducer Measurement Imaging Mode

Cased Hole Mode

Transit Time

100144761

Calibrator P/N 100144761

Calibration 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.

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Figure 1. INSITE Program Manager

Figure 2. Service Selection

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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

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Calibrate on the CAST-V Shop Calibration window to acquire the data. Click Next to go to step 2.

Figure 5. Select the Transducer Type and Frequency

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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 7. CAST-V Shop Calibration Step 2 of 2

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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. The calibration summary should be displayed as follows:

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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:

Measurement

Reference Shop

Shop

Difference

Mud Cell Offset

40.60

40.60

0.0000

Mud Cell TT

0.000

0.000

0.0000

14

14

0.0000

Mud Cell Gain Mud Cell AMP Transducer Offset Transducer TT Transducer Deviation

0

Tolerance

Units

+/- 5

uS .2uS

107

108

-1.0000

-4.35

-3.87

-0.4800

46

46

0.0000

uS

2

2

0.0000

uS

7 +/- 3

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:

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uS

Figure 9. CAST-V Cased Hole Graphic Display

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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 There is no after or post survey calibration for the CAST-V tool.

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Section 4

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.

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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.

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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.

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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 hole, the SDDT can be removed.

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Figure 13. Service Selection Screen

Figure 14. Saving the Service

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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.

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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. 4.

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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.

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Data = Green Sequence Updating

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

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Figure 19. CAST-V View--Cased Hole Mode

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Data = 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.

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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. Max Amp. This is the largest measured amplitude of the first arrival waveform for the sample point. Min Amp. This is the smallest measured amplitude of the first arrival waveform for the sample point. Max Radius: This is the largest measured internal radius of the borehole measured for

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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 Speed. This indicates the motor speed in revolution per second. 2/6/2009

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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.:

Bad Shots Indicator

Figure 18. Bad Shot Indicator Window

Bad Shot Indexes The following are the bad shot indexes monitored by the system: Tool Pick Error. This error occurs when the first arrival picked by the tool is not correct. Those shots with bad pick time errors will be indicated by bars with green color across them. Travel Time Error. This error occurs when the calculated travel time is in error. This

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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: AVOD = AVID + 2 * AVTK

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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 (a0, b0, c0, d0) 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.

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Section 5

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.

Figure 18. CAST-V LQC Indicators

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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” (0.10.9). 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.

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Section 6

Section 6 – Maintenance General Maintenance 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 Orings 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, apply Slick50 grease or an equivalent grease under the threaded ring. 2/6/2009

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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

(NOTE1)

READ

SCALE

ITEMS CHECKED Through wires Chassis ground Through wires Power ground (same as chassis)

(NOTE2)

1-5 6 7 - 10

CHASSIS CHASSIS CHASSIS

OPEN SHORT OPEN

RX100 RX100 RX100

11

CHASSIS

SHORT

RX100

12 - 13 14 15 16 17 (+) 17 (-)

N.C. CHASSIS CHASSIS N.C. CHASSIS CHASSIS

OPEN OPEN

RX100 RX100

Through wires Through wires

RX100 RX100

+15 VDC power input +15 VDC power input

18 (+/-)

CHASSIS

10K-12K 600-800 17003300

RX100

-15 VDC power input

19 20 21 22 23 24 (+/-) 25 (+/-)

N.C. CHASSIS CHASSIS CHASSIS N.C. CHASSIS CHASSIS

OPEN OPEN OPEN

RX100 RX100 RX100 RX10K RX10K

Magnetometer Y axis output Magnetometer X axis output

26 (+/-)

CHASSIS

RX100

Inclinometer X axis output

27 (+/-)

CHASSIS

RX100

Inclinometer Y axis output

28

CHASSIS

15K-23K 15K-23K 25004100 25004100 46005000 SHORT

RX100

ACTUAL READING

Temperature output of inclinometer package Signal Ground

29 CHASSIS RX100 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).

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FROM TO UPHOLE DOWNHOLE 1 2 3 4 5 6 7 8 9 10 14 15 20 21 22 35 36 37

1 2 3 4 5 6 7 8 9 10 14 15 20 21 22 35 36 37

READ

SCALE

ITEMS CHECKED

ACTUAL

READING SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT SHORT

RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1 RX1

Through wires Through wires Through wires Through wires Through wires Chassis ground Through wires Through wires Through wires Through wires Through wires Through wires Through wires Through wires Through wires Through wires Through wires Through wires

Directional Sub Check The Directional Sub requires two types of measurement checks: a magnetometermeasurement check (the azimuth) and an inclinometer-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.

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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 Directional Sub Chassis Assembly (100144795) onto the test stand (Figure 3.1).

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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.

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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. a.

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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.

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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 FROM (NOTE 1)

TO

READ

SCALE

ITEMS CHECKED

READING

(NOTE 2)

1

2

OPEN

RX1

3

4

VARIABLE

RX100

6

CHASSIS

SHORT

RX1

1-5

6

OPEN

RX100

7-37

6

OPEN

RX100

7 11 12 13 14 15 16-19

9 N.C. N.C. N.C. 21 21 N.C.

OPEN

RX100

Scanner Transducer Identification Resistor, If Used Chassis Ground Wire Circuits Which Should Be Open To Chassis Circuits Which Should Be Open To Chassis Mud Transducer

55-70 55-70

RX1 RX1

Resolver Output Winding Resolver Output Winding

20

GND

OPEN

RX100

20

21

OPEN

RX100

23-34 35

N.C. 36

9-10

RX1

2/6/2009

ACTUAL

Shield (Pin 20) For Resolver Wires Shield (Pin 20) For Resolver Wires Motor Winding

8-39

CAST-V FOM

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.

The check valve must bottom out in the housing so that the fill plug to be installed above it properly.

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CAST-V FOM

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.

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CAST-V FOM

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).

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3.4 RELATED MAINTENANCE Information for this subsection will be supplied at a later date.

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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.

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CAST-V FOM

Accessory List CAST-V ACCESSORY LIST

3

LOC. 00001 00002 00003 00004 00005 00006 00007 00008 00009 00010 00011 00012

PART NO. 100132254 100000710 100011418 100116010 100144851 100144843 100144808 .88774 100144811 10145231 100144847 100144846

QTY. 1 1 1 1 1 1 1 1 3 1 1 1

00013

120040355

1

DESCRIPTION TOOL—CHASSIS INSERTION/REMOVAL TOOL--CONTACT INSERTION/REMOVAL SUPPORT TOOL -- 3-5/8 DITS STANDARD WRENCH--SPANNER 3-1/2 X 11/32 DIA CYLINDER--SEAL SIZING 3 TOOL--BEARING INSTALLATION 3 TOOL--INSTALLATION THREADED RING 3 PUMP--HYDRAULIC HAND OPERATED TUBE--OIL FILL 3/8-16 UNC 3 CALIBRATION STAND ASSY-- SED-C BRACKET--CALIBRATION STAND ADAPTER--CALIBRATION STAND CALIBRATION STAND ASSY-DIRECTIONAL

These are parts supplied with the CAST-V

2/6/2009

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CAST-V FOM

Primary Spare Parts List The location numbers in Primary Spare Parts List apply to specific sections of the tool as follows: 1. Locations 1 through 15 are specific to the Electronics Chassis Assembly (100144825). 2. Locations 20 through 23 are specific to the Electronic Assembly (100144828). 3. Location 30 is specific to the Preamp/Fire PC board (100144872). 4. Locations 35 and 36 are specific to the Pre-Regulator PC board (100144705). 5. Locations 40 and 41 are specific to the Commutator PC board (100144793). 6. Locations 45 through 48 are specific to the Directional Sub Assembly (100144803). 7. Locations 55 through 63 are specific to the Directional Sub Chassis Assembly (100144795). 8. Locations 70 through 76 are specific to the Scanner Assembly (100144779). 9. Locations 80 through 105 are specific to the Scanner Housing Assembly (100144780). CAST-V PRIMARY SPARE PARTS LOC. 00001 00002 00003 00004 00005 00006 00007 00008 00009 00010 00011 00012 00013 00014 00015 00020 00021 00022 00023 00030 00035 00036 00040

2/6/2009

PART NO. QTY. DESCRIPTION 100000697 10 SPEC - CONTACT ASSY - PIN - .094 DIA 100000698 10 INSULATOR ASSY – PIN - .094 DIA 100128287 1 DIODE - ZENER - 5.6V - 5% - 10W - DO-4 100123683 4 SCREW - BIND HD - #8-32NC X 1/2 100139627 4 WSHR,150 UF CAP 100161035 4 SCREW - CAP - SKT HD - #6-32UNC X 1/4 100161035 4 WSHR,LOCK,SPLIT,#6 100123579 4 SCREW - BIND HD - #6-32NC X 3/8 100123571 4 NUT 6-32 100124489 1 THERMAL COMPOUND - THERMALCOTE - 2 OZ 100000706 10 CONTACT ASSY - SOCKET - .094 DIA 100161028 24 SCREW - BIND HD - #4-40NC X 7/16 100125368 1 CAP 150.0U 270V TA RH 100123682 20 SCREW - BIND HD - PHL - #8-32 X 3/8 100011464 1 SPRING - BUTTON - 3-5/8 DITS STANDARD 100000708 1 RING - SNAP - 3-5/8 DITS STANDARD 100132235 1 RING - SPLIT - BEVELED - 3-5/8 DITS 100000709 1 RING - SPLIT - SPACER - 3-5/8 DITS 100011468 1 RING - THREADED - 3-1/4-6 STUB ACME 100009697 2 TRANSISTOR - MTP2P50 - POWER MOSFET 100121739 1 RESISTOR - 6.2K OHM - 3W - 5% - 200C 100009647 3 CAPACITOR - 22UF - 75V - 20% - 85C 100116563 3 TRANSISTOR - IRF9630 - HEXFET - 200V

8-46

CAST-V FOM

00041 00045 00046

2/6/2009

100117397 100132235 100000708

3 1 1

TRANSISTOR - IRF840 - HEXFET - 500V RING - SPLIT - BEVELED - 3-5/8 DITS RING - SNAP - 3-5/8 DITS STANDARD

8-47

CAST-V FOM

CAST-V PRIMARY SPARE PARTS LIST (707.55637) LOC. 00047 00048 00055 00056 00057 00058 00059

PART NO. 100000709 100011468 100000706 100000707 100000698 100132931 100113325

QTY. 1 1 10 10 10 10 4

00060

100114162

4

00061 00062

100124699 100114161

4 4

00063

100011464

1

00070 00071 00072 00073 00074 00075 00076 00080 00081

100144811 100143688 100143708 100144807 100010966 100010903 100143712 100010818 100144807

1 1 1 1 2 2 1 10 2

00082

100013290

1

00083 00084 00085 00086

100128687 100144812 100000522 100011468

8 1 3 1

00087

100132886

1

00088

100000708

1

00089

100132885

1

00090 00091 00092

100116600 100124102 100123488

3 1 4

00093

100144840

1

00094 00095 00096

100123776 100128703 100011002

4 1 1

2/6/2009

DESCRIPTION RING - SPLIT - SPACER - 3-5/8 DITS RING - THREADED - 3-1/4-6 STUB ACME CONTACT ASSY - SOCKET - .094 DIA INSULATOR ASSY - SOCKET - .094 DIA INSULATOR ASSY - PIN - .094 DIA SPEC - CONTACT ASSY - PIN - .094 DIA STANDOFF - 1.00 LG - 1/4 DIA - #6-32 SCREW - FH MACH - #4-40 X 3/16 BRASS STANDOFF 6-32X1/4 1/4 HEX SCREW - FH MACH - #6-32NC X 3/8 SPRING - BUTTON - 3-5/8 DITS STANDARD TUBE - OIL FILL - 3/8-16 UNC TRANSDUCER ASSY - SIDE TERMINAL TRANSDUCER ASSY - 350 KHZ - BROWN PLUG - 3/8-16 UNC-2A WSHR-WAV RING - RETAINING - INTERNAL - MEDIUM TRANSDUCER ASSY - 450 KHZ - BLACK TERMINAL - SWAGE TYPE - .040 PLUG - 3/8-16 UNC-2A TRANSDUCER ASSY - RADIAL SEAL VITON SCREW - FLAT HD - PHL - #10-32 X 1/4 VALVE ASSY - CHECK - 3/8-16 UNC O-RING - 568-011 - FLUOROC - 75 DURO RING - THREADED - 3-1/4-6 STUB ACME RING - SPLIT - BEVELED - NONMAGNETIC RING - SNAP - 3-5/8 DITS STANDARD RING - SPLIT - SPACER - NONMAGNETIC PIN - SPIROL - 1/8 X 5/16 -BECU SOLDER LUG #8 SCREW - FH MACH - #4-40NC X 3/16 PC BRD ASSY - TERMINAL TRANSDUCER WASHER - LOCK - SPLIT - #10 - STNLS SEAL ASSY - SHAFT - BELLOWS - 1 INCH O-RING - 568-127 - FLUOROC - 75 DURO

8-48

CAST-V FOM

00097 00098 00099 00100

2/6/2009

100125921 100123868 100123897 100124254

1 3 4 2

O-RING - 568-120 - FLUOROC - 75 DURO SCREW - SET - 1/4-28NF X 5/16 - STNLS SCREW - CAP - SKT HD - 1/4-20 X 5/8 BEARING - BALL - RADIAL - DBL SHIELD

8-49

CAST-V FOM

CAST-V PRIMARY SPARE PARTS LIST (707.55637) LOC. 00101 00102 00103

PART NO. 100115334 100111516 100123802

QTY. 1 8 8

00104

100161052

4

00105

100008104

5

2/6/2009

DESCRIPTION PIN - SPIROL - 3/32 X 5/8 - 302 STNLS TERMINAL - STUD - 1480D-7-11 SCREW - CAP - SKT HD - #10-32UNF X ½ SCREW - CAP - SKT HD - #10-32UNF X 3/8 CONTACT - SOCKET - FEMALE

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CAST-V FOM

Optional Spare Parts List The location numbers in Optional Spare Parts List apply to specific sections of the tool as follows: Locations 1 through 10 are specific to the Scanner Assembly (100144779 & 100144780). Locations 11 through 22 are specific to the Electronics Assembly (100144825). Locations 23 through 35 are specific to the Directional Sub Assembly (100144795).

LOC. 00001 00002 00003 00004 00005 00006 00007 00011 00012 00013 00014 00015 00016 00017 00018 00019 00020 00023 00024 00025

CAST-V OPTIONAL SPARE PARTS LIST (707.55638) PART NO. QTY. DESCRIPTION SLIP RING ASSY - CAPSULE - 8 100144777 1 CONTACT 100144785 1 MOTOR - DC - BRUSHLESS - 3.00 OD 100144783 1 RESOLVER - BRUSHLESS - KEYED 100144781 1 SHAFT - EXTENSION 100144782 1 KEY - SHAFT - MOTOR/RESOLVER 100144771 1 SHAFT - SCANNER 100000793 1 CONNECTOR - 19 PIN - DUAL PRESSURE 100144794 1 PC BRD ASSY - R TO D 100144793 1 PC BRD ASSY - COMMUTATOR 100144817 1 PC BRD ASSY - SLOW ADC 100144870 1 PROGRAMMED BOARD ASSY - V40 PROGRAMMED BOARD ASSY 100144869 1 AQUISITION PC BRD ASSY - DATA ACQUISITION 100144621 1 CAST 100144872 1 PC BRD ASSY - PREAMP/FIRE - CAST-D 100144706 1 PWR SPLY ASSY - CAST - 82V/+5V/ 100132435 1 CHOKE - FILTER - 1.2 HY - SWITCHING TRANSFORMER - POWER - 60 HZ 100000779 1 DOWNHOLE SENSOR - MAGNETIC NORTH - 106517100123252 1 PL-08 INCLINOMETER - BIAXIAL - TENSOR 100143582 1 7043 100144805 1 PC BRD ASSY - COMPASS Page 60

Preventive Maintenance (PM-1) Supplies List

The location numbers in Preventive Maintenance Supplies List apply to specific sections

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of the tool as follows: Locations 1 through 29 are specific to the Scanner Assembly (100144779 & 100144780). Locations 30 through 39 are specific to the Directional Sub Chassis Assembly (100144795). Locations 40 through 49 are specific to the Directional Sub Assembly (100144803). Locations 50 through 59 are specific to the Electronics Chassis Assembly (100144825). Locations 60 and 61 are specific to the Electronic Assembly (100144828 and 707.55567). CAST-V PREVENTIVE MAINTENANCE (PM-1) LIST (707.55639) LOC. 00001 00002 00003 00004 00005 00006 00007 00008 00009 00010 00011 00012 00014 00015 00016 00017 00018 00019 00020 00021 00022 00023 00030 00031 00040 00041 00050 00051 00060 00061

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PART NO. 100011003 100115650 100000231 100009302 100113872 100011006 100000522 100125943 100125950 100144807 100011004 100120120 100120121 100000526 100011005 100125957 100128703 100125954 1000110021 100124775 100125921 100000527 100115650 100009302 100000231 100009302 100115650 100009362 100000231 100009362

QTY. 1 1 2 1 2 2 3 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 2 1 1

DESCRIPTION O-RING - 568-132 - FLUOROC - 75 DURO O-RING - 568-225 - FLUOROC - 75 DURO O-RING - 568-231 - FLUOROC - 95 DURO O-RING - 568-231 - FLUOROC - 75 DURO O-RING - 568-129 - NITRILE - 90 DURO O-RING - 568-232 - FLUOROC - 75 DURO O-RING - 568-011 - FLUOROC - 75 DURO O-RING - 568-212 - FLUOROC - 75 DURO O-RING - 568-221 - FLUOROC - 75 DURO PLUG - 3/8-16 UNC-2A O-RING - 568-223 - FLUOROC - 75 DURO BEARING - PISTON - SLYDRING - 1.500 RING ASSY - CGT - 1.500 BORE - .304 O-RING - 568-126 - FLUOROC - 75 DURO O-RING - 568-226 - FLUOROC - 75 DURO O-RING - 568-233 - FLUOROC - 75 DURO SEAL ASSY - SHAFT - BELLOWS - 1 INCH O-RING - 568-229 - FLUOROC - 75 DURO O-RING - 568-127 - FLUOROC - 75 DURO OIL - TURB OIL - EXXON O-RING - 568-120 - FLUOROC - 75 DURO O-RING - 568-129 - FLUOROC - 75 DURO O-RING - 568-225 - FLUOROC - 75 DURO O-RING - 568-231 - FLUOROC - 75 DURO O-RING - 568-231 - FLUOROC - 95 DURO O-RING - 568-231 - FLUOROC - 75 DURO O-RING - 568-225 - FLUOROC - 75 DURO O-RING - 568-231 - FLUOROC - 75 DURO O-RING - 568-231 - FLUOROC - 95 DURO O-RING - 568-231 - FLUOROC - 75 DURO

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TROUBLESHOOTING Troubleshooting information for this subsection will be supplied at a later date.

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INTRODUCTION This section contains reference material that may be helpful during the operation, maintenance, and repair of the CAST-V. It includes a list of supplemental reference documents, a list of Operation Engineering Bulletins (OEB). Other important information that supports this manual can also be found in the appendices of this manual. They are as follows: 1. Appendix A. Head and Transducer Selection Chart, contains the casing sizes and weights and recommendations for the appropriate head and transducer. 2. Appendix B. Changing the CAST-V Head Assembly, contains the instructions for removing an existing Head from the Scanner Assembly and replacing it with another. 3. Appendix C. Over-Body Centralizer Installation, contains the instructions for installing the Over-Body Centralizer to the CAST-V toolstring. SUPPLEMENTAL REFERENCE MATERIAL Manual 100146455. HLS Safety and Health Manual, is a separate manual containing information about equipment care and personal safety. It is useful in shop and field operations. Technical Manual 100009548. Circumferential Acoustic Scanning Tool—Visualization (CASTV) Service Manual is a separate manual containing important information about the operation and maintenance of the CAST-V. This document is useful in shop and field operations. Technical Manual 100009443. Circumferential Acoustic Scanning Tool—Visualization (CASTV) Image Mode Field Operations Manual is a separate manual containing important information about the field operations and maintenance of the CAST-V in Open Hole environments. This document is useful in shop and field operations. Technical Manual 100004305. Circumferential Acoustic Scanning Tool—Visualization (CASTV) Engineering Documentation Package is a separate manual containing condensed engineering drawings of the CAST-V. This document is useful in shop and field operations.

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Section 6 – Reference Material

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Appendix A

Appendix A – CAST JOB PLANNER This section describes the CAST Job planner in details. The engineer should thoroughly familiarize himself with this section to clearly understand the how different parameter selection affects the quality of the data.

The CAST Job Planner (CJP) User’s Manual

Clovis Bonavides Mar-28th-2006

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INDEX This document is divided into the following sections and subsections: a.

Introduction

1. Overview a. The Planner Modes (Recommendation & Simulation) b. The Input Panels c. The Results Panel d. The Results Validation Bar e. The Remarks Panel f. The Data Acquisition Timing Diagram g. The INSITE Service Configuration Window h. The Planner’s Title 2. Starting the Planner a. Bringing it alive b. Selecting the Well Environment c. Choosing the Service (Application) d. Selecting which CAST Tool e. Features offered by each Application f. Selecting the Pipe Material g. Choosing the Planner Mode 3. The Input Panels a. The Fluid Properties panel b. The Pipe / Well Data panel c. Maximum Eccentricity d. Available Heads e. End of Transducer Ringing Noise f. Outer Pipe g. Outer Pipe OD h. Outer Pipe Weight i. Annulus Delta-T 4. The Results Panel a. Scanning Head Size b. Transducer Type c. Remark d. Pipe ID / Well Size e. Pipe Thickness f. Pipe Resonance Frequency g. Effective Head Radius h. Transducer Position i. Scanning Head Clearance j. minTT / avgTT / maxTT k. Maximum Eccentricity l. 2nd Reflection m. Annulus Size / Annulus TT / Outer Pipe TT n. Horizontal Resolution o. # Samples / Shot p. Optimum #Shots / Scan 2/6/2009

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q. r. s. t. u. v.

# Shots / Scan Tool # Shots / Scan Vertical Resolution Waveform Length Sampling Interval Inhibit Time Setting

5. The Data Acquisition Panel a. Waveform Length b. Sampling Interval c. Shots / Scan d. Scans / Foot e. Max Log Speed (MLS) f. Min Motor Speed @ MLS g. Absolute Maximum Motor Speed h. Tools in Combination i. Bandwidth Usage j. Telemetry Speed choices i. Slow Telemetry ii. Medium Telemetry iii. Fast Telemetry k. Maximum Line Speed for Current Motor Speed l. Minimum motor Speed for current Line Speed 6. The Results Validation Bar 7. The Data Acquisition Timing Diagram a. Mute Time b. End of Transducer Noise c. Inhibit Time d. minTT e. avgTT f. maxTT g. Second Reflection Region h. Outer Pipe Signals Region 8. The Remarks Panel 9. The MENU bar a. Saving files in EXCEL format b. Saving / Opening files in .CJP format c. Displaying the INSITE Configuration Window d. Generating and Editing a Header e. Generating a Report f. Printing a Report g. Setting up the Pipe Material 10. About…..

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1)

Introduction

The new CAST Job Planner (CJP) provides a single screen interface for planning both a CAST-V (INSITE only) or a CAST-V (CLASS or INSITE) job and for visualizing the most important parameters and features that may affect the data acquisition and the final CAST log output. Future versions will cover for the INSITE and for the Monocable (Ultralink telemetry) versions of the CAST, as they become available. The figure below presents a sample view of the new Planner, configured for a CAST-V tool.

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2)

Overview

Important Note: The new CAST Job Planner (CJP) must be run using a minimum screen resolution of 1024 X 768 pixels. A screen resolution of 1280 X 1024 pixels or better is recommended.

The new CAST Job Planner (CJP) provide in a single screen a complete visualization of all major inputs and outputs required for successfully programming a CAST log. It intends to covers all different versions of CAST tools. At the time of this writing, March of 2006, it handles the CAST-V and the CAST-V (CAST-V). It also handles different pipe materials, such as fiberglass, chrome and titanium or a user defined (by Acoustic Slowness and Density) material. The CJP was programmed so as to immediately display a newly computed screen display each time the user changes an input that can affect a result. A change normally requires a click, a mouse focus change or pressing the ENTER key to take effect. Also, changes in font colors and remarks are used to provide immediate feedback about the validity of the job setup parameters’ set. The new Planner also aims to help the user better understand CAST logging, focusing on the logic that lies behind the data acquisition. When the CJP is loaded it displays a set of values corresponding to a configuration setup for a Cased Hole Cement Inspection Job in a 7”, 23 lbs/ft casing. The Data Acquisition Timing Diagram is empty at this point. A full set of results and a complete CJP screen is only obtained after the clicking a radio button or a check box or after entering a new value into one of the text input boxes. The text input boxes have built-in value limits – for instance the Fluid Weight input box will only accept values between 4.00 and 25.00. Similar validation logic also applies in other cases. As an additional example you can not check the Extended Cans box if you have the Adjustable Head box unchecked, as you can not install an extended can if you don’t have such a scanning head available. In summary, there are a number of context-based constraints that the CJP takes in consideration. Many context sensitive features may be allowed, blanked or automatically set by the Planner. This behavior depends mainly on the Tool Type, on the Well Environment, on the type of Application or on the Planner running mode. Most items displayed on the CJP have mouse-over tips providing on-spot help. In fact they make a great part of this document quite redundant. The first entries to be selected are the Well Environment (CH or OH), the Application (service type – Cement Inspection, Casing Inspection or Imaging) and the Tool Type (CAST-V or CAST-V as of March / 2006). After this point the user starts to enter the input parameters grouped in 3 panels on the upper left side of the Planner and (if needed) his data acquisition setup, including some DITS tools that he may be combining with the CAST. Abundant use of colors is made to provide immediate visual feedback on possible service configuration problems. A “catch-all” type of feature is the Results Validation bar. After entering the required inputs the user is advised to click on the command button “Show the INSITE Service Configuration Window”. A window - shown in the next page - listing the user inputs and the CJP outputs that must be entered in the CAST service configuration (INSITE) pops up. The right side panel 2/6/2009

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contains all the parameters that must be entered into the INSITE parameter editor. Notice that these parameters are the same ones displayed at the bottom of the “Results” panel, with a distinct background color. Although the Planner will in most circumstances be able to detect configuration problems and make the right recommendation, some border-line conditions may not be handled optimally. In these circumstances or whenever in doubt about the Planner’s results the user is encouraged to request the advice from the CAST Subject Matter Expert in Houston.

A brief explanation of each major feature of the CAST Job Planner follows in the next few pages.

A - The Planner Running Modes (Recommendation and Simulation) The CJP can be run in 2 modes. The first one – named Recommendation Mode – is the default mode and should be used for planning a job under the most common situations. Actually, in normal circumstances, this is the only mode that one should need to run for planning a CAST field job. In Recommendation Mode the CJP will deliver all configuration parameters automatically. These parameters are optimized based on the inputs entered by the user. The Simulation Mode is evoked by checking the box shown in the figure below, located on the bottom left-hand side of the Planner.

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A second mode - named Simulation Mode – is intended as a “what-if” type tool, allowing the user to obtain results under a simulated configuration setup different from the configuration recommended by the Planner. This mode is very useful for testing the feasibility of running the CAST service under certain arbitrary conditions related to the job environment and / or to the tool / system setup. In Simulation Mode the user is allowed to choose an Imaging transducer. The only present difference between the existing transducer that causes different outputs is the fact that the Effective Head Radius (EHR) of the stepped transducer is .15” less than the EHR of the flat transducers. B - The Input Panels These panels are covered are covered in sections 3) and 4) of this document. They group the primary user entries related to the well environment (casing size / weight, well ID, fluid properties, outer casing, etc) and to the scanning head and tool setup (maximum eccentricity, available heads, head sizes for simulation purposes, etc). C - The Results Panel This panel groups the most important output parameters, some of which must be entered for properly setting up the INSITE real time data acquisition service. These service configuration outputs are the Transducer Type, the Scanning Head type and transducer position (translated by the Eff. Head Radius parameter). These configuration outputs have a distinguished color from most other outputs.

D- The Results Validation Bar This bar, located right below the Results panel, shows in different colors (BLUE, RED or BROWN) to indicate the validity of the current Planner configuration setup.

E - The Remarks Panel

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This panel contains 4 fields for displaying text messages. In most cases these messages carry diagnostics information to help the user figure out the origin of the trouble detected by the Planner in the job configuration parameters. Some remarks may also be purely informative. As there is a maximum displaying capacity, the messages are normally ranked in terms of importance. Note: A 5th Remark Field is displayed on the upper right side of the Planner. Its main purposes are to indicate problems and to provide a more textual description of the transducer’s position inside the scanning head.

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F - The Data Acquisition Timing Diagram This new feature displays horizontal bars and vertical tabs showing the main timing events related with well ultrasonic data acquisition. Additionally, the most important landmarks are textually described on the diagram. The figure below illustrates the Timing Diagram for TA (Time / Amplitude) mode.

G - The INSITE Service Configuration Window The INSITE Service Configuration Window (ISCW) is displayed by clicking on the command bottom illustrated below, which is located right below the Data Acquisition Timing Diagram.

The figure below shows an ISCW example. Each time an input parameter is changed the ISCW disappears.

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The panel on the right side of the ISCW displays the parameters produced by the Planner that must be entered by the user into the INSITE parameter editor to configure the job accordingly. The telemetry setup field displays the recommended / simulated telemetry option in terms of DITS words reserved for the CAST service. You should be aware that the highest bandwidth option (612 words / DITS frame) can only be used by the CAST-V (CAST-V) and that the 170 words/frame and the 238 words/frame telemetry options do not apply to the CAST-V. These 2 options (170 wpf and 238 wpf) are only used by the CAST-V. The Fluid Travel Time (FTT), shown on the left side panel (User Inputs), is normally not a direct entry into the Planner, unless the user knows it anticipatedly or wants to use a fixed FTT. In most cases this value will have been derived by the Planner based on the fluid type (Water or Oil based) and on the fluid weight inputs.

H - The Planner’s Title Bar The caption on the Planner’s title bar reflects the main setup parameters that influence the service setting both in CLASS and in INSITE, which are:

1. The running mode. In Recommendation mode no mention to the running mode is done but in Simulation the title wording explicitly mentions it.

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2. The Data Acquisition mode: Imaging (Time & Amplitude – TA) or Waveforms (WF) mode. 3. The Pipe Material - always explicitly shown on the Planner’s title.

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3)

Starting the Planner …

The CAST Job Planner (CJP) can be run both as a “free-riding” stand alone application or it can be called from the CAST service in INSITE. This program uses the Matlab Components Run Time library (MCR), which must be installed in your computer before you can use it. It takes quite a while to show on the screen when using MCR versions prior to 7.1, which is the version currently (Mar-2006) featured in INSITE. When running CJP as a stand-alone program, select the Run command in Windows, change the current directory to C:\CJP (if installed in the C drive) and type CJP. When running it from INSITE just double-click the Job Planner button to start the CJP application. The top of the CJP screen looks like this:

This is called the Primary Input Panel. Basic information should be entered by the user in these 3 panels, which tell the Planner the following information: 1. The Well Environment. Two options are available: a. Cased Hole – CH. The Planner allows any operating mode (TA or WF). b. Open Hole – OH. The Planner forces using the TA mode. 2. The Application. Three options are available: a. Cement Inspection – this option forces the tool to transmit waveforms, i.e. it must operate in WF mode. The Planner also sets the Vertical Resolution to 4 scans / ft. This can be changed only by running the Planner in Simulation Mode. b. Pipe Inspection – the only difference between this application and Cement Inspection is the Vertical Resolution, automatically set by the Planner (in Recommendation Mode) to 12 scans / ft. c. Imaging – this is equivalent to plan for the tool to operate in TA mode. Therefore, Imaging and TA mode are equivalent. Notice that you can this application applies to any well environment (CH and OH). 3. The Tool Type. Four options are shown but only two are active as of March-2006: a. CAST-V – the DITS CAST-V tool. b. CAST-V – the DITS CAST-V tool. c. UltraLink CAST – future product, inactive button. d. INSITE CAST – future product, inactive button. These 3 choices set the context for planning a CAST job. The Planner will automatically change some labels, based on the settings of these three panels. It will also allow certain choices and disallow the ones that make no sense in the job context. As an example, in Imaging (TA) mode it allows the user to choose which transducer to use, as shown by the picture on the right.

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The user should have clearly in mind what the implications of each of these options are. The table presented below presents the main features provided by each option.

Environment / Feature Cased Hole Open Hole Pipe Thickness Pipe / Well ID Impedance Map Amplitude Map Travel Time Map Pipe OD (ID + THK)

Tool Mode TA , WF TA WF TA, WF WF TA, WF TA, WF WF

Cement Inspection 9 8 9 9 9 9 9 9

Pipe Inspection 9 8 9 9 8 9 9 9

Imaging 9 9 8 9 8 9 9 8

An additional feature of the new Planner is the ability to program a job for pipes made from a material different from steel. In this respect the Planner is ahead of the real time software, which presently does not yet provide support for any pipe material except steel. This is presented in this section because it would be one of the most fundamental user inputs. The data acquisition can still benefit from this new feature but because it has been yet tested in practice (as of March-2006) you are advised to use it with caution and contact the CAST Subject Matter Expert if a job shows up for logging in non-steel pipes.

not

This choice is activated from the top menu (=> Environment => Pipe Material). The window shown below pops up main CJP disappears. After selecting the pipe material, the CJP screen is displayed again. Among 4 defined materials a Custom Material option is also presented. The custom material is defined, for the purposes of the Planner in terms of its Acoustic Slowness and its Density. Most outputs presented by the Planner, including transducer type and scanning size are affected by the material choice.

When the Planner starts it comes in Recommendation mode. To perform Simulations just check the box (“Run the Planner in Simulation Mode”) shown by the picture on the right.

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head

4)

The User Input Panels

The User Input panels are comprised by: • • •

The Fluid Properties panel The Pipe / Well Data panel The Other Inputs panel

The outlook of each one of these panels may vary, depending on the well environment (Open Hole or Cased Hole), on the service type (Imaging -TA or Cement / Pipe Inspection – WF), on the mode (Recommendation or Simulation) and on the user’s choice for the Fluid Travel Time which can be either estimated by the Planner or directly typed in. These different configurations are represented in the figures displayed below.

A) The Fluid Properties Panel The main purpose of this panel is to deliver a Fluid Travel Time (FTT) upon which many of the calculations used for setting up the service configuration depend. When the FTT is Known box is not checked the Planner uses the fluid type (OBM – oil based mud or WBM – water based mud) and the fluid weight to estimate FTT. FTT influences all timing calculations displayed by the Planner. FTT can also be directly input, by checking the FTT is Known box. This option is shown on the right hand side figured shown above.

B) The Pipe / Well Data Panel This panel changes its lay-out based on the well environment – OH or CH. In cased holes the user must type in the pipe Outer Diameter (OD) and the pipe Weight. These entries are used for calculating pipe Internal Diameter (ID) and pipe thickness (THK). The transducer choice for the Cement Inspection and Pipe Inspection applications is governed exclusively by THK, as THK determines the fundamental transverse mode resonance frequency of the pipe. 2/6/2009

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In open holes the user is required to enter the well ID, which will usually be the bit size.

C) The Other Inputs Panel This panel groups several entries that are necessary for the Planner to select the scanning head size and to estimate the 2-way first arrival time of a signal reflected by an outer pipe string, when checked as present. Max Eccentricity – the user must type the expected maximum eccentricity value in this box, which has a default value of .15” that should work reasonably well for most cases. The maximum eccentricity influences the minimum and maximum Travel Time estimations, which are used for selecting the scanning head in Recommendation mode. It is strongly recommended never to set the max ECTY value at less than .10”. For Open Hole the user should in most cases set this value at .25”. As a side note, Eccentricity becomes more critical as the Internal Diameter gets smaller. The Planner does not allow the user to enter ECTY larger than .25” in Recommendation mode but this tolerance is increased to 1.00” in Simulation mode. End of Transducer Ringing Noise – this value (ETRN) represents the start of the region where the ringing noise has died out to a level where the signal can be considered “clean”. The ringing noise is generated when the transducer if fired and depends on the mechanical and acoustic characteristics of a given transducer. This value influences the choice of the scanning head. This value should be in the range from 30µs to 50µs. In Recommendation mode the Planner chooses the largest possible scanning head among those available that produces a minimum Travel Time (minTT) higher than ETRN.As a matter of fact it uses only the Effective Head Radius in these calculations. In Simulation mode, any calculated TT values below ETRN are displayed red. Available Heads – in Recommendation mode these check boxes indicate the Planner what type of “special” scanning heads are available for use. Quite logically, the Planner ignores any type of scanning head not checkmarked. Notice that the “normal” scanning heads are always considered as available. In Simulation mode this sub-panel changes to a list box displaying all existing (as of March-2006) scanning heads with their different transducer positions. Each different transducer placement option inside a scanning head implies in a different Effective Head Radius (EHR). Outer Pipe – when logging in a Cased Hole environment, if the logged pipe nd string is located inside a 2 pipe string the outer pipe may cause interference on the recorded signals. The planner offers a feature that helps predict if this kind of interference is possible. Although this feature is based on a value that is generally unknown (the annulus material’s Slowness) and assumes the the inner pipe is centralized inside the outer pipe, it is still helpful if one plays with educated guesses. The “Outer Pipe” feature is invoked by checking the box shown in the picture above. It prompts the user to enter 3 values in the 3 edit boxes which should contain, from left to right, the following values: 1. Outer Pipe Diameter (inches) 2. Outer Pipe Weight (lbs/ft) 3. Annulus Slowness (Delta-T in µs/ft) A rule of thumb for setting the Annulus Delta-T is: for cement use ~110 µs / ft, for water use ~200 µs / ft, for brines use ~180 µs/ft and for oil based muds use ~225 µs/ft. These inputs are used by the Planner to calculate the 2-way travel time of the signal reflected by the outer pipe, which determines the start of the region where these signals start to arrive. This region is represented in the Data Acquisition Timing Diagram.

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5)

The Results Panel

The Results panel presents most of the CJP outputs. A field may be displayed with a different title and also be blanked out, depending on whether the Planner is being run in Recommendation or Simulation mode or on whether the well environment is Open Hole or Cased Hole.

The outputs that are needed by the user for programming the service in INSITE are presented using a different background color – blue/grey – from the other outputs. Apart from the Transducer type and from the Scanning Head configuration 5 other parameters are needed. These are shown at the bottom of this panel. A remark field is also presented besides the Transducer and the Head Size display. It is used to display either the transducer slot in a given scanning head or to indicate a problem with the job configuration, as detected by the Planner. The bottom of the Results panel is used for a special feature dedicated to inform the user about how a given motor speed or about how a given line speed can influence the data acquisition. This feature is discussed in detail in Section 6 of this document. Recommended / Simulated Head Size – in Recommendation mode this field is used for displaying the Planner’s recommended scanning head. In Simulation mode it displays the scanning head selected by the user. Recommended / Simulated Transducer – in Recommendation mode this field is used for displaying the Planner’s recommended transducer. In Simulation mode it displays the transducer selected by the user. Remark – the remark field on the top right corner is used for informing what scanning head slot is to be used or to indicate a problem related to the input configuration parameters. 2/6/2009

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Pipe ID / Well Size – pipe Internal Diameter (CH) or Well Size (OH), in inches. Pipe ID is calculated as ID = sqrt (OD^2 – PipeWeight / K ) where K is a constant that depends on the pipe’s material and equals 2.713 for steel. Pipe Thickness – approximate nominal inner pipe thickness, in inches. It is calculated as THK = (OD – ID) / 2. Notice that pipe Thickness is derived from the pipe OD and the pipe Weight, it does not come from a look-up table. This value has wide-ranging implications on many of the recommendations done by the Planner when the tool is to be run in WF mode, and in many other calculations whose results are displayed on the Results Panel. It governs the transducer selection, the Sampling Interval and the recorded Waveform Length. The Impedance calculations are heavily affected by the Thickness measurement. Pipe Res Freq – fundamental transverse mode resonance frequency (RF) of the pipe, in KHz. It depends on the acoustic slowness property (S) of the pipe material and on the pipe’s thickness. It is calculated as RF = S / (2 * THK). The value of S for steel is assumed .2243 us / inch. Effective Head Radius – this value represents the effective distance, in inches, between the transducer’s sensitive element and the tool axis. It depends on the size of the scanning head and on the position (internal slot) where the transducer is installed. Transducer Position – some heads offer more than one position where the transducer can be installed. The head size and the transducer position set the offset of the transducer from the center of the tool and influence signal strength and travel time. This position corresponds to the place where the snap ring that holds the transducer in place is installed and is expressed as an integer number that is zero for single-slot heads and a number higher than zero that grows with growing distance between the center of the tool and the slot’s location. Avg Radial Clearance – distance in inches between head OD and pipe ID, when the head is centered in the well, i.e. when eccentricity is zero. It is calculated as ARC = (Well ID – Head ID) / 2 Min TT – minimum 2-way travel time, in μs. It occurs when the transducer is closest to the borehole wall. The diagram below, where the inner circle represents the scanning head OD and the outer circle represents the hole ID, illustrates MinTT, MaxTT and AvgTT conceptually Notice that as eccentricity approaches zero minTT, maxTT converge to avgTT. Max TT – maximum 2-way travel time, in μs. It occurs when the transducer is farthest from the borehole wall. Avg TT – average 2-way travel time, in μs. It’s always the average of maxTT and minTT. It can also be interpreted as the travel time that results when the head is perfectly centered inside a round hole. Maximum Ecty – maximum eccentricity, in inches. This value is the same value entered by the user in the Max ECTY edit box. Notice that the difference between the maximum and the minimum Travel Times (maxTT – minTT) increase with increasing Eccentricity. The relationship between these quantities is better illustrated with a graphic diagram, as presented below.

Max TT Max TT = Min TT = Avg TT Min TT

Avg TT = (Min TT + Max TT) / 2

Eccentered Scanning Head

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Centered Scanning Head – the center of the scanning head coincides with the center of the hole.

Tool Acronym (FOM or Service Manual) 75

TT 2nd Reflection – 2-way travel time of the acoustic signal’s 2nd reflection, in μs. It is calculated as TT_2nd_Reflection = 2 * avgTT. The diagram on the left represents the first (thicker line) and the 2nd (thinner line) transmitted and reflected signals

1st reflection Pipe Wall

Xdcr nd 2 reflection

Part of the acoustic energy that is reflected back from the pipe wall is reflected back by the transducer and hits the pipe wall again. The interval between the transducer firing and the first arrival of the 2nd reflection is twice the travel time of the first arrival. This signal may interfere with the recorded signal. Depending on FTT, on the distance between the transducer and the pipe’s inner wall and on the length of the recorded waveform.

Optm. # Shots / Scan – optimum number of shots / scan. It is calculated as OptSpS = ID / XHR where XHR is the transducer’s horizontal resolution. As smaller pipes have a smaller perimeter and each transducer has a fixed horizontal resolution, fewer shots are needed as the size of the pipe decreases and yet full horizontal coverage can be provided. The Planner (in Recommendation Mode) automatically recommends using the shots/scan option that is equal to or right above the calculated optimum value. Recommended / Simulated #Shots / Scan – optimum number of shots / scan actually acquired by the tool. The tool data acquisition system offers a limited set of options for this parameter, which are listed in the corresponding list box in the DACQ Panel. THK Outer Pipe – thickness, in inches, of the outer pipe, which is always assumed as made of steel. All values related to the outer pipe are blanked when there no outer pipe is indicated on the Planner or when the well environment is set as Open Hole. Annulus Size – distance between the inner pipe OD and the outer pipe OD, in μs, assuming these pipes are concentric. Annulus TT – 2-way travel time of the signal inside the annular space, in μs. The inner and outer pipes are assumed to be concentric. TT Outer Pipe – estimated 2-way travel time of the signal reflected by the outer pipe, in μs. This result is influenced by avgTT, by the size and the slowness of the annulus material (for cement use ~110 µs / ft, for water use ~200 µs / ft, for brines use ~180 µs/ft and for oil based muds use ~225 µs/ft), by the thickness of the inner pipe and by the inner pipe material’s slowness (57 us / ft for steel). When the annulus space is small the signal reflected by the outer pipe may interfere with the recorded signal. This concern grows with growing recorded waveform length. TTouter_pipe = avgTT + 2 * THKinner_pipe * inner_pipeSlowness + 2 * AnnulusSize * AnnulusSlowness XDCR Horz Resol – transducer horizontal resolution, in inches. This parameter is dependent on the geometrical and on the frequency characteristics of the transducer and is defined as the horizontal dimension of a feature .05” dip - think of it as a .05” deep groove along the longitudinal axis of a 9-5/8” pipe (this can be considered as a flat surface) - that is clearly identified by the transducer. Samples / Shot – number of samples in each waveform. This is simply the Waveform Length divided by the Sampling Interval. This value together with the number of shots per scan and the number of scans per foot (Vertical Resolution) has a pronounced influence on the maximum log speed as it affects the amount of data that 2/6/2009

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must be transmitted for each scan.

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Recommended / Simulated Vert Resol – recommended or simulated vertical resolution (SVR) in scans / foot. In Rec mode this value is set to a predetermined number, as detailed below:

Application Cement Inspection Pipe Inspection Imaging

Data Type

Recommended SVR (scans / ft)

waveforms waveforms time / amplitude

4 12 36

The final vertical resolution of log depends ultimately on how many scans got acquired in each foot of well traversed by the tool. So, this number basically depends on the tool speed, on the scanning motor speed and on the effective uphole data transmission throughput of the tool. Recommended / Simulated # Shots / Scan – recommended / simulated number of shots per scan. The CAST-V tool offers a set of possible values for this parameter. In the CAST-V this is a fixed number (100 for waveforms, 200 for TA). When recommended by the Planner this value assures full horizontal coverage of the pipe / borehole. Waveform Length – length, in μs, of the recorded waveform associated with each shot. Notice that this parameter only makes sense when the tool is working in waveforms mode (WF mode) as in imaging (TA mode) only the shot’s maximum amplitude and first arrival 2-way travel time are recorded. Sampling Interval – time interval between consecutive samples, in μs, of the transmitted waveforms. The tool always samples the signals at 5 MHz, which corresponds to a sampling interval of .2μs. The signals are then down-sampled to the first 5 multiples of .2μs. Notice that this parameter only makes sense when the tool is working in waveforms mode (WF mode). Recmd. Inhibit Setting – to reduce the possibility of picking up a wrong travel time it is recommended to “inhibit” the data acquisition until a few microseconds before the minimum travel time estimated by the Planner. This concept is valid for ultrasonic data acquisition in general, so it applies to any one of the CAST versions. In the CAST-V the data acquisition process starts when the transmitter is fired and the echoed acoustic signal is sampled at 5MHz, which corresponds to a sampling interval of .2µs. When we set the Inhibit Time at, say, 250 we are telling the tool not to work with the first 250 samples, i.e. to ignore the first 50 µs of the acquired waveform. The logic behind the Planner’s Inhibit Time recommendation is explained in section F of this chapter, which describes the Data Acquisition Timing Diagram. You are recommended – with the CAST-V this can always be during logging – to look at the complete waveform to check that the Inhibit Time Setting is properly set. With the CAST-V this can only be done by setting the tool in “WAVE” mode, which is not a valid possible to do while logging. In WAVE mode the CAST real time screen displays the complete waveform, with time in the horizontal scale. The CLASS DO CAST-V command allows you to set the inhibit time in µs (not in nbr of samples, as for the CAST-V). You should set up the Inhibit time at where the signal is clean and always leave at least a 6 µs slack before the first arrival time to allow for possible earlier arrivals. The other outputs, illustrated on the bottom of the Results panel (see next figure) are explained in detail in the Data Acquisition section of this manual.

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6)

The Data Acquisition Panel

General – the Data Acquisition Panel helps the user select a suitable acquisition scheme when he runs the Planner in provides in a Simulation mode. It is basically passive during Recommendation mode, except for selecting the CAST (V or F) bandwidth, which is expressed in words / DITS frame. It provides in a single snapshot a complete view of the most important parameters governing the data acquisition The figures shown below are examples of the DACQ panel

Notice that the DACQ panel configuration changes in accordance with the CAST tool type. In this sense the DACQ panel will only present choices that actually exist for a given tool type. For instance, for the CAST-V the number of shots per scan is dependent only on the service type (TA or WF) and therefore no selection listbox for this parameter is provided. Instead, an uneditable label is used in this case to display the value of this parameter. For the CAST-V, the telemetry choice is in practice dictated by the choice of the telemetry instrument. Therefore the display is changed to show the different telemetry instruments. For the CAST-V three choices exist, independently of the service type or of the well environment. Note: the Planner always assumes that a D4TG is used for running the CAST-V. The Planner only changes the telemetry scheme (words / frame) for the CAST automatically when the user changes the tool type. After that the user can change the CAST telemetry choice without the Planner interfering, using the radio buttons on the bottom of the panel. Tools in Combination – a set of checkboxes for 5 different DITS tools informs the Planner about if they are to be combined with the CAST. The Tool String field will display in red font if the output capacity of the telemetry instrument is exceeded. Listboxes – four listboxes are available for programming the recorded Waveform Length, Sampling Interval, Number of Shots / Scan and Vertical Resolution. These choices are only allowed when they actually apply, which is the case with the CAST-V, and are not active in Recommendation mode. They increase with the down key – think about them as depth, as you go down the depth increases. A listbox choice is effectively activated only when the listbox is left-clicked. 2/6/2009

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The DACQ panel outputs are combined with the time results from the Results panel to generate the Data Acquisition Timing Diagram. The effects of the user choices are immediately displayed on all parameters that are affected by his choice. These parameters are described next. Max Logging Speed (MLS) – this is the maximum line speed (log speed) allowed by the telemetry output capacity of the downhole tool string that will transmit the required number of scans per foot for the current data acquisition configuration, as chosen by the user (Simulation Mode) or recommended by the Planner (Recommendation Mode). In other words, if you run the tool above this speed you will get less information than what is shown in the Vertical Resolution (Scans / Ft) display. Min Motor Rev / Sec @ MLS (MMS) – this is the minimum motor speed at the maximum logging speed allowed by the telemetry (the MLS parameter described above), in revolutions per seconds. You should turn the motor faster than this value so as to fully benefit from the telemetry throughput. If you turn it slower bandwidth will be wasted as the transducer produces data at a slower pace than the downhole telemetry system is able to send. By turning the motor slower than this value and running the tool at MLS you will obtain less scans per foot than specified in the Planner, in whichever mode. As your MLS increases, i.e. as the telemetry system becomes able to transmit more data the minimum scanning speed of the motor also increases. Therefore to get the specified (or superior) vertical resolution, if you can not rotate the motor at this minimum speed, you’ll have to limit the line speed. This limit is calculated by the Planner using the resources shown below, located on the bottom of the Results Panel. So let’s suppose that the minimum motor rev is 8 rps for achieving a certain vertical resolution at MLS (23 ft / min) but you can only turn the scanning head at 5 rps. Using the “Set current speed for…” panel you click on the Motor radio button to inform the Planner that you want to set the current motor speed to, say, 5 rps. The Planner displays, in this particular case that the maximum logging speed is 15 fpm. So you can not run the tool at full speed (as dictated by the telemetry) to produce an image of a given vertical resolution because you can not scan fast enough. This situation happens most frequently when using a large scanning head and is more likely to happen with a CAST-V because it requires 5 revolutions per scan in waveform (WF) mode. In WF mode the CAST-V requires 1 revolution / scan. Both tools require 1 rev / scan in TA (Imaging) mode. The reverse situation may also occur – if the line speed is limited below the MLS value, for whatever reason, the minimum speed required for the scanning head decreases. In this case, check the Line / Winch radio button to set the current line speed. The Planner displays the minimum motor speed required for the input line speed. Absolute Maximum Motor Speed (AMMS) – if the scanning head is turned too fast, at a certain point the transducer may be fired before the data acquisition system has finished processing or even acquiring the signal from the previous shot. This situation must be avoided – it will cause loss of information at the best and a data acquisition system jam that may require tool reinitialization at the worst. In a nutshell, do not turn the motor faster than the absolute maximum motor speed. Try to keep the motor speed 1 rev / second or more above the minimum motor speed @ MLS. The AMMS will usually be much higher than the MMS, in the great majority of the situations normally found in field jobs there will be a huge gap between these 2 values.

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Bandwidth in Words / Frame – maximum number of words / DITS frame allowed by the DITS telemetry instrument. The number of DITS words used by the CAST tool and used by the whole tool string – CAST plus the checked DITS tools – are displayed below this field. At the bottom of the DACQ panel are the radio boxes which represent the bandwidth taken by the CAST. As already explained, this bandwidth (BW) is in the great majority of the cases dictated by the telemetry instrument for the CAST-V but can be directly specified for a CAST-V. For waveform mode you are recommended to choose the highest possible BW choice allowed by your tool string. For time / amplitude mode choose 306 words / frame. A higher CAST BW choice would result in wasted transmission bandwidth, as the MMS (min motor speed) would be too high, thus nullifying the benefit of the adopting a faster telemetry. For the CAST-V three DITS telemetry formats are available. The slowest format, named “Slow Tel”, reserves 306 words per frame for the CAST and is mainly intended for use in TA (Time & Amplitude - Imaging) mode. This format maintains compatibility with possible tool combinations that were in use before using a CAST-V. In fact both tools are very similar when it comes to running them in TA mode, and the gain in speed actually only occurs when the CAST-V is using less than 200 words / shot, since in this case it will be transmitting less data for every scan. This format must be used when the CAST-V is used with other data-intensive tools such as the WSTT and EMI, under both TA and WF modes. Two new telemetry formats were created for use with the CAST-V and these were intended for use in WF (Waveforms) mode: 1. The “Medium Tel” format uses 476 words / frame and keeps the CAST-V compatible for use in combination with an M305-based CBL tool. 2. The “Fast Tel” format uses 612 words / frame. It is intended for use mainly when the CAST-V is run alone. It still allows this tool to be combined with low data rate tools such as an SDDT, an NGRT, Caliper, etc. It should be the preferred format for cement and pipe inspection services where a CBL tool is not required since it permits logging at much higher speed than any other format thus bringing considerable rig time savings.

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7)

The Results Validation Bar

This bar, located right above the Remarks panel, may display in 3 colors – blue, red and brown. A BLUE bar indicates no problems with the job setup. A BROWN bar indicates that there is a problem that does not prevent you from using the current setup or that the setup can be optimized. In most cases it points to a problem with the telemetry choice. A RED bar indicates a severe problem that almost certainly requires that one or more parameters be changed in order to properly program a CAST job. When the validation bar displays RED expect to see one or more messages and probably also some results displayed in red font on the Results panel. The remarks and the redcolored results text boxes in the Results panel will in most cases provide a good hint about the nature of the problem that is adversely affecting the Planner’s outputs. A few examples of the results validation bar showing its different colors are displayed in the next page. In the last case (BROWN bar) a lower telemetry mode is being recommended. However the job could be done using the current configuration by reducing the motor speed. The bottom remark is indicating ineffective use of the available telemetry bandwidth.

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8)

The Data Acquisition Timing Diagram

The Data Acquisition Timing Diagram is presented as a line graph at the bottom of the Planner. It aims to provide a snapshot of the critical timing parameters that are involved in the CAST data acquisition process, as anticipated by the Planner using the information supplied by the user. It constitutes a good diagnosis tool and can be used also when running in the Planner in Simulation Mode. The diagram is not displayed when the results validation bar goes RED.

The figure above shows an example of the Timing Diagram. The basic reference is (time Zero) is the instant when the transducer is fired. Additionally to the transducer firing time the Timing Diagram prints a mark at each one of these timing events: 1. Mute Region – follows immediately after the firing. This region, equivalent to 28µs is the minimum inhibit time (corresponding to 140 samples, 28 X 5 = 140) that the user can program. 2. End of Ring Noise – time at which all transducer ringing noise is supposed to have died out. This value is programmable and may vary between individual transducers and is set at 36µs by default. 3. Inhibit Time (IT) – this parameter applies only to the CAST-V and is also programmable. Inhibit Time, marked with a vertical orange line, is the time at which the data acquisition actually considers as the start of valid data. Although the acquisition process is initiated at the time the transducer is fired, all data acquired up to IT is ignored for recording purposes. The Planner uses the following logic for the IT recommendation: a. In Cased Hole it subtracts 6µs the minimum Travel Time (minTT), and converts the result to the nbr of acquisition sampling intervals equivalent to that time. Each interval is .2 µs long. It then rounds down that number to a multiple of 10. In practice this is equivalent to say that IT is the even nbr of µs immediately below minTT-6. b. In Open Hole it makes the same calculation as above and also calculates what 2-way Travel time results if the well ID is .5” below the bit size – this calculation involves the Fluid Travel Time. The lower of these 2 calculations is then converted to the number of acquisition sampling intervals and rounded down to a multiple of 10. 4. minTT – minimum 2-way first arrival Travel Time. 5. avgTT – average 2-way first arrival Travel Time. 6. maxTT – maximum 2-way first arrival Travel Time. For each one of items 4, 5 and 6 a line of size equivalent to the length of the recorded waveform is drawn showing the time region over which the shots get recorded. These lines are not displayed in Imaging (TA) mode. 2/6/2009

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At the bottom of the diagram, a black line illustrates the time range covered by the recorded data, as expected by the Planner. 7. 2nd Reflection Region – region where signals originating from a 2nd reflection (signal bouncing between xdcr Ù pipe) of the acoustic wave arrive at the transducer. This line is colored RED when a large portion of the 2nd reflection region overlaps with the recorded waveform. Notice that overlap region is calculated based on the value of avgTT – there will be more overlap (signal interference) when the transducer is nearer to the pipe / borehole wall and less overlap (signal interference) as the distance between the transducer and the pipe / borehole wall increases. In more quantitative terms, for each shot an overlap will exist whenever the recorded waveform is longer than that shot’s 2-way Travel Time. 8. Arrivals from 2nd Pipe – region where signals from the outer pipe (if the outer pipe box is checked) arrive at the transducer. It is colored RED only when the Planner sees considerable overlap with the incoming signals. There are several justifications for this approach. The main one is that these signals are much smaller than the signals from the inner pipe.

9)

The REMARKS Panel

The REMARKS panel is comprised of 4 text fields that are used to display messages. The messages may be indicative of errors, warnings or just informative. As already mentioned, they are ranked in terms of importance when the Planner is run in Recommendation mode, so messages that are more critical appear on top of ones considered less critical. An example (resulting from somewhat unrealistic inputs) of a Remarks Panel display is provided below for illustration purposes.

Perhaps the main objective of these remarks is didactic, i.e. to guide the user with respect to the consequences of his inputs, especially when they bring results that the Planner interprets as being problematic. These remarks are saved in all file formats supported by the Planner. 2/6/2009

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9)

The Top MENU Bar

The main components of the CJP top menu bar, shown above, are: 1. File o

Exit – closes the CJP program.

o

Save – saves the Planner variables (inputs and outputs) in digital format with .CJP extension.

o

Save As – saves the Planner variables in digital format under an arbitrary (new or old) file name, with the .CJP extension.

o

Save as EXCEL Spreadsheet – saves the Planner variables – including remarks and header – as an MS-EXCEL spreadsheet (.xls extension) for user convenience. Notice that the results are saved in 3 separate sheets in the MS-EXCEL workbook. The workbook comes with 6 sheets, 3 of which are used by the Planner, and is always named CJP_Results.xls. No resource is provided for reading the Planner inputs from an EXCEL spreadsheet.

o

Open – opens a saved .CJP file and configures the Planner accordingly.

o

Edit Header Data – the .CJP file and the report generated by the Planner may contain a header. The header editing window, a screenshot of which is shown below, is accessed by clicking on this option. The data entered in the header fields is saved when the user presses the “Update Header Data” command button.

2. Print

The header data is saved in all file saving formats supported by the Planner. The figures shown here present a Header Editing Window and a view of the

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same saved in EXCEL format. o

Print Report – this option prints the report generated using Menu => Tools => Make Report. This command generates an ASCII file that has a name composed of the Client and Well Name strings, with a .rep extension (like CVJP_New Client_Well #0001.rep).

o

Print Screen – this resource is still being developed and may not be working in some systems currently used in the field.

o

Make Report – read the “Print Report” item above.

o

Show INSITE Inputs Window – this command has exactly the same functionality of left-clicking the “Show the INSITE Service Configuration Window” command button displayed on the bottom of the Planner screen.

3. Tools

4. Environment o Select Pipe Material – allows the user to change the pipe material between steel, titanium, fiberglass and chrome. A “Custom Material” option allows setting up for an arbitrary material defined through its Acoustic Slowness and Density properties. 5. About – displays information on the program, like version, author, release date, etc.

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Appendix B

Appendix B – Insert Name

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