SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

ULTRASONIC CEMENT BOND EVALUATION

R. M, Havira
Schlumberger-Doll Research
Ridgefield, Connecticut

March 18, 1982

ABSTRACT

The commercial version of a new method for acoustically investigating the quality of a cement bond
behind casing was discussed in an earlier paper. The technique employs an ultrasonic pulse source
having a frequency spectrum selected to stimulate a selected radial segment of the casing into a
thickness resonance. The selected frequency spectrum enhances the reverberations between the inner
and outer walls of the casing so that the rate of decay of the reverberations can be related to the mediti
behind the casing.

In this paper the theory of the measurement will be treated in greater detail, and laboratory as well as
early field tests made with the research protype are presented. An overview of the theory of
measurement, laboratory and field results are presented. Key objectives achieved are the distinction
between good and bad bonding, the reduction of ambiguities due to microannuli, and the
circumferential resolution necessary to detect channeling.

INTRODUCTION
#=-
Present oilfield cementing practice requires both a shear and a hydraulic bond between the cement and
casing. The shear bond mechanically supports the casing in the hole, while the hydraulic bond blocks
the flow of fluids across a cemented area. Of primary importance is the evaluation of hydraulic
bonding, since most cement jobs provide adequate mechanical support to hold the pipe in place.
Effective hydraulic bonding means that the cement must hydraulically seal the formation as well as the
casing.

Techniques for improving primary-cement bonding include pipe movement (rotation and/or
reciprocation), use of scratchers, pipe centralization and use of well-conditioned muds. The casing is
sometimes coated with an epoxy loaded with a sand or gravel mixture to improve adhesion. Yet, even
after these techniques are applied, bad bonding remains a common problem. N

The bad bond can take many forms: a channel in the cement column, a microannulus, or mill varnish
softening on the surface of the casing causing the cement to appear completely unbended on the
cement bond log.

Present cement bond logging (CBL) tools use a transmitter and a receiver usually spaced three feet
apart, and operate at a frequency of approximately 20 kHz. Sonic energy emitted by the transmitter
travels through the casing and is detected at the receiver. When the pipe is unbended, this signal
amplitude is large, but is reduced when cement is bonded to the pipe. Because the physics of the
measurement require shear coupling to the pipe, any interruption (such as a very small microannulus
around the pipe) will appear as a bad bond even when this annulus between pipe and formation is
hydraulically secure, The source and receiver are omni-directional, making the location of channeling
difficult to establish. Cement bond logging, unlike many other services, has no alternative physical
measurement for confirmation, except for the variable density display.
,,#%

-1-
SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

Different physical phenomena were investigated as a replacement for the CBL; however, only ultrasonic
.....
energy with its ability to be finely focused to achieve the necessary spatial resolution appeared to be
viable.

While ultrasonic energy has the desired characteristics for spatial resolution, the means of utilizing this
energy for the above purposes was not obvious. The considerations that were made in arriving at a
final measurement scheme are discussed in the remainder of the paper.

OBJECTIVES

The primary objectives of a tool to overcome the shortcomings of conventional CBL technology are: to
provide hydraulic-bond evaluation in the presence of microannuli; to achieve sufficent circumferential
resolution to permit the detection of channeling; and if possible, to permit an evaluation of formation
bonding.

PHYSICS OF ULTRASONIC CEMENT EVALUATION

Pulse echo techniques in which a short burst of acoustic energy is emitted using a single transducer
serving as both the transmitter and receiver were considered first. These techniques have been
successively employed ~n non-destructive testing, sonar, medical applications and even in the borehole
as a televiewer. An acoustic source in the form of a 1 disc is most used. At ultrasonic frequencies,
the wavefront from such a source is a reasonable approximation to a plane wave.

The wavefront in casing is focused cylindrically to allow the use of a planar-layered model to analyze
the borehole environment normal to the casing axis, similar to the models used in seismic work.
o.

The model consists of .a mud layer, the casing, a microannulus, cement, and the formation (Figure 1).
The transducer shown acts as both transmitter and receiver, and is oriented so that the beam is normal
to the casing. For the purpose of discussion, the transmitted compressional wave is first assumed to be
a unit impulse, and only a single media behind the casing is considered.

Figure 2 depicts the reflection and transmission of this sound beam incident on the casing, bounded on
either side by semi-infinite layers. The angle of incidence is assumed to be (and in fact is very nearly)
normal, but since the time axis is along the horizontal, it appears on the figure as though the beam
were at non-normal incidence. The beam which is incident on the casing is divided into reflected and
transmitted parts. Such division happens each time the beam strikes a different interface. The units of
time are given in the two-way travel time in the casing. The time sequence of the reflected wave r(t)
can be written in terms of a Laplace transform R(s) as

R(s) =rO+
[
l+rO
1rl [lrO 1e ST+
ll+rOlrlrOrl[l-role-2T
where
z~zo
rO= reflection coefficient
z~+zo
Zz,
r[ = reflection coefficient
Z,+ Z*
Zn = impedance of nth layer.

-2-
 SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

T= twoway travel time given by 2L/C.

Z0,Z1,Z2
= acoustic impedance of each layer with Z1 > Z2 ZZO.

L= thickness of the layer.

c= compressional sound velocity of the layer

in closed form
r.+ rl esT
R(s) =
1 +r~le-sT

Then the reflection coefficient as a function of time can be written as

r(nT) = ~
~(nT)-[%]exp[-nlnlr@ll
n=O12,,, ...

Typically for good bond conditions (neat cement) and bad bond conditions (water) with a light mud
filling the borehole.
rO = 0.937 light mud

rlB = 0.937 bad bond

r]G = 0.731 good bond

A time response is shown in Figure 3 for both good and bad bonds. The amplitude of the first
reflection (rO) is about ten times larger than the remaining reflections and is independent of the media
behind the casing. The time units AT are given corresponding to the two-way travel time in the casing.
Note that, except for the first reflection, the response is given by an exponential decay with the time
constant a function of both the fluid filling the casing and the material outside of the casing, As can be
seen, the rate of decay is relatively fast for a good bond as compared to a bad bond. Therefore, one
method to determine the difference between a good bond and a bad bond would be to measure the rate
of decay of these reverberations in the casing. To do so would mean losing the amplitude information
present since there is on the order of a thirty percent difference in amplitude of the reflections in this
decaying tail. Therefore, to combine both the rate of decay and this amplitude difference in one
measurement, the area of the envelope defined by these reverberations after one two-way travel time
delay, T, can be compared for both a good and a bad bond. That is

Thus, there is almost a four to one contrast between good and bad bond conditions; this is an
extremely sharp contrast by any standard. When the density of the fluid increases, this ratio is reduced
but it is still greater than two.

Clearly this analysis shows the utility of an ultrasonic technique for cement bond evaluation. From the
above, it would also appear that a pulse should be used which is short enough to have decayed to zero
before the next interface is reached by the leading edge of the pulse. This would be valid except for
practical considerations, such as casing roughness, transducer size, grain size in the steel, and
,P attenuation in the mud. Furthermore, using this method the microannulus should appear as a good

-3-
SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

bond rather than a bad bond as is frequently seen using former techniques. -%

Since a hydraulic seal is the objective of a good cementing job, consideration was given to the probable
dimensions of a microannulus. With the standard CBL tools, the well is often pressured up to
eliminate the effects of a microannulus. In most cases, the added pressure is only on the order of 200-
500 psi, with the maximum pressure needed to correct for a change of fluids in the casing being less
than 2000 psi.

During the cementing process the well is often pressured up to a maximum of 2000 psi while the
cement sets. When this pressure is released a microannulus results, the thickness of which can be
determined from Figure 4.

To have the microannulus correspond to a good hydraulic bond, consideration must be given to the
casing thickness and the frequencies that might be employed in such a measurement. Since the signal
is reverberating in the casing, the lowest frequency is determined by the fundamental resonant
frequency of the casing. That is,

where
V, = casing compressional velocity

tC = casing thickness

For the range of casing sizes presently employed, this corresponds to a frequency range of 200-600 kHz.
The casing can also resonate any integer multiple of the fundamental frequency. ,.~.

In order for a microannulus to have a negligible effect on the response, it must appear to be
ultrasonically transparent. Rather than perform extensive simulations, a continuous wave analysis can
be used since the energy presented to the microannulus is basically at the resonant frequency of the
casing. The energy transmitted across a section bounded on either side by infinite media is given by

4 Zlzo

at= l:+Icoslftw)
+l:+asinl:twl
where

k. = wavelength

t~ = thin water section thickness

The energy transmitted across a thin water section bounded by steel and cement as a function of
wavelength is shown in Figure 5. It is evident that the annulus need only be a small fraction of a
wavelength to adversely affect the transmission across it. Therefore, in order to minimize the effect of
the microannulus, the lowest possible frequency should be used. This frequency is determined then by
the fundamental resonant frequency of the casing. To cover all casing thicknesses, a broad-band pulse
containing either the fundamental or harmonic frequency of the casing thickness must be used, Ideally
by having a transducer with a bandwidth of 300 kHz and a center frequency of 450 kHz, the entire n,

-4-
 SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

casing thickness range can be covered by a single transducer. Should more sensitivity to microannulus
P
conditions be desired, high frequencies can be used.

This is a fortuitous result in that the predicted microannulus has a dimension on the order of 0.002
which corresponds to a a very small portion of a wavelength thus making the microannulus appear as a
good hydraulic seal.

Thus far the measurement method (i.e., integration of the envelope of the reverberations) and
frequency range have been determined. Cement-to-formation bonding and microannulus effect on the
response must yet be discussed. Figure 6 shows the response of the casing, including the formation,
using a broad-band pulse as discussed above. The formation return signal will in general be lower in
amplitude than shown due to a lower con~rast between the cement and formation impedance, borehole
rugosity and eccentering of the casing in the borehole. For these reasons, only the reverberations in
the casing are being used at present. A research tool incorporates a digitizer to study formation effects.

Figure 7 shows the waveforms and spectra for the emitted pulse, and received waveforms for both good
and bad bonding. Observe that the depth of the notch at the casing resonant frequency is deep for a
bad bond and shallow for a good bond. For a microannulus, the depth of this notch and the rate of
decay of the reverberations is a function of the microannulus thickness.

To demonstrate the effect of different microannulus thicknesses on tool response, a series of

calculations was performed as shown in Figure 8 for a 29 lb 9 5/8 casing. The signal processing
performed in these calculations was first to full-wave rectify the wave as shown in figure 9, and then
integrate the windowed portion from 6 to 40 microseconds after the beginning of the waveform. The
bad bond reading corresponds to a water layer behind the casing that is infinite in extent. It is
interesting that annuli large enough to provide hydraulic communication produce readings larger than
,#@-.. the bad bond reading shown, due to constructive interference. Small microannuli (<0.003) will be
seen as good bonding.

Therefore, this ultrasonic method easily differentiates between good and bad bonds, provides
circumferential resolution, is relatively insensitive to microannuli, and potentially can determine the
cement-to-formation bond quality. This has been supported both experimentally and theoretically.

TOOL DESIGN

To determine the applicability of this measurement under field conditions, an experimental sonde was
designed.

In order to provide a reasonable amount of circumferential resolution, the sonde was built with eight
transducers approximately 1 in diameter arranged in a helix at a spacing of 45, as shown in Figure 10.
These transducers can be adjusted before logging to maintain a nominal 2 from the casing, to allow for
severe mud attenuation, and to prevent interference between successive cycles. Each transducer is
excited, and when the signal is detected the integration of the reverberations begins after a suitable
delay. Since the casing reflection is a constant, it is used for adjusting a variable-gain amplifier to keep
the peak of this signal within a narrow amplitude window.

The gain control compensates for attenuation due to mud and eccentering effects. Normalization of the
signal allows eccentering up to about 0.4. The variable-gain amplifier is digitally controlled, and its
value is also used as a measure of the mud attenuation. Additionally, the transit time in the mud is
measured to determine the amount of eccentering. The measurements telemetered to the surface
are: averaged values of the peak amplitude of the reflected signal W 1, the integrated reverberation W z,
P the gain, and mud transit times.

-5-
SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

A log was generated corresponding to W~W1, a normalized energy ratio. Logs of the mud transit time ....,,
and gain can also be made for use in verifying the quality of the log and as an internal caliper.

FIELD RESULTS

Figure 11 is a section from the first log of the research version of the Cement Evaluation Tool run at
3600 ft/hr. This log agreed well with another run at 6000 ft/hr. At a logging speed of 3600 ft/hr, data
are averaged over 2, whereas at 6000 ft/hr, the data are averaged for approximately 3. Each of the
eight traces represents the energy ratio W~W1 for one transducer. This log has several interesting
features--where the commercial CBL definitively shows a good bond, the CET also shows a good bond.
However, there are definite differences, such as around 3710, where the CBL shows a bad bond but
the CET tool shows good bonding on every channel. A possible explanation is a microannulus. Where
bad bonds exist, the periodic bonding (shown by the CET) may tend to reduce the amplitude of the
standard CBL, due to the acoustic filtering of the signal over a 3 interval. There is also a good
agreement at 3600 that is the result of a casing collar.

SUMMARY AND CONCLUSIONS

An overview of Ultrasonic Cement Bond Evaluation has been presented. Several key objectives were
met, such as permitting a clear distinction between good and bad bonding, reducing the likelihood of
ambiguities due to microannuli, and providing the circumferential resolution necessary to detect
channeling. In addition, the measurement is much less sensitive to eccentering than is the conventional
CBL. The field data presented are consistent with these conclusions.

,-.

d-%

-6-
 SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

Cement
Formation I Microannulus

Casing
/

Rellwtad Beam

o
(1 +ro)r, ll ro)
Mud
0 Iv Laver o
500 KHz
Transducer
I

n
Slml
1 I layw I 1

I
I I
C8manl I
z I layer 2
I
I
I
L

I. -I -
[1 +Io)(l +r,

Transmitlad @@mm
L --
j

I
-J
0 0.5 1.0 1.5 Time

Figure 2 Sound Reflection and Transmission by Casing

Figure 1 Ultrasonic Cement Evaluation Model

-- - 29# 9.518 Casing

14# 5-1/2 Casing

5 10 15 20
o
11111
0.05 AT Time Units

0.1
o.151 Bad Bond

E
.=
u
.
=a T

z
c
.-0
Zm
= 10 15
5
1%
0
11
AT Time Units o 1 2 3
0,05. .

0.1 . Pressure Differential

Good Bond Psl x 103

0.15 1

Figure 3 Time Response to a Unit Impulse Figure 4 Microannulus Thickness vs Pressure Differential
Across Casing

-7-
SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

~
Figure 5
0,01 0.02 0.03
Ratio of Microannulus

Transmission coefficient
004 0,05 0.06
Thicknass to Wavelength

vs Microannu]us
0.07
Iwl

Thick.
k~
b:~
Transminad PUIM Frequency m I MHZI
Srmctra
10

ness

1.0

w 0
o 0,5
FIW8ncV in ( MHz)
Swctra
1.0

Transducer

300

200 -
r
Ckng
II
II
II
I
I

i
+--llA ,
Microannulus
0 05
Frtqwncy in ( MHz)
spectra
10

100 -

+--/)!(,
loo -

200 -

300 -

400 ,
0 0.5 10
Good Bond Fraqu8ncy in ( MHz)
spectra
Casing Reverberant ion Reflection
Reflection in from Figure 7 Temporal and Frequency Response
Casing Format ion

Figure 6 Typical waveform

-8-
 SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

1.2

1.0

0.8

a
m
c
0

~ 0.6
a
= <
z

0.4

0.2

0 , , 4
I 0.01 0.02 0.03 0.04
Microannulus Thickness
(inches)

Figure 8 Tool Response to Different MjCrOannU]i

1 DD 33/8

Rectified Waveform OD 4
N
Figure 10 Cement Evaluation Tool

K----- T2 ---+
Gate

Figure 9 Rectified Waveform

-9-
SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

-%
I CET 1 rzirl
I -3 div = Bad Bond I / (rnv)I
o 5 (Typ. 8 Traces) 1 ~1 div = Good Bond ~ ~
*o do
1
0

ii
,Periudic
. Bonding-
-

-m ,

-Casing
Collar

-Good
Bond

Figure 11 Log Example

-1o-
 SPWLA TWENTY-THIRD ANNUAL LOGGING SYMPOSIUM, JULY 6-9, 1982

REFERENCES

Froelich, B., Pittman, D., and Seeman, B., Cement Evaluation Tool - A New Approach to Cement
Bond Logging, SPE paper 10207, presented at San Antonio, Texas, October 5-7, 1981

Froelich, B., Dumont, A., Pittman, D., Seeman, B., and Havira, M., Ultrasonic Imaging of Material
Mechanical Properties Through Steel Pipes, IEEE Proceeding - Ultrasonic Symposium, Chicago,
III., October 14-16, 1981

Kinsler, L. E., and Frey, A. R., Fundamentals of Acoustics: John Wiley and Sons, Inc., New York
1950.

Robinson, E. A., Multichannel Time Series With Digital Computer Programs: Holdan Day, San
Francisco, 1967.

Havira, R. M., Ultrasonic Bond Evaluation in Multilayered Media: J. of the Acoustical Society of
America, Supplement 1, vol. 66, Fall 1979, p. 41, November 26-30, 1979.

Havira, R. M., Method and Apparatus for Acoustically Investigating a Casing and Cement Bond in a
Borehole: U.S. Patent 4,255,798, March 10, 1981.

N
ABOUT THE AUTHOR

MARK HAVIRA received his B.S., M.S. and Ph.D degrees in Electrical Engineering from the
Pennsylvania State University. He joined Schlumberger Weston Components in 1970. In 1974 he
transferred to Schlumberger-Doll Research, where as leader of the Ultrasonic-Spectroscopy program he
developed the Cement Evaluation Tool (CET). In 1979 he became Manager of the Rock Physics
Laboratory. He is a member of the IEEE and has published numerous papers on optimization
techniques and acoustic simulation in IEEE and JASA.

- 11 -