Pulsed Eddy Current Logging Technology for Through-Tubing Casing Break Detection up to the Third Tubular

Improving the production from heavy oil wells with steam injection presents a complex and critical challenge in terms of ensuring the continued integrity of the tubulars in these wells. The extreme thermal stresses introduced by steam injection and the temperature fluctuations along the wellbore can lead to casing failures, including collapses or fractures, that threaten well performance. Identifying and managing these risks requires effective monitoring and early detection of potential casing damage. One effective method for achieving this is through pulsed eddy current (PEC) electromagnetic (EM) casing inspection logs, which provide crucial data that can inform risk mitigation strategies. A significant advantage of PEC technology is its ability to provide continuous monitoring over the life of the well. By conducting baseline inspections before steam injection and subsequent periodic inspections, PEC allows operators to track changes in well integrity over time. This time-lapse approach is critical for identifying potential issues before they escalate into costly failures. Another key advantage of PEC technology is its ability to detect casing breaks without requiring tubing retrieval, significantly reducing operational costs and downtime associated with workover operations. This paper delves into the use of PEC casing inspection technology to monitor thermal well integrity with overviews of the physics, the deployment process, and the methodology designed to efficiently detect casing breaks, particularly in the third tubular section. This is crucial, as thermal casing breaks tend to occur near casing collars, presenting challenges in accurate identification through conventional methods. The paper also provides a comparison of PEC results with traditional multifinger caliper logs, validating its reliability. Case studies are shared to demonstrate successful PEC applications in detecting casing breaks in both second and third tubulars, highlighting the PEC technology’s nearly 100% success rate across hundreds of heavy oil wells and reinforcing its effectiveness in helping operators maintain their thermal well integrity.