Advancing Casing Deformation Detection: A Scalable Real-Time Anomaly Detection Approach Using High Frequency CCL Data
Abstract Casing deformation during hydraulic fracturing in unconventional reservoirs presents significant challenges, reducing well productivity, increasing costs, and restricting lateral access. While multi-finger calipers offer reliable diagnostics, they are often costly and typically used after issues arise. In contrast, the Casing Collar Locator (CCL) is routinely deployed, offering a cost-effective and scalable diagnostic alternative. This study evaluates the use of high-frequency CCL data for real-time anomaly detection, aiming to identify potential casing deformation earlier and proactively reduce the unstimulated lateral length with preventive actions. The goal is to give completion engineers timely insights that lower intervention costs and improve operational efficiency. The study proposes an end-to-end workflow including data ingestion, data processing, machine learning model deployment, and real-time visualizations. High-frequency CCL data (750Hz) is analyzed using an unsupervised anomaly detection algorithm based on isolation forests, eliminating the need for labeled datasets. The approach includes (1) validating the predictions with actual deformation events, (2) testing wireline data processing methods, and (3) applying downsampling algorithms. Techniques like frequency tuning, normalization, and downsampling (to 30–75Hz) improve efficiency without compromising resolution. A collar tagging method helps distinguish true deformation from collar-induced signals. CCL data is combined with stage and well context for accurate depth matching and real-time anomaly scoring. The developed Anomaly Detection Tool (ADT) has successfully identified casing deformations in multiple wells in a high-impact region. The model flagged deformation risks early, preventing operational disruptions. Notably, collar tagging enhances model precision by filtering collar-related signal noise. Higher resolution (0.01m sampling) sharpened anomaly resolution and improved detection. Overlaying the runs and anomalies enabled confirmation of casing degradation trends. Field testing included two phases: a shadow mode deployment where ADT findings supported contingency planning (e.g., slim plugs, longer stages) that enabled full lateral stimulation; and a live field test, where near real-time results informed operational decisions as deformation signals evolved, offering operators critical lead time for intervention planning. This study presents a scalable, real-time casing deformation detection system leveraging machine learning and ubiquitous CCL data without requiring additional tools or expensive sensors. The novelty lies in the use of an unsupervised learning approach, which performs well in the absence of labeled data and adapts across geologies and operational styles. Signal processing advancements, including collar tagging, further elevate the tool's reliability. This methodology was first developed in the Vaca Muerta formation and has since been validated across U.S. and Canadian basins, confirming its generalizability. Future work will focus on integrating supervised learning as labels mature to further improve precision and usability.
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