Cathodic Protection of Well Casings Using E-Log I Criteria

Paper No.
06071
CATHODIC PROTECTION OF WELL CASINGS USING E-LOG I CRITERIA
Ernest W. Klechka, P.E.

Gerhardus H. Koch Ph.D.
Angel R. Kowalski
CC Technologies
5777 Frantz Road
Dublin, Ohio 43017
Abdul Wahab Al-Mithin

Emad Al-Nasser
Kuwait Oil Company (K.S.C.)
Ahmadi Kuwait
ABSTRACT
For well casings it is difficult to directly measure cathodic protection potentials along the
length of the well casing. The E-log I criterion is described in RP0186-2001(1) Application of
Cathodic Protection for External Surfaces of Steel Well Casings, which stated that adequate
protection is achieved with a voltage at least as negative (cathodic) as that originally
established at the beginning of the Tafel segment of the E-log I curve. This voltage shall be
measured between the structure surface and a saturated copper-copper sulfate half cell
contacting the electrolyte.
In order to establish the proper current density for weld, E-log I testing was conducted on
several wells. The results of well testing are presented. The test results were in good
agreement with the 1.0 A/cm2 used for design of the test.
Key words: Cathodic Protection, E-log I, Tafel,
INTRODUCTION
The external surfaces of steel well casings are protected from external corrosion by applying
cathodic protection. RP0186-2001 Application of Cathodic Protection for External Surfaces
of Steel Well Casings is intended as a guide for establishing minimum requirements for
corrosion control when cathodic protection is practical and cost effective (1). This standard
Copyright
2006 NACE International. Requests for permission to publish this manuscript in any form, in part or in whole must be in writing to NACE International,
Conferences Division, 1440 South Creek Drive, Houston, Texas 77084. The material presented and the views expressed in this paper are solely those of
the author(s) and are not necessarily endorsed by the Association. Printed in the U.S.A.
Santhosh Prabhu - Invoice INV-1122819-M6M5H5, downloaded on 12/18/2016 3:35PM - Single-user license only, copying/networking pro
applies only to well casing exteriors and not to internal corrosion, or to corrosion of other
surface or downhole equipment.
Criterion for cathodic protection given in RP0186-2001 Application of Cathodic Protection for
External Surfaces of Steel Well Casings states the cathodic protection current applied to the
casing shall be considered adequate when measurements indicate that a net flow of current
to the casing has eliminated all anodic areas. Methods for determining specific current
density criterion can be developed with information obtained from:
1. A casing potential profile tool used to measure voltage drop (IR) across a portion of
well casing in service;
2. Current density calculations based on well completion practices
3. Mathematical modeling including current attenuation modeling.
4. E-log-I test results
In 1 a casing profile tool requires lowering a tool into the weld which was not acceptable. If
the required current density is know then method 2 or 3 can be used. However, because the
current density needed to be determined, E-log I appeared to be the correct choice.
Therefore, E-log-I testing was selected to determine the current density need to protect the
wells in Kuwait. According to RP0186-2001 the average current density can be use to
calculate the quantity of current required to prevent external corrosion. Current densities
used for these calculations can range from 1 to 20 A/cm2. If the total external surface area
of the well casing can be calculated then the current density can be calculated from the
current required based on E-log I.
David Kroon, et al in an August 2004 article in MATERIAL PERFORMANCE titled Cathodic
Protection of Well Casings in Abu Dhabi found that E-log-I testing can be used to define a
current density range for CP (2).
E-LOG I TEST METHOD (APPENDIX B OF RP0186-20001)

Six wells in Kuwait were selected for E-log-I evaluation. E-log-I testing is used to determine
the minimum cathodic protection current required for protection of a well.
In order to test the six wells in Kuwait, each wells was electrically isolated.
Temporary testing ground beds at each well were constructed. These temporay ground beds
consisted of four or five 2.5 cm diameter rods 2 m long driven into the ground and connected
to the positive terminal of temporary rectifiers capable of generating the required DC current.
A copper/copper sulfate reference electrode was used to measure the potential of the well
casing. The reference electrode was placed beyond the influence of the test ground bed.
The basic test set up for E-log-I testing is shown in figure 1.
For design of the test, the amount of current needed was estimated at 1 A/cm2. Current
was applied in approximately 10 equal steps. Once the test began, the current was applied
for approximately 10 minutes, the interrupted potentials and current was measured, and the
current increased to the next step. If the test was interrupted, the well was allowed to
depolarize and the test was started over.
INTERPERTATION OF E-LOG I TESTING
The E-log I curve criterion is based upon RP0186-2001 Application of Cathodic Protection
for External Surfaces of Steel Well Casings, which stated that for interpretation of the test
results adequate protection is achieved when the current required is equal to the current at
the intersection of the tangent of the initial part of the curve and the tangent of the Tafel
segment of the curve, or the first point on the Tafel segment. Figure 3 shows these results
for well MN-1.
The Tafel region starts where the rate of the oxidation (corrosion) reaction is negligibly small
in comparison with the rate of the reduction reaction. Depending on the Tafel slopes for the
oxidation and reduction reactions, the beginning of the Tafel region can vary between 50 and
100 mV cathodically from the native potential.
This measurement technique, originally developed for applying the E-log I curve criterion, is
now most commonly used to determine the minimum current required for protection. The
well-to-soil potential, determined by using a remote reference electrode, is plotted as a
function of the current output of a cathodic protection system. Typically, an interrupted
survey technique is used. Off potentials are used for constructing the E-log I plot in order to
accurately establish the curve. The potential required to achieve a desired minimum current
value is identified on the curve. This value should be at least as negative as the value at the
beginning of the Tafel region of the E-log I curve. Once the potential and current values have
been established, future surveys consist of checking the current output of the CP system and
the potential of the structure with respect to the remote reference electrode, placed in the
same location as was used in the original E-log I tests.
Because of the elaborate nature of the technique, its use is generally limited to structures
where conventional means of assessment are difficult. Examples include river crossings for
pipelines, well casings, and piping networks in concentrated areas such as industrial parks.
The technique can give erroneous results in areas of stray currents.
The reference electrode must be placed in the same location each time the potential is
measured. Furthermore, there is no guarantee that a repeat E-log I curve will yield the same
results as the original curve.
E-LOG I TESTING RESULTS

With wells, lack of access for local structure to soil potential measurement prevents the use
of many test techniques normally used for pipeline and near grade structures. E-log-I tests
are generally the most feasible at grade electrochemical current requirement test
measurement available for wells.
First estimate the current required is based on outside surface area of the well casing using a
1.0 A/cm2 current demand for the well casing.
Surface area for a well casing can be calculated using the following formula:
As=dL (1)
Where:
d=diameter in cm
L=length (depth) of casing in cm
For example for MN-29 the casing depths is a follows:
13-3/8-inch diameter 530 feet
9-5/8-inch diameter 5021 feet
7-inch diameter 6547 feet
Because we are interested in the total out surface area we need to sum the surface areas of
each casing in order to get the total surface area.
As= {[3.14*13.375-in*2.54 cm/in*530-ft*12in/ft*2.54cm/in]
+ [3.14*9.626-in*2.54cm/in* (5021-530-ft) *12in/ft*2.54cm/in]
+ [3.14*13.375-in*2.54cm/in*(6547-5021-ft) *12in/ft*2.54cm/in]}
=1.48*107 cm2
Estimate current required for MN-29 using the following formula:
I= As*I (2)
I=1.48*107 cm2 * 1.0*10-6 A/ cm2 = 14.8 A
E-LOG I TESTING RESULTS

In order to perform an E-log I test the well must be electrically isolated, a temporary ground
bed should be located a sufficient distance from the well to give optimum current along the
casing, and foreign rectifiers or other DC sources that could influence the test should be
located.
Wells MN1 1 and MN 29 were tested using E-log-I techniques. The test data for well MN-1 is
shown in table 1. The data for well MN-1 was plotted on semi log paper as shown in Figure
3. Well MN 1 indicated a current requirement of 18 A. The data for well MN 29 is shown in
Table 2 and is plotted in Figure 4. This data indicates that a current requirement of 12 A is
needed for MN-29.
Next welds UG2 9 and UG 12 were tested. Data for well UG 9 is shown in table 3; data for
UG 12 in shown in Table 4. The data for UG 9 is plotted in Figure 5 and the data for UG 12 is
plotted in Figure 6. The current demand, as determined by E-log I testing, for UG 9 was 10.5
A while the current demand at UG 12 was determined to be 12.5 A.
Finally, wells UG 40 and UG 38 were tested. Data for well UG38 is shown in table 5; data for
UG 40 in shown in Table 6. The data for UG38 is plotted in Figure 7 and the data for UG 40 is
plotted in Figure 8. The current demand, as determined by E-log I testing, for UG 38 was 20A
and for UG 40 the current demand was determined to be 34 A.
The estimated current required for all six wells are shown in Table 7. For five (5) of the wells
casing data was available. E-log-I data and the calculated casing area were used to
calculate the current density required for each well using the equation given below.
Ireq = IElogI / As (3)
As shown in the last column of Table 7, the calculated required current densities ranged from
0.61 A/cm2 to 0.91 A/cm2. These calculated required current densities are in good
agreement with the estimated current density used for the initial current demand calculations
1
MN - Minigish Oil Field
2
UG - Um Gudir Oil Field
of 1.0 A/cm2. Therefore, for any additional wells for which the casing dimensions are known
the theoretical current demand can be calculated using the external surface area of the well
casing and current demand of 1.0 A/cm2.
E-LOG-I CONCLUSIONS
E-log I testing is used to determine the cathodic protection current needed to protect a well.
Using the casing sizes and depths, the external surface area of the well casings can be
calculated. Using the casing surface area and a current density of 1.0 A/cm2 the current
required for each well was calculated. These calculations can be used to design and adjust
the cathodic protection systems for wells in this area.
Based on the E-log I data, the current density required can be calculated using the E-log I
current required divided by the external surface area in cm2. As can be seen in Table 7 the
current density required ranged from 0.61 to 0.91 A/cm2. Based on these results E-log I and
current demand calculations can be used to define a current range for cathodic protection.
Although it is preferable to electrically isolate flowlines from the well casings, it is not always
possible to do so effectively and economically. Flowlines above ground can be tested to
determine their effect on the current available from the cathodic protection system.
TABLES
TABLE 1. E-LOG-I TEST - WELL # MN 1
WELL # MN 1 KUWAIT
# Condition VDC ADC Potential ohm
Inst. Off On
No current -685 -685
1 10% 3.8 2.8 -748 -764 1.36
2 20% 9.8 8.1 -764 -818 1.20
3 30% 15.9 13.5 -782 -882 1.18
4 40% 21.6 18.6 -804 -925 1.16
5 50% 26.8 23.1 -820 -970 1.16
6 60% 32.4 27.8 -836 -1019 1.17
7 70% 38.3 33.0 -850 -1065 1.16
8 80% 43.8 37.6 -865 -1111 1.16
9 90% 48.6 42.8 -879 -1154 1.14
10 100% 55.0 47.3 -892 -1199 1.16
TABLE 2. E-LOG-I TEST - WELL # MN 29
WELL # MN 29 KUWAIT
# Condition VDC ADC Potential ohm
Inst. Off On
1 10% 4.4 2.1 -650 -672 2.09
2 20% 10.4 5.3 -662 -716 1.96
3 30% 15.9 8.1 -676 -758 1.96
4 40% 21.6 11.1 -695 -808 1.95
5 50% 28.6 14.8 -715 -863 1.93
6 60% 34.0 17.5 -731 -907 1.94
7 70% 39.7 20.6 -748 -956 1.93
8 80% 45.6 23.8 -764 -1001 1.92
9 90% 51.0 26.6 -777 -1047 1.92
10 100% 57.6 30.1 -794 -1094 1.91
TABLE 3. E-LOG-I TEST - WELL # UG 9
Well # UG 9 Kuwait
Potential
# Condition VDC ADC Inst. Off On ohm
1 10% 5.35 1.5 -776 -783 3.47
2 20% 10.3 4.7 -780 -793 2.51
3 30% 15.7 8.2 -785 -808 2.37
4 40% 21.9 12.0 -793 -826 2.28
5 50% 27.8 15.5 -803 -846 2.26
6 60% 33.8 19.3 -812 -865 2.23
7 70% 40.3 22.6 -823 -885 2.22
8 80% 46.7 22.6 -831 -894 2.68
Well # UG 12 Kuwait
Potential
# Condition VDC ADC Inst. Off On ohm
1 10% 3.58 1.8 -749 -773 1.99
2 20% 9.76 5.1 -765 -833 1.91
3 30% 15.3 8.3 -774 -882 1.85
4 40% 21.2 11.4 -790 -957 1.86
5 50% 26.6 14.3 -806 -990 1.86
6 60% 32.7 17.6 -830 -1055 1.86
7 70% 38 20.5 -837 -1086 1.85
8 80% 44.7 23.9 -851 -1157 1.87
9 90% 50.1 26.1 -863 -1210 1.92
10 100% 56 29.1 -874 -1256 1.92
TABLE 5. E-LOG-I TEST - WELL # UG 38A
Well # UG 38A Kuwait

Potential
Inst.
# Condition VDC ADC Off On ohm
1 6% 7.77 3.7 -599 -631 2.10
2 10 % 15.2 7.3 -606 -664 2.08
3 14 % 22.5 10.9 -616 -703 2.07
4 18 % 29.9 14.5 -622 -737 2.06
5 22 % 37.2 18 -628 -771 2.07
6 26 % 44.6 21.5 -633 -803 2.07
7 30 % 51.8 25 -638 -836 2.07
8 34 % 59.3 28.5 -645 -873 2.08
9 38 % 66.9 32 -653 -908 2.09
10 42 % 74.1 35.4 -660 -941 2.09
11 46 % 81.3 38.8 -667 -974 2.10
Well # UG 40 Kuwait
Potential
Inst.
# Condition VDC ADC Off On ohm
1 5 5.9 4.4 -619 -654 1.34
2 10 15 11.5 -631 -714 1.30
3 15 24.2 18.3 -638 -778 1.32
4 18 29.7 22.5 -646 -818 1.32
5 21 35 26.4 -653 -856 1.33
6 24 40.4 30.3 -661 -893 1.33
7 27 45.8 34.1 -668 -929 1.34
8 30 51 37.8 -676 -966 1.35
9 33 56.7 41.8 -681 -1002 1.36
10 36 61.9 45.6 -687 -1035 1.36
11 39 67 49.2 -703 -1083 1.36
TABLE 7. CALCULATED CURRENT REQUIRED COMPARED TO E-LOG I CURRENT
MEASUREMENTS.
Calculated Current
Calculated Calculated current
Current Required based
Well Area density
Requirement on E-log I
cm2 microamperes/cm 2
Amps1 testing
MN-01 18.0
MN-29 1.48E+07 14.8 12.0 0.81
UG-09 1.73E+07 17.3 10.5 0.61
UG-12 1.43E+07 14.3 12.5 0.84
UG-38A 2.38E+07 23.8 15.0 0.63
UG-40 2.38E+07 23.8 21.0 0.91
1
Estimated required current density =1.0 A/cm2
FIGURES
FIGURE 1 TEST SET-UP FOR E-LOG-I TESTING
Electrical isolation
Voltmeter
Rectifier
Test ground bed
+ - Reference Electrode
Well Casing
FIGURE 2 TYPICAL WELL CASING (MN-29)
133/8"
casing.
@ 530 ft-DD.
95/8"casing
@ 5021 ft-DD.
TOC @ 6547 ft-DD.
7" casing
shoe
@ 6547 ft-DD.
TD @ 6550ft-
DD.
10
MN 1 E log i
-725
1.0 10.0 100.0
-750
-775
Potential e (mV)
-800
-825
-850
-875
-900
Log i
FIGURE 3 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL MN 1

Using the Tafel slopes the current required for well MN 1 is approximately 18A.
MN 29 E log i
-625
1.0 10.0 100.0
-675
Potential e (mV)
-725
-775
-825
Log i
FIGURE 4 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL MN 29

Using the Tafel slopes the current required for well MN 29 is approximately 12 A.
11
UG 9 E log i
-750
1 10 100
-775
-800
Potential e (mV)
-825
-850
-875
Log i
FIGURE 5 E LOG I PLOTTED ON SEMI-LOG PAPER WELL UG 9

Using the Tafel slopes the current required for well UG 9 is approximately 10.5 A
UG 12 E log i
-700
1 10 100
-725
-750
-775
Potential e (mV)
-800
-825
-850
-875
-900
Log i
FIGURE 6. E LOG I PLOTTED ON SEMI-LOG PAPER WELL UG 12

Using the Tafel slopes the current required for well UG 12 is approximately 12.5 A
12
UG 38A E log i
-575
1 10 100
Potential e (mV) -600
-625
-650
-675
Log i
FIGURE 7 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL UG 38A

Using the Tafel slopes the current required for well UG 38A is approximately 20 A
UG 40 Day 2 E log i
-600
1 10 100
-625
-650
Potential e (mV)
-675
-700
-725
Log i
FIGURE 8 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL UG 40

Using the Tafel slopes the current required for well UG 40 is approximately 34 A
13
REFERENCES
1. NACE Standard RP0186-2001 Application of Cathodic Protection for External
Surfaces of Steel Well Casings
2. Kroon, David H.; Williams, Gerald D.; Moosavi, Ali N.; Cathodic Protection of Well
Casings in Abu Dhabi, MATERIALS PERFORMANCE, August 2004
14

Cathodic Protection of Well Casings Using E-Log I Criteria

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Cathodic Protection of Well Casings Using E-Log I Criteria

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Paper No.

Ernest W. Klechka, P.E.

Abdul Wahab Al-Mithin

E-LOG I TEST METHOD (APPENDIX B OF RP0186-20001)

E-LOG I TESTING RESULTS

E-LOG I TESTING RESULTS

TABLE 2. E-LOG-I TEST - WELL # MN 29

TABLE 4. E-LOG-I TEST - WELL # UG 12

Well # UG 38A Kuwait

TABLE 6. E-LOG-I TEST - WELL # UG 40

FIGURE 1 TEST SET-UP FOR E-LOG-I TESTING

FIGURE 2 TYPICAL WELL CASING (MN-29)

TOC @ 6547 ft-DD.

FIGURE 3 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL MN 1

FIGURE 4 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL MN 29

FIGURE 5 E LOG I PLOTTED ON SEMI-LOG PAPER WELL UG 9

FIGURE 6. E LOG I PLOTTED ON SEMI-LOG PAPER WELL UG 12

Potential e (mV) -600

FIGURE 7 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL UG 38A

FIGURE 8 E-LOG-I PLOTTED ON SEMI-LOG PAPER - WELL UG 40

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