Apparatus for advancing a wellbore using high power laser energy

• US 8,820,434 B2
• Filed: 08/19/2009
• Issued: 09/02/2014
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Zediker, Mark S., Land, Mark S., Rinzler, Charles C., Faircloth, Brian O., Koblick, Yeshaya, Moxley, Joel F.
• Primary Examiner(s): Gay, Jennifer H
• Assistant Examiner(s): GITLIN, ELIZABETH C GOTTLIEB
• Application Number:
  US12/544,038
• Publication Number:
  US 20100044104A1
• Time in Patent Office: 1,840 Days
• Field of Search: 175/16, 385 12- 13, 385 88- 94, 219/121.7, 219/121.84
• US Class Current: 175/16
• CPC Class Codes: E21B 10/60 characterised by conduits or nozzles for drilling fluids for roller bits E21B10/18; for percussion drill bits E21B10/38
• CPC Class Codes: E21B 21/103 Down-hole by-pass valve arrangements, i.e. between the inside of the drill string and the annulus valves specifically for maintaining circulation of drilling fluid while connecting or disconnecting tubular joints E21B21/019
• CPC Class Codes: E21B 29/00 Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
• CPC Class Codes: E21B 43/11 Perforators; Permeators
• CPC Class Codes: E21B 7/14 Drilling by use of heat, e.g. flame drilling
• CPC Class Codes: E21B 7/15 of electrically generated heat

Abstract

Delivering high power laser energy to form a borehole deep into the earth using laser energy. Down hole laser tools, laser systems and laser delivery techniques for advancement, workover and completion activities. A laser bottom hole assembly (LBHA) for the delivery of high power laser energy to the surfaces of a borehole, which assembly may have laser optics, a fluid path for debris removal and a mechanical means to remove earth.

Claims

1. A laser bottom hole assembly comprising;

a. a first rotating housing;

b. a second fixed housing;

c. the first housing being rotationally associated with the second housing;

d. a fiber optic cable for transmitting a laser beam, the cable having a proximal end and a distal end, the proximal end adapted to receive a laser beam from a laser source, the distal end optically associated with an optical assembly;

e. at least a portion of the optical assembly fixed to the first rotating housing, whereby the fixed portion rotates with the first housing;

f. a mechanical assembly fixed to the first rotating housing, whereby the assembly rotates with the first housing and is capable of applying mechanical forces to a surface of a borehole upon rotation; and

,

g. a fluid path associated with first and second housings, the fluid path having a distal and proximal opening, the distal opening adapted to discharge the fluid toward the surface of the borehole, whereby fluid for removal of waste material is transmitted by the fluid path and discharged from the distal opening toward the borehole surface to remove waste material from the borehole.

2. The assembly of claim 1, wherein the rotating portion of the optics comprises a beam shaping optic.

3. The assembly of claim 1, wherein the rotating portion of the optics comprises a scanner.

4. The assembly of claim 1, comprising a rotation motor.

5. The assembly of claim 4, wherein in the rotation motor is a mud motor.

6. The assembly of claim 1, wherein the mechanical assembly comprises a conical stand-off device.

7. The assembly of claim 1, wherein the mechanical assembly comprises a drill bit.

8. The assembly of claim 1, wherein the mechanical assembly comprises a three-cone drill bit.

9. The assembly of claim 1, wherein the mechanical assembly comprises a PDC bit.

10. The assembly of claim 1, wherein the mechanical assembly comprises a PDC tool.

11. The assembly of claim 1, wherein the mechanical assembly comprises a PDC cutting tool.

12. The assembly of claim 1, wherein the fluid path is adapted to reduce debris from a laser beam path.

13. A laser bottom hole assembly comprising:

a. a first rotating housing;

b. a second fixed housing;

c. the first housing being rotationally associated with the second housing;

d. an optical assembly, the assembly having a first portion and a second portion;

e. a fiber optic cable for transmitting a laser beam, the cable having a proximal end and a distal end, the proximal end adapted to receive a laser beam from a laser source, the distal end optically associated with the optical assembly;

f. the fiber proximal and distal ends fixed to the second housing;

g. the first portion of the optical assembly fixed to the first rotating housing;

the second portion of the optical assembly fixed to the second fixed housing, whereby the first portion of the optical assembly rotates with the first housing;

h. a mechanical assembly fixed to the first rotating housing, whereby the assembly rotates with the first housing and is capable of applying mechanical forces to a surface of a borehole upon rotation; and

,

i. a fluid path associated with first and second housings, the fluid path having a distal and proximal opening, the distal opening adapted to discharge the fluid toward the surface of the borehole, the distal opening fixed to the first rotating housing, whereby fluid for removal of waste material is transmitted by the fluid path and discharged from the distal opening toward the borehole surface to remove waste material from the borehole;

j. wherein upon rotation of the first housing the optical assembly first portion, the mechanical assembly and proximal fluid opening rotate substantially concurrently.

14. A laser bottom hole assembly comprising:

a. a first rotating housing;

b. a second fixed housing;

c. the first housing being rotationally associated with the second housing;

d. a motor for rotating the first housing;

e. a fiber optic cable for transmitting a laser beam;

the cable having a proximal end and a distal end, the proximal end adapted to receive a laser beam from a laser source, the distal end optically associated with an optical assembly;

f. at least a portion of the optical assembly fixed to the first rotating housing, whereby the fixed portion rotates with the first housing;

g. a mechanical assembly fixed to the first rotating housing, whereby the assembly rotates with the first housing and is capable of applying mechanical forces to a surface of a borehole upon rotation; and

,

h. a fluid path associated with first and second housings, the fluid path having a distal and proximal opening, the distal opening adapted to discharge the fluid toward the surface of the borehole, whereby fluid for removal of waste material is transmitted by the fluid path and discharged from the distal opening toward the borehole surface to remove waste material from the borehole.

15. A laser down hole assembly comprising:

a. a means for providing rotation;

b. a means for providing a high power laser beam, comprising a high power optical fiber having a core and a cladding;

c. a means for manipulating the laser beam, comprising a laser beam optic;

d. a means for mechanically removing material;

e. a means for providing a fluid flow; and

,

f. a means for selectively coupling and for providing simultaneous and uniform rotation of the means for providing rotation, the means for manipulating the laser beam, the means for mechanically removing material, and the means for providing a fluid flow, whereby the high power optical fiber is not rotated.

16. The assembly of claim 15, wherein the means for rotation comprises a housing.

17. The assembly of claim 16, wherein the housing comprises a first part and a second part.

18. The assembly of claim 17, wherein the first part of the housing is fixed and the second part of the housing rotates.

19. The assembly of claim 17 wherein the first part of the housing rotates and the second part of the housing is fixed.

20. The assembly of claim 15, wherein the means for providing a high power laser beam is a fiber optic cable.

21. The assembly of claim 15, wherein the means for providing a high power laser beam comprises a plurality of fiber optic cables.

22. The assembly of claim 15, wherein the means for providing rotation is selected from the group consisting of a down hole motor, an electric motor, and a mud motor.

23. The assembly of claim 15, wherein the laser beam optic is selected from the group consisting of a beam shaping optic, a beam directing optic, beam shaping and directing optics, an optic capable of handling over 20 kW of power, an optical manipulator, an array, a refractive lens, a diffractive lens, a transmissive grating, a reflective lens, a collimator, an aspheric lens, a spherical lens, a convex lens, a negative lens, a bi-convex lens, and an achromatic doublet.

24. The assembly of claim 15, wherein the laser beam optic comprises a lens capable of shaping the laser beam into a spot.

25. The assembly of claim 24, wherein the spot is substantially circular.

26. The assembly of claim 24, wherein the spot is substantially linear.

27. The assembly of claim 24, wherein the spot is substantially a cross shape.

28. The assembly of claim 15, wherein the laser beam optic is capable of handling a power per area of about 1 kW/cm² to about 1 MW/cm².

29. The assembly of claim 15, comprising a drive assembly selected from the group consisting of an axle, a drive shaft, a drive train, and a gear.

30. A laser bottom hole assembly comprising:

a. a housing;

b. a means for providing a high power laser beam;

c. an optical assembly, the optical assembly providing an optical path upon which the laser beam travels from the optical assembly to a surface;

d. a means for creating an area of high pressure along the optical path; and

,

e. a means for providing aspiration pumping for the removal of waste material from the area of high pressure.

31. A laser bottom hole assembly comprising:

a. a means for providing rotation comprising a housing, wherein the housing comprises a first part and a second part, and wherein the first part of the housing is fixed and the second part of the housing rotates;

b. a means for providing a high power laser beam;

c. a means for manipulating the laser beam;

d. a means for mechanically removing material;

e. a means for providing a fluid flow; and

,

f. a means for coupling the rotation means, the manipulation means, the mechanical removal means, and the fluid flow means to provide simultaneous and uniform rotation of said means.

32. A laser bottom hole assembly comprising:

a. a means for providing rotation comprising a housing, wherein the housing comprises a first part and a second part, and wherein the first part of the housing rotates and the second part the housing is fixed;

b. a means for providing a high power laser beam;

c. a means for manipulating the laser beam;

d. a means for mechanically removing material;

e. a means for providing a fluid flow; and

,

f. a means for coupling the means for providing rotation, the means for manipulating, the means for the mechanically removing material, and the means for providing a fluid flow to provide simultaneous and uniform rotation of said means for coupling.

33. A laser bottom hole assembly comprising:

a. a body, the body having a first end and a second end;

b. a means for providing a high power laser beam;

c. an optical assembly, the optical assembly providing an optical path upon which the laser beam travels, the optical assembly positioned within the body, and the optical path extending from the optical assembly to and beyond the second end; and

,

d. a means for creating an area of high pressure along the optical path; and

,

e. a means for providing aspiration pumping for removal of waste material from the beam path.

34. The laser bottom hole assembly of claim 33, wherein the optical assembly is positioned between the first end and the second end.