Method and system for advancement of a borehole using a high power laser

• US 8,826,973 B2
• Filed: 08/19/2009
• Issued: 09/09/2014
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Moxley, Joel F., Land, Mark S., Rinzler, Charles C., Faircloth, Brian O., Zediker, Mark S.
• Primary Examiner(s): GAY, JENNIFER HAWKINS
• Application Number:
  US12/543,986
• Publication Number:
  US 20100044103A1
• Time in Patent Office: 1,847 Days
• Field of Search: 254/134.3 FT, 254/134.3 R, 254/134.4, 166/77.1, 166/242.2, 166/380, 166/385, 166/384, 166/77.2, 166/65.1
• US Class Current: 166/77.2
• 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

There is provided a system, apparatus and methods for the laser drilling of a borehole in the earth. There is further provided with in the systems a means for delivering high power laser energy down a deep borehole, while maintaining the high power to advance such boreholes deep into the earth and at highly efficient advancement rates, a laser bottom hole assembly, and fluid directing techniques and assemblies for removing the displaced material from the borehole.

Claims

1. A spool assembly for rotatably coupling high power laser transmission cables for use in advancing boreholes, comprising:

a. a base;

b. a spool, the spool supported by the base through a load bearing bearing;

c. hollow tubing having a first end and a second end;

d. the hollow tubing comprising a means for transmitting a high power laser beam;

e. the spool comprising an axle around which the coiled tubing is wound, the axle supported by the load bearing bearing;

f. a first non-rotating optical connector for optically connecting a laser beam source to the axle;

g. a rotatable optical connector optically associated with the first optical connector;

whereby a laser beam is capable of being transmitted from the first optical connector to the rotatable optical connector; and

,

h. a rotating optical connector optically associated with the rotatable optical connector;

optically associated with the transmitting means; and

, mechanically associated with the axle;

i. whereby the spool is capable of transmitting a laser beam from the first optical connector through the rotatable optical connector and into the transmitting means during winding and unwinding of the tubing on the spool while maintaining sufficient power to advance a borehole.

2. The spool of claim 1, comprising a rotational transition optical assembly, the optical assembly comprising:

a. a non-rotating adapter for receiving the non-rotating connector;

b. a non-rotation lens adjacent the non-rotating adapter, the non-rotating lens characterizing a Fourier Transform plane; and

,

c. a rotatable adapter for receiving the rotatable connector.

3. The spool of claim 1, comprising an isolation means associated with the rotational transition optical assembly, wherein the optical assembly is substantially isolated from movement of the load bearing bearings.

4. The spool of claim 3, wherein the isolation means comprises a precision bearing.

5. The spool of claim 3, wherein the means for transmitting the high power laser beam comprises a plurality of optical fibers characterized by having the ability to transmit a laser beam having at least about 20 kW of power and having a length of at least about 3000 feet and having a core having a diameter of at least about 500 μ

m.

6. The spool of claim 1, comprising a means for isolating vibrations, whereby the transmission of a laser beam within the rotating spool are substantially unaffected by a vibration from the rotating spool.

7. The spool of claim 6, wherein the means for transmitting the high power laser beam comprises an optical fiber characterized by having the ability to transmit a laser beam having at least about 15 kW of power and having a length of at least about 3000 feet.

8. The spool of claim 6, wherein the means for transmitting the high power laser beam comprises two optical fibers characterized by each optical fiber having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 3000 feet.

9. The spool of claim 6, wherein the means for transmitting the high power laser beam comprises a plurality of optical fibers characterized by having the ability to transmit a laser beam having at least about 15 kW of power and having a length of at least about 3000 feet.

10. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises an optical fiber characterized by having the ability to transmit a laser beam having at least about 15 kW of power and having a length of at least about 3000 feet.

11. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises two optical fibers characterized by each optical fiber having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 3000 feet.

12. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises three optical fibers characterized by each optical fiber having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 3000 feet.

13. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises an optical fiber characterized by having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 500 feet and having a core having a diameter of at least about 200 μ

m.

14. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises an optical fiber characterized by having the ability to transmit a laser beam having at least about 20 kW of power and having a length of at least about 3000 feet and having a core having a diameter of at least about 500 μ

m.

15. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises three optical fibers characterized by each optical fiber having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 3000 feet and having a core having a diameter of at least about 200 μ

m.

16. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises an optical fiber having a core having a diameter of at least about 500 μ

m.

17. The spool of claim 1, wherein the means for transmitting the high power laser beam comprises an optical fiber having a core having a diameter of at least about 200 μ

m.

18. The spool of claim 1, wherein the hollow tubing comprises a coiled tubing containing a fluid line and a second line.

19. The spool of claim 1, comprising a means for providing buoyancy to the means for transmitting the high power laser beam.

20. A spool assembly for rotatably coupling high power laser transmission cables for use in advancing boreholes, comprising:

a. a base;

b. a spool, the spool supported by the base through a load bearing bearing;

c. a means for providing laser energy;

d. coiled tubing having a first end and a second end;

e. the coiled tubing comprising a means for transmitting a high power laser beam;

f. the spool comprising an axle around which the coiled tubing is wound, the axle supported by the load bearing bearing;

g. a first non-rotating optical connector for optically connecting a laser beam from the means for providing laser energy to the axle;

h. a rotatable optical connector optically associated with the first optical connector;

whereby a laser beam is capable of being transmitted from the first optical connector to the rotatable optical connector; and

,

i. a rotating optical connector optically associated with the rotatable optical connector, optically associated with the transmitting means and associated with the axle;

j. whereby the spool is capable of transmitting a laser beam from the first optical connector through the rotatable optical connector and into the transmitting means during winding and unwinding of the tubing on the spool while maintaining sufficient power to advance a borehole.

21. The spool of claim 20 wherein the means for providing laser energy is a single optical fiber from a laser.

22. The spool of claim 21 wherein the means for transmitting a high power laser beam is an optical fiber.

23. The spool of claim 21 wherein the means for transmitting a high power laser beam is a pair of optical fibers.

24. The spool of claim 21 wherein the means for transmitting a high power laser beam is a plurality of optical fibers.

25. The spool of claim 20 wherein the means for providing laser energy is a pair of optical fibers from a laser.

26. The spool of claim 25 wherein the means for transmitting a high power laser beam is an optical fiber.

27. The spool of claim 25 wherein the means for transmitting a high power laser beam is a pair of optical fibers.

28. The spool of claim 25 wherein the means for transmitting a high power laser beam is a plurality of optical fibers.

29. The spool of claim 20 wherein the means for providing laser energy is a plurality of optical fibers from a laser.

30. The spool of claim 29 wherein the means for transmitting a high power laser beam is an optical fiber.

31. The spool of claim 29 wherein the means for transmitting a high power laser beam is a pair of optical fibers.

32. The spool of claim 29 wherein the means for transmitting a high power laser beam is a plurality of optical fibers.

33. The spool of claim 20 wherein the means for providing laser energy is a plurality of lasers.

34. The spool of claim 20 wherein the means for providing laser energy is a pair of lasers.

35. The spool of claim 20 wherein the means for transmitting a high power laser beam is an optical fiber.

36. The spool of claim 20 wherein the means for transmitting a high power laser beam is a pair of optical fibers.

37. The spool of claim 20 wherein the means for transmitting a high power laser beam is a plurality of optical fibers.

38. A spool assembly for rotatably coupling high power laser transmission cables for use in advancing boreholes, comprising:

a. a base;

b. a spool, the spool supported by the base through a load bearing bearing;

c. hollow tubing having a first end and a second end;

d. the hollow tubing comprising a means for transmitting a high power laser beam;

e. the spool comprising an axle around which the coiled tubing is wound, the axle supported by the load bearing bearing;

f. a first non-rotating optical connector for optically connecting a laser beam source to the axle;

g. a rotatable optical connector optically associated with the first optical connector;

whereby a laser beam is capable of being transmitted from the first optical connector to the rotatable optical connector; and

,

h. a rotational transition optical assembly, the optical assembly comprising;

i. a non-rotating adapter for receiving the non-rotating connector;

ii. a first lens adjacent the non-rotating adapter, the first lens characterizing a Fourier Transform plane;

iii. a rotatable adapter for receiving the rotatable connector; and

, iv. the rotatable adapter substantially in the Fourier Transform plane;

i. whereby the spool is capable of transmitting a laser beam from the first optical connector through the rotatable optical connector and into the transmitting means during winding and unwinding of the tubing on the spool while maintaining sufficient power to advance a borehole.

39. The spool of claim 38, comprising an isolation means associated with the rotational transition optical assembly, wherein the optical assembly is substantially isolated from movement of the load bearing bearings.

40. The spool of claim 39, wherein the isolation means comprises a precision bearing.

41. The spool of claim 38, wherein the means for transmitting the high power laser beam comprises two optical fibers characterized by each optical fiber having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 3000 feet and having a core having a diameter of at least about 500 μ

m.

42. The spool of claim 38, wherein the means for transmitting the high power laser beam comprises a plurality of optical fibers characterized by having the ability to transmit a laser beam having at least about 20 kW of power and having a length of at least about 3000 feet and having a core having a diameter of at least about 500 μ

m.

43. The spool of claim 38, wherein the means for transmitting the high power laser beam comprises an optical fiber characterized by having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 500 feet.

44. The spool of claim 38, wherein the hollow tubing comprises a coiled tubing containing a fluid line and a data line.

45. The spool of claim 38, comprising a means for providing buoyancy to the means for transmitting the high power laser beam.

46. A spool assembly for rotatably coupling high power laser transmission cables for use in advancing boreholes, comprising:

a. a base;

b. a spool, the spool supported by the base through a load bearing bearing;

c. hollow tubing having a first end and a second end;

d. the hollow tubing comprising a means for transmitting a high power laser beam;

e. the spool comprising an axle around which the coiled tubing is wound, the axle supported by the load bearing bearing;

f. a first non-rotating optical connector for optically connecting a laser beam source to the axle;

g. a rotatable optical connector optically associated with the first optical connector;

whereby a laser beam is capable of being transmitted from the first optical connector to the rotatable optical connector; and

,

h. a rotational transition optical assembly, the optical assembly comprising;

i. a non-rotating adapter for receiving the non-rotating connector;

ii. a launch lens adjacent the non-rotating adapter, the launch lens characterizing a Fourier Transform plane;

iii. a rotatable adapter for receiving the rotatable connector; and

,

iv. the rotatable connector as received by the rotatable adapter optically associated with the Fourier Transform plane;

i. whereby the spool is capable of transmitting a laser beam from the first optical connector through the rotatable optical connector and into the transmitting means during winding and unwinding of the tubing on the spool while maintaining sufficient power to advance a borehole.

47. The spool of claim 46, wherein the rotating connector is substantially within the axle.

48. The spool of claim 47, wherein the non-rotating connector is exterior to the axle.

49. The spool of claim 46, comprising an isolation means associated with the rotational transition optical assembly, wherein the optical assembly is substantially isolated from movement of the load bearing bearings.

50. The spool of claim 49, wherein the isolation means comprises a precision bearing.

51. The spool of claim 49, wherein the means for transmitting the high power laser beam comprises three optical fibers characterized by each optical fiber having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 3000 feet and having a core having a diameter of at least about 500 μ

m.

52. The spool of claim 49, wherein the means for transmitting the high power laser beam comprises an optical fiber having a core having a diameter of at least about 500 μ

m.

53. The spool of claim 46, wherein the means for transmitting the high power laser beam comprises a plurality of optical fibers characterized by having the ability to transmit a laser beam having at least about 15 kW of power and having a length of at least about 3000 feet.

54. The spool of claim 46, wherein the means for transmitting the high power laser beam comprises an optical fiber characterized by having the ability to transmit a laser beam having at least about 10 kW of power and having a length of at least about 500 feet and having a core having a diameter of at least about 500 μ

m.