High power laser downhole cutting tools and systems

• US 8,936,108 B2
• Filed: 03/13/2013
• Issued: 01/20/2015
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Zediker, Mark S., Rinzler, Charles C., Faircloth, Brian O., Koblick, Yeshaya, Moxley, Joel F.
• Primary Examiner(s): GAY, JENNIFER HAWKINS
• Application Number:
  US13/800,879
• Publication Number:
  US 20140060930A1
• Time in Patent Office: 678 Days
• Field of Search: 175/57, 175/11, 175/15, 175/16, 166/65.1, 219/121.7, 219/121.72, 385/100, 372/4
• 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

Downhole cutting systems, devices and methods for utilizing 10 kW or more laser energy transmitted deep into the earth with the suppression of associated nonlinear phenomena. Systems and devices for the laser cutting operations within a borehole in the earth. These systems and devices can deliver high power laser energy down a deep borehole, while maintaining the high power to perform cutting operations in such boreholes deep within the earth.

Claims

1. A downhole cutting system for providing high power laser to perform laser cutting operationswithin boreholes, the system comprising:

a. a source for high powered laser energy capable of providing a high power laser beam having a power greater than about 10 kW;

a chiller operably associated with the high power laser source;

b. an optical fiber for transmitting the laser beam from the high power laser to a predetermined location in a borehole to perform a laser cutting operation;

c. the optical fiber in optical communication with the high power laser source and in optical and mechanical association with a laser tool assembly containing laser optics;

d. the optical fiber associated with a means to suppress Stimulated Brillouin Scattering arising from the transmission of the greater than about 10 kW laser beam;

e. whereby substantially all power of the high power laser beam is delivered from the laser tool assembly to the predetermined location in the borehole to perform the laser cutting operation.

2. The downhole cutting system of claim 1, wherein the cutting operation is selected from the group consisting of pipe cutting, casing cutting, and window cutting.

3. The downhole cutting system of claim 2, wherein the optical fiber has a length of at least 3,000 feet.

4. The downhole cutting system of claim 2, wherein the optical fiber has a length of at least 5,000 feet.

5. The downhole cutting system of claim 2, wherein the optical fiber has a length of at least 10,000 feet.

6. A downhole cutting system for providing high power laser energy to perform laser cutting operations within borehole the system comprising:

a. a high powered laser source capable of providing a high power laser beam having a power of at least about 10 kW and a beam parameter product of about less than about 100 mm milliard;

b. an optical cable for transmitting the laser beam from the high power laser source to a downhole laser tool assembly comprising a high power laser optic; and

having a length of at least about 2,000 feet; and

,

c. a means for suppressing nonlinear scattering phenomena arising from the transmission of the laser beam having a power of at least about 10 kW;

d. whereby, the high power laser beam is delivered from the downhole laser tool assembly to a location in a borehole with sufficient power to perform a laser cutting operation.

7. The system of claim 6, wherein the cutting operation is window cutting.

8. The system of claim 7, wherein the optical cable comprises an optical fiber comprising a core having a core diameter of at least about 300 microns, a first protective member and a second protective member, wherein the protective members are selected from the group consisting of a steel tube, a polymer coating, a polyimide, an acrylate, a carbon polyamide, and a carbon coating.

9. A downhole cutting system for providing high power laser energy to perform laser cutting operations within boreholes,the system comprising:

a. a high powered laser source capable of providing a high power laser beam having a power of at least about 10 kW, an M² of less than about 2, and a beam parameter product of about less than about 100 mm milliard;

b. an optical cable for transmitting the laser beam from the high power laser source to a downhole laser tool assembly comprising a high power laser optic; and

having a length of at least about 4,000 feet; and

,

c. a means for suppressing nonlinear scattering phenomena arising from the transmission of the laser beam having a power of at least about 10 kW; and

d. whereby, the high power laser beam is delivered from the downhole laser tool assembly to a location in a borehole with sufficient power to perform a laser cutting operation.

10. The downhole cutting system of claim 9, wherein the cutting operation is selected from the group consisting of pipe cutting, casing cutting, and window cutting.

11. The downhole cutting system of claim 10, wherein the optical cable comprises an optical fiber comprising a core having a core diameter of at least about 300 microns, a first protective member and a second protective member, wherein the protective members are selected from the group consisting of a steel tube, a polymer coating, a polyimide, an acrylate, a carbon polyamide, and a carbon coating.

12. The downhole cutting system of claim 9, wherein the optical cable comprises an optical fiber comprising a core having a core diameter of at least about 300 microns, a first protective member and a second protective member, wherein the protective members are selected from the group consisting of a steel tube, a polymer coating, a polyimide, an acrylate, a carbon polyamide, and a carbon coating.

13. The downhole cutting system of claim 9, wherein the high power laser source comprises a combination of a plurality of laser sources, wherein each laser source of the combination is capable of providing a high power laser beam characterized by a linewidth;

wherein the means for suppressing comprises a combination of the laser beams from the plurality of laser sources, and a combined laser beam characterized by an effective linewidth greater than the linewidth of a laser beam from a laser source from the plurality of laser sources; and

wherein the combined beam is characterized by having a power of at least about 20 kW.

14. The downhole cutting system of claim 9, wherein the optical cable has a means for break detection.

15. The downhole cutting system of claim 9, wherein the optical cable comprises a plurality of optical fibers.

16. the downhole cutting system of claim 9, wherein the optical cable comprises a multimode optical fiber.