Laser systems and methods for the removal of structures

• US 9,089,928 B2
• Filed: 08/02/2012
• Issued: 07/28/2015
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Zediker, Mark S., Grubb, Daryl L., De Witt, Ronald A., Deutch, Paul D., Moxley, Joel F., Marshall, Scott A., Linyaev, Eugene J., Schroit, Sam N., Kolachalam, Sharath K.
• Primary Examiner(s): Heinrich, Samuel M
• Application Number:
  US13/565,345
• Publication Number:
  US 20140231085A1
• Time in Patent Office: 1,090 Days
• Field of Search: 166/285, 166/297, 166/376, 166/377, 166/361, 166/386, 175/5, 294261-4265, 405/156, 405/184.1, 219/121.67, 219/121.72, 219/121.83, 376/326
• US Class Current: 1/1
• CPC Class Codes: B08B 7/0042 by laser
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 26/00 Working by laser beam, e.g. welding, cutting or boring
• CPC Class Codes: B23K 26/0096 Portable laser equipment, e.g. hand-held laser apparatus surgical laser instruments A61B18/20, Dental Lasers A61C1/0046, Hand-held laser dental apparatus for curing resins A61C19/004
• CPC Class Codes: B23K 26/04 Automatically aligning, aiming or focusing the laser beam, e.g. using the back-scattered light
• CPC Class Codes: B23K 26/064 by means of optical elements, e.g. lenses, mirrors or prisms
• CPC Class Codes: B23K 26/0652 comprising prisms
• CPC Class Codes: B23K 26/106 inside the workpiece
• CPC Class Codes: B23K 26/12 in a special atmosphere, e.g. in an enclosure
• CPC Class Codes: B23K 26/1224 in vacuum
• CPC Class Codes: B23K 26/127 in an enclosure
• CPC Class Codes: B23K 26/14 using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor B23K26/12 takes precedence
• CPC Class Codes: B23K 26/146 the fluid stream containing a liquid
• CPC Class Codes: B23K 26/1464 Supply to, or discharge from, nozzles of media, e.g. gas, powder, wire
• CPC Class Codes: B23K 26/38 by boring or cutting
• CPC Class Codes: B63B 17/00 Vessels parts, details, or accessories, not otherwise provided for vehicle fittings for preventing or indicating unauthorised use or theft of vehicles in general B60R25/00; propeller guards, line cutters or other means for protecting propellers or rudders B63H5/165; protection of power legs of outboard propulsion units B63H20/36; locking devices for boats, surfboards or parts or accessories thereof E05B73/007
• CPC Class Codes: B63B 19/00 Arrangements or adaptations of ports, doors, windows, port-holes, or other openings or covers scuppers B63B13/00; arrangements of watertight doors in bulkheads B63B43/24
• CPC Class Codes: B63B 21/00 Tying-up; Shifting, towing, or pushing equipment; Anchoring of buoys B63B22/04; dynamic anchoring B63H25/00 ; equipment for shipping on coasts, in harbours or on other fixed marine structures, e.g. for landing purposes, E02B
• CPC Class Codes: B63B 35/00 Vessels or similar floating structures specially adapted for specific purposes and not otherwise provided for
• CPC Class Codes: B63B 35/28 Barges or lighters underwater-towed barges B63G8/42; for transporting logs B63B35/62
• CPC Class Codes: E02B 2017/0052 : Removal or dismantling of offshore structures from their offshore location
• CPC Class Codes: E02D 17/00 : Excavations; Bordering of excavations; Making embankments soil-shifting apparatus E02F; earth drilling E21
• CPC Class Codes: E21B 19/002 : specially adapted for underwater drilling E21B19/09, E21B19/143 take precedence
• CPC Class Codes: E21B 29/02 : by explosives or by thermal or chemical means freeing stuck objects by explosives E21B31/002
• CPC Class Codes: E21B 33/13 : Methods or devices for cementing, for plugging holes, crevices or the like

Abstract

There is provided high power laser systems, high power laser tools, and methods of using these tools and systems for cutting, sectioning and removing structures objects, and materials, and in particular, for doing so in difficult to access locations and environments, such as offshore, underwater, or in hazardous environments, such as nuclear and chemical facilities. Thus, there is also provided high power laser systems, high power laser tools, and methods of using these systems and tools for removing structures, objects, and materials located offshore, under bodies of water and under the seafloor.

Claims

1. A method of removing a section of a member from an offshore structure comprising:

a. operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

b. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam path;

c. positioning the laser cutting tool adjacent a member of the offshore structure, whereby the laser beam path extends from the cutting tool to the member;

d. propagating a high power laser beam along the beam path and moving the beam path and laser beam thereby cutting the member, whereby a section of the member is formed in a predetermined manner; and

,

e. removing the section from the structure.

2. The method of claim 1, wherein the member is located below a surface of a body of water.

3. The method of claim 1, wherein the member is a tubular and the cut is an inside-to-outside cut.

4. The method of claim 1, wherein the member is a tubular and the cut is an outside-to-inside cut.

5. The method of claim 1, wherein at least a portion of the member is located above a surface of a body of water.

6. The method of claim 1, wherein at least a portion of the member is located below a sea floor.

7. The method of claim 1, wherein at least a portion of the member is in a sea floor.

8. The method of claim 1, wherein the laser beam path is positioned in a body of water.

9. The method of claim 1, wherein the laser beam path is positioned below a sea floor.

10. The method of claim 2, wherein the laser beam propagated along the beam path is at least about 5 kW.

11. The method of claim 3, wherein the laser beam propagated along the beam path is at least about 10 kW.

12. The method of claim 4, wherein the laser beam propagated along the beam path is at least about 15 kW.

13. The method of claim 1, wherein the laser beam propagated along the beam path is at least about 5 kW.

14. The method of claim 1, wherein the laser beam propagated along the beam path is at least about 10 kW.

15. The method of claim 1, wherein the high power laser system comprises a laser cutting platform that is positioned above a surface of a body of water;

the laser cutting platform, comprising;

an operably associated device for hoisting;

an operably associated laser cutting device for cutting; and

, an operably associated device for holding;

wherein the operably associated laser cutting device defines a second beam path; and

, propagating a laser beam along the second beam path.

16. The method of claim 15, wherein the laser beam propagated along the cutting tool beam path is at least 5 kW and the laser beam propagated along the second beam path is at least 5 kW.

17. The method of claim 1, comprising hoisting the section from a body of water.

18. The method of claim 1, comprising hoisting the section from below a sea floor.

19. The method of claim 1, comprising verifying completion of a cut prior to removing the section.

20. The method of claim 19, wherein the verifying is passive.

21. The method of claim 20, wherein the verifying is real-time and based at least in part on monitoring the laser beam.

22. The method of claim 19, wherein the verifying is based at least in part on laser range finding.

23. A method of cutting a member from an offshore structure comprising:

a. operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

b. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam delivery path;

c. locating the laser cutting tool in a cutting position for cutting a member of the offshore structure, whereby the laser beam path extends from the cutting tool to the member;

d. propagating a high power laser beam along the beam path, thereby cutting the member, and changing a relative position of the member and the laser beam path in a predetermined laser beam delivery pattern, whereby the laser beam cuts the member in a predetermined pattern; and

,

e. the laser beam having a power of at least about 5 kw.

24. The method of claim 23, wherein the member is a tubular and the predetermined delivery pattern is a continuous ring around the inner circumference of the tubular, whereby a section of the member is formed.

25. The method of claim 23, wherein the laser beam delivery pattern forms an opening for affixing a lifting device.

26. The method of claim 24, wherein the cut is a complete cut.

27. The method of claim 26, comprising passive verification of the complete cut.

28. The method of claim 27, wherein the passive verification is real-time and based at least in part on monitoring the laser beam.

29. The method of claim 27, wherein the passive verification is based at least in part on laser range finding.

30. The method of claim 23, wherein the member is a platform jacket.

31. The method of claim 23, wherein the member is a tubular extending below the sea floor, and the laser beam propagated along the beam path strikes a tubular below the sea floor.

32. The method of claim 23, wherein the member is a tubular extending below the surface of a body of water, and the laser beam propagated along the beam path strikes a tubular below the surface of the body of water.

33. The method of claim 23, wherein the laser beam propagated along the beam path strikes an inner tubular positioned in an outer tubular in a circular pattern.

34. The method of claim 23, wherein the predetermined pattern comprises a land area and a cut area.

35. The method of claim 23, wherein the predetermined pattern comprises a single pass pattern of beam delivery, wherein the laser beam completely severs a section of the member in a single pass of the laser beam.

36. The method of claim 35, wherein the member is a selected from the group consisting of a single tubular, a conductor, a multistring tubular, and a multistring cemented tubular.

37. The method of claim 23, wherein the laser beam is delivered in a predetermined beam delivery pattern comprising a substantially vertical beam path.

38. The method of claim 23, wherein the laser beam is delivered in a predetermined beam delivery pattern comprising a substantially horizontal beam path.

39. The method of claim 23, wherein the laser beam is delivered in a predetermined beam delivery pattern comprising a substantially vertical beam path and a substantially horizontal beam path.

40. The method of claim 23, wherein the laser beam is delivered in a predetermined beam delivery pattern comprising a substantially axial beam path.

41. The method of claim 23, wherein the laser beam is delivered in a predetermined beam delivery pattern comprising a substantially radial beam path.

42. The method of claim 23, wherein the laser beam is delivered in a predetermined beam delivery pattern comprising a substantially axial beam path and a substantially radial beam path.

43. A method of removing a section of a member from an offshore structure comprising:

a. operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

b. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam path;

c. positioning the laser cutting tool adjacent a member of the offshore structure, whereby the laser beam path extends from the cutting tool to the member;

d. propagating a high power laser beam along the beam path and moving the beam path and laser beam thereby cutting the member, whereby a section of the member is formed in a predetermined manner;

e. changing a relative position of a member to be cut and the laser beam path, whereby the laser beam strikes the member below the surface of the body of water and thereby cuts the member below the surface of the body of water; and

,

f. removing the section from the structure.

44. The method of claim 43, wherein the laser beam path when the laser beam is propagated along the beam path is positioned below a seafloor of the body of water.

45. The method of claim 43, wherein the laser beam path when the laser beam is propagated along the beam path is positioned in a mudline of the body of water.

46. The method of claim 43, wherein the laser beam path when the laser beam is propagated along the beam path is positioned below a mudline of the body of water.

47. The method of claim 43, wherein the offshore structure is an oil platform.

48. The method of claim 43, wherein the offshore structure is a jacket and pile structure.

49. The method of claim 43, wherein the offshore structure is a monopile structure.

50. The method of claim 43, wherein the offshore structure is a pipeline.

51. The method of claim 43, wherein the offshore structure is a bridge support.

52. The method of claim 43, wherein the member comprises an inner steel tubular, and an outer steel tubular.

53. The method of claim 43, wherein the inner steel tubular and the outer steel tubular define an annulus.

54. The method of claim 53, wherein the annulus is at least partially filled with a gas.

55. The method of claim 53, wherein the annulus is at least partially filled with a solid material.

56. The method of claim 55, wherein the solid material is cement.

57. The method of claim 43, wherein the laser beam propagated along the beam path strikes an inner tubular positioned within an outer tubular and whereby upon completion of the cutting the inner tubular is severed and the outer tubular is not cut by the laser beam.

58. The method of claim 43, wherein the laser beam propagated along the beam path strikes an inner tubular positioned within an outer tubular and whereby upon completion of the cutting the inner tubular is severed and the outer tubular is severed.

59. A method of removing a section of a member from an offshore structure comprising:

a. selecting a structure that extends below a surface of the earth, the structure having members, the members comprising a tubular extending from the structure to below the surface of the earth;

b. determining a configuration of at least some of the members;

c. formulating a plugging and abandonment plan for the well based in part upon the configuration of at least some of the members;

d. the plugging and abandonment plan comprising;

cutting a member at a predetermined location within the well and removing the member above the cut from the well;

placing a plug within the well;

cutting and removing all members from the well at least about three feet below the surface of the earth;

e. operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

f. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam path;

g. positioning the laser cutting tool adjacent at least one of the members of the offshore structure;

h. whereby the laser beam path extends from the cutting tool to the member;

i. propagating a high power laser beam along the beam path and moving the beam path and laser beam thereby cutting the members, whereby a section of the member is formed in a predetermined manner, and,

j. removing the section from the structure.

60. The method of claim 59, performing additional cutting of the tubular or member with a high power laser beam.

61. The method of claim 59, performing additional cutting of the tubular or member exclusively with a high power laser beam.

62. The method of claim 59, wherein the surface of the earth is a sea floor.

63. A method of removing a section of a member from an offshore structure comprising:

a. selecting a borehole in a surface of the earth forming a well, the borehole having a member contained therein, the member extending below the surface of the earth;

b. the member comprising a tubular;

c. placing a first plug within the borehole;

d. operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

e. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam path;

f. positioning the laser cutting tool adjacent a member of the offshore structure, whereby the laser beam path extends from the cutting tool to the member;

g. propagating a high power laser beam along the beam path and moving the beam path and laser beam thereby cutting the members at a location within the borehole, whereby a section of the member is formed in a predetermined manner;

h. removing the section from the structure;

i. placing a second plug within the borehole, the second plug being located closer to the surface of the earth than the first plug;

j. delivering a high power laser beam along a beam path to cut all additional members within the borehole at a second location above the second plug, wherein the delivery of the laser beam completely severs all the additional tubulars at the location within the borehole; and

,

k. removing all of the severed additional members from the borehole above the second location, wherein the borehole above the second location is free from the additional members.

64. The method of claim 63, wherein the second location is at least about 3 feet below the surface of the earth and the surface of the earth is a sea floor.

65. The method of claim 63, wherein the second location is at least about 5 feet below the surface of the earth and the surface of the earth is a sea floor.

66. The method of claim 65, wherein the second location is at least about 10 feet below the surface of the earth and the surface of the earth is a sea floor.

67. The method of claim 66, wherein the second location is at least about 15 feet below the surface of the earth and the surface of the earth is a sea floor.

68. A method of removing a section of a member from an offshore structure comprising:

a. Operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

b. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam path;

c. positioning the laser cutting tool adjacent a member of the offshore structure, whereby the laser beam path extends from the cutting tool to the member

d. whereby some of the members may be conductors in a body of water;

e. propagating a high power laser beam along the beam path and moving the beam path and laser beam thereby cutting the member, whereby a section of the member is formed in a predetermined manner;

f. wherein the laser beam may server the member at about the location, thereby creating a severed section of the member above the location;

g. removing the section from the structure; and

,

h. raising the severed section of the member above the surface of the body of water.

69. A method of removing a section of a member from an offshore structure comprising:

a. operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

b. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam path;

c. positioning the laser cutting tool adjacent a member of the offshore structure, whereby the laser beam path extends from the cutting tool to the member;

d. positioning the beam delivery path between the delivery assembly and a location of the offshore structure;

e. propagating a high power laser beam along the beam delivery path, the laser beam having a beam property

f. scanning the high power laser beam from a location on the offshore structure to a second location on the offshore structure at a scan rate, whereby the beam property and scan rate are such that any contaminants on the structure may be removed from the offshore structure without substantial damage to the offshore structure;

g. positioning the laser cutting tool at a desired cutting location;

h. propagating a high power laser beam along the beam path and moving the beam path and laser beam thereby cutting the member, whereby a section of the member is formed in a predetermined manner; and

,

i. removing the section from the structure.

70. The method of claim 69, wherein the beam property is a power of the beam.

71. The method of claim 69, wherein the beam property is a pulse rate of the beam.

72. The method of claim 69, wherein the beam is pulsed.

73. The method of claim 69, wherein the beam property is a duty cycle.

74. A method of removing a section of a member from an offshore structure comprising:

a. operably associating a high power laser system with an offshore structure, the high power laser system comprising a high power laser and a high power laser cutting tool;

b. the high power laser cutting tool defining a laser beam delivery path for delivery of a high power laser beam along the beam path;

c. positioning the laser cutting tool adjacent a member of the offshore structure, whereby the laser beam path extends from the cutting tool to the member;

d. the member being in a body of water;

e. determining a laser cutting plan for cutting the offshore structure into sections of a predetermined size and weight, and implementing the plan by;

f. propagating a high power laser beam along the beam path and moving the beam path and laser beam thereby cutting the member, whereby a section of the member is formed in a predetermined manner;

g. removing the section from the structure; and

h. removing the section from the body of water.

75. The method of claim 74, wherein a majority of the predetermined sections are less than about 500 tons in weight.

76. The method of claim 74, wherein a majority of the predetermined sections are less than about 200 tons in weight.

77. The method of claim 74, wherein a majority of the predetermined sections are less than about 100 tons in weight.

78. The method of claim 74, wherein a majority of the predetermined sections are less than about 50 tons in weight.

79. The methods of claim 74, comprising a laser beam having a wavelength of greater than about 1000 nm to about 1550 nm.