High power laser energy distribution patterns, apparatus and methods for creating wells

• US 9,284,783 B1
• Filed: 03/28/2013
• Issued: 03/15/2016
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Faircloth, Brian O., Zediker, Mark S., Rinzler, Charles C., Koblick, Yeshaya, Moxley, Joel F.
• Primary Examiner(s): Harcourt, Brad
• Application Number:
  US13/852,719
• Publication Number:
  US 20160090790A1
• Time in Patent Office: 1,083 Days
• US Class Current: 1/1
• 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 providing a laser beam to borehole surface in a predetermined and energy deposition profile. The predetermined energy deposition profiles may be uniform or tailored to specific downhole applications. Optic assemblies for obtaining these predetermined energy deposition profiles are further provided.

Claims

1. A system for forming a well in the earth comprising:

a. a high power laser source;

b. a bottom hole assembly comprising a housing, the housing defining a cavity;

c. a fiber optically connecting the laser source with the bottom hole assembly, such that a laser beam from the laser source is transmitted to the bottom hole assembly;

d. a means for providing the laser beam to a surface of a borehole;

e. a beam power deposition optic having a property of changing an energy distribution profile within the laser beam; and

,

f. the cavity at least partially containing;

i. the means for providing the laser beam to the surface of the borehole; and

,

ii. the providing means comprising the beam power deposition optic;

g. wherein, the laser beam as delivered from the bottom hole assembly illuminates the surface of the borehole with a substantially even energy deposition profile on the surface.

2. The system of claim 1, wherein the laser source provides a plurality of laser beams to the fiber.

3. The system of claim 1, wherein the laser beam has a substantially uniform profile at the fiber bottom hole assembly connection.

4. The system of claim 1, wherein the laser beam is at least about 20 kW at the fiber bottom hole assembly connection.

5. The system of claim 1, wherein the laser beam is at least about 15 kW at the fiber bottom hole assembly connection.

6. The system of claim 1, wherein the laser source is at least about 20 kW.

7. The system of claim 1, wherein the bottom hole assembly comprises a motor.

8. The system of claim 1, wherein the surface of the borehole comprises a bottom surface of the borehole.

9. The system of claim 1, wherein the bottom hole assembly comprises an electric motor.

10. The system of claim 1, wherein the bottom hole assembly comprises a means for transferring rotational motion.

11. A system for forming a borehole in the earth comprising:

a. a high power laser source;

b. a laser delivery assembly;

c. an optical fiber comprising;

i. a first and a second end;

ii. a length between the first and second ends;

iii. the first end being optically associated with the laser source; and

,

iv. the fiber having a length of at least about 1000 ft;

d. a means for delivering a laser beam from the laser source to a surface of the borehole, wherein the means includes a beam power deposition optic having a property of changing an energy distribution profile within the laser beam; and

;

e. the laser delivery means connected to and optically associated with the second end of the optical fiber;

f. a means for providing a substantially uniform energy deposition; and

,

g. the laser delivery means comprising the means for providing the substantially uniform energy deposition.

12. The system of claim 11, wherein the laser delivery means comprises an optical assembly.

13. The system of claim 11, wherein the laser delivery means is contained within the laser delivery assembly.

14. The system of claim 11, wherein the laser delivery means is contained within the laser delivery assembly and the laser delivery assembly comprises a rotating optical assembly.

15. The system of claim 11, wherein the laser delivery assembly comprises an electric motor.

16. The system of claim 11, wherein the laser source provides more than one laser beam.

17. The system of claim 11, wherein the surface of the borehole comprises a bottom surface of the borehole.

18. The system of claim 11, wherein the laser beam has a substantially uniform profile at the fiber second end.

19. The system of claim 11, wherein the laser beam is at least about 15 kW at the fiber second end.

20. The system of claim 11, wherein the laser source is from at least about 40 kW.

21. The system of claim 11, wherein the laser source is at least about 25 kW.

22. A system for creating a borehole comprising:

a. a high power laser source;

b. a bottom hole assembly;

c. a fiber optically connecting the laser source with the bottom hole assembly, such that a laser beam from the laser source is transmitted to the bottom hole assembly;

d. a means for providing the laser beam to a surface of the borehole; and

,

e. a beam power deposition optic having a property of changing an energy distribution profile within the laser beam;

f. the bottom hole assembly comprising;

i. the means for providing the laser beam to the surface of the borehole;

ii. the providing means comprising the beam power deposition optic; and

,

iii. the means for providing the laser beam to the bottom surface configured to provide a predetermined energy deposition profile;

g. wherein, the laser beam as delivered from the bottom hole assembly illuminates the surface of the borehole with a predetermined energy deposition profile.

23. The system of claim 22, wherein the predetermined energy deposition profile is biased toward an outside area of a bottom surface of the borehole surface.

24. The system of claim 22, wherein the predetermined energy deposition profile is biased toward an inside area of a bottom surface of the borehole surface.

25. The system of claim 22, comprising a mechanical removal means.

26. The system of claim 22, wherein the laser beam at the bottom hole assembly has a power of at least about 15 kW.

27. A system for advancing a borehole in the earth comprising:

a. a high power laser source;

b. a bottom hole assembly; and

,

c. a fiber optically connecting the laser source with the bottom hole assembly, such that a laser beam from the laser source is transmitted to the bottom hole assembly;

d. the bottom hole assembly comprising;

a means for providing a laser beam to a bottom surface of the borehole in a predetermined pattern, wherein the means for providing a laser beam to a bottom surface of the borehole further comprises a means for changing an energy distribution profile within the laser, an wherein the predetermined pattern is configured to illuminate a majority of the borehole bottom surface and in a predetermined energy deposition profile.

28. The system of claim 27, wherein the laser beam at the bottom hole assembly has a power of at least about 15 kW.

29. A system for creating a borehole comprising:

a. a high power laser source;

b. a bottom hole assembly; and

,

c. a fiber optically connecting the laser source with the bottom hole assembly, such that a laser beam from the laser source is transmitted to the bottom hole assembly, the laser beam at the bottom hole assembly having a power of at least about 5 kW;

d. the bottom hole assembly comprising;

a means for providing a substantially elliptical shaped laser beam spot having a power of at least about 5 kW to the bottom surface of the borehole in a rotating manner to thereby provide a predetermined energy deposition profile to the bottom surface of the borehole.

30. A method of forming a borehole using a laser, the method comprising:

a. advancing a high power laser beam transmission fiber into a borehole;

i. the borehole having a bottom, a side wall, a top opening, and a length extending between the bottom and the top opening of at least about 5000 feet;

ii. the transmission fiber comprising a distal end, a proximal end, and a length extending between the distal and proximal ends, the distal end being advanced into the borehole;

iii. the transmission means comprising a means for transmitting high power laser energy,

b. providing a laser beam, having a power of least about 10 kW, to the proximal end of the transmission fiber;

c. transmitting the power of the laser beam down the length of the transmission fiber so that the beam exits the distal end, having a first energy distribution profile, and enters a laser delivery assembly; and

,

d. directing the laser beam, having a power of at least about 5 kW, and having the second energy distribution profile, in a predetermined pattern defining a pattern area; and

, wherein the predetermined pattern provides a predetermined and substantially uniform energy deposition profile to a surface of the borehole, whereby the borehole is completed, in part, based upon the interaction of the laser beam with the surface of the borehole.

31. A system for creating a hole comprising:

a. a high power laser source generating a high power laser beam;

b. a bottom hole assembly comprising;

a means for providing the high power laser beam to a bottom surface of a borehole, wherein the means for providing the high power laser beam comprises beam power deposition optics;

c. a fiber optically connecting the high power laser source with the bottom hole assembly, such that the high power laser beam from the high power laser source is transmitted to the bottom hole assembly, the high power laser beam at the bottom hole assembly having a power of at least about 1 kW;

d. wherein, the high power laser beam as delivered from the bottom hole assembly illuminates a bottom surface of the borehole with the high power laser beam having a power of at least about 1 kW in a substantially even energy deposition profile on the bottom surface.

32. The system of claim 31, wherein the laser bottom hole assembly comprises a housing defining a cavity.

33. A system for creating a borehole in the earth comprising:

a. a high power laser source;

b. a bottom hole assembly;

c. an optical fiber comprising;

i. a first end and a second end;

ii. a length between the first and second ends that is at least 1000 ft; and

,

iii. the first end being optically associated with the laser source;

d. a means for delivering a laser beam from the laser source to a surface of the borehole, wherein the means for delivering a laser beam comprises a means for providing a substantially uniform energy deposition to the bottom of the borehole and is connected to and optically associated with the second end of the optical fiber.

34. A system for creating a borehole in the earth comprising:

a. a high power laser source;

b. a bottom hole assembly; and

,

c. a fiber optically connecting the high power laser source with the bottom hole assembly, such that a high power laser beam from the laser source is transmitted to the bottom hole assembly, the high power laser beam in the fiber having a power of at least about 5 kW;

d. the bottom hole assembly comprising;

a means for providing a laser beam shot pattern to an area of the borehole in a predetermined shot pattern configured to illuminate a majority of the area with a laser beam having a power of at least about 5 kW and in a predetermined energy deposition profile to the area.

35. A system for creating a borehole in the earth comprising:

a. a high power laser source;

b. a bottom hole assembly; and

,

c. a fiber optically connecting the high power laser source with the bottom hole assembly, such that a high power laser beam from the laser source is transmitted to the bottom hole assembly, the high power laser beam in the fiber at the fiber having a power of at least about 5 kW;

d. the bottom hole assembly comprising;

a means for providing a substantially elliptical shaped laser beam spot having at power of at least about 5 kW to the bottom surface of the borehole in a rotating manner to thereby provide a predetermined energy deposition to the bottom surface of the borehole.

36. A method of forming a borehole using a laser, the method comprising:

a. advancing a transmission fiber into a borehole;

i. the borehole having a bottom surface, a top opening, and a length extending between the bottom surface and the top opening of at least about 1000 feet;

ii. the transmission fiber comprising a distal end, a proximal end, and a length extending between the distal and proximal ends, the distal end being advanced down the borehole;

b. providing a laser beam, having at least about 10 kW, to the proximal end of the transmission means;

c. transmitting the power of the laser beam down the length of the transmission fiber so that the beam exits the distal end and enters a laser bottom hole assembly; and

,

d. directing the laser beam, having at least about 5 kW, in a predetermined pattern to provide a predetermined and substantially uniform energy deposition profile to the surface of the borehole whereby the length of the borehole is increased, in part, based upon the interaction of the laser beam with the bottom of the borehole.

37. A system for creating a hole comprising:

a. a high power laser source generating a high power laser beam;

b. a laser delivery assembly comprising;

an optics configuration capable of providing the high power laser beam to a bottom surface of a borehole, wherein the optics configuration comprises beam power deposition optics;

c. a fiber optically connecting the high power laser source with the laser delivery assembly, such that the high power laser beam from the high power laser source is transmitted to the laser delivery assembly, the high power laser beam at the laser delivery assembly having a power of at least about 1 kW;

d. wherein, the high power laser beam as delivered from the bottom hole assembly illuminates a bottom surface of the borehole with the high power laser beam having a power of at least about 1 kW in a substantially even energy deposition profile on the bottom surface.

38. A system for creating a borehole in the earth comprising:

a. a high power laser source;

b. a bottom hole assembly;

an optical fiber comprising;

a first end and a second end;

a length between the first and second ends that is at least 1000 ft;

the first end being optically associated with the laser source;

d. a laser delivery assembly capable of delivering a laser beam from the laser source to a surface of the borehole, wherein the laser delivery assembly comprises a means for providing a substantially uniform energy deposition to the bottom of the borehole and is connected to and optically associated with the second end of the optical fiber.

39. A system for creating a borehole in the earth comprising:

a. a high power laser source;

b. a bottom hole assembly; and

,

c. a fiber optically connecting the high power laser source with the bottom hole assembly, such that a high power laser beam from the laser source is transmitted to the bottom hole assembly, the high power laser beam in the fiber having a power of at least about 5 kW;

d. the bottom hole assembly comprising;

an optical assembly capable of providing a laser beam shot pattern to an area of the borehole in a predetermined shot pattern configured to illuminate a majority of the area with a laser beam having a power of at least about 5 kW and in a predetermined energy deposition profile to the area.

40. The system of claim 39, wherein the optical assembly contains a beam power deposition optic having a property of changing an energy distribution profile within the laser beam.