High power laser-mechanical drilling bit and methods of use

• US 9,562,395 B2
• Filed: 02/23/2012
• Issued: 02/07/2017
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Grubb, Daryl L., Kolachalam, Sharath K., Faircloth, Brian O., Rinzler, Charles C., Allen, Erik C., Underwood, Lance D., Zediker, Mark S.
• Primary Examiner(s): GITLIN, ELIZABETH C GOTTLIEB
• Application Number:
  US13/403,615
• Publication Number:
  US 20120255774A1
• Time in Patent Office: 1,811 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 7/14 Drilling by use of heat, e.g. flame drilling

Abstract

An apparatus with a high power laser-mechanical bit for use with a laser drilling system and a method for advancing a borehole. The laser-mechanical bit has a beam path and mechanical removal devices that provide for the removal of laser-affected rock to advance a borehole.

Claims

1. A flat bottom fixed cutter laser-mechanical bit comprising:

a. a bottom section having a central axis, a width and a flat bottom end, wherein the bottom end is configured to engage a borehole surface;

b. a beam path channel defined, in part, by a plurality of beam blades, wherein the beam path channel forming a shape, wherein the shape includes at least one member of a group comprising;

a rectangle and an ellipse extends across the width of the flat bottom end of the bottom section and through the central axis;

c. a plurality of cutter blades; and

,

d. the cutter blades and the beam blades each having a lower end;

e. wherein, the lower ends are configured to be essentially coplanar, thereby defining the flat bottom end;

f. whereby, the bit is capable of laser-mechanical drilling an essentially flat bottom borehole; and

,

g. a beam blade having a passage in fluid communication with a junk slot, the junk slot being located on the exterior surface of the bit.

2. The laser-mechanical bit of claim 1, wherein the beam blades comprise a first and second pair of blades.

3. The laser-mechanical bit of claim 1, comprising a means for limiting the depth of cut.

4. The laser-mechanical bit of claim 3, wherein the means for limiting the depth of cut, the beam blades and the cutter blades have substantially the same height.

5. The laser-mechanical bit of claim 3, the means for limiting the depth of cut has a greater height than the beam blades and the cutter blades.

6. The laser-mechanical bit of claim 5, wherein the beam path channel comprises a beam path slot in a side surface of the bottom section.

7. The laser-mechanical bit of claim 3, wherein the bottom section width is at least about 4 inches;

and the beam blades have a height of at least about 1;

4 inch and a width of at least about 1% inches.

8. The laser-mechanical bit of claim 7, wherein the beam path channel comprises a beam path slot in a side surface of the bottom section.

9. The laser-mechanical bit of claim 1, wherein the bottom section width is at least about 6 inches;

and the beam blades have a height of at least about 1h inch and a width of at least about 2% inches.

10. The laser-mechanical bit of claim 9, having a beam path angle of greater than 90 degrees.

11. The laser-mechanical bit of claim 9, having a beam path angle of from about 90 degrees to about 135 degrees.

12. The laser-mechanical bit of claim 9, having a beam path angle of about 90 degrees.

13. The laser-mechanical bit of claim 9, having a beam path angle of about 135 degrees.

14. The laser-mechanical bit of claim 9, having a beam path angle of less than about 150 degrees.

15. The laser-mechanical bit of claim 1, wherein the beam path channel comprises a beam path slot in a side surface of the bottom section.

16. The laser-mechanical bit of claim 15, having a beam path angle of greater than 90 degrees.

17. The laser-mechanical bit of claim 15, having a beam path angle of from about 90 degrees to about 135 degrees.

18. The laser-mechanical bit of claim 15, having a beam path angle of less than about 150 degrees.

19. The laser-mechanical bit of claim 1, comprising a body section associated with the bottom section;

and a beam path slot in a side surface of the bottom section and extending into a side surface of the body section.

20. The laser-mechanical bit of claim 1, wherein the beam path channel comprises a beam path slot in a side surface of the bottom section.

21. The laser-mechanical bit of claim 1, wherein the beam path channel comprises a beam path slot in a side surface of the bottom section.

22. The laser-mechanical bit of claim 1, having a beam path angle of greater than about 90 degrees.

23. The laser-mechanical bit of claim 1, having a beam path angle of from about 90 degrees to about 135 degrees.

24. The laser-mechanical bit of claim 1, having a beam path angle of about 90 degrees.

25. The laser-mechanical bit of claim 1, having a beam path angle of about 135 degrees.

26. The laser-mechanical bit of claim 1, having a beam path angle of less than about 150 degrees.

27. The laser-mechanical bit of claim 1, having a beam path angle of from about 90 degrees to about 135 degrees.

28. The laser-mechanical bit of claim 1, having a beam path angle of less than about 150 degrees.

29. A laser-mechanical bit comprising:

a. a bit body section and bottom section;

b. the bottom section comprising two beam blades, the bottom section defining a

     1) portion of a beam path channel and

     2) a portion of a beam path slot forming a shape, wherein the shape formed by the beam blades includes at least one member of a group comprising;

a rectangle and an ellipse, and wherein the beam path slot is in fluid communication with the beam blades and the beam path channel;

c. a means for boring with mechanical force; and

,

d. at least one beam blade has a passage in fluid communication with a junk slot, the junk slot being located along the exterior surface of the bit; and

e. wherein the beam path channel extends across the width of the bottom section; and

f. wherein the means for boring comprises a pair of blades each comprising a cutter;

the beam blade comprises an inner surface and an outer surface, wherein the inner surface defines an inner plane and outer surface defines an outer plane;

wherein the inner plane is adjacent a laser beam path and wherein the outer plane is removed from the laser beam path; and

at least a portion of the cutter is positioned within the inner plane.

30. The bit of claim 29, wherein the beam path slot extends into the bit body section.

31. The bit of claim 29, wherein the beam blades extend along an outer side of the bottom section and along at least a portion of an outer side of the bit body section.

32. The bit of claim 29, comprising four beam blades.

33. The bit of claim 29, wherein the means for boring'"'"'s cutters are juxtaposed.

34. A laser-mechanical drilling bit for advancing a borehole in the earth, the bit comprising:

a. a body characterized by a bottom end configured for engagement with a borehole surface;

b. a beam path channel containing a laser beam path;

wherein the beam path channel divides the bottom end into a first and a second section;

c. the first bottom end section having a beam blade, a cutter blade, and a means for limiting the depth of cut; and

,

d. the second bottom end section having a beam blade, a cutter blade, and a means for limiting the depth of cut,

e. the bottom section comprising two beam blades, the bottom section defining both

     1) a portion of a beam path channel and

     2) a portion of a beam path slot, forming a shape, wherein the shape formed by the beam blades includes at least one member of a group comprising;

a rectangle and an ellipse, and wherein the beam path slot is in fluid communication with the beam blades and the beam path channel;

f. a means for boring with mechanical force; and

,

g. a beam blade has a passage in fluid communication with a junk slot, the junk slot being located along the exterior surface of the bit.

35. The bit of claim 34, wherein the means for limiting the depth of cut comprises a blade having depth limiters along a bottom end of the blade.

36. The bit of claim 34, wherein the means for limiting the depth of cut comprises depth limiters positioned on a beam blade.

37. The bit of claim 34, wherein the first bottom end section has a beam path angle of from about 90 degrees to about 135 degrees.

38. The bit of claim 34, wherein the first bottom end section and the second bottom end section have beam path angles from about 90 degrees to about 135 degrees.

39. The bit of claim 38, wherein the first bottom end section beam path angle is substantially the same as the second bottom end section beam path angle.

40. The bit of claim 34, having a beam path angle of less than about 150 degrees.

41. The bit of claim 34, the beam blade passage in fluid communication with a helical shaped junk slot.

42. The bit of claim 41, wherein the junk slot is defined at least in party by the beam blade.

43. The bit of claim 34, wherein the junk slot is defined at least in party by the beam blade.

44. A laser-mechanical drilling bit for advancing a borehole in the earth, the bit comprising:

a. a body characterized by a bottom end configured for engagement with a borehole surface;

b. a beam path channel;

wherein the beam path channel divides the bottom end into a first and a second section;

c. a beam path slot having an angled end, and forming a shape, wherein the shape includes at least one member of a group comprising;

a rectangle and an ellipse, wherein the beam path slot is in optical and fluid communication with the beam path channel and a junk slot, the junk slot being located along the exterior surface of the bit;

d. the first bottom end section having a beam blade, a plurality of cutter blades, and a means for limiting the depth of cut; and

,

e. the second bottom end section having a beam blade, a plurality of cutter blades, and a means for limiting the depth of cut.

45. The bit of claim 44, wherein the first bottom end section has a beam path angle of from about 90 degrees to about 135 degrees.

46. The bit of claim 44, wherein the first bottom end section and the second bottom end section have beam path angles from about 90 degrees to about 135 degrees.

47. The bit of claim 46, wherein the first bottom end section beam path angle is substantially the same as the second bottom end section beam path angle.

48. A laser-mechanical drilling bit for advancing a borehole in the earth, the bit comprising:

a. a body characterized by a bottom end and a central axis of rotation, wherein the bottom end is configured for engagement with a borehole surface;

b. a beam path contained within a channel;

wherein the beam path, wherein the beam path is in fluid communication with a junk slot, the junk slot being located along the exterior surface of the bit, and divides the bottom end into a first and a second section;

c. the first bottom end section having a beam blade, a cutter blade, and a means for limiting the depth of cut;

d. the second bottom end section having a beam blade, a cutter blade, and a means for limiting the depth of cut;

e. the first bottom end section cutter blade comprising a plurality of cutters, and the second bottom end section cutter blade comprising a plurality of cutters; and

,

f. the cutters positioned with respect to the central axis of rotation, whereby during rotation and deliver of a laser beam through the beam path to a surface of the borehole, each cutter will contact a laser-affected surface.

49. The bit of claim 48, comprising a plurality of first bottom end section cutter blades and a plurality of second bottom end section cutter blades.

50. The bit of claim 49, comprising at least 10 cutters.

51. The bit of claim 49, comprising at least 12 cutters.

52. The bit of claim 48, comprising at least 6 cutters.