High power laser decomissioning of multistring and damaged wells

• US 9,664,012 B2
• Filed: 12/13/2013
• Issued: 05/30/2017
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Grubb, Daryl L., Zediker, Mark S., Faircloth, Brian O., Deutch, Paul D., Marshall, Scott A., De Witt, Ronald A.
• Primary Examiner(s): Thompson, Kenneth L
• Application Number:
  US14/105,949
• Publication Number:
  US 20140090846A1
• Time in Patent Office: 1,264 Days
• Field of Search: 166277, 166248, 166 98, 166 99, 166178, 166285, 166290, 166376, 166377, 166301, 166297, 166298, 21912167, 21912176
• 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 33/1204 permanent; drillable
• CPC Class Codes: E21B 33/13 Methods or devices for cementing, for plugging holes, crevices or the like
• CPC Class Codes: E21B 43/11 Perforators; Permeators

Abstract

High power laser systems, high power laser tools, and methods of using these tools and systems for opening up damaged wells and 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. And, high power laser systems, high power laser tools, and methods of using these systems and tools for providing rock-to-rock plugs for decommissioning of wells.

Claims

1. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

2. The method of claim 1, wherein the laser delivery pattern comprises a slot essentially parallel to the axis of the borehole, the slot having a length or at least about 20 feet.

3. The method of claim 2, wherein the laser delivery pattern comprises a plurality of slots essentially parallel to the axis of the borehole, the slots having a length or at least about 20 feet.

4. The method of claim 3, wherein the slots are essentially evenly places around the walls of a tubular in the borehole.

5. The method of claim 2, wherein the laser the laser delivery pattern comprises a plurality of circular slots extending transverse to the axis of the well and around the wall of the well.

6. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the borehole has an axis and the plugging material channel has a length along the borehole axis of at least about 200 feet; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

7. The method of claim 6, wherein the removed material comprises a tubular.

8. The method of claim 6, wherein the removed material comprises a plurality of tubulars.

9. The method of claim 6, wherein the removed material comprises a plurality of essentially concentric tubulars.

10. The method of claim 9, wherein the concentric tubulars are coaxial.

11. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam has a power of at least about 5 kW;

wherein the borehole has an axis and the plugging material channel has a length along the borehole axis of at least about 100 feet; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

12. The method of claim 11, wherein the removed material comprises a tubular.

13. The method of claim 11, wherein the removed material comprises a plurality of tubulars.

14. The method of claim 11, wherein the removed material comprises a plurality of tubulars and the formation.

15. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam has a power of at least about 10 kW;

wherein the borehole has an axial length and the plugging material channel has a length along the borehole axis of at least about 50 feet; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

16. The method of claim 15, wherein the removed material comprises a tubular.

17. The method of claim 15, wherein the removed material comprises a plurality of tubulars.

18. The method of claim 15, wherein the removed material comprises a plurality of tubulars, the formation, and cement.

19. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam has a power of at least about 10 kW;

wherein the borehole has an axial length and the plugging material channel has a length along the borehole axis of at least about 50 feet;

wherein the laser beam delivery pattern extends through a borehole wall and into a formation adjacent the borehole, whereby a portion of the plug material pathway extends to and into the formation defining a notch; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

20. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam delivery pattern comprises a slot pattern that extends through a tubular within the well and extends through a borehole wall and into a formation adjacent the borehole, wherein the plug material pathway provides the capability for a rock to rock seal when filled with a plugging material; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

21. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam delivery pattern comprises a slot pattern that extends through a tubular within the well and extends through a borehole wall and into a formation adjacent the borehole, wherein the plug material pathway provides the capability for a rock to rock seal when filled with a plugging material; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

22. A method of servicing a damaged well, the method comprising:

advancing a high power laser delivery tool to a damaged section of the well, the damaged section of the well comprising a pinched casing and inner tubular; and

, directing a high power laser beam from the high power laser delivery tool toward the damaged section of the well in a predetermined laser delivery pattern, the predetermined laser delivery pattern intersecting the pinched casing;

whereby the laser beam removes the pinched casing;

wherein the damaged section of the well is located between a first undamaged section of the well and a second undamaged section of the well, and the laser delivery pattern removes the pinched casing and any other material in its path, thereby bridging the first and second undamaged sections of the well.

23. The method of claim 22, wherein the laser delivery pattern comprises a volumetric pattern selected from the group consisting of:

a linear pattern, an elliptical patent, a conical pattern, a fan shaped pattern and a circular pattern.

24. The method of claim 22, wherein the laser beam delivered along the delivery pattern cuts a control line.

25. A method of decommissioning a well, comprising:

a. positioning a high power laser cutting tool in a borehole to be decommissioned;

b. the borehole having a plurality of tubulars;

c. delivering a high power laser beam from the high power laser tool in a predetermined pattern, whereby the laser beam volumetrically removes material in the borehole, the removed material including a control line;

d. thereby forming a rock to rock plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern; and

,

e. filling the plugging material channel with a material, wherein a rock to rock plug is formed, thereby sealing the well.

26. The method of claim 25, wherein the material removed comprises a tubular, cement and the formation.

27. The method of claim 25, wherein the laser beam delivery pattern comprises a slot pattern that extends through a tubular within the well and extends through a borehole wall and into a formation adjacent the borehole, wherein the plug material pathway provides the capability for a rock to rock seal when filled with a plugging material.

28. The method of claim 25, wherein the laser beam delivery pattern comprises a plurality of disc shaped patterns.

29. The method of claim 25, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

30. The method of claim 25, wherein the tubulars are essentially concentric.

31. The method of claim 30, wherein the tubulars are coaxial.

32. The method of claim 30, wherein the material removed comprises a portion of all of the tubulars.

33. The method of claim 25, wherein the material removed comprises a formation.

34. The method of claim 33, wherein the borehole has an axial length and the plugging material channel has a length along the borehole axis of at least about 50 feet.

35. The method of claim 25, wherein the laser beam has a power of at least about 10 kW.

36. The method of claim 35, wherein the laser beam delivery pattern extends through a borehole wall and into a formation adjacent the borehole, whereby a portion of the plug material pathway extends to and into the formation defining a notch.

37. The method of claim 25, wherein the borehole has an axis and the plugging material channel has a length along the borehole axis of at least about 200 feet.

38. The method of claim 37, wherein the laser beam delivery pattern comprises a plurality of pie shaped patterns.

39. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

the borehole having a plurality of tubulars;

delivering a high power laser beam from the high power laser tool in a predetermined pattern, whereby the laser beam volumetrically removes material in the borehole; and

, thereby forming a rock to rock plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam has a power of at least about 10 kW; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

40. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

the borehole having a plurality of tubulars;

delivering a high power laser beam from the high power laser tool in a predetermined pattern, whereby the laser beam volumetrically removes material in the borehole; and

, thereby forming a rock to rock plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the tubulars are essentially concentric; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

41. The method of claim 40, wherein the laser beam delivery pattern comprises an elliptical pattern that extends through a tubular within the well and extends through a borehole wall and into a formation adjacent the borehole.

42. A method of decommissioning a damaged well, the method comprising:

advancing a high power laser delivery tool to a damaged section of the well;

directing a high power laser beam from the high power laser delivery tool toward the damaged section of the well in a predetermined laser delivery pattern;

the laser beam delivered along the predetermined laser delivery pattern, at least in part, opens the damaged section of the well;

advancing decommissioning equipment through the laser opened section of the well to a lower section of the well; and

, performing an operation on the lower section of the well;

wherein the damaged section of the well is located between a first undamaged section of the well and a second undamaged section of the well, and the laser delivery pattern removes a pinched casing and any other material in its path, thereby bridging the first and second undamaged sections of the well.

43. The method of claim 42, wherein the laser delivery pattern comprises a volumetric pattern selected from the group consisting of:

a linear pattern, an elliptical patent, a conical pattern, a fan shaped pattern and a circular pattern.

44. The method of claim 42, where in the operation performed on the lower section of the well comprises an operation selected from the group consisting of plugging, decommissioning, forming a rock to rock seal, laser cutting tubulars, forming a plurality of spaced apart plugs, and plug back to sidetrack.

45. The method of claim 42, where in the operation performed on the lower section of the well comprises:

a. positioning a high power laser cutting tool in a borehole to be decommissioned;

b. delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

,

c. forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern.

46. The method of claim 45, wherein the laser beam delivery pattern extends through a borehole wall and into a formation adjacent the borehole, whereby a portion of the plug material pathway extends to and into the formation defining a notch.

47. The method of claim 45, wherein the laser beam delivery pattern comprises a slot pattern that extends through all tubulars within the well and extends through a borehole wall and into a formation adjacent the borehole, wherein the plug material pathway provides the capability for a rock to rock seal when filled with a plugging material.

48. The method of claim 45, wherein the laser beam delivery pattern comprises a plurality of pie shaped patterns.

49. The method of claim 45, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

50. The method of claim 45, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

51. The method of claim 45, wherein the laser beam has a power of at least about 10 kW.

52. The method of claim 51, wherein the laser beam delivery pattern comprises a slot pattern that extends through a tubular within the well and extends through a borehole wall and into a formation adjacent the borehole, wherein the plug material pathway provides the capability for a rock to rock seal when filled with a plugging material.

53. The method of claim 45, wherein the borehole has an axis and the plugging material channel has a length along the borehole axis of at least about 200 feet.

54. The method of claim 53, wherein the laser beam delivery pattern comprises a slot pattern that extends through a plurality of tubulars and extends through a borehole wall and into a formation adjacent the borehole.

55. The method of claim 45, wherein the borehole has an axis and the plugging material channel has a length along the borehole axis of at least about 100 feet.

56. The method of claim 55, wherein the laser bam delivery pattern comprises a plurality of disc shaped patterns.

57. A method of decommissioning a well, comprising:

positioning a high power laser cutting tool in a borehole to be decommissioned;

delivering a high power laser beam from the high power laser tool in a predetermined pattern to the borehole, whereby the laser beam volumetrically removes material in the borehole; and

, forming a plugging material channel, the plugging material channel essentially corresponding to the predetermined laser beam delivery pattern;

wherein the laser beam has a power of at least about 5 kW;

wherein the borehole has an axis and the plugging material channel has a length along the borehole axis; and

, wherein the laser beam delivery pattern comprises a plurality of volumetric removal patterns spaced along an axial direction of the borehole, at least two of the volumetric removal patterns configured in a staggered overlying relationship, whereby at least one volumetric removal patterns intersects a control line in the well.

58. The method of claim 57, wherein the laser beam delivery pattern comprises a plurality of pie shaped patterns.

59. The method of claim 57, wherein the laser beam delivery pattern comprises a plurality of disc shaped patterns.