METHODS AND APPARATUS FOR DELIVERING HIGH POWER LASER ENERGY TO A SURFACE

• US 20100044105A1
• Filed: 08/19/2009
• Published: 02/25/2010
• Est. Priority Date: 08/20/2008
• Status: Active Grant

• Current Assignee: Foro Energy, Inc.
• Original Assignee: Foro Energy, Inc.
• Inventors: Faircloth, Brian O., Rinzler, Charles C., Koblick, Yeshaya, Moxley, Joel F., Zediker, Mark S.
• Granted Patent: US 8,424,617 B2
• Time in Patent Office: Days
• 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

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 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 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;

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

ii. the providing means comprising beam power deposition optics;

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

2. The system of claim 1, wherein the laser source provides more than one laser beams.

3. The system of claim 1, wherein the laser source provides a plurality of laser beams.

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

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

6. The system of claim 1, wherein the laser beam has a super-Gaussian profile at the fiber bottom hole assembly connection.

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

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

9. The system of claim 1, wherein the laser beam is at least about 3 kW at the fiber bottom hole assembly connection.

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

11. The system of claim 1, wherein the laser beam is at least about 10 kW at the fiber bottom hole assembly connection.

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

13. The system of claim 1, wherein the laser source is at least about 10 kW.

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

15. The system of claim 1, wherein the laser beam is at least about 10 kW at the fiber bottom hole assembly connection.

16. 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;

i. having a first and a second end;

ii. having a length between the first and second ends;

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

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;

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

,

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

17. The system of claim 16 wherein the laser delivery means comprises an optical assembly.

18. The system of claim 16 wherein the laser delivery means is a laser bottom hole assembly.

19. The system of claim 16 wherein the laser delivery means comprises a bottom hole assembly comprising a rotating optical assembly.

20. The system of claim 19 wherein the bottom hole assembly comprises a mud motor.

21. The system of claims 16 wherein the substantial uniformity means comprises a micro-optics array;

22. The system of claim 16, 17, 18, 19 and 20 wherein the substantial uniformity means comprises an axicon lens.

23. The system of claim 16 wherein the laser source provides more than one laser beams.

24. The system of claim 16 wherein the laser source provides a plurality of laser beams.

25. The system of claim 16 wherein the laser beam has a Gaussian profile at the fiber second end.

26. The system of claim 16 wherein the laser beam has a substantially Gaussian profile at the fiber second end.

27. The system of claim 16 wherein the laser beam has a super-Gaussian profile at the fiber second end.

28. The system of claim 16 wherein the laser beam has a substantially uniform profile at the fiber second end.

29. The system of claim 16 wherein the laser beam is at least about 1 kW at the fiber second end.

30. The system of claim 16 wherein the laser beam is at least about 3 kW at the fiber second end.

31. The system of claim 16 wherein the laser beam is at least about 5 kW at the fiber second end.

32. The system of claim 16 wherein the laser beam is at least about 10 kW at the fiber second end.

33. The system of claim 16 wherein the laser beam is at least about 15 kW at the fiber second end.

34. The system of claim 16 wherein the laser source is from at least about 5 kW to about 20 kW.

35. The system of claim 16 wherein the laser source is at least about 15 kW.

36. The system of claim 16 wherein the laser source is at least about 5 kW.

37. 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 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;

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

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

,

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

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

38. The system of claim 37, wherein the predetermined energy deposition profile is biased toward the outside area of the borehole surface.

39. The system of claim 37, wherein the predetermined energy deposition profile is biased toward the inside area of the borehole surface.

40. The system of claim 37, wherein the predetermined energy deposition profile is comprises at least two concentric areas having different energy deposition profiles.

41. The system of claim 37, wherein the predetermined energy deposition profile is provided by a series of laser shot patterns.

42. The system of claim 37, wherein the predetermined energy deposition profile is provided by a scattered laser shot pattern.

43. The system of claim 37, comprising a mechanical removal means.

44. The system of claim 43, where in the predetermined energy deposition profile is based upon the mechanical stresses applied by the mechanical removal means.

45. The system of claim 43, wherein the predetermined energy deposition profile has at least two areas of differing energy and the energies in the areas correspond inversely to the mechanical forces applied by the mechanical means.

46. 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 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;

i. a means for providing the laser beam shot pattern to a surface of the borehole in a predetermined shot pattern and in a predetermined energy deposition profile.

47. 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 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;

i. a means for providing a substantially elliptical shaped laser beam shot pattern to the bottom surface of the borehole in a rotating manner to thereby provided a predetermined shot pattern and a predetermined energy deposition profile.

48. A method of advancing a borehole using a laser, the method comprising:

a. advancing a high power laser beam transmission means 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 means 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;

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

b. providing a high power laser beam to the proximal end of the transmission means;

c. transmitting substantially all of the power of the laser beam down the length of the transmission means so that the beam exits the distal end;

d. transmitting the laser beam from the distal end to an optical assembly in a laser bottom hole assembly,

e. the laser bottom hole assembly directing the laser beam to the bottom surface of the borehole; and

,

f. providing a predetermined energy deposition profile to the bottom of the borehole;

g. whereby the length of the borehole is increased, in part, based upon the interaction of the laser beam with the bottom of the borehole.

49. A method of advancing 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 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 high power laser beam 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 to the bottom surface of the borehole in a substantially uniform energy deposition profile;

e. whereby the length of the borehole is increased, in part, based upon the interaction of the laser beam with the bottom of the borehole.

50. A method of advancing 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 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 high power laser beam 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 in a predetermined pattern to provide a predetermined energy deposition profile to the bottom 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.

51. A method of advancing 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 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 high power laser beam 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 in a predetermined pattern to provide a predetermined energy deposition profile to the bottom 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.

52. A laser bottom hole assembly for creating a borehole in the earth comprising:

a. a laser beam path;

b. a first chamber along the beam path;

c. a rotatable optical connector means located along the beam path;

d. a beam shaping optics located along the beam path;

e. a beam power deposition optics located along the beam path;

f. a second chamber along the beam path, the second chamber containing the beam shaping optics, the beam power optics and an incompressible transmissive fluid; and

,

g. a beam delivery opening in the laser bottom hole assembly along the beam path;

h. whereby, a laser beam is capable of traveling along the laser beam path and exiting the bottom hole assembly through the delivery opening so that it may illuminate a borehole surface.

53. A laser bottom hole assembly for creating a borehole in the earth comprising:

a. a laser beam path;

b. a first chamber along the beam path;

c. a rotatable optical connector means located along the beam path;

d. a beam shaping optics located along the beam path;

e. a second chamber along the beam path, the second chamber containing the beam shaping optics, the beam power optics and an incompressible transmissive fluid; and

,

f. a beam delivery opening in the laser bottom hole assembly along the beam path;

g. whereby, a laser beam traveling through the bottom hole assembly along the beam path travels through b), then c) then e) and then f).

54. A laser bottom hole assembly for creating a borehole in the earth comprising:

a. a laser beam path;

b. a first chamber along the beam path;

c. an optical connector means located along the beam path;

d. a collimating optics located along the beam path;

e. an axicon optics located along the beam path;

f. a second chamber along the beam path, the second chamber comprising d) and e), and a means to resist downhole pressures; and

,

g. a beam delivery opening in the laser bottom hole assembly along the beam path;

h. whereby, a laser beam is capable of traveling along the laser beam path and exiting the bottom hole assembly through the delivery opening so that it may illuminate a borehole surface.