OPTICAL FEEDBACK TO MONITOR AND CONTROL LASER ROCK REMOVAL
Methods, systems, and devices related to downhole wellbore operations such as drilling and completing wells in an earth formation that include a laser device. The method includes lasing a rock and detecting an optical response of the lased rock. It can be determined from the optical response whether the lased rock is responding as specified (e.g. spalling, melting, etc.) If the lased rock is not responding as specified, one or more laser parameters are adjusted to achieve the specified response. Spalling is determined by the detection of sparks, or other light that erratically changes in intensity over time, by an optical detector. The detection of steady light may indicate other types of rock removal mechanisms, such as melt or dissociation.
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The present disclosure relates generally to rock removal using a laser, and more particularly, to adjusting laser power of rock removal based on optical feedback.
BACKGROUNDOnce a wellbore has been drilled and one or more zones of interest have been reached, a well casing is run into the wellbore and is set in place by injecting cement or other material into the annulus between the casing and the wellbore. The casing, cement and formation are then perforated to enable flow of fluid from the formation into the interior of the casing. In some cases, the casing can be omitted.
SUMMARYAspects of the present disclosure are directed to systems, apparatuses, and methods for removing subterranean rock with a laser. Certain aspects of the implementations include, lasing subterranean rock around a well bore from inside the well bore. Emissions, such as optical and/or thermal emissions, can be detected from the lased rock. It can be determined whether the detected emissions from the lased rock indicates a specified material removal mechanism. If the detected emissions do not indicate the specified material removal mechanism is taking place, one or more laser cutting parameters can be adjusted until emissions detected from the lased rock indicates the specified material removal mechanism.
Certain aspects of the implementations are directed to a well laser system for use in a subterranean well. The system may include a laser apparatus configured to produce a laser beam, and direct the laser beam towards a subterranean rock. An optical detector may also be included and may be configured to detect light emitted from the rock. A controller may be communicatively coupled to the optical detector. The controller configured to receive a signal from the optical detector, determine from the signal whether the rock is responding as specified, and adjust a parameter of the laser if the rock is not responding as specified.
Certain aspects of the implementations are directed to a well apparatus for rock removal. The well apparatus may include a laser tool configured for insertion into the well and to direct laser energy onto rock. The laser tool may include a laser or may include optics that direct a laser beam produced by a terrestrially-located laser. The apparatus may also include a detector configured for insertion into the well and to detect emissions emitted from the rock. A controller can be configured to adjust power of a laser based on emissions detected from the rock.
Certain aspects of the implementations may include assessing an optical profile of the emissions detected from the lased rock for characteristic properties of the specified material removal mechanisms. A characteristic property of a material removal mechanism may include a detection of steady emissions. In other instances, a characteristic property of a specified material removal mechanism may include a detection of a rapidly time-varying emissions.
In certain aspects of the implementations, the detected emission intensity indicates that the lased rock is spalling.
In certain aspects of the implementations, the emission intensity indicate a specified material removal mechanism if the emissions fluctuate with a frequency above a specified threshold value.
In certain aspects of the implementations, adjusting the one or more laser parameters may include changing beam irradiance of the laser in response to the optical response profile of the emissions detected from the lased rock.
In certain aspects of the implementations, detecting emissions from the lased rock may include receiving light from the lased rock for a period of time.
In certain aspects of the implementations, detecting emissions from the lased rock may include detecting a steady emission intensity, the method further comprising determining that the lased rock is not spalling based on detecting the steady emission intensity. Certain implementations also may include determining that the rock is melting based on detecting the steady emissions. In some implementations, it may be determined that the rock is dissociating based on detecting the steady emissions.
In certain aspects of the implementations, lasing subterranean rock may include perforating a sidewall of the well bore.
In certain aspects of the implementations, lasing subterranean rock may include drilling the well bore.
In certain aspects of the implementations, the controller may include a processor communicatively coupled to the controller and configured to receive signals from the detector and output emissions information to the controller.
In certain aspects of the implementations, the controller is configured to automatically adjust the irradiance of the laser energy when the detected emissions from the rock indicate that the rock is not responding as specified. In certain aspects of the implementations, the light detected from the rock indicates that the rock is not spalling when the emissions have a varying intensity with respect to time below a threshold value.
In certain aspects of the implementations, the controller is configured to maintain the power of the laser when the emissions detected from the rock indicate that the rock is spalling.
In certain aspects of the implementations, the controller is configured to determine that the rock is spalling when emission intensity detected has varying intensities with respect to time, the variations in intensities occurring with a frequency above a threshold value.
Certain implementations may include a reflector configured to reflect a laser beam towards the rock and to reflect the emission from the rock to the light detector. Some implementations may include a dichroic reflector, the dichroic reflector configured to reflect a laser beam towards the rock and to transmit the light emitted from the rock to the light detector.
In certain aspects of the implementations, the optical detector may include a spot detector.
In certain aspects of the implementations, the optical detector may include a line detector.
In certain aspects of the implementations, the optical detector may include a two-dimensional detector array.
The details of one or more embodiments of the present disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTIONHigh power laser technology may be used for drilling and perforating downhole hydrocarbon formations. The amount of energy required to remove a given volume or mass of rock is defined as specific energy. An efficient rock removal process will result in a low specific energy while an inefficient process will exhibit a high specific energy. For a particular rock sample, the specific energy required to cut or drill through it depends on the laser parameters applied. These parameters include irradiance, laser power, spot size, laser on time, purge time, delay time between laser off and purge on.
Rock is often not a homogenous, isotropic material and its properties and composition change from well to well and from one location within a well to another and localized changes in physical or chemical composition, saturation, cracks or veins of dissimilar materials may require changing of the laser parameters in order to initiate a laser drilled hole and additional changes to the laser parameters may be required “on the fly” as the laser cut hole into the rock progresses.
The present disclosure is directed to systems, methods, and apparatuses for remotely detecting when laser drilling, perforating or other rock removal processes are efficient or inefficient. If an existing set of laser parameters results in inefficient removal, these parameters may be adjusted while the laser is down-hole until efficient removal is reestablished. In this way, a set of laser parameters resulting in efficient laser rock removal can be used at all times. This will result in quicker, more cost effective laser rock drilling, perforating or removal with improved hole geometry.
Several mechanisms exist for laser rock removal, including spallation, melting, dissociation, and vaporization.
Similar plots can be made where other laser parameters are changed and the remainder are held constant, however a general pattern emerges that specific energy increases when melting starts occurring.
Spallation and/or melting may be determined by the optical signature of the rock during laser illumination. The absorption of incident laser energy can result in rapid local heating of the rock surface. A portion of absorbed energy is re-radiated from the target region in the form of thermal emissions governed by Planck's law. Temperatures in excess of 800 C. are commonly attained in tenth-second timeframes when subjected to high power laser energy. Thermal emission's thus typically peak in the visible or near-IR region of the electro-magnetic spectrum. Current generation of high power lasers utilized in industrial applications are capable of delivering very high quality beams with near Gaussian intensity profiles, especially if delivered via a long spatially filtering fiber optic. Thermal emission from a flat, homogeneous rock surface impacted with such a laser beam resembles a solid circular glowing spot. Thermal emission and incident beam intensity profiles are highly correlated, with the region of brightest thermal emission coinciding with the peak of the incident beam profile. In practice, rough rock surfaces and non-uniform conductivity result in more complex thermal emission regions.
In the absence of material removal mechanisms, a constant incident laser power would be expected to yield increasingly bright thermal emission at lower wavelength until the energy input and output balance and a steady state temperature is attained. In practice, material removal processes typically initiate prior to obtaining steady state, provided a sufficiently high power laser is employed.
Under the most desirable material removal conditions, the sudden energy input resulting from laser incidence induces thermal stresses that shear rock grains and heat pore spaces in the rock matrix, causing grains and bits of rock matrix to be ejected from the surface. This condition is known as spallation. The ejected material often exhibits strong visible thermal emission signatures resulting in easy visual tracking of these particulates. The visual effect of observing many ejected grains rapidly moving radially outward from a central bright region at the site of laser incidence greatly resembles a type of burning firework known as a “sparkler”. A sparkler is a form of pyrotechnic comprised of a wire coated with a mixture containing an oxidizer; a fuel (e.g. charcoal and sulfur); a metal powder (e.g. iron, steel or aluminum); and a combustible binder (e.g. starch or sugar). When ignited at one end of the wire, this pyrotechnic burns slowly and releases a shower of white hot sparks.
Efficient spallation results in lower than otherwise observed thermal heating of the rock surface since much of the heated material is quickly ejected from the rock surface. Furthermore, this process typically maintains rock temperatures below the melt transition temperature. As such, key thermal emission signatures indicating spallation are a dynamic, low average intensity, longer wavelength signal corresponding to relatively low rock surface intensity in the presence of visible tracers of ejecta moving outward from the point of laser-rock interaction.
In contrast, when the laser parameters result in rock melting, the visual effect is different from spallation. When melt is occurring, no sparks are observed; instead, the optical response is a steadily glowing center where melted material tends to puddle in the center. Occasional melted rock may drip out of the hole, but generally, the light emission observed from melting is much less dynamic that that observed during spallation. See
Dissociation is a process by which rock is heated and then wet. The rock material can undergo a chemical reaction, turning the calcium carbonate into CaO2. The CaO2 is soluble in water. In some instances, dissociation may be desirable, and the optical response that indicates a rock that is undergoing dissociation can be identified using a detector to detect the emitted light from the rock.
The optical response of the lased rock can be detected and used to adjust laser parameters while the laser is down-hole. For example, an optical detector can receive the light emitted from the lased rock, and the variation in light intensity over time for a given spatial area of reference can be used to determine whether spallation is occurring (e.g., a high variation in light intensity over time) or whether melt is occurring (e.g., a low variation in light intensity over time) or whether neither is occurring.
Turning to
Power and/or signals may be communicated between the surface and the laser tool 20. Wireline 18 may include one or more electrical conductors which may convey electrical power and/or communication signals. Wireline 18 may additionally or alternatively include one or more optical fibers which may convey light (e.g. laser) power, optical spectra, and/or optical communication signals. Neither the communication of power, nor signals to/from the surface, are necessary for the operation of the implementations. In lieu of such communication, downhole batteries and/or downhole generators may be used to supply the laser tool 20 power. A downhole processor may be employed to control the laser tool 20, with relatively little (as compared to wireline) or no communication from the surface. For example, instructions for performing operations may be preprogrammed into the processor (ex. processor 44 in
In implementations incorporating a tubing string 19, the tubing may be continuous tubing or jointed pipe and may be a drilling string. The tubing string 19 may incorporate a wireline 18 as described above. Tubing string 19 may be “wired drill pipe,” i.e. a tubing having communication and power pathways incorporated therein, such as the wired drill pipe. The tubing string 19 may contain a smaller tubing string within for conveying fluids such as those used in the fluid based light path described below or for conveying chemicals used by the laser.
As discussed above, the laser tool 20 may be configured for use in analyzing material using laser-induced breakdown spectroscopy (LIBS). In LIBS, at least a portion of the material being sampled is heated, for example to a plasma or an incandescent state, and the wavelength spectrum and intensity of the light it emits is measured to determine a chemical characteristic of the material, for example, the chemical elements of the material. The light may be in either or both of the visible and invisible spectrums. The laser tool 20 can also be configured to determine a physical characteristic of the material, such as its temperature or thermal properties. The laser tool 20 can operate to heat the rock of the subterranean zone 12 (or other material being analyzed) in situ, i.e. without removing the rock of the subterranean zone 12, using laser beam 26 while the laser tool 20 is operating to remove material (drilling or perforating) or apart from operation of the laser tool 20 to remove material.
If configured to both remove and analyze material, the laser tool 20 can be configured to remove material and heat the material being removed or the remaining material to emit light 36 during the same duty cycle or during separate cycles. For example, the laser tool 20 can remove material during a first duty cycle and operate to heat material, at the same location or a different location, in a second duty cycle.
The power of the laser beam 26 can be equal from cycle to cycle, vary from cycle to cycle, or the laser beam can be fired in non-cyclical pulses of varying power. For example, it may be desirable to use a multi-pulse technique to heat the subterranean zone 12 to enable use of a lower powered laser than is necessary to heat the subterranean zone in a single pulse. In a multi-pulse technique, a first laser beam pulse is fired toward the material being analyzed to generate a cavity in the material and/or the interceding or surrounding materials, such as well fluids and drilling mud, resulting from rapidly expanding vaporized material. A second, higher power pulse is then fired into the material being analyzed to heat the material to a plasma or incandescent state. The multi-pulse technique may also encompass firing the first laser beam in a higher power pulse than the second laser beam pulse (e.g. for blasting away interceding material). Additional laser beam pulses may be fired, of higher or lower power than the first and second laser beam pulses, as is desired. For example, a third laser beam pulse may be fired to perforate the subterranean zone rock.
As a heated portion of the subterranean zone may continue to emit light for a brief period of time after the laser beam has ceased being directed at the location, the optical detector 48 can be operated to receive emitted light 36 either (or both) while the laser beam 26 is being directed at the location and afterwards, for example during an off cycle of the laser beam 26 or while the laser beam 26 is being directed to heat or remove material in a different location. It is also within the scope of the disclosure to re-heat the subterranean zone at some time after the laser tool 20 has been operated to remove material at the location, and thereafter use the optical detector 48 to receive the emitted light 36.
In
The laser beam may be pulsed, cycled, or modulated by pulsing, cycling, or modulating the control signal, and/or using an optical chopper, shutter, digital micro-mirror device, Kerr cell, or other mechanical, electrical, or photonics based light switching device to shutter, pulse, cycle, or modulate the emitted beam. In some implementations, the laser pulse duration may be on the order of 10 nanoseconds. A Kerr cell is one electro-optical device that may be used to provide shuttering on the order of such speeds.
As discussed above, the laser beam 26 is generated by a laser 24. The laser beam 26 impinges a reflector 30 and is reflected towards the wall of the well bore 10. The laser beam 26 is directed through a window 54 in the casing 14. The laser beam 26 then impinges the layers of the well bore, as discussed above, to create the perforation 22. Put differently, lasing the subterranean rock includes perforating a sidewall of the well bore 10.
When the laser beam 26 impinges on the rock, the rock may respond optically. Light emitted by the rock can traverse a path towards the reflector 30 and towards optical detector 48. The optical response of the lased rock can be detected by the optical detector 48, which can send signals to a controller 38 (described in
In certain implementations, the optical detector 48 resides behind the reflector 30. As discussed above, reflector 30 may be dichroic, allowing the laser beam 26 to reflect towards the window 54, while allowing the emitted light from the rock surface and ejecta to transmit through the reflector 30. In other implementations, the detector 48 may reside at other locations in the well bore (e.g., within or outside of a down-hole tool). For example, the reflector 30 may reflect light from the ejecta towards the surface, and the detector can be positioned to detect light reflected from the reflector 30.
Turning briefly to
Returning to
Use of an adjustable focusing array 28 enables the laser beam 26 to be more precisely focused on the material being removed or heated than a fixed focusing array 28, for example, when there is movement of the laser tool 20 relative to the subterranean zone 12. An adjustable focusing array 28 also enables the laser beam 26 to be focused on the end wall of the material being removed as the end wall moves deeper into the subterranean zone. In removing material, the laser beam 26 can be first focused on the closest surface of the material to be removed then adjusted to maintain focus as the surface from which material is being removed moves deeper into the material. In the case of perforating a well bore 10, the laser beam 26 can be first focused on the interior of the casing 14 and adjusted to maintain focus at an end wall of the perforation 22 as the perforation deepens through the casing 14, the cement 16 and into the subterranean zone 12. In heating a material being analyzed to emit light, the laser beam 26 can be focused on the material being analyzed. The focal length and/or properties of the laser beam may be actively manipulated, for example to compensate for movement of the laser tool 20 relative to the material being heated or removed.
A length to the desired location can be determined using a distance meter, such as an acoustic or optical distance meter, configured to measure a distance between the laser tool 20 and the material being removed or analyzed. That length can then be used in determining a focal length at which to focus the adjustable focusing array 28. Optical distance meter (or range finding) technologies are known, for example using a laser beam and a photo diode to detect the light returned from the subterranean zone whose range is of interest wherein a modelable relationship exists between the distance to be measured, the focal point of the laser beam, and the intensity of the returns. By varying the focal point of the beam and monitoring the intensity of the returns, the distance to the subterranean zone may be inferred. Alternatively, a distance, relative distance, or change in distance may be inferred with a single focal point by correlating intensity to a model or experimental data, or monitoring intensity decrease or increase at different times during a process (e.g. the perforating) expected to result in a change in such distance. As another alternative, optical time domain reflectometry may be employed as is known to measure the time a flight of a pulse of light to and from the subterranean zone, from which distance may be determined. The laser beam used by the optical distance meter 66 may be from a laser beam device 24 used for removing or heating material, or maybe a separate beam from a separate device.
When using a fixed focusing array 28, constraining the relative tool/subterranean zone movement so that the distance from the well bore 10 wall to the fixed focusing array 28 remains fixed in relation to the focusing array's focal length ensures that the laser beam 26 will maintain the desired focus. In an adjustable focusing array 28, it may be desirable to constrain relative tool/subterranean zone movement to reduce the magnitude of focal length adjustments necessary to maintain focus. Relative laser tool/subterranean zone movement can be reduced by sizing the exterior of the laser tool 20 close to the diameter of the well bore 10 or by providing the laser tool 20 with one or more stabilizer fins that project to a diameter that is close to the diameter of the well bore 10. Movement of the laser tool 20 relative to the subterranean zone can be further reduced by providing one or more extendable stabilizers, that can be selectively expanded to reside close to or in contact with the wall of the well bore 10.
Although the laser beam device 24 can be oriented to fire directly towards the material being removed or heated in one or more trajectories, the illustrative laser tool 20 is configured with the laser beam device 24 firing into a reflector 30. The reflector 30 directs the laser beam 26 toward the subterranean zone 12 and may be operated to assist in focusing the laser beam 26 or operate alone in (when no focusing array 28 is provided) focusing the laser beam 26 into the material being removed. In the illustrative laser tool 20 of
The laser beam 26 may be directed to remove material or heat various points around the well bore 10 and in varying patterns. In an illustrative laser tool 20 having a reflector 30, the reflector 30 can be movable in one or more directions of movement by a remotely controlled servo 32 to control the direction, i.e. trajectory, of the reflected laser beam 26. In a laser tool where the laser beam device 24 fires directly into the subterranean zone 12 or in a laser tool having a reflector 30, the laser beam device 24 can be movable by control servo to control the trajectory of the laser. In lieu of or in combination with a reflector 30, the laser beam can be directed into the subterranean zone 12 using a light path (see
In the illustrative example of
By directing the laser beam 26 relative to the laser tool 20, with reflector 30, light path 104, or otherwise, the laser tool 20 can remain in a single position (without further adjustments or reorientation) and remove or heat material in multiple locations around the well bore 10. Accordingly, the number of adjustments and/or orientations of the laser tool 20 during an entire operation are reduced. Physically moving the laser tool 20 is time-consuming relative to adjustment of the laser trajectory using the configurations described herein (ex. by moving reflector 30). Therefore, the ability to reach multiple trajectories without moving the laser tool 20 reduces the amount of time necessary to perform operations (drilling, perforating, subterranean zone analysis).
According to the concepts described herein, the laser beam 26 can be manipulated with multiple degrees of freedom and focal points to remove material in many different patterns. So for example, a slice or thin wedge can be removed from the wall of the well bore 10, orthogonal to and along the length of the well bore 10, and orthogonal to a subterranean zone bedding plane, with a larger thickness at its distal end from the well bore 10, and exposing far more subterranean zone surface than traditional perforating operations. The concepts described herein enable a perforation hole to be shaped (such as by providing slots, rather than tubes or pits) to minimize fluid pressure down-draw. Multiple shapes can be envisioned within the implementations which may promote hydrocarbon recovery rate, total recovery and efficiency.
In the illustrative laser tool 20, the laser beam 26 can be directed to remove or heat material circumferentially about the well bore 10 by actuating the control servo 32 to rotate the reflector 30 about a longitudinal axis of the well bore 10 and/or actuating the reflector 30 to move along the transverse axis of the well bore 10. The laser beam 26 can be directed to remove or heat material along the axis of the well bore 10 by actuating the control servo 32 to rotate the reflector 30 about a transverse axis of the well bore 10 or move along the longitudinal axis of the well bore 10. The laser beam 26 can be directed to remove or heat material in an area that is larger than could be removed in a single trajectory, by actuating the reflector 30 to rotate about and/or translate along at least two axes, for example the longitudinal and transverse axis. The laser beam 26 would then be directed in two or more different trajectories to substantially adjacent locations on the material being heated or removed. For example, by directing the laser beam 26 to project on the material being removed or heated at quadrants of a circle, the laser beam 26 can substantially remove or heat the material in a circular shape. By directing the laser beam 26 in two or more trajectories at the same location, the laser tool 20 can remove material to form a conical perforation having a largest diameter at the opening or having a smallest diameter at the opening. Also, the laser beam 26 may be directed in one or more trajectories to form a perforation in the earth formation, and concurrently while forming the perforation or subsequently, be directed in one or more trajectories to widen the perforation. The laser beam 26 can also be directed in two or more different trajectories to remove or heat material of the earth formation in a substantially continuous area or two or more disparate areas.
The laser being directable can be also be used to drill more efficiently and/or with unique hole characteristics, as compared to both the classic drill-bit drilling and prior non-directable laser drilling. In drilling with the laser beam 26, the laser beam 26 would be directed axially rather than radially, and the laser beam tool 20 would be conveyed on the bottom of the bottom hole assembly in place of the drilling bit (see
Using the directionality of the material removal allows formation of a specified hole or perforation section shape designed and executed for purposes of enhanced production. For example the hole or perforation can be formed in a rectangular, oval, elliptical, or other hole section with a longer axis aligned to expose greater (as compared to a circular cross-section) amount of the producing subterranean zone, or aligned to provide greater exposure to an axis of preferred permeability, or preferential production (or non-production) of oil, water, gas, or sand. Such specified hole or perforation section shape may be designed and executed for purposes of well bore or perforation stability, for example a rectangular, oval, or elliptical shape being employed with a longer axis aligned with the principal stress field, for increased stability and reduced tendency of collapse as compared to a circular cross-section.
The power of the laser beam 26 can be selected such that the duty cycle necessary to remove the material in the desired manner (crack, chip, spall, melt or vaporize) and/or heat the material to emit light allows enough time during off cycles of a given trajectory for the laser beam 26 to be directed in one or more additional trajectories. In other words, if the duty cycle necessary to remove and/or heat the material in the desired manner is 10%, the 90% off cycle can be utilized by re-directing the laser beam 26 to remove and/or heat material from one or more additional positions in the well bore 10. The duty cycle for the various positions can be substantially equal or one or more of the positions can have a different duty cycle. For example, the various positions may have a different duty cycle if one or more of the positions are a different material, if it is desired to remove material at a different rate in different positions, or if it is desired to remove material in one or more positions and merely heat material in one or more different positions to emit light. The laser beam 26 can be cycled or pulsed to achieve the required duty cycle or the laser beam 26 can be continuous and moved from position to position to achieve the duty cycle for each respective position. In either manner, the laser tool 20 operates to multiplex removal of material in one or more positions, for example to form one or more perforations 22, substantially concurrently. Likewise if it is desired to drill or perforate a hole that is larger than the laser beam 26 can form on a single trajectory or that otherwise must be formed with two or more trajectories, the same multiplexing technique can be used to remove material in the two or more trajectories substantially concurrently. More so, one or more positions on the earth formation can be heated to emit light substantially concurrently using this multiplexing technique.
In a laser tool 20 configured to analyze material, the optical detector 48 is provided to receive emitted light 36 from the subterranean zone 12. In an embodiment that communicates with the surface, the optical detector 48 is coupled to the surface by a communication link 40. The communication link 40 can be a fiber optic or light path for communicating data or light to the surface or can be an electrical or other type of link. The communication link 40 can be used to transmit wavelength spectra or signals indicative of wavelength spectra to the surface for analysis (ex. analysis using a surface based spectrometer and processor for determining the chemical characteristics of the material being analyzed). In an embodiment where the optical detector 48 determines the wavelength spectrum of the emitted light 36, the optical detector 48 can include a pyrometer and/or spectrometer 42 (
In the illustrative embodiment of
Some or all of the components of the laser tool 20 can be encased in a housing 52. The housing 52 has one or more windows 54 adapted to allow passage of the laser beam 26 out of the housing 52 and emitted light 36 into the housing 52. The size and shape of the windows 54 accommodate the aiming capabilities of the laser beam 26 and receipt of emitted light 36. The windows 54 are further adapted to withstand the elevated pressures and temperatures experienced in the well bore 10. Some examples of materials for constructing the windows 54 may be silica, sapphire, or numerous other materials of appropriate optical and strength properties. The windows 54 may have anti-reflection coatings applied to one or both surfaces to maximize the transmission of optical power there-through while minimizing reflections. The windows 54 may comprise a plurality of optical fibers positioned to direct the laser beam 26 or collect emitted light 36 from multiple locations about the well bore 10, for example the optical fibers may be fanned radially about the laser tool 20.
If efficient rock removal is detected, then the counter can be incremented (C=C+1) (712). Laser parameters can be maintained or further refined to optimize spallation signal strengths or rates, or overall process efficiency. A determination can then be made whether C=Cmax (714). Cmax is maximum number of laser shots or pulses for a particular lasing iteration. Cmax can be used to train the control system and can be used to ensure that sufficient sample space of data is collected to determine whether the rock removal is occurring efficiently. If the counter does not equal a maximum value, then lasing continues and the perforation depth can be monitored (716). It can be determined whether a desired depth is achieved (716). If the depth has not been achieved, the laser continues to perforate the well bore, and light detection continues from (704). If the depth is achieved, the laser can stop perforating (720), and other processes can commence (including those that use the laser, such as spectroscopic analyses).
If the counter is equal to its maximum value (and efficient rock removal is detected), then the counter is reset to zero (C=0) (708). The laser parameters can be adjusted (710). In this case, the laser parameters can be adjusted so that a new lasing area is chosen or new laser parameters are selected to test whether efficient rock removal can be achieved using different parameters.
If rock removal is determined to be inefficient (e.g., no spalling is detected), then the counter is reset to zero (C=0) (708). The laser parameters can be adjusted (710). The laser parameters include, among other things, laser power, irradiance (power/unit area), purge delay, orifice size on purge lance, purge velocity, the number of purges, etc. Laser power can be reduced to a point below that which would cause melt (see
Other parameters can also be varied. For example, laser irradiance can be varied be changing the laser power or by changing the spot size area using lenses. The laser delay can also be varied. Delay may allow the melted rock to cool and solidify. The solidified rock can be removed to expose a “clean” rock surface for further lasing and removal. Cycle delay can also be varied (that is, the time between lasing and purging).
Various configurations of the disclosed systems, devices, and methods are available and are not meant to be limited only to the configurations disclosed in this specification. Even though numerous characteristics and advantages have been set forth in the foregoing description together with details of illustrative implementations, the disclosure is illustrative only and changes may be made within the principle of the disclosure. Accordingly, other embodiments are within the scope of the following claims.
Claims
1. A method for removing subterranean rock with a laser, the method comprising:
- from inside a well bore, lasing subterranean rock around the well bore;
- detecting emissions from the lased rock;
- determining whether the detected emissions from the lased rock indicate a specified material removal mechanism; and
- if the detected emissions do not indicate the specified material removal mechanism, adjusting one or more laser cutting parameters until emissions detected from the lased rock indicates the specified material removal mechanism.
2. The method of claim 1, further comprising assessing an optical profile of the emissions detected from the lased rock for characteristic properties of the specified material removal mechanisms.
3. The method of claim 2, wherein a characteristic property of a specified material removal mechanism comprises a detection of a rapidly time-varying emissions.
4. The method of claim 2, wherein a characteristic property of a material removal mechanism comprises a detection of steady emissions.
5. The method of claim 1, wherein the detected emissions indicate that the lased rock is spalling.
6. The method of claim 1, wherein the emission intensity indicate a specified material removal mechanism if the emissions fluctuate with a frequency above a specified threshold value.
7. The method of claim 1, wherein adjusting the one or more laser parameters comprises, in response to the emissions detected from the lased rock, changing one or more of beam irradiance of the laser, laser power, laser spot size, laser on time, purge time, or delay time between laser shut-off and purge turn-on.
8. The method of claim 1, wherein detecting emissions from the lased rock comprises receiving light from the lased rock for a period of time.
9. The method of claim 1, wherein detecting emissions from the lased rock comprises detecting a steady emission intensity, the method further comprising determining that the lased rock is not spalling based on detecting the steady emission intensity.
10. The method of claim 9, further comprising determining that the rock is melting based on detecting the steady emissions.
11. The method of claim 10, further comprising determining that the rock is dissociating based on detecting the steady emissions.
12. The method of claim 1, where lasing subterranean rock comprises perforating a sidewall of the well bore.
13. The method of claim 1, where lasing subterranean rock comprises drilling the well bore.
14. A well apparatus for rock removal, comprising:
- a laser tool configured for insertion into the well and to direct laser energy onto rock;
- a detector configured for insertion into the well and to detect emissions emitted from the rock; and
- a controller configured to adjust power of a laser based on emissions detected from the rock.
15. The apparatus of claim 14, wherein the controller comprises a processor communicatively coupled to the controller and configured to receive signals from the detector and output emissions information to the controller.
16. The apparatus of claim 14, wherein, when the detected emissions from the rock indicate that the rock is not responding as specified, the controller is configured to automatically adjust one or more of an irradiance of the laser energy, laser power, laser spot size, laser on time, purge time, or delay time between laser shut-off and purge turn-on.
17. The apparatus of claim 16, wherein the detected emissions from the rock indicates that the rock is not spalling when the emissions have a varying intensity with respect to time below a threshold value.
18. The apparatus of claim 14, wherein the controller is configured to maintain the power of the laser when the emissions detected from the rock indicate that the rock is spalling.
19. The apparatus of claim 14, wherein the controller is configured to determine that the rock is spalling when emission intensity detected has varying intensities with respect to time, the variations in intensities occurring with a frequency above a threshold value.
20. The apparatus of claim 14, further comprising a reflector configured to reflect a laser beam towards the rock and to reflect the emission from the rock to the detector.
21. The apparatus of claim 14, further comprising a dichroic reflector, the dichroic reflector configured to reflect a laser beam towards the rock and to transmit the light emitted from the rock to the detector.
22. The apparatus of claim 14, further wherein the detector comprises one of an optical spot detector, an optical line detector, or a two-dimensional array detector.
23. A well laser system for use in a subterranean well comprising:
- a laser apparatus configured to: produce a laser beam, and direct the laser beam towards a subterranean rock;
- an optical detector configured to detect light emitted from the rock; and
- a controller communicatively coupled to the optical detector, the controller configured to: receive a signal from the optical detector, determine from the signal whether the rock is responding as specified; and adjust a parameter of the laser if the rock is not responding as specified.
24. The system of claim 23, wherein the controller comprises a processor configured to receive signals from the optical detector and output instructions to the controller to adjust the power of the laser if the rock is not responding as specified.
25. The system of claim 23, wherein the controller is configured to automatically adjust the power of the laser when the light detected from the rock indicates that the rock is not spalling.
26. The system of claim 25, wherein the controller determines that the rock is not spalling when no sparks are detected by the optical detector.
27. The system of claim 26, wherein the controller further determines that the rock is dissociating when the light detected is a steady glow.
28. The system of claim 26, wherein the controller further determines that the rock is melting when the light detected is a steady glow.
29. The system of claim 23, wherein the controller is configured to maintain the power of the laser when sparks are detected by the optical detector.
30. The system of claim 23, wherein the laser apparatus further comprises a dichroic reflector, the dichroic reflector configured to reflect a laser beam towards the rock and to transmit the light emitted from the rock to the optical detector.
31. The system of claim 23, wherein the optical detector comprises a spot detector.
32. The system of claim 23, wherein the optical detector comprises a line detector.
33. The system of claim 23, wherein the optical detector comprises a two-dimensional detector array.
Type: Application
Filed: Dec 31, 2012
Publication Date: Jul 3, 2014
Applicant: Halliburton Energy Services, Inc. (Houston, TX)
Inventors: Neal Gregory Skinner (Lewisville, TX), Timothy Holiman Hunter (Duncan, OK), Colin John Hawthorn (Barrington, IL), Lloyd S. Wilkiel (Westchester, IL), James Louis (Chicago, IL)
Application Number: 13/731,743
International Classification: E21B 7/14 (20060101);