Wellbore drilling and completion system using laser head

Abstract

A wellbore drilling and completion system using a laser head implements a method of completing a wellbore. A wellbore drill bit is rotated through the subterranean region to form a wellbore. Rotating the wellbore drill bit through the subterranean region causes portions of the subterranean region to be released into the wellbore as cuttings. A laser head attached to the wellbore drill bit emits a laser beam that is incident on a portion of the drill cuttings. The laser beam heats the portion of the drill cuttings to consolidate and form a casing of the wellbore.

Description

[0001] Priority claim

[0002] This application claims priority to U.S. Patent Application No. 17 / 845,287, filed on June 21, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates to forming and completing a wellbore. Background Art

[0004] The hydrocarbons trapped in the underground reservoir can rise to the surface of the earth (i.e., production) through a wellbore formed from the surface to the underground reservoir. A wellbore drilling system is used to drill a wellbore through an underground area (e.g., a formation, a portion of a formation, or multiple formations) to an underground reservoir. At a higher level, the wellbore drilling system includes a drill bit connected to the end of a drill string. The drill string is rotated and weight is applied to the drill bit to drill through the underground area. A wellbore drilling fluid (also called drilling mud) flows through the drill string in a downhole direction along the wellbore. The drilling fluid leaves the drill bit through a port defined in the drill bit and flows in an uphole direction along the wellbore through an annulus defined by the outer surface of the drill string and the inner wall of the wellbore. As the drilling fluid flows to the surface, it carries any drill cuttings and debris released into the wellbore during the drilling process as the drilling is performed. When penetrating the underground area, the drill cuttings and debris are released from the underground area as the drill bit breaks the rock. When mixed with the drilling fluid, the cuttings and debris form a solid slurry that flows to the surface. At the surface, the cuttings and debris are filtered and the wellbore drilling fluid can be recirculated into the wellbore to continue drilling. The cuttings and debris carried to the surface by the drilling fluid provide useful information about the wellbore being formed and the drilling process, among other information. When the wellbore is formed, sections of the wellbore are cased by lowering and installing a pipe into the wellbore. Summary of the invention

[0005] This specification describes technologies related to wellbore drilling and completion systems using laser heads.

[0006] Certain aspects of the subject matter described herein can be implemented as a method of completing a wellbore. A wellbore drill bit is rotated through a subterranean region to form a wellbore. The wellbore drill bit is rotated through the subterranean region such that a portion of the subterranean region is released into the wellbore as drill cuttings. A laser head attached to the wellbore drill bit emits a laser beam that is incident on a portion of the drill cuttings. The laser beam heats the portion of the drill cuttings to consolidate and form a casing of the wellbore.

[0007] Aspects combinable with any other aspect include the following features: Rotating the laser head with the wellbore drill bit while rotating the wellbore drill bit through the subterranean zone Rotating the laser head heats the portion of the drill cuttings along an inner circumference of the wellbore.

[0008] Aspects combinable with any other aspect include the following features: emitting the laser beam at the portion of the drill cuttings such that the laser beam pushes the portion of the drill cuttings toward an inner wall of the wellbore before the laser beam heats the portion of the drill cuttings to consolidate and form the casing of the wellbore.

[0009] Aspects that may be combined with any other aspect include the following features: A nozzle is positioned near the wellbore drill bit. A filling material is discharged through the nozzle. The filling material is to be heated and consolidated by the laser beam together with the portion of the drill cuttings to form a casing of the wellbore.

[0010] Aspects that may be combined with any of the other aspects include the following features: Flowing the fill material from the surface of the wellbore to the nozzle.

[0011] Aspects that may be combined with any other aspect include the following features. To emit the laser beam, a fiber optic cable is guided from the surface of the wellbore to the laser head. The laser beam is transmitted from the surface via the fiber optic cable.

[0012] Aspects that may be combined with any other aspect include the following features: The fiber optic cable is rotated together with the wellbore drill bit and the laser head.

[0013] Aspects combinable with any of the other aspects include the following features: The laser head is mounted to be located upward along the wellbore relative to the wellbore drill bit.

[0014] Aspects combinable with any other aspect include the following features: A separator member is mounted between the laser head and the wellbore drill bit. The separator member directs the drill cuttings toward a path of the laser beam.

[0015] Certain aspects of the subject matter described herein can be implemented as a wellbore completion apparatus including a wellbore drill bit and a laser head. The wellbore drill bit is configured to rotate and drill through a subterranean region to form a wellbore. While rotating and drilling through the subterranean region, the wellbore drill bit is configured to release a portion of the subterranean region into the wellbore as drill cuttings. The laser head is attached to the wellbore drill bit. The laser head is configured to emit a laser beam that, when incident on a portion of the drill cuttings, heats the portion of the drill cuttings to consolidate and form a casing of the wellbore.

[0016] Aspects combinable with any other aspect include the following features: The laser head is configured to rotate with the wellbore drill bit to heat drill cuttings along an inner circumference of the wellbore.

[0017] Aspects combinable with any other aspect include the following features: The laser head is configured to emit the laser beam to push the portion of the drill cuttings toward an inner wall of the wellbore before the portion of the drill cuttings is heated to consolidate and form a casing of the wellbore.

[0018] Aspects combinable with any other aspect include the following features: A plurality of nozzles are mounted to the laser head. The plurality of nozzles are configured to flow a fill material to be heated and consolidated by the laser beam together with the portion of the drill cuttings to form a casing of the wellbore.

[0019] Aspects combinable with any other aspect include the following features: The completion device includes a flow path from the surface of the wellbore to the plurality of nozzles. The flow path is configured to flow the fill material from the surface of the wellbore.

[0020] Aspects combinable with any other aspect include the following features: The completion device includes a plurality of fiber optic cables, each extending from the surface of the wellbore to the laser head, and each fiber optic cable is configured to transmit the laser beam from the surface of the wellbore.

[0021] Aspects combinable with any of the other aspects include the following features: The laser head is mounted to be located upward along the wellbore relative to the wellbore drill bit.

[0022] Aspects combinable with any other aspect include the following features: The completion device includes a separator member mounted between the laser head and the wellbore drill bit. The separator member is configured to direct the drill cuttings toward a path of the laser beam.

[0023] Aspects combinable with any other aspect include the following features: The separator member includes an adjustable arm and a curved plate, each of the adjustable arm and the curved plate being adjustable to direct the drill cuttings toward the path of the laser beam.

[0024] Certain aspects of the subject matter described herein can be implemented as a method of completing a wellbore. A wellbore drilling assembly rotates a wellbore drill bit through a subterranean region to form a wellbore. Rotating the wellbore drill bit through the subterranean region causes portions of the subterranean region to be released into the wellbore as drill cuttings. A laser head is attached to the wellbore drill bit. The laser head is configured to emit a laser beam. The laser beam emitted from the laser head pushes the drill cuttings toward an inner wall of the wellbore. The laser beam emitted from the laser head heats the drill cuttings pushed to the inner wall of the wellbore. The heating causes the drill cuttings to melt and form a casing on the inner wall of the wellbore.

[0025] The details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a schematic diagram of an example of a wellbore completion apparatus having a laser head based wellbore drilling and completion system.

[0027] Figure 2 is a schematic diagram of an example of a wellbore completion device in combination with a wellbore drill bit and a laser head.

[0028] Figure 3 It is used to transmit the laser beam to Figure 2 Schematic diagram of an example of a fiber optic feed portion of a wellbore completion device.

[0029] Figure 4 is a flow chart of an example of a process for completing a wellbore using a laser head based wellbore drilling and completion system.

[0030] Figure 5 is a schematic diagram of an example of a wellbore completion device that emits two laser beams.

[0031] Figure 6 Is Figure 5 Schematic diagram of an example of a laser beam with an annular profile emitted by a wellbore completion device.

[0032] Figure 7 Yes Operation Figure 5 An example workflow of a wellbore completion process.

[0033] Figure 8 is a flow chart of an example of a process for completing a wellbore with a laser head emitting two laser beams.

[0034] Like reference numbers and designations in the various drawings represent like elements. DETAILED DESCRIPTION

[0035] Drilling operations for oil and gas use drilling equipment to drill the wellbore, mud tanks to circulate the wellbore drilling fluid (also called wellbore drilling mud or mud), and casing to install the wellbore. Casing is used to maintain wellbore stability and prevent collapse and sand production. When drilling a wellbore, a large casing (which is called a conductor casing) is first installed. Then, cement is pumped between the casing and the formation to form a cased wellbore. Then, drilling continues deeper, stops, and an intermediate casing is installed. Again, cement is pumped between the formation and the cement, and between the conductor casing and the intermediate casing to cement the well. Another casing (which is the smallest casing) is installed between the intermediate casing and the production casing with cement. The casing aspect of conventional drilling operations can be time-consuming and resource-intensive. In order to perform casing operations, multiple casings as well as cement and mud are stored at the well site, occupying a large surface area.

[0036] The present disclosure describes the use of high-power laser technology in conventional drilling operations to make casing while drilling. In some aspects, mechanical and rotary drilling is used to drill a wellbore through a subterranean area, and a laser beam emitted from a laser head attached to a wellbore drill bit is used to consolidate drill cuttings to form a casing on the inner wall of the wellbore. In some aspects, a first laser beam is used to drill (or form) the wellbore in a downward direction of the wellbore, and a second laser beam is used to consolidate the drill cuttings to form a casing on the inner wall of the wellbore. In some aspects, the laser beam applies a force to the drill cuttings to push the drill cuttings toward the inner wall of the wellbore. In some aspects, an acoustic signal transmitted from an acoustic source applies a force to the drill cuttings to push the drill cuttings toward the inner wall of the wellbore. Other aspects will be described below.

[0037] The use of high-power lasers to perform casing manufacturing (casing) while drilling, whether used alone or in combination with mechanical rotary drilling, will eliminate the need for a large investment in casing materials, cement, and the time used for casing manufacturing. The technology described in this article applies high-power lasers, which are attractive to the oil and gas industry due to the unique properties of lasers (such as precision, reliability, control, and cost). For example, the technology described in this disclosure uses the ability of lasers to quickly raise the temperature of rocks and sands (such as sandstone) to up to 2000°C in three seconds. In addition, the technology described in this article can reduce the equipment footprint required to form a wellbore by eliminating the need for drilling equipment with a large footprint and using relatively small footprint equipment (such as laser generators and coolers) that can be installed on coiled tubing units and trailers. The laser is a versatile tool that can be used to perform a variety of operations. The same laser energy source can be used from drilling to production wells by simply changing the tool. Such capabilities play an important role in achieving net zero goals.

[0038] Figure 11 is a schematic diagram of a wellbore completion 100 having a laser head based wellbore drilling and completion system 102. A wellbore 104 may extend from a surface 106 through the earth to one or more subsurface areas of interest 108. The wellbore completion 100 includes a surface unit 110 positioned above the surface 106 for lowering the wellbore completion 100 through the wellbore 104 and controlling the operation of the wellbore drilling and completion system 102, as described below. The surface unit 110 may include a laser source (shown later) and may lower a fiber optic cable 112 connected to the laser source. The wellbore completion 100 includes additional components such as a wellhead, a drill string assembly supported by a drilling equipment structure, and a fluid circulation system for filtering used drilling fluid from the wellbore and providing clean drilling fluid to the drill string assembly (not shown).

[0039] As described below, in some embodiments, the wellbore completion device 100 can form a wellbore with a combination of a conventional wellbore drilling assembly including a wellbore drill bit and a laser beam. In some embodiments, the wellbore completion device 100 can form a wellbore with a combination of two laser beams emitted by the same laser source or respective laser sources. In all embodiments described in the present disclosure, the laser beam is used to melt and consolidate the drill cuttings to the inner wall of the wellbore 104 to form a casing. The interaction between the laser beam and the drill cuttings causes the drill cuttings to undergo a phase change due to the increase in temperature. Different temperature levels at which the laser increases the temperature of the drill cuttings will have different effects on the drill cuttings themselves. The laser source can be selected based on the ability of the laser beam to increase the temperature of the drill cuttings to two different temperature levels. In turn, different temperature levels can be selected based on the rock type of the underground area where the wellbore 104 being drilled is located. For example, sandstone melts at around 1400°C, while limestone decomposes at around 1100°C. Subsurface rocks exfoliate (ie, break into small fragments) at about 400° C., and clay collapses in a temperature range between 300° C. and 570° C. The laser beam emitted by the laser source may be adjusted to provide a power that allows the temperature to reach the melting point of the drill cuttings.

[0040] Figure 2 1 is a schematic diagram of a wellbore completion device 201 in combination with a wellbore drill bit 202 and a laser head 204, both of which are mounted to the end of a drill string 206, which is configured to rotate and drill through a subterranean region to form a wellbore 104. While rotating and drilling through the subterranean region, the wellbore drill bit 202 releases portions of the subterranean region into the wellbore 104 as drill cuttings 208. Figure 2As shown, laser head 204 is attached to wellbore drill bit 202. Laser head 204 can emit laser beam 210. When laser beam 210 is incident on a portion of drill cuttings 208, laser beam 210 heats the portion of drill cuttings 208 to consolidate and form casing 212 of wellbore 104.

[0041] In some embodiments, the laser head 204 is configured to rotate with the wellbore drill bit 202 to heat the drill cuttings 208 along the inner circumference of the wellbore 104. That is, the laser beam 210 emitted by the laser head 204 heats all drill cuttings 208 encountered by the laser beam 210 from the laser head 204 to the inner wall of the wellbore 104. Because the laser head 204 rotates, the laser beam 210 follows a generally circular path that defines the inner circumference of the wellbore 104. All drill cuttings 208 that the laser beam 210 contacts while following the generally circular path will be heated. In addition to heating the drill cuttings 208, the laser beam 210 also pushes the drill cuttings 208 toward the inner wall of the wellbore 104. When the drill cuttings 208 are pushed to the inner wall of the wellbore 104 and heated, the drill cuttings 208 melt and consolidate, and after cooling, solidify to form a casing 212 on the inner wall of the wellbore 104.

[0042] One end of the fiber optic cable 112 is connected to a laser head 204 and the other end is connected to a laser source 200 positioned on the surface 106. In some embodiments, the laser source 200 can be positioned within the surface unit 110. In some embodiments, the laser source 200 emits an ytterbium fiber laser or other type of high power laser beam with sufficient power to heat and melt the drill cuttings 208. The wellbore completion device 201 includes a fiber optic feed through which the fiber optic cable 112 extends from the laser source 200 to the laser head 204.

[0043] Figure 3 300 is a schematic diagram of an example of a fiber optic feed 300. In some embodiments, the fiber optic feed 300 is connected to a laser head 204, which is configured to rotate with a wellbore drill bit. The laser head 204 includes a rotating member 302, which is configured to be mounted to a drill string 206 and rotate with the drill string 206 ( Figure 1 ) rotates together. The laser head 204 also includes a laser head mounted to the drill string 206 ( Figure 2 ) of the annular member 304. The annular member 304 and the rotating member 302 are configured to be connected to the drill string 206 ( Figure 2 ) rotates together. The fiber optic cable 112 extends from the surface 106 to the fiber feed 300, specifically through the rotating member 302, and to the annular member 304. In some embodiments, a second fiber optic cable 306 (or more fiber optic cables) can be routed from the surface 106 to the laser head 204.

[0044] In some embodiments, the annular member 304 defines one or more openings 308 through which the laser beam 210 transmitted by the fiber optic cable 112 exits the annular member 304 to be emitted into the wellbore 104 ( Figure 1 ) in the wellbore 104. The annular member 304 may include optical components (e.g., lenses, mirrors, similar optical components) to change the path of the laser beam 210 from an axial direction relative to the longitudinal axis of the wellbore 104 (and additionally, focus or collimate or otherwise manipulate) to a radial direction relative to the longitudinal axis. The fiber feed 300 is coupled to the drill string 206 ( Figure 2 ) in combination with the emission of the laser beam 210 through the opening 308 produces a radial laser beam that is incident on drill cuttings released from the subterranean region as the wellbore drill bit drills through the subterranean region.

[0045] The ability to melt and consolidate drill cuttings to form a casing for the wellbore 104 depends in part on the type of rock in the subterranean region. For example, rocks containing quartz may form casing when drilling. On the other hand, in some embodiments, certain other types of rock (e.g., carbonates with low quartz content) may be combined with the fill material 214 to form a casing, as described in reference to FIG. Figure 2 As described.

[0046] like Figure 2 and Figure 3 As shown, in some embodiments, the annular member 304 ( Figure 3 ) may define a plurality of nozzles 310 configured to flow a fill material 214 into the wellbore 104. The fill material 214 may include any combination of sand, iron powder, other minerals, or materials that, when heated and melted with the drill cuttings, form a solid casing after cooling and solidification. In some embodiments, the fill material 214 is pumped from the surface into the wellbore 104, for example, through the flow path 218. In some embodiments, the fill material 214 is stored in a storage container 216 attached to the drill string 206 and lowered into the wellbore 104. In some embodiments, the fill material 214 may be pumped through the flow path 218 to reach the storage container 216. During operation, the fill material 214 may flow into the wellbore 104 through the nozzles 310. The fill material 214 mixes with the drill cuttings 208, and the resulting mixture is pushed toward the inner wall of the wellbore 104 by the laser beam 210. The laser beam 210 heats the mixture, which solidifies to form a casing 212 for the wellbore 104 .

[0047] like Figure 2As shown, the laser head 204 is mounted uphole relative to the wellbore drill bit 202. In some embodiments, a separator member 220 (e.g., a separator packer) is mounted between the laser head 204 and the wellbore drill bit 202. The separator member 220 is configured to direct the drill cuttings 208 toward the path of the laser beam 210. To this end, the separator member includes an adjustable arm 222 and a bending plate 224. One end of the adjustable arm 222 is attached to the separator member 220, and the separator member 220 is positioned downhole relative to the nozzle 310 through which the filling material 214 flows into the wellbore 104. In addition, the adjustable arm 222 is positioned uphole relative to the drill bit 202. The other end of the adjustable arm 222 is attached to the center of the bending plate 224 in an articulated manner, and the articulated manner allows the bending plate to pivot around the adjustable arm 222. The curved plate 224 has a curvature. During operation, when drill cuttings 208 are released near the drill bit 202, the position of the adjustable arm 222 is adjusted to orient the curved plate 24 to receive a portion of the drill cuttings 208 and direct the received portion toward the laser beam 210. The adjustable arm 222 can be controlled from the surface. For example, a camera or other sensor downhole can be used to view and sense the strength of the rock separated from the underground area. Based on the sensed input, the adjustable arm can be moved to control the volume of drill cuttings directed toward the laser beam.

[0048] Figure 4 Flowchart of an example of a process 400 for completing a wellbore using a laser head-based wellbore drilling and completion system. At 402, a wellbore drill bit (e.g., wellbore drill bit 202) is rotated through a subterranean region to form a wellbore (e.g., wellbore 104). Rotating the wellbore drill bit through the subterranean region causes a portion of the subterranean region to be released into the wellbore as drill cuttings (e.g., drill cuttings 208). At 404, a portion of the drill cuttings is pushed toward an inner wall of the wellbore using a laser beam (e.g., laser beam 210). At 408, the portion of the drill cuttings is heated using the laser beam, thereby causing the portion of the drill cuttings to consolidate and form a casing on the inner wall of the wellbore.

[0049] As described above, the hybrid drill bit (i.e., the wellbore drill bit 202 with the laser head 204) will have the fiber optic cable 112 during rotary drilling through the underground area. As the wellbore drill bit 202 rotates and removes material from the underground area to form drill cuttings 208, the laser beam 210 is turned on to emit a controlled beam that travels along the inner circumference of the wellbore. In some embodiments, a wellbore drilling fluid is also circulated. The wellbore drilling fluid can be a special optical fluid (e.g., a halogenated hydrocarbon or similar fluid) that allows the laser beam 210 to travel through while also carrying the drill cuttings 208 to the surface 106. The separator member 220 directs a portion of the drill cuttings 208 toward the laser beam 210, which pushes the drill cuttings 208 toward the inner wall of the wellbore 104, while heating and melting the drill cuttings 208 to form a casing on the inner wall of the wellbore 104. To push the drill cuttings 208 toward the inner wall of the wellbore 104, the laser head 204 may include a purge nozzle that can flow a gas or fluid to push the drill cuttings 208 toward the wall of the wellbore 104. In some embodiments, the laser head 204 may also include a cooling nozzle (not shown) that can flow a coolant (e.g., a gas or fluid) to cool the heated drill cuttings or fill material or both to aid consolidation and solidification. The wellbore drill bit 202 continues to be lowered into the underground area as the wellbore 104 becomes deeper. The mud flows any drill cuttings 208 that are not consolidated to the surface 106 of the wellbore 104.

[0050] Figure 5 is a schematic diagram of an example of a wellbore completion apparatus 500 that emits two laser beams. Wellbore completion apparatus 500 is a wellbore drilling assembly configured to form a wellbore 502 (similar to wellbore 104) through a subsurface region 504. The wellbore drilling assembly includes a laser head 506 that can generate two laser beams—a first laser beam 508 that is emitted in a downward direction within the wellbore 502; and a second laser beam 510 that is emitted in a radial direction within the wellbore 502. The first laser beam 508 causes a portion of the subsurface region 504 to be released into the wellbore 502 as drill cuttings (similar to drill cuttings 208). The second laser beam 510, when incident on a portion of the drill cuttings, generates a laser beam similar to reference 502. Figure 2-4 In the manner described, this portion of the drill cuttings is consolidated and forms the casing of the wellbore 502.

[0051] In operation, the wellbore completion apparatus 500 is rotated within the wellbore 502 while being lowered within the wellbore 502 in a downward direction along the wellbore. The first laser beam 508 heats rock in the subsurface region 504 to a temperature that causes the rock to flake off and be released from the subsurface region 504 as drill cuttings. In some embodiments, the first laser beam 508 has a conical profile, wherein the diameter of the bottom of the conical profile is at least as large as the inner diameter of the wellbore 502 formed through the subsurface region 504. Wellbore drilling mud or other fluid may flow through the wellbore 502 while the first laser beam 508 heats and flakes rock in the subsurface region 504. The second laser beam 510 is incident on the drill cuttings as the wellbore drilling mud carries the drill cuttings along an upward direction along the wellbore toward the surface of the wellbore 502. As shown in FIG. Figure 6 As shown, the second laser beam 510 may have an annular profile to push drill cuttings toward the inner wall of the wellbore 502 and heat and consolidate the drill cuttings on the inner wall of the wellbore 502 to form a casing 516 of the wellbore 502 .

[0052] In some embodiments, the laser head 506 is configured to rotate with the wellbore drill bit 202 to heat the drill cuttings 208 along the inner circumference of the wellbore 104. That is, the laser beam 210 emitted by the laser head 204 heats all drill cuttings 208 encountered by the laser beam 210 from the laser head 204 to the inner wall of the wellbore 104. Because the laser head 204 rotates, the laser beam 210 follows a generally circular path that defines the inner circumference of the wellbore 104. All drill cuttings 208 that the laser beam 210 contacts while following the generally circular path will be heated. In addition to heating the drill cuttings 208, the laser beam 210 also pushes the drill cuttings 2082 toward the inner wall of the wellbore 104. When the drill cuttings 208 are pushed to the inner wall of the wellbore 104 and heated, the drill cuttings 208 melt and solidify to form a casing 212 on the inner wall of the wellbore 104.

[0053] Figure 6 Is Figure 5 Schematic diagram of an example of a laser beam 510 with an annular profile emitted by a wellbore completion device. Figure 2), the wellbore completion device 500 may include a laser source (not shown) positioned at the surface of the wellbore 502. One end of the fiber optic cable 600 is connected to the laser head 506 and the other end is connected to the laser source positioned on the surface of the wellbore 502. The laser source emits an ytterbium fiber laser or other type of high-power laser beam 604 with sufficient power to heat and melt drill cuttings. The wellbore completion device 500 includes a fiber optic feed through which the fiber optic cable 602 extends from the laser source to the laser head 506. In some embodiments, the fiber optic feed includes a casing or a thin plate through which the fiber optic cable 600 passes from the surface of the wellbore 502 to the laser head 506. Additionally, the fiber optic feed includes an optical component 602 (e.g., an optical cone, an optical reflector, an optical lens, a similar device, or any combination thereof) mounted on the laser head 506. The laser beam 604 exits the fiber optic cable 600 and enters the optical component 600, which both changes the direction of the laser beam 604 from axial along the longitudinal axis of the wellbore 502 to radial along the longitudinal axis and also transforms the profile of the laser beam 604 into the annular profile of the second laser beam 510. The drill cuttings that flow into the path of the annular profile of the second laser beam 510 are heated, melted, and consolidated to form the casing 516 of the wellbore 500.

[0054] return Figure 5 In some embodiments, the wellbore completion device 500 includes a sound source 512 mounted to the wellbore drilling assembly. The sound source 512 is configured to transmit an acoustic signal 514 to acoustically direct drill cuttings toward the inner wall of the wellbore 502. The sound source 512 can operate while the laser head 506 emits the first laser beam 508 and the second laser beam 510. For example, the sound source 512 can be mounted on the wellbore completion device 500 between the first laser beam 508 and the second laser beam 510. The sound source 512 can be arranged so that the acoustic signal 514 pushes the drill cuttings in an upward direction of the wellbore and in a radial direction, thereby forcing the drill cuttings to encounter the second laser beam 510. In some embodiments, the sound source 512 can be arranged so that the acoustic signal 514 pushes the drill cuttings only in the radial direction, and the force that pushes the drill cuttings in the upward direction of the wellbore is provided by the drilling mud flowing through the wellbore 502.

[0055] In some embodiments, wellbore completion assembly 500 may define a plurality of nozzles 518 (similar to nozzles 310 ( Figure 3 )), the plurality of nozzles 518 are configured to cause the filling material 520 (similar to the filling material 214 ( Figure 2)) into the wellbore 502. The fill material 520 may include any combination of sand, iron powder, other minerals, or materials that, when heated and melted with the drill cuttings, form a solid casing. In some embodiments, the fill material 520 is pumped from the surface into the wellbore 502, for example, by a flow path similar to the flow path 218 ( Figure 2 ) flow path. In some embodiments, the fill material 520 is stored in a similar storage container 216 ( Figure 2 ) and is lowered into the wellbore 502. During operation, the packing material 520 can flow into the wellbore 502 through the nozzle 518. The packing material 520 is mixed with the drill cuttings, and the resulting mixture is pushed toward the inner wall of the wellbore 502 by the laser beam 510. The laser beam 510 heats the mixture, which solidifies to form the casing 516 of the wellbore 502.

[0056] Figure 7 Yes Operation Figure 5 1 and 2. An exemplary workflow of a process of completing a wellbore completion apparatus of the present invention is provided. At 702, a wellbore tool including a wellbore completion apparatus 500 is lowered into a wellbore 502. The objective of the wellbore tool is to drill and casing a subterranean region 504. At 704, a first laser beam 508 is turned on. The conical shape of the first laser beam 508 covers and exfoliates the rock in the subterranean region 504, thereby releasing rock fragments as drill cuttings. The power of the first laser beam 508 can be adjusted to provide sufficient power to raise the temperature of the rock above the rock melting temperature to achieve drilling by sublimation. At 706, circulation of a wellbore drilling mud is turned on. In some embodiments, an optical fluid (e.g., a halogenated hydrocarbon fluid) can be used in a manner similar to that previously described in lieu of or in addition to the wellbore drilling mud.

[0057] At 708, the nozzle 518 is turned on to inject the filling material 520 into the wellbore 504. In order to push the drill cuttings toward the inner wall of the wellbore 502, the laser head 506 may include a purge nozzle that can flow a gas or fluid to push the drill cuttings toward the wall of the wellbore 502. In some embodiments, the laser head 506 may also include a cooling nozzle (not shown) that can flow a coolant (e.g., a gas or fluid) to cool the heated drill cuttings or the filling material or both to aid consolidation and solidification. At 710, the sound source 512 is turned on to emit the sound waves 514 to direct the drill cuttings and filling material 520 toward the inner wall of the wellbore 502. At 712, the second laser beam 510 is turned on. As previously described, the second laser beam 510 has an annular profile that is incident on the drill cuttings and filling material that have been directed toward the inner wall of the wellbore 502 by the sound waves 514. The second laser beam 510 heats the drill cuttings and filler material to melt, consolidate, and solidify the mixture to form a casing on the inner wall of the wellbore 502. At 714, the laser drilling described in steps 702 to 712 continues as the wellbore completion 500 is lowered into the wellbore 500 and as the wellbore 502 is formed. At 716, the injection of filler material 520 continues as the wellbore is drilled to form the casing. As the wellbore 502 becomes deeper, the wellbore completion 500 continues to be lowered into the underground zone 504. The mud causes any unconsolidated drill cuttings to flow to the surface of the wellbore 502.

[0058] Figure 8 800 is a flow chart of an example of a process 800 for completing a wellbore using a laser head that emits two laser beams. At 802, the laser head emits a first laser beam. The laser head is mounted to a wellbore drilling assembly positioned within a wellbore formed in a subterranean region. The first laser beam is emitted in the wellbore in a downward direction along the wellbore, thereby causing a portion of the subterranean region to be released into the wellbore as drill cuttings. At 804, the laser head emits a second laser beam. The second laser beam is emitted in a radial direction within the wellbore. The second laser beam is incident on a portion of the drill cuttings, causing the portion of the drill cuttings to consolidate and form a casing of the wellbore. At 806, while emitting the first laser beam and the second laser beam, the drill cuttings are acoustically directed toward an inner wall of the wellbore.

[0059] Thus, specific embodiments of the present subject matter have been described. Other embodiments are also within the scope of the following claims. In some cases, the actions described in the claims can be performed in a different order and still achieve the desired results. In addition, the processes described in the figures do not necessarily require the specific order or sequential order shown to achieve the desired results. In some embodiments, multitasking and parallel processing may be advantageous. In addition, the aspects described with reference to any figure or any embodiment can be combined with the aspects described using any other figure or any other embodiment.

Claims

1. A method for completing a wellbore, the method comprising: rotating a wellbore drill bit through a subterranean zone to form a wellbore, wherein rotating the wellbore drill bit through the subterranean zone causes portions of the subterranean zone to be released into the wellbore as drill cuttings; as well as A laser beam is emitted through a laser head attached to the wellbore drill bit, the laser beam being incident on a portion of the drill cuttings, wherein the laser beam heats the portion of the drill cuttings to consolidate and form a casing of the wellbore.

2. The method of claim 1 , further comprising rotating the laser head with the wellbore drill bit while rotating the wellbore drill bit through the subterranean zone, wherein rotating the laser head heats the portion of the drill cuttings along an inner circumference of the wellbore.

3. The method of claim 1 , wherein the laser beam is emitted onto the portion of the drill cuttings such that: the laser beam pushes the portion of the drill cuttings toward an inner wall of the wellbore before the laser beam heats the portion of the drill cuttings to consolidate and form the casing of the wellbore.

4. The method of claim 1 , further comprising discharging a packing material through a nozzle positioned adjacent to the wellbore drill bit, the packing material to be heated and consolidated by the laser beam along with the portion of the drill cuttings to form the casing of the wellbore.

5. The method of claim 4, further comprising flowing the fill material from the surface of the wellbore to the nozzle.

6. The method of claim 1 , wherein emitting the laser beam comprises: directing a fiber optic cable from the surface of the wellbore to the laser head; as well as The laser beam is transmitted from the surface via the fiber optic cable.

7. The method of claim 6, further comprising rotating the fiber optic cable with the wellbore drill bit and the laser head.

8. The method of claim 1, further comprising mounting the laser head upwardly along the wellbore relative to the wellbore drill bit.

9. The method according to claim 8, further comprising: installing a separator member between the laser head and the wellbore drill bit; as well as The drill cuttings are directed toward the path of the laser beam by the separator member.

10. The method of claim 9, wherein the separator member comprises an adjustable arm and a curved plate, wherein directing the drill cuttings toward the path of the laser beam through the separator member comprises adjusting a position of the adjustable arm or a position of the curved plate to direct the drill cuttings toward the path of the laser beam.

11. A wellbore completion device, comprising: a wellbore drill bit configured to rotate and drill through a subterranean zone to form a wellbore, wherein, while rotating and drilling through the subterranean zone, the wellbore drill bit is configured to release portions of the subterranean zone into the wellbore as drill cuttings; and A laser head is attached to the wellbore drill bit, the laser head being configured to emit a laser beam that, when incident on a portion of the drill cuttings, heats the portion of the drill cuttings to consolidate and form a casing of the wellbore.

12. The wellbore completion device of claim 11, wherein the laser head is configured to rotate with the wellbore drill bit to heat drill cuttings along an inner circumference of the wellbore.

13. The wellbore completion apparatus of claim 11, wherein the laser head is configured to emit the laser beam to push the portion of the drill cuttings toward an inner wall of the wellbore before the portion of the drill cuttings is heated to consolidate and form the casing of the wellbore.

14. The wellbore completion device of claim 11, further comprising a plurality of nozzles mounted to the laser head, wherein the plurality of nozzles are configured to flow a packing material to be heated and consolidated by the laser beam together with the portion of the drill cuttings to form the casing of the wellbore.

15. The wellbore completion apparatus of claim 14, further comprising a flow path from the surface of the wellbore to the plurality of nozzles, the flow path being configured to flow the fill material from the surface of the wellbore.

16. The wellbore completion apparatus of claim 11, further comprising a plurality of fiber optic cables, each fiber optic cable extending from the surface of the wellbore to the laser head, each fiber optic cable configured to transmit the laser beam from the surface of the wellbore.

17. The wellbore completion device of claim 11, wherein the laser head is mounted to be located upward along the wellbore relative to the wellbore drill bit.

18. The wellbore completion apparatus of claim 17, further comprising a separator member mounted between the laser head and the wellbore drill bit, the separator member being configured to direct the drill cuttings toward a path of the laser beam.

19. The wellbore completion apparatus of claim 18, wherein the separator member comprises an adjustable arm and a flex plate, each of which is adjustable to direct the drill cuttings toward the path of the laser beam.

20. A method of completing a wellbore, the method comprising: rotating a wellbore drill bit through a subterranean region to form a wellbore with a wellbore drilling assembly, wherein rotating the wellbore drill bit through the subterranean region causes portions of the subterranean region to be released into the wellbore as drill cuttings, wherein a laser head is attached to the wellbore drill bit, wherein the laser head is configured to emit a laser beam; pushing the drill cuttings toward the inner wall of the wellbore by the laser beam emitted from the laser head; as well as The drill cuttings pushed to the inner wall of the wellbore are heated by the laser beam emitted from the laser head, wherein the heating causes the drill cuttings to melt and form a casing on the inner wall of the wellbore.

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