Downhole Laser Beam Combining for Low-Loss Deep Perforation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing downhole laser tooling is ineffective at delivering high power laser energy at depth due to significant energy loss and heat generation, which can damage transmission equipment.
Innovation Solution
A downhole assembly that utilizes a system of optical pathways, reflectors, and reshaping lenses to combine low-power laser beams into a high-power main beam, minimizing energy loss and heat generation by redirecting beams radially outward and then axially, using a main beam optical assembly to enhance power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high power laser energy is transmitted through optical pathways to downhole depth, then the laser power delivery capability is improved, but energy loss increases significantly (up to 60% power loss at 10,000 feet)
Solution Approach 1:
The patent divides a single high-power laser transmission into multiple lower-power parallel transmissions through separate optical pathways (e.g., multiple fiber optic cables). Each pathway carries a portion of the total energy, reducing the power level in each individual transmission channel and thereby minimizing energy loss and heat generation in each pathway while maintaining the capability to deliver high total power when combined at the downhole assembly.
Solution Approach 2:
The patent combines multiple lower-power laser beams from separate optical pathways into a single high-power main beam at the downhole assembly using beam combining optics. This merging process occurs after the individual beams have traveled through the optical pathways with reduced energy loss, allowing the system to achieve high power delivery at depth while avoiding the energy loss and heat generation problems associated with transmitting a single high-power beam through the same pathways.
2Power
If high power laser energy is transmitted to downhole depth, then the laser power delivery capability is improved, but heat generation increases significantly, potentially damaging transmission equipment
Solution Approach 1:
The patent segments the high-power laser transmission into multiple parallel lower-power beams transmitted through separate optical pathways. By distributing the total power across multiple channels, the heat generation in each individual pathway is reduced proportionally, preventing the excessive heat accumulation that would occur in a single high-power pathway and protecting the transmission equipment from thermal damage.
Solution Approach 2:
The patent merges multiple low-heat-generation laser beams at the downhole assembly into a single high-power beam for the actual perforation or drilling operation. The beam combining optics integrate the multiple lower-temperature beams into one high-power beam only at the point where the energy is needed, ensuring that the transmission pathways remain cool while the operational beam achieves the necessary power level.
3Loss of energy
If multiple optical pathways are used to reduce energy loss, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The patent designs the downhole assembly with universal beam combining optics that can integrate multiple optical pathways into a single output beam. This multi-functional optical system serves both as a beam combiner and as the primary laser source for perforation operations, eliminating the need for separate high-power laser sources at downhole depth and simplifying the overall system architecture despite the presence of multiple transmission pathways.
Solution Approach 2:
The patent introduces beam combining optics as an intermediary component at the downhole assembly that mediates between the multiple incoming optical pathways and the final high-power beam output. This intermediary device efficiently merges the multiple lower-power beams into one high-power beam, managing the complexity of multiple pathways by providing a unified interface for energy delivery to the formation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system efficiently delivers high-power laser energy to the downhole environment with reduced energy loss and heat generation, enabling effective perforation and drilling operations.
Implementation Method 1
a first reflector and a second reflector each movable between an activated position and a deactivated position, the first and second reflectors being arranged to reflect the first and second energy beams, respectively, radially outward and away from the tool axis when in the activated position
Implementation Method 2
a first reshaping lens and a second reshaping lens each arranged within the interior space, the first and second reshaping lenses being arranged to receive and redirect the first and second energy beams, respectively, when the first and second reflectors are in the deactivated position
Implementation Method 3
a main beam optical assembly operable to combine the first and second energy beams received from the first and second reshaping lenses into a combined energy beam that is directed along the tool axis when the first and second reflectors are in the deactivated position
Data Source
AI summary
A system includes a laser generating source, a downhole assembly, and a plurality of optical pathways extending between the laser generating source and the downhole assembly. The downhole assembly includes a tool housing, a plurality of reflectors, a plurality of reshaping lenses, and a main beam optical assembly. The reflectors are each movable between an activated position and a deactivated position, and are arranged to reflect energy beams radially outward away from the tool housing when in the activated position. The reshaping lenses are arranged to receive and redirect the energy beams when the reflectors are in the deactivated position. The main beam optical assembly is operable to combine the energy beams received from the reshaping lenses into a combined energy beam that is axially directed when the reflectors are in the deactivated position.