Downhole Laser Milling Head for Precise Casing Window Cutting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional mechanical methods for drilling and removing materials in subterranean wells are time-consuming and inaccurate, particularly when creating holes or windows in casing or dealing with stuck materials.

Innovation Solution

A laser system with a drilling head, scanner assembly, and cutter assembly, utilizing fiber optic cables to direct laser beams in various patterns for precise material removal, including circular, longitudinal, and helical cutting, to efficiently cut and remove stuck materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical milling tools are used to create holes or windows in casing, then the casing can be cut through, but the process is time-consuming and inaccurate

Engineering Contradiction:

Improvecutting accuracyVSAvoidoperation time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces mechanical milling tools with a laser-based system. The laser drilling head directs a high-energy laser beam to drill through the casing, while the laser cutter assembly uses a laser to cut windows or holes. This substitution of mechanical energy with optical energy eliminates the time-consuming and inaccurate mechanical grinding process, providing precise and rapid material removal without physical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and parameters of the laser beam through various optical components. The laser scanner assembly moves the laser beam axially and rotates it around the central axis, while the cutter lens directs the beam in circumferential or helical patterns. By controlling parameters such as beam position, direction, and pattern, the system achieves precise cutting accuracy while maintaining high operational speed.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If mechanical milling tools are used to remove stuck materials in the wellbore, then the materials can be ground into smaller pieces, but the process is slow and labor-intensive

Engineering Contradiction:

Improvematerial removal rateVSAvoidoperation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces mechanical grinding tools with a laser-based drilling system. The laser drilling head directs a high-energy laser beam at the stuck material, rapidly vaporizing or melting it into small pieces that can be flushed out by fluid flow. This optical-based approach dramatically increases the material removal rate compared to slow mechanical grinding, reducing operation time while maintaining high productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If mechanical tools are used for drilling and completion operations, then materials can be removed, but the process lacks precision and reliability

Engineering Contradiction:

Improveoperation reliabilityVSAvoidcutting precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical drilling and cutting tools with a laser-based system that offers superior precision and reliability. The laser drilling head provides consistent, contactless drilling, while the laser cutter assembly with its scanner and lens systems delivers precise, controllable cuts. The optical-based system eliminates mechanical wear, friction, and variability, providing more reliable and precise operations compared to mechanical tools.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 laser system provides precise and reliable material removal, enabling efficient cutting of casing and stuck materials into small pieces that can be easily flushed out, improving the accuracy and speed of operations in subterranean well maintenance.

Implementation Method 1

laser head drilling to remove stuck material in the well bore

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

laser scanner assembly has a scanner head operable to direct a scanner laser beam and to move both axially along a length of the laser tool body and rotate around a central axis of the laser tool body

Methodology Applied

Scientific EffectLaser beam scanning: Laser

Implementation Method 3

laser cutter assembly has a cutter head operable to direct a cutter laser beam and to rotate around the central axis of the laser tool body

Methodology Applied

Scientific EffectLaser beam cutting: Laser

Data Source

PatentUS11821276B2Laser milling and removal tool and methods

Publication Date: 2023.11.21 SAUDI ARABIAN OIL CO

AI summary

Systems and methods for cutting objects within a subterranean well include a laser system having a laser drilling head located at a terminal downhole end of a laser tool body directing a head laser beam in a direction downhole. A laser scanner assembly located within the laser tool body has a scanner head directing a scanner laser beam and can move both axially along a length of the laser tool body and rotate around a central axis of the laser tool body. A laser cutter assembly located within the laser tool body has a cutter head directing a cutter laser beam and can rotate around the central axis of the laser tool body. A cable bundle formed of a plurality of fiber optic cables extends from an uphole end of the laser tool body to each of the laser drilling head, the laser scanner assembly, and the laser cutter assembly.