Downhole Laser Scanner Tool for Precision Perforation
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Solution Overview
Problem
Conventional well stimulation methods, such as shaped charges and milling technology, lack precision and can cause deformation and sanding of formations, while existing laser technologies struggle with power loss at depth, leading to inefficient perforation processes.
Innovation Solution
A laser-based system using a fiber optic cable with a direction unit, compact scanner, and laser head that controls the shape and direction of a laser beam to create precise openings in formations by adjusting the rotation ratio of motorized mirrors, allowing for controlled perforation and alignment with stress directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If shaped charges are used for perforation, then effective penetration is achieved, but control is poor leading to compaction, deformation and sanding of the formation
Solution Approach 1:
The patent replaces mechanical perforation systems (shaped charges, bullet perforating) with a laser-based system. The laser beam is transmitted through a fiber optic cable downhole and focused onto the formation to create openings, eliminating the need for mechanical charges that cause uncontrolled penetration and formation damage.
Solution Approach 2:
The patent controls the laser beam parameters including power (500-2500W), focal length, and beam direction to precisely shape the perforation openings. The motorized scanner adjusts the beam angle and position to create controlled openings aligned with stress directions, transforming the uncontrolled mechanical penetration into a precisely controllable thermal process.
2Shape
If milling technology is used to cut casing for sidetrack, then casing cutting is achieved, but the process takes time and lacks accuracy
Solution Approach 1:
The patent replaces mechanical milling technology with laser-based cutting. The focused laser beam rapidly heats and removes material from the casing, creating openings for sidetracks much faster than mechanical milling while maintaining precision through electronic control of beam position and power.
Solution Approach 2:
The laser cutting process uses pulsed or intermittent laser application, allowing rapid heating and melting of the casing material followed by removal, creating efficient cutting action that is both fast and accurate compared to continuous mechanical milling.
3Power
If conventional laser technologies are used downhole, then laser perforation is attempted, but power loss and accuracy in creating controlled openings occur
Solution Approach 1:
The patent uses a fiber optic cable as an intermediary to transmit laser power from the surface to the downhole location. This allows the laser source to remain at the surface while delivering high power (500-2500W) accurately to the formation, overcoming the limitations of conventional laser systems that lose power and precision in downhole applications.
Solution Approach 2:
The patent replaces conventional mechanical or electrical laser transmission systems with an optical fiber-based laser delivery system. This substitution enables maintaining laser power and precision in the downhole environment by using the fiber optic cable as a guided light pathway, eliminating power loss and accuracy issues of previous approaches.
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
Enables robust and precise perforation with less power loss, creating openings that are resistant to collapse and aligned with formation stress, enhancing fluid communication between the formation and wellbore.
Implementation Method 1
sublimating the formation to produce the opening
Implementation Method 2
focusing the laser beam in the focusing lens to produce a focused laser
Implementation Method 3
collimating the focused beam in the collimating lens to produce a directed beam
Implementation Method 4
vacuuming the dust and vapor with the vacuum nozzle
Data Source
AI summary
A method to control the shape of an opening in a formation including the steps of emitting a laser beam from a fiber optic cable into a direction unit, focusing the laser beam in the focusing lens to produce a focused laser, collimating the focused beam in the collimating lens to produce a directed beam, directing the directed beam onto a motorized master, where the compact scanner further comprises a motorized slave, wherein the motorized master comprises a master mirror and a master motor, wherein the motorized slave comprises a slave mirror and a slave motor, operating the motorized master and the motorized slave to produce a controlled beam, where the controlled beam moves in a movement pattern, introducing the controlled beam to a laser head, sublimating the formation to produce the opening, and vacuuming the dust and vapor with the vacuum nozzle.