Hybrid Laser Milling Tool for Faster Well Casing Removal
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Solution Overview
Problem
Conventional milling tools for removing well casings face issues such as excessive friction leading to tool damage, dulling, and low penetration rates, making the process costly and inefficient.
Innovation Solution
A hybrid-milling tool combining a laser head and milling knives, where the laser creates a helical groove in the casing wall to weaken it before the knives cut through, enhancing penetration and tool longevity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional milling tools are used to remove well casing, then the milling process can be performed, but excessive friction causes tool damage and dulling, requiring frequent replacement
Solution Approach 1:
The patent combines laser technology with conventional milling tools to create a hybrid system. The laser head is integrated into the milling tool assembly, allowing simultaneous or sequential laser heating and mechanical milling. This merging of thermal and mechanical processes enables the laser to soften the casing material before milling, reducing friction and tool wear while maintaining high productivity
Solution Approach 2:
The patent changes the physical state of the casing material by applying laser energy to heat and soften it before mechanical removal. This parameter change (temperature increase) makes the otherwise hard and abrasive steel casing more ductile and easier to mill, thereby extending tool life and reducing frequent replacements
2Productivity
If conventional milling tools are used to cut through steel casing, then casing removal is achieved, but the rate of penetration is low, resulting in costly operations
Solution Approach 1:
The laser performs preliminary action by heating and softening the casing material before the milling knives engage. This pre-conditioning of the material reduces the energy required for mechanical cutting, increases the rate of penetration, and lowers overall operational costs by reducing the time and energy needed for each meter of casing removal
3Productivity
If high power laser is used to create helical groove in casing wall, then penetration rate increases, but device complexity increases due to integration of laser head and fiber optic cable
Solution Approach 1:
The fiber optic cable is nested within the milling tool assembly, running through the hollow interior of the tool body to reach the laser head. This nesting approach minimizes external complexity while delivering high power laser energy to the cutting point, allowing the hybrid tool to achieve high penetration rates without excessive structural complexity
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 hybrid approach eases the milling process, increases penetration rates, and extends the life of milling tools by first weakening the casing with a laser before cutting, reducing friction and tool wear.
Implementation Method 1
generating a laser beam from a laser power generator, directing the laser beam from the laser power generator, through a fiber optic cable, to the laser head of the hybrid-milling tool, and emitting the laser beam from the laser head at a first laser power
Implementation Method 2
The laser head may be rotated about a central axis of the hybrid-milling tool while the laser beam is emitted from the laser head to create a helical groove in the casing wall with the laser beam in the target section
Data Source
AI summary
A downhole tool includes a milling rotary body, a fiber optic cable extending through the milling rotary body, one or more milling knives extending outwardly from the milling rotary body at an end of the milling rotary body, and a laser head extending from the second end of the milling rotary body. The fiber optic cable is connected to the laser head, and the laser head is configured to rotate about a central axis of the milling rotary body.