Systems, tools and methods for high power laser surface decommissioning and downhole welding

A high power laser tool comprising:

• a. a first assembly, and a second assembly;
• b. a spar having a length, the spar mechanically and rotationally associating the second assembly and the first assembly;
• c. the second assembly comprising a housing, the housing comprising an optics assembly and a laser beam exit port;
• the optics assembly comprising a lens and a beam path angle changing optical member, whereby the optics assembly provides for a laser beam path through the lens, making a bend at the beam path angle changing optical member, and exiting the housing through the laser beam exit port;
• and,
• d. the high power optical fiber located within the spar.

A high power laser tool comprising:

• a. a first assembly, and a second assembly;
• b. a spar having a length, the spar mechanically and rotationally associating the second assembly and the first assembly;
• c. the second assembly comprising a housing, the housing comprising an optics assembly and a laser beam exit port;
• the optics assembly comprising a lens and a beam path angle changing optical member, whereby the optics assembly provides for a laser beam path through the lens, making a bend at the beam path angle changing optical member, and exiting the housing through the laser beam exit port;
• and,
• d. a laser beam isolation means, wherein the tool has equal to or lower than a Class I accessible emission limit.

A high power laser system having a high power laser tool for deployment in a structure to be cut, the system comprising:

• a. a high power laser field unit comprising a high power laser and a laser umbilical, the laser umbilical comprising a high power laser optical fiber, the high power laser optical fiber having a distal end, a proximal end, and defining a length there between, the proximal end of the optical fiber in optical communication with the high power laser;
• b. the distal end of the optical fiber in optical communication with a high power laser tool;
• c. the high power laser tool comprising:
• i. an upper section, and a lower section;
• ii. a spar having a length, the spar mechanically and rotationally associating the upper section and the lower section, whereby the lower section is rotatable with respect to the upper section;
• iii. the lower section in optical association with the optical fiber, the lower section comprising a housing, the housing comprising a laser beam exit port and a laser beam path, wherein the laser beam path exits the housing through the laser beam exit port;
• and,
• d. a means to provide optical shielding, wherein the tool has equal to or lower than a Class I accessible emission limit.

A Class I high power laser tool for surface and near surface deployment in a tubular to be cut, the tool comprising:

• a. a first assembly, and a second assembly;
• b. a spar having a length, the spar mechanically associating the second assembly and the first assembly, whereby the second assembly is located about the length of the spar from the first assembly;
• c. the second assembly comprising a housing, the housing comprising an optics assembly in optical communication with a high power optical fiber and a laser beam exit port, wherein the optics assembly defines a laser beam path exiting the housing through the laser beam exit port;
• and,
• d. the first assembly comprising a means for shielding the laser beam path, whereby the tool has equal to or lower than a Class I accessible emission limit.

A high power laser decommissioning tool for performing a laser decommissioning operation on a structure, the tool comprising:

• a. an upper section, comprising a base plate;
• a middle section, comprising a spar having a length of at least about 5 feet;
• and a lower section, comprising a laser cutter;
• whereby the middle section connects the upper and lower sections;
• b. a rotational assembly, comprising a motor and a transfer assembly;
• c. the rotational assembly mounted on the base plate and rotationally associated with the spar, whereby the rotational assembly is capable of rotating the spar;
• and,
• d. an engagement and locking device, whereby when the tool is deployed the tool is held in place during laser operations.

A method of removing a structure located in the earth, the method comprising:

• a. positioning a laser decommission systems in the area of a structure to removed from the ground, the laser decommissioning system comprising a high power laser and a laser decommissioning tool;
• b. the structure at least partially located in the earth, having an exterior surface, and extending down under a surface of the earth for at least 50 feet;
• c. the structure having an opening at or near the surface of the earth;
• d. placing the laser decommissioning tool in optical association with the structure, whereby a laser beam path from the laser beam tool is located at a depth below the surface of the earth;
• e. delivering the laser beam along the laser beam path to the structure in a laser beam pattern, wherein the accessible emission limit is equal to or lower than a Class I, and whereby the structure is cut;
• and,
• f. removing the structure above the cut from the earth.

A method of performing down hole high power laser welding operations on a target structure within a borehole in the earth, the method comprising:

• a. optically associating a high power laser tool with a source of a high power laser beam, whereby the laser tool can deliver a high power laser beam along a beam path;
• b. operationally associating the laser tool with a target structure in a borehole in the earth;
• whereby the laser beam path is through a free space partially defined by a distance between the laser beam tool to the target structure;
• c. providing a controlled and predetermined atmosphere in the free space;
• and,
• d. propagating the laser beam through the controlled and predetermined atmosphere and performing a laser welding operation on the target structure.