# US 2014/0190949 A1 · Systems, tools and methods for high power laser surface decommissioning and downhole welding > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0190949 A1 - Document ID: US20140190949A1 - Status: Published application - Kind: A1 - Application number: 14/213,212 - Filed: 2014-03-14 - Published: 2014-07-10 - Earliest claimed: 2012-08-02 - Assignees: Foro Energy, Inc. - Inventors: Mark S. Zediker; Daryl L. Grubb; Brian O. Faircloth; Kenneth L. Havlinek; Scott A. Marshall - Web page: https://patentgrep.com/patent/US20140190949A1 ## CPC - B23K 26/282: of tube sections - B23K 26/106: {inside the workpiece} - B23K 26/38: by boring or cutting - E21B 23/00: Apparatus for displacing, setting, locking, releasing or removing tools, packers or the like in boreholes or wells (setting of casings, screens or liners E21B43/10) - E21B 29/00: Cutting or destroying pipes, packers, plugs or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground - B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract There are provided using high power laser systems for performing decommissioning welding and repair of structures in boreholes, off-shore, and other remote and hazardous locations. In a particular embodiment the laser system is a Class I system. ## Claims ### Claim 1 A high power laser tool for deployment in a tubular to be cut, the tool comprising: a. a first assembly, and a second assembly; b. a spar having a length and mechanically and rotationally associating the second assembly and the first assembly, thereby defining a distance between the second assembly and the first assembly; and, whereby the second assembly is rotatable with respect to 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 rotating the spar and an engagement device, wherein upon deployment of the tool the first assembly is capable engaging the tubular and rotating the spar and the second assembly to cut the tubular with a laser beam at a predetermined depth. ### Claim 2 (depends on 1) The tool of claim 1, wherein the engagement device comprises a wedge. ### Claim 3 (depends on 1) The tool of claim 1, wherein the engagement device comprises a centering device. ### Claim 4 (depends on 1) The tool of claim 1, wherein the first assembly comprises an optical slip ring. ### Claim 5 (depends on 1) The tool of claim 1, wherein the high power optical fiber extends through the first assembly and is located within the spar. ### Claim 6 (depends on 1) The tool of claim 1, wherein the first assembly comprises an optical slip ring and wherein the high power optical fiber is in optical communication with the optical slip ring. ### Claim 7 (depends on 1) The tool of claim 1, wherein the first assembly comprises an optical slip ring and wherein the high power optical fiber is in optical communication with the optical slip ring and wherein the high power optical fiber is located within the spar. ### Claim 8 (depends on 1) The tool of claim 1, wherein the spar is at least about 5 feet long. ### Claim 9 (depends on 1) The tool of claim 1, wherein the spar is at least about 15 feet long. ### Claim 10 (depends on 1) The tool of claim 1, wherein the spar is at least about 20 feet long. ### Claim 11 (depends on 1) The tool of claim 1, wherein the engagement device comprises a centering device and wherein the spar is at least about 10 feet long. ### Claim 12 (depends on 1) The tool of claim 1, wherein the first assembly comprises an optical slip ring and wherein the spar is at least about 10 feet long. ### Claim 13 (depends on 1) The tool of claim 1, wherein the high power optical fiber extends through the first assembly and is located within the spar and wherein the spar is at least about 10 feet long. ### Claim 14 (depends on 1) The tool of claim 1, wherein the first assembly comprises an optical slip ring and wherein the high power optical fiber is in optical communication with the optical slip ring and wherein the spar is at least about 10 feet long. ### Claim 15 (depends on 1) The tool of claim 1, wherein the length of the spar is adjustable, whereby the distance between the first assembly and the second assembly can be changed. ### Claim 16 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less. ### Claim 17 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the engagement device comprises a wedge. ### Claim 18 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the first assembly comprises an optical slip ring. ### Claim 19 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the high power optical fiber extends through the first assembly and is located within the spar. ### Claim 20 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the first assembly comprises an optical slip ring and wherein the high power optical fiber is in optical communication with the optical slip ring and wherein the high power optical fiber is located within the spar. ### Claim 21 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the engagement device comprises a centering device and wherein the spar is at least about 10 feet long. ### Claim 22 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the first assembly comprises an optical slip ring and wherein the spar is at least about 10 feet long. ### Claim 23 (depends on 1) The tool of claim 1, wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the length of the spar is adjustable, whereby the distance between between the first assembly and the second assembly can be changed. ### Claim 24 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of an electric motor, a DC electric motor, a pneumatic motor, a step motor, a gear box, a torsional device and a transmission. ### Claim 25 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of an electric motor, a hand crank, a gearbox, a transmission and a belt drive, and wherein the engagement device comprises a centering device. ### Claim 26 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of an electric motor, a DC electric motor, a pneumatic motor, a step motor, a gear box, a torsional device and a transmission, and wherein the first assembly comprises an optical slip ring. ### Claim 27 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of an electric motor, a hand crank, a gearbox, a transmission and a belt drive, and wherein the first assembly comprises an optical slip ring and wherein the high power optical fiber is in optical communication with the optical slip ring and wherein the high power optical fiber is located within the spar. ### Claim 28 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of an electric motor, a DC electric motor, a pneumatic motor, a step motor, a gear box, a torsional device and a transmission, and wherein the spar is at least about 5 feet long. ### Claim 29 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of a motor, an electric motor, a hand crank, a gearbox, a chain drive, a gear drive, a transmission and a belt drive, and wherein the length of the spar is adjustable, whereby the distance between the first assembly and the second assembly can be changed. ### Claim 30 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of a motor, an electric motor, a hand crank, a gearbox, a chain drive, a gear drive, a transmission and a belt drive, and wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less. ### Claim 31 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of a motor, an electric motor, a hand crank, a gearbox, a chain drive, a gear drive, a transmission and a belt drive, and wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the engagement device comprises a centering device. ### Claim 32 (depends on 1) The tool of claim 1, wherein the means for rotating the spar comprises a device selected from the group consisting of a motor, an electric motor, a hand crank, a gearbox, a chain drive, a gear drive, a transmission and a belt drive, and wherein the tool as deployed during normal operation has an accessible emission limit of 2.0×10−3 k1k2 Wcm−2 sr−1 radiance or less and wherein the first assembly comprises an optical slip ring. ### Claim 33 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. ### Claim 34 (depends on 33) The tool of claim 33, comprising an engagement device. ### Claim 35 (depends on 33) The tool of claim 33, comprising an engagement device comprising a device selected from the group consisting of a wedge, an inflatable bladder and a band. ### Claim 36 (depends on 33) The tool of claim 33, comprising: a means for rotating the spar comprising a device selected from the group consisting of a motor, an electric motor, a hand crank, a gearbox, a chain drive, a gear drive, a transmission and a belt drive; and a laser beam isolation means, wherein the tool as deployed has equal to or lower than a Class I accessible emission limit. ### Claim 37 (depends on 33) The tool of claim 33, comprising a laser beam isolation means, wherein the tool has equal to or lower than a Class I accessible emission limit. ### Claim 38 (depends on 37) The tool of claim 37, wherein the accessible emission limit is equal to or less than about 2.0×10−3 k1k2 Wcm−2 sr−1 radiance. ### Claim 39 (depends on 33) The tool of claim 33, comprising an engagement device and a centering device. ### Claim 40 (depends on 33) The tool of claim 33, wherein the first assembly comprises an optical slip ring. ### Claim 41 (depends on 33) The tool of claim 33, comprising: a means for rotating the spar; and a laser beam isolation means, wherein the tool as deployed has equal to or lower than a Class I accessible emission limit; and wherein the first assembly comprises an optical slip ring. ### Claim 42 (depends on 41) The tool of claim 41, wherein the accessible emission limit is equal to or less than about 2.0×10−3 k1k2 Wcm−2 sr−1 radiance. ### Claim 43 (depends on 33) The tool of claim 33, comprising: a means for rotating the spar attached to the first assembly; and a laser beam isolation means, wherein the tool as deployed has equal to or lower than a Class I accessible emission limit; and wherein the first assembly comprises an optical slip ring. ### Claim 44 (depends on 33) The tool of claim 33, comprising: a means for rotating the spar attached to the second assembly; and a laser beam isolation means, wherein the tool as deployed has equal to or lower than a Class I accessible emission limit; and wherein the first assembly comprises an optical slip ring. ### Claim 45 (depends on 33) The tool of claim 33, wherein the spar is at least about 5 feet long. ### Claim 46 (depends on 33) The tool of claim 33, wherein the spar is at least about 10 feet long. ### Claim 47 (depends on 33) The tool of claim 33, wherein the spar is at least about 15 feet long. ### Claim 48 (depends on 33) The tool of claim 33, wherein the spar is at least about 20 feet long. ### Claim 49 (depends on 37) The tool of claim 37, wherein the spar is at least about 10 feet long. ### Claim 50 (depends on 38) The tool of claim 38, wherein the spar is at least about 10 feet long. ### Claim 51 (depends on 33) The tool of claim 33, wherein the length of the spar is adjustable, whereby the distance between the first assembly and the second assembly can be changed. ### Claim 52 (depends on 37) The tool of claim 37, wherein the length of the spar is adjustable, whereby the distance between the first assembly and the second assembly can be changed. ### Claim 53 (depends on 38) The tool of claim 38, wherein the length of the spar is adjustable, whereby the distance between the first assembly and the second assembly can be changed. ### Claim 54 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. ### Claim 55 (depends on 54) The tool of claim 54, wherein the accessible emission limit is equal to or less than about 2.0×10−3 k1k2 Wcm−2 sr−1 radiance. ### Claim 56 (depends on 54) The tool of claim 54, wherein the laser beam isolation means comprises a conical shield optically sealing the first assembly against the tubular when deployed. ### Claim 57 (depends on 55) The tool of claim 55, wherein the laser beam isolation means comprises a conical shield optically sealing the first assembly against the tubular when deployed. ### Claim 58 (depends on 54) The tool of claim 54, wherein the laser beam isolation means comprises a hood. ### Claim 59 (depends on 55) The tool of claim 55, wherein the laser beam isolation means comprises a hood. ### Claim 60 (depends on 54) The tool of claim 54, wherein the laser beam isolation means comprises a hood and a laser energy suppression device. ### Claim 61 (depends on 55) The tool of claim 55, wherein the laser beam isolation means comprises a hood and a laser energy suppression device. ### Claim 62 (depends on 54) The tool of claim 54, wherein the laser beam isolation means comprises a hood and a laser monitor. ### Claim 63 (depends on 55) The tool of claim 55, wherein the laser beam isolation means comprises a hood and a laser monitor. ### Claim 64 (depends on 54) The tool of claim 54, wherein the laser beam isolation means comprises a hood and a sensor. ### Claim 65 (depends on 55) The tool of claim 55, wherein the laser beam isolation means comprises a hood and a laser sensor. ### Claim 66 (depends on 54) The tool of claim 54, wherein the laser beam isolation means comprises a hood and an interlock. ### Claim 67 (depends on 55) The tool of claim 55, wherein the laser beam isolation means comprises a hood and an interlock. ### Claim 68 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. ### Claim 69 (depends on 68) The tool of claim 68, wherein the accessible emission limit is equal to or less than about 2.0×10−3 k1k2 Wcm−2 sr−1 radiance. ### Claim 70 (depends on 68) The tool of claim 68, comprising a means for rotating the spar. ### Claim 71 (depends on 70) The tool of claim 70, wherein the means for rotating the spar comprises a device selected from the group consisting of a motor, an electric motor, a hand crank, a gearbox, a chain drive, a gear drive, a transmission and a belt drive; and a laser beam isolation means, wherein the tool as deployed has equal to or lower than a Class I accessible emission limit. ### Claim 72 (depends on 69) The tool of claim 69, comprising a means for rotating the spar. ### Claim 73 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. ### Claim 74 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. ### Claim 75 (depends on 74) The tool of claim 74, wherein the engagement and locking device comprises a wedge. ### Claim 76 (depends on 74) The tool of claim 74, wherein the engagement and locking device comprises a plurality of wedges. ### Claim 77 (depends on 74) The tool of claim 74, wherein the engagement and locking device is attached to the base plate. ### Claim 78 (depends on 33) The tool of claim 33, wherein the beam path angle changing optical member, comprises a mirror. ### Claim 79 (depends on 33) The tool of claim 33, wherein the beam path angle changing optical member, comprises a TIR prism. ### Claim 80 (depends on 34) The tool of claim 34, wherein the beam of the beam path is about 90 degrees. ### Claim 81 (depends on 34) The tool of claim 34, wherein the beam path angle changing optical member, comprises a mirror. ### Claim 82 (depends on 34) The tool of claim 34, wherein the beam path angle changing optical member, comprises a TIR prism. ### Claim 83 (depends on 36) The tool of claim 36, wherein the beam path angle changing optical member, comprises a mirror. ### Claim 84 (depends on 38) The tool of claim 38, wherein the beam path angle changing optical member, comprises a TIR prism. ### Claim 85 (depends on 41) The tool of claim 41, wherein the beam of the beam path is about 90 degrees. ### Claim 86 (depends on 54) The tool of claim 54, wherein the beam path angle changing optical member, comprises a mirror. ### Claim 87 (depends on 54) The tool of claim 54, wherein the beam path angle changing optical member, comprises a TIR prism. ### Claim 88 (depends on 54) The tool of claim 54, wherein the beam of the beam path is about 90 degrees. ### Claim 89 (depends on 55) The tool of claim 55, wherein the beam path angle changing optical member, comprises a mirror. ### Claim 90 (depends on 56) The tool of claim 56, wherein the beam path angle changing optical member, comprises a TIR prism. ### Claim 91 (depends on 66) The tool of claim 66, wherein the beam of the beam path is about 90 degrees. ### Claim 92 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. ### Claim 93 (depends on 92) The method of claim 92, wherein the laser beam is at least about 5 kW. ### Claim 94 (depends on 92) The method of claim 92, wherein the laser beam is at least about 15 kW. ### Claim 95 (depends on 92) The method of claim 92, wherein the structure is a tubular and the area is a hydrocarbon well site to be decommissioned. ### Claim 96 (depends on 92) The method of claim 92, wherein the structure is a conductor and the area is a hydrocarbon well site to be decommissioned. ### Claim 97 (depends on 92) The method of claim 92, wherein the structure is a multistring conductor and the area is a hydrocarbon well site to be decommissioned. ### Claim 98 (depends on 92) The method of claim 92, wherein the decommissioning tool is at least partially within the structure and the laser cut is an inside to outside cut. ### Claim 99 (depends on 92) The method of claim 92, wherein the earth remains adjacent to the outer surface of the structure while the structure is in the earth. ### Claim 100 (depends on 92) The method of claim 92, wherein the earth is removed from the exterior of the structure to at or below the depth, thereby creating a space, defining a distance, between the earth and the exterior of the structure. ### Claim 101 (depends on 100) The method of claim 100, wherein the distance is less than about 10 feet. ### Claim 102 (depends on 100) The method of claim 100, wherein the distance is less than about 5 feet. ### Claim 103 (depends on 100) The distance of claim 100, wherein the distance is less than about 1 foot. ### Claim 104 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. ### Claim 105 (depends on 104) The method of claim 104, wherein the target structure is a patch covering a damaged section of a tubular. ### Claim 106 (depends on 104) The method of claim 104, wherein the target structure is a casing junction in a multi-junction well configuration. ### Claim 107 (depends on 104) The method of claim 104, wherein the laser welding operation is selected from the group consisting autogenous welding, laser-hybrid welding, keyhole welding, lap welding, filet welding, butt welding and non-autogenous welding.