U.S. patent application number 13/403132 was filed with the patent office on 2012-10-18 for method of high power laser-mechanical drilling.
Invention is credited to Erik C. Allen, Brian O. Faircloth, Mark S. Zediker.
Application Number | 20120261188 13/403132 |
Document ID | / |
Family ID | 46721225 |
Filed Date | 2012-10-18 |
United States Patent
Application |
20120261188 |
Kind Code |
A1 |
Zediker; Mark S. ; et
al. |
October 18, 2012 |
METHOD OF HIGH POWER LASER-MECHANICAL DRILLING
Abstract
There is provided a laser-mechanical method for drilling
boreholes that utilizes specific combinations of high power
directed energy, such as laser energy, in combination with
mechanical energy to provide a synergistic enhancement of the
drilling process.
Inventors: |
Zediker; Mark S.; (Castle
Rock, CO) ; Faircloth; Brian O.; (Evergreen, CO)
; Allen; Erik C.; (Minneapolis, MN) |
Family ID: |
46721225 |
Appl. No.: |
13/403132 |
Filed: |
February 23, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12544038 |
Aug 19, 2009 |
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13403132 |
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12543968 |
Aug 19, 2009 |
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12544038 |
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12543986 |
Aug 19, 2009 |
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12543968 |
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61446041 |
Feb 24, 2011 |
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61446312 |
Feb 24, 2011 |
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61446040 |
Feb 24, 2011 |
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61446043 |
Feb 24, 2011 |
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61446042 |
Feb 24, 2011 |
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61153271 |
Feb 17, 2009 |
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61106472 |
Oct 17, 2008 |
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61102730 |
Oct 3, 2008 |
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61090384 |
Aug 20, 2008 |
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61153271 |
Feb 17, 2009 |
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61090384 |
Aug 20, 2008 |
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61102730 |
Oct 3, 2008 |
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61106472 |
Oct 17, 2008 |
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Current U.S.
Class: |
175/15 ;
175/16 |
Current CPC
Class: |
E21B 10/60 20130101;
E21B 7/14 20130101 |
Class at
Publication: |
175/15 ;
175/16 |
International
Class: |
E21B 7/15 20060101
E21B007/15; E21B 7/00 20060101 E21B007/00 |
Goverment Interests
[0002] This invention was made with Government support under Award
DE-AR0000044 awarded by the Office of ARPA-E U.S. Department of
Energy. The Government has certain rights in this invention.
Claims
1. A method of directed energy mechanical drilling comprising: a.
providing directed energy to a surface of a material; b. providing
mechanical energy to the surface; and, c. wherein the ratio of
directed energy to mechanical energy is greater than about 5; and,
d. whereby a borehole is advance through the surface of the
material.
2. A method directed energy mechanical drilling comprising: a.
providing directed energy to a surface of a material; b. providing
mechanical energy to the surface; and, c. wherein the ratio of
directed energy to mechanical energy is greater than about 10; and,
d. whereby a borehole is advance through the surface of the
material.
3. A method of directed energy mechanical drilling comprising: a.
providing directed energy to a surface of a material; b. providing
mechanical energy to the surface; and, c. wherein the ratio of
directed energy to mechanical energy is greater than about 20; and,
d. whereby a borehole is advance through the surface of the
material.
4. A method of directed energy mechanical drilling comprising: a.
providing directed energy to a surface of a material; b. providing
mechanical energy to the surface; and, c. wherein the ratio of
directed energy to mechanical energy is greater than about 40; and,
d. whereby a borehole is advance through the surface of the
material.
5. A directed energy mechanical drilling comprising: a. providing
directed energy to a surface; b. providing mechanical energy to the
surface; and, c. wherein the ratio of directed energy to mechanical
energy is greater than about 2; and, d. whereby a borehole is
advance through the surface of the material.
6. A method of directed energy mechanical drilling comprising: a.
providing high power laser directed energy to a surface of a
material; b. providing mechanical energy to the surface; and, c.
wherein the ratio of high power laser directed energy to mechanical
energy is greater than about 5; and, d. whereby a borehole is
advance through the surface of the material.
7. A method directed energy mechanical drilling comprising: a.
providing high power laser directed energy to a surface of a
material; b. providing mechanical energy to the surface; and, c.
wherein the ratio of high power laser directed energy to mechanical
energy is greater than about 10; and, d. whereby a borehole is
advance through the surface of the material.
8. A method of directed energy mechanical drilling comprising: a.
providing high power laser directed energy to a surface of a
material; b. providing mechanical energy to the surface; and, c.
wherein the ratio of high power laser directed energy to mechanical
energy is greater than about 20; and, d. whereby a borehole is
advance through the surface of the material.
9. A method of directed energy mechanical drilling comprising: a.
providing high power laser directed energy to a surface of a
material; b. providing mechanical energy to the surface; and, c.
wherein the ratio of high power laser directed energy to mechanical
energy is greater than about 40; and, d. whereby a borehole is
advance through the surface of the material.
10. A directed energy mechanical drilling comprising: a. providing
high power laser directed energy to a surface; b. providing
mechanical energy to the surface; and, c. wherein the ratio of
directed energy to mechanical energy is greater than about 2; and,
d. whereby a borehole is advance through the surface of the
material.
11. The method of claim 6, wherein the high power laser directed
energy has a power of at least about 40 kW.
12. The method of claim 8, wherein the surface is not substantially
melted by the laser energy.
13. The method of claim 8, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds.
14. The method of claim 9, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 1000
pounds.
15. The method of claim 11, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 1000
pounds.
16. The methods of claim 9, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds and wherein the borehole is advanced at a rate of
penetration of at least about 10 feet per hour.
17. The methods of claim 11, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds and wherein the borehole is advanced at a rate of
penetration of at least about 10 feet per hour.
18. The methods of claim 6, wherein the high power laser directed
energy has a power of at least about 20 kW and the mechanical
energy is provided by a bit having a weight-on-bit less than about
2000 pounds and wherein the borehole is advanced at a rate of
penetration of at least about 20 feet per hour.
19. The methods of claim 8, wherein the high power laser directed
energy has a power of at least about 20 kW and the mechanical
energy is provided by a bit having a weight-on-bit less than about
2000 pounds and wherein the borehole is advanced at a rate of
penetration of at least about 20 feet per hour.
20. The methods of claim 10, wherein the high power laser directed
energy has a power of at least about 20 kW and the mechanical
energy is provided by a bit having a weight-on-bit less than about
2000 pounds and wherein the borehole is advanced at a rate of
penetration of at least about 20 feet per hour.
21. The methods of claim 8, wherein the high power laser directed
energy has a power of at least about 50 kW and the mechanical
energy is provided by a bit having a weight-on-bit less than about
2000 pounds and wherein the borehole is advanced at a rate of
penetration of at least about 20 feet per hour.
22. The methods of claim 6, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds and wherein the borehole is advanced at a rate of
penetration the rate of penetration of at least about 20 feet per
hour through material having an average hardness of about 20 ksi or
greater.
23. The method of claim 6, wherein the borehole is advanced for
greater than about 500 feet.
24. The methods of claim 9, wherein the borehole is advanced for
greater than about 5,000 feet.
25. A method of advancing a borehole in the earth using high power
laser mechanical drilling techniques, the method comprising: a.
directing laser energy, in a moving pattern, to a bottom surface of
a borehole in the earth; b. heating the earth with the directed
laser energy to a point below the melting point; c. providing
mechanical energy to the heated earth; d. wherein the ratio of
laser energy to mechanical energy is greater than about 2; and, e.
whereby the borehole is advanced
26. The method of claim 25, wherein the laser energy has a power of
about 20 kW or greater.
27. The method of claim 25, wherein the power/area of the laser
energy on the surface of the bottom of the borehole is about 50
W/cm.sup.2 or greater.
28. The method of claim 25, wherein the power/area of the laser
energy on the surface of the bottom of the borehole is about 75
W/cm.sup.2 or greater.
29. The method of claim 25, wherein the power/area of the laser
energy on the surface of the bottom of the borehole is about 100
W/cm.sup.2 or greater.
30. The method of claim 25, wherein the power/area of the laser
energy on the surface of the bottom of the borehole is about 200
W/cm.sup.2 or greater.
31. The method of claim 25, wherein the power/area of the laser
energy on the surface of the bottom of the borehole is about 300
W/cm.sup.2 or greater.
32. The method of claim 29, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds.
33. The method of claim 30, wherein mechanical energy is provided
by a bit having a weight-on-bit less than about 1000 pounds.
34. The method of claim 28, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds and wherein the borehole is advanced at a rate of
penetration of at least about 10 feet per hour.
35. The method of claim 28, wherein the mechanical energy is
provided by a bit having a weight-on-bit, wherein the weight-on-bit
is less than about 2000 pounds and wherein the borehole is advanced
at a rate of penetration of at least about 20 feet per hour.
36. The method of claim 30, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds and wherein borehole is advances at a rate of penetration of
at least about 10 feet per hour through material having an average
hardness of about 20 ksi or greater.
37. The method of claim 30, wherein the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds and wherein the borehole is advanced at a rate of
penetration of at least about 20 feet per hour through material
having an average hardness of about 20 ksi or greater.
38. The method of claim 36, wherein the borehole is advanced for
greater than about 1,000 feet.
39. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of material having a hardness greater than
about 30 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
while propagating a laser beam against the borehole surface; with
an RPM of from about 240 to about 720, a WOB of less than about
2,000 lbs, a DE Power/Area of about 90 W/cm.sup.2 to about 560
W/cm.sup.2, and an ME Power/Area of about 4 W/cm.sup.2 to about 250
W/cm.sup.2; c. whereby the borehole is advanced at an ROP of at
least about 10 ft/hr.
40. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of material having a hardness greater than
about 30 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
while propagating a laser beam against the borehole surface; with
an RPM of from about 600 to about 800, a WOB of less than about
5,000 lbs, a DE Power/Area of about 40 W/cm.sup.2 to about 250
W/cm.sup.2, and an ME Power/Area of about 200 W/cm.sup.2 to about
3000 W/cm.sup.2; c. whereby the borehole is advanced at an ROP of
at least about 15 ft/hr.
41. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of material having a hardness greater than
about 20 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
while propagating a laser beam against the borehole surface; with
an RPM of from about 600 to about 1250, a WOB of from about 500 to
about 5,000 lbs, a DE Power/Area of about 90 W/cm.sup.2 to about
570 W/cm.sup.2, and an ME Power/Area of about 40 W/cm.sup.2 to
about 270 W/cm.sup.2; c. whereby the borehole is advanced at an ROP
of at least about 10.
42. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of hard rock material, having a hardness
greater than about 20 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
with an RPM of about 250, a WOB of from about 1,000 lbs, a DE
Power/Area of about 370 W/cm.sup.2, and an ME Power/Area of about
40 W/cm.sup.2; and, c. whereby the borehole is advanced at an ROP
of at least about 20 ft/hr.
43. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of hard rock material, having a hardness
greater than about 20 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
with an RPM of from about 720, a WOB of from about 2,000 lbs, a DE
Power/Area of about 190 W/cm.sup.2, and an ME Power/Area of about
250 W/cm.sup.2; and, c. whereby the borehole is advanced at an ROP
of at least about 50 ft/hr.
44. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of hard rock material, having a hardness
greater than about 20 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
with an RPM of from about 720, a WOB of from about 2,000 lbs, a DE
Power/Area of about 370 W/cm.sup.2, and an ME Power/Area of about
250 W/cm.sup.2; and, c. whereby the borehole is advanced at an ROP
of at least about 50 ft/hr.
45. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of hard rock material, having a hardness
greater than about 20 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
with an RPM of from about 720, a WOB of from about 5,000 lbs, a DE
Power/Area of about 290 W/cm.sup.2, and an ME Power/Area of about
240 W/cm.sup.2; and, c. whereby the borehole is advanced at an ROP
of at least about 20 ft/hr.
46. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of hard rock material, having a hardness
greater than about 20 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
with an RPM of from about 1,200, a WOB of from about 500 lbs, a DE
Power/Area of about 470 W/cm.sup.2, and an ME Power/Area of about
100 W/cm.sup.2; and, c. whereby the borehole is advanced at an ROP
of at least about 30 ft/hr.
47. A method of laser-mechanical drilling a borehole in a formation
having at least 500 feet of hard rock material, having a hardness
greater than about 20 ksi, the method comprising: a. providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; b.
rotating the laser-mechanical bit against a surface of the borehole
with an RPM of from about 720, a WOB of from about 2,000 lbs, a DE
Power/Area of about 470 W/cm.sup.2, and an ME Power/Area of about
250 W/cm.sup.2; and, c. whereby the borehole is advanced at an ROP
of at least about 30 ft/hr.
48. A method of laser-mechanical drilling a borehole in a
formation, the method comprising: a. providing a laser-mechanical
bit into a borehole, the laser-mechanical bit in optical
communication with a high power laser beam source; b. applying from
the high power laser beam source a high power laser beam to a
surface of the borehole, wherein the high power laser beam
generates an intensity ranging from about 150 to about 250
W/cm.sup.2 on a surface of the borehole for an elapsed time
sufficient to cause a surface temperature rise in the range from
about 400 degrees C. to about 1,000 degrees C., whereby a laser
applied surface is formed; c. applying a mechanical force to the
laser applied surface, wherein the mechanical force generates an
intensity ranging from about 30 to about 250 W/cm.sup.2 to remove
the laser applied surface of the borehole.
Description
[0001] This application: (i) claims, under 35 U.S.C.
.sctn.119(e)(1), the benefit of the filing date of Feb. 24, 2011 of
U.S. provisional application Ser. No. 61/446,041; (ii) claims,
under 35 U.S.C. .sctn.119(e)(1), the benefit of the filing date of
Feb. 24, 2011 of U.S. provisional application Ser. No. 61/446,312;
(iii) claims, under 35 U.S.C. .sctn.119(e)(1), the benefit of the
filing date of Feb. 24, 2011 of U.S. provisional application Ser.
No. 61/446,040; (iv) claims, under 35 U.S.C. .sctn.119(e)(1), the
benefit of the filing date of Feb. 24, 2011 of U.S. provisional
application Ser. No. 61/446,043; (v) claims, under 35 U.S.C.
.sctn.119(e)(1), the benefit of the filing date of Feb. 24, 2011 of
U.S. provisional application Ser. No. 61/446,042; (vi) is a
continuation-in-part of U.S. patent application Ser. No. 12/544,038
filed Aug. 19, 2009, which claims under 35 U.S.C. .sctn.119(e)(1)
the benefit of the filing date of Feb. 17, 2009 of U.S. provisional
application Ser. No. 61/153,271, the benefit of the filing date of
Oct. 17, 2008 of U.S. provisional application Ser. No. 61/106,472,
the benefit of the filing date of Oct. 3, 2008 of U.S. provisional
application Ser. No. 61/102,730, and the benefit of the filing date
of Aug. 20, 2008 of U.S. provisional application Ser. No.
61/090,384; (vii) is a continuation-in-part of U.S. patent
application Ser. No. 12/543,968 filed Aug. 19, 2009; and (viii) is
a continuation-in-part of U.S. patent application Ser. No.
12/543,986 filed Aug. 19, 2009, which claims under 35 U.S.C.
.sctn.119(e)(1) the benefit of the filing date of Feb. 17, 2009 of
U.S. provisional application Ser. No. 61/153,271, the benefit of
the filing date of Oct. 17, 2008 of U.S. provisional application
Ser. No. 61/106,472, the benefit of the filing date of Oct. 3, 2008
of U.S. provisional application Ser. No. 61/102,730, and the
benefit of the filing date of Aug. 20, 2008 of U.S. provisional
application Ser. No. 61/090,384, the entire disclosures of each of
which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0003] The present inventions relate to high power laser energy
tools and systems and methods.
[0004] As used herein, unless specified otherwise, "high power
laser energy" means a laser beam having at least about 1 kW
(kilowatt) of power. As used herein, unless specified otherwise
"great distances" means at least about 500 m (meter). As used
herein the term "substantial loss of power," "substantial power
loss" and similar such phrases, mean a loss of power of more than
about 3.0 dB/km (decibel/kilometer) for a selected wavelength. As
used herein the term "substantial power transmission" means at
least about 50% transmittance.
[0005] As used herein, unless specified otherwise, the term "earth"
should be given its broadest possible meaning, and includes, the
ground, all natural materials, such as rocks, and artificial
materials, such as concrete, that are or may be found in the
ground, including without limitation rock layer formations, such
as, granite, basalt, sandstone, dolomite, sand, salt, limestone,
rhyolite, quartzite and shale rock.
[0006] As used herein, unless specified otherwise, the term
"borehole" should be given it broadest possible meaning and
includes any opening that is created in a material, a work piece, a
surface, the earth, a structure (e.g., building, protected military
installation, nuclear plant, offshore platform, or ship), or in a
structure in the ground, (e.g., foundation, roadway, airstrip, cave
or subterranean structure) that is substantially longer than it is
wide, such as a well, a well bore, a well hole, a micro hole,
slimhole, a perforation and other terms commonly used or known in
the arts to define these types of narrow long passages. Wells would
further include exploratory, production, abandoned, reentered,
reworked, and injection wells. Although boreholes are generally
oriented substantially vertically, they may also be oriented on an
angle from vertical, to and including horizontal. Thus, using a
vertical line, based upon a level as a reference point, a borehole
can have orientations ranging from 0.degree. i.e., vertical, to
90.degree.,i.e., horizontal and greater than 90.degree. e.g., such
as a heel and toe and combinations of these such as for example "U"
and "Y" shapes. Boreholes may further have segments or sections
that have different orientations, they may have straight sections
and arcuate sections and combinations thereof; and for example may
be of the shapes commonly found when directional drilling is
employed. Thus, as used herein unless expressly provided otherwise,
the "bottom" of a borehole, the "bottom surface" of the borehole
and similar terms refer to the end of the borehole, i.e., that
portion of the borehole furthest along the path of the borehole
from the borehole's opening, the surface of the earth, or the
borehole's beginning. As used herein unless specified otherwise,
the terms "side" and "wall" of a borehole should to be given their
broadest possible meaning and include the longitudinal surfaces of
the borehole, whether or not casing or a liner is present, as such,
these terms would include the sides of an open borehole or the
sides of the casing that has been positioned within a borehole.
Boreholes may be made up of a single passage, multiple passages,
connected passages and combinations thereof, in a situation where
multiple boreholes are connected or interconnected each borehole
would have a borehole bottom. Boreholes may be formed in the sea
floor, under bodies of water, on land, in ice formations, or in
other locations and settings.
[0007] Boreholes are generally formed and advanced by using
mechanical drilling equipment having a rotating drilling tool,
e.g., a bit. For example and in general, when creating a borehole
in the earth, a drilling bit is extending to and into the earth and
rotated to create a hole in the earth. In general, to perform the
drilling operation the bit must be forced against the material to
be removed with a sufficient force to exceed the shear strength,
compressive strength or combinations thereof, of that material.
Thus, in conventional drilling activity mechanical forces exceeding
these strengths of the rock or earth must be applied. The material
that is cut from the earth is generally known as cuttings, e.g.,
waste, which may be chips of rock, dust, rock fibers and other
types of materials and structures that may be created by the bit's
interactions with the earth. These cuttings are typically removed
from the borehole by the use of fluids, which fluids can be
liquids, foams or gases, or other materials know to the art.
[0008] As used herein, unless specified otherwise, the term
"advancing" a borehole should be given its broadest possible
meaning and includes increasing the length of the borehole. Thus,
by advancing a borehole, provided the orientation is not
horizontal, e.g., less than 90.degree. the depth of the borehole
may also be increased. The true vertical depth ("TVD") of a
borehole is the distance from the top or surface of the borehole to
the depth at which the bottom of the borehole is located, measured
along a straight vertical line. The measured depth ("MD") of a
borehole is the distance as measured along the actual path of the
borehole from the top or surface to the bottom. As used herein
unless specified otherwise the term depth of a borehole will refer
to MD. In general, a point of reference may be used for the top of
the borehole, such as the rotary table, drill floor, well head or
initial opening or surface of the structure in which the borehole
is placed.
[0009] As used herein, unless specified otherwise, the terms
"ream", "reaming", a borehole, or similar such terms, should be
given their broadest possible meaning and includes any activity
performed on the sides of a borehole, such as, e.g., smoothing,
increasing the diameter of the borehole, removing materials from
the sides of the borehole, such as e.g., waxes or filter cakes, and
under-reaming.
[0010] As used herein, unless specified otherwise, the terms "drill
bit", "bit", "drilling bit" or similar such terms, should be given
their broadest possible meaning and include all tools designed or
intended to create a borehole in an object, a material, a work
piece, a surface, the earth or a structure including structures
within the earth, and would include bits used in the oil, gas and
geothermal arts, such as fixed cutter and roller cone bits, as well
as, other types of bits, such as, rotary shoe, drag-type, fishtail,
adamantine, single and multi-toothed, cone, reaming cone, reaming,
self-cleaning, disc, three cone, rolling cutter, crossroller, jet,
core, impreg and hammer bits, and combinations and variations of
the these.
[0011] Mechanical bits cut rock with shear stresses created by
rotating a cutting surface against the rock and placing a large
amount of weight-on-bit ("WOB"). Mechanical bits cut rock by
applying crushing (compressive) and/or shear stresses created by
rotating a cutting surface against the rock and placing a large
amount of WOB. In the case of a bit made of the material
polycrystalline diamond compact ("PDC"), e.g., a PDC bit, this
action is primarily by shear stresses and in the case of roller
cone bits this action is primarily by crushing (compression) and
shearing stresses. For example, the WOB applied to an 83/4'' PDC
bit may be up to 15,000 lbs, and the WOB applied to an 83/4''
roller cone bit may be up to 60,000 lbs. When mechanical bits are
used for drilling hard and ultra-hard rock excessive WOB, rapid bit
wear, and long tripping times result in an effective drilling rate
that is essentially economically unviable. The effective drilling
rate is based upon the total time necessary to complete the
borehole and, for example, would include time spent tripping in and
out of the borehole, as well as, the time for repairing or
replacing damaged and worn bits.
[0012] As used herein, unless specified otherwise, the term "drill
pipe" should be given its broadest possible meaning and includes
all forms of pipe used for drilling activities; and refers to a
single section or piece of pipe. As used herein the terms "stand of
drill pipe," "drill pipe stand," "stand of pipe," "stand" and
similar type terms are to be given their broadest possible meaning
and include two, three or four sections of drill pipe that have
been connected, e.g., joined together, typically by joints having
threaded connections. As used herein the terms "drill string,"
"string," "string of drill pipe," string of pipe" and similar type
terms are to be given their broadest definition and would include a
stand or stands joined together for the purpose of being employed
in a borehole. Thus, a drill string could include many stands and
many hundreds of sections of drill pipe.
[0013] As used herein, unless specified otherwise, the term
"tubular" should be given its broadest possible meaning and
includes drill pipe, casing, riser, coiled tube, composite tube,
vacuum insulated tubing ("VIT), production tubing and any similar
structures having at least one channel therein that are, or could
be used, in the drilling industry. As used herein the term "joint"
is to be given its broadest possible meaning and includes all types
of devices, systems, methods, structures and components used to
connect tubulars together, such as for example, threaded pipe
joints and bolted flanges. For drill pipe joints, the joint section
typically has a thicker wall than the rest of the drill pipe. As
used herein the thickness of the wall of tubular is the thickness
of the material between the internal diameter of the tubular and
the external diameter of the tubular.
SUMMARY
[0014] There has been a long-standing need for rapidly and
efficiently drilling boreholes into hard and very hard materials,
and to do so with minimal damage to the drilling bit. The present
inventions, among other things, solve these and other needs by
providing the articles of manufacture, devices and processes taught
herein.
[0015] Thus, there is provided herein a method of directed energy
mechanical drilling having the steps of: providing directed energy
to a surface of a material; providing mechanical energy to that
surface; so that the ratio of directed energy to mechanical energy
is greater than about 5; and, in this manner a borehole is advance
through the surface of the material.
[0016] Further, there is provided a method directed energy
mechanical drilling having steps including: providing directed
energy to a surface of a material; providing mechanical energy to
the surface; so that the ratio of directed energy to mechanical
energy is greater than about 10; and, in this manner a borehole is
advance through the surface of the material.
[0017] Moreover, there is provided a method of directed energy
mechanical drilling including the following: providing directed
energy to a surface of a material; providing mechanical energy to
the surface; so that the ratio of directed energy to mechanical
energy is greater than about 20; and, in this manner a borehole is
advance through the surface of the material.
[0018] Still further, there is provided a method of providing
directed energy to a surface of a material and providing mechanical
energy to the surface; in a manner where the ratio of directed
energy to mechanical energy is greater than about 40; and, in this
manner a borehole is advance through the surface of the
material.
[0019] Further still, there is provided directed energy mechanical
drilling by directing directed energy to a surface of a material
and directing mechanical energy to the surface in a ratio of
directed energy to mechanical energy that is greater than about 2
and this manner a borehole is advance through the surface of the
material.
[0020] Additionally, there is provided a method of directed energy
mechanical drilling having the steps of: providing high power laser
directed energy to a surface of a material; providing mechanical
energy to the surface; and, so that the ratio of high power laser
directed energy to mechanical energy is greater than about 5; and,
in this manner a borehole is advance through the surface of the
material.
[0021] Yet still additionally, there is provided a directed energy
mechanical drilling method of providing high power laser directed
energy to a surface of a material; providing mechanical energy to
the surface; in the ratio of high power laser directed energy to
mechanical energy that is greater than about 10; and, thus
advancing a borehole through the surface of the material.
[0022] Additionally, there is provided a method of directed energy
mechanical drilling by providing high power laser directed energy
to a surface of a material, providing mechanical energy to the
surface, so that the ratio of high power laser directed energy to
mechanical energy is greater than about 20; and, in this manner a
borehole is advance through the surface of the material.
[0023] Still further, there is provided a method of directed energy
mechanical drilling having steps including: providing high power
laser directed energy to a surface of a material; providing
mechanical energy to the surface; and, so that the ratio of high
power laser directed energy to mechanical energy is greater than
about 40; and, in this manner a borehole is advance through the
surface of the material.
[0024] Yet additionally, there is provided a directed energy
mechanical drilling method by providing high power laser directed
energy to a surface; providing mechanical energy to the surface; in
a ratio of directed energy to mechanical energy that is greater
than about 2 and, thus advancing a borehole through the surface of
the material are utilized.
[0025] Still further, the methods may also include steps,
conditions and parameters in which: the directed energy is high
power laser energy and in which the high power laser directed
energy has a power of at least about 40 kW; the surface is not
substantially melted by the laser energy; the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds; the mechanical energy is provided by a bit having a
weight-on-bit less than about 1000 pounds; the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds so that the borehole is advanced at a rate of penetration of
at least about 10 feet per hour; the mechanical energy is provided
by a bit having a weight-on-bit less than about 2000 pounds so that
the borehole is advanced at a rate of penetration of at least about
10 feet per hour; the high power laser directed energy has a power
of at least about 20 kW and the mechanical energy is provided by a
bit having a weight-on-bit less than about 2000 pounds so that the
borehole is advanced at a rate of penetration of at least about 20
feet per hour; the high power laser directed energy has a power of
at least about 20 kW and the mechanical energy is provided by a bit
having a weight-on-bit less than about 2000 pounds so that the
borehole is advanced at a rate of penetration of at least about 20
feet per hour; the high power laser directed energy has a power of
at least about 20 kW and the mechanical energy is provided by a bit
having a weight-on-bit less than about 2000 pounds so that the
borehole is advanced at a rate of penetration of at least about 20
feet per hour; the high power laser directed energy has a power of
at least about 50 kW and the mechanical energy is provided by a bit
having a weight-on-bit less than about 2000 pounds so that the
borehole is advanced at a rate of penetration of at least about 20
feet per hour; the mechanical energy is provided by a bit having a
weight-on-bit less than about 2000 pounds so that the borehole is
advanced at a rate of penetration the rate of penetration of at
least about 20 feet per hour through material having an average
hardness of about 20 ksi (kilopound per square inch) or greater;
the borehole is advanced for greater than about 500 feet; and the
borehole is advanced for greater than about 5,000 feet.
[0026] Moreover, there is provided a method of advancing borehole
in the earth using high power laser mechanical drilling techniques,
the method involving: directing laser energy, in a moving pattern,
to a bottom surface of a borehole in the earth; heating the earth
with the directed laser energy to a point below the melting point;
providing mechanical energy to the heated earth; so that the ratio
of laser energy to mechanical energy is greater than about 2; and,
in this manner the borehole is advanced
[0027] Furthermore, the methods may also include steps, conditions
and parameters in which: the laser energy has a power of about 20
kW or greater; the power/area of the laser energy on the surface of
the bottom of the borehole is about 50 W/cm.sup.2 or greater; the
power/area of the laser energy on the surface of the bottom of the
borehole is about 75 W/cm.sup.2 or greater; the power/area of the
laser energy on the surface of the bottom of the borehole is about
100 W/cm.sup.2 or greater; the laser energy on the surface of the
bottom of the borehole is about 200 W/cm.sup.2 or greater; the
power/area of the laser energy on the surface of the bottom of the
borehole is about 300 W/cm.sup.2 or greater; the mechanical energy
is provided by a bit having a weight-on-bit less than about 2000
pounds; the mechanical energy is provided by a bit having a
weight-on-bit less than about 1000 pounds; the mechanical energy is
provided by a bit having a weight-on-bit less than about 2000
pounds and so that the borehole is advanced at a rate of
penetration of at least about 10 feet per hour; the mechanical
energy is provided by a bit having a weight-on-bit, so that the
weight-on-bit is less than about 2000 pounds and so that the
borehole is advanced at a rate of penetration of at least about 20
feet per hour; the mechanical energy is provided by a bit having a
weight-on-bit less than about 2000 pounds and so that borehole is
advances at a rate of penetration of at least about 10 feet per
hour through material having an average hardness of about 20 ksi or
greater; the mechanical energy is provided by a bit having a
weight-on-bit less than about 2000 pounds and so that the borehole
is advanced at a rate of penetration of at least about 20 feet per
hour through material having an average hardness of about 20 ksi or
greater; and the borehole is advanced for greater than about 1,000
feet, greater than about 2,000 feet, and greater than then about
5,000 feet and greater than about 10,000 feet.
[0028] Moreover, there is provided a method of laser-mechanical
drilling a borehole in a formation having at least 500 feet of
material having a hardness greater than about 30 ksi by: providing
a laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; rotating
the laser-mechanical bit against a surface of the borehole while
propagating a laser beam against the borehole surface; with an RPM
of from about 240 to about 720, a WOB of less than about 2,000 lbs,
a DE Power/Area of about 90 W/cm.sup.2 to about 560 W/cm.sup.2, and
an ME Power/Area of about 4 W/cm.sup.2 to about 250 W/cm.sup.2; and
in this manner the borehole is advanced at an ROP of at least about
10 ft/hr.
[0029] Further, there is provided a method of laser-mechanical
drilling a borehole in a formation having at least 500 feet of
material having a hardness greater than about 30 ksi by: providing
a laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; rotating
the laser-mechanical bit against a surface of the borehole while
propagating a laser beam against the borehole surface; with an RPM
of from about 600 to about 800, a WOB of less than about 5,000 lbs,
a DE Power/Area of about 40 W/cm.sup.2 to about 250 W/cm.sup.2, and
an ME Power/Area of about 200 W/cm.sup.2 to about 3000 W/cm.sup.2;
and, in this manner the borehole is advanced at an ROP of at least
about 15 ft/hr.
[0030] Additionally, there is provided a method of laser-mechanical
drilling a borehole in a formation having at least 500 feet of
material having a hardness greater than about 20 ksi by: providing
a laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; rotating
the laser-mechanical bit against a surface of the borehole while
propagating a laser beam against the borehole surface; with an RPM
of from about 600 to about 1250, a WOB of from about 500 to about
5,000 lbs, a DE Power/Area of about 90 W/cm.sup.2 to about 570
W/cm.sup.2, and an ME Power/Area of about 40 W/cm.sup.2 to about
270 W/cm.sup.2; and in this manner the borehole is advanced at an
ROP of at least about 10.
[0031] Yet additionally, there is provided a method of
laser-mechanical drilling a borehole in a formation having at least
500 feet of hard rock material, having a hardness greater than
about 20 ksi by: providing a laser-mechanical bit into a borehole,
the laser-mechanical bit in optical communication with a high power
laser beam source; rotating the laser-mechanical bit against a
surface of the borehole with an RPM of about 250, a WOB of from
about 1,000 lbs, a DE Power/Area of about 370 W/cm.sup.2, and an ME
Power/Area of about 40 W/cm.sup.2; and, in this manner the borehole
is advanced at an ROP of at least about 20 ft/hr.
[0032] Yet still further, there is provided a method of
laser-mechanical drilling a borehole in a formation having at least
500 feet of hard rock material, having a hardness greater than
about 20 ksi, the method having the steps of: providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; rotating
the laser-mechanical bit against a surface of the borehole with an
RPM of from about 720, a WOB of from about 2,000 lbs, a DE
Power/Area of about 190 W/cm.sup.2, and an ME Power/Area of about
250 W/cm.sup.2; and, in this manner the borehole is advanced at an
ROP of at least about 50 ft/hr.
[0033] Further still, there is provided a method of
laser-mechanical drilling a borehole in a formation having at least
500 feet of hard rock material, having a hardness greater than
about 20 ksi by: providing a laser-mechanical bit into a borehole,
the laser-mechanical bit in optical communication with a high power
laser beam source; rotating the laser-mechanical bit against a
surface of the borehole with an RPM of from about 720, a WOB of
from about 2,000 lbs, a DE Power/Area of about 370 W/cm.sup.2, and
an ME Power/Area of about 250 W/cm.sup.2; and, in this manner the
borehole is advanced at an ROP of at least about 50 ft/hr.
[0034] Still further, there is provided a method of
laser-mechanical drilling a borehole in a formation having at least
500 feet of hard rock material, having a hardness greater than
about 20 ksi by: providing a laser-mechanical bit into a borehole,
the laser-mechanical bit in optical communication with a high power
laser beam source; rotating the laser-mechanical bit against a
surface of the borehole with an RPM of from about 720, a WOB of
from about 5,000 lbs, a DE Power/Area of about 290 W/cm.sup.2, and
an ME Power/Area of about 240 W/cm.sup.2; and, in this manner the
borehole is advanced at an ROP of at least about 20 ft/hr.
[0035] Moreover, there is provided a method of laser-mechanical
drilling a borehole in a formation having at least 500 feet of hard
rock material, having a hardness greater than about 20 ksi, this
method includes: providing a laser-mechanical bit into a borehole,
the laser-mechanical bit in optical communication with a high power
laser beam source; rotating the laser-mechanical bit against a
surface of the borehole with an RPM of from about 1,200, a WOB of
from about 500 lbs, a DE Power/Area of about 470 W/cm.sup.2, and an
ME Power/Area of about 100 W/cm.sup.2; and, in this manner the
borehole is advanced at an ROP of at least about 30 ft/hr.
[0036] Still further, a method of laser-mechanical drilling a
borehole in a formation having at least 500 feet of hard rock
material, having a hardness greater than about 20 ksi, by:
providing a laser-mechanical bit into a borehole, the
laser-mechanical bit in optical communication with a high power
laser beam source; rotating the laser-mechanical bit against a
surface of the borehole with an RPM of from about 720, a WOB of
from about 2,000 lbs, a DE Power/Area of about 470 W/cm.sup.2, and
an ME Power/Area of about 250 W/cm.sup.2; and, in this manner the
borehole is advanced at an ROP of at least about 30 ft/hr.
[0037] Furthermore, there is also provided a method of
laser-mechanical drilling a borehole in a formation by: providing a
laser-mechanical bit into a borehole, the laser-mechanical bit in
optical communication with a high power laser beam source; applying
from the high power laser beam source a high power laser beam to a
surface of the borehole, so that the high power laser beam
generates an intensity ranging from about 150 to about 250
W/cm.sup.2 on a surface of the borehole for an elapsed time
sufficient to cause a surface temperature rise in the range from
about 400 degrees C. to about 1,000 degrees C. and thus forming a
laser applied surface; and applying a mechanical force to the laser
applied surface, so that the mechanical force generates an
intensity ranging from about 30 to about 250 W/cm.sup.2 to remove
the laser applied surface of the borehole.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1A is a perspective view of an embodiment of a fixed
cutter laser-mechanical bit in accordance with the present
invention.
[0039] FIG. 1B is a bottom view of the bit of FIG. 1A.
[0040] FIG. 1C is a cross section view of the bit of FIGS. 1A and
1B taken along line 1C-1C.
[0041] FIG. 2 is a schematic of an embodiment of a high power laser
drilling, workover and completion unit in accordance with the
present invention.
[0042] FIG. 3 is a chart showing various directed energy
regimes.
[0043] FIG. 4 is schematic of chips of basalt.
[0044] FIG. 5 is a schematic of chips of dolomite.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] The present inventions relate to directed energy mechanical
drilling methods that utilize high power directed energy in
conjunction with mechanical forces. These methods may find uses in
many different types of materials and structures, such as metal,
stone, composites, concrete, the earth, and structures in the
earth. In particular, these methods may find preferable uses in
situations and environments where advancing a borehole with
conventional, e.g., non-directed energy technology, was difficult
or impossible, because, for example, the remoteness of the area
where the borehole was to be advanced, difficult environmental
conditions or other factors that placed great, and at times
insurmountable burdens on conventional drilling or boring
technologies. These methods also find preferable uses in situations
where reduced noise and vibrations, compared to conventional
technologies, are desirable or a requisite.
[0046] In general, the present methods involve the application of
directed energy and mechanical forces to a surface, e.g., the
bottom of a borehole, to remove material and advance the borehole.
The directed energy and mechanical forces are preferably applied in
a rotating or revolving manner, so that they are so moved about or
on the surface to be drilled (i.e., the drilling surface), e.g.,
the bottom of a borehole. "Directed energy" would include, for
example, optical laser energy, non-optical laser energy,
microwaves, sound waves, plasma, electric arcs, flame, flame jets,
steam and combinations of the foregoing, as well as, water jets
(although a water jet may be viewed as having a mechanical
interaction with the drilling surface, for the purpose of this
specification it will be characterized amongst the group of
directed energies, based upon the following specific definition of
mechanical energy), and other forms of energy that are not
"mechanical energy" as defined in these specifications. "Mechanical
energy," as used herein, is limited to energy that is transferred
to the drilling surface by the interaction or contact of a solid
object, e.g., a drill bit cutter, roller cone, or a saw blade, with
the drilling surface.
[0047] These methods provide for the application of unique
combinations of directed energy and mechanical force to obtain a
synergism. This synergism enables these methods to advance
boreholes through very hard materials, such as hard rocks and ultra
hard rocks, with very low WOB, e.g., less than about 5,000 lbs,
less than about 2000 lbs and preferably about 1000 lbs or less.
This reduction in WOB has the potential benefit of providing for
substantially longer drilling bit life, longer drilling times where
the bit can remain in the borehole, and reduced tripping, which in
turn has the potential to greatly reduce the cost of drilling a
borehole. In addition to reducing WOB, in other processes, such as
in a cutting application, the associated mechanical forces that are
needed may similarly be greatly reduced.
[0048] In general, and using drilling a borehole in the earth as an
illustrative example, as the bit is rotated in the bottom of the
borehole, the directed energy is propagated at the bottom surface
(and potentially side and gauge surfaces). The directed energy
weakens (and may also partially remove, and remove) the material so
contacted, i.e., directed energy affected material. The mechanical
devices, e.g., cutters, then rotate in the borehole, contacting and
removing the directed energy affected material (and potentially
some additional material). However, it is preferable, as shown by
the examples below, that the mechanical cutter, and the mechanical
energy that it delivers, is only sufficient to remove the directed
energy affected material. In this way the life of the cutters is
preserved, damage is minimized, and the amount of heat built up
from friction is controlled and preferably in some embodiments kept
to a minimum.
[0049] Preferably, in these methods the source of directed energy
is a high power laser beam. Thus, and more preferably the laser
beam, or beams, may have 10 kW, 20 kW, 40 kW, 80 kW or more power;
and have a wavelength in the range of from about 445 nm
(nanometers) to about 2100 nm, preferably in the range of from
about 800 to 1900 nm, and more preferably in the ranges of from
about 1530 nm to 1600 nm, from about 1060 nm to 1080 nm, and from
about 1800 nm to 1900 nm. Further, the types of laser beams and
sources for providing a high power laser beam may be the devices,
systems, optical fibers and beam shaping and delivery optics that
are disclosed and taught in the following US patent applications
and US Patent Application Publications: Publication No. US
2010/0044106, Publication No. US 2010/0044105, Publication No. US
2010/0044103, Publication No. US 2010/0044102, Publication No. US
2010/0215326, Publication No. 2012/0020631, Ser. No. 13/210,581,
and Ser. No. 61/493,174, the entire disclosures of each of which
are incorporated herein by reference. The source for providing
rotational movement may be a string of drill pipe rotated by a top
drive or rotary table, a down hole mud motor, a down hole turbine,
a down hole electric motor, and, in particular, may be the systems
and devices disclosed in the following US patent applications and
US Patent Application Publications: Publication No. US
2010/0044106, Publication No. US 2010/0044104, Publication No. US
2010/0044103, Ser. No. 12/896,021, Ser. No. 61/446,042 and Ser. No.
13/211,729, the entire disclosures of each of which are
incorporated herein by reference. The high power lasers for example
may be fiber lasers or semiconductor lasers having 10 kW, 20 kW, 50
kW or more power and, which emit laser beams with wavelengths
preferably in about the 1064 nm range, about the 1070 nm range,
about the 1360 nm range, about the 1455 nm range, about the 1550 nm
range, about the 1070 nm range, about the 1083 nm range, or about
the 1900 nm range (wavelengths in the range of 1900 nm may be
provided by Thulium lasers). Thus, by way of example, there is
contemplated the use of four, five, or six, 20 kW lasers to provide
a laser beam in a bit having a power greater than about 60 kW,
greater than about 70 kW, greater than about 80 kW, greater than
about 90 kW and greater than about 100 kW. One laser may also be
envisioned to provide these higher laser powers.
[0050] Preferably, the source of mechanical energy is a fixed
cutter drill bit or roller cone used as part of a laser-mechanical
bit. In general, the components of a laser mechanical bit may be
made from materials that are known to those of skill in the art for
such applications or components, or that are later developed for
such applications. For example, the bit body may be made from
steel, preferably a high-strength, weldable steel, such as SAE
9310, or cemented carbide matrix material. The blades may be made
from similar types of material. The blades and the bit body may be
made, for example by milling, from a single piece of metal, or they
may be separately made and affixed together. The cutters may be
made from for example, materials such as polycrystalline diamond
compact ("PDC"), grit hotpressed inserts ("GHI"), and other
materials known to the art or later developed by the art. Cutters
are commercially available from for example US Synthetic,
MegaDiamond, and Element 6. The roller cone arms may be made from
steel, such as SAE 9310. Like the blades, the arms and the bit body
may be made from a single piece of metal, or they may be made from
separate pieces of metal and affixed together. Roller cone inserts,
for example, may be made from sintered tungsten carbide insert
("TCI") or the roller cones may be made with milled teeth ("MTs").
Roller cones, roller cone inserts, and roller cones and leg
assemblies, may be obtained commercially from Varel International,
while TCI may be obtained from for example Kennametal or ATI Firth
Sterling. It is preferred that the inner surface of the beam path
be made of material that does not absorb the laser energy, and
thus, it is preferable that such surfaces be reflective or polished
surfaces. It is also preferred that any surfaces of the bit that
may be exposed to reflected laser energy, reflections, also be
non-absorptive, minimally absorptive, and preferably be polished or
made reflective of the laser beam.
[0051] An example of such a bit and system to provide the high
power laser energy and mechanical energy are set forth in FIGS. 1A
to C, and in FIG. 2.
[0052] In FIGS. 1A, 1B and 1C there is shown views of an embodiment
of a fixed cutter type laser-mechanical bit. Thus, there is
provided a laser-mechanical bit 100 having a body section 101 and a
bottom section 102. The bottom section 102 has mechanical blades
103, 104, 105, 106, 107, 108, 109, and 110.
[0053] The bit body 101 may have a receiving slot for each
mechanical blade. For example, in FIG. 1A receiving slots, 111,
112, 113, are 114 are identified. Note that with respect to blades,
of the type shown as blades 108, 109 and 110, the receiving slots
may be joined or partially joined, into a unitary opening. The bit
body 101 has side surfaces or areas, e.g., 115a, 115b, 117 in which
the blade receiving slots are formed. The bit body 101 has surfaces
or areas, e.g., 116a, 116b for supporting gauge pads, e.g., 141.
The bit body 101 further has surfaces 119a, 119b, 119c, 119d, that
in this embodiment are substantially normal to the surfaces 115a,
115b, 116a, 116b, which surfaces 115a, 115b, have part of the blade
receiving slots formed therein. The surface 119 a, 119b, 119c, 119d
are connected to surfaces 115a, 115b, 116a, 116b by angled surfaces
or areas 118a, 118b, 118c, 118d.
[0054] The bit is further provided with beam blades, 120, 121, 122,
123. In this embodiment the beam blades are positioned along
essentially the entirely of the width of the bit 100 and merge at
the end 126 of beam path slot 125 into a unitary structure. The
inner surfaces or sides of the beam blades form, in part, slot 125.
The outer surfaces or sides of the beam blades also form a sidewall
for the junk slots, e.g., 170. Thus, the beam blades are positioned
in both the bit body section 101 and the bottom section 102. Other
positions and configurations of the beam blades are contemplated.
In the embodiment of FIGS. 1A and 1B the bottom of the beam blades
is located at about the same level as the depth of cut limiters,
e.g., 146, that are located on blades 103, 107, i.e. depth of cut
blades, and slightly below the bottom of the cutters, e.g., 134. As
used herein "bottom" refers to the section of the bit that is
intended to engage or be closest to the bottom of a borehole, and
top of the bit refers to the section furthers away from the bottom.
The distance between the top and the bottom of the bit would be the
bit length, or longitudinal dimension; and the width would be the
dimension transverse to the length, e.g., the outside diameter of
the bit, as used herein unless specified otherwise.
[0055] The longitudinal position of the bottom of the beam blades
with respect to the cutters and any depth of cut limiters, e.g.,
the beam blades relative proximity to the bottom of the borehole,
may be varied in each bit design and configuration and will depend
upon factors such as the power of the laser beam, the type of rock
or earth being drilled, the flow of and type of fluid used to keep
the beam path clear of cuttings and debris. In general it is
preferable that the longitudinal positioning of the bottoms of the
beam blades, any depth of cut limiter blades and the cutter blades
all be relatively close, as shown in FIG. 1A, although other
positions and configurations are envisioned.
[0056] A beam path 124 is formed in the bit, and is bordered, in
part, by the inner surfaces or sides of the beam blades 120, 121,
122, 123 and the inner ends of blades 103, 105, 107 and 109. In
this embodiment the beam path extends through the center axis 161
of the bit and divides the bit into two separate sections, as more
clearly seen in FIG. 1B. Thus, it is preferable that the structures
and their configuration on one side of the beam path 124, be
similar, and more preferably the same, as the structures on the
other side of the beam path 124, which is the case for this
embodiment. This positioning and configuration is preferred,
although other positions and configurations are contemplated. The
beam path 124 should be close to, but preferably not touch the beam
blades or the beam blade inner surfaces. When using high power
laser energy, and in particular laser energy greater than 5 kW, 10
kW, 20 kW, 40 kW, 80 kW and greater, if the beam path, and, in
particular, the laser beam 160, which is propagated along the beam
path, contacts a blade it will melt or otherwise remove that
section of the blade in the beam path, and potentially damage the
remaining section of the blade, bit, or other bit structure or
component that is struck.
[0057] The beam path in this embodiment also serves as a fluid path
for a fluid, such as air, nitrogen, or a transmissive, or
substantially transmissive liquid to the laser beam. This fluid is
used to keep the laser beam path clear and also to remove or help
remove cuttings from the borehole. Configurations, systems and
methods for providing and removing such fluids in laser drilling,
and for keeping the beam path clear, as well as, the removal of
cuttings from the borehole, during laser drilling are provided in
the following US patent applications and US Patent Application
Publications: Publication No. US 2010/0044102, Publication No. US
2010/0044103, Publication No. US 2010/0044104, Ser. No. 12/896,021,
Ser. No. 13/211,729, Ser. No. 13/210,581 and Ser. No. 13/222,931,
the entire disclosures of each of which are incorporated herein by
reference.
[0058] The beam blades 120, 121, 122 and 123 form a beam path slot
125, which slot has ends, e.g., 126a, 126b. In this embodiment,
although other configurations and positions are contemplated, the
beam path slot 125 extends from the bottom section 102 partially
into the bit body section 101. The beam path slot 125 may also have
end sections 126a, 126b, these end sections 126a, 126b, are angled,
such that they do not extend into the beam path. The beam pattern,
e.g., the shape of the area of illumination by the laser upon the
bottom of the borehole, or at any cross section of the beam as it
is traveling toward the area to be cut, e.g., a borehole surface,
when the bit is not in rotation, in this embodiment is preferably a
narrow ellipse or rectangular type of pattern, and more preferably
may be such a generally elliptical rectangular pattern where less
energy or on laser energy is provided to center of pattern. (In
FIG. 1B the laser beam 160 is shown as having a beam pattern that
is substantially rectangular.) The beam path for this pattern
expands from the optics, not shown, until it strikes the bottom of
the borehole (see and compare, FIG. 1C showing a cross section of
the laser beam 160 and the beam path 161, with FIG. 1B showing the
bottom view of the laser beam pattern, and thus, the shape of the
area of illumination of the bottom surface of the borehole by the
laser beam when the beam is not rotating). It should additionally
be noted that in this embodiment the beam path is such that the
area of illumination of the bottom of the borehole surface is
wider, i.e., a larger diameter, than the diameter of the bit, put
about the same as the outer diameter of the gauge cutters. It is
contemplated that the area of illumination may be equal to the bit
diameter (excluding or including gauge cutters and/or gauge reamers
as forming the outer diameter of the bit), substantially the same
as the bit diameter (excluding or including gauge cutters and/or
gauge reamers as forming the outer diameter of the bit), greater
than the bit diameter (excluding or including gauge cutters and/or
gauge reamers as forming the outer diameter of the bit). The bottom
of the end section 126 also defines the end of the slot 125 with
respect to the outer surface of the bit body. In this embodiment
the end of the slot 125 is at about the same longitudinal position
as the end of the blades, e.g., 127.
[0059] The slot, beam slot or beam path slot refers to the opening
or openings, e.g., a slot, in the sides, or side walls, of the bit
that permit the beam path and the laser beam to extend out of, or
from the side of the bit, as illustrated, by way of example, in
FIG. 1C.
[0060] In the embodiment of FIGS. 1A-C there are provided gauge
cutters, 128, 129, 130, 131. The gauge cutters are located on
blades 105, 106, 109 and 110. Blades 106 and 110 only support gauge
cutters 128, 130. Blades 105, 109 support gauge cutters 131, 129,
as well as, bottom cutters 132, 133, 134, 138, 139, 140, which
cutters remove material from the bottom of the borehole, after it
has been softened, or otherwise weakened, e.g., laser-affected
material, by the laser beam 160. Depending upon the configuration
and shape of the laser beam, the gauge cutters may also be removing
laser-affected rock or material. Gauge pads, e.g., 141 are
positioned in surfaces of the bit body, e.g., 116a. In this
embodiment gauge reamers 142, 143, 144, 145 are positioned in
blades 104, 105 (and also similarly positioned in blades 108, 109
although not seen in FIG. 1A). Blades 103 and 107 have depth of cut
limiters, e.g., 146. The blades, and in particular the blades
having cutters, may have internal passages for cooling, e.g., vents
or ports, such as, e.g., 147, 148, 149 (it being noted that the
actual openings for vents 148, 149, are not seen in the view of
FIG. 1A).
[0061] As best illustrated in FIG. 1B, the cutters are positioned
with respect to each other, such that they each take a slightly
different path along the bottom of the borehole, in this way each
cutter is assisting in the removal of laser-affected rock, and
preferably does not encounter any rock that has not first been
affected by the laser. In this embodiment the distance of travel by
a cutter before it contacts laser-affected rock is shown by arc
162. Arc 162 defines an angle between the laser beam path, and in
this embodiment the laser beam, and the plane of the blade
supporting the cutters. This angle, which may be referred to as the
"beam path angle," can be from about 90 degrees to about 140
degrees, about 100 degrees to about 130 degrees, and about 110
degrees to about 120 degrees. Beam path angles of less than 90
degrees may be employed, but are not preferred, as they tend to not
give enough time for the heat deposited by the laser to affect the
rock before the cutter reaches the area of laser affected rock.
(Greater angles than 140 degrees may be employed, however, at
greater angles space and strength of component issues can become
significant, as the blades have very little space in which to be
positioned.) Additionally, when multiple blades are used, each
blade could have the same, substantially the same, or a different
angle (although care should be taken when using different angles to
make certain that the cutters and overall engagement with the
borehole surface is properly balanced.) In the embodiment of FIG.
1B this angle, defined by arc 162, is 135 degrees.
[0062] This angle between the laser beam (and the beam path, since
generally in a properly functioning bit they are coincident) and
the cutter position has a relationship to, and can be varied and
selected to, address and maximize, efficiency based upon several
factors, including for example, the laser power that is delivered
to the rock, the reflectivity and absorptivity of the rock to the
laser beam, the rate and depth to which the laser beam's energy is
transmitted into the rock, the thermal properties of the rock, the
porosity of the rock, and the speed, i.e., RPM at which the bit is
rotated. Thus, as the laser is fired, e.g., a laser beam is
propagated, along its beam path from optics to the surface of the
borehole, a certain amount of time will pass from when the laser
first contacts a particular area of the surface of the borehole
until the cutter revolves around and reaches that point. This time
can be referred to as soak time. Depending upon the above factors,
the soak time can be adjusted, and optimized to a certain extent by
the selection of the cutter-laser beam angle.
[0063] The bit 100 has channels, e.g., junk slots, 170, 171 that
provide a space between the bit 100 and the wall or side surface
150 of the borehole, for the passage of cuttings up the borehole.
The relationship of the gauge cutters 129, 128, 131, 130 as well as
other components of the bit 100 to the wall of the borehole 150 can
been seen in FIG. 1B.
[0064] The blades that support the cutters, 104, 105, 106, 108,
109, 110, i.e., the cutter blades, in the embodiment of FIGS. 1A-C,
are essentially right angle shaped. Thus, the bottom section of the
blades, i.e., the lower end holding the cutters that engage the
bottom and/or gauge of the borehole, and also the associated bottom
of the cutters positioned in that end (e.g., cutters 134,133,
132,129), are along an essentially straight line that forms a right
angle with the side section of the blades, i.e., the side end
holding the cutters that engage the side and/or gauge of the
borehole, and also the associated side of the cutters positioned in
that end (e.g., cutters 142, 144, 129) form a right angle. This
right angle configuration of all of the cutter blades, as shown in
the embodiment of FIG. 1, is referred to as a flat bottom
configuration, or a flat bottom laser-mechanical bit. Thus, the
lower ends of the blades, as well as their associated cutters, are
essentially co-planar and thus provided the flat bottom of the
bottom section 102 of the bit 100. Accordingly, in laser
mechanical-bits, having fixed cutters, it is preferable that the
bottom of the bit, as primarily defined by the end of the cutter
blades, and the position of the cutters in those ends, is
essentially flat and more preferably flat, and as such will engage
the borehole in an essentially even manner, and more preferably an
even manner, and will in general provide a borehole with an
essentially flat bottom and more preferably a flat bottom.
[0065] In the bit of FIG. 1 the cutters, e.g., 134, 133, 132, gauge
cutters, e.g., 129, and gauge reamers, e.g., 144, 142, may be PDC;
and the gauge pads, e.g., 141, may be carbide inserts, which
provides for impact resistance, enhanced wear, as well as bit
stability.
[0066] Further examples of laser-mechanical bits, beam paths, beam
patterns including split beam patterns, hybrid-laser-mechanical
bits, beam path angles and related processes and systems are
disclosed and taught in the following U.S. patent applications Ser.
No. 61/446,043 and co-filed patent application having attorney
docket no. 13938/79 (Foro s13a), the entire disclosures of each of
which are incorporated herein by reference.
[0067] Thus, in general, and by way of example, there is provided
in FIG. 2 a high efficiency laser drilling system 1000 for creating
a borehole 1001 in the earth 1002. FIG. 2 provides a cut away
perspective view showing the surface of the earth 1030 and a cut
away of the earth 1002 below the surface 1030. In general and by
way of example, there is provided a source of electrical power
1003, which provides electrical power by cables 1004 and 1005 to a
laser 1006 and a chiller 1007 for the laser 1006. The laser
provides a laser beam, i.e., laser energy, that can be conveyed by
a laser beam transmission means 1008 to a spool of tubing 1009. A
source of fluid 1010 is provided. The fluid is conveyed by fluid
conveyance means 1011 to the spool of tubing 1009.
[0068] The spool of tubing 1009, e.g., coiled tubing, composite
tubing or other conveyance device, is rotated to advance and
retract the tubing 1012. Preferred examples of such conveyance
means are disclosed and taught in the following US patent
applications and US Patent Application Publications: Publication
No. US 2010/0044106, Publication No. US 2010/0044104, Publication
No. US 2010/0044105, Publication No. US 2010/0044103, Publication
No. US 2010/0215326, Publication No. 2012/0020631, Ser. No.
13/210,581, Ser. No. 13/366,882 and Ser. No. 13/211,729, the entire
disclosures of each of which are incorporated herein by reference.
Thus, the laser beam transmission means 1008 and the fluid
conveyance means 1011 are attached to the spool of tubing 1009 by
means of rotating coupling means 1013. The tubing 1012 contains a
means to transmit the laser beam along the entire length of the
tubing, i.e., "long distance high power laser beam transmission
means," to the bottom hole assembly, 1014. The tubing 1012 also
contains a means to convey the fluid along the entire length of the
tubing 1012 to the bottom hole assembly 1014.
[0069] Additionally, there is provided a support structure 1015,
which holds an injector 1016, to facilitate movement of the tubing
1012 in the borehole 1001. Further other support structures may be
employed, for example, such structures could be derrick, crane,
mast, tripod, or other similar type of structure or hybrid and
combinations of these. As the borehole is advance to greater depths
from the surface 1030, the use of a diverter 1017, a blow out
preventer (BOP) 1018, and a fluid and/or cutting handling system
1019 may become necessary. The tubing 1012 is passed from the
injector 1016 through the diverter 1017, the BOP 1018, a wellhead
1020 and into the borehole 1001.
[0070] The fluid is conveyed to the bottom 1021 of the borehole
1001. At that point the fluid exits at or near the bottom hole
assembly 1014 and is used, among other things, to carry the
cuttings, which are created from advancing a borehole, back up and
out of the borehole. Thus, the diverter 1017 directs the fluid as
it returns carrying the cuttings to the fluid and/or cuttings
handling system 1019 through connector 1022. This handling system
1019 is intended to prevent waste products from escaping into the
environment and separates and cleans waste products and either
vents the cleaned fluid to the air, if permissible environmentally
and economically, as would be the case if the fluid was nitrogen,
or returns the cleaned fluid to the source of fluid 1010, or
otherwise contains the used fluid for later treatment and/or
disposal.
[0071] The BOP 1018 serves to provide multiple levels of emergency
shut off and/or containment of the borehole should a high-pressure
event occur in the borehole, such as a potential blow-out of the
well. The BOP is affixed to the wellhead 1020. The wellhead in turn
may be attached to casing. For the purposes of simplification the
structural components of a borehole such as casing, hangers, and
cement are not shown. It is understood that these components may be
used and will vary based upon the depth, type, and geology of the
borehole, as well as, other factors.
[0072] The downhole end 1023 of the tubing 1012 is connected to the
bottom hole assembly 1014. The bottom hole assembly 1014 contains
optics for delivering the laser beam 1024 to its intended target,
in the case of FIG. 1, the bottom 1021 of the borehole 1001. The
bottom hole assembly 1014, for example, also contains means for
delivering the fluid.
[0073] Thus, in general this system operates to create and/or
advance a borehole by having the laser create laser energy in the
form of a laser beam. The laser beam is then transmitted from the
laser through the spool and into the tubing. At which point, the
laser beam is then transmitted to the bottom hole assembly where it
is directed toward the surfaces of the earth and/or borehole.
[0074] Without being bound by the following theory providing an
explanation for the synergistic effects the present method obtains,
and without being bound by the following theory of energy-rock
interaction, physics and thermodynamics, the following theory is
offered by way of illustration and to assist in the understanding
of, and explanation for, the surprising and never before obtained
results of these methods.
[0075] Thus, this process can be viewed as a hybrid
thermal/mechanical process in which thermally-induced compressive
stresses are generated in a thin skin of rock at the drilling
surface. These thermally induced stresses create fractures parallel
to the surface of the rock and give rise to rock removal from the
borehole via chips of material. Mechanical cutter action is present
primarily to ensure continuous removal of the fractured material,
which in the presence of laser energy only might not be completely
expelled from the surface. The physics of the process and
experimental and theoretical results indicate that higher rates of
penetration can be achieved by increases in laser power delivered
to the drilling surface.
[0076] When laser power is absorbed by a rock, the response depends
on both the intensity of the impinging laser power, as well as, the
illumination time. As shown in the chart of FIG. 3, the material
response can generally include several regimes, which may be
generally classified as: an ultrafast regime 310, a heating regime
320, a melting regime 330, and a vaporization regime 340. Various
processes may occur along these regimes, such as shock hardening
341, drilling 342, glazing 331, cutting 332, welding 333, cladding
334, stereo lithography 321, and transformation hardening 322. At
laser intensities and times below the melting of rock, regime 340,
lies the regime in which spallation or rock fragmentation occur, as
shown in regime area 350. The spallation regime 350 is the
preferred area in which it is presently believed that the greatest
synergistic benefit for the tailored directed energy mechanical
energy process may occur.
[0077] When laser power is absorbed by the rock, a thin layer of
rock near the surface of the sample is rapidly heated. The
thickness of the layer is determined both by the quantity of
absorbed laser power, and the thermal properties of the rock. Rock
is a naturally insulating material, which means that the
propagation of heat into the rock is slow, and the heated region
may by necessity be very near the surface. In an unconstrained rock
sample, laser absorption would cause the heated region to expand in
volume. However, in a drilling environment, the heated rock is
constrained on all sides by the surrounding rock mass, and the
result is a thermally induced stress state in the heated section
that is compressive in nature.
[0078] When the magnitude of the thermally induced stress reaches a
level comparable to the compressive strength of the rock, it
induces fracture in the direction of the maximum compressive stress
(i.e., parallel to the heated surface). Under sufficiently large
stress, these fractures can extend to very long distances until
they intersect with the surface, resulting in the formation of
chips, in a process known as "spallation". Turning to FIG. 4, these
chips 401, 402, 403, 404 are characterized by a high aspect ratio,
e.g., the lateral dimensions 1.48'' arrow 411, and 1.87'' arrow 412
are much greater than the thickness 0.140'' of chip 404. These
chips, e.g., 401 of FIG. 4 are basalt. Similar characteristics of
dolomite chips are shown in FIG. 5. Thus, chips 501, 502, 503, 504,
505, 506, 507, 508, 509, 510, and 511 are characterized by a high
aspect ratio, e.g., the lateral dimensions 1.06'' arrow 521, and
1.52'' arrow 522, are much greater than the thickness 0.182'' of
chip 511.
[0079] However, spallation without a mechanical removal mechanism
may be and at time has been shown to be an unreliable drilling
solution. Not every rock type spalls (e.g., a spallable limestone
is believed to have never been identified, for example), and
macroscopic fractures in the rock mass can inhibit the spallation
process. Although the generation of thermal stress and
stress-induced fracture is likely a universal rock response, the
explosive release of spalled chips is presently believed to be
material specific.
[0080] The introduction of mechanical action to a primarily thermal
process, then, can increase robustness in a synergistic manner by
removing the thermally fractured and damaged material without
relying on explosive spallation for rock removal. For a combined
thermal/mechanical process, a laser represents an ideal directed
energy source, as a high flux of energy can be delivered to the
rock over a precisely controlled area designed to minimize heat
loads on the mechanical cutters. In the preferred method of
operation the role of the mechanical cutters is to provide a
minimum amount of pressure sufficient to remove the damaged
material; and so that they do not otherwise contribute
substantially to the rate of material removal.
[0081] The surface temperature of the rock during the process may
generally be around 250-650.degree. C., which is the temperature
rise sufficient to generate compressive stresses comparable to the
strength of the rock; broader ranges are provide in the table of
examples and may prove advantageous for various tailored drilling
conditions and parameters, Under intense laser power, the surface
temperature rise may be sufficient to melt rock directly under the
laser beam. This melting would reduce or eliminate the thermal
stresses responsible for laser processing, and is therefore
preferably a condition to be avoided for this method of processing.
Processes whereby the rock surface is melted allowed to cool and
then scraped off are contemplated. Such processes do not rely upon
a spallation regime and thus may have a broader application to
different materials and in particular materials that do not exhibit
spallation. Thus, this directed energy mechanical energy process is
not material specific.
[0082] The methods provided herein can further be understood by the
exemplary conditions and parameters set forth in the examples of
Table 1. As used in the Table 1, the headings have the following
meanings:
[0083] WOB: Weight on bit. Force applied by the bit. Units of
pounds.
[0084] ROP: Rate of penetration. This is the speed of advancement
of the drilling surface. Units of feet per hour.
[0085] RPM: Rotation speed of the bit in revolutions per
minute.
[0086] Torque: the degree of twist applied by the bit. Units of
foot-pounds.
[0087] Mechanical power: The power transmitted to the rock by the
bit, given by the equation torque*RPM. Units of kilowatts.
[0088] Ratio of DE/ME: The ratio of directed energy or directed
laser energy to mechanical energy is the delivered directed laser
energy (DE) divided by the delivered mechanical energy (ME).
Dimensionless number.
[0089] DE Power/Area: The directed energy laser power per unit of
drilling surface area. Units are Watts per square centimeter.
[0090] ME Power/Area: The delivered mechanical energy power per
unit of drilling surface area. Units are Watts per square
centimeter.
TABLE-US-00001 TABLE 1 Compressive Sonic Velocity Hole Diameter
Example # Rock Type Strength (ksi) (m/s) Porosity (%) Laser Power
(kW) RPM (inches) WOB 1 Sandstone 35 4800 3.8% 5 120 3.25 200 2
Sandstone 35 4800 3.8% 5 240 3.25 1000 3 Sandstone 35 4800 3.8% 5
360 3.25 200 4 Sandstone 35 4800 3.8% 5 720 3.25 2000 5 Sandstone
35 4800 3.8% 10 120 3.25 200 6 Sandstone 35 4800 3.8% 10 240 3.25
1000 7 Sandstone 35 4800 3.8% 10 360 3.25 200 8 Sandstone 35 4800
3.8% 10 720 3.25 2000 9 Sandstone 35 4800 3.8% 10 1200 3.25 500 10
Sandstone 35 4800 3.8% 15 120 3.25 200 11 Sandstone 35 4800 3.8% 15
240 3.25 1000 12 Sandstone 35 4800 3.8% 15 360 3.25 200 13
Sandstone 35 4800 3.8% 15 720 3.25 2000 14 Sandstone 35 4800 3.8%
15 1200 3.25 500 15 Sandstone 35 4800 3.8% 20 120 3.25 200 16
Sandstone 35 4800 3.8% 20 240 3.25 1000 17 Sandstone 35 4800 3.8%
20 360 3.25 200 18 Sandstone 35 4800 3.8% 20 720 3.25 2000 19
Sandstone 35 4800 3.8% 20 1200 3.25 500 20 Sandstone 35 4800 3.8%
25 240 3.25 1000 21 Sandstone 35 4800 3.8% 25 360 3.25 200 22
Sandstone 35 4800 3.8% 25 720 3.25 2000 23 Sandstone 35 4800 3.8%
25 1200 3.25 500 24 Sandstone 35 4800 3.8% 30 240 3.25 1000 25
Sandstone 35 4800 3.8% 30 360 3.25 200 26 Sandstone 35 4800 3.8% 30
720 3.25 2000 27 Sandstone 35 4800 3.8% 30 1200 3.25 500 28
Sandstone 35 4800 3.8% 10 240 6 1500 29 Sandstone 35 4800 3.8% 10
360 6 3000 30 Sandstone 35 4800 3.8% 10 720 6 2000 31 Sandstone 35
4800 3.8% 10 1200 6 500 32 Sandstone 35 4800 3.8% 20 120 6 500 33
Sandstone 35 4800 3.8% 20 240 6 1500 34 Sandstone 35 4800 3.8% 20
360 6 3000 35 Sandstone 35 4800 3.8% 20 720 6 2000 36 Sandstone 35
4800 3.8% 20 1200 6 500 37 Sandstone 35 4800 3.8% 30 120 6 500 38
Sandstone 35 4800 3.8% 30 240 6 1500 39 Sandstone 35 4800 3.8% 30
360 6 3000 40 Sandstone 35 4800 3.8% 30 720 6 2000 41 Sandstone 35
4800 3.8% 30 1200 6 500 42 Sandstone 35 4800 3.8% 40 120 6 500 43
Sandstone 35 4800 3.8% 40 240 6 1500 44 Sandstone 35 4800 3.8% 40
360 6 3000 45 Sandstone 35 4800 3.8% 40 720 6 2000 46 Sandstone 35
4800 3.8% 40 1200 6 500 47 Sandstone 35 4800 3.8% 50 120 6 500 48
Sandstone 35 4800 3.8% 50 240 6 1500 49 Sandstone 35 4800 3.8% 50
360 6 3000 50 Sandstone 35 4800 3.8% 50 720 6 2000 51 Sandstone 35
4800 3.8% 50 1200 6 500 52 Sandstone 35 4800 3.8% 60 240 6 1500 53
Sandstone 35 4800 3.8% 60 360 6 3000 54 Sandstone 35 4800 3.8% 60
720 6 2000 55 Sandstone 35 4800 3.8% 60 1200 6 500 56 Sandstone 35
4800 3.8% 70 240 6 1500 57 Sandstone 35 4800 3.8% 70 360 6 3000 58
Sandstone 35 4800 3.8% 70 720 6 2000 59 Sandstone 35 4800 3.8% 70
1200 6 500 60 Sandstone 35 4800 3.8% 80 360 6 3000 61 Sandstone 35
4800 3.8% 80 720 6 2000 62 Sandstone 35 4800 3.8% 80 1200 6 500 63
Sandstone 35 4800 3.8% 15 240 8.5 2000 64 Sandstone 35 4800 3.8% 15
360 8.5 3500 65 Sandstone 35 4800 3.8% 15 720 8.5 5000 66 Sandstone
35 4800 3.8% 15 1200 8.5 1000 67 Sandstone 35 4800 3.8% 30 120 8.5
1000 68 Sandstone 35 4800 3.8% 30 240 8.5 2000 69 Sandstone 35 4800
3.8% 30 360 8.5 3500 70 Sandstone 35 4800 3.8% 30 720 8.5 5000 71
Sandstone 35 4800 3.8% 45 120 8.5 1000 72 Sandstone 35 4800 3.8% 45
240 8.5 2000 73 Sandstone 35 4800 3.8% 45 360 8.5 3500 74 Sandstone
35 4800 3.8% 45 720 8.5 5000 75 Sandstone 35 4800 3.8% 45 1200 8.5
1000 76 Sandstone 35 4800 3.8% 60 120 8.5 1000 77 Sandstone 35 4800
3.8% 60 240 8.5 2000 78 Sandstone 35 4800 3.8% 60 360 8.5 3500 79
Sandstone 35 4800 3.8% 60 720 8.5 5000 80 Sandstone 35 4800 3.8% 60
1200 8.5 1000 81 Sandstone 35 4800 3.8% 75 120 8.5 1000 82
Sandstone 35 4800 3.8% 75 240 8.5 2000 83 Sandstone 35 4800 3.8% 75
360 8.5 3500 84 Sandstone 35 4800 3.8% 75 720 8.5 5000 85 Sandstone
35 4800 3.8% 75 1200 8.5 1000 86 Sandstone 35 4800 3.8% 90 120 8.5
1000 87 Sandstone 35 4800 3.8% 90 240 8.5 2000 88 Sandstone 35 4800
3.8% 90 360 8.5 3500 89 Sandstone 35 4800 3.8% 90 720 8.5 5000 90
Sandstone 35 4800 3.8% 90 1200 8.5 1000 91 Sandstone 35 4800 3.8%
105 120 8.5 1000 92 Sandstone 35 4800 3.8% 105 240 8.5 2000 93
Sandstone 35 4800 3.8% 105 360 8.5 3500 94 Sandstone 35 4800 3.8%
105 720 8.5 5000 95 Sandstone 35 4800 3.8% 105 1200 8.5 1000 96
Sandstone 35 4800 3.8% 120 240 8.5 2000 97 Sandstone 35 4800 3.8%
120 360 8.5 3500 98 Sandstone 35 4800 3.8% 120 720 8.5 5000 99
Sandstone 35 4800 3.8% 120 1200 8.5 1000 100 Dolomite 30 5400 3.2%
5 240 3.25 1000 101 Dolomite 30 5400 3.2% 5 360 3.25 200 102
Dolomite 30 5400 3.2% 5 720 3.25 2000 103 Dolomite 30 5400 3.2% 10
120 3.25 200 104 Dolomite 30 5400 3.2% 10 240 3.25 1000 105
Dolomite 30 5400 3.2% 10 360 3.25 200 106 Dolomite 30 5400 3.2% 10
720 3.25 2000 107 Dolomite 30 5400 3.2% 10 1200 3.25 500 108
Dolomite 30 5400 3.2% 15 120 3.25 200 109 Dolomite 30 5400 3.2% 15
240 3.25 1000 110 Dolomite 30 5400 3.2% 15 360 3.25 200 111
Dolomite 30 5400 3.2% 15 720 3.25 2000 112 Dolomite 30 5400 3.2% 15
1200 3.25 500 113 Dolomite 30 5400 3.2% 20 120 3.25 200 114
Dolomite 30 5400 3.2% 20 240 3.25 1000 115 Dolomite 30 5400 3.2% 20
360 3.25 200 116 Dolomite 30 5400 3.2% 20 720 3.25 2000 117
Dolomite 30 5400 3.2% 20 1200 3.25 500 118 Dolomite 30 5400 3.2% 25
120 3.25 200 119 Dolomite 30 5400 3.2% 25 240 3.25 1000 120
Dolomite 30 5400 3.2% 25 360 3.25 200 121 Dolomite 30 5400 3.2% 25
720 3.25 2000 122 Dolomite 30 5400 3.2% 25 1200 3.25 500 123
Dolomite 30 5400 3.2% 30 120 3.25 200 124 Dolomite 30 5400 3.2% 30
240 3.25 1000 125 Dolomite 30 5400 3.2% 30 360 3.25 200 126
Dolomite 30 5400 3.2% 30 720 3.25 2000 127 Dolomite 30 5400 3.2% 30
1200 3.25 500 128 Dolomite 30 5400 3.2% 10 240 6 1500 129 Dolomite
30 5400 3.2% 10 360 6 3000 130 Dolomite 30 5400 3.2% 10 720 6 2000
131 Dolomite 30 5400 3.2% 10 1200 6 500 132 Dolomite 30 5400 3.2%
20 120 6 500 133 Dolomite 30 5400 3.2% 20 240 6 1500 134 Dolomite
30 5400 3.2% 20 360 6 3000 135 Dolomite 30 5400 3.2% 20 720 6 2000
136 Dolomite 30 5400 3.2% 20 1200 6 500 137 Dolomite 30 5400 3.2%
30 120 6 500 138 Dolomite 30 5400 3.2% 30 240 6 1500 139 Dolomite
30 5400 3.2% 30 360 6 3000 140 Dolomite 30 5400 3.2% 30 720 6 2000
141 Dolomite 30 5400 3.2% 30 1200 6 500 142 Dolomite 30 5400 3.2%
40 120 6 500 143 Dolomite 30 5400 3.2% 40 240 6 1500 144 Dolomite
30 5400 3.2% 40 360 6 3000 145 Dolomite 30 5400 3.2% 40 720 6 2000
146 Dolomite 30 5400 3.2% 40 1200 6 500 147 Dolomite 30 5400 3.2%
50 120 6 500 148 Dolomite 30 5400 3.2% 50 240 6 1500 149 Dolomite
30 5400 3.2% 50 360 6 3000 150 Dolomite 30 5400 3.2% 50 720 6 2000
151 Dolomite 30 5400 3.2% 50 1200 6 500 152 Dolomite 30 5400 3.2%
60 120 6 500 153 Dolomite 30 5400 3.2% 60 240 6 1500 154 Dolomite
30 5400 3.2% 60 360 6 3000 155 Dolomite 30 5400 3.2% 60 720 6 2000
156 Dolomite 30 5400 3.2% 60 1200 6 500 157 Dolomite 30 5400 3.2%
70 120 6 500 158 Dolomite 30 5400 3.2% 70 240 6 1500 159 Dolomite
30 5400 3.2% 70 360 6 3000 160 Dolomite 30 5400 3.2% 70 720 6 2000
161 Dolomite 30 5400 3.2% 70 1200 6 500 162 Dolomite 30 5400 3.2%
80 120 6 500 163 Dolomite 30 5400 3.2% 80 240 6 1500 164 Dolomite
30 5400 3.2% 80 360 6 3000 165 Dolomite 30 5400 3.2% 80 720 6 2000
166 Dolomite 30 5400 3.2% 80 1200 6 500 167 Dolomite 30 5400 3.2%
15 120 8.5 1000 168 Dolomite 30 5400 3.2% 15 240 8.5 2000 169
Dolomite 30 5400 3.2% 15 360 8.5 3500 170 Dolomite 30 5400 3.2% 15
720 8.5 5000 171 Dolomite 30 5400 3.2% 15 1200 8.5 1000 172
Dolomite 30 5400 3.2% 30 120 8.5 1000 173 Dolomite 30 5400 3.2% 30
240 8.5 2000 174 Dolomite 30 5400 3.2% 30 360 8.5 3500 175 Dolomite
30 5400 3.2% 30 720 8.5 5000 176 Dolomite 30 5400 3.2% 45 120 8.5
1000 177 Dolomite 30 5400 3.2% 45 240 8.5 2000 178 Dolomite 30 5400
3.2% 45 360 8.5 3500 179 Dolomite 30 5400 3.2% 45 720 8.5 5000 180
Dolomite 30 5400 3.2% 60 120 8.5 1000 181 Dolomite 30 5400 3.2% 60
240 8.5 2000 182 Dolomite 30 5400 3.2% 60 360 8.5 3500 183 Dolomite
30 5400 3.2% 60 720 8.5 5000 184 Dolomite 30 5400 3.2% 75 120 8.5
1000 185 Dolomite 30 5400 3.2% 75 240 8.5 2000 186 Dolomite 30 5400
3.2% 75 360 8.5 3500 187 Dolomite 30 5400 3.2% 75 720 8.5 5000 188
Dolomite 30 5400 3.2% 75 1200 8.5 1000 189 Dolomite 30 5400 3.2% 90
120 8.5 1000 190 Dolomite 30 5400 3.2% 90 240 8.5 2000 191 Dolomite
30 5400 3.2% 90 360 8.5 3500 192 Dolomite 30 5400 3.2% 90 720 8.5
5000 193 Dolomite 30 5400 3.2% 90 1200 8.5 1000 194 Dolomite 30
5400 3.2% 105 120 8.5 1000 195 Dolomite 30 5400 3.2% 105 240 8.5
2000 196 Dolomite 30 5400 3.2% 105 360 8.5 3500 197 Dolomite 30
5400 3.2% 105 720 8.5 5000 198 Dolomite 30 5400 3.2% 105 1200 8.5
1000 199 Dolomite 30 5400 3.2% 120 120 8.5 1000 200 Dolomite 30
5400 3.2% 120 240 8.5 2000 201 Dolomite 30 5400 3.2% 120 360 8.5
3500 202 Dolomite 30 5400 3.2% 120 720 8.5 5000 203 Dolomite 30
5400 3.2% 120 1200 8.5 1000 204 Granite 20 4700 1.5% 5 240 3.25
1000 205 Granite 20 4700 1.5% 5 360 3.25 200 206 Granite 20 4700
1.5% 5 720 3.25 2000 207 Granite 20 4700 1.5% 5 1200 3.25 500 208
Granite 20 4700 1.5% 10 120 3.25 200 209 Granite 20 4700 1.5% 10
240 3.25 1000 210 Granite 20 4700 1.5% 10 360 3.25 200 211 Granite
20 4700 1.5% 10 720 3.25 2000 212 Granite 20 4700 1.5% 15 240 3.25
1000 213 Granite 20 4700 1.5% 15 360 3.25 200 214 Granite 20 4700
1.5% 15 720 3.25 2000 215 Granite 20 4700 1.5% 20 720 3.25 2000 216
Granite 20 4700 1.5% 25 720 3.25 2000 217 Granite 20 4700 1.5% 25
1200 3.25 500 218 Granite 20 4700 1.5% 30 720 3.25 2000 219 Granite
20 4700 1.5% 30 1200 3.25 500 220 Granite 20 4700 1.5% 10 120 6 500
221 Granite 20 4700 1.5% 10 240 6 1500 222 Granite 20 4700 1.5% 10
360 6 3000 223 Granite 20 4700 1.5% 10 720 6 2000 224 Granite 20
4700 1.5% 20 120 6 500 225 Granite 20 4700 1.5% 20 240 6 1500 226
Granite 20 4700 1.5% 20 360 6 3000 227 Granite 20 4700 1.5% 20 720
6 2000 228 Granite 20 4700 1.5% 20 1200 6 500 229 Granite 20 4700
1.5% 30 240 6 1500 230 Granite 20 4700 1.5% 30 360 6 3000 231
Granite 20 4700 1.5% 30 720 6 2000 232 Granite 20 4700 1.5% 30 1200
6 500 233 Granite 20 4700 1.5% 40 240 6 1500 234 Granite 20 4700
1.5% 40 360 6 3000 235 Granite 20 4700 1.5% 40 720 6 2000 236
Granite 20 4700 1.5% 40 1200 6 500 237 Granite 20 4700 1.5% 50 360
6 3000 238 Granite 20 4700 1.5% 50 720 6 2000 239 Granite 20 4700
1.5% 50 1200 6 500 240 Granite 20 4700 1.5% 60 720 6 2000 241
Granite 20 4700 1.5% 60 1200 6 500 242 Granite 20 4700 1.5% 70 720
6 2000 243 Granite 20 4700 1.5% 70 1200 6 500 244 Granite 20 4700
1.5% 80 1200 6 500
245 Granite 20 4700 1.5% 15 120 8.5 1000 246 Granite 20 4700 1.5%
15 240 8.5 2000 247 Granite 20 4700 1.5% 15 360 8.5 3500 248
Granite 20 4700 1.5% 15 720 8.5 5000 249 Granite 20 4700 1.5% 30
120 8.5 1000 250 Granite 20 4700 1.5% 30 240 8.5 2000 251 Granite
20 4700 1.5% 30 360 8.5 3500 252 Granite 20 4700 1.5% 30 720 8.5
5000 253 Granite 20 4700 1.5% 30 1200 8.5 1000 254 Granite 20 4700
1.5% 45 120 8.5 1000 255 Granite 20 4700 1.5% 45 240 8.5 2000 256
Granite 20 4700 1.5% 45 360 8.5 3500 257 Granite 20 4700 1.5% 45
720 8.5 5000 258 Granite 20 4700 1.5% 45 1200 8.5 1000 259 Granite
20 4700 1.5% 60 240 8.5 2000 260 Granite 20 4700 1.5% 60 360 8.5
3500 261 Granite 20 4700 1.5% 60 720 8.5 5000 262 Granite 20 4700
1.5% 75 240 8.5 2000 263 Granite 20 4700 1.5% 75 360 8.5 3500 264
Granite 20 4700 1.5% 75 720 8.5 5000 265 Granite 20 4700 1.5% 90
360 8.5 3500 266 Granite 20 4700 1.5% 90 720 8.5 5000 267 Granite
20 4700 1.5% 105 720 8.5 5000 268 Granite 20 4700 1.5% 120 720 8.5
5000 269 Basalt 40 5100 2.1% 5 120 3.25 200 270 Basalt 40 5100 2.1%
5 240 3.25 1000 271 Basalt 40 5100 2.1% 5 360 3.25 200 272 Basalt
40 5100 2.1% 5 720 3.25 2000 273 Basalt 40 5100 2.1% 10 240 3.25
1000 274 Basalt 40 5100 2.1% 10 360 3.25 200 275 Basalt 40 5100
2.1% 10 720 3.25 2000 276 Basalt 40 5100 2.1% 10 1200 3.25 500 277
Basalt 40 5100 2.1% 15 720 3.25 2000 278 Basalt 40 5100 2.1% 15
1200 3.25 500 279 Basalt 40 5100 2.1% 20 720 3.25 2000 280 Basalt
40 5100 2.1% 20 1200 3.25 500 281 Basalt 40 5100 2.1% 10 240 6 1500
282 Basalt 40 5100 2.1% 10 360 6 3000 283 Basalt 40 5100 2.1% 10
720 6 2000 284 Basalt 40 5100 2.1% 10 1200 6 500 285 Basalt 40 5100
2.1% 20 240 6 1500 286 Basalt 40 5100 2.1% 20 360 6 3000 287 Basalt
40 5100 2.1% 20 720 6 2000 288 Basalt 40 5100 2.1% 20 1200 6 500
289 Basalt 40 5100 2.1% 30 360 6 3000 290 Basalt 40 5100 2.1% 30
720 6 2000 291 Basalt 40 5100 2.1% 30 1200 6 500 292 Basalt 40 5100
2.1% 40 720 6 2000 293 Basalt 40 5100 2.1% 40 1200 6 500 294 Basalt
40 5100 2.1% 50 1200 6 500 295 Basalt 40 5100 2.1% 15 120 8.5 1000
296 Basalt 40 5100 2.1% 15 240 8.5 2000 297 Basalt 40 5100 2.1% 15
360 8.5 3500 298 Basalt 40 5100 2.1% 15 720 8.5 5000 299 Basalt 40
5100 2.1% 15 1200 8.5 1000 300 Basalt 40 5100 2.1% 30 120 8.5 1000
301 Basalt 40 5100 2.1% 30 240 8.5 2000 302 Basalt 40 5100 2.1% 30
360 8.5 3500 303 Basalt 40 5100 2.1% 30 720 8.5 5000 304 Basalt 40
5100 2.1% 45 240 8.5 2000 305 Basalt 40 5100 2.1% 45 360 8.5 3500
306 Basalt 40 5100 2.1% 45 720 8.5 5000 307 Basalt 40 5100 2.1% 45
1200 8.5 1000 308 Basalt 40 5100 2.1% 60 360 8.5 3500 309 Basalt 40
5100 2.1% 60 720 8.5 5000 310 Basalt 40 5100 2.1% 60 1200 8.5 1000
311 Basalt 40 5100 2.1% 75 720 8.5 5000 312 Basalt 40 5100 2.1% 75
1200 8.5 1000 313 Basalt 40 5100 2.1% 90 720 8.5 5000 314 Basalt 40
5100 2.1% 90 1200 8.5 1000 315 Basalt 40 5100 2.1% 105 1200 8.5
1000 Surface Temp. Mechanical DE Power/Area ME Power/Area Example #
ROP (ft/hr) Rise (DegC.) Torque (ft-lbs) Power (kW) Ratio of DE/ME
(W/cm{circumflex over ( )}2) (W/cm{circumflex over ( )}2) 1 5.5 434
13.1 0.22 22.3 93.4 4.2 2 6.6 341 65.7 2.24 2.2 93.4 41.8 3 5.7 341
13.1 0.67 7.4 93.4 12.6 4 15.9 170 131.4 13.44 0.4 93.4 251.0 5
10.6 651 13.1 0.22 44.7 186.8 4.2 6 12.4 504 65.7 2.24 4.5 186.8
41.8 7 11.7 467 13.1 0.67 14.9 186.8 12.6 8 19.4 308 131.4 13.44
0.7 186.8 251.0 9 13.1 338 32.9 5.60 1.8 186.8 104.6 10 14.5 866
13.1 0.22 67.0 280.3 4.2 11 17.1 660 65.7 2.24 6.7 280.3 41.8 12
16.8 592 13.1 0.67 22.3 280.3 12.6 13 24.4 416 131.4 13.44 1.1
280.3 251.0 14 19.2 410 32.9 5.60 2.7 280.3 104.6 15 17.5 1081 13.1
0.22 89.3 373.7 4.2 16 20.9 814 65.7 2.24 8.9 373.7 41.8 17 21.2
717 13.1 0.67 29.8 373.7 12.6 18 29.1 514 131.4 13.44 1.5 373.7
251.0 19 24.9 481 32.9 5.60 3.6 373.7 104.6 20 24.0 968 65.7 2.24
11.2 467.1 41.8 21 24.9 841 13.1 0.67 37.2 467.1 12.6 22 33.4 608
131.4 13.44 1.9 467.1 251.0 23 30.0 550 32.9 5.60 4.5 467.1 104.6
24 26.6 1121 65.7 2.24 13.4 560.5 41.8 25 28.1 965 13.1 0.67 44.7
560.5 12.6 26 37.2 700 131.4 13.44 2.2 560.5 251.0 27 34.8 619 32.9
5.60 5.4 560.5 104.6 28 3.7 311 182.0 6.20 1.6 54.8 34.0 29 6.5 217
364.0 18.60 0.5 54.8 102.0 30 5.6 204 242.6 24.80 0.4 54.8 136.0 31
3.4 257 60.7 10.34 1.0 54.8 56.7 32 6.6 575 60.7 1.03 19.4 109.6
5.7 33 7.4 451 182.0 6.20 3.2 109.6 34.0 34 9.7 362 364.0 18.60 1.1
109.6 102.0 35 9.2 312 242.6 24.80 0.8 109.6 136.0 36 7.2 322 60.7
10.34 1.9 109.6 56.7 37 9.6 754 60.7 1.03 29.0 164.5 5.7 38 10.8
582 182.0 6.20 4.8 164.5 34.0 39 13.1 480 364.0 18.60 1.6 164.5
102.0 40 12.9 398 242.6 24.80 1.2 164.5 136.0 41 11.0 381 60.7
10.34 2.9 164.5 56.7 42 12.2 933 60.7 1.03 38.7 219.3 5.7 43 13.8
711 182.0 6.20 6.5 219.3 34.0 44 16.3 591 364.0 18.60 2.2 219.3
102.0 45 16.4 478 242.6 24.80 1.6 219.3 136.0 46 14.6 439 60.7
10.34 3.9 219.3 56.7 47 14.3 1112 60.7 1.03 48.4 274.1 5.7 48 16.5
839 182.0 6.20 8.1 274.1 34.0 49 19.2 699 364.0 18.60 2.7 274.1
102.0 50 19.8 555 242.6 24.80 2.0 274.1 136.0 51 18.1 497 60.7
10.34 4.8 274.1 56.7 52 18.9 966 182.0 6.20 9.7 328.9 34.0 53 21.8
805 364.0 18.60 3.2 328.9 102.0 54 22.9 630 242.6 24.80 2.4 328.9
136.0 55 21.5 554 60.7 10.34 5.8 328.9 56.7 56 21.0 1093 182.0 6.20
11.3 383.7 34.0 57 24.2 910 364.0 18.60 3.8 383.7 102.0 58 25.8 705
242.6 24.80 2.8 383.7 136.0 59 24.7 611 60.7 10.34 6.8 383.7 56.7
60 26.3 1015 364.0 18.60 4.3 438.6 102.0 61 28.5 780 242.6 24.80
3.2 438.6 136.0 62 27.8 668 60.7 10.34 7.7 438.6 56.7 63 2.7 274
343.8 11.71 1.3 41.0 32.0 64 4.5 195 601.6 30.75 0.5 41.0 84.0 65
14.6 94 859.4 87.85 0.2 41.0 240.0 66 2.6 224 171.9 29.28 0.5 41.0
80.0 67 4.9 481 171.9 2.93 10.2 81.9 8.0 68 5.5 385 343.8 11.71 2.6
81.9 32.0 69 7.0 313 601.6 30.75 1.0 81.9 84.0 70 14.5 188 859.4
87.85 0.3 81.9 240.0 71 7.4 616 171.9 2.93 15.4 122.9 8.0 72 8.2
485 343.8 11.71 3.8 122.9 32.0 73 9.7 405 601.6 30.75 1.5 122.9
84.0 74 15.5 274 859.4 87.85 0.5 122.9 240.0 75 8.4 330 171.9 29.28
1.5 122.9 80.0 76 9.6 750 171.9 2.93 20.5 163.9 8.0 77 10.7 582
343.8 11.71 5.1 163.9 32.0 78 12.3 490 601.6 30.75 2.0 163.9 84.0
79 17.4 349 859.4 87.85 0.7 163.9 240.0 80 11.2 375 171.9 29.28 2.0
163.9 80.0 81 11.6 884 171.9 2.93 25.6 204.9 8.0 82 13.0 678 343.8
11.71 6.4 204.9 32.0 83 14.7 572 601.6 30.75 2.4 204.9 84.0 84 19.6
416 859.4 87.85 0.9 204.9 240.0 85 14.0 419 171.9 29.28 2.6 204.9
80.0 86 13.3 1018 171.9 2.93 30.7 245.8 8.0 87 15.1 774 343.8 11.71
7.7 245.8 32.0 88 17.0 652 601.6 30.75 2.9 245.8 84.0 89 21.9 479
859.4 87.85 1.0 245.8 240.0 90 16.7 463 171.9 29.28 3.1 245.8 80.0
91 14.9 1152 171.9 2.93 35.9 286.8 8.0 92 17.0 869 343.8 11.71 9.0
286.8 32.0 93 19.1 731 601.6 30.75 3.4 286.8 84.0 94 24.2 539 859.4
87.85 1.2 286.8 240.0 95 19.3 506 171.9 29.28 3.6 286.8 80.0 96
18.8 964 343.8 11.71 10.2 327.8 32.0 97 21.1 810 601.6 30.75 3.9
327.8 84.0 98 26.3 598 859.4 87.85 1.4 327.8 240.0 99 21.8 549
171.9 29.28 4.1 327.8 80.0 100 5.1 207 65.7 2.24 2.2 93.4 41.8 101
4.1 218 13.1 0.67 7.4 93.4 12.6 102 21.7 79 131.4 13.44 0.4 93.4
251.0 103 7.7 406 13.1 0.22 44.7 186.8 4.2 104 9.2 310 65.7 2.24
4.5 186.8 41.8 105 8.3 295 13.1 0.67 14.9 186.8 12.6 106 21.6 159
131.4 13.44 0.7 186.8 251.0 107 9.7 211 32.9 5.60 1.8 186.8 104.6
108 10.6 536 13.1 0.22 67.0 280.3 4.2 109 12.7 406 65.7 2.24 6.7
280.3 41.8 110 12.1 371 13.1 0.67 22.3 280.3 12.6 111 22.9 232
131.4 13.44 1.1 280.3 251.0 112 14.1 256 32.9 5.60 2.7 280.3 104.6
113 12.9 666 13.1 0.22 89.3 373.7 4.2 114 15.6 500 65.7 2.24 8.9
373.7 41.8 115 15.4 446 13.1 0.67 29.8 373.7 12.6 116 25.4 298
131.4 13.44 1.5 373.7 251.0 117 18.3 300 32.9 5.60 3.6 373.7 104.6
118 14.7 796 13.1 0.22 111.6 467.1 4.2 119 18.0 593 65.7 2.24 11.2
467.1 41.8 120 18.2 521 13.1 0.67 37.2 467.1 12.6 121 28.0 358
131.4 13.44 1.9 467.1 251.0 122 22.1 342 32.9 5.60 4.5 467.1 104.6
123 16.2 926 13.1 0.22 134.0 560.5 4.2 124 20.0 686 65.7 2.24 13.4
560.5 41.8 125 20.7 596 13.1 0.67 44.7 560.5 12.6 126 30.5 416
131.4 13.44 2.2 560.5 251.0 127 25.6 384 32.9 5.60 5.4 560.5 104.6
128 2.9 187 182.0 6.20 1.6 54.8 34.0 129 8.2 106 364.0 18.60 0.5
54.8 102.0 130 6.4 100 242.6 24.80 0.4 54.8 136.0 131 2.5 161 60.7
10.34 1.0 54.8 56.7 132 4.7 359 60.7 1.03 19.4 109.6 5.7 133 5.5
278 182.0 6.20 3.2 109.6 34.0 134 9.0 203 364.0 18.60 1.1 109.6
102.0 135 8.0 179 242.6 24.80 0.8 109.6 136.0 136 5.2 203 60.7
10.34 1.9 109.6 56.7 137 6.9 468 60.7 1.03 29.0 164.5 5.7 138 8.0
359 182.0 6.20 4.8 164.5 34.0 139 11.0 282 364.0 18.60 1.6 164.5
102.0 140 10.4 237 242.6 24.80 1.2 164.5 136.0 141 7.9 240 60.7
10.34 2.9 164.5 56.7 142 8.8 577 60.7 1.03 38.7 219.3 5.7 143 10.2
438 182.0 6.20 6.5 219.3 34.0 144 13.1 353 364.0 18.60 2.2 219.3
102.0 145 12.9 288 242.6 24.80 1.6 219.3 136.0 146 10.5 276 60.7
10.34 3.9 219.3 56.7 147 10.5 685 60.7 1.03 48.4 274.1 5.7 148 12.2
516 182.0 6.20 8.1 274.1 34.0 149 15.2 420 364.0 18.60 2.7 274.1
102.0 150 15.3 337 242.6 24.80 2.0 274.1 136.0 151 13.1 311 60.7
10.34 4.8 274.1 56.7 152 11.9 792 60.7 1.03 58.1 328.9 5.7 153 14.0
593 182.0 6.20 9.7 328.9 34.0 154 17.0 486 364.0 18.60 3.2 328.9
102.0 155 17.5 384 242.6 24.80 2.4 328.9 136.0 156 15.5 346 60.7
10.34 5.8 328.9 56.7 157 13.1 900 60.7 1.03 67.7 383.7 5.7 158 15.6
670 182.0 6.20 11.3 383.7 34.0 159 18.8 551 364.0 18.60 3.8 383.7
102.0 160 19.6 430 242.6 24.80 2.8 383.7 136.0 161 17.9 381 60.7
10.34 6.8 383.7 56.7 162 14.2 1008 60.7 1.03 77.4 438.6 5.7 163
17.1 747 182.0 6.20 12.9 438.6 34.0 164 20.3 615 364.0 18.60 4.3
438.6 102.0 165 21.6 476 242.6 24.80 3.2 438.6 136.0 166 20.1 415
60.7 10.34 7.7 438.6 56.7 167 1.5 215 171.9 2.93 5.1 41.0 8.0 168
2.2 162 343.8 11.71 1.3 41.0 32.0 169 5.5 94 601.6 30.75 0.5 41.0
84.0 170 19.7 46 859.4 87.85 0.2 41.0 240.0 171 2.1 133 171.9 29.28
0.5 41.0 80.0 172 3.5 301 171.9 2.93 10.2 81.9 8.0 173 4.1 236
343.8 11.71 2.6 81.9 32.0 174 6.3 176 601.6 30.75 1.0 81.9 84.0
175 19.8 92 859.4 87.85 0.3 81.9 240.0 176 5.3 384 171.9 2.93 15.4
122.9 8.0 177 6.1 299 343.8 11.71 3.8 122.9 32.0 178 8.0 239 601.6
30.75 1.5 122.9 84.0 179 19.7 138 859.4 87.85 0.5 122.9 240.0 180
7.0 465 171.9 2.93 20.5 163.9 8.0 181 7.9 359 343.8 11.71 5.1 163.9
32.0 182 9.8 294 601.6 30.75 2.0 163.9 84.0 183 19.7 183 859.4
87.85 0.7 163.9 240.0 184 8.4 546 171.9 2.93 25.6 204.9 8.0 185 9.6
418 343.8 11.71 6.4 204.9 32.0 186 11.5 345 601.6 30.75 2.4 204.9
84.0 187 20.1 228 859.4 87.85 0.9 204.9 240.0 188 10.2 262 171.9
29.28 2.6 204.9 80.0 189 9.7 627 171.9 2.93 30.7 245.8 8.0 190 11.2
476 343.8 11.71 7.7 245.8 32.0 191 13.2 395 601.6 30.75 2.9 245.8
84.0 192 20.9 270 859.4 87.85 1.0 245.8 240.0 193 12.1 289 171.9
29.28 3.1 245.8 80.0 194 10.9 708 171.9 2.93 35.9 286.8 8.0 195
12.6 534 343.8 11.71 9.0 286.8 32.0 196 14.7 444 601.6 30.75 3.4
286.8 84.0 197 21.9 310 859.4 87.85 1.2 286.8 240.0 198 14.0 316
171.9 29.28 3.6 286.8 80.0 199 11.9 789 171.9 2.93 41.0 327.8 8.0
200 13.9 592 343.8 11.71 10.2 327.8 32.0 201 16.1 493 601.6 30.75
3.9 327.8 84.0 202 23.1 348 859.4 87.85 1.4 327.8 240.0 203 15.8
342 171.9 29.28 4.1 327.8 80.0 204 7.3 481 65.7 2.24 2.2 93.4 41.8
205 5.2 507 13.1 0.67 7.4 93.4 12.6 206 47.9 177 131.4 13.44 0.4
93.4 251.0 207 7.4 331 32.9 5.60 0.9 93.4 104.6 208 8.7 1097 13.1
0.22 44.7 186.8 4.2 209 11.5 800 65.7 2.24 4.5 186.8 41.8 210 10.2
748 13.1 0.67 14.9 186.8 12.6 211 48.4 354 131.4 13.44 0.7 186.8
251.0 212 14.7 1099 65.7 2.24 6.7 280.3 41.8 213 14.0 985 13.1 0.67
22.3 280.3 12.6 214 48.7 530 131.4 13.44 1.1 280.3 251.0 215 48.8
706 131.4 13.44 1.5 373.7 251.0 216 48.8 883 131.4 13.44 1.9 467.1
251.0 217 26.2 898 32.9 5.60 4.5 467.1 104.6 218 48.7 1060 131.4
13.44 2.2 560.5 251.0 219 29.5 1030 32.9 5.60 5.4 560.5 104.6 220
2.8 606 60.7 1.03 9.7 54.8 5.7 221 4.4 423 182.0 6.20 1.6 54.8 34.0
222 18.5 232 364.0 18.60 0.5 54.8 102.0 223 14.3 197 242.6 24.80
0.4 54.8 136.0 224 5.7 951 60.7 1.03 19.4 109.6 5.7 225 7.4 701
182.0 6.20 3.2 109.6 34.0 226 18.4 464 364.0 18.60 1.1 109.6 102.0
227 14.4 393 242.6 24.80 0.8 109.6 136.0 228 7.0 465 60.7 10.34 1.9
109.6 56.7 229 10.0 953 182.0 6.20 4.8 164.5 34.0 230 18.5 695
364.0 18.60 1.6 164.5 102.0 231 15.9 570 242.6 24.80 1.2 164.5
136.0 232 10.3 580 60.7 10.34 2.9 164.5 56.7 233 12.2 1199 182.0
6.20 6.5 219.3 34.0 234 19.2 917 364.0 18.60 2.2 219.3 102.0 235
18.1 730 242.6 24.80 1.6 219.3 136.0 236 13.4 692 60.7 10.34 3.9
219.3 56.7 237 20.4 1130 364.0 18.60 2.7 274.1 102.0 238 20.3 882
242.6 24.80 2.0 274.1 136.0 239 16.3 801 60.7 10.34 4.8 274.1 56.7
240 22.3 1029 242.6 24.80 2.4 328.9 136.0 241 19.0 910 60.7 10.34
5.8 328.9 56.7 242 24.2 1173 242.6 24.80 2.8 383.7 136.0 243 21.5
1019 60.7 10.34 6.8 383.7 56.7 244 23.8 1127 60.7 10.34 7.7 438.6
56.7 245 2.1 503 171.9 2.93 5.1 41.0 8.0 246 3.5 347 343.8 11.71
1.3 41.0 32.0 247 12.6 193 601.6 30.75 0.5 41.0 84.0 248 43.5 110
859.4 87.85 0.2 41.0 240.0 249 4.5 770 171.9 2.93 10.2 81.9 8.0 250
5.7 573 343.8 11.71 2.6 81.9 32.0 251 12.5 387 601.6 30.75 1.0 81.9
84.0 252 43.9 219 859.4 87.85 0.3 81.9 240.0 253 5.8 381 171.9
29.28 1.0 81.9 80.0 254 6.5 1028 171.9 2.93 15.4 122.9 8.0 255 7.9
767 343.8 11.71 3.8 122.9 32.0 256 13.0 573 601.6 30.75 1.5 122.9
84.0 257 44.1 328 859.4 87.85 0.5 122.9 240.0 258 8.4 477 171.9
29.28 1.5 122.9 80.0 259 9.9 955 343.8 11.71 5.1 163.9 32.0 260
14.2 744 601.6 30.75 2.0 163.9 84.0 261 44.3 437 859.4 87.85 0.7
163.9 240.0 262 11.6 1138 343.8 11.71 6.4 204.9 32.0 263 15.6 906
601.6 30.75 2.4 204.9 84.0 264 44.5 546 859.4 87.85 0.9 204.9 240.0
265 17.0 1062 601.6 30.75 2.9 245.8 84.0 266 44.6 655 859.4 87.85
1.0 245.8 240.0 267 44.6 764 859.4 87.85 1.2 286.8 240.0 268 44.6
874 859.4 87.85 1.4 327.8 240.0 269 4.0 1122 13.1 0.22 22.3 93.4
4.2 270 4.8 868 65.7 2.24 2.2 93.4 41.8 271 4.2 849 13.1 0.67 7.4
93.4 12.6 272 12.1 432 131.4 13.44 0.4 93.4 251.0 273 8.8 1339 65.7
2.24 4.5 186.8 41.8 274 8.4 1219 13.1 0.67 14.9 186.8 12.6 275 14.3
803 131.4 13.44 0.7 186.8 251.0 276 9.7 851 32.9 5.60 1.8 186.8
104.6 277 17.6 1107 131.4 13.44 1.1 280.3 251.0 278 14.1 1061 32.9
5.60 2.7 280.3 104.6 279 20.6 1388 131.4 13.44 1.5 373.7 251.0 280
17.9 1265 32.9 5.60 3.6 373.7 104.6 281 2.7 782 182.0 6.20 1.6 54.8
34.0 282 4.9 549 364.0 18.60 0.5 54.8 102.0 283 4.2 501 242.6 24.80
0.4 54.8 136.0 284 2.4 613 60.7 10.34 1.0 54.8 56.7 285 5.4 1185
182.0 6.20 3.2 109.6 34.0 286 7.1 949 364.0 18.60 1.1 109.6 102.0
287 6.8 798 242.6 24.80 0.8 109.6 136.0 288 5.3 798 60.7 10.34 1.9
109.6 56.7 289 9.5 1286 364.0 18.60 1.6 164.5 102.0 290 9.5 1041
242.6 24.80 1.2 164.5 136.0 291 8.1 971 60.7 10.34 2.9 164.5 56.7
292 12.0 1270 242.6 24.80 1.6 219.3 136.0 293 10.8 1141 60.7 10.34
3.9 219.3 56.7 294 13.3 1309 60.7 10.34 4.8 274.1 56.7 295 1.5 856
171.9 2.93 5.1 41.0 8.0 296 1.9 674 343.8 11.71 1.3 41.0 32.0 297
3.4 482 601.6 30.75 0.5 41.0 84.0 298 11.1 244 859.4 87.85 0.2 41.0
240.0 299 1.9 527 171.9 29.28 0.5 41.0 80.0 300 3.5 1262 171.9 2.93
10.2 81.9 8.0 301 4.0 991 343.8 11.71 2.6 81.9 32.0 302 5.1 805
601.6 30.75 1.0 81.9 84.0 303 11.1 488 859.4 87.85 0.3 81.9 240.0
304 5.9 1282 343.8 11.71 3.8 122.9 32.0 305 7.1 1065 601.6 30.75
1.5 122.9 84.0 306 11.7 719 859.4 87.85 0.5 122.9 240.0 307 6.2 826
171.9 29.28 1.5 122.9 80.0 308 8.9 1309 601.6 30.75 2.0 163.9 84.0
309 12.9 924 859.4 87.85 0.7 163.9 240.0 310 8.3 957 171.9 29.28
2.0 163.9 80.0 311 14.4 1112 859.4 87.85 0.9 204.9 240.0 312 10.3
1086 171.9 29.28 2.6 204.9 80.0 313 15.9 1292 859.4 87.85 1.0 245.8
240.0 314 12.2 1213 171.9 29.28 3.1 245.8 80.0 315 14.1 1339 171.9
29.28 3.6 286.8 80.0
[0091] In these examples of drilling conditions and parameters, the
laser power is to be delivered to the rock surface. The examples
are for use with air as the fluid for drilling, and may be utilized
with, by way of example, the bits and systems that are described in
FIGS. 1A-C and 2 of this specification and with the bits and
systems disclosed and taught in U.S. patent applications Ser. No.
61/446,043 and co-filed patent application having attorney docket
no. 13938/79 (Foro s13a).
[0092] Thus, from the forgoing examples, which provide various
illustrative laser-mechanical drilling conditions and parameters,
there is contemplated generally, and by way of further example, a
method of laser-mechanical drilling a borehole in a formation
having at least 500 feet, at least about 1,000 ft, at least about
5,000 and at least about 10,000 feet of material having a hardness
greater than about 15 ksi, greater than about 20 ksi, greater than
about 30 ksi, and greater than about 40 ksi and at drilling rates,
e.g., ROP, of at least about 10 ft/hr, at least about 20 ft/hr, at
least about 30 ft/hr and at least about 40 ft/hr. Such methods in
generally would include, by way of example, drilling under the
following conditions and parameters: (i) an RPM of from about 240
to about 720, a WOB of less than about 2,000 lbs, a DE Power/Area
of about 90 W/cm.sup.2 to about 560 W/cm.sup.2, and an ME
Power/Area of about 4 W/cm.sup.2 to about 250 W/cm.sup.2; (ii) an
RPM of from about 600 to about 800, a WOB of less than about 5,000
lbs, a DE Power/Area of about 40 W/cm.sup.2 to about 250
W/cm.sup.2, and an ME Power/Area of about 200 W/cm.sup.2 to about
3000 W/cm.sup.2; (iii) an RPM of from about 600 to about 1250, a
WOB of from about 500 to about 5,000 lbs, a DE Power/Area of about
90 W/cm.sup.2 to about 570 W/cm.sup.2, and an ME Power/Area of
about 40 W/cm.sup.2 to about 270 W/cm.sup.2; (iv) an RPM of about
250, a WOB of from about 1,000 lbs, a DE Power/Area of about 370
W/cm.sup.2, and an ME Power/Area of about 40 W/cm.sup.2; (v) an RPM
of from about 720, a WOB of from about 2,000 lbs, a DE Power/Area
of about 190 W/cm.sup.2, and an ME Power/Area of about 250
W/cm.sup.2; (vi) an RPM of from about 720, a WOB of from about
2,000 lbs, a DE Power/Area of about 370 W/cm.sup.2, and an ME
Power/Area of about 250 W/cm.sup.2; (vii) an RPM of from about 720,
a WOB of from about 5,000 lbs, a DE Power/Area of about 290
W/cm.sup.2, and an ME Power/Area of about 240 W/cm.sup.2; (viii) an
RPM of from about 1,200, a WOB of from about 500 lbs, a DE
Power/Area of about 470 W/cm.sup.2, and an ME Power/Area of about
100 W/cm.sup.2; (ix) an RPM of from about 720, a WOB of from about
2,000 lbs, a DE Power/Area of about 470 W/cm.sup.2, and an ME
Power/Area of about 250 W/cm.sup.2; and, combinations and
variations of these.
[0093] Many other uses for the present inventions may be developed
or realized and thus, the scope of the present inventions is not
limited to the foregoing examples, uses conditions, and
applications. For example, in addition to the forgoing examples and
embodiments, the implementation of these directed/mechanical energy
processes may find applications in down hole tools, and may also be
utilized in holes openers, perforators, reamers, whipstocks, and
other types of boring tools.
[0094] The present inventions may be embodied in other forms than
those specifically disclosed herein without departing from their
spirit or essential characteristics. The described embodiments are
to be considered in all respects only as illustrative and not
restrictive.
* * * * *