U.S. patent application number 14/997072 was filed with the patent office on 2016-06-30 for system and assemblies for transferring high power laser energy through a rotating junction.
This patent application is currently assigned to FORO ENERGY, INC.. The applicant listed for this patent is FORO ENERGY, INC.. Invention is credited to Brian O. Faircloth, Jason D. Fraze, Daryl L. Grubb, Ryan P. McKay, Ryan J. Norton, Charles C. Rinzler, Mark S. Zediker.
Application Number | 20160187588 14/997072 |
Document ID | / |
Family ID | 49292260 |
Filed Date | 2016-06-30 |
United States Patent
Application |
20160187588 |
Kind Code |
A1 |
Norton; Ryan J. ; et
al. |
June 30, 2016 |
SYSTEM AND ASSEMBLIES FOR TRANSFERRING HIGH POWER LASER ENERGY
THROUGH A ROTATING JUNCTION
Abstract
There are provided high power laser devices and systems for
transmitting a high power laser beam across a rotating assembly,
including optical slip rings and optical rotational coupling
assemblies. These devices can transmit the laser beam through the
rotation zone in free space or within a fiber.
Inventors: |
Norton; Ryan J.; (Houston,
TX) ; McKay; Ryan P.; (Littleton, CO) ; Fraze;
Jason D.; (Littleton, CO) ; Rinzler; Charles C.;
(Boston, MA) ; Grubb; Daryl L.; (Houston, TX)
; Faircloth; Brian O.; (Evergreen, CO) ; Zediker;
Mark S.; (Castle Rock, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FORO ENERGY, INC. |
Houston |
TX |
US |
|
|
Assignee: |
FORO ENERGY, INC.
Houston
TX
|
Family ID: |
49292260 |
Appl. No.: |
14/997072 |
Filed: |
January 15, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13782942 |
Mar 1, 2013 |
9244235 |
|
|
14997072 |
|
|
|
|
13366882 |
Feb 6, 2012 |
9138786 |
|
|
13782942 |
|
|
|
|
13210581 |
Aug 16, 2011 |
8662160 |
|
|
13366882 |
|
|
|
|
12543986 |
Aug 19, 2009 |
8826973 |
|
|
13210581 |
|
|
|
|
12544136 |
Aug 19, 2009 |
8511401 |
|
|
12543986 |
|
|
|
|
61605401 |
Mar 1, 2012 |
|
|
|
61153271 |
Feb 17, 2009 |
|
|
|
61106472 |
Oct 17, 2008 |
|
|
|
Current U.S.
Class: |
385/26 |
Current CPC
Class: |
G02B 6/3604 20130101;
G02B 6/3871 20130101; G02B 6/2817 20130101; H01S 3/08 20130101;
G02B 6/4296 20130101; G02B 6/32 20130101; G02B 6/3897 20130101;
G02B 2006/4297 20130101 |
International
Class: |
G02B 6/36 20060101
G02B006/36; G02B 6/42 20060101 G02B006/42 |
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 rotational junction transmission device for transmitting very
high power laser energy, the device comprising: a. a housing having
a first end and a second end; b. a first plate rotatably affixed to
the first end of the housing, and a second plate affixed to the
second end of the housing, wherein the first and second plates and
the housing define a rotation junction there between; c. a means
for transferring a laser beam having at least about 20 kW of power
across the rotation junction.
2.-6. (canceled)
7. A self adjusting optical slip ring for transmitting high power
laser energy across a rotational transition, the slip ring
comprising: a first connector defining a mechanical, optical and
thermal tolerance; a second connector defining a mechanical,
optical and thermal tolerance; a launching body optics defining a
mechanical, optical and thermal tolerance; a receiving body optics
defining a mechanical, optical and thermal tolerance tolerance; and
all tolerances below a predetermined level, whereby the optical
slip ring is self-aligning.
8. An optical rotational coupling assembly, the assembly
comprising: a. a continuous length of a high power umbilical having
a first end section and a second end section; b. the end sections
on either side of a rotational junction; c. wherein the first end
is fixed in a non-rotatable manner; and, d. wherein the second end
rotatable, in a manner that does not twist the umbilical; e.
whereby the assembly is capable of delivering a laser beam across
the rotational junction.
9. The assembly of claim 8, wherein the assembly comprises: a first
non-rotating drum, a second rotating drum, and a revolving arm
assembly.
10. The assembly of claim 8, wherein the umbilical is configured in
a reversible helix.
Description
[0001] This application: (i) claims, under 35 U.S.C.
.sctn.119(e)(1), the benefit of the filing date of Mar. 1, 2012 of
provisional application Ser. No. 61/605,401; (ii) is a
continuation-in-part of U.S. patent application Ser. No.
13/210,581; (iii) is continuation-in-part of U.S. patent
application Ser. No. 13/366,882; (iv) is a continuation-in-part of
U.S. patent application Ser. No. 12/543,986; and, (iv) is a
continuation-in-part of U.S. patent application Ser. No.
12/544,136, which claims under 35 U.S.C. .sctn.119(e)(1) the
benefit of the filing date of Feb. 17, 2009 of provisional
application Ser. No. 61/153,271 and the benefit of the filing date
of Oct. 17, 2008 of provisional application Ser. No. 61/106,472,
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 conveyance
and deployment systems for use with high power laser tools and
systems and in high power laser operations. More particularly, the
present inventions relate to systems, methods and structures for
deploying equipment and conveying high power laser energy, alone or
in conjunction with other items, such as, data, electricity, gases
and liquids, to remote, difficult to access or hazardous locations,
such as oil wells, boreholes in the earth, pipelines, underground
mines, natural gas wells, geothermal wells, surface mines, subsea
structures, or nuclear reactors. The delivered high power laser
energy and other items may be used at the remote location for
activities, such as, monitoring, cleaning, controlling, assembling,
drilling, machining, powering equipment, milling, flow assurance,
decommissioning, plugging, abandonment, drilling, perforating, work
overs, completions, and fracturing.
[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, unless
specified otherwise, 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 high
power laser umbilical should be given its broadest possible
meaning, and would generally include: a high power laser optical
fiber; one, two, three, four or more high power laser optical
fibers in a bundle or assembly; a high power laser fiber(s) in a
protective covering(s), and a high power laser fiber(s) in a more
complex conveyance structure(s) having other channels for conveying
other materials such as fluids, wires, communication optical
fibers, support structures and the like; and, would include without
limitation all of the high power laser transmission structures and
configurations disclosed and taught in the following US Patent
Applications Publication Nos.: 2010/0044106; 2010/0215326;
2010/0044103; 2012/0020631; 2012/0068006; and 2012/0266803, the
entire disclosures of each of which are incorporated herein by
reference.
[0006] When operating in high power laser regimes, e.g., greater
than 1 kW, greater than 10 kW, greater than 20 kW, greater 50 kW,
greater than 80 kW, about 100 kW and greater, the difficulties and
problems associated with transmitting this high power laser energy
across a rotating junction increase by several orders of magnitude
compared with telecommunications power levels, e.g.,
milliwatts.
SUMMARY
[0007] There is a need to deploy high power laser umbilicals over
great distance from wound, coiled or compact configurations. This
need extends to delivering high power laser energy from the
umbilicals during deployment and recovery. The present inventions,
among other things, solve these needs by providing the articles of
manufacture, devices and processes taught herein.
[0008] Thus, there is provided herein a a rotational junction
transmission device for transmitting very high power laser energy,
the device having: a housing having a first end and a second end; a
first plate rotatably affixed to the first end of the housing, and
a second plate affixed to the second end of the housing, wherein
the first and second plates and the housing define a rotation
junction there between; a means for transferring a laser beam
having at least about 20 kW of power across the rotation
junction.
[0009] Further it is provided that this device may further have one
or more of: a pair of optical blocks, wherein each pair of optical
blocks is optically associated with a laser beam path, whereby the
optical block pair is capable of transmitting the laser beam across
a rotation junction; and at least one of the pair of optical blocks
passes through a second laser beam path; an optical block having a
plurality of transmissive reflective surfaces with in the block; at
least four high power laser couplers; an optical block that has at
least four transmissive reflective surfaces and each surface is
optically associated with a high power optical fiber; and a ratchet
mechanism.
[0010] Additionally there is provided a self adjusting optical slip
ring for transmitting high power laser energy across a rotational
transition, the slip ring having: a first connector defining a
mechanical, optical and thermal tolerance; a second connector
defining a mechanical, optical and thermal tolerance; a launching
body optics defining a mechanical, optical and thermal tolerance; a
receiving body optics defining a mechanical, optical and thermal
tolerance tolerance; and all tolerances below a predetermined
level, whereby the optical slip ring is self-aligning.
[0011] Still further there is provided an optical rotational
coupling assembly, the assembly having: a continuous length of a
high power umbilical having a first end section and a second end
section; the end sections on either side of a rotational junction;
wherein the first end is fixed in a non-rotatable manner; and,
wherein the second end rotatable, in a manner that does not twist
the umbilical; whereby the assembly is capable of delivering a
laser beam across the rotational junction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0013] FIG. 1A is a 1/4 cross sectional view of the embodiment of
FIG. 1.
[0014] FIG. 1B is a cross sectional view of the embodiment of FIG.
1.
[0015] FIG. 2 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0016] FIG. 2A is a cross sectional view of the embodiment of FIG.
2.
[0017] FIG. 3 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0018] FIG. 4 is a schematic view of an embodiment of a rotational
junction transmission device in accordance with the present
inventions.
[0019] FIG. 5 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0020] FIGS. 5A-5G are illustrations of the components of the
embodiment of FIG. 5.
[0021] FIGS. 6A & 6B are perspective views of an embodiment of
a rotational junction transmission device in accordance with the
present inventions.
[0022] FIGS. 6C & 6D are cross sectional view of the embodiment
of FIGS. 6A and 6B.
[0023] FIG. 6E is a histogram of an embodiment of a self-adjusting
optical slip ring of the present inventions.
[0024] FIG. 7 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0025] FIG. 8 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0026] FIG. 8A is a cross section of the embodiment of FIG. 8
[0027] FIG. 9 is a cut away perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0028] FIG. 9A is a perspective view of a component of the
embodiment of FIG. 9.
[0029] FIG. 10 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0030] FIG. 11 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0031] FIG. 12 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0032] FIG. 12A is a cross sectional view of the embodiment of FIG.
12.
[0033] FIG. 13 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0034] FIG. 13A is a cross sectional view of the embodiment of FIG.
13.
[0035] FIG. 14A is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0036] FIG. 14B is a plan view of the embodiment of FIG. 14B.
[0037] FIGS. 15A & 15B are perspective views of an embodiment
of a rotational junction transmission device in accordance with the
present inventions.
[0038] FIG. 15C is a cross sectional view of the embodiment of
FIGS. 15A and 15B.
[0039] FIG. 16 is a schematic of an embodiment of a rotational
junction transmission system in accordance with the present
inventions.
[0040] FIG. 17 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0041] FIG. 18 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0042] FIG. 18A is an enlarged cross sectional view of a section of
the embodiment of FIG. 18.
[0043] FIG. 19 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0044] FIG. 19A is a cross sectional view of the embodiment of FIG.
19 as shown during assembly.
[0045] FIG. 20 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0046] FIG. 21 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0047] FIG. 22 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0048] FIG. 23 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0049] FIG. 24 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0050] FIG. 25 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0051] FIG. 26 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0052] FIG. 27 is a cross sectional view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0053] FIG. 28 is a perspective sectional view of an embodiment of
a rotational junction transmission device in accordance with the
present inventions.
[0054] FIG. 28A is a cutaway view of a structure of the embodiment
of FIG. 28.
[0055] FIG. 29 is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
present inventions.
[0056] FIG. 29A is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
embodiment of FIG. 29.
[0057] FIG. 29B is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
embodiment of FIG. 29.
[0058] FIG. 29C is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
embodiment of FIG. 29.
[0059] FIG. 29D is a perspective view of an embodiment of a
rotational junction transmission device in accordance with the
embodiment of FIG. 29.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] In general, the present inventions relate to systems,
methods and equipment for deploying high power laser umbilicals
from a wound, coiled or compact configuration to a deployed
condition and for returning the umbilical from the deployed
condition to the wound, coiled or compact configuration. In
particular the present inventions relate to transmitting high power
laser energy through the umbilical during deployment, during
recovery and both.
[0061] Turning to FIG. 1 there is shown a perspective view of an
embodiment of an optical slip ring ("OSR"). The OSR 100 has a gear
box 101, a drive wheel 102 and a housing 103. The housing 103 has a
front plate 104, which moves, rotates, with respect to the housing
103. The housing has a back plate 105 that is fixed with the
housing 103, i.e., it does not rotate with respect to housing 103.
Drive wheel 102 drives front plate 104.
[0062] Front plate has high power laser connectors 106, 107, 108,
109, 110, 111, 112, which rotate with front plate 104. Each
connector has a high power laser umbilical, e.g., 106a, 107a, 109a,
112a, respectively associated with it. Housing 103 has high power
laser connectors 106b, 113, 114, 115, 109b, 107b, 112b. These
connectors are fixed with the housing. Each connector has a high
power laser umbilical 106c, 113c, 114c, 115c, 109c, 107c 112c
respectively associated with it.
[0063] In this embodiment the connectors and fibers in one section,
e.g., face plate 104, are rotationally associated with the
connectors and umbilicals in another section, e.g., housing 103.
Being rotationally associated either the face plate or the housing
may be fixed with the other section rotating. Preferably, the
fixed, non-rotating section is optically associated with the high
power laser. Thus, in one configuration of the embodiment of FIG. 1
umbilicals, e.g., 106a, 107a, 109a, 112a are each optically
associated with a high power laser, e.g., a 20 kW fiber laser; and
umbilicals 106c, 113c, 114c, 115c, 109c, 107c, 112c are optically
associated with one or more high power laser tools. In another
configuration umbilicals 106c, 113c, 114c, 115c, 109c, 107c, 112c
are each optically associated with a high power laser, e.g., a 20
kW fiber laser; and umbilicals, e.g., 106a, 107a, 109a, 112a are
optically associated with one or more laser tools. The umbilicals
in this embodiment may be, for example, high power optical fibers
in a metal tube ("FIMT")
[0064] The OSR 100 may be associated with a reel having a long
length of high power laser umbilical for use in deploying a high
power laser tool. This umbilical may be at least about 500 feet, at
least about 1,000 feet long, at least about 5,000 feet long, at
least about 10,000 feet long and longer. As the long umbilical is
unwound and deployed the OSR 100 permits the high power laser beams
to be transmitted across rotating junctions that are contained
within the housing 103. Thus, depending upon the diameter of the
reel, the OSR 100 permits the seven about 20 kW laser beams to be
transmitted and preferably continuously transmitted through, at
least about 20 rotations, at least about 50 rotations, at least
about 80 rotations, and more. These rotations may be in a first
direction, e.g., unwinding and in the opposite direction, e.g.,
winding.
[0065] Turning to FIG. 1A there is shown a 1/4 cross sectional view
of the OSR of the embodiment of FIG. 1. Optical blocks 120, 121,
122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132 are located
inside of housing 103. Optical blocks 131, 129, 127, 125, 123, 121
rotate with face plate 104, and have beam channels 133, 134, 135,
136, 137, 138. These blocks have bearings, e.g., 156, positioned
between them and the housing 103. The face plate 104 has bearing
assembly 139 between it and the housing 103. Optical blocks 120,
122, 124, 126, 128, 130, 132 rotate with the housing 103. These
optical blocks further each have a first annular window, e.g., 150,
a second annular window, e.g., 151 and a spacer band, e.g., 152
having a gap, e.g., 153. These optical blocks further each have a
laser beam launch channel, e.g., 154.
[0066] Thus, the embodiment of FIG. 1, as seen in FIG. 1A provides
for seven independent laser beam paths, 140, 141, 142, 143, 144,
145, 146. Beam path 140 is on the rotation axis of the OSR 100.
Beam path 140 is the only beam path that is entirely on the axis
from entering the housing until passing through its rotational
junction. Beam path 140 leaves connector 112, travels to reflector
163, where it is directed into the laser beam launch channel and
through the gap in the spacer band and into connector 112b. Beam
path 141 enters the face plate in an off-axis manner. Beam path 114
travels from connector 107 through the annular windows associated
with optical block 120 to reflector 160, where it is directed into
optical block 121 and reflector 161. Upon leaving reflector 161 the
laser beam path is now on axis, until it reaches reflector 162 and
is then directed into the beam launch channel 154, through gap 153
in spacer band 152, and into connector 107b. Thus, the transition
of the beam path between rotation and non-rotating blocks occurs
when the beam path, and thus the beam, is on axis, i.e., on the
axis of rotation of the OSR 100, and between optical block 121
(fixed with the front plate) and 122 (fixed with the housing).
[0067] FIG. 1B is a cross sectional view of the embodiment of FIG.
1. Axle 170 has rotary supports, e.g., 172, and inner drive wheels,
e.g., 171. The inner drive wheels rotate the optical blocks, e.g.,
121, that are associated with the wheels maintain this rotation
with the rotation of the front plate.
[0068] Turning to FIG. 2 there is shown a perspective view of an
OSR 200. The OSR 200 that has a rotary junction 201 having a first
housing 204 and a second housing 205. The first housing 204 has a
high power connector 202. The second housing 205 is connected to a
cover 206. The first housing and the second housing form rotation
junction 201. In this manner the cover 206 section and the
umbilical 202a section are rotatable with respect to each other.
The cover has seven beam tubes, 230, 231, 232, 233, 234, 235, 236
optically and mechanically associated with it. Each beam tube has a
high power connector 207, 208, 209, 210, 211, 212, 213,
respectively, associated with it, and each connector has a high
power umbilical 207a, 208a, 209a, 210a, 211a, 212a, 213a,
respectively, associated with it.
[0069] A cross sectional view of the embodiment of FIG. 2, is shown
in FIG. 2A. The housings 204 and 205 (which form the rotation
junction 201) have bearings 215. The laser beam 217 traveling along
laser beam path 277 leaves the connector 202 and enters an optical
element, e.g., collimating lens 218, and traveling in collimated
space enters transmissive and reflective optical block assembly
216. Upon entering optical block assembly 216 the laser beam 217,
traveling along the laser beam path, encounters a series of
partially reflective and partially transmissive surfaces 216a,
216b, 216c, 216d, 216e, 216f, and a final reflective surface 216g.
For each surface a predetermined amount, e.g., power, of the laser
beam 217 is reflected into the beam tubes. Thus, surface 216a
reflects a predetermined amount of laser beam 217, as laser beam
217a into beam tube 230 and lens 218a, which focuses and launches
the laser beam 217a into connector 207. The remaining laser beam
217 is transmitted through surface 216a and reaches surface 216b,
where the reflecting and transmitting process is repeated. This
occurs on down the line until the last surface 216g, which is
completely reflective, reflects the remaining laser beam 217 into
the beam tube 236, lens 218g and into the associated connector.
Thus, surface 216b reflects a predetermined amount of laser beam
217, as laser beam 217b into beam tube 231 and lens 218b, which
focuses and launches the laser beam 217b into connector 208.
Surface 216c reflects a predetermined amount of laser beam 217, as
laser beam 217c into beam tube 232 and lens 218c, which focuses and
launches the laser beam 217c into connector 209. Surface 216d
reflects a predetermined amount of laser beam 217, as laser beam
217d into beam tube 233 and lens 218d, which focuses and launches
the laser beam 217d into connector 210. Surface 216e reflects a
predetermined amount of laser beam 217, as laser beam 217e into
beam tube 234 and lens 218e, which focuses and launches the laser
beam 217e into connector 211. Surface 216f reflects a predetermined
amount of laser beam 217, as laser beam 217f into beam tube 235 and
lens 218f, which focuses and launches the laser beam 217f into
connector 212.
[0070] The percentage reflectance of each surface can be determined
so that the incoming laser beam is split into seven laser beams of
even power, or different and predetermined powers. Thus, for
example, a 141 kW incoming beam could be split into seven 20 kW
beams (the one lost kW accounting for losses through the optical
block and lenses, and is merely provide to identify that losses in
the optical block and lens assemblies in the OSR occur, and should
preferably be kept to a minimum. If not, cooling means for the
optical block and lens assemblies will be needed). Additionally,
surface 216g may be less than completely reflective, allowing for a
sensor to be placed on its other side to monitor if beam 217
travels the entire length of the optical block 216. These sensors
allow for the input beam parameters to be monitored. The umbilicals
in this embodiment may be, for example, high power optical fibers
in a metal tube ("FIMT"). The surfaces could also be reflective and
transmissive based upon specific wavelengths. In this manner the
optical block and the OSR could function as a beam combiner or a
beam splitter, depending upon the direction of travel of the laser
beams. This would also, in certain situation, permit one channel or
beam to be not operational, while the others could still be
operating.
[0071] FIG. 3 is a cross sectional view of an embodiment of an OSR
300 that uses the splitting optical block concept of the embodiment
of FIG. 2 to also provide for monitoring of back reflections and
other information on a channel, i.e., split beam path, by channel
basis. The OSR 300 that has a rotary junction 301 having a first
housing 304 and a second housing 305. The first housing 304 has a
high power connector 302. The second housing 305 is connected to a
cover 306. The first housing and the second housing form rotation
junction 301. In this manner the cover 306 section and the
umbilical 302a section are rotatable with respect to each other.
The cover has seven beam tubes, 308, 309, 310, 311, 312, 313, 314
optically and mechanically associated with it. Each beam tube has a
high power connector, e.g., 307, respectively, associated with it,
and each connector has a high power umbilical, e.g., 307a,
respectively, associated with it.
[0072] The housings 304 and 305 (which form the rotation junction
301) have bearings 315. The laser beam 317 traveling along a laser
beam path leaves the connector 302 and enters an optical element,
e.g., collimating lens 318, and traveling in collimated space
enters transmissive and reflective optical block assembly 316. Upon
entering optical block assembly 316 the laser beam 317, traveling
along the laser beam path, encounters a series of partially
reflective and partially transmissive surfaces 316a, 316b, 316c,
316d, 316e, 316f, and a final reflective surface 316g. For each
surface a predetermined amount, e.g., power, of the laser beam 317
is reflected into the beam tubes. Thus, surface 316a reflects a
predetermined amount of laser beam 317, as laser beam 317a into
beam tube 308 and lens 318a, which focuses and launches the laser
beam 317a into connector 307. The remaining laser beam 317 is
transmitted through surface 316a and reaches surface 316b, where
the reflecting and transmitting process is repeated. This occurs on
down the line until the last surface 316g, which is completely
reflective, reflects the remaining laser beam 317 into the beam
tube 314, lens 318g and into the connector. Thus, surface 316b
reflects a predetermined amount of laser beam 317, as laser beam
317b into beam tube 309 and lens 318b, which focuses and launches
the laser beam 317b into the connector. Surface 316c reflects a
predetermined amount of laser beam 317, as laser beam 317c into
beam tube 310 and lens 318c, which focuses and launches the laser
beam 317c into the connector. Surface 316d reflects a predetermined
amount of laser beam 317, as laser beam 317d into beam tube 311 and
lens 318d, which focuses and launches the laser beam 317d into the
connector. Surface 316e reflects a predetermined amount of laser
beam 317, as laser beam 317e into beam tube 312 and lens 318e,
which focuses and launches the laser beam 317e into the connector.
Surface 316f reflects a predetermined amount of laser beam 317, as
laser beam 317f into beam tube 313 and lens 318f, which focuses and
launches the laser beam 317f into connector 313. The umbilicals in
this embodiment may be, for example, high power optical fibers in a
metal tube ("FIMT").
[0073] The reflective-transmissive surfaces, e.g., 316 provide the
ability to have monitors, sensors and the like associated with
them. Thus, for example, back reflections that are transmitted back
up to the OSR by the umbilical would in be partially transmitted by
the reflective surfaces 316a, 316b, 316c, 316d, 316e, 316f, and
along monitoring beam paths 331a, 331b, 331c, 331d, 331e, 331f,
respectively, through monitoring beam path optics, e.g., focusing
lens, 319a, 319b, 319c, 319d, 319e, 319f, respectively, to sensors
314a, 314b, 314c, 314d, 314e, 314f respectively. Sensors are
associated with data transmission assembly (e.g., optical,
electric, or wireless) 320
[0074] In the embodiments of FIGS. 1, 2 and 3 seven umbilicals were
used for illustrative purposes, and because that is the preferred
number for packing in a circular configuration, based upon the size
of the connector, e.g., one centered with six around it. Preferably
a passively cooled connector of the type provided in US Patent
Application Publication No. 2013/0011102, the entire disclosure of
which is incorporated herein by reference, can be used. The
elimination of the water cooling lines simplifies the configuration
of the system, increases reliability, and provides for potentially
a smaller size OSR. Commercially available high power water cooled
connectors may also be used. It should further be understood that
more or less umbilicals may be used.
[0075] In FIG. 4 there is provided a conveyance structure handling
apparatus 400 having a housing 420 and an opening 421. Apparatus
400 has an assembly 421 for winding and unwinding the high power
conveyance structure 410. The assembly 421 has roller 422, 423. In
this embodiment the structure is stored in a helix 425 that can be
unwound and rewound as the tool is deployed and recovered. The
distal end of the conveyance structure has a connecting apparatus
430, which could be a fiber that is fused to a fiber in a tool or
other laser equipment, a fiber termination coupled to mechanical
connecting means, a commercially available high power water cooled
connecter, or more preferably a connector of the type provided in
US Patent Application Publication No. 2013/0011102, the entire
disclosure of which is incorporated herein by reference. The
proximal end 440 may be optically associated with a high power
laser source. This type of device could be mounted with the laser
as a modular system, an integrated system, a unified mobile system,
or separate from and optically associable with a high power laser
or laser cabin.
[0076] In FIG. 5 there is provided a prospective cutaway view of an
embodiment of a wrapping type optical coupling rotation assembly
("ORCA"). In general, ORCAs enable the high power laser energy to
be transmitted across a rotation junction without requiring the
beam to be launched through free space, e.g., the laser beam can be
transmitted across a rotating junction while remaining within the
optical fiber or other total internal reflection optical
transmission structure.
[0077] The ORCA 5000 has an outer housing 5001 that is affixed to
plate 5002. An inner shaft member or central support 5007 is
affixed to plate 5003. Two high power laser umbilicals 5004, 5006,
e.g., optical fibers in protective outer coverings, enter plate
5003 through cable feed through assembly 5011. Plate 5003 and shaft
5007 rotate together and plate 5002 and outer housing 5001 rotate
together. Inside of the outer housing 5001 and around shaft 5007 is
wrap assembly section 5008. Wrap assembly section 5008 is made up
of many links, e.g., 5009, 5010. There is also a second cable feed
through 5012, 5001 and a second plate 5003.
[0078] In FIG. 5A there is shown a perspective view of the wrap
assembly section 5008, and the center axis 5013 around which the
wrap is positioned. One, two, three, four or more of these wrap
sections may be joined together in this embodiment of an ORCA to
provide for a greater number of revolutions, and thus, longer
deployment distance from an associated umbilical real. In FIGS. 5B
and 5C there are shown the two rotating components of the ORCA
5000. The plate-shaft assembly 5003-5007 are shown with respect to
the axis 5013. On the inner surface of plate 5003 there are PTFE
(Teflon.RTM.) bearings 5018, 5019, 5020. These bearings engage the
inner surface 5022 of outer housing 5001 and provide for smooth
rotation. Bolt 5017 holds assembly 5003-5007 axially in place with
respect to assembly 5001-5002, while still allowing relative
rotation between 5007 and 5002. Bolt holes, e.g., 5021 are provided
for attaching the ORCA, and in particular the rotation assembly
5003-5007 to a reel having the deployment umbilical. The
plate-outer housing assembly 5002-5001 has bolt holes 5016 to affix
the assembly and manage reaction torque as the components are
rotated. Turning to FIGS. 5D, 5E and 5F there are provided
perspective view of the linkages in the wrap section, and a diagram
showing their preferred geometry. The link 5009, is shown with
umbilicals 5004, 5006 positioned in the link. The link 5009 forms a
trapezoidal tray 5023 that holds the fibers and other cables or
conveyance structures. Base 2024 has a long side wall 5025 and a
short side wall 5030, which are connected to the base 5024 short
side 5026 and the base 5024 long side 5025 respectively. The tray
5023 has angled sides 5027, 5027 for connecting to an adjacent
link. FIG. 5G provides a diagram and formula for determining an
example of the shape of the tray and its angled sides. During
operation, a multitude of trapezoidal trays 5023 form an
approximation of a conical frustrum. The geometry of the frustrum
in addition to other parameters, predetermines the minimum bend
radius that the umbilicals 5004 and 5006 will experience during
operation. One, two, three, four or more of these conical frustrum
wrap sections may be joined together in this embodiment of an ORCA
to provide for a greater number of revolutions, and thus, longer
deployment distance from an associated umbilical real.
[0079] The short side wall 5030 has pins 5041, 5040 and holes 5060,
5061. These holes and pins are used to connect the tray 5023 to
connecting hinge plate 5031. Bolts 5042, 5043 extend through holes
5032, 5061 and 5033, 5061 when the hinge is positioned with links
(see FIG. 5D). Holes 5045 and 5046 are used to hold tie down bar
5044. Hinge plate 5031 has a first arcuate cut out 5034, and a
second arcuate cut out 5035, which function with pins 5041, 5040.
Surface 5036, 5037 of arcuate cut outs 5034, 5035, engage the pins,
e.g., 5041, 5040.
[0080] Self-aligning high power OSRs overcome the problems of
contamination, e.g., dirt in the high power laser beam path, that
can occur when adjustments are made, and in particular when
adjustments are made in the field. Further, adjustment mechanisms,
because they are adjustable, by their nature go out of adjustment
over time and with use, which can be problematic in high power
regimes. For example, a 20 kW laser beam that moves out of
alignment by only a few microns can destroy the entire OSR. Thus,
these self-aligning embodiments overcome these problems. (ORCAs
also overcome these problems, because the beam is kept contained in
the optical fiber through the rotation junction.) By self-aligning
it is meant that the optical components are configured in the OSR
such that no adjustment mechanisms are necessary after the OSR has
been assembled and sealed. Thus, as assembled in the OSR the
optical components are aligned to transmit high power laser energy,
e.g., 10 kW, 20 kW, 50 kW or more, across the free space of a
rotation junction. During use and through multiple revolutions in
one direction of rotation and then in the other, and under
environment conditions and vibrations, the optical components
remain aligned, without the need for adjustment.
[0081] Thus, for example, an self aligning OSR may have the
following operating parameters of Table I (below) and remain self
aligning over that entire range of parameters.
TABLE-US-00001 Max Laser power 20 kW Wavelength 1060-1080 nm NA
.2-.24 Max loss 2% Max operational 5G rms vibration Shock 9G
Temperature 0-140 F. Humidity 0-100%
[0082] Turning to FIGS. 6A and 6B there is provided an embodiment
of a self-aligning high power OSR 600, having optical assembly 680
for receiving the high power laser beam from the laser, and optics
assembly 681 which rotates and launches the high power laser beam
from the OSR 600. Optics assembly 680 has an umbilical, e.g.,
shielded optical fiber 682 and an associated strain relief clamp
621. Optical assembly 681 has an umbilical, e.g., shielded optical
fiber 683 and an associated strain relief clamp 627. Housing 601
has a first end that is attached to back plate 613 having a back
plate surface 684 and a second end that is attached to optics
assembly 680. The housing 601 is attached to and supported by frame
614 of base 625. Back plate 684 and housing 601 are fixed to base
625, which preferably does not rotate. Front plate 606 rotates. The
OSR has cooling lines 685, 686, 671, 626, 672, 603, electric lines,
e.g., 617 electrical or sensor inputs or connectors 650, 651, 652,
(the fourth connector 652a is obscured from view in FIG. 6A),
electrical or sensor outputs or connectors 607, 653, 655, 654, as
well as, pins 657, 656, (which can be used to engage a reel) and
ports 688, 689, which are associated with a manifold 687.
[0083] Further, thermal lensing affects may be avoided by using
materials such as Suprasil.
[0084] Turning to FIGS. 6C and 6D there are provided cross
sectional views of OSR 600 along lines C-C and D-D of FIG. 6B,
respectively. Thus, the OSR has a housing 601 that is fixed to back
plate 684. The other, i.e., non-high power, slip ring components,
such as electrical, data, fluid, are positioned on the interior of
back plate 684 and between back plate 684 and rotating plate 606.
Thus contained in the area between the back plate 684 and the
rotating plate 606 are an electrical slip ring 612, a rotating
plate 605 for a fluid slip ring and a stationary plate 613 that
together make up a fluid slip ring. The main rotary plate 606 has a
preload nut 615, and bearings 616, 611, which are on an optical
tube body 608 connected to the rotary plate 606. A rotary seal 604
is provided for the fluid slip ring.
[0085] The path of the laser beam through the OSR and the rotation
junction is as follows. A fiber connector 620 is optically
associated with fiber 682 and is positioned in body 623 of optics
assembly 680. A strain relief housing 622 surrounds a portion of
the connector 620. The fiber connector 620 launches high power
laser beam 690 along a beam path toward non-rotating optic 692.
Optic 692 collimates the laser beam and launches the collimated
beam 693 across the rotational junction and to the rotating optic
694, which focuses the laser beam 696 into the receiving fiber
connector 620a that is in optical tube body 608 of rotating optics
assembly 681. Ledges 692 and 695 hold optics 692 and 694
respectively.
[0086] To obtain a self-aligning OSR all key tolerances in the
system must be analyzed, and optimized, to provide for the laser
beam 696 to be targeted in correct location and within a
predetermined acceptable limit. These tolerances include, for
example, mechanical component manufacturing tolerances, optical
component tolerances, worst case NA, worst case thermal effects,
worst case vibration effects, and others. These tolerances are then
evaluated under a Monte Carlo analysis, and as seen in FIG. 6E
provide distribution curve 651 of likely spot size variability. A
predetermined point is selected 650 at which a remainder 652 of
variability is acceptable. As long as the total system remains
below line 650 the OSR will be self-aligning. Thus, for example,
line 650 represents the receiving fiber O, and the amount of the
curve to the right of 650 is the risk of the OSR not working.
[0087] In FIG. 7 there is provided an embodiment of a handling
apparatus that is configured to provide figure-8 looped wraps. This
configuration does not require an optical slip ring and does not
place twist in the conveyance structure. Thus, in FIG. 7 there is
provided a Figure-8 looping apparatus 712 having a base 701. The
base has two wrapping posts 705, 706. The umbilical, e.g., a
conveyance structure 702 has a proximal end 703, which may be
connected to a high power laser or laser cabin, and a distal end
704, which is paid out and may be associated with a laser tool. As
shown in FIG. 7, the conveyance structure is formed into several
figure-8 loops, one located above the next. Thus, for purpose of
illustration, four such loops are shown: a first loop 707 which is
lowest and adjacent the base 701; a second loop 708, which is
generally above the first loop 707, a third loop 709, which is
generally above the second loop 708, and a fourth loop 710, which
is generally above the third loop 709. Although four loops are
shown, it is understood that for a conveyance structure a km or
longer, many more, hundreds and potentially thousands, of such
figure-8 loops will be present.
[0088] In FIG. 8 there is provided a perspective view of a ratchet
type optical transmission system 800 for transmitting laser energy
across a rotation junction. One one side of the drum 802 there are
seven connectors, e.g., 803, 805, 807, that have high power optical
fibers e.g., 808, 806, 804 associated with them. On the other side
of drum 802 are also seven connectors, e.g., 809, 811, that have
high power laser fibers, e.g., 810, 812 associated with them.
Turning to FIG. 8A, which shows a cross section of the transmission
device 800, two rotating discs 813, 814, are positioned within the
drum 802 and supported by bearing assemblies 830, 812. The drum 802
is held by support 801.
[0089] In operation the laser beams are fired and travel along
laser beam paths, e.g., 818, 816 that travel through openings,
e.g., 815, 817 in the disks. In operation disks 814 and 813 rotate
together as the laser beams are fired, when the disks have rotated
to a point where the twisting of the fibers is at a predetermined
maximum, the outer lasers, e.g., 816, are shut off, and the disks
whose fibers are attached to the laser (or other non-rotating
component of the system) is rotated in the reverse direction to
relieve the stress from twisting. When the reverse rotation is
taking place, the other disk can continue to rotate in a forward
direction, additionally the center laser beam 817 can continue to
be fired. Once the twisting stress has been released, the two disks
can then rotate together with all lasers firing.
[0090] Turning to FIG. 9 there is shown a cutaway perspective view
of a ratchet type optical transmission system 900 for transmitting
laser energy across a rotation junction. The system 900 has frame
902 that supports a non-rotating disc 903 and a rotating disc 914.
Disc 903 has five fibers and connectors, e.g., 904, 905 associated
with it. Disc 914, which rotates, has six optical fibers and
connectors, e.g., 911, 913, 910 associated with it, and a
receptacle 908, 909, 912 associated with each. In operation as disc
914 rotates the mechanism 906 will move socket 907, having a
connector 905 from one receptacle 908 to an adjacent receptacle
909. During the movement of the socket the laser beam for that
particular connector will have to be turned off, leaving the other
four lasers to be fired. This process can then be repeated over
again in a step wise operation where at least four laser beams are
always firing as the rotation disc 914 is rotated. FIG. 9A is a
detailed perspective view of the ratchet mechanism without the
frame 902 and non-rotating disc 903.
[0091] Generally the reels that may be used with the rotational
junction transmission devices can be for example any reel that has
a laser umbilical wound around its axle or central hub so that the
umbilical is capable of being unwound, e.g., deployed, from the
reel and wound onto the reel, e.g., retrieved. The umbilicals may
have lengths of greater than about 0.5 km, about 1 km, about 2 km,
about 3 km and greater and may have: a core; a cladding; a coating;
a first protective layer; and, a second protective layer as well as
other passages and wires. The umbilicals may be capable of
transmitting high power laser energy for its length with a power
loss of less than about 2 dB/km and more preferably less than about
1 dB/km and still more preferably less than about 0.5 dB/km and yet
more preferably about 0.3 dB/km. The outer diameter of the reel
when wound is preferably less than about 6 m (meters) to facilitate
transporting of the spool by truck.
[0092] An embodiment of an OSR incorporated into the hollow axle of
a spool has the spool in a configuration that has a hollow central
axis, or such an axis is associated with the spool, where the
optical power is transmitted to the input end of the optical fiber,
e.g., as shown in FIG. 11. The beam will be launched down the
center of the spool, the spool rides on precision bearings in
either a horizontal or vertical orientation to prevent any tilt of
the spool as the fiber is spooled out. It is optimal for the axis
of the spool to maintain an angular tolerance of about +/-10
micro-radians, which is preferably obtained by having the optical
axis isolated and/or independent from the spool axis of rotation.
The beam when launched into the fiber is launched by a lens which
is rotating with the fiber at the Fourier Transform plane of the
launch lens, which is insensitive to movement in the position of
the lens with respect the laser beam, but sensitive to the tilt of
the incoming laser beam. The beam, which is launched in the fiber,
is launched by a lens that is stationary with respect to the fiber
at the Fourier Transform plane of the launch lens, which is
insensitive to movement of the fiber with respect to the launch
lens. The spool's outer plate may be mounted to the spool support
using a Delrin plate, while the inner plate floats on the spool and
pins rotate the assembly. The optical fiber slip ring is attached
to the stationary fiber, and communicates power across the rotating
spool hub to the rotating fiber.
[0093] A general type of spool embodiment is to use a stationary
spool similar to a creel and rotate the distal end of the structure
or the laser tool attached to the distal end of the fiber in the
structure, as the conveyance structure spools out to keep the
conveyance structure and thus the fiber from twisting as it is
extracted from the spool. The fiber can be designed to accept a
reasonable amount of twist along its length. Using this type of the
approach if the conveyance structure, and thus, the fiber could be
pre-twisted around the spool then as the conveyance structure and
the fiber are extracted from the spool, the conveyance structure
straightens out and there is no need for the fiber and in
particular its distal end to be rotated as the conveyance structure
is paid out. There may be a series of tensioners that can suspend
the fiber down the hole, or if the hole is filled with water to
extract the debris from the bottom of the hole, then the fiber can
be encased in a buoyant casing that will support the weight of the
fiber and its casing the entire length of the hole. In the
situation where the distal end does not rotate and the fiber is
twisted and placed under twisting strain, there will be the further
benefit of reducing SBS.
[0094] A further illustration of an optical connection for a
rotation spool is provided in FIG. 10, wherein there is illustrated
a spool 1000 and a support 1001 for the spool 1000. The spool 1000
is rotatable mounted to the support 1001 by load bearing bearings
1002. An input optical cable 1003, which transmits a laser beam
from a laser source (not shown in this figure) to an optical
coupler 1005. The laser beam exits the connector 1005 and passes
through optics 1009 and 1010 into optical coupler 1006, which is
optically connected to an output optical cable 1004. The optical
coupler 1005 is mounted to the spool by a preferably non-load
bearing 1008 (e.g., the bearing 1008 is not carrying, or is
isolated or at least partially isolated from, the weight of the
spool assembly), while coupler 1006 is mounted to the spool by
device 1007 in a manner that provides for its rotation with the
spool. In this way as the spool is rotated, the weight of the spool
and coiled tubing is supported by the load bearing bearings 1002,
while the rotatable optical coupling assembly allows the laser beam
to be transmitted from cable 1003 which does not rotate to cable
1004 which rotates with the spool.
[0095] A cross sectional view of an embodiment of a rotational
junction transmission device used with a spool of coiled tubing
1109 is shown in FIG. 11. The device has two rotating coupling
assemblies 1113. One of said coupling assemblies has an optical
rotating coupling assemblies 1102 and the other has a fluid
rotating coupling assemblies 1103. The optical rotating coupling
assemblies 1102 can be in the same structure as the fluid rotating
coupling assemblies 1103 or they can be separate. Thus, preferably,
two separate coupling assemblies are employed. Additional rotating
coupling assemblies may also be added to handle other cables, such
as for example cables for downhole probes.
[0096] The optical rotating coupling assembly 1102 is connected to
a hollow precision ground axle 1104 with bearing surfaces 1105,
1106. The laser transmission assemblies 1108 is optically coupled
to the hollow axle 1104 by optical rotating coupling assemblies
1102, which permits the laser beam to be transmitted from the laser
transmission assemblies 1108 into the hollow axle 1104. The optical
rotating coupling assemblies for example may be made up of a QBH
connector, a precision collimator, and a rotation stage, for
example a Precitec collimator through a Newport rotation stage to
another Precitec collimator and to a QBH collimator. To the extent
that excessive heat builds up in the optical rotating coupling
cooling should be applied to maintain the temperature at a desired
level.
[0097] The hollow axle 1104 then transmits the laser beam to an
opening 1107 in the hollow axle 1104, which opening contains an
optical coupler 1110 that optically connects the hollow axle 1104
to the long distance high power laser beam transmission assemblies
1125 that may be located inside of a tubing 1112. Thus, in this way
the laser transmission assemblies 1108, the hollow axle 1104 and
the long distance high power laser beam transmission assemblies
1125 are rotatably optically connected, so that the laser beam can
be transmitted from the laser to the long distance high power laser
beam transmission assemblies 1125.
[0098] Turning to FIGS. 12 and 12A there is shown an embodiment of
an OSR 1200. The OSR 1200 has a housing 1201 that has a
non-rotating plate 1202, which is bolted to the housing 1201. The
plate 1202 has fluid fittings, e.g., 1206 and an electrical
connector 1210. There is a non-rotating optical assembly face 1204
that has a fitting for a connector 1203, and fluid fittings, e.g.,
1205. On the rotating side 1230, there are fluid fittings, e.g.,
1205a, a rotating receptacle 1204 for a connector. The laser beam
path 1208 travels from receptacle 1203 to receptacle 1204. An
electrical line 1207 is also provided. A light detector or other
type of sensor 1240 may be positioned in the area where the laser
beam is in free space in the rotational junction. This sensor can
be used to monitor the conditions of the OSR, laser beam and
potentially the laser operation and down stream parameters. Cooling
chambers 1245a and 1245b are a series of drilled holes that
encompass the optical assemblies. Cooling chamber 1245a is
non-rotating and cooling chamber 1245b is rotating. These cooling
chambers may have a flowing fluid such as water, other cooling
liquids and well as additives to e.g., prevent freezing. They may
also have solid materials that readily transmit heat for the area,
such as copper rods or they may use heat pipes.
[0099] Turning to FIGS. 13 and 13A there is shown an OSR 1300 that
has a non-rotating housing 1301, having cooling fluid ports, e.g,
1306 and an optical assembly body 1302. The OSR 1300 has a rotating
plate 1303, with fluid ports, e.g., 1306, 1307. There is also
provided a fluid slip ring 1320 and an electrical slip ring 1322.
The rotating plate 1303 has a non-rotating cap 1321. A lens spacer
1323 is used in this embodiment. There is also provided a ledge
1325 for the positioning of a monitoring fiber (not shown) that is
preferably generally parallel to the laser beam and beam path 1350,
to detect back reflections. There is a temperature sensor 1326, and
a beam monitoring sensor 1305. There is further provided an annulus
1324 for the placement of a desiccant, as well as to provide water
sealing and other environmental protections. This monitoring system
may also be designed and configured to provide cut
verification.
[0100] An embodiment of a rotational junction transmission device
to pay out and retrieve, or for extending and retrieving, the
umbilical is a stationary spool or creel. As illustrated, by way of
example, in FIGS. 14A and 14B there is provided a creel 1409 that
is stationary and which contains coiled within the long distance
high power laser beam transmission means 1425. That means is
connected to the laser beam transmission umbilical 1408, which is
connected to the laser (not shown in this figure). In this way the
laser beam may be transmitted into the long distance high power
laser beam transmission fiber associated with, or being, the
umbilical and that structure may be deployed down a borehole, or to
a remote location where the high power laser energy may be
utilized, by for example a high power laser tool. The long distance
high power laser beam transmission umbilical may be for example, a
coiled tubing, line structure, or composite tube, on the creel. The
optical fiber associated therewith may preferably be an armored
optical fiber of the type provided herein. In using the creel
consideration should be given to the fact that the umbilical and
thus the optical fiber will be twisted when it is deployed. To
address this consideration the distal end of the fiber, the
umbilical, the bottom hole assembly, or the laser tool, may be
slowly rotated to keep the optical cable untwisted, the umbilical
may be pre-twisted, the umbilical and optical fiber may be designed
to tolerate the twisting and combinations and variations of
these.
[0101] In FIGS. 15A, 15B, and 15C there is provided an embodiment
of a handling apparatus. In this embodiment a reverse wrap
conveying structure is utilized. Thus, there is a reverse wrap
conveying structure 1500 having a first preformed helical section
1501, a second helical section 1502, which is an opposite helix
from the first. These sections are connected by a flip back hinge
like section 1503. Several passages may be contained within this
structure, for example a high pressure air conduit 1505, a high
power laser fiber 1506, an electrical cable 1507, and a monitoring
laser fiber 1508. The hardware and outer components for this type
of reverse wrap conveying structure may be obtained from Igus,
under the trade name TWISTERBAND. This type of reverse wrap
conveying structure is an example of a conveying structure that can
also function as a handling apparatus.
[0102] Turning to FIG. 16 there is shown a schematic for the
integration of a rotational junction transmission assembly 1614
into or with a laser system, and preferably a field laser system.
The laser 1601 provides energy transfer 1605 to the assembly 1614
and is in data/information communication 1606 with the assembly
1614. A chiller 1602 is in material exchange 1607, e.g., cooling
water, with the assembly 1614. A reel 1603 is physically touching
1607 the assembly 1614. A data acquisition system 1604 is in
data/information communication 1609 with the assembly 1614. The
umbilical 1610 is in physical contact 1613, energy transfer 1612,
and data/information communication 1611 with the assembly 1614. The
assembly 1614 includes a input connector 1624, optics 1625,
electrical connections 1624, fluid connections 1627, an electrical
slip ring 1628, a fluid slip ring 1629, bearings 1623, external
seals 1622, diagnostic fiber 1621, real mount 1620, output
connector 1619, additional diagnostics 1618, internal seals 1617,
and fluid cooling 1616. An OSR is is used by way of example, in
this FIG. 16, but could be an ORCA or any of the other rotational
junction transmission devices of this specification.
[0103] Turning to FIG. 17 there is provided an embodiment of a lens
mounting assembly for providing alignment free optics. The lens
1702 is positioned in body 1701. Spacer 1704 is shaped with a
surface that tracks the shape of the lens 1702 and held in place by
retaining member, spring, 1709 and locking member 1705. The laser
beam 1706 travels along a beam path, which includes free space
1708.
[0104] Turning to FIG. 18 there is provided an OSR assembly having
a lens 1801 spacer 1820 and a second lens 1802. The beam path 1807
and direction 1803 of the forward propagating beam is shown. In
this embodiment a fiber 1804 is used as a back reflection monitor
or detection device. Turning to FIG. 18A the fiber face 1825 is
located near to, and preferably adjacent the back 1805 of lens
1801, but out side of the beam path and beam 1807. In this manner
if back reflections emanate from lens 1802, in the direction of
lens 1801 they will enter the fiber face 1825 and go into the fiber
1804 where they can be detected by a suitable monitor.
[0105] Turning to FIG. 19 there is provided a OSR having a
connector receptacles 1910, 1901, metering tubes 1909, 1902 (for
setting or adjusting the focal length), a lens cell 1908 that is
positioned against a metering tube 1909. A flange 1923 is also
provided. The lens cell is held in place by screw 1923. There are
provided bearings 1907, 1905 that provide for the rotation of
housing 1906 with respect to shaft 1904. There is also provided a
sensor 1925 and a locking means 1924 for lens cell 1903. Turing to
FIG. 19A there is shown an alignment and adjustment mechanism 1920
having alignment nobs 1922 and 1921 for aligning the lens cell,
before the OSR is completely assembled. In this embodiment there is
also provide a shim to adjust focus.
[0106] Turing to FIG. 20 there is provided a section 2002 of an OSR
having a connector receptacle 2001 an inner tube 2003, an outer
tube 2004, which is biased against inner tube 2003 by wave spring
2007. The outer tube 2004 has a lens cell 2006. The relative
positions of inner tube 2003 and outer tube 2004 can be adjusted by
focus adjustment assembly 2005. Thus, as the inner tube is move in
and out the focus can be changed and adjusted.
[0107] Turning to FIG. 21 there is provided an OSR having a Risley
prism adjustment mechanism. Thus, the assembly has a first lens
cell 2100 that can rotate with respect to the second lens cell
2101. A Risley prism assembly, having a first prism 2109, a second
prism 2108 and adjustment knobs 2107 and 2106 is located between
the lens cells. By adjusting the knobs the positions of the Risley
prisms are changed and the laser beams path can be adjusted or
directed. Housing 2013 has bearings 2105, and 2104 to facilitate
rotation.
[0108] Turning to FIG. 22 there is provided an embodiment of a bore
sight OSR. In this embodiment the laser beam is not in collimated
space as it crosses the rotational junction. Thus, OSR has a
connector receptacle 2201 a diagnostics passage 2203, an optics
package 2208, which receives and focuses the laser beam 2209 toward
connector receptacle 2207. An electronic and fluid slip ring
assembly 2204 is provided. Bearing assemblies 2205 permits the
rotating plate 2206 having the connector receptacle 2207 to rotate
with respect to the focused laser beam 2209. In this embodiment the
fluid and electrical slip ring assemblies have there own bearings,
so that they do not affect optical performance.
[0109] Turning to FIG. 23 there is shown an embodiment of a section
of an OSR. The connector receptacle 2304 has optical baffles 2303
that are associated with the laser beam path 2310. The connector
receptacle 2304 is held in position by spring 2305 and aluminum
member 2312 and steel member 2311, which join at interface 2302 and
collectively provide for athermlization (along with the specific
determination of the angle at which they meet) over a specified
temperature range. There is a lens cell 2307 that is located in
body 2301. Body 2301 has a fluid flow passage 2309 that is fed by
fluid ports, e.g., 2306. There is a baffle 2350 positioned in the
fluid flow passage to increase dwell time of the cooling fluid, and
improve the movement of the fluid through the cooling fluid flow
passage by requiring it to take have a longer flow path.
[0110] In FIG. 24, there is provided an embodiment of an OSR 2404
that has a partially reflective and transmissive optical element
2410 that is placed in the laser beam path. This element 2410 will
reflect back reflected light to lens 2408 which focused the back
reflected light on detector 2409 with sends a signal along a wire
2407. There is also provided a fluid slip ring 2411 and an
electrical slip ring 2401. The direction of the forward propagating
laser beam path is shown by arrow 2450.
[0111] In FIG. 25 there is provided an embodiment of an OSR 2506
that has a partially reflective and transmissive optical element
2503 that is placed in the laser beam path. The element 2503 will
reflect back reflected light into a reflective element 2502 that
directs the back reflected light to a lens 2510 and a detector
2509. The direction of the forward propagating laser beam is shown
by arrow 2550. There is also provided a fluid slip ring 2508 and
fluid ports 2511, 2501 and an electrical slip ring 2504 with
electrical lines 2505, 2507.
[0112] In FIG. 26 there is provided an embodiment of an OSR 2601
that has a partially reflective and transmissive optical element
2606 that is place in the laser beam path. The element 2606 will
reflect back reflected light into lens 2607 which focuses the back
reflect light to sensor assembly 2607. The direction of the forward
propagating laser beam is shown by arrow 2650.
[0113] In FIG. 27 there is provided an embodiment of an OSR 2701
that has a partially reflective and transmissive optical element
2706 that is place in the laser beam path. The element 2706 will
reflect back reflected light into lens 2707 which focuses the back
reflect light to a reflector 2708, which then directs the back
reflected light to a sensor 2709. The direction of the forward
propagating laser beam is shown by arrow 2750.
[0114] Turning to FIG. 28 there is provided an embodiment of an
ORCA utilizing a dual drum assembly. The ORCA 2800 has a first drum
2801 and a second drum 2802. Drum 2801 is attached to plate 2822
and is fixed, e.g., it does not rotate. Drum 2802 rotates and
rotates at the same speed as the umbilical deployment reel (not
shown in the figure). The umbilical 2803 enters the plate 2822 and
wraps around stationary drum 2801. The umbilical then goes over the
revolving arm assembly 2805 having rollers 2806, 2807. A gear box
2808 provide for the revolving arm assembly 2805 to revolve in the
same direction as rotating drum 2802 but to do so at a slower
speed. Thus, for example, if rotating drum were to make 2 complete
rotations, revolving arm assembly would have made 1 complete
rotation. This has the effect of unwinding the umbilical from
stationary drum 2801 and winding it onto rotating drum 2802 while
that drum is rotating. (Similarly if revolving and rotating in the
other direction the umbilical 2803 will be unwrapped from drum 2802
and wrapped onto drum 2803). Further, while this wrapping process
is occurring on drum 2802 the length 2804 of umbilical 2803
extending out from opening 2809 does not change; and this length is
rotating (e.g., the direction of arrow 2811, which is showing
retrieval) around axis 2810, which axis is also the axis of the
umbilical deployment reel. Thus, end 2812 of the umbilical does not
rotate and end 2804 of the umbilical rotates, without the need for
the laser beam to be launched through free space. FIG. 28A shows a
more detailed cut away view of the umbilical 2803, as having five
FIMTs.
[0115] The relative speeds of the revolving arm assembly and the
rotating drum can vary as needed, in accordance with the
anticipated speed of the deployment reel, the length of the
deployment umbilical, the bending capability of the umbilical and
the optical fibers, the relative diameters of the drums, and other
considerations. However, it should be noted that when the diameter
of two drums are the same the revolving arm must be twice as fast
as the rotating drum, i.e., when the drum makes one rotation, the
arm as revolved around twice.
[0116] In FIG. 29 there is shown an embodiment of a two drum ORCA
having an embodiment of the revolving arm assembly with a level
winder mechanism. The OCRA 2900 has a stationary drum 2901, a
rotating drum 2902, and a revolving arm assembly 2903. The
revolving arm assembly 2903 has a gearbox housing 2904, an arm 2905
and a winder mechanism 2906, which is driven by belt 2907. The
revolving arm assembly 2903 also has roller guide mechanisms 2920,
2921. Thus, as the umbilical is wound to and from the drums 2901,
2902 the winder mechanism 2906 moves the guide mechanisms back and
forth so as to evenly, or uniformly, wind and unwind the umbilical
from the drums. This prevents bunching and tangling of the
umbilical during the winding and unwinding process. A more detailed
view of the winding mechanism 2906 is provided in FIG. 29A. A more
detailed view of roller guide mechanism 2920 is provided in FIG.
29B, where there are four guide wheels 2970, 2971, 2972, 2973 held
between plates 2974, 2975. The gear box assembly 2930 is shown in
FIG. 29C (with the gear box housing 2904 and the tensioner assembly
2940 not shown). A tensioner assembly 2940 is shown in FIG. 29D.
This assembly has a series of wound band springs, e.g., 2941 that
provide tension during winding and unwinding so as to keep the
rotations and revolutions under control. The tensioner assembly
2940 also provides a rotational reserve capacity that allows for
differential winding of stationary drum 2901 and rotating drum 2902
as needed due to the fact that a full reel has a slightly larger
diameter than an empty reel.
[0117] The rotational junction transmission devices, e.g., a
rotating coupler, an OSR, an ORCA, a ratchet type optical
transmission system, and others may find applications in activities
such as: off-shore activities; subsea activities; decommissioning
structures such as, oil rigs, oil platforms, offshore platforms,
factories, nuclear facilities, nuclear reactors, pipelines,
bridges, etc.; cutting and removal of structures in refineries;
civil engineering projects and construction and demolitions;
concrete repair and removal; mining; surface mining; deep mining;
rock and earth removal; surface mining; tunneling; making small
diameter bores; oil field perforating; oil field fracking; well
completion; window cutting; well decommissioning; well workover;
precise and from a distance in-place milling and machining; heat
treating; drilling and advancing boreholes; workover and
completion; flow assurance; and, combinations and variations of
these and other activities and operations.
[0118] A single high power laser may be utilized in the system,
tools and operations, or there may be two or three high power
lasers, or more. High power solid-state lasers, specifically
semiconductor lasers and fiber lasers are preferred, because of
their short start up time and essentially instant-on capabilities.
The high power lasers for example may be fiber lasers, disk lasers
or semiconductor lasers having 5 kW, 10 kW, 20 kW, 50 kW, 80 kW or
more power and, which emit laser beams with wavelengths in the
range from about 455 nm (nanometers) to about 2100 nm, preferably
in the range about 400 nm to about 1600 nm, about 400 nm to about
800 nm, 800 nm to about 1600 nm, about 1060 nm to 1080 nm, 1530 nm
to 1600 nm, 1800 nm to 2100 nm, and more preferably about 1064 nm,
about 1070-1080 nm, about 1360 nm, about 1455 nm, 1490 nm, or about
1550 nm, or about 1900 nm (wavelengths in the range of 1900 nm may
be provided by Thulium lasers). An example of this general type of
fiber laser is the IPG YLS-20000. The detailed properties of which
are disclosed in US patent application Publication Number
2010/0044106. Thus, by way of example, there is contemplated the
use of four, five, or six, 20 kW lasers to provide a laser beam
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.
[0119] The various embodiments of rotational junction transmission
devices, e.g., a rotating coupler, an OSR, an ORCA, a ratchet type
optical transmission system, and others set forth in this
specification may be used with various high power laser systems and
conveyance structures and systems, in addition to those embodiments
of the Figures and Examples in this specification. For example,
embodiments of rotational junction transmission devices, e.g., a
rotating coupler, an OSR, an ORCA, a ratchet type optical
transmission system, and others may be used for, in, or with, the
systems, lasers, tools and methods disclosed and taught in the
following US patent applications and patent application
publications: Publication No. 2010/0044106; Publication No.
2010/0215326; Publication No. 2012/0275159; Publication No.
2010/0044103; Publication No. 2012/0267168; Publication No.
2012/0020631; Publication No. 2013/0011102; Publication No.
2012/0217018; Publication No. 2012/0217015; Publication No.
2012/0255933; Publication No. 2012/0074110; Publication No.
2012/0068086; Publication No. 2012/0273470; Publication No.
2012/0067643; Publication No. 2012/0266803; Ser. No. 61/745,661;
and Ser. No. 61/727,096, the entire disclosure of each of which are
incorporated herein by reference.
[0120] Embodiments of rotational junction transmission devices,
e.g., a rotating coupler, an OSR, an ORCA, a ratchet type optical
transmission system, and others may also be used with: other high
power laser systems that may be developed in the future; and with
existing non-high power laser systems, which may be modified,
in-part, based on the teachings of this specification, to create a
high power laser system. Further, the various embodiments of
devices systems, tools, activities and operations set forth in this
specification may be used with each other in different and various
combinations. Thus, for example, the configurations provided in the
various embodiments of this specification may be used with each
other; and the scope of protection afforded the present inventions
should not be limited to a particular embodiment, configuration or
arrangement that is set forth in a particular embodiment, example,
or in an embodiment in a particular Figure.
[0121] The invention may be embodied in other forms than those
specifically disclosed herein without departing from its spirit or
essential characteristics. The described embodiments are to be
considered in all respects only as illustrative and not
restrictive.
* * * * *