Temperature compensator for improved sealing

Abstract

Methods and apparatus for performing wellbore operations. A thermal compensator is introduced into a wellbore having a temperature. The thermal compensator comprises: an outer layer comprising a first material; an inner layer comprising a second material; the core body is arranged between the inner layer and the outer layer; wherein the core comprises a third material. The third material has a higher coefficient of thermal expansion than the first material and the second material. The core contracts when the wellbore temperature decreases, and contraction of the core moves the outer layer such that the outer layer applies a force to a structure adjacent to the outer layer.

Description

Technical Field

[0001] The present disclosure generally relates to using a temperature compensator for a sealing operation, and more particularly to using a temperature compensator to maintain sealing integrity in a high-temperature environment that is subjected to a cooling period. Background Art

[0002] Sealing elements can be used to form seals in high-temperature environments such as wellbores. In some wellbore operations, wellbore cooling may occur naturally or may be induced via temperature cycling or other operations. Some sealing elements can have a coefficient of thermal expansion that is greater than that of adjacent wellbore tools (e.g., a steel mandrel containing the sealing element or the surrounding steel wellbore tubing). This difference in the coefficient of thermal expansion can cause the sealing element to contract more than the adjacent wellbore tools during a cooling period. In such cases, the sealing element may contract more than the adjacent wellbore tools.

[0003] Temperature compensation is the process of adjusting the performance of a system to compensate for the effects caused by temperature changes. The present invention provides improved devices and methods for sealing in environments that are subjected to temperature fluctuations. Brief Description of the Drawings

[0004] Exemplary embodiments of the present disclosure are described in detail below with reference to the accompanying drawings, which are incorporated herein by reference and in which:

[0005] Figure 1A is a schematic diagram showing an exemplary thermal compensator in its neutral state according to one or more embodiments described herein;

[0006] Figure 1B is a schematic diagram showing Figure 1A an exemplary thermal compensator in its contracted state according to one or more embodiments described herein;

[0007] Figure 1C is a schematic diagram showing Figure 1A an exemplary thermal compensator in its expanded state according to one or more embodiments described herein;

[0008] Figure 2A is a schematic diagram showing another exemplary thermal compensator in its neutral state according to one or more embodiments described herein;

[0009] Figure 2B is a schematic diagram showing Figure 2A an exemplary thermal compensator in its contracted state according to one or more embodiments described herein;

[0010] Figure 2C is a schematic diagram showing Figure 2ASchematic diagram of an exemplary thermal compensator;

[0011] Figure 3 is a schematic diagram showing another example thermal compensator in its neutral state according to one or more examples described herein;

[0012] Figure 4 is a schematic diagram showing, according to one or more examples described herein, such as mounted on a mandrel Figure 3 of the thermal compensator;

[0013] Figure 5 is a schematic diagram showing another example thermal compensator in its neutral state according to one or more examples described herein; and

[0014] Figure 6 is a perspective view showing another example thermal compensator in its neutral state as implemented with a wellbore tool and arranged adjacent to a sealing element according to one or more examples described herein.

[0015] The illustrated drawings are merely exemplary and are not intended to confirm or imply any limitations regarding the environment, architecture, design, or process in which different examples may be implemented. Detailed Description

[0016] The present disclosure generally relates to using temperature compensators for sealing operations, and more particularly to using temperature compensators to maintain seal integrity in high-temperature environments subject to cooling periods.

[0017] In the following detailed description of several illustrative examples, reference is made to the accompanying drawings, which form a part hereof, and in which specific examples are shown by way of illustration. These examples are described in sufficient detail to enable those skilled in the art to practice these examples, and it should be understood that other examples may be utilized and logical, structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosed examples. To avoid details that are not necessary for enabling those skilled in the art to practice the examples described herein, certain information known to those skilled in the art may be omitted from the description. Accordingly, the following detailed description should not be considered limiting, and the scope of the illustrative examples is defined only by the appended claims.

[0018] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, etc., used in this specification and the associated claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the examples of the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. It should be noted that when "about" appears at the beginning of a numerical list, "about" modifies each number in the numerical list. In addition, in some numerical lists of ranges, some of the lower limits listed may be greater than some of the upper limits listed. Those skilled in the art will recognize that a selected subset will require selecting an upper limit that is greater than the selected lower limit.

[0019] In the following discussion and in the claims, the terms "comprising" and "including" are used in an open-ended fashion and should therefore be interpreted to mean "including but not limited to". Unless otherwise indicated, as used throughout this document, "or" need not be mutually exclusive.

[0020] The terms uphole and downhole can be used to refer to the position of various components relative to the bottom or end of a well. For example, a first component described as being uphole from a second component can be further from the end of the well compared to the second component. Similarly, a first component described as being downhole from a second component can be positioned closer to the end of the well compared to the second component.

[0021] The examples described herein relate to using a temperature compensator to maintain seal integrity in a wellbore environment subject to temperature fluctuations such as cooling or thermal cycling periods. The temperature compensator is configured to have a negative coefficient of thermal expansion (hereinafter "CTE"). The temperature compensator is formed from a combination of a low CTE material and a high CTE material. One advantage of the temperature compensator is that the temperature compensator can expand when the surrounding environment cools. Another advantage of the temperature compensator is that, upon cooling, the resulting expansion of the temperature compensator can be used to compensate, to some extent, for the shrinkage of adjacent sealing elements such as elastomeric seal elements. Another advantage is that the temperature compensator can be disposed on the same steel mandrel as the sealing element. In some examples, the combination of a positive CTE sealing element and a negative CTE temperature compensator can result in a seal element-compensator system having a CTE approximate to that of an adjacent steel mandrel, wellbore tubing, or other wellbore tool or tool assembly, thereby providing the seal element-compensator system with a degree of expansion / contraction that can be substantially synchronous with an adjacent steel mandrel, wellbore tubing, or other wellbore tool or tool assembly.

[0022] The thermal compensator includes a combination of a low CTE material and a high CTE material. The combination and arrangement of these components produce a negative CTE device that has an effective negative CTE that allows the thermal compensator to expand upon cooling. The degree of expansion and contraction and the temperature range over which these effects occur vary with the low CTE material selected, the high CTE material selected, and their relative configuration within the thermal compensator.

[0023] The thermal compensator expands in a cooling environment to exert a force on an adjacent structure (e.g., a seal element). A cooling environment is any environment in which the temperature decreases, such as a wellbore. In some instances, the rate of decrease can be a factor of the expansion rate of the thermal compensator. Faster rates of environmental cooling can cause a faster expansion rate of the thermal compensator. Slower rates of environmental cooling can cause a slower expansion rate of the thermal compensator. In any case, the thermal compensator will expand in any cooling environment. The force exerted on the adjacent structure can be maintained as long as the ambient temperature continues to cool or as long as the ambient temperature remains at the temperature at which the thermal compensator expands. If the environment begins to warm, the thermal compensator may begin to contract. If the contraction continues, the thermal compensator may contract to the point where it no longer exerts pressure on the adjacent structure.

[0024] Figure 1A is a schematic view showing an exemplary thermal compensator (generally 5). The thermal compensator 5 includes a housing that is divided into two component parts that clamp and at least partially surround a core 20. These two parts are referred to as an inner layer 10 and an outer layer 15. The inner layer 10 is the housing component closest to the wellbore tool (in this instance, the wellbore is the mandrel 25) on which the thermal compensator 5 is disposed. The outer layer 15 is the housing component furthest from the mandrel 25 but closest to an adjacent tubing string (not shown) that will surround the thermal compensator 5. The inner layer 10 and the outer layer 15 include a low CTE material. The inner layer 10 is fixed to the mandrel 25 and does not translate along the outside of the mandrel 25, but the size of this inner layer will expand / contract due to fluctuating temperatures. The inner layer 10 can be bolted, welded, threaded, screwed, glued, swaged, or otherwise fixed to the mandrel 25 in any manner readily apparent to one of ordinary skill in the art. In some instances, the inner layer 10 and the outer layer 15 include the same low CTE material. In other instances, the inner layer 10 and the outer layer 15 can include different low CTE materials. The core 20 includes a high CTE material. It should be understood that the exact CTE of the high and low CTE materials is not limited to any particular value or range. As used herein, a "high CTE material" refers to a material having a CTE higher than that of the low CTE material. As used herein, a "low CTE material" refers to a material having a CTE lower than that of the high CTE material. In some instances, the high CTE material and the low CTE material have a difference of at least 5×10 -6 / °C and preferably greater than 20×10 -6The linear coefficient of thermal expansion per °C. For example, carbon steel has a CTE of 11×10 -6 / °C in the temperature range from 20°C to 200°C. Aluminum has a CTE of 23×10 -6 / °C in the temperature range from 20°C to 200°C. If carbon steel and aluminum are used in combination in the thermal compensator 5, the carbon steel will be the low CTE material and will form one or both of the inner layer 10 and the outer layer 15. The aluminum will be the high CTE material and will form the core 20. The inner layer 10 is joined to the core 20 by physical connection or hydrostatic pressure. The outer layer 15 is also joined to the core 20 by physical connection or hydrostatic pressure. Connection points 30 are shown at the ends of the core 20. The leftmost end of the core 20 joins the core 20 to the inner portion of the lip 35 of the outer layer 15. The rightmost end of the core 20 joins the core 20 to the inner portion of the lip 35 of the inner layer 10. This arrangement can be reversed in alternative instances. The joining of the core 20 to the lips 35 of the inner layer 10 and the outer layer 15 allows the core 20 to function somewhat like a piston, except that the core 20 moves the outer layer 15 through the contraction and expansion of the core 20 itself. Additionally, the expansion and contraction of the outer layer 15 and the inner layer 10 also cause the outer layer 15 to move relative to the mandrel 25.

[0025] The optional connection points 30 are locations for potential joining mechanisms between the core 20 and the inner layer 10 or the outer layer 15. The joining mechanism can be a threaded connection, a bolted connection, a riveted connection, a brazed connection, a press - fit connection, an adhesive (using an adhesive) connection, or a welded connection to fix the ends of the core 20 to the inner portions of the lips 35 of the outer layer 15 and the inner layer 10. In some instances discussed in more detail below, the joining mechanism can be an approximate hydrostatic pressure at the connection points 30 rather than a physical mechanism. In some instances, the core 20 can be a high CTE fluid that is sealed within the outer layer 15 and the inner layer 10 via an O - ring or other type of sealing element sufficient to form a fluid - tight seal. In this particular instance, the hydrostatic pressure holds the inner layer 10 and the outer layer 15 to the core 20. If the outer layer 15 and / or the inner layer 10 separate from the core 20, an air space will form in the sealed region around the core 20, and the surrounding hydrostatic pressure will push these components together to enclose the air space. Thus, as long as there is hydrostatic pressure, the outer layer 15 and the inner layer 10 will remain joined to the core 20.

[0026] Figure 1BShows the thermal compensator 5 when the ambient temperature increases. As the temperature increases, the higher CTE core 20 expands more compared to the lower CTE inner layer 10 and outer layer 15. Since the expansion of the core 20 is greater than the expansion of the outer layer 15, the core 20 pulls the outer layer 15 in a direction that causes the outer layer 15 to contract relative to the boundary line shown on the right side of the thermal compensator 5. The inner layer 10 remains fixed to the mandrel 25. The boundary line represents the relative position of adjacent wellbore tools such as sealing elements, and the expansion of the thermal compensator can act on these adjacent wellbore tools. In this example, the temperature compensator 5 is applying a reduced pressure to the adjacent wellbore tools represented by the boundary line.

[0027] Figure 1C Shows the thermal compensator 5 when the ambient temperature cools. As the temperature decreases, the higher CTE core 20 contracts more compared to the lower CTE inner layer 10 and outer layer 15. Since the contraction of the core 20 is greater than the contraction of the outer layer 15, the core 20 pulls the outer layer 15 in a direction that causes the outer layer 15 to expand relative to the boundary line shown on the right side of the thermal compensator 5. The inner layer 10 remains fixed to the mandrel 25. The boundary line represents the relative position of adjacent wellbore tools such as sealing elements, and the expansion of the thermal compensator can act on these adjacent wellbore tools. This expansion of the outer layer 15 provides the effect of a net negative CTE thermal compensator 5 that expands as the temperature cools. This expansion occurs even though the thermal compensator 5 has a material with a positive and large CTE for the core 20. In this example, the temperature compensator 5 applies a pressure to the adjacent wellbore tools represented by the boundary line. This pressure can assist the adjacent wellbore tools in maintaining their functionality during this cooling period. For example, this pressure applied to an adjacent sealing element can force the sealing element to remain fully expanded, thereby improving the sealing integrity.

[0028] Figure 2A Is a schematic view of another example thermal compensator (generally 105) stacked in multiple layers circumferentially. The thermal compensator 105 includes two cores 120 of a series of high CTE materials separated by an intermediate layer 140. This arrangement allows the thermal compensator 105 to achieve a displacement distance Figures 1A to 1C longer than that of the single-core thermal compensator 5. Advantageously, when remaining in a neutral state Figures 1A to 1CThis longer displacement distance is achieved when the thermal compensator 5 has the same length. The thermal compensator 105 includes a housing that is divided into three component parts that grip and at least partially surround two cores 120. These three parts are referred to as an inner layer 110, an outer layer 115, and an intermediate layer 140. The inner layer 110 is the housing component closest to the wellbore tool (in this instance, the wellbore tool is the mandrel 125) on which the thermal compensator 105 is disposed. The outer layer 115 is the housing component farthest from the mandrel 125 but closest to the adjacent tubing (not shown) that will surround the thermal compensator 105. The intermediate layer 140 is disposed between the inner layer 110 and the outer layer 115. The inner layer 110, the intermediate layer 140, and the outer layer 115 include low CTE materials. The inner layer 110 is fixed to the mandrel 125 and does not translate along the exterior of the mandrel 125, but the size of this inner layer expands / contracts due to fluctuating temperatures. The inner layer 110 can be bolted, welded, threaded, screwed, glued, swaged, or otherwise fixed to the mandrel 125 in any manner that would be readily apparent to one of ordinary skill in the art. In some instances, the inner layer 110, the intermediate layer 140, and the outer layer 115 include the same low CTE material. In other instances, the inner layer 110, the intermediate layer 140, and the outer layer 115 can include different low CTE materials. The cores 120 include high CTE materials. A first core 120 is disposed between the inner layer 110 and the intermediate layer 140. A second core 120 is disposed between the outer layer 115 and the intermediate layer 140. The cores 120 can include the same or different high CTE materials. It should be understood that the exact CTE of the high and low CTE materials is not limited to any particular value or range. The inner layer 110 is coupled to one of the cores 120 using a physical connection or hydrostatic pressure. The outer layer 115 is coupled to the other core 120 using a physical connection or hydrostatic pressure. The intermediate layer 140 is coupled to both cores 120 using a physical connection or hydrostatic pressure. Connection points 130 are shown at the ends of the cores 120. The rightmost end of the core 120 that is coupled to the inner layer 110 is coupled to the inner portion of the lip 35 of the inner layer 110. The leftmost end of the core 120 that is coupled to the inner layer 110 is coupled to the inner portion of the lip 35 of the intermediate layer 140. The rightmost end of the core 120 that is coupled to the outer layer 115 is coupled to the inner portion of the lip 35 of the intermediate layer 140. The leftmost end of the core 120 that is coupled to the outer layer 115 is coupled to the inner portion of the lip 35 of the outer layer 115. The coupling of the cores 120 to the lips 135 of the inner layer 110, the intermediate layer 140, and the outer layer 115 allows the cores 120 to function somewhat like pistons, except that the cores 120 move the intermediate layer 140 and the outer layer 115 through the contraction and expansion of the cores 120 themselves. Additionally, the expansion and contraction of the outer layer 115, the intermediate layer 140, and the inner layer 110 also cause the intermediate layer 140 and the outer layer 15 to move relative to the mandrel 125.

[0029] Optional connection point 130 is the location of a potential coupling mechanism between core 120 and inner layer 110, intermediate layer 140, or outer layer 115. The coupling mechanism can be a threaded connection, bolted connection, riveted connection, brazed connection, press fit connection, adhesive (using an adhesive) connection, or welded connection to secure the end of core 120 to the inner portion of the lip 135 of outer layer 115, intermediate layer 140, and inner layer 110. In some examples discussed in more detail below, the coupling mechanism can be hydrostatic pressure at connection point 130 rather than a physical mechanism. In some examples, core 120 can be a high CTE fluid that is sealed within outer layer 115, intermediate layer 140, and inner layer 110 via an O-ring or other type of seal element sufficient to form a fluid-tight seal. In this particular example, hydrostatic pressure holds inner layer 110, intermediate layer 140, and outer layer 115 to their respective cores 120. If outer layer 115, intermediate layer 140, and / or inner layer 110 attempt to separate from core 120, an air space is formed in the sealed area around core 120, and the surrounding hydrostatic pressure will push these components together to close the air space. Thus, as long as hydrostatic pressure exists, outer layer 115, intermediate layer 140, and inner layer 110 will remain coupled to their respective cores 120.

[0030] Figure 2B Shows thermal compensator 105 when the ambient temperature increases. As the temperature increases, the higher CTE core 120 expands more than the lower CTE inner layer 110, intermediate layer 140, and outer layer 115. Since the expansion of core 120 is greater than the expansion of intermediate layer 140 and outer layer 115, the core pulls intermediate layer 140 and outer layer 115 to retract the intermediate layer and the outer layer relative to the boundary line shown on the right side of thermal compensator 105. Inner layer 110 remains fixed to mandrel 125. The boundary line represents the relative position of a neighboring wellbore tool such as a seal element. In this example, temperature compensator 105 is applying a reduced pressure to the neighboring wellbore tool represented by the boundary line.

[0031] Figure 2CShows the thermal compensator 105 when the ambient temperature cools. As the temperature drops, the higher CTE core 120 shrinks more than the lower CTE inner layer 110, intermediate layer 140, and outer layer 115. Since the shrinkage of the core 120 is greater than the shrinkage of the intermediate layer 140 and outer layer 115, the core pulls the intermediate layer 140 and outer layer 115 to cause the intermediate layer and the outer layer to expand relative to the boundary line shown on the right side of the thermal compensator 105. The inner layer 110 remains fixed on the mandrel 125. The boundary line represents the relative position of a neighboring wellbore tool such as a seal element. This expansion of the intermediate layer 140 and outer layer 115 provides the effect of a net negative CTE thermal compensator 105 that expands as the temperature cools. Although the thermal compensator 105 has a material with a positive and large CTE for the core 120, this expansion still occurs during cooling. In this example, the temperature compensator 105 applies pressure to the neighboring wellbore tool represented by the boundary line. This pressure can assist the neighboring wellbore tool in maintaining its functionality during this cooling period. For example, this pressure applied to a neighboring seal element can force the seal element to remain fully expanded, thereby improving seal integrity. Additionally, the thermal compensator 105 can be capable of achieving twice the stroke of a single-core 120 thermal compensator of the same length.

[0032] Figure 3 is a schematic diagram of the thermal compensator 205. The function of the thermal compensator 205 is similar to that of Figures 1A to 1C thermal compensator 5. As the temperature cools, the thermal compensator 205 expands in length to apply pressure to a neighboring wellbore tool or assembly. Additionally, the thermal compensator 205 includes an O-ring seal 255. The O-ring seal 255 seals the core 220 within the inner layer 210 and outer layer 215. This arrangement allows for the optional use of a fluid core 220. The fluid core 220 can be any fluid (e.g., silicone oil) having a CTE higher than that of the low CTE inner layer 210 and outer layer 215. For example, the core 220 can be silicone oil, and the inner layer 210 and outer layer 215 can include steel. The thermal compensator 205 can also contain a fill port (not shown) at any convenient location. In some alternative examples, a high CTE material with poor compressive strength (such as an elastomeric material or a polymer such as polytetrafluoroethylene) can be used instead of the fluid for the core 220.

[0033] Figure 4 is on the mandrel 225 Figure 3 schematic diagram of the thermal compensator 205. The thermal compensator 205 is disposed between the wedges 250 and is configured to be adjacent to a seal element 245 on its right side. Two O-ring seals 255 seal the core 220 within the inner layer 210 and outer layer 215. This arrangement allows for the optional use of a fluid core 220, as described above with respect to Figure 3is shown and discussed. As the temperature decreases, the higher CTE core 220 shrinks more than the lower CTE inner layer 210 and outer layer 215. Since the shrinkage of the core 220 is greater than the shrinkage of the outer layer 215, the outer layer 215 expands against the seal element 245 on the right side of the thermal compensator 205. The inner layer 210 remains fixed to the mandrel 225. This expansion of the outer layer 215 provides the effect of the net negative CTE thermal compensator 205 that expands as the temperature cools. This expansion pressure can assist the adjacent seal element 245 in maintaining its expanded state during cooling fluctuations, which can improve the seal integrity.

[0034] Figure 5 An alternative example of a thermal compensator 305 is shown. The geometries of the core 320, inner layer 310, and outer layer 315 have been changed such that the core includes a lip 335 and the inner layer 310 and outer layer 315 do not include lips. The connection point 330 couples the core 320 to the inner layer 310 and outer layer 315, as described above. The function of the thermal compensator 305 is similar to other examples of thermal compensators described herein, except that the load path has been changed. For example, in Figure 1C the tension in the core 20 pulls the opposite ends of the inner layer 10 and outer layer 15 adjacent to the core towards each other (i.e., the ends of the inner layer 10 and outer layer 15 that include the lip 35 are pulled towards each other). In Figure 5 the compressive force in the core 320 pushes the opposite ends of the inner layer 310 and outer layer 315 adjacent to the core towards each other (i.e., the ends of the inner layer 310 and outer layer 315 adjacent to the lip 335 of the core 320 are pushed towards each other). Thus, the arrangement of the thermal compensator 305 allows the core 320 to push the inner layer 310 and outer layer 315 rather than pull them when shrinkage of the core 320 occurs.

[0035] Figure 6Shown is a thermal compensator 405 that is a component of wellbore tool 450 and is disposed on the wellbore tool. The thermal compensator 405 is positioned proximate to a seal element 410. Wedges 415 hold the seal element 410 and the thermal compensator 405 in place during run-in and use in the wellbore. Slip 420 may be disposed distally on each wedge 415, as shown. Finally, the thermal compensator 405, the seal element 410, the wedges 415, and the slips 420 may all be placed on a mandrel 425. When in a desired position, the seal element 410 may be deployed to seal an adjacent wellbore zone. The thermal compensator 405 may apply a force to the adjacent seal element 410. The thermal compensator 405 may be placed under compression during deployment of the seal element 410. The force applied by the thermal compensator 405 to the seal element 410 may range from a 1,000 pound compression load to a 100,000 pound compression load. If a temperature cycle or other temperature fluctuations occur, the thermal compensator 405 may be used to assist in maintaining the seal integrity of the elastomeric element 410 by helping to provide a more consistent compression load on the element 410.

[0036] It should be clearly understood that Figures 1A to 6 the example systems shown are merely general applications of the principles of the present disclosure in practice, and a wide variety of other examples are possible. Accordingly, the scope of the present disclosure is not limited in any way to the Figures 1A to 6 details as described herein.

[0037] As discussed above, the thermal compensator may or may not have seals between the inner, outer, and / or intermediate layers and the core. In some examples, these layers alone will be sufficient to protect the core from contact with wellbore fluids and potential corrosion by wellbore fluids. In other examples, O-rings or other types of seal elements may be provided between the inner, outer, and / or intermediate layers and the core.

[0038] Low CTE materials can include but are not limited to zirconium tungstate, co-extruded iron nickel oxide, invar alloy, titanium, carbon steel, stainless steel, chromium alloy, nickel alloy, ceramic, tungsten, glass, or any combination of materials. High CTE materials can include but are not limited to aluminum, brass, lead, polyamide-imide thermoplastic, polyetheretherketone, polyvinyl chloride, polyvinyl alcohol, acrylonitrile-butadiene-styrene, polytetrafluoroethylene, polyamide, polycarbonate, polyethylene, polysulfone, polyvinylidene fluoride or polyvinylidene difluoride, epoxy resin, rubber, paraffin wax, water, silicone oil, petroleum products, alcohol, glycerol, salt, or any combination of materials. It should be understood that low CTE and high CTE are relative values to each other. A low CTE material can be any material sufficient for use in a wellbore and having a CTE lower than the selected high CTE material. Similarly, a high CTE material can be any material sufficient for use in a wellbore and having a CTE higher than the selected low CTE material. In some instances, the high CTE material and the low CTE material have a linear thermal expansion coefficient that differs by at least 5×10 -6 / °C and preferably greater than 20×10 -6 / °C. In a cooling environment, some negative CTE materials can expand in one direction while contracting in other directions. Although these materials have a negative CTE in one direction, they are still not sufficient for use in current instances. In some instances, the low CTE material and / or the high CTE material can be an alloy or can be alloyed with other materials.

[0039] A thermal compensator can be used in applications where a negative TCE device is desired. The thermal compensator can be used in conjunction with compression-set packer elements of other wellbore tools and components. Additionally, the thermal compensator can be used in various wells. For example, the thermal compensator can be used in: geothermal wells; injection wells injecting water, steam, carbon dioxide, or hydrogen; and production wells.

[0040] In an alternative instance, any of the thermal compensators described herein can be used along a tubing string to compensate for the thermal expansion of steel tubing. Traditionally, a swivel joint can be used to accommodate the thermal expansion of steel tubing. However, a swivel joint may require dynamic seals and may be difficult to transfer load or torque. The thermal compensator can replace the swivel joint. The tubing joint will be configured as a thermal compensator and will contract as the wellbore is heated. The thermal compensator can support tensile, compressive, and / or torque loads. Additionally, the thermal compensator can be keyed such that torque can be transferred through the negative thermal compensator.

[0041] Exemplary thermal compensators disclosed herein can directly or indirectly affect one or more components or devices associated with or in contact with the thermal compensator, such components being, for example but not limited to, wellbore casings, wellbore liners, completion strings, insert strings, drill strings, coiled tubing, wirelines, wire ropes, drill pipes, drill collars, mud motors, downhole motors and / or pumps, cement pumps, surface-mounted motors and / or pumps, centralizers, turbochargers, scratchers, floats (e.g., shoes, collars, valves, etc.), logging tools and associated telemetry equipment, actuators (e.g., electromechanical devices, hydromechanical devices, etc.), sliding sleeves, production sleeves, plugs, screens, filters, flow control devices (e.g., inflow control devices, autonomous inflow control devices, outflow control devices, etc.), couplings (e.g., electrohydraulic wet connections, dry connections, inductive couplings, etc.), control lines (e.g., electrical, fiber optic, hydraulic, etc.), monitoring lines, drill bits and reamers, sensors or distributed sensors, downhole heat exchangers, valves and corresponding actuation devices, tool seals, packers, cement plugs, bridge plugs and other wellbore isolation devices or components, etc.

[0042] A thermal compensator is provided in accordance with the present disclosure and the illustrated drawings. An example thermal compensator includes: an outer layer including a first material; an inner layer including a second material; and a core disposed between the inner layer and the outer layer; wherein the core includes a third material. The third material has a higher coefficient of thermal expansion than the first material and the second material.

[0043] Additionally or alternatively, the thermal compensator may individually or in combination include one or more of the following features. The first material and the second material may be of the same type of material. The thermal compensator may further include an intermediate layer between the outer layer and the inner layer, and the intermediate layer may include a fourth material. The core may be a first core and disposed between the inner layer and the intermediate layer. The thermal compensator may further include a second core, the second core including a fifth material. The second core may be disposed between the intermediate layer and the outer layer, and the fifth material may have a higher coefficient of thermal expansion than the first material and the fourth material. The fifth material and the third material may be of the same type of material. The core may include two ends, wherein one end of the core is coupled to the inner layer, and the second end of the core is coupled to the outer layer. The core may be sealed between the inner layer and the outer layer. The outer layer and the inner layer may each include an end that includes a lip. The core may include two ends, wherein each end includes a lip, and each lip is coupled to one of the inner layer or the outer layer, and the inner layer and the outer layer do not include lips. The core may be solid. The core may be fluid. The first material and the second material may each include a material selected from the group consisting of zirconium tungstate, coextruded iron nickel oxide, invar alloy, titanium, carbon steel, stainless steel, chromium alloy, nickel alloy, ceramic, tungsten, glass, and any combination thereof; and wherein the third material includes a material selected from the group consisting of aluminum, brass, lead, polyamide-imide thermoplastic, polyetheretherketone, polyvinyl chloride, polyvinyl alcohol, acrylonitrile-butadiene-styrene, polytetrafluoroethylene, polyamide, polycarbonate, polyethylene, polysulfone, polyvinylidene fluoride or polyvinylidene difluoride, epoxy resin, rubber, paraffin wax, water, silicone oil, petroleum products, alcohol, glycerin, salt, and any combination thereof.

[0044] A method for performing a wellbore operation in a subterranean formation is provided in accordance with the present disclosure and the illustrated figures. An example method includes introducing a thermal compensator into a wellbore having a temperature. The thermal compensator includes: an outer layer that includes a first material; an inner layer that includes a second material; and a core disposed between the inner layer and the outer layer; wherein the core includes a third material. The third material has a higher coefficient of thermal expansion than the first material and the second material. When the wellbore temperature decreases, the core contracts; wherein the contraction of the core causes the outer layer to move such that the outer layer exerts a force on a structure adjacent to the outer layer.

[0045] Additionally or alternatively, the method may individually or in combination include one or more of the following features. The structure adjacent to the outer layer may be a sealing element. The thermal compensator may be disposed on a mandrel, and the structure adjacent to the outer layer is a compression seat packer. The first material and the second material may be of the same type of material. The thermal compensator may further include an intermediate layer between the outer layer and the inner layer, and the intermediate layer may include a fourth material. The core may be a first core and disposed between the inner layer and the intermediate layer. The thermal compensator may further include a second core, the second core including a fifth material. The second core may be disposed between the intermediate layer and the outer layer, and the fifth material may have a higher coefficient of thermal expansion than the first material and the fourth material. The fifth material and the third material may be of the same type of material. The core may include two ends, wherein one end of the core is coupled to the inner layer, and the second end of the core is coupled to the outer layer. The core may be sealed between the inner layer and the outer layer. The outer layer and the inner layer may each include an end that includes a lip. The core may include two ends, wherein each end includes a lip, and each lip is coupled to one of the inner layer or the outer layer, and the inner layer and the outer layer do not include lips. The core may be solid. The core may be fluid. The first material and the second material may each include a material selected from the group consisting of zirconium tungstate, co-extruded iron nickel oxide, invar alloy, titanium, carbon steel, stainless steel, chromium alloy, nickel alloy, ceramic, tungsten, glass, and any combination thereof; and wherein the third material includes a material selected from the group consisting of aluminum, brass, lead, polyamide-imide thermoplastic, polyetheretherketone, polyvinyl chloride, polyvinyl alcohol, acrylonitrile-butadiene-styrene, polytetrafluoroethylene, polyamide, polycarbonate, polyethylene, polysulfone, polyvinylidene fluoride or polyvinylidene difluoride, epoxy resin, rubber, paraffin wax, water, silicone oil, petroleum products, alcohol, glycerol, salt, and any combination thereof.

[0046] A system for performing wellbore operations in a subterranean formation is provided in accordance with the present disclosure and the illustrated figures. An example system includes a thermal compensator that includes: an outer layer that includes a first material; an inner layer that includes a second material; a core that is disposed between the inner layer and the outer layer; wherein the core includes a third material. The third material has a higher coefficient of thermal expansion than the first material and the second material, and the core is configured to contract when the temperature of the wellbore decreases. The contraction of the core causes the outer layer to move such that the outer layer applies a force to a sealing element. The system further includes a sealing element adjacent to the outer layer.

[0047] Additionally or alternatively, the system may individually or in combination include one or more of the following features. The system may further include a mandrel, and the thermal compensator and the seal element may be disposed on the mandrel. The seal element may be a compression seated packer. The first material and the second material may be of the same type of material. The thermal compensator may further include an intermediate layer between the outer layer and the inner layer, and the intermediate layer may include a fourth material. The core may be a first core and disposed between the inner layer and the intermediate layer. The thermal compensator may further include a second core, the second core including a fifth material. The second core may be disposed between the intermediate layer and the outer layer, and the fifth material may have a higher coefficient of thermal expansion than the first material and the fourth material. The fifth material and the third material may be of the same type of material. The core may include two ends, wherein one end of the core is coupled to the inner layer, and the second end of the core is coupled to the outer layer. The core may be sealed between the inner layer and the outer layer. The outer layer and the inner layer may each include an end that includes a lip. The core may include two ends, wherein each end includes a lip, and each lip is coupled to one of the inner layer or the outer layer, and the inner layer and the outer layer do not include lips. The core may be solid. The core may be fluid. The first material and the second material may each include a material selected from the group consisting of zirconium tungstate, coextruded iron nickel oxide, invar alloy, titanium, carbon steel, stainless steel, chromium alloy, nickel alloy, ceramic, tungsten, glass, and any combination thereof; and wherein the third material includes a material selected from the group consisting of aluminum, brass, lead, polyamide-imide thermoplastic, polyether ether ketone, polyvinyl chloride, polyvinyl alcohol, acrylonitrile-butadiene-styrene, polytetrafluoroethylene, polyamide, polycarbonate, polyethylene, polysulfone, polyvinylidene fluoride or polyvinylidene difluoride, epoxy resin, rubber, paraffin wax, water, silicone oil, petroleum product, alcohol, glycerol, salt, and any combination thereof.

[0048] The foregoing description provides various examples of the systems and methods of use disclosed herein, which may contain alternative combinations of different method steps and components. It should be understood that although individual examples may be discussed herein, the present disclosure encompasses all combinations of the disclosed examples, including but not limited to different combinations of components of the system, combinations of method steps, and properties. It should be understood that compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps. The systems and methods may also "consist essentially of various components and steps" or "consist of various components and steps." Additionally, as used in the claims, the indefinite article "(a)" or "(an)" is defined herein to mean one or more than one of the elements it introduces.

[0049] For the sake of brevity, only certain ranges are explicitly disclosed in this document. However, ranges from any lower limit can be combined with any upper limit to recite ranges not explicitly recited, and ranges from any lower limit can be combined with any other lower limit to recite ranges not explicitly recited. In the same manner, ranges from any upper limit can be combined with any other upper limit to recite ranges not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within that range are specifically disclosed. Specifically, even if not explicitly enumerated, each value range disclosed herein (in the form of "about a to about b", or equivalently "approximately a to b", or equivalently "about a - b") should be understood to recite every number and range subsumed within a broader value range. Thus, each point or individual value can serve as its own lower or upper limit or any other lower or upper limit in combination with any other point or individual value to recite ranges not explicitly recited.

[0050] One or more illustrative examples of the present disclosure are presented and exemplified herein. For clarity, not all features of actual implementations are described or shown in this application. Thus, the disclosed systems and methods are well suited to obtain the recited purposes and advantages, as well as those inherent therein. The specific examples disclosed above are merely illustrative, as the teachings of the present disclosure can be modified and practiced in different but equivalent ways, which will be apparent to those skilled in the art who benefit from the teachings herein. Additionally, details of the construction or design shown herein are not intended to be limited except as described in the appended claims. Thus, it is apparent that the specific illustrative examples disclosed above can be altered, combined, or modified, and all such variations are considered to be within the scope of the present disclosure. The systems and methods illustratively disclosed herein can be practiced appropriately in the absence of any element not specifically disclosed herein and / or any optional element disclosed herein.

[0051] Although the present disclosure has been described in detail along with its advantages, it should be understood that various changes, substitutions, and alterations can be made without departing from the spirit and scope of the present disclosure as defined by the appended claims.

Claims

1. A thermal compensator, the thermal compensator comprising: An outer layer, the outer layer comprising a first material; An inner layer, the inner layer comprising a second material; A core, the core being disposed between the inner layer and the outer layer; wherein the core comprises a third material; Wherein the third material has a higher coefficient of thermal expansion than the first material and the second material.

2. The thermal compensator according to claim 1; wherein the first material and the second material are of the same type.

3. The thermal compensator according to claim 1; the thermal compensator further comprising an intermediate layer between the outer layer and the inner layer; wherein the intermediate layer comprises a fourth material; wherein the core is a first core and is disposed between the inner layer and the intermediate layer; wherein the thermal compensator further comprises a second core, the second core comprising a fifth material; wherein the second core is disposed between the intermediate layer and the outer layer; wherein the fifth material has a higher coefficient of thermal expansion than the first material and the fourth material.

4. The thermal compensator according to claim 3; wherein the fifth material and the third material are of the same type.

5. The thermal compensator according to claim 1; wherein the core comprises two end portions; wherein one end portion of the core is coupled to the inner layer; and wherein the second end portion of the core is coupled to the outer layer.

6. The thermal compensator according to claim 1; wherein the core is sealed between the inner layer and the outer layer.

7. The thermal compensator according to claim 1; wherein the outer layer and the inner layer each comprise an end portion, the end portion comprising a lip.

8. The thermal compensator according to claim 1; wherein the core comprises two end portions; wherein each end portion comprises a lip; wherein each lip is coupled to one of the inner layer or the outer layer; and wherein the inner layer and the outer layer do not comprise lips.

9. The thermal compensator according to claim 1; wherein the core is solid.

10. The thermal compensator according to claim 1; wherein the core is fluid.

11. The thermal compensator according to claim 1; wherein the first material and the second material each comprise a material selected from the group consisting of zirconium tungstate, co-extruded iron nickel oxide, invar alloy, titanium, carbon steel, stainless steel, chromium alloy, nickel alloy, ceramic, tungsten, glass, and any combination thereof; and wherein the third material comprises a material selected from the group consisting of aluminum, brass, lead, polyamide-imide thermoplastic, polyether ether ketone, polyvinyl chloride, polyvinyl alcohol, acrylonitrile butadiene styrene, polytetrafluoroethylene, polyamide, polycarbonate, polyethylene, polysulfone, polyvinylidene fluoride or polyvinylidene difluoride, epoxy resin, rubber, paraffin wax, water, silicone oil, petroleum products, alcohol, glycerol, salt, and any combination thereof.

12. A method for performing wellbore operations: Introduce a thermal compensator into a wellbore having a temperature; Wherein the thermal compensator comprises: An outer layer, the outer layer comprising a first material; An inner layer, the inner layer comprising a second material; A core, the core being disposed between the inner layer and the outer layer; wherein the core comprises a third material; Wherein the third material has a higher coefficient of thermal expansion than the first material and the second material; Wherein the core contracts when the wellbore temperature decreases; wherein the contraction of the core causes the outer layer to move, such that the outer layer exerts a force on a structure adjacent to the outer layer.

13. The method according to claim 12, wherein the structure adjacent to the outer layer is a sealing element.

14. The method according to claim 12, wherein the thermal compensator is disposed on a mandrel, and the structure adjacent to the outer layer is a compression-set packer.

15. The method according to claim 12; wherein the thermal compensator further comprises an intermediate layer between the outer layer and the inner layer; wherein the intermediate layer comprises a fourth material; wherein the core is a first core and is disposed between the inner layer and the intermediate layer; wherein the thermal compensator further comprises a second core, the second core comprising a fifth material; wherein the second core is disposed between the intermediate layer and the outer layer; wherein the fifth material has a higher coefficient of thermal expansion than the first material and the fourth material.

16. The method according to claim 12; wherein the core comprises two end portions; wherein one end portion of the core is coupled to the inner layer; and wherein the second end portion of the core is coupled to the outer layer.

17. A system for performing wellbore operations, the system comprising: A thermal compensator, the thermal compensator comprising: An outer layer, the outer layer comprising a first material; An inner layer, the inner layer comprising a second material; A core, the core being disposed between the inner layer and the outer layer; wherein the core comprises a third material; Wherein the third material has a higher coefficient of thermal expansion than the first material and the second material; wherein the core is configured to contract when the temperature of the wellbore decreases; wherein the contraction of the core causes the outer layer to move, such that the outer layer exerts a force on a sealing element; and the sealing element; wherein the sealing element is adjacent to the outer layer.

18. The system according to claim 17, wherein the system further comprises a mandrel, and the thermal compensator and the sealing element are disposed on the mandrel.

19. The system according to claim 17, wherein the sealing element is a compression-set packer.

20. The system according to claim 17, wherein the thermal compensator further comprises an intermediate layer between the outer layer and the inner layer; wherein the intermediate layer comprises a fourth material; wherein the core is a first core and is disposed between the inner layer and the intermediate layer; wherein the thermal compensator further comprises a second core, the second core comprising a fifth material; wherein the second core is disposed between the intermediate layer and the outer layer; wherein the fifth material has a higher coefficient of thermal expansion than the first material and the fourth material.

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