EXPANDABLE METAL FOR JUNCTION LOCKING AND JUNCTION SEAL APPLICATIONS

Abstract

EXPANDABLE METAL FOR JUNCTION LOCKING AND JUNCTION SEAL APPLICATIONS. The invention relates to a junction, a method for forming a junction, and a well system comprising a junction. The junction, in one aspect, comprises a first threaded element, the first element being formed of a first material, and a second threaded element threaded with the first threaded element, the second threaded element being formed of a second material. In one or more aspects, the first and second threaded elements define an overlap space. In one or more other aspects, an expandable metal gasket is located in at least a portion of the overlap space, the expandable metal gasket comprising a metal configured to expand in response to hydrolysis.

Description

Title of Invention: EXPANDABLE METAL FOR JUNCTION LOCKING AND JUNCTION SEALING APPLICATIONS CONTEXT

[0001] Traditional joints that achieve anchoring and / or sealing between two different parts can be achieved using a combination of geometric mechanical joining processes and sealing elements or inserts (e.g., elastomer / plastic / metal). For example, geometric mechanical joining processes, including non-sealing threads, circlips, collets, Ratch Latch™, locking rings, bolting / riveting, and other types of locking processes are often used. In other cases, sealing and / or anchoring can be achieved using special sealing threads, such as premium threads or torque connections, but generally only on round tubular geometries.Other traditional joining processes to provide anchoring and / or sealing include friction / clamp / shrink fit, swaging, welding / brazing and similar fusion processes. BRIEF DESCRIPTION

[0002] Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0003] [Fig.l] illustrates a well system designed, fabricated and operated according to one or more embodiments of the disclosure;

[0004] [Fig.2A], [Fig.2B] and [Fig.2C] illustrate an embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0005] [Fig.3A], [Fig.3B] and [Fig.3C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0006] [Fig.4A], [Fig.4B] and [Fig.4C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0007] [Fig.5A], [Fig.5B] and [Fig.5C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0008] [Fig.6A], [Fig.6B] and [Fig.6C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0009] [Fig.7A], [Fig.7B] and [Fig.7C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0010] [Fig.8A], [Fig.8B] and [Fig.8C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0011] [Fig.9A], [Fig.9B] and [Fig.9C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure;

[0012] [Fig.lOA], [Fig.lOB] and [Fig.lOC] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure; and

[0013] [Fig. 11A], [Fig. 11B] and [Fig. 11C] illustrate an alternative embodiment of a junction designed, manufactured and operated according to an embodiment of the disclosure. DETAILED DESCRIPTION

[0014] In the following drawings and descriptions, like parts are generally marked throughout the description and drawings with the same reference numerals, respectively. The drawings are not necessarily to scale. Certain features of the disclosure may be shown enlarged to scale or in a somewhat simplified form, and some details of certain elements may not be shown for the sake of clarity and brevity. The present disclosure may be embodied in embodiments of various forms.

[0015] Specific embodiments are described in detail and are shown in the drawings, it being understood that the present disclosure is to be considered exemplary of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully appreciated that the various teachings of the embodiments described herein may be used separately or in any suitable combination to produce the desired results.

[0016] Unless otherwise indicated, the use of the terms "connect," "engage," "couple," "attach," or any other similar term describing an interaction between elements is not intended to limit the interaction to a direct interaction between the elements and may also include an indirect interaction between the described elements.

[0017] Unless otherwise indicated, the use of the terms "top," "upper," "up," "top-of-hole," "upstream," or other similar terms shall be construed to generally refer to the ground surface; likewise, the use of the terms "bottom," "lower," "down," "bottom-of-hole," or other similar terms shall be construed to generally refer to the downhole terminal end of a well, regardless of the orientation of the wellbore. The use of one or more of the foregoing terms shall not be construed to refer to positions along a perfectly vertical axis. Unless otherwise indicated, the use of the term "subterranean formation" shall be construed to encompass both the areas below the exposed land surface and areas below the land surface covered by water, such as oceans or freshwater bodies.

[0018] The present invention describes a method of joining two or more similar and / or dissimilar materials using a novel expandable metal, for example to help strengthen and / or seal the join (e.g., gasket in an application). As will be more fully understood below, the expandable metal starts as metal, and after being subjected to a reactive fluid, it transforms into a hard, fluid-impermeable material. In some embodiments, the hard, fluid-impermeable material contains some unreacted expandable metal, and thus may be self-healing and / or self-healing.

[0019] Expandable metal has many different applications when joining two elements together, and provides certain advantages (e.g., incremental and / or radical advantages) over existing joints. For example, expandable metal can be used to join any combination of two or more elements with various shapes and different interfacing / mating geometries, either as a primary joint and / or seal, or as a backup joint and / or seal for currently available methods. In addition, expandable metal may have certain in-situ healing and / or repair properties, if for example, degradation of the joint later occurs. Expandable metal can be used to join round, circular but not round, or other mathematical geometries.Additionally, the expanding metal can be used with threaded elements, as well as locking rings, sealing rings, locks, etc., for fastening and sealing, while maintaining, for example, 360-degree contact.

[0020] Finally, expandable metal joints (e.g., anchored and / or sealed joints) offer cost-effective and relatively fast internal solutions (applied at the time of assembly, e.g., applied uphole but activated downhole, allowing the tubular connection and associated junction to be broken and reassembled many times at the surface, as activation only occurs downhole; applied uphole but activated before being placed downhole; applied downhole and activated downhole; etc.) for joining two or more elements, with threaded fasteners, or alternatively in place of press / shrink fits or welding / brazing, among others.

[0021] Accordingly, in at least one embodiment, the expandable metal seals may be used as a thread treatment to improve material-to-material sealing (e.g., metal-to-metal sealing). For example, the simplicity of application of the expandable metal seals may be utilized either in replacement of more expensive sealing connections, or as a complement to current premium designs. In addition, less expensive straight threads using the expandable metal seal can provide the performance normally achieved by premium threads. In addition, premium metal-to-metal sealing connections would be less sensitive to surface finish and tolerancing and would therefore improve the reliability of these connections. In addition, more robust metal-to-metal connections would simplify assembly, as material properties and assembly details are less critical to performance.

[0022] Additionally, expanded metal joints may be used in certain applications where the heat required to weld or braze two surfaces together adversely affects the metallurgy of the surfaces. For example, in certain high H2S or CO2 applications, the well features must be manufactured in accordance with National Association of Corrosion Engineers (NACE) standards. Unfortunately, the heat required to weld or braze the two surfaces together damages the corrosion resistance of both surfaces, meaning they no longer meet the NACE standard and therefore cannot be used. Nevertheless, expanded metal joints perform the same as welded or brazed joints, if not better, and do not require the extreme heat to form them. As a result, expanded metal joints could be used while still meeting the NACE standard.

[0023] [Fig. 1] illustrates a well system 100 designed, manufactured, and operated in accordance with one or more embodiments of the disclosure, and having one or more expandable metal seals or expanded metal seals 160 in accordance with any of the embodiments, aspects, applications, variations, designs, etc. disclosed in the following paragraphs. The well system 100 in at least one embodiment has a platform 120 positioned on a subterranean formation 110 located below the earth's surface 115. The platform 120, in at least one embodiment, has a hoist 125 and a derrick 130 for raising and lowering a downhole transportation means 140, such as a drill string, casing string, production tubing, coiled tubing, etc. Although a land-based oil and gas platform 120 is illustrated in [Fig.l], the scope of this disclosure is not limited thereto, and therefore could potentially be applied to offshore applications. The teachings of this disclosure may also be applied to other land-based multilateral wells other than the one illustrated.

[0024] The well system 100 in one or more embodiments includes a main wellbore 145. The main wellbore 145, in the illustrated embodiment, includes casing 150, 155, which may have different tubular diameters. In at least one embodiment, the casing 150, 155 includes expandable metal joints or expanded metal joints 160 according to one or more embodiments of the disclosure. One or more lateral wellbores 170 may extend from the main wellbore 145, in one or more embodiments. Further, a plurality of multilateral junctions 175 may be positioned at the junctions between the main wellbore 145 and the lateral wellbores 170. Each multilateral junction 175 may include a y-block designed, manufactured, or operated according to the disclosure. The multilateral junctions 175, in one or more embodiments, may include expandable metal or expanded metal according to any of the embodiments, aspects, applications, variations, designs, etc. disclosed in the following paragraphs, including the use of expandable metal or expanded metal for the joints therein.

[0025] The well system 100 may further include one or more ICVs 180 positioned at various positions within the main wellbore 145 and / or one or more of the lateral wellbores 170. The ICVs 180 may include an ICV designed, manufactured, or operated in accordance with the disclosure. As discussed above, one or more of the ICVs 180 could include expandable metal or expanded metal in accordance with any of the embodiments, aspects, applications, variations, designs, etc. disclosed in the following paragraphs, for example, with respect to any of the junctions within the ICVs 180. Although the ICVs 180 have been illustrated and described, other embodiments exist in which one or more ICDs, AICDs, screens, etc. may be used in addition to or instead of one or more of the ICVs 180 illustrated in [Fig.l]. ICDs, AICDs, screens, etc.may also comprise expandable metal or expanded metal according to any of the embodiments, aspects, applications, variations, designs, etc. disclosed in the following paragraphs. The well system 100 may further comprise a control unit 190. The control unit 190, in this embodiment, is operable to provide control to or signals received from one or more downhole devices.

[0026] In some embodiments, one or more portions of the well system 100 may include one or more expandable metal joints or expanded metal joints (e.g., anchor, seal, or anchor and seal joints) that have been formed with pre-expansion metal (e.g., metal configured to expand in response to hydrolysis) according to one or more embodiments of the disclosure. After the pre-expansion metal has been subjected to a reactive fluid, the one or more junctions would include expanded metal in accordance with one or more embodiments of the disclosure.

[0027] The expanded metal gasket, in at least one embodiment, expands to at least partially fill the overlap space between the two or more members being joined. The overlap space in at least one embodiment includes the space created between opposing surfaces of the two or more members, regardless of relative orientation (e.g., parallel to the longitudinal axis of the two or more members, perpendicular to the longitudinal axis of the two or more members, or inclined relative to the longitudinal axis of the two or more members). In some embodiments, the expanded metal gasket expands to generally fill the overlap space. The phrase generally fill, as that term is used herein, is intended to indicate that at least 20% of the overlap space is filled.In other embodiments, the expanded metal gasket expands to substantially fill, and in still other embodiments expands to overfill, the overlap space between the two or more members being joined. The phrase substantially fill, as that term is used herein, is intended to indicate that at least 50% of the overlap space is filled, and the phrase overfill, as that term is used herein, is intended to indicate that at least 75% of the overlap space is filled.

[0028] The expanded metal gasket in the overlap space, in one or more embodiments, has a volume not exceeding 25,000 cm3. In yet another embodiment, the overlap space has a volume not exceeding 7,750 cm3. In some embodiments, the expanded metal gasket has a volume ranging from about 31.5 mm3 to about 5,813 cm3. In yet another embodiment, the expanded metal gasket has a volume ranging from about 4,282 mm3 to about 96,700 mm3. Nevertheless, the volume of the expanded metal gasket must be designed to provide adequate anchoring and / or sealing for the two or more members being joined (e.g., without expanding excessively to areas outside the overlap space), but otherwise is not limited to specific values.

[0029] Again, in some embodiments, the expanded metal gasket has residual unreacted expandable metal therein. For example, in some embodiments, the expanded metal gasket is intentionally designed to have residual unreacted expandable metal therein. The residual unreacted expandable metal has the advantage of allowing the expanded metal gasket to self-heal if cracks or other abnormalities subsequently appear. However, other embodiments may exist in which no residual unreacted expandable metal exists in the expanded metal gasket.

[0030] The expandable metal, in some embodiments, can be described as expanding into a cement-like material. In other words, the metal changes from the metal to micron-scale particles, and then these particles expand and lock together to, essentially, lock the expanded metal seal in place. reaction may, in some embodiments, occur in less than two days (e.g., less than 24 hours in some cases) in a reactive fluid and at acceptable temperatures. However, the reaction time may vary depending on the reactive fluid, the expandable metal used, the downhole temperature, and the surface area to volume (SA:V) ratio of the expandable metal.

[0031] In some embodiments, the reactant fluid may be a brine solution such as may be produced during well completion activities, and in other embodiments, the reactant fluid may be one of the additional solutions discussed herein. The expandable metal is electrically conductive in some embodiments. The expandable metal, in some embodiments, has a yield strength greater than about 8,000 psi, e.g., 8,000 psi + / - 50%.

[0032] Hydrolysis of the expandable metal can create a metal hydroxide. The forming properties of alkaline earth metals (Mg - Magnesium, Ca - Calcium, etc.) and transition metals (Zn - Zinc, Al - Aluminum, etc.) in hydrolysis reactions demonstrate structural characteristics favorable for use with the present disclosure. Hydration results in an increase in the size of the hydration reaction and results in the formation of a metal hydroxide which can precipitate from the fluid.

[0033] The hydration reactions of magnesium are:

[0034] Mg + 2H2O -> Mg(OH)2 + H2,

[0035] where Mg(OH)2 is also known as brucite. Another hydration reaction uses the hydrolysis of aluminum. The reaction forms a material known as Gibbsite, bayerite, boehmite, aluminum oxide, and norstrandite, depending on the form. Possible hydration reactions of aluminum are:

[0036] Al + 3H2O -> A1(OH)3 + 3 / 2 H2.

[0037] Al + 2H2O -> Al O(OH) + 3 / 2 H2

[0038] Al + 3 / 2 H2O -> U2 A12O3 + 3 / 2 H2

[0039] Another hydration reaction uses calcium hydrolysis. The calcium hydration reaction is:

[0040] Ca + 2H2O -> Ca(OH)2 + H2,

[0041] where Ca(OH)2 is known as portlandite and is a common hydrolysis product of Portland cement. Magnesium hydroxide and calcium hydroxide are considered relatively insoluble in water. Aluminum hydroxide can be considered an amphoteric hydroxide, which has solubility in strong acids or strong bases. Alkaline earth metals (e.g., Mg, Ca, etc.) work well for expandable metal, but transition metals (Al, etc.) also work well for expandable metal. In one embodiment lization, the metal hydroxide is dehydrated by swelling pressure to form a metal oxide.

[0042] In one embodiment, the expandable metal used may be a metal alloy. The expandable metal alloy may be an alloy of the base expandable metal with other elements to either adjust the strength of the expandable metal alloy, adjust the reaction time of the expandable metal alloy, or adjust the strength of the resulting metal hydroxide by-product, among other adjustments. The expandable metal alloy may be alloyed with elements that improve the strength of the metal such as, but not limited to, Al - Aluminum, Zn - Zinc, Mn - Manganese, Zr - Zirconium, Y - Yttrium, Nd - Neodymium, Gd - Gadolinium, Ag - Silver, Ca - Calcium, Sn - Tin and Re - Rhenium, Cu - Copper.In some embodiments, the expandable metal alloy may be alloyed with a dopant that promotes corrosion, such as Ni - Nickel, Fe - Iron, Cu - Copper, Co - Cobalt, Ir - Iridium, Au - Gold, C - Carbon, Ga - Gallium, In - Indium, Mg - Mercury, Bi - Bismuth, Sn - Tin and Pd - Palladium.

[0043] Optionally, non-expandable components may be added to the starting metal materials. For example, non-reactive ceramic, elastomer, plastic, epoxy, glass, or metal components may be embedded in the expandable metal or coated on the surface of the expandable metal. In still other embodiments, the non-expandable components are metal fibers, a composite weave, a polymer ribbon, or ceramic granules, among others.

[0044] Alternatively, the starting expandable metal may be the metal oxide. For example, calcium oxide (CaO) with water will produce calcium hydroxide in an energetic reaction. Due to the higher density of calcium oxide, this may have a volumetric expansion of 260% (e.g., a conversion of 1 mole of CaO may result in a volume increase from 9.5 cc to 34.4 cc). In one variation, the expandable metal is formed in a serpentinite reaction, a hydration reaction, and metamorphic reaction. In one variation, the resulting material resembles a mafic material. Additional ions may be added to the reaction, including silicate, sulfate, aluminate, carbonate, and phosphate. The metal may be alloyed to increase reactivity or to control oxide formation.The expandable metal alloy can be constructed in a solid solution process where the elements are combined with molten metal or a metal alloy. Alternatively, the expandable metal alloy could be constructed with a powder metallurgy process. The metal alloy can be a mixture of the metal and the metal oxide. For example, a mixture of aluminum powder and aluminum oxide can be ground together to increase the reaction rate. The expandable metal can be formed using a variety of other different processes. For example. For example, the expandable metal may be cast, forged, extruded, sintered, welded, milled, lathe-machined, stamped, 3D printed, eroded, or a combination thereof. In at least one other embodiment, the expandable metal is deposited (e.g., plated, electroplated, CVD deposited, etc.) onto one or more portions of the joint.

[0045] The expandable metal may also take various shapes and / or configurations and remain within the scope of the disclosure. In at least one embodiment, the expandable metal is formed into a thin sheet of expandable metal that may be placed around a portion of the joint, much like Teflon tape would be placed around a threaded joint. In at least one other embodiment, the thin sheet of expandable metal could have an adhesive on at least one side thereof. In at least one embodiment, the thin sheet of expandable metal would have a thickness (ts) ranging from 2.5 µm to 2,500 µm. In yet another embodiment, the thin sheet of expandable metal would have a thickness (ts) ranging from 10 µm to 250 µm, and in yet another embodiment, the thin sheet of expandable metal would have a thickness (ts) ranging from 15 µm to 30 µm.Further, in at least one embodiment, the expandable thin metal sheet would have a width (ws) ranging from 6 mm to 90 cm, and in some embodiments would be wound upon itself in a ribbon-like manner (e.g., similar to how adhesive tape and / or Teflon tape is wound upon itself, e.g., having a core member, and a protective cover). In yet another embodiment, the expandable thin metal sheet would have a width (ws) ranging from 25 mm to 45 cm, and in yet another embodiment would have a width (ws) ranging from 100 mm to 30 cm. Further, when the expandable thin metal sheet is wound as a ribbon, it may have a length (ls) of at least 5 m long. In yet another embodiment, the thin expandable metal sheet could have a length (ls) of at least 16 m long, and in yet another embodiment at least 32 m long.

[0046] In yet another embodiment, the expandable metal may be formed into a single long member, multiple short members, rings, among others, which may fit around a portion of the junction. In another embodiment, the expandable metal may be formed into a long expandable metal wire, which may in turn be wrapped around a portion of the junction. The wire diameters need not be of circular cross-section, but may be of any cross-section. For example, the wire cross-section could be oval, rectangular, star-shaped, hexagonal, keystone, hollow braided, woven, twisted, among others, and remain within the scope of the disclosure. In at least one embodiment, the expandable metal wire would have a minimum diameter (dw) ranging from 2.5 µm to 2,500 µm.The term minimum diameter, as that term is used, is intended to mean the minimum cross-sectional length intersecting a center point of the wire, regardless of . or the cross-sectional shape. In yet another embodiment, the expandable metal wire would have a minimum diameter (dw) ranging from 10 μm to 250 μm, and in yet another embodiment, the expandable metal wire would have a minimum diameter (dw) ranging from 15 μm to 30 μm. Further, in at least one embodiment, the expandable metal wire would have a length (lw) of at least 5 m long and would be wound upon itself in a weld-like manner (e.g., in the same manner that weld is wound upon itself, e.g., having a central element). In yet another embodiment, the expandable metal wire could have a length (lw) of at least 16 m long, and in yet another embodiment of at least 32 m long.

[0047] In some other embodiments, the expandable metal is a collection of individual separate pieces of the metal held together with a carrier and / or a bonding agent. For example, the individual separate pieces of the metal may be suspended in a paste or gel. The paste and / or gel, in at least one embodiment, may include a desiccant (e.g., a hydroscopic substance used as a drying agent) to retard any reaction. In yet another embodiment, the individual separate pieces or metal may be suspended in a non-water-based grease or wax (e.g., a hydrocarbon-based grease or wax), a polymer, or an emulsion, all of which lose viscosity with increased temperature. In at least one embodiment, the paste, gel, grease, or wax has a viscosity ranging from 5,000 cP to 5,000,000 cP at 25°C.In yet another embodiment, the paste, gel, grease or wax has a viscosity ranging from 50,000 cP to 500,000 cP at 25°C, and in yet another embodiment the paste, gel, grease or wax has a viscosity ranging from 100,000 cP to 300,000 cP at 25°C.

[0048] In some embodiments, the set of individual separate pieces of the expandable metal is a set of different sized individual separate pieces of expandable metal. For example, in some embodiments, a first volume of a larger one of the set of individual separate pieces of the expandable metal is at least 5 times a second volume of a smaller one of the set of individual separate pieces of the expandable metal. In another embodiment, a first volume of a larger one of the set of individual separate pieces of the expandable metal is at least 50 times a second volume of a smaller one of the set of individual separate pieces of the expandable metal. Further, while some embodiments utilize different sized pieces of expandable metal, other embodiments exist in which each of the pieces of expandable metal is substantially (e.g., within 10%) the same.Additionally, in some embodiments, the set of individual separate pieces of metal eg. expandable may comprise two or more different expandable metals or one expandable metal and one metal oxide.

[0049] In some other embodiments, the set of individual separate pieces of the metal, whether combined as a paste, gel, grease, or wax, further comprises a plurality of encapsulated reactive fluid microspheres. The plurality of encapsulated reactive fluid microspheres could be a plurality of water microspheres, as is often used in the cosmetics industry. The reactive fluid is often encapsulated in a polymer shell (e.g., an epoxy). However, in other embodiments, the reactive fluid is encapsulated in a hydrophobic shell (e.g., such as a Janus particle), a glass shell, an emulsion shell, etc. In at least one embodiment, the plurality of encapsulated reactive fluid microspheres have a diameter (dm) ranging from 2 μm to 2,000 μm.In at least one further embodiment, the plurality of encapsulated reactive fluid microspheres has a diameter (dm) ranging from 50 pm to 1000 pm, and in yet another embodiment, the plurality of encapsulated reactive fluid microspheres has a diameter (dm) ranging from 100 pm to 200 pm.

[0050] In operation, the plurality of encapsulated reactant fluid microspheres would remain intact prior to bringing the two different members together, but would burst when the two different members of the junction are brought into contact with each other, and thereby begin the conversion of the expandable metal seal into an expanded metal seal. In at least one embodiment, wherein the two different members are two different threaded members, threading the two members together may burst the plurality of encapsulated reactant fluid units to begin the reaction.

[0051] In some other embodiments, the expandable metal is an expandable metal powder. For example, the expandable metal powder may be similar to powdered graphite, but the powder is constructed using expandable metal.

[0052] In addition to the embodiments discussed above, a retardant coating may be applied to one or more portions of the expandable metal to retard the expansion reactions. In one embodiment, the material configured to retard the hydrolysis process is a fusible alloy. In another embodiment, the material configured to retard the hydrolysis process is a eutectic material. In yet another embodiment, the material configured to retard the hydrolysis process is a wax, oil, or other non-reactive material.

[0053] Turning to Figures 2A-2C, various different manufacturing states for a junction 200 designed, manufactured, and operated in accordance with the disclosure are illustrated. [Fig. 2A] illustrates the junction 200 before expansion, [Fig. 2B] illustrates the junction 200 after expansion, and [Fig. 2C] illustrates the junction 200 after expansion and containing residual unreacted expandable metal therein. The junction 200 of the embodiment of Figures 2A-2C includes a first member 210 and a second member 220. Although not required, the first member 210 and the second member 220 may be a first tubular member and a second tubular member, as illustrated in the embodiment discussed with respect to Figures 2A-2C. Accordingly, in at least one embodiment, the first member 210 and the second member 220 define a centerline (CL). In other embodiments, however, one or both of the first member 210 or the second member 220 are not tubular members. In at least one embodiment, the second member 220 is a collar coupled to the first member 210.

[0054] According to one or more embodiments of the disclosure, the first element 210 comprises a first material (M1) and the second element 220 comprises a second material (M2). In some embodiments, the first material (M1) and the second material (M2) are the same material, but in other embodiments, the first material (M1) and the second material (M2) are different materials. In at least one embodiment, both the first material (M1) and the second material (M2) comprise metal, including steel in at least one embodiment.

[0055] In the illustrated embodiment, and in accordance with one embodiment of the disclosure, the first member 210 and the second member 220 overlap. Depending on the design, the overlap may be face-to-face, end-to-end, end-to-end, or any other overlap, as well as combinations thereof. The first member 210 and the second member 220, in the illustrated embodiment, thus define an overlap space 230. The overlap space 230, in at least one or more embodiments, helps define the type of junction. For example, in the embodiment of Figures 2A-2C, the overlap space 230 is a single-stage overlap space, thereby forming a single-stage junction. In addition, because the first member 210 and the second member 220 have threads 235, a threaded junction is formed.In the illustrated embodiment, the threads 235 are straight threads, and thus the threaded joint is a non-premium threaded joint.

[0056] In the illustrated embodiment, the first element 210 has a first wall thickness (ti) proximate the overlap space 230 and the second element 220 has a second wall thickness (t2) proximate the overlap space 230. According to at least one embodiment, the first wall thickness (ti) and the second wall thickness (t2) do not exceed 45.0 cm. According to at least one other embodiment, the first wall thickness (ti) and the second wall thickness wall thickness (t2) do not exceed 30.0 cm. However, in yet at least one other embodiment, the first wall thickness (ti) and the second wall thickness (t2) do not exceed 15 cm, or even do not exceed 5 cm. In at least one embodiment, the overlap space has a thickness (t3) that is a fraction of the first wall thickness (ti) or the second wall thickness (t2). For example, in at least one embodiment, the thickness (t3) is less than 1 / 3 of the first wall thickness (ti) or the second wall thickness (t2). In yet another embodiment, the thickness (t3) is less than 1 / 5 of the first wall thickness (ti) or the second wall thickness (t2).In yet another embodiment, the thickness (t3) is less than 1 / 10 of the first wall thickness (ti) or the second wall thickness (t2), or even less than 1 / 20 of the first wall thickness (ti) or the second wall thickness (t2).

[0057] In the illustrated embodiment, the first member 210 has a length (LJ and the second member 220 has a length (L2). In at least one embodiment, the length (Li) and the length (L2) are at least 1 meter. In at least one other embodiment, the length (Li) and the length (L2) are at least 3 meters. In yet another embodiment, the length (Li) and the length (L2) are in the range of 6 meters to 12 meters, or more. In the illustrated embodiment, at least a portion of the overlap space 230 (and thus the resulting expanded metal junction) is parallel to the length (Li) and / or the length (L2), thereby providing a set of straight threads.As will be discussed below, other embodiments exist in which at least a portion of the overlap space 230 (and thus the resulting expanded metal junction) is angled relative to the length (LJ) and / or the length (L2), thereby providing a set of tapered threads.

[0058] With reference to [Fig. 2A], an expandable metal seal 240 is located at least partially within the overlap space 230. The expandable metal seal 240, in accordance with one or more embodiments of the disclosure, comprises a metal configured to expand in response to hydrolysis. The expandable metal seal 240, in the illustrated embodiment, may comprise any of the expandable metals discussed above, or any combination thereof. In addition, the expandable metal seal 240 may take any of the various shapes and / or configurations discussed above. However, in the embodiment of [Fig. 2A], the expandable metal seal is a thin sheet of expandable metal positioned between the threads 235 of the first member 210 and the second member 220.In some embodiments, the thin, expandable metal sheet is malleable, and thus can take the shape of the threads 235 when the first member 210 and the second member 220 are joined.

[0059] The expandable metal seal 240 may have a variety of different lengths and thicknesses, for example depending on the amount of anchoring, as well as whether it is desired for the expandable metal seal 240 to act as a seal when subjected to a reactive fluid, and remain within the scope of the disclosure. In the embodiment of [Fig. 2A], the expandable metal seal 240 separates substantially all of the threads 235 of the first member 210 and the second member 220. In other embodiments, however, the expandable metal seal 240 is positioned between only a lesser portion of the threads 235 of the first member 210 and the second member 220. In such an embodiment, the expandable metal seal 240 may be positioned proximate to a leak source, remote from a leak source, or positioned at a midpoint of the leak source.

[0060] Referring to [Fig. 2B], there is illustrated the expandable metal gasket 240 illustrated in [Fig. 2A] after subjecting it to a reactive fluid to expand the metal in the overlap space 230, and thereby form an expanded metal gasket 250. In the illustrated embodiment, the expanded metal gasket 250 generally fills the overlap space, as that term is defined above. In still other embodiments, the expanded metal gasket 250 substantially fills the overlap space 230, as that term is defined above, or in still other embodiments, the expanded metal gasket 250 overfills the overlap space 230, as that term is defined above, or fully fills the overlap space 230 in still another embodiment.

[0061] Notwithstanding the foregoing, the expanded metal gasket 250 may have a variety of different volumes and remain within the scope of the disclosure. Such volumes, as expected, are a function of the size of the overlap space 230, the volume of the expandable metal gasket 240, and the composition of the expandable metal gasket 240, among other factors. Nevertheless, in at least one embodiment, the expanded metal gasket 250 has a volume no greater than 25,000 cm3. In yet another embodiment, the overlap space has a volume no greater than 7,750 cm3. In at least one further embodiment, the expanded metal gasket 250 has a volume ranging from about 31.5 mm3 to about 5,813 cm3, and in yet another embodiment, the expanded metal gasket 250 has a volume ranging from about 4,282 mm3 to about 96,700 mm3.

[0062] Referring to [Fig. 2C], there is illustrated the expandable metal joint 240 illustrated in [Fig. 2A] after subjecting it to a reactive fluid to expand the metal in the overlap space 230, and thereby form an expanded metal junction 260 having residual unreacted expandable metal therein. In one embodiment, the expanded metal junction 260 has at least 1% residual unreacted expandable metal therein. In yet another embodiment, the expanded metal junction 260 has at least 3% residual unreacted expandable metal therein. In yet another embodiment, expanded metal junction 260 has at least 10% residual unreacted expandable metal therein and, in some embodiments, at least 20% residual unreacted expandable metal therein.

[0063] Turning now to Figures 3A-3C, there are illustrated various different manufacturing states for a junction 300 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 3A] illustrates the junction 300 before expansion, [Fig. 3B] illustrates the junction 300 after expansion, and [Fig. 3C] illustrates the junction 300 after expansion and containing residual unreacted expandable metal therein. The junction 300 of Figures 3A-3C is similar in many respects to the junction 200 of Figures 2A-2C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The junction 300 differs, in essence, from the junction 200, in that at least a portion of the overlap space 330 (and thus the resulting expanded metal junction) is inclined with respect to the length (Li) and / or the length (L2), thereby providing a set of tapered threads.Therefore, the junction 300 of Figures 3A-3C is configured as a premium threaded junction.

[0064] Turning now to Figures 4A-4C, there are illustrated various different manufacturing states for a junction 400 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 4A] illustrates the junction 400 before expansion, [Fig. 4B] illustrates the junction 400 after expansion, and [Fig. 4C] illustrates the junction 400 after expansion and containing residual unreacted expandable metal therein. The junction 400 of Figures 4A-4C is similar in many respects to the junction 200 of Figures 2A-2C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The junction 400 differs, in essence, from the junction 200 in that the expandable metal joint 440 is a threaded expandable metal insert.For example, a portion of one or both of the first member 210 or the second member 220 could be modified, either in the manufacturing process or subsequently (e.g., by cutting a gland therein), so that the threaded expandable metal insert can be placed at least partially within the overlap space 230 (e.g., within the gland). The expandable metal seal 440 would, when subjected to the reacting fluid, expand in the same manner as the expandable metal seal 240. Accordingly, what results is an expanded metal seal 450 ([Fig. 4B]), and / or an expanded metal seal 460 having residual unreacted expandable metal therein ([Fig. 4C]).

[0065] Turning now to Figures 5A to 5C, various states of manufacture are illustrated. different for a junction 500 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 5A] illustrates the junction 500 before expansion, [Fig. 5B] illustrates the junction 500 after expansion, and [Fig. 5C] illustrates the junction 500 after expansion and containing residual unreacted expandable metal therein. The junction 500 of Figures 5A-5C is similar in many respects to the junction 200 of Figures 2A-2C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The junction 500 differs, in essence, from the junction 200 in that the expandable metal joint 540 is an unthreaded expandable metal insert.For example, a portion of one or both of the first member 210 or the second member 220 could be modified, either in the manufacturing process or subsequently (e.g., by cutting a gland therein), such that the unthreaded expandable metal insert can be placed at least partially within the overlap space 230 (e.g., within the gland). The expandable metal seal 540 would, when subjected to the reacting fluid, expand in the same manner as the expandable metal seal 240. Accordingly, what results is an expanded metal seal 550 ([Fig. 5B]), and / or an expanded metal seal 560 having residual unreacted expandable metal therein ([Fig. 5C]).

[0066] Turning now to Figures 6A-6C, there are illustrated various different manufacturing states for a junction 600 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 6A] illustrates the junction 600 before expansion, [Fig. 6B] illustrates the junction 600 after expansion, and [Fig. 6C] illustrates the junction 600 after expansion and containing residual unreacted expandable metal therein. The junction 600 of Figures 6A-6C is similar in many respects to the junction 200 of Figures 2A-2C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features.The junction 600 differs, in essence, from the junction 200, in that the expandable metal seal 640 is a deposited expandable metal seal that has been deposited on one or more of the surfaces of the first member 210 or the second member 220 (e.g., deposited on the threads 235 of the first member 210 or the second member 220). The expandable metal seal 640 may be deposited using any of the aforementioned methods, as well as methods learned later. The expandable metal seal 640 would, when subjected to the reactant fluid, expand in the same manner as the expandable metal seal 240. Accordingly, what results is an expanded metal seal 650 ([Fig. 6B]), and / or an expanded metal seal 660 having residual unreacted expandable metal therein ([Fig. 6C]).

[0067] Turning now to Figures 7A to 7C, various states of manufacture are illustrated. different for a junction 700 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 7A] illustrates the junction 700 before expansion, [Fig. 7B] illustrates the junction 700 after expansion, and [Fig. 7C] illustrates the junction 700 after expansion and containing residual unreacted expandable metal therein. The junction 700 of Figures 7A-7C is similar in many respects to the junction 200 of Figures 2A-2C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The junction 700 differs, in essence, from the junction 200 in that the expandable metal joint 740 comprises a set of individual separate pieces of the metal 744 held together with a backing and / or bonding agent 748.The set of individual separate pieces of metal 744 held together with a backing and / or bonding agent 748 may comprise any of the materials discussed above. The expandable metal gasket 740 would, when subjected to the reacting fluid, expand in the same manner as the expandable metal gasket 240. Accordingly, what results is an expanded metal gasket 750 ([Fig. 7B]), and / or an expanded metal gasket 760 having residual unreacted expandable metal therein ([Fig. 7C]).

[0068] Turning now to Figures 8A-8C, there are illustrated various different manufacturing states for a junction 800 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 8A] illustrates the junction 800 before expansion, [Fig. 8B] illustrates the junction 800 after expansion, and [Fig. 8C] illustrates the junction 800 after expansion and containing residual unreacted expandable metal therein. The junction 800 of Figures 8A-8C is similar in many respects to the junction 700 of Figures 7A-7C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The junction 800 differs, in essence, from the junction 700 in that the expandable metal seal 840 further includes a plurality of encapsulated reactive fluid microspheres 844.The plurality of encapsulated reactive fluid microspheres 844 may comprise any of the encapsulated reactive fluid microspheres discussed above. The expandable metal seal 840 would, when subjected to the reactive fluid, expand in the same manner as the expandable metal seal 740. Accordingly, what results is an expanded metal seal 850 ([Fig. 8B]), and / or an expanded metal seal 860 having residual unreacted expandable metal therein ([Fig. 8C]).

[0069] Turning now to Figures 9A-9C, there are illustrated various different manufacturing states for a junction 900 designed, manufactured and operated according to an alternative embodiment of the disclosure. [Fig. 9A] illustrates the junction 900 before expansion, [Fig. 9B] illustrates the junction 900 after expansion, and [Fig. 9C] illustrates the junction 900 after expansion and containing residual unreacted expandable metal therein. The junction 900 of Figures 9A-9C is similar in many respects to the junction 200 of Figures 2A-2C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The junction 900 differs, in essence, from the junction 200 in that the expandable metal seal 940 is positioned at an end face (e.g., one or more end faces) where the first member 210 and the second member 220 engage each other. The expandable metal seal 940 would expand, when subjected to the reacting fluid, in the same manner as the expandable metal seal 240. Accordingly, what results is an expanded metal seal 950 ([Fig.9B]), and / or an expanded metal seal 960 having residual unreacted expandable metal therein ([Fig.9C]).

[0070] Turning now to Figures 10A-10C, there are illustrated various different manufacturing states for a joint 1000 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 10A] illustrates the joint 1000 before expansion, [Fig. 10B] illustrates the joint 1000 after expansion, and [Fig. 10C] illustrates the joint 1000 after expansion and containing residual unreacted expandable metal therein. The joint 1000 of Figures 10A-10C is similar in many respects to the joint 700 of Figures 7A-7C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The joint 1000 differs, in essence, from the joint 700 in that the first member 1010 and the second member 1020 are non-threaded members.

[0071] Turning now to Figures 1 1A-1 1C, there are illustrated various different manufacturing states for a joint 1100 designed, manufactured, and operated in accordance with an alternative embodiment of the disclosure. [Fig. 11A] illustrates the joint 1100 before expansion, [Fig. 11B] illustrates the joint 1100 after expansion, and [Fig. 11C] illustrates the joint 1100 after expansion and containing residual unreacted expandable metal therein. The joint 1100 of Figures 1 1A-1 1C is similar in many respects to the joint 800 of Figures 8A-8C. Accordingly, like reference numerals have been used to illustrate similar, if not identical, features. The joint 1100 differs, in essence, from the joint 800 in that the first member 1110 and the second member 1120 are non-threaded members.

[0072] Aspects disclosed in the present invention include:

[0073] A. A joint, the joint comprising: 1) a first threaded member, the first member being formed of a first material; 2) a second threaded member threaded with the first threaded member, the second threaded member being formed of a second material, the first and second threaded members defining an overlap space; and 3) an expandable metal gasket located in at least a portion of the overlap space. In a preferred embodiment, the expandable metal seal comprises a metal configured to expand in response to hydrolysis.

[0074] B. A method for forming a joint, the method comprising: 1) threading a first threaded member formed of a first material with a second threaded member formed of a second material, the threading defining an overlap space, the overlap space having an expandable metal seal located in at least a portion thereof, the expandable metal seal comprising a metal configured to expand in response to hydrolysis; and 2) subjecting the expandable metal seal to a reactive fluid to expand the metal in the overlap space and thereby form an expanded metal seal.

[0075] C. A well system, the well system comprising: 1) a wellbore extending through one or more subterranean formations; 2) a tubular member positioned within the wellbore, the tubular member comprising; a) a first threaded member formed of a first material; b) a second threaded member formed of a second material, the first and second threaded members being threaded together and defining an overlap space; and c) an expanded metal seal positioned at least partially within the overlap space, the expanded metal seal comprising a metal that has expanded in response to hydrolysis.

[0076] Aspects A, B and C may have a combination of one or more of the following additional features: Feature 1: wherein the expandable metal seal is positioned between the threads of the first and second threaded members. Feature 2: wherein at least a portion of the overlap space is parallel to a length (Li) of the first threaded member or a length (L2) of the second threaded member, thereby providing a set of straight threads. Feature 3: wherein at least a portion of the overlap space is inclined relative to a length (Li) of the first threaded member or a length (L2) of the second threaded member, thereby providing a set of tapered threads. Feature 4: wherein the expandable metal seal is a threaded expandable metal insert. Feature 5: wherein the threaded expandable metal insert is positioned within a gland in the first threaded member or the second threaded member.Item 6: wherein the expandable metal seal is an unthreaded expandable metal insert. Item 7: wherein the unthreaded expandable metal insert is positioned within a gland in the first threaded member or the second threaded member. Item 8: wherein the expandable metal seal is a deposited expandable metal seal located along the threads of the first threaded member or the second threaded member. Item 9: wherein the expandable metal seal comprises an assembly of individual separate pieces of expandable metal held together with a carrier and / or a bonding agent. Item 10: wherein the metal seal. expandable further comprises a plurality of encapsulated reactive fluid microspheres. Item 11: wherein the expandable metal seal is positioned at an end face where the first threaded member and the second threaded member engage each other. Item 12: wherein the expandable metal seal is a threaded expandable metal insert positioned within a gland in the first threaded member or the second threaded member. Item 13: wherein the expandable metal seal is a non-threaded expandable metal insert positioned within a gland in the first threaded member or the second threaded member. Item 14: wherein the expandable metal seal further comprises a plurality of encapsulated reactive fluid microspheres.Element 15: wherein threading the first threaded member with the second threaded member bursts one or more of the plurality of encapsulated reactive fluid microspheres, thereby subjecting the expandable metal seal to the reactive fluid to expand the metal in the overlapping space and thereby form the expanded metal seal. Element 16: wherein the expandable metal seal is positioned at an end face where the first threaded member and the second threaded member engage each other. Element 17: wherein the expanded metal seal has residual unreacted expandable metal therein.

[0077] Those skilled in the art to which this application relates will understand that other additions, deletions, substitutions and modifications may be made to the described embodiments.

Claims

Claims

1. A joint, comprising: a first threaded member (210), the first member being formed of a first material; a second threaded member (220) threaded with the first threaded member, the second threaded member (220) being formed of a second material, the first (210) and second threaded members (220) defining an overlap space (230); and an expandable metal joint (240) located in at least a portion of the overlap space (230), the expandable metal joint (240) comprising a metal configured to expand in response to hydrolysis.

2. The junction of claim 1, wherein the expandable metal seal (240) is positioned between the threads of the first (210) and second threaded members (220).

3. The junction of claim 1, wherein at least a portion of the overlapping space (230) is parallel to a length (LJ) of the first threaded member (210) or a length (L2) of the second threaded member (220), thereby providing a set of straight threads (235).

4. A joint according to claim 1, wherein at least a portion of the overlap space (230) is inclined relative to a length (LJ) of the first threaded member (210) or a length (L2) of the second threaded member (220), thereby providing a set of tapered threads.

5. The joint of claim 1, wherein the expandable metal joint (240) is a threaded expandable metal insert, or optionally wherein the threaded expandable metal insert is positioned within a gland in the first threaded member (210) or the second threaded member (220).

6. The joint of claim 1, wherein the expandable metal joint (240) is an unthreaded expandable metal insert, or optionally wherein the unthreaded expandable metal insert is positioned within a gland in the first threaded member (210) or the second threaded member (220).

7. The junction of claim 1, wherein the expandable metal seal (240) is a deposited expandable metal seal located along the threads of the first threaded member (210) or the second threaded member (220).

8. The junction of claim 1, wherein the expandable metal seal (740) comprises an assembly of individual separate pieces of expandable metal (744) held together with a carrier and / or a bonding agent (748), or optionally wherein the expandable metal seal (840) further comprises a plurality of encapsulated reactive fluid microspheres (844).

9. The junction of claim 1, wherein the expandable metal joint (940) is positioned at an end face where the first threaded member (210) and the second threaded member (220) engage each other.

10. A method of forming a joint, comprising: threading a first threaded member (210) formed of a first material with a second threaded member (220) formed of a second material, the threading defining an overlap space (230), the overlap space (230) having an expandable metal seal (240) located in at least a portion thereof, the expandable metal seal (240) comprising a metal configured to expand in response to hydrolysis; and subjecting the expandable metal seal (240) to a reactive fluid to expand the metal in the overlap space (230) and thereby form an expanded metal seal.

11. The method of claim 10, wherein the expandable metal seal (240) is positioned between the threads of the first (210) and second threaded members (220).

12. The method of claim 10, wherein the expandable metal seal (240) is a threaded expandable metal insert positioned within a gland in the first threaded member (210) or the second threaded member (220), or optionally wherein the expandable metal seal (240) is an unthreaded expandable metal insert positioned within a gland in the first threaded member (210) or the second threaded member (220), or optionally wherein the expandable metal seal (240) is a deposited expandable metal seal (240) located along the threads of the first threaded member (210) or the second threaded member (220).

13. The method of claim 10, wherein the expandable metal seal (740) comprises an assembly of individual separate pieces (744) of expandable metal held together with a backing and / or a bonding agent (748), or optionally wherein the metal seal expandable (840) further comprises a plurality of encapsulated reactive fluid microspheres (844), or optionally wherein threading the first threaded member (210) with the second threaded member (220) bursts one or more of the plurality of encapsulated reactive fluid microspheres (844), thereby subjecting the expandable metal gasket (840) to the reactive fluid to expand the metal in the overlap space and thereby form the expanded metal gasket.

14. The method of claim 10, wherein the expanded metal seal (860) has residual unreacted expandable metal therein.

15. Well system (100), comprising: a wellbore (145) extending through one or more subterranean formations; a tubular member positioned within the wellbore, the tubular member comprising; a first threaded member (210) formed of a first material; a second threaded member (220) formed of a second material, the first and second threaded members being threaded together and defining an overlapping gap (230); and an expanded metal gasket positioned at least partially in the overlap space, the expanded metal gasket comprising a metal that has expanded in response to hydrolysis.

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