Well assembly coupling

Assemblies that can be disposed in a subterranean bore and that can facilitate branch wellbore creation are described. An assembly can include threadedly coupled components having inner and outer sealing members in grooves. The sealing member can cooperate with the components to provide a pressure seal. The assembly can also include a venting member for equalizing pressure in a chamber defined by the coupled components. One of the components can be made from aluminum. At least part of that component can be coated with a coating material that is nonconductive.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to an assembly for subterranean fluid production and, more particularly (although not necessarily exclusively), to a threaded coupling of an assembly.

BACKGROUND

Hydrocarbons can be produced through a wellbore traversing a subterranean formation. The wellbore may be relatively complex. For example, the wellbore can include multilateral wellbores and/or sidetrack wellbores. Multilateral wellbores include one or more lateral wellbores extending from a parent (or main) wellbore. A sidetrack wellbore is a wellbore that is diverted from a first general direction to a second general direction. A sidetrack wellbore can include a main wellbore in a first direction and a secondary wellbore diverted from the main wellbore and in a second general direction. A multilateral wellbore can include a window to allow lateral wellbores to be formed. A sidetrack wellbore can include a window to allow the wellbore to be diverted to the second general direction.

A window can be formed by positioning a casing joint and a whipstock in a casing string at a desired location in the main wellbore. The whipstock can deflect one or more mills laterally (or in another orientation) relative to the casing string. The deflected mills penetrate part of the casing joint to form the window in the casing string through which drill bits can form the lateral wellbore or the secondary wellbore.

Casing joints are often made from high-strength material. The high-strength material may also be non-corrosive to withstand corrosive elements, such as hydrogen sulfide and carbon dioxide, which may be present in the subterranean environment. Milling a portion of the high-strength material can be difficult and can create a large amount of debris, such as small pieces of the casing joint, that can affect detrimentally well completion and hydrocarbon production. Even casing joints having a portion of a sidewall with a smaller thickness through which a window can be milled can introduce debris, particularly if the casing joints are made from a dense, high-strength material. The debris can prevent the whipstock from being retrieved easily after milling is completed, plug flow control devices, damage seals, obstruct seal bores, and interfere with positioning components in the main bore below the casing joint.

Casing joints with pre-milled windows can be used to reduce or eliminate debris. The pre-milled windows can include a fiberglass outer liner to prevent particulate materials from entering the inner diameter of the casing string. The fiberglass outer liner can be milled easily and milling the fiberglass outer liner can result in less debris as compared to drilling a window through a casing joint made from high-strength material.

The casing joint can experience high pressure in a subterranean formation. Additional support may be desired in view of the high pressure on the casing joint. An aluminum sleeve can be provided exterior to the casing joint at the location of the window to provide the additional support. O-rings can be provided at each end of the aluminum sleeve to provide a seal between the aluminum sleeve and the casing joint. The aluminum sleeves and the O-rings increase the outer diameter of the casing string. In some applications, the outer diameter may be increased by one or more inches. An increase in outer diameter can be unacceptable in some situations. Material through which milling is easier can be located in the opening to avoid increasing the diameter. Coupling the material to the other components of a casing string can be difficult, however.

Therefore, an assembly with material through which a window can be formed is desirable that can include a mechanism by which the material is coupled to other components of a casing string.

SUMMARY

Certain embodiments of the present invention are directed to threadedly coupling two components in which one component is easier to mill than the other component. The coupled components can have inner and outer sealing members in grooves. The sealing member can cooperate with the components to provide a pressure seal. The coupled components can also include a venting member for equalizing pressure in a chamber defined by the coupled components. One of the components can be made from aluminum. At least part of that component can be coated with a coating material that improves wear resistance of the aluminum component.

In one aspect, an assembly capable of being disposed in a subterranean bore is provided. The assembly includes a first component, a second component, an inner sealing member, and an outer sealing member. The second component is threadedly coupled to the first component to define an inner region. The first component is easier to mill than the second component. The inner sealing member and the outer sealing member can cooperate with the first component and the second component to provide a pressure seal between the inner region and an environment exterior to the first component and the second component.

In at least one embodiment, the inner sealing member is disposed in a first component groove. The outer sealing member disposed in a second component groove.

In at least one embodiment, the inner sealing member and the outer sealing member each comprise at least one of a ring seal, a T-seal, a bonded seal, or an injectable sealing material.

In at least one embodiment, the inner sealing member includes part of the first component coupled by a metal-to-metal interference fit to part of the second component to form a seal against an inside pressure. The outer sealing member includes another part of the first component coupled by a metal-to-metal interference fit to another part of the second component to form a seal against an outside pressure.

In at least one embodiment, the first component is made from aluminum.

In at least one embodiment, the assembly includes a sleeve disposed in the inner region such that at least part of the sleeve is adjacent to at least part of the first component. The sleeve can reduce at least one of wear or corrosion of at least part of the assembly.

In at least one embodiment, the sleeve is coupled to the first component by at least one of a mechanical fastener, an adhesive, a weld, a snap ring, or a castellation.

In at least one embodiment, the first component is made from aluminum and it includes an inner wall having threads for coupling to the second component. The threads are coated by a coating material capable of being between the threads and the second component when the threads are coupled to the second component. The coating material is nonconductive.

In at least one embodiment, the second component threadedly coupled to the first component defines at least one chamber between the first component and the second component. The assembly also includes a venting member in fluid communication with the at least one chamber and in fluid communication with an area outside of the first component and the second component.

In at least one embodiment, the first component includes a first element and a second element. The first element is threadedly coupled to the second component. The second element can be milled after being disposed in the bore. The second element is made from a material that includes at least one of fabric reinforced polymer, carbon fiber, fiberglass, para-aramid synthetic fiber, silicon carbide, aluminum, or carbon nanotubes.

In another aspect, a casing joint of a casing string capable of being disposed in a bore of a subterranean formation is described. The casing joint includes a first component, a second component, and a venting member. The second component is threadedly coupled to the first component to define at least one chamber between the first component and the second component. The first component is easier to mill than the second component. The venting member is in fluid communication with the chamber and in fluid communication with an area outside of the second component threadedly coupled to the first component.

In at least one embodiment, the venting member can equalize pressure of the at least one chamber with the pressure of the area outside of the second component threadedly coupled to the first component.

In at least one embodiment, the venting member includes a pressure compensator that can decrease a differential pressure of the chamber.

In at least one embodiment, the venting member is a channel for allowing an epoxy to traverse to the chamber. The epoxy can seal the chamber from an area outside of the second component threadedly coupled to the first component.

In another aspect, an assembly that can be disposed in a bore of a subterranean formation is described. The assembly includes a first component made from aluminum. The first component includes an inner wall that has threads for coupling to a second component to define an inner region and to provide a pressure seal between the inner region and an environment exterior to the first component and the second component. The threads are coated by a coating material capable of being between the threads and the second component when the threads are coupled to the second component. The coating material is nonconductive.

In at least one embodiment, the first component includes an outer wall that has a second coating material disposed on at least part of the outer wall. The second coating material is more corrosion resistant than aluminum or nonconductive.

In at least one embodiment, the coating material and the second coating material are the same type of material.

In at least one embodiment, the threads can be coated by the coating material by at least one of soft anodize coating, electroless nickel plating, anodized coating, a nano high velocity oxygen fuel (HVOF) coating, or thermal spray coating.

In at least one embodiment, the coating material of the threads is at least one of polytetrafluoroethylene, a plastic, a ceramic, a nonconductive material, or a metal.

In another aspect, a casing string that can be disposed in a bore is described. The casing string includes steel joints and an aluminum joint coupled to a steel joint. The aluminum joint includes an inner wall. At least part of the inner wall is coated with a coating material to improve wear resistance of the inner wall.

In at least one embodiment, the coating material is at least one of an epoxy-phenolic material, epoxy and polyphenylene sulfide composite material, or a synergistic coating material.

In at least one embodiment, the aluminum joint includes an outer wall. At least part of the outer wall is coated with a second coating material to improve wear resistance of the outer wall and to improve corrosion resistance of the outer wall.

In at least one embodiment, the second coating material is the same type of material as the coating material.

In at least one embodiment, the coating material coating at least part of the inner wall is capable of improving corrosion resistance of the inner wall.

These illustrative aspects and embodiments are mentioned not to limit or define the invention, but to provide examples to aid understanding of the inventive concepts disclosed in this application. Other aspects, advantages, and features of the present invention will become apparent after review of the entire application.

DETAILED DESCRIPTION

Certain aspects and embodiments of the present invention relate to assemblies capable of being disposed in a bore, such as a wellbore, of a subterranean formation and through which windows can be formed. An assembly according to certain embodiments of the present invention can include at least one casing joint that can provide support for a casing string in a high pressure and high temperature environment of a subterranean well. The assembly can avoid an increase in the outer diameter of the casing string and avoid introducing a large amount of debris after the window is formed through milling. An example of a high pressure and high temperature subterranean wellbore environment is one with a pressure greater than 2500 PSI and a temperature greater than 250° F.

An assembly according to some embodiments is part of a casing string that includes a steel joint coupled to an aluminum joint. The aluminum joint has an inner wall that is coated with a material to improve its wear resistance.

In some embodiments, the casing joint includes components that are coupled at a threaded portion of each component. For example, one component can include annular rings and grooves that form a threaded portion. The threaded portion can be tapered to a smaller cross-sectional thickness at an end of the threaded portion. The threaded portion can be on an inner wall or an outer wall of the component.

Similarly, a second component, which may be a casing string, can include annular rings and grooves to form a threaded second component portion. The threaded second component portion can also be tapered to a smaller cross-sectional thickness at an end of the threaded second component portion. The threaded second component portion can be located in an inner wall or an outer wall of the second component, depending on the location of the threaded first component portion. For example, if the threaded first component portion is located in an inner wall of the first component, the threaded second component portion is located in an outer wall of the second component. If the threaded first component portion is located in an outer wall, the threaded second component portion is located in an inner wall of the second component.

In some embodiments, the material from which the second component is made expands at a different rate or expands by a different amount than the material from which the first component is made. The grooves of the first component can be configured to allow for such differences in expansion rates/amounts, such as the second component expanding more than the first component, but maintain the coupling between the components.

The end of the second component having the smaller cross-sectional thickness can be located near or adjacent to part of the first component having a larger cross-sectional thickness. The end of the first component having the smaller cross-sectional thickness can be located near or adjacent to part of the second component having a larger cross-sectional thickness. The grooves of each can receive at least some of the annular rings. The second component can be coupled to the first component through the threaded portions by a compression joint, an interference fit, rotating one of the components with respect to the other, or other suitable coupling type.

The threadedly coupled components can provide a pressure seal between an inner region defined by the coupled components and an environment exterior to the coupled components. For example, the threaded coupling can allow the first component to withstand higher burst pressure than otherwise. As an assembly is run into a well, the hydrostatic pressure increases in the environment exterior to the coupled components. The coupled components can allow the pressure in the inner region to remain at a constant pressure, even when the pressure in the environment exterior to the assembly increases substantially. Assemblies according to some embodiments can withstand a high-pressure differential, such as a pressure differential of 22,000 PSI.

An assembly according to some embodiments can include one or more sealing members disposed between the components. Examples of a sealing member include a ring seal (such as an O-ring), a T-seal, a bonded seal, and an injectable sealing material. In some embodiments, the first component includes a groove in which an inner sealing member is disposed and the second component includes a groove in which an outer sealing member is disposed. The inner sealing member and the outer sealing member can cooperate with the components to provide the pressure seal between the inner region and the environment. For example, the outer sealing member can support the lower thickness parts of the second component, such as by allowing the second component to be forced against the outer sealing member when the second component experiences a collapse (i.e. external) pressure. The inner sealing member can support the lower thickness parts of the first component, such as by allowing the second component to be forced against the inner sealing member when the first component experiences a burst (i.e. internal) pressure.

The coupled components can define one or more chambers between the coupled components. A venting member can be included that is in fluid communication with a chamber and with an area outside of the components. The venting member may equalize pressure between the chamber and the area. The venting member can include any suitable component capable of regulating pressure. In some embodiments, the venting member is a pressure compensator capable of decreasing a differential pressure of a sealing member disposed between the first component and the second component and in proximity to the chamber. In some embodiments, the venting member is a channel through which an epoxy can be inserted and caused to be located in the chamber to seal the chamber from the area outside of the components.

In other embodiments, an inner sealing member is formed by part of the first component coupling to part of the second component by a metal-to-metal interference fit to form a seal against inside pressures (i.e. those pressures from an inner region defined by the first component coupled to the second component). The outer sealing member can be formed by a second part of the first component coupling to a second part of the second component by a metal-to-metal interference fit to form a seal against outside pressures (i.e. those pressures from an environment exterior to the first component coupled to the second component).

The components can be made from different materials. For example, the second component can be made from a high-strength material that can retain its original structure and integrity for a long time in a high pressure and high temperature subterranean environment. The first component can be made from a lower strength material that can retain its original structure and integrity for a shorter amount of time in the high pressure and high temperature subterranean environment and that can be milled easier than the high-strength material. For example, the material from which the second component is made can be sufficient to provide tensile strength for the assembly and the material from which the first component is made can withstand burst and collapse pressures.

The first component can retain its general shape and integrity during positioning of the assembly in a wellbore and for at least some amount of time in the wellbore after positioning. The first component can generate less debris after being milled as compared to the second component. Furthermore, the first component can provide less resistance to milling than the second component. Accordingly, a whipstock or deflector can be positioned relative to the first component to deflect a mill toward the first component to form a window in the first component to allow a branch wellbore to be created from a parent wellbore. In some embodiments, the first component includes a third type of material coupled to the material of the threaded portion. A window can be easily milled or drilled through the third type of material.

A “parent wellbore” is a wellbore from which another wellbore is drilled. It is also referred to as a “main wellbore.” A parent or main wellbore does not necessarily extend directly from the earth's surface. For example, it could be a branch wellbore of another parent wellbore.

A “branch wellbore” is a wellbore drilled outwardly from its intersection with a parent wellbore. Examples of branch wellbores include a lateral wellbore and a sidetrack wellbore. A branch wellbore can have another branch wellbore drilled outwardly from it such that the first branch wellbore is a parent wellbore to the second branch wellbore.

Assemblies according to certain embodiments of the present invention can include additional components to provide pressure support. An example of such a component is a sleeve that can be located in the inner region defined by threadedly coupled components. Part of the inner sleeve can be adjacent to the threaded portions of the components. Part of the inner sleeve can also be adjacent to the non-threaded portions of the component that is lower in strength. The inner sleeve can be coupled to that component, such as via a shear screw locking system that provides room for thermal expansion or a snap ring, for example. The inner sleeve may provide support to that component prior to it being milled or drilled. The inner sleeve may also be coupled to the component of higher strength, such as by brazing, mechanical fastening or other suitable connection means.

In some embodiments, an inner sleeve that includes a castellation is disposed in the inner region. The castellation can carry torque from one end of the assembly to another end of the assembly.

FIG. 1shows a well system110with an assembly118according to one embodiment of the present invention. The well system110includes a parent wellbore112that extends through various earth strata. The parent wellbore112includes a casing string116cemented at a portion of the parent wellbore112.

The casing string116includes an assembly118interconnected with the casing string116. The assembly118can include a joint120at which a first component122is coupled to a second component124of the assembly118. The assembly118can be positioned at a desired location to form a branch wellbore126from the parent wellbore112. The desired location can be an intersection128between the parent wellbore112and the branch wellbore126. The assembly118can be positioned using various techniques. Examples of positioning techniques include using a gyroscope and/or an orienting profile.

Branch wellbore126is depicted with dotted lines to indicate it has not yet formed. To form the branch wellbore126, a whipstock can be positioned in the inner diameter of the casing string116relative to the first component122of the assembly118and below the intersection128. For example, keys or dogs associated with the whipstock can cooperatively engage an orienting profile to anchor the whipstock to the casing string116and to orient rotationally an inclined whipstock surface toward the first component122.

Cutting tools, such as mills and drills, are lowered through the casing string116and deflected toward the first component122. The cutting tools mill through the first component122and the subterranean formation adjacent to the window to form the branch wellbore126. In some embodiments, the first component122is made from a material that is different from the material from which the second component124is made and that has a lower strength than the material from which the second component124is made. The first component122can be configured to support the assembly118when the assembly118is positioned and after positioning, without requiring an external sleeve or otherwise. Certain embodiments of the first component122can generate less debris during milling as compared to the second component124.

Assemblies according to various embodiments of the present invention can be in any desirable configuration to support branch wellbore formation and to interconnect with a casing string.FIGS. 2A,2B, and2C depict an assembly202according to one embodiment of the present invention. The assembly202includes a first component206coupled to a second component208. The second component208includes two segments210,212between which the first component206is positioned. The first component206can be made from a material through which a window can be milled or drilled to allow a branch wellbore to be formed. Examples of materials from which the first component206can be made include aluminum, aluminum alloys (such as 7075 aluminum or 6061 aluminum), copper-based alloys, magnesium alloys, free-cutting steels, cast irons, carbon fiber, reinforced carbon fiber, and low carbon steel alloys (such as 1026 steel alloy or 4140 steel alloy). The second component208can be made from a corrosive resistant material, such as 13-chromium, 28-chromium, or other stainless steel or nickel alloy.

The assembly202includes two coupling joints: (1) segment210coupled to the first component206; and (2) segment212coupled to first component206. Because the coupling mechanisms of these two coupling joints are the same or similar, the following describes only segment210coupled to first component206. The same concepts are applicable to body segment212coupled to first component206. Furthermore, assemblies according to some embodiments include only one coupling joint.

The segment210may be substantially tubular and can include a threaded portion214in an outer wall of the segment210. The first component206can include a threaded first component portion216in an inner wall of the first component206. The first component206may also be substantially tubular. The threaded portion214can be coupled to the threaded first component portion216to couple the first component206to the second component208. For example, the threaded portion214can include annular grooves and rings capable of engaging annular rings and grooves, respectively, of the threaded first component portion216. AlthoughFIGS. 2A-Cdepict the threaded portion214in the outer wall of the segment210and the threaded first component portion216in the inner wall of the first component206, certain assemblies can include a threaded portion in an inner wall of a segment and can include a threaded first component portion in an outer wall of a first component.

The threaded portion214can be tapered to a smaller cross-sectional thickness at an end218of the threaded portion214. Similarly, the threaded first component portion216can be tapered to a smaller cross-sectional thickness at an end220of the threaded first component portion216. The tapered portions can allow the second component208and the first component206to couple without increasing a diameter of the casing string. For example, the end218can be positioned adjacent to part of the threaded first component portion216with a cross-sectional thickness greater than the end220. Likewise, the end220can be positioned adjacent to part of the threaded portion214with a cross-sectional thickness greater than the end218.

The second component208coupled to the first component206can define an inner region222and can provide a pressure seal between the inner region222and an environment224exterior to the second component208coupled to the first component206. In some embodiments, sealing members can be positioned between the threaded portion214and the threaded first component portion216.FIG. 2Cdepicts outer sealing members226,228disposed between the end220and part of the threaded portion214with a greater cross-sectional thickness than the end218. The outer sealing members226,228can be disposed in grooves in the second component208. The outer sealing members226,228can support the end220, which has a relatively low thickness, such as by allowing the first component206to be forced against the outer sealing members226,228when the first component206experiences a collapse (i.e. external) pressure from the environment224exterior to the second component208coupled to the first component206. Inner sealing members230,232are shown disposed in grooves of the first component206that are between the end218and the part of the threaded first component portion216with a greater cross-sectional thickness than the end220. Inner sealing members230,232can support the end218of the second component208, which has a relatively low thickness, such as by allowing the second component208to be forced against the inner sealing members230,232when the second component208experiences a burst (i.e. internal) pressure from the inner region222.

In other embodiments, an inner sealing member is formed by part of the first component206coupling to part of the second component208by a metal-to-metal interference fit to form a seal against pressures from inner region222. The outer sealing member can be formed by a second part of the first component206coupling to a second part of the second component208by a metal-to-metal interference fit to form a seal against pressures from environment224.

A branch wellbore can be created by forming an opening in a wall of the first component206. When the assembly202is disposed in a wellbore, a cutting tool can be deflected toward the first component206. Because the first component206has a lower tensile strength than the second component208, the cutting tool can be guided to the first component206because it presents to the cutting tool a lower resistance than does the second component208. The cutting tool can mill or drill through the first component206and create an opening that is a window through which the branch wellbore can be formed.

In some embodiments, the segments210,212are made from a different material than the material from which part (or all) of the first component206is made. These different materials may have different coefficients of thermal expansion. For example, the material from which the first component206is made may expand at a higher rate or expand more than the material from which the segments210,212are made. The annular rings and grooves of each of the threaded portion214and the threaded first component portion216can be configured to account for such expansion. In some embodiments, the annular rings of the threaded first component portion216and the grooves of the threaded portion214are configured such that space of a certain amount is present between a side of an annular ring and a side of a groove before the assembly202is exposed to the environment of a wellbore. The space allows the threaded first component portion216to expand and allow the second component208and the first component206to remain coupled.

An inner surface of the first component206can be coated with a coating material that can increase wear resistance of the inner surface. The increased wear resistance can prevent wear by the first component206when it contacts downhole tools. Examples of downhole tools include drill pipe, drill collars, drill bits, reamers, stabilizers, tubing, packers, screens, and stimulation tools. The coating material can resist wear of tools rotating (and being tripped) through an inner region defined by the first component. The coating material, however, can be milled and/or drilled such that a window can be created in the first component206. Any type of coating material can be used. The coating material may also increase the corrosion resistant properties of the inner wall. In some embodiments, the coating material is a material that is nonconductive when in service conditions. Examples of suitable coating material include an epoxy-phenolic material such as Tube-Kote® Aluminum Pipe Coating, TK-34AL available from National Oilwell Varco of Houston, Tex.; an epoxy and polyphenylene sulfide composite material such as External Tubular Coating available from National Oilwell Varco; and a synergistic coating material such as Magnaplate HCR® available from General Magnaplate Corp. of Linden, N.J.

In some embodiments, the threaded first component portion216and/or an outer surface234of first component206is coated with one or more corrosion resistant materials, such as the coating material described above or a different material. For example, the first component206can be made from aluminum, which may be more susceptible to some types of corrosion from the subterranean wellbore environment, such as from fresh water, chemicals, brine fluids (e.g. calcium chloride, sodium chloride, potassium chloride, calcium bromide, potassium bromide, and combinations of these), or otherwise. In some embodiments, an inner surface of the first component206is coated with the more corrosion resistant material. Furthermore, the threaded first component portion216may be more susceptible to galvanic corrosion due to contact with the threaded portion214, which may be steel. All or part of the first component206can be coated by a coating material that is more corrosion resistant than aluminum. In some embodiments, an inner wall of the first component206is coated with a coating material to improve its wear resistance. Examples of suitable coating material include the materials identified as suitable coating materials for the inner surface and also include polytetrafluoroethylene, which is known by the brand name, Teflon® available from E. I. du Pont de Nemours and Company, Wilmington, Del., and SafeGard Organic Anodize Seal from SanChem, Inc. of Chicago, Ill.

In some embodiments, the threaded first component portion216is coated with a coating material that is different than a coating material by which the outer surface234is coated. In other embodiments, the coating materials are the same type of coating material. Certain coating materials may reduce wear, reduce affects from abrasion, increase hardness, and improves frictional properties of the first component206.

The first component206can be coated using any suitable process. Examples of suitable coating processes include soft anodize coating, anodized coating, electroless nickel plating, hard anodized coating, ceramic coatings, carbide beads coating, plastic coating, thermal spray coating, a nano high velocity oxygen fuel (HVOF) coating, and metallic coating. Sacrificial anodes can also be used. In some embodiments, the threaded portion214is also is treated or coated to reduce galvanic corrosion and galling of surfaces. For example, cooper plating can be used on the threaded portion214to reduce galling when contacting aluminum. Examples of other coatings include molydeum sulfide and suitable polymers.

FIG. 3depicts an assembly302according to a second embodiment of the present invention. The assembly302includes a second component304coupled to a first component306in a similar manner as the coupling depicted and described with reference to the embodiment inFIGS. 2A-C. The assembly302includes a sleeve308disposed in an inner region310defined by the second component304coupled to the first component306. Sleeve308is depicted as being in an inner circumferential portion of the assembly302. Sleeves according to various embodiments can have any suitable configurations, including configurations that surround an entire inner circumferential portion of an assembly and configurations that do not surround an entire inner circumferential portion of an assembly. In some embodiments, the sleeve308is made from easily millable material that can assist in protecting an outer sleeve, for example an outer sleeve made from aluminum, from corrosion and wear, and can also support the outer sleeve during axial loading.

The sleeve308can also provide support to the second component304coupled to the first component306to prevent detrimental effects experienced from burst and/or collapse pressures, for example. In some embodiments, the second component304, first component306, and sleeve308provide a pressure seal between the inner region310and an environment312exterior to the second component304and the first component306. The sleeve308may be made from any type of suitable material. Examples of suitable materials include fiberglass, carbon fiber, fabric reinforced polymer, and low carbon steel.

The sleeve308can be coupled to the first component306by any suitable means309. Examples of suitable means309include an adhesive, a weld, a snap ring, a mechanical fastener, and a castellation. The sleeve308can also be coupled to the second component304by any suitable means. Examples of suitable means for coupling the sleeve308to the second component include a snap ring or a shear screw and pin. The sleeve308may be easily milled and/or drilled to create a window in a wall of the sleeve308through which an opening in the first component306and through which a branch wellbore can be created. In other embodiments, the sleeve308includes a pre-milled opening through which a mill or a drill can pass. For example, the opening can be located adjacent part of the first component306that can be milled.

The sleeve308can provide wear resistance during rotation of drilling equipment in the assembly302or otherwise. In some embodiments, the sleeve includes one or more wear pads positioned on an inner surface and/or an outer surface of the sleeve308. The wear pads can provide additional wear resistance and the wear pads may be made from materials such as composites or carbides.

The sleeve308can include a castellation314configured to carry torque from a first end316of the assembly302to a second end318of the assembly302. In other embodiments, the sleeve308does not include the castellation314, or includes the castellation314but does not carry torque.

FIG. 4depicts an assembly402according to a third embodiment of the present invention. The assembly402includes a second component404coupled to a first component406in a similar manner as the coupling depicted and described with reference to the embodiment inFIGS. 2A-C. The first component406includes three elements: a first coupling element408, a second coupling element410, and a window element412. The first coupling element408and the second coupling element410are configured to couple to portions of the second component404in a manner similar to the coupling inFIGS. 2A-C. The first coupling element408can be made from the same or different material than the second coupling element410. In some embodiments, the first coupling element408and the second coupling element410are made from the same material as the material from which the second component404is made.

The window element412may be made from a material that is easier to mill and drill than the materials from which the first coupling element408and the second coupling element410are made. For example, the material from which window element412is made may have a lower tensile strength than the material from which the first coupling element408and the second coupling element410are made. Examples of materials from which the window element412can be made include fabric reinforced polymer, carbon fiber, fiberglass, para-aramid synthetic fiber, silicon carbide, aluminum, and carbon nanotubes. The window element412can be coupled to the first coupling element408and the second coupling element410using any suitable coupling mechanisms. Examples of suitable coupling mechanisms include a weld, a rivet, a flange, brazing, and via a bonding agent.

An opening that is a window can be made in the window element412. A branch wellbore can be created through the window. Milling or drilling through the lower tensile strength material can be easier, and may result in less debris, than drilling or milling through a higher tensile strength material, such as the material(s) from which the first coupling element408, second coupling element410, and second component404are made.

In some embodiments, the assembly402includes a sleeve, such as the sleeve308fromFIG. 3, disposed in an inner region defined by the second component404and the first component406. The sleeve can support the first component406, including the window element412before the window element412is milled or drilled.

Assemblies according to some embodiments of the present invention include one or more chambers between threadedly coupled components. The chambers may be sealed and exhibit pressure on the components. The assemblies can include venting members that can equalize pressure of the chambers and an area outside of the components to reduce the pressure. The area outside of the components can include an inner region defined by the coupled components and an environment exterior to the coupled components.

FIG. 5depicts a cross-sectional view of a threaded coupling502that includes a first component504threadedly coupled to a second component506and venting members508,510. The first component504may be made from a material having a lower strength than the material from which the second component506is made. The first component504coupled to the second component506can define one or more chambers (not shown) between the components. The venting members508,510can each allow pressure to equalize between the chambers and an area512outside of the first component504and the second component506. In some embodiments, the venting members508,510are ports through which pressure in the chamber can equalize with the pressure outside of the components.

Venting chambers in an assembly can enhance the sealing capability of the threaded coupling. Venting the chambers may also increase the burst resistance and the collapse resistance of the threaded coupling and preventing corrosive fluid from contacting threads to increase corrosion resistance of the threaded coupling.

FIG. 6depicts part of an assembly602with a venting member604that includes a pressure compensator606disposed in the venting member604. The pressure compensator606can decrease differential pressure between a chamber608and an area outside of the assembly602. The pressure compensator606can include a piston610that is configured to change position in the pressure compensator to equalize the pressure. In some embodiments, a spring (not shown) can be positioned under the piston610. The spring can hold the piston610in an “out” position until exterior pressure increases to level that causes the spring to be compressed, resulting in a lower pressure differential.

In other embodiments, a venting member for an assembly can provide a channel through which an epoxy or other substance can traverse to one or more chambers. The epoxy or other substance can harden in the chamber to seal the chamber from the area outside of the threaded coupling.

FIGS. 7A-7Ddepict an assembly702in which epoxy704is introduced to seal a chamber706.FIG. 7Ashows a venting member708coupled to a tube710for introducing epoxy704and a venting tube712for facilitating epoxy introduction.FIG. 7Bdepicts epoxy704being introduced through the tube710to the venting member708. The venting member708can provide a channel through which the epoxy704traverses to the chamber706. The epoxy can fill the chamber706, as shown inFIG. 7C. The epoxy704can be configured to harden after a certain amount of time and seal the chamber706from the area714outside of the assembly702, as shown inFIG. 7D. The chamber706can be plugged after filling with epoxy704that then hardens, such that a pressure seal is maintained. The epoxy704may be any suitable material capable of bonding to the surfaces and include sufficient elasticity after hardening to maintain a seal when the components experience thermal expansion.

As stated above, sealing members according to various embodiments of the present invention can be any suitable structure that can cooperate with the components to provide a seal between an inner region and an environment exterior to the components.FIG. 2C, for example, depicts rings, such as O-rings, as sealing members.FIGS. 8 and 9depict other types of sealing members.FIG. 8, for example, depicts a T-seal804in a groove802between threadedly coupled components806,808. Embodiments of the T-seal804can prevent or eliminate the spiral or twisting failure that can occur with other sealing mechanisms. A back-up ring810can be included with the T-seal804. An example of T-seal804is Parker's T-Seal available from Parker Hannifin Corp. of Cleveland, Ohio.

FIG. 9depicts sealing members that are bonded seals902,904. Each of the bonded seals902,904is physically bonded to either component906or component908. The bonded seals902,904can each be bonded to one of the components906,908on one to three sides.

Other types of sealing members include ring seals that can be molded to a suitable shape, but installed prior to creating threads on a component. In other embodiments, the ring seals are stretched such that the ring seals can be slid into a desired position.