Abstract:
An expandable translating joint comprises a first expandable tubular member having a lower end with a recessed inner wall portion and a second expandable tubular member having an upper end with a recessed outer wall portion. The second expandable tubular member is partially disposed within the first expandable tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion. A retainer is coupled to the recessed inner wall portion of the first expandable tubular member and disposed within the recessed outer wall portion of the lower second expandable tubular member. An expansion cone is operable to move axially through and radially expand the first and second expandable tubulars. The first expandable tubular can translate relative to the second tubular member both before and after expansion.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    None 
       BACKGROUND 
       [0002]    This disclosure relates generally to methods and apparatus for lining wellbores. More specifically, this disclosure relates to methods and apparatus for providing a wellbore tubular that can accommodate axial expansion or contraction after radial expansion and installation into a wellbore. 
         [0003]    During hydrocarbon exploration and production, a wellbore typically traverses a number of zones within a subterranean formation. A tubing string, such as a casing or liner, may be established in the wellbore to create flow paths from the multiple producing zones to the surface of the wellbore. Efficient production is highly dependent on the inner diameter of the tubing string, with greater inner diameters producing more hydrocarbons or allowing inserted equipment with appropriate pressure ratings to be used in well completions. To provide larger inner diameters to installed tubing strings, technologies have been developed that allow for tubing strings to be radially expanded after installation in a wellbore. Radially expanding tubing strings in the wellbore allows installation of larger diameter tubulars than would otherwise be possible. 
         [0004]    In the case of wells of substantial depth, and particularly wells where the downhole temperatures are substantially in excess of or below the surface temperatures, problems have been encountered due to excessive axial expansion or contraction of the elongated tubing string. For example, in the treatment or stimulation of the well, it is common to introduce fluids at surface ambient temperature into the tubing string. In some cases, the fluid is introduced as steam at elevated temperatures. When the major portions of the tubing string are at a much higher temperature initially, this inherently results in a cooling, and hence a substantial contraction of the tubing string, resulting in the production of substantial tensile stress in the tubing string between its surface connection and the set packer. Similarly, in the production phase of such wells, the production fluid is normally at a temperature substantially in excess of the temperature of the majority of the tubing string, resulting in a substantial expansion of the tubing string and the production of a substantial compressive force on the tubing string. Additionally, changes in fluid pressure inside and outside the tubing string play a major role in the development of substantial tension or compressive forces in the tubing string. 
         [0005]    To address the described expansion or contraction of the downhole tubulars, a translating joint, or expansion joint can be disposed in the tubing string. A translating joint is an axially moveable or telescoping device or component designed to enable relative movement between two fixed assemblies in the event of thermal expansion or contraction. Further, the translating joint may have rotational or torque transmitting capability so that rotation can be accomplished through the joint to the right or to the left in order to perform required operations on various pieces of apparatus carried by the tubing string. 
         [0006]    The principles of the present disclosure are directed to overcoming one or more of the limitations of the existing apparatus and processes for increasing fluid injection or hydrocarbon production during treatment, completion and production of subterranean wells. 
         [0007]    Thus, there is a continuing need in the art for methods and apparatus that enable a radially expanded tubular string to compensate for axial loads applied after installation into a wellbore. 
       BRIEF SUMMARY OF THE DISCLOSURE 
       [0008]    An expandable translating joint comprises a first expandable tubular member having a lower end with a recessed inner wall portion and a second expandable tubular member having an upper end with a recessed outer wall portion. The second expandable tubular member is partially disposed within the first expandable tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion. A retainer is coupled to the recessed inner wall portion of the first expandable tubular member and disposed within the recessed outer wall portion of the lower second expandable tubular member. An expansion cone is operable to move axially through and radially expand the first and second expandable tubulars. The first expandable tubular can translate relative to the second tubular member both before and after expansion. 
         [0009]    In some embodiments, a seal groove is disposed proximate to the upper end of the second expandable tubular member. In some embodiments, the seal groove is disposed between the upper end and the recessed outer wall portion of the second expandable tubular member. In some embodiments, a seal member is disposed in the seal groove and in sealing engagement with the recessed inner wall portion of the first expandable tubular member. In some embodiments, the first expandable tubular member is rotationally constrained relative to the second expandable tubular member. In some embodiments, a plurality of axial tabs extend from the upper end of the second expandable tubular member and are engaged with a corresponding plurality of axial grooves formed in the first expandable tubular member. In some embodiments, a plurality of retainer pins couple the retainer to the first expandable tubular member. In some embodiments, the retainer is welded to the first expandable tubular member. 
         [0010]    An expansion system comprises an upper tubular member having a lower end with a recessed inner wall portion and a lower tubular member having an upper end with a recessed outer wall portion. The lower tubular member is partially disposed within the upper tubular member such that the recessed inner wall portion at least partially surrounds the recessed outer wall portion. A retainer is coupled to the upper tubular member and disposed within the recessed outer wall portion of the lower tubular member. An expansion cone is operable to move axially through and radially expand the upper and lower tubulars, wherein the upper tubular can translate relative to the lower tubular member both before and after expansion. 
         [0011]    In some embodiments, a seal groove is disposed proximate to the upper end of the lower tubular member. In some embodiments, the seal groove is disposed between the upper end and the recessed outer wall portion of the lower tubular member. In some embodiments, a seal member is disposed in the seal groove and in sealing engagement with the recessed inner wall portion of the upper tubular member. In some embodiments, the upper tubular member is rotationally constrained relative to the lower tubular member. In some embodiments, a plurality of axial tabs extends from the upper end of the lower tubular member and engages a corresponding plurality of axial grooves formed in the upper tubular member. In some embodiments, a plurality of retainer pins couples the retainer to the upper tubular member. In some embodiments, the retainer is welded to the upper tubular member. 
         [0012]    A method comprises inserting an upper end of a lower tubular member into a recessed inner wall portion of an upper tubular member, coupling a retainer to a lower end of the upper tubular member, wherein the retainer is disposed within a recessed outer wall portion of the lower tubular member, and axially translating an expansion cone through the upper and lower tubular members so as to radially expand the upper and lower tubular members, wherein the upper tubular can translate relative to the lower tubular member both before and after expansion. 
         [0013]    In some embodiments, the method also includes forming a seal between the lower tubular member and the recessed inner wall portion of the upper tubular member. In some embodiments, the method also includes rotationally constraining the upper tubular member relative to the lower tubular member both before and after expansion. In some embodiments, the retainer is coupled to the upper tubular member by a plurality of retainer pins. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    For a more detailed description of the embodiments of the present disclosure, reference will now be made to the accompanying drawings, wherein: 
           [0015]      FIG. 1  is a partial sectional view of an expandable translating joint in an unexpanded condition. 
           [0016]      FIG. 2  is a partial sectional view of the lower tubular member of an expandable translating joint. 
           [0017]      FIG. 3  is a partial sectional view of the upper tubular member of an expandable translating joint. 
           [0018]      FIG. 4  is a partial sectional view of the retainer of an expandable translating joint. 
           [0019]      FIGS. 5A-5E  are partial sectional views illustrating the expansion of an expandable translating joint. 
           [0020]      FIG. 6  is a partial sectional view of an expandable translating joint in an expanded condition. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the various figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure. 
         [0022]    Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term “or” is intended to encompass both exclusive and inclusive cases, i.e., “A or B” is intended to be synonymous with “at least one of A and B,” unless otherwise expressly specified herein. 
         [0023]    Referring initially to  FIG. 1 , an expandable translating joint  10  includes a lower tubular member  12 , an upper tubular member  14 , and a retainer  16 . The retainer  16  may be coupled to the upper tubular member  14  by retainer pins  18  or by welding, brazing, screws, or other means. The lower tubular member  12  includes a plurality of axial tabs  20  that engage corresponding axial grooves  22  formed on the inner wall of the upper tubular member  14 . A seal member  24  is disposed in the annulus between the lower tubular member  12  and the upper tubular member  14 . 
         [0024]    Referring now to  FIG. 2 , the lower tubular member  12  includes a main body  26  having a recessed outer wall section  28  disposed between full thickness wall portion  34  and upper wall portion  35 . The upper wall portion  35  may have the same wall thickness as full thickness wall portion  34  or may have a reduced wall thickness. The lower tubular member  12  may be formed from a single length of tubular or may be constructed by coupling the main body  26  to an upper body  36  that includes a seal groove  30  and axial tabs  20  formed in the upper wall portion  35 . The main body  26  may be coupled to the upper body  36  via a weld seam  32  or some other joining means. 
         [0025]    Referring now to  FIG. 3 , upper tubular member  14  includes axial grooves  22  and a recessed inner wall section  38  that may include a plurality of mounting holes  40 . In certain embodiments, the outer diameter of the upper tubular member  13  may increase in the portion including the axial grooves  22  and the recessed inner wall section  38 . As shown in  FIG. 4 , retainer  16  includes a plurality of mounting holes  42  corresponding to the mounting holes  40  on the upper tubular member  14 . Retainer pins  18  are sized so as to fit into both sets of mounting holes  40 ,  42  and substantially flush with the inner diameter of the retainer  16  and the outer diameter of the upper tubular member  14  when fully assembled (as shown in  FIG. 1 ). 
         [0026]    With reference to  FIGS. 1-4 , translating joint  10  is assembled by first sliding the retainer  16  onto the recessed outer wall section  28  of the main body  26  of the lower tubular member  12 . Once the retainer  16  is in place, the upper body  36  can be coupled to the main body  26  to form the lower tubular member  12 . A seal member  24  is then installed into the seal groove  30 . The lower tubular member  12  is then inserted into the upper tubular member  14  and until axial tabs  20  engage with axial grooves  22  and the mounting holes  40  on the upper tubular member  14  are aligned with the mounting holes  42  on the retainer  16 . Retainer pins  18  are inserted through the aligned mounting holes  40 ,  42  and affixed in place by welding, brazing, threads, or other means to hold the retainer pins  18  in place. To facilitate expansion of the translating joint  10 , the lower tubular member  12 , upper tubular member  14 , and retainer  16  are constructed from materials that can be radially expanded. 
         [0027]    Once translating joint  10  is fully assembled, the lower tubular member  12  can move axially relative to the upper tubular member  14  as limited by the travel of the retainer  16  within the recessed outer wall section  28  of the main body. The engagement of the axial tabs  20  and the axial grooves  22  prevents rotation of the upper tubular member  14  relative to the lower tubular member  12 . The seal member  24  is compressed between the upper tubular member  14  and the lower tubular member  12  so as to maintain pressure integrity of the translating joint  10 . 
         [0028]    The lower tubular member  12  and the upper tubular member  14  may include threads on their respective distal ends for assembling the translating joint  10  into a string of casing, or other wellbore tubular. Once assembled into a wellbore tubular, the tubular and translating joint  10  can be run into a wellbore and radially expanded using any number of expansion methods. As illustrated in  FIGS. 5A-5E , the translating joint  10  may be radially expanded by moving an expansion cone  50  axially through the translating joint  10 . The expansion cone  50  may be moved through the translating joint  10  by the application of a direct axial force (through pulling or pushing) and/or the application of a differential pressure across the expansion cone  50 . 
         [0029]      FIG. 5A  illustrates the initiation of expansion of a translating joint  10  where an expansion cone  50  is moving upward through the translating joint  10  and has begun expansion of the lower tubular member  12 . Prior to expansion, the translating joint  10  is in the position illustrated in  FIG. 1  with the axial tabs  20  substantially fully engaged with the axial grooves  22 . As the expansion cone  50  moves axially through the lower tubular member  12 , the lower tubular member  12  radially expands as shown in  FIG. 5B . As the expansion cone  50  expands the upper end of the lower tubular member  12  where the upper tubular member  14  overlaps the lower tubular member  12 , the expansion of the lower tubular member  12  pushes outward into and expands the upper tubular member  14 . During this process, the upper tubular member  14  is also pushed axially upward until retained by the retainer  16 , as shown in  FIG. 5D  and  FIG. 6 . Once the expansion cone  50  has passed fully through the translating joint  10 , the upper tubular member  14  can be moved downward relative to the lower tubular member  12  in response to axial compression of the translating joint, as shown in  FIG. 5E . 
         [0030]    While the disclosure is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and description. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the disclosure to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present disclosure.