Multilateral junction having expanding metal sealed and anchored joints

Abstract

Provided is a multilateral junction. The multilateral junction, in one aspect, includes a y-block. The multilateral junction additionally includes a mainbore leg coupled to the y-block, the mainbore leg defining a second overlapping space, and a lateral bore leg coupled to the y-block, the lateral bore leg defining a third overlapping space. The multilateral junction, in this aspect, additionally includes an expanded metal joint located in at least a portion of the second overlapping space or the third overlapping space, the expanded metal joint comprising a metal that has expanded in response to hydrolysis.

What is claimed is: 
     
         1 . A multilateral junction, comprising:
 a y-block, the y-block including;
 a housing having a first end and a second opposing end; 
 a single first bore extending into the housing from the first end, the single first bore defining a first centerline; and 
 second and third separate bores extending into the housing and branching off from the single first bore, the second bore defining a second centerline and the third bore defining a third centerline; 
   a mainbore leg coupled to the second bore for extending into the main wellbore, the mainbore leg and the second bore defining a second overlapping space;   a lateral bore leg coupled to the third bore for extending into the lateral wellbore, the lateral bore leg and the third bore defining a third overlapping space; and   an expanded metal joint located in at least a portion of the second overlapping space or the third overlapping space, the expanded metal joint comprising a metal that has expanded in response to hydrolysis.   
     
     
         2 . The multilateral junction as recited in  claim 1 , wherein the expanded metal joint is a lateral wellbore leg expanded metal joint located in at least a portion of the third overlapping space. 
     
     
         3 . The multilateral junction as recited in  claim 2 , wherein the lateral bore leg is a D-shaped tube. 
     
     
         4 . The multilateral junction as recited in  claim 2 , further including a main wellbore leg expanded metal joint located in at least a portion of the second overlapping space, the main wellbore leg expanded metal joint comprising the metal that has expanded in response to hydrolysis. 
     
     
         5 . The multilateral junction as recited in  claim 2 , wherein the third bore has a first wall thickness (t 1 ) proximate the third overlapping space and the lateral wellbore leg has a second wall thickness (t 2 ) proximate the third overlapping space, and further wherein the first wall thickness (t 1 ) and the second wall thickness (t 2 ) are no more than 5.0 cm. 
     
     
         6 . The multilateral junction as recited  claim 2 , wherein the lateral wellbore leg expanded metal joint is a first lateral wellbore leg expanded metal joint, and further including a second lateral wellbore leg expanded metal joint located in at least a portion of the third overlapping space, the second lateral wellbore leg expanded metal joint comprising the metal that has expanded in response to hydrolysis. 
     
     
         7 . The multilateral junction as recited in  claim 6 , further including an elastomeric sealing member positioned between the first lateral wellbore expanded metal joint and the second lateral wellbore expanded metal joint. 
     
     
         8 . The multilateral junction as recited in  claim 2 , wherein the third bore has a first inside diameter (d 1 ) proximate the third overlapping space and the lateral wellbore leg has a second inside diameter (d 2 ) proximate the third overlapping space, and further wherein the lateral wellbore leg expanded metal joint is positioned less than a distance (D p ) from the end of the third bore or lateral wellbore leg, the distance (D p ) equal to or less than four times the first inside diameter (d 1 ). 
     
     
         9 . The multilateral junction as recited in  claim 2 , wherein an overlap distance (D o ) between the third bore and the lateral wellbore leg is less than 40 cm. 
     
     
         10 . The multilateral junction as recited in  claim 1 , wherein the expanded metal joint includes residual unreacted expandable metal therein. 
     
     
         11 . The multilateral junction as recited in  claim 1 , wherein the expanded metal joint is a single step expanded metal joint. 
     
     
         12 . A method for deploying a multilateral junction, comprising:
 providing a y-block, the y-block including;
 a housing having a first end and a second opposing end; 
 a single first bore extending into the housing from the first end, the single first bore defining a first centerline; and 
 second and third separate bores extending into the housing and branching off from the single first bore, the second bore defining a second centerline and the third bore defining a third centerline; 
   attaching a mainbore leg to the second bore for extending into the main wellbore, the mainbore leg and the second bore defining a second overlapping space;   attaching a lateral bore leg to the third bore for extending into the lateral wellbore, the lateral bore leg and the third bore defining a third overlapping space, and further wherein the third overlapping space has a lateral wellbore leg pre-expansion joint located at least partially therein, the lateral wellbore leg pre-expansion joint comprising a metal configured to expand in response to hydrolysis; and   subjecting the lateral wellbore leg pre-expansion joint to an activation fluid to expand the metal in the third overlapping space and thereby form a lateral wellbore leg expanded metal joint in the third overlapping space.   
     
     
         13 . The method as recited in  claim 12 , further including positioning the multilateral junction including the lateral wellbore leg expanded metal joint downhole. 
     
     
         14 . The method as recited in  claim 11 , wherein the lateral bore leg is a D-shaped tube. 
     
     
         15 . The method as recited in  claim 12 , further including a main wellbore leg expanded metal joint located in at least a portion of the second overlapping space, the main wellbore leg expanded metal joint comprising the metal that has expanded in response to hydrolysis. 
     
     
         16 . The method as recited in  claim 12 , wherein the third bore has a first wall thickness (t 1 ) proximate the third overlapping space and the lateral wellbore leg has a second wall thickness (t 2 ) proximate the third overlapping space, and further wherein the first wall thickness (t 1 ) and the second wall thickness (t 2 ) are no more than 5.0 cm. 
     
     
         17 . The method as recited  claim 12 , wherein the lateral wellbore leg expanded metal joint is a first lateral wellbore leg expanded metal joint, and further including a second lateral wellbore leg expanded metal joint located in at least a portion of the third overlapping space, the second lateral wellbore leg expanded metal joint comprising the metal that has expanded in response to hydrolysis. 
     
     
         18 . The method as recited in  claim 17 , further including an elastomeric sealing member positioned between the first lateral wellbore expanded metal joint and the second lateral wellbore expanded metal joint. 
     
     
         19 . The method as recited in  claim 12 , wherein the expanded metal joint includes residual unreacted expandable metal therein. 
     
     
         20 . The method as recited in  claim 12 , wherein the expanded metal joint is a single step expanded metal joint. 
     
     
         21 . A well system, comprising:
 a wellbore;   production tubing positioned within the wellbore;   a multilateral junction, the multilateral junction including;
 a y-block, the y-block including; 
 a housing having a first end and a second opposing end; 
 a single first bore extending into the housing from the first end, the single first bore defining a first centerline; and 
 second and third separate bores extending into the housing and branching off from the single first bore, the second bore defining a second centerline and the third bore defining a third centerline; 
   a mainbore leg coupled to the second bore for extending into the main wellbore, the mainbore leg and the second bore defining a second overlapping space;   a lateral bore leg coupled to the third bore for extending into the lateral wellbore, the lateral bore leg and the third bore defining a third overlapping space; and   an expanded metal joint located in at least a portion of the second overlapping space or the third overlapping space, the expanded metal joint comprising a metal that has expanded in response to hydrolysis.   
     
     
         22 . The well system as recited in  claim 1 , wherein the expanded metal joint is a lateral wellbore leg expanded metal joint located in at least a portion of the third overlapping space.