Expandable wellbore junction

Abstract

Multiple wellbores are interconnected utilizing a deflection device having a guide layer of lower hardness than the body of the deflection device, and a cutting tool having a guide portion and being operative to cut through the deflection device guide layer and a tubular structure lining a wellbore.

1. A method of interconnecting first and second wellbores, the method comprising the steps of:
 positioning a deflection device within the first wellbore, the deflection device having a substantially longitudinally extending guide layer outwardly overlying a body of the deflection device, and the guide layer having a hardness substantially less than that of the body, and  
 displacing a cutting tool substantially longitudinally relative to the deflection device, a guide portion of the cutting tool contacting the guide layer, thereby guiding the cutting tool to cut an opening through a tubular structure lining the first wellbore while cutting through the guide layer.  
 
     
     
       2. The method according to  claim 1  wherein the positioning step further comprises engaging the deflection device with an orienting device within the first wellbore. 
     
     
       3. The method according to  claim 2 , further comprising the step of engaging a wellbore connector with the orienting device. 
     
     
       4. The method according to  claim 3 , further comprising the step of extending a portion of the wellbore connector laterally outward into the opening. 
     
     
       5. The method according to  claim 3 , further comprising the step of drilling the second wellbore through the wellbore connector. 
     
     
       6. The method according to  claim 5 , further comprising the step of sealingly engaging the wellbore connector with a tubular member extending into the second wellbore. 
     
     
       7. Apparatus for forming an opening through a tubular structure lining a wellbore, the apparatus comprising:
 an elongated body having a generally longitudinally extending outer side surface portion positionable to face the intended opening location on the tubular structure, and along which a cutting tool may be moved while forming the opening; and  
 a guide layer attached to the outer side surface portion, the guide layer having a hardness substantially less than that of the body and being removable by a cutting tool as it moves along the outer side surface portion while forming the opening.  
 
     
     
       8. The apparatus according to  claim 7 , wherein the body further has an opening device engagement portion attached thereto, the engagement portion being configured for engagement with an orienting profile positioned in the wellbore. 
     
     
       9. The apparatus according to  claim 7 , wherein the body further has a laterally inclined deflection surface formed thereon proximate an end of the body. 
     
     
       10. The apparatus according to  claim 9 , wherein the guide layer is not attached to the deflection surface. 
     
     
       11. The apparatus according to  claim 7 , further comprising a cutting tool releasably secured to the body. 
     
     
       12. The apparatus according to  claim 11 , wherein the cutting tool includes a guide portion, the guide portion contacting the guide layer and being guided longitudinally thereby when the cutting tool is displaced longitudinally relative to the body. 
     
     
       13. The apparatus according to  claim 11 , wherein the cutting tool is configured to cut through the guide layer when the cutting tool is displaced longitudinally relative to the body. 
     
     
       14. A system for interconnecting a tubular member to a wellbore connector in a subterranean well, the system comprising:
   the wellbore connector expanded within the well;        the tubular member expanded within and connected to the expanded wellbore connector; and        the wellbore connector providing fluid communication between each of at least three wellbores.     
     
     
       15. The system according to  claim 14 , wherein the tubular member is expanded within a flow passage of the wellbore connector. 
     
     
       16. The system according to  claim 14 , wherein the tubular member is sealed within the wellbore connector. 
     
     
       17. The system according to  claim 14 , wherein the tubular member is plastically deformed within the wellbore connector. 
     
     
       18. The system according to  claim 14 , further comprising a grip member providing gripping engagement between the tubular member and the wellbore connector. 
     
     
       19. A system for interconnecting a tubular member to a wellbore connector in a subterranean well, the system comprising:
   the wellbore connector expanded within the well, the expanded wellbore connector providing a connection between at least three wellbores;        the tubular member expanded within and connected to the expanded wellbore connector; and        a sealing material positioned between the tubular member and the wellbore connector.     
     
     
       20. The system according to  claim 19 , wherein the sealing material is positioned overlying a radially reduced portion of the tubular member, the radially reduced portion being expanded outward when the tubular member is expanded. 
     
     
       21. The system according to  claim 20 , further comprising a grip member embedded in the sealing material. 
     
     
       22. A method of interconnecting a tubular member to a flow passage in a subterranean well, the method comprising the steps of:
   expanding a wellbore connector in the well, the wellbore connector having the flow passage formed therein;        then expanding the tubular member within the expanded wellbore connector; and        providing fluid communication between each of at least three wellbores via the wellbore connector.     
     
     
       23. The method according to  claim 22 , wherein the wellbore connector expanding step further comprises expanding the flow passage. 
     
     
       24. The method according to  claim 23 , wherein the tubular member expanding step further comprises expanding the tubular member within the expanded flow passage. 
     
     
       25. The method according to  claim 22 , wherein the tubular member expanding step further comprises sealing between the tubular member and the wellbore connector. 
     
     
       26. The method according to  claim 22 , wherein the tubular member expanding step further comprises securing the tubular member to the wellbore connector. 
     
     
       27. The method according to  claim 22 , wherein the tubular member is a portion of a hanger, and wherein the tubular member expanding step further comprises setting the hanger in the wellbore connector. 
     
     
       28. The method according to  claim 22 , wherein the wellbore connector expanding step further comprises conforming the flow passage to a generally cylindrical shape. 
     
     
       29. The method according to  claim 22 , wherein the tubular member expanding step further comprises plastically deforming the tubular member. 
     
     
       30. The method according to  claim 22 , wherein the tubular member expanding step further comprises swaging the tubular member outward. 
     
     
       31. A method of interconnecting a tubular member to a flow passage in a subterranean well, the method comprising the steps of:
   expanding a wellbore connector in the well, the wellbore connector having the flow passage formed therein; and        then expanding the tubular member within the expanded wellbore connector, including compressing an elastomeric member within the tubular member.     
     
     
       32. A method of interconnecting a tubular member to a flow passage in a subterranean well, the method comprising the steps of:
   expanding a wellbore connector in the well, the wellbore connector having the flow passage formed therein; and        then expanding the tubular member within the expanded wellbore connector, the tubular member having a sealing material externally disposed thereon.     
     
     
       33. The method according to  claim 32 , wherein the tubular member expanding step further comprises sealingly engaging the sealing material with the flow passage. 
     
     
       34. The method according to  claim 32 , wherein a grip member is embedded in the sealing material, and wherein the tubular member expanding step further comprises grippingly engaging the grip member with the flow passage. 
     
     
       35. The method according to  claim 32 , wherein the sealing material is disposed on a radially reduced portion of the tubular member, and wherein the tubular member expanding step further comprises outwardly displacing the radially reduced portion. 
     
     
       36. The method according to  claim 35 , wherein the radially reduced portion comprises a minimum internal dimension of the tubular member prior to the tubular member expanded step. 
     
     
       37. The method according to  claim 36 , wherein in the tubular member expanding step, the radially reduced portion no longer comprises the minimum internal dimension of the tubular member. 
     
     
       38. The method according to  claim 32 , wherein the sealing material is disposed radially inward relative to an outer side surface of the tubular member prior to the tubular member expanding step, and wherein the tubular member expanding step further comprises displacing the sealing material outward past the outer side surface. 
     
     
       39. A method of interconnecting a tubular member to a flow passage in a subterranean well, the method comprising the steps of:
   expanding a wellbore connector in the well, the wellbore connector having the flow passage formed therein; and        then expanding the tubular member within the expanded wellbore connector, the tubular member having a grip member externally disposed thereon.     
     
     
       40. The method according to  claim 39 , wherein in the tubular member expanding step, the grip member is circumferentially continuous about the tubular member. 
     
     
       41. The method according to  claim 39 , wherein in the tubular member expanding step, the grip member is circumferentially corrugated about the tubular member. 
     
     
       42. The method according to  claim 39 , wherein the tubular member expanding step further comprises circumferentially expanding the grip member. 
     
     
       43. The method according to  claim 39 , wherein the tubular member expanding step further comprises preventing relative axial and rotational displacement between the tubular member and the flow passage by gripping engagement between the grip member and the flow passage. 
     
     
       44. The method according to  claim 39 , wherein the tubular member expanding step further comprises sealingly engaging the grip member with the flow passage. 
     
     
       45. The method according to  claim 39 , wherein the grip member is embedded in a sealing material, and wherein the tubular member expanding step further comprises sealingly engaging the sealing material with the flow passage. 
     
     
       46. The method according to  claim 39 , wherein the tubular member expanding step further comprises utilizing the grip member to prevent extrusion of a sealing material on the tubular member. 
     
     
       47. The method according to  claim 39 , wherein the grip member is disposed on a radially reduced portion of the tubular member, and wherein the tubular member expanding step further comprises outwardly displacing the radially reduced portion. 
     
     
       48. The method according to  claim 47 , wherein the radially reduced portion comprises a minimum internal dimension of the tubular member prior to the tubular member expanding step. 
     
     
       49. The method according to  claim 48 , wherein in the tubular member expanding step, the radially reduced portion no longer comprises the minimum internal dimension of the tubular member. 
     
     
       50. The method according to  claim 49 , wherein the grip member is disposed radially inward relative to an outer side surface of the tubular member prior to the tubular member expanding step, and wherein the tubular member expanding step further comprises displacing the grip member outward past the outer side surface. 
     
     
       51. A method of interconnecting a tubular member to a flow passage in a subterranean well, the method comprising the steps of:
   forming the flow passage in a wellbore connector;        expanding the wellbore connector flow passage in the well;        attaching an expandable hanger to the tubular member; and        expanding the hanger within the expanded flow passage by expanding the tubular member.     
     
     
       52. The method according to  claim 51 , wherein the hanger expanding step further comprises sealing between the hanger and the flow passage. 
     
     
       53. The method according to  claim 51 , wherein the hanger expanding step further comprises preventing relative displacement between the hanger and the flow passage. 
     
     
       54. The method according to  claim 51 , wherein the flow passage expanding step further comprises conforming the flow passage to a generally cylindrical shape. 
     
     
       55. The method according to  claim 51 , wherein the hanger expanding step further comprises plastically deforming the hanger. 
     
     
       56. The method according to  claim 51 , wherein the hanger expanding step further comprises swaging the hanger outward. 
     
     
       57. The method according to  claim 51 , wherein the hanger expanding step further comprises compressing an elastomeric member within the hanger. 
     
     
       58. The method according to  claim 51 , wherein in the hanger expanding step, the hanger has a sealing material externally disposed thereon. 
     
     
       59. The method according to  claim 58 , wherein the hanger expanding step further comprises sealingly engaging the sealing material with the flow passage. 
     
     
       60. The method according to  claim 58 , wherein a grip member is embedded in the sealing material, and wherein the hanger expanding step further comprises grippingly engaging the grip member with the flow passage. 
     
     
       61. The method according to  claim 58 , wherein the sealing material is disposed on a radially reduced portion of the hanger, and wherein the expanding step further comprises outwardly displacing the radially reduced portion. 
     
     
       62. The method according to  claim 61 , wherein the radially reduced portion comprises a minimum internal dimension of the hanger prior to the expanding step. 
     
     
       63. The method according to  claim 62 , wherein in the hanger expanding step, the radially reduced portion no longer comprises the minimum internal dimension of the hanger. 
     
     
       64. The method according to  claim 62 , wherein the sealing material is disposed radially inward relative to an outer side surface of the hanger prior to the hanger expanding step, and wherein the hanger expanding step further comprises displacing the sealing material outward past the outer side surface. 
     
     
       65. The method according to  claim 51 , wherein in the hanger expanding step, the hanger has a grip member externally disposed thereon. 
     
     
       66. The method according to  claim 65 , wherein in the hanger expanding step, the grip member is circumferentially continuous about the hanger. 
     
     
       67. The method according to  claim 65 , wherein in the hanger expanding step, the grip member is circumferentially corrugated about the hanger. 
     
     
       68. The method according to  claim 65 , wherein the hanger expanding step further comprises circumferentially expanding the grip member. 
     
     
       69. The method according to  claim 65 , wherein the hanger expanding step further comprises preventing relative axial and rotational displacement between the hanger and the flow passage by griping engagement between the grip member and the flow passage. 
     
     
       70. The method according to  claim 65 , wherein the hanger expanding step further comprises sealingly engaging the grip member with the flow passage. 
     
     
       71. The method according to  claim 65 , wherein the grip member is embedded in a sealing material, and wherein the hanger expanding step further comprises sealingly engaging the sealing material with the flow passage. 
     
     
       72. The method according to  claim 65 , wherein the hanger expanding step further comprises utilizing the grip member to prevent extrusion of a sealing material on the hanger. 
     
     
       73. The method according to  claim 65 , wherein the grip member is disposed on a radially reduced portion of the hanger, and wherein the hanger expanding step further comprises outwardly displacing the radially reduced portion. 
     
     
       74. The method according to  claim 73 , wherein the radially reduced portion comprises a minimum internal dimension of the hanger prior to the hanger expanding step. 
     
     
       75. The method according to  claim 74 , wherein in the hanger expanding step, the radially reduced portion no longer comprises the minimum internal dimension of the hanger. 
     
     
       76. The method according to  claim 65 , wherein the grip member is disposed radially inward relative to an outer side surface of the hanger prior to the hanger expanding step, and wherein the hanger expanding step further comprises displacing the grip member outward past the outer side surface.