Abstract: The present invention provides apparatus and methods for completing a wellbore using expandable tubulars. In one aspect, the invention includes a tubular member with an expandable portion at a lower end constructed and arranged to be expanded into contact with a previously expanded liner. At an upper end of the tubular is a polish bore receptacle permitting the tubular to be tied back to the surface of the well with production tubing. In another aspect, the invention provides a method of completing a well comprising expanding a liner top into a cased wellbore to hang the liner and, thereafter running a tubular member into the wellbore.

Abstract: A method and apparatus for creating a seal between two coaxial strings of pipe. The method and apparatus have utility in one embodiment for sealing the annulus between the tubing and the casing within a hydrocarbon wellbore. According to the method of the present invention, an expander tool is positioned at a selected depth within the tubing, and then actuated in order to expand the tubing against the inner wall of the casing wall. The expander tool is rotated in order to provide a fluid seal in the annulus. In this way, the tubing string becomes its own packer. In the preferred embodiment, an elastomeric seal is provided around the outer surface of the tubing to enhance the fluid seal. Further, a slip ring is provided around the outer surface of the tubing to provide a gripping means between the tubing and the casing. In the preferred embodiment, rollers of the expander tool are aligned with the seal ring and slip ring before expansion.

Abstract: A method and apparatus for creating a seal between two coaxial strings of pipe are provided. The method and apparatus have utility in one embodiment for sealing the annulus between the tubing and the casing within a hydrocarbon wellbore. According to the method of the present invention, an expander tool is positioned at a selected depth within the tubing, and then actuated in order to expand the tubing against the inner wall of the casing wall. Multiple configurations of the expander tool are disclosed. The expander tool is rotated in order to provide a fluid seal in the annulus. In this way, the tubing string becomes its own packer. In one embodiment, a seal ring is provided around the outer surface of the tubing to enhance the fluid seal. Further, a slip ring is provided around the outer surface of the tubing to provide a gripping means between the tubing and the casing.

Abstract: The present invention provides apparatus and methods for expanding an expandable sand screen in the wellbore and then fracturing the wellbore. In one aspect of the invention, an expandable sand screen includes a perforated inner pipe and outer shroud. The outer shroud includes a plurality of longitudinal channels that retain their general shape after the expandable sand screen is expanded. In the expanded state, the channels provide a fluid conduit along an area between the screen and the wall of the wellbore. In a subsequent fracturing operation, slurry travels along the conduits permitting communication of the fracturing slurry with hydrocarbon bearing formations.

Abstract: The present invention provides apparatus and methods for completing a wellbore using expandable tubulars. In one aspect, the invention includes a tubular member with an expandable portion at a lower end constructed and arranged to be expanded into contact with a previously expanded liner. At an upper end of the tubular is a polish bore receptacle permitting the tubular to be tied back to the surface of the well with production tubing. In another aspect, the invention provides a method of completing a well comprising expanding a liner top into a cased wellbore to hang the liner and, thereafter running a tubular member into the wellbore.

Abstract: An improved expansion assembly for an expander tool is provided. The expander tool is used to expand a surrounding tubular body within a wellbore. The expansion assembly first comprises a piston disposed within a recess of the expander tool. The top surface of the piston defines a bearing cavity configured to closely receive a roller. A shoe is further disposed on the top surface of the piston to receive a lower portion of the roller. In one arrangement, the roller is a tapered cylindrical roller actuated by hydraulic pressure applied from within the bore of the expander tool. Actuation of the tool forces the pistons to radially extend away from the body of the tool within the recesses. This, in turn, causes the roller members to engage the inner surface of the surrounding tubular body to be expanded. Rotation of the expander tool causes the rollers to at least partially rotate within the bearing cavity.

Abstract: Then invention generally provides an apparatus and method for providing a more uniform gravel pack in the well bore. An alternative pathway is provided within the apparatus to by-pass a sand bridge formed in the wellbore. The reentry point of the slurry into the wellbore can be predetermined based upon the conditions of the formation.

Abstract: An apparatus for preventing erosion of wellbore components comprises a wellscreen and a coating disposed on the wellscreen. The coating includes a metal-based coating and preferably nickel and phosphorous. The coating may also be organic-based such as phenolic resin containing ceramic or cermet. A method for fabricating an erosion and corrosion resistant wellbore component by providing the wellbore component and treating the wellbore component with erosion resistant materials. The treating step is conducted by plating the wellbore component, preferably by electroless plating. The treating step further comprises heat treatment of the wellbore component subsequent to plating. An additional step of inserting the treated wellbore component into a wellbore may also be conducted.