Method for using expandable tubulars

Abstract

An improved method for completing wells, such as hydrocarbon wells, is provided. In one aspect, methods are provided for deploying an expandable tubular, such as an expandable sand screen, in a hydrocarbon well. According to methods of the present invention, a sand screen is lowered into a wellbore. Thereafter, cement is injected into the wellbore so as to place a column of cement in the annular region between the tubular and the surrounding formation. The cement is then treated so as to imbue greater permeability and/or porosity characteristics. The cement serves to reinforce the sand screen, providing it with both improved physical strength and improved sand filtering ability. At the same time, the sand screen serves to reinforce and strengthen the cement sheath placed in the wellbore.

1 . A method for using an expandable tubular within a wellbore, comprising the steps of: 
 running the tubular into the wellbore;    locating the tubular in the wellbore adjacent a producing zone;    expanding the tubular radially outward along a desired length; and    placing cement in an annular region defined by the area between the expanded tubular and the surrounding wellbore.    
     
     
         2 . The method of  claim 1 , wherein the wellbore along the producing zone is an open hole wellbore, allowing fluid communication between an earth formation at the producing zone and the expanded tubular.  
     
     
         3 . The method of  claim 1 , wherein the wellbore along the producing zone is cased with a string of perforated casing, allowing fluid communication between an earth formation at the producing zone and the expanded tubular.  
     
     
         4 . The method of  claim 1 , wherein the cement is a permeable and porous cement that permits fluids to flow from the earth formation to the expanded tubular.  
     
     
         5 . The method of  claim 4 , wherein the method is conducted to remedy a failed completion.  
     
     
         6 . The method of  claim 4 , wherein the step of placing cement in the annular region is performed by injecting cement through a tubular string, and then forcing a portion of the injected cement around the bottom of the expanded tubular and up into the annular region.  
     
     
         7 . The method of  claim 4 , further comprising the step of: 
 removing substantially all of any cement disposed within the expanded tubular, leaving a cylindrical cement column in the annular region around the tubular.    
     
     
         8 . The method of  claim 7 , wherein the step of removing substantially all of the cement disposed within the tubular is performed by drilling out the cement after it has substantially cured.  
     
     
         9 . The method of  claim 4 , wherein the tubular is an expandable sand screen.  
     
     
         10 . The method of  claim 9 , further comprising the step of: 
 injecting a treating fluid into and through the sand screen in order to contact and treat the cement column, the treating fluid increasing the permeability of the set cement.    
     
     
         11 . The method of  claim 10 , wherein the step of injecting the treating fluid is performed after the step of expanding the sand screen.  
     
     
         12 . The method of  claim 4 , wherein the cement is comprised of a hydraulic cement, a particulate cross-linked gel containing an internal breaker which after time causes said gel to break into a liquid, and water present in an amount sufficient to form a slurry.  
     
     
         13 . The method of  claim 12 , further comprising the step of: 
 injecting a treating fluid into and through the sand screen in order to contact and treat the cement column, the treating fluid increasing the permeability of the set cement; and    wherein the cement is further comprised of a particulate solid that is soluble in the presence of the treating fluid.    
     
     
         14 . The method of  claim 1 , wherein the step of expanding the tubular is performed by using an expander tool, the expander tool comprising a tapered cone portion urged axially within the tubular.  
     
     
         15 . The method of  claim 14 , wherein the expander tool further comprises a hydraulically actuated tool portion.  
     
     
         16 . A method for forming a permeable cement sand barrier in a wellbore, the wellbore having a wall, the method comprising the steps of: 
 deploying a perforated expandable tubular at a selected depth;    expanding the tubular;    injecting a permeable cement composition into the annulus formed between the wall of the wellbore and the perforated expandable tubular; and    allowing the cement composition to set.    
     
     
         17 . The method of  claim 16 , wherein the permeable cement defines a composition comprised of: 
 a hydraulic cement,    a particulate cross-linked gel containing an internal breaker which after time causes the gel to break into a liquid, allowing the particulate cross-linked gel containing the internal breaker to break so that vugs and channels are formed in the cement composition as the cement composition sets; and    water present in an amount sufficient to form a slurry.    
     
     
         18 . The method of  claim 17 , further comprising the step of: 
 allowing the particulate cross-linked gel containing the internal breaker to break.    
     
     
         19 . The method of  claim 18 , 
 wherein the cement composition further comprises an acid soluble particulate solid; and    the method further comprises the step of introducing an acid solvent into the perforated pipe whereby the acid solvent flows through the perforations in the pipe and into contact with the set cement composition so as to dissolve the acid soluble particulate solid, thereby creating channels for the flow of hydrocarbons therethrough.    
     
     
         20 . The method of  claim 19 , wherein the cement composition further comprises: 
 a gas present in an amount sufficient to form a foam; and    a mixture of foaming and foam stabilizing surfactants.    
     
     
         21 . The method of  claim 16 , wherein the perforated expandable tubular is an expandable sand screen.  
     
     
         22 . A method for using an expandable tubular within a wellbore, comprising the steps of: 
 running the tubular into the wellbore;    locating the tubular in the wellbore adjacent a producing zone;    placing cement in an annular region defined by the area between the tubular and the surrounding wellbore; and    expanding the tubular radially outward along a desired length before the cement has cured.    
     
     
         23 . The method of  claim 22 , wherein the expandable tubular is an expandable sand screen.  
     
     
         24 . The method of  claim 22 , further comprising the step of: 
 hanging the expandable sand screen within the wellbore before the step of expanding the sand screen radially is conducted.