System and method for preventing sand production into a well casing having a perforated interval

Abstract

A well completion system and method for preventing sand production into a well casing ( 38 ) having a perforated interval ( 42 ) is disclosed. The system comprises a sand control screen ( 40 ) having expandable end sections ( 60, 62 ) each of which having an attachment member ( 72, 74 ) positioned exteriorly therearound. An expander tool ( 44 ) is operably disposed within the sand control screen ( 40 ) such that when the sand control screen ( 40 ) is positioned within the well casing ( 38 ) across the perforated interval ( 42 ), the expander tool ( 44 ) radially expands the end sections ( 60, 62 ) such that the attachment members ( 72, 74 ) are placed in contact with the interior of the well casing ( 38 ), thereby creating a fluid seal and a friction grip between the end sections ( 60, 62 ) and the well casing ( 38 ).

What is claimed is:  
     
         1 . A method for preventing sand production into a well casing having a perforated interval positioned within a wellbore, the method comprising the steps of: 
 installing the well casing within the wellbore;    disposing a sand control screen having expandable end sections within the well casing across the perforated interval; and    setting the sand control screen by radially expanding the end sections, thereby creating a friction grip between the end sections and the well casing.    
     
     
         2 . The method as recited in  claim 1  wherein the step of setting the sand control screen by radially expanding the end sections further comprises expanding the end sections with an expander tool having two expander members, each of the expander members expanding one of the end sections by traveling longitudinally therethrough.  
     
     
         3 . The method as recited in  claim 2  wherein the step of setting the sand control screen by radially expanding the end sections further comprises simultaneously expanding the end sections.  
     
     
         4 . The method as recited in  claim 2  wherein the step of setting the sand control screen by radially expanding the end sections further comprises sequentially expanding the end sections.  
     
     
         5 . The method as recited in  claim 2  wherein the step of setting the sand control screen by radially expanding the end sections further comprises hydraulically operating the expander tool.  
     
     
         6 . The method as recited in  claim 5  wherein the step of hydraulically operating the expander tool further comprises providing fluid pressure to the expander tool from the surface via a tubing string.  
     
     
         7 . The method as recited in  claim 5  wherein the step of hydraulically operating the expander tool further comprises providing fluid pressure to the expander tool from a downhole fluid source.  
     
     
         8 . The method as recited in  claim 2  wherein the step of setting the sand control screen by radially expanding the end sections further comprises electrically operating the expander tool.  
     
     
         9 . The method as recited in  claim 2  wherein the step of setting the sand control screen by radially expanding the end sections further comprises moving the expander members toward one another to expand the end sections.  
     
     
         10 . The method as recited in  claim 2  wherein the step of setting the sand control screen by radially expanding the end sections further comprises moving the expander members away from one another to expand the end sections.  
     
     
         11 . The method as recited in  claim 2  wherein the step of setting the sand control screen by radially expanding the end sections further comprises contacting a frustaconical surface of the expander members with an inner radial surface of the end sections.  
     
     
         12 . The method as recited in  claim 1  wherein the step of setting the sand control screen by radially expanding the end sections further comprises creating a fluid seal between the well casing and the end sections.  
     
     
         13 . A method for preventing sand production into a well casing having a perforated interval positioned within a wellbore, the method comprising the steps of: 
 installing the well casing within the wellbore;    disposing a sand control screen having expandable end sections within the well casing across the perforated interval; and    setting the sand control screen by radially expanding the end sections with an expander tool having two expander members, each of the expander members expanding one of the end sections by contacting a frustaconical surface of the expander members with an inner radial surface of the end sections and traveling longitudinally therethrough, thereby creating a fluid seal and a friction grip between the end sections and the well casing.    
     
     
         14 . The method as recited in  claim 13  wherein the step of setting the sand control screen by radially expanding the end sections further comprises simultaneously expanding the end sections.  
     
     
         15 . The method as recited in  claim 13  wherein the step of setting the sand control screen by radially expanding the end sections further comprises sequentially expanding the end sections.  
     
     
         16 . The method as recited in  claim 13  wherein the step of setting the sand control screen by radially expanding the end sections further comprises hydraulically operating the expander tool.  
     
     
         17 . The method as recited in  claim 16  wherein the step of hydraulically operating the expander tool further comprises providing fluid pressure to the expander tool from the surface via a tubing string.  
     
     
         18 . The method as recited in  claim 16  wherein the step of hydraulically operating the expander tool further comprises providing fluid pressure to the expander tool from a downhole fluid source.  
     
     
         19 . The method as recited in  claim 13  wherein the step of setting the sand control screen by radially expanding the end sections further comprises electrically operating the expander tool.  
     
     
         20 . The method as recited in  claim 13  wherein the step of setting the sand control screen by radially expanding the end sections further comprises moving the expander members toward one another to expand the end sections.  
     
     
         21 . The method as recited in  claim 13  wherein the step of setting the sand control screen by radially expanding the end sections further comprises moving the expander members away from one another to expand the end sections.  
     
     
         22 . A well completion system for preventing sand production into a well casing having a perforated interval, the well casing positioned within a wellbore, the system comprising: 
 a sand control screen having expandable end sections, the sand control screen positioned within the well casing across the perforated interval;    a pair of attachment members one positioned exteriorly about each of the end sections; and    an expander tool operably disposed within the sand control screen and adapted to radially expand the end sections such that the attachment members are places in contact with the well casing, thereby creating a friction grip between the end sections and the well casing.    
     
     
         23 . The system as recited in  claim 22  wherein the expander tool simultaneously expands the end sections.  
     
     
         24 . The system as recited in  claim 22  wherein the expander tool sequentially expands the end sections.  
     
     
         25 . The system as recited in  claim 22  wherein the expander tool is hydraulically operated.  
     
     
         26 . The system as recited in  claim 25  wherein the expander tool is hydraulically operated by fluid pressure provided from the surface via a tubing string.  
     
     
         27 . The system as recited in  claim 25  wherein the expander tool is hydraulically operated by providing fluid pressure from a downhole fluid source.  
     
     
         28 . The system as recited in  claim 22  wherein the expander tool is electrically operated.  
     
     
         29 . The system as recited in  claim 22  wherein the expander tool further comprises two expander members, each of the expander members expanding one of the end sections by traveling longitudinally therethrough.  
     
     
         30 . The system as recited in  claim 29  wherein the expander members move toward one another to expand the end sections.  
     
     
         31 . The system as recited in  claim 29  wherein the expander members move away from one another to expand the end sections.  
     
     
         32 . The system as recited in  claim 29  wherein the expander members each have a frustaconical surface that contacts an inner radial surface of the end sections to expand the end sections.  
     
     
         33 . The system as recited in  claim 22  wherein the attachment members create a fluid seal with the well casing when the attachment members are placed in contact with the well casing.  
     
     
         34 . A well completion system for preventing sand production into a well casing having a perforated interval, the well casing positioned within a wellbore, the system comprising: 
 a sand control screen having expandable end sections, the sand control screen positioned within the well casing across the perforated interval;    a pair of attachment members one positioned exteriorly about each of the end sections; and    an expander tool operably disposed within the sand control screen having two expander members, each of the expander members adapted to radially expand one of the end sections by traveling longitudinally therethrough such that the attachment members are placed in contact with the well casing, thereby creating a friction grip between the end sections and the well casing.    
     
     
         35 . The system as recited in  claim 34  wherein the expander tool simultaneously expands the end sections.  
     
     
         36 . The system as recited in  claim 34  wherein the expander tool sequentially expands the end sections.  
     
     
         37 . The system as recited in  claim 34  wherein the expander tool is hydraulically operated.  
     
     
         38 . The system as recited in  claim 37  wherein the expander tool is hydraulically operated by fluid pressure provided from the surface via a tubing string.  
     
     
         39 . The system as recited in  claim 37  wherein the expander tool is hydraulically operated by providing fluid pressure from a downhole fluid source.  
     
     
         40 . The system as recited in  claim 34  wherein the expander tool is electrically operated.  
     
     
         41 . The system as recited in  claim 34  wherein the expander members move toward one another to expand the end sections.  
     
     
         42 . The system as recited in  claim 34  wherein the expander members move away from one another to expand the end sections.  
     
     
         43 . The system as recited in  claim 34  wherein the expander members each have a frustaconical surface that contacts an inner radial surface of the end sections to expand the end sections.  
     
     
         44 . The system as recited in  claim 34  wherein the attachment members create a fluid seal with the well casing when the attachment members are placed in contact with the well casing.