Multiple expansion sand screen system and method

Abstract

In one embodiment, a wellbore completion method includes disposing an expandable screen assembly into a wellbore, in which the expandable screen assembly includes a base pipe, an intermediate expansion system, and a screen element. The method further includes radially expanding the base pipe and radially expanding the intermediate expansion system after radially expanding the base pipe.

1 . A wellbore completion method, comprising: 
 disposing an expandable screen assembly into a wellbore, the expandable screen assembly comprising a base pipe, an intermediate expansion system disposed outside the base pipe, and a screen element disposed outside the intermediate expansion system;    radially expanding the base pipe; and    radially expanding the intermediate expansion system after radially expanding the base pipe.    
   
   
       2 . The method of  claim 1 , further comprising disposing a completion fluid into an annular space between a wall of the wellbore and the expandable screen assembly.  
   
   
       3 . The method of  claim 1 , wherein radially expanding the intermediate expansion system comprises chemically expanding.  
   
   
       4 . The method of  claim 1 , wherein radially expanding the intermediate expansion system comprises thermally expanding.  
   
   
       5 . The method of  claim 1 , wherein radially expanding the intermediate expansion system comprises electrically expanding.  
   
   
       6 . The method of  claim 1 , wherein radially expanding the intermediate expansion system comprises mechanically expanding.  
   
   
       7 . A wellbore completion system, comprising: 
 an expandable screen assembly configured to be disposed into a wellbore, the expandable screen assembly comprising a base pipe, an intermediate expansion system outside of the base pipe, and a screen element outside of the intermediate expansion system;    an expander operable to radially expand the base pipe; and    an actuation system operable to radially expand the intermediate expansion system.    
   
   
       8 . The system of  claim 7 , further comprising a pump operable to dispose a completion fluid into an annular space between a wall of the wellbore and the expandable screen assembly.  
   
   
       9 . The system of  claim 7 , wherein the expander comprises a cone expander.  
   
   
       10 . The system of  claim 7 , wherein the actuation system comprises a chemical expansion system.  
   
   
       11 . The system of  claim 7 , wherein the actuation system comprises a thermal expansion system.  
   
   
       12 . The system of  claim 7 , wherein the actuation system comprises a electrical expansion system.  
   
   
       13 . The system of  claim 7 , wherein the actuation system comprises a mechanical expansion system.  
   
   
       14 . The system of  claim 7 , wherein the actuation system comprises a plurality of expandable spheres.  
   
   
       15 . A wellbore completion method, comprising: 
 disposing an expandable screen assembly into a wellbore, the expandable screen assembly comprising a base pipe, an intermediate expansion system, and a screen element;    radially expanding the intermediate expansion system; and    radially expanding the base pipe after radially expanding the intermediate expansion system.    
   
   
       16 . The method of claim  1 . 5 , further comprising disposing a completion fluid into an annular space between a wall of the wellbore and the expandable screen assembly.  
   
   
       17 . The method of  claim 15 , wherein radially expanding the intermediate expansion system comprises chemically expanding.  
   
   
       18 . The method of  claim 15 ,, wherein radially expanding the intermediate expansion system comprises thermally expanding.  
   
   
       19 . The method of  claim 15 , wherein radially expanding the intermediate expansion system comprises electrically expanding.  
   
   
       20 . The method of  claim 15 , wherein radially expanding the intermediate expansion system comprises mechanically expanding.  
   
   
       21 . An expandable screen assembly, comprising: 
 a base pipe;    an intermediate expansion system outside of the base pipe;    an actuation system operable to radially expand the intermediate expansion system; and    a screen element outside of the intermediate expansion system.    
   
   
       22 . The system of  claim 21 , wherein the actuation system comprises a chemical expansion system.  
   
   
       23 . The system of  claim 21 , wherein the actuation system comprises a thermal expansion system.  
   
   
       24 . The system of  claim 21 , wherein the actuation system comprises a electrical expansion system.  
   
   
       25 . The system of  claim 21 , wherein the actuation system comprises a mechanical expansion system.  
   
   
       26 . The system of  claim 21 , wherein the actuation system comprises a plurality of expandable spheres.