Evaluating the Success and Potential of Zirconia Sand Screens as High Erosion Resistant Sand Screen in Mahakam Field

Abstract The pursuit of reliable and cost-effective sand management solutions in sand prone reservoirs has led to the development of through tubing sand control technologies in the Mahakam Field since 2019. While mesh and ceramic sand screens have already been industrialized and widely applied, they continue to face challenges such as screen erosion and mechanical failure. Zirconia sand screens were introduced as a novel sand control solution that represents a new generation of wire wrapped screen filtration media. These screens are built using high strength zirconia profiles arranged in a continuous series, replicating the geometry of traditional wire wrapped screens while providing significantly greater erosion resistance and mechanical durability. With a Knoop hardness of 13 GPa, compared to 1.5 GPa for stainless steel SS316L, zirconia is particularly suited for harsh downhole environments where erosion is a major concern. The screens were deployed using slickline conveyance methods with optimized packer assemblies, allowing for efficient installation in existing wells through thru tubing operations, minimizing the need for costly workovers. Field trials began in three reservoirs and later expanded to four additional sites. From 2021 to 2025, a total of 135 installations were conducted, of which 107 were successful. Only five screens failed due to erosion or sand influx. This performance marks the highest success rate among all screen types used in the Mahakam Field. Furthermore, peak gas flow rates reached up to 4.3 MMscfd, surpassing the typical 2.5 MMscfd threshold observed in SCON reservoirs. Economically and operationally, zirconia sand screens have proven to be a cost-effective alternative to conventional gravel packs, offering enhanced sand retention, greater durability, and suitability for high risk, sand producing gas wells.