Experimental Assessment and Computational Analysis of Erosion in Sand Control Screens for Oil and Gas Wells

Abstract This study addresses a critical challenge faced by the oil and gas industry: erosion of sand control screens used in well production operations. The objective is to evaluate sand screen erosion rates through experimental testing and computational modeling, with the goal of establishing practical solutions for improving sand screen performance and creating production plans that increase longevity. By examining erosion behavior under realistic conditions, this study aims to enhance the industry's ability to predict and manage sand screen erosion-related failures in harsh environments. Erosion testing was conducted on wire-wrap sand screen coupon samples with sand slurry approach velocities between 1.2 ft/s and 2.0 ft/s to simulate aggressive production conditions. Three measurement techniques, optical microscopy, maximum particle passed (MPP), and filter cut point (FCP), were used to assess sand screen gap changes before and after erosion. Additionally, computational fluid dynamics (CFD) simulations, incorporating the Discrete Phase Model (DPM), were performed to replicate the experimental conditions, capturing fluid flow dynamics, particle tracking, and erosion mechanisms. The CFD model was calibrated against experimental data to improve accuracy and refine erosion predictions. This combined approach enhances the assessment of erosion behavior and enables more reliable predictions of sand screen performance in harsh well environments that cannot be economically replicated in a laboratory. Experimental results showed predictable differences in erosion rates and screen gap expansion across different measurement methods. Optical microscopy and MPP exhibited agreement, while comparatively, FCP underestimated erosion, though all methods were found to have valuable insights. CFD simulations successfully captured the erosion trends observed in testing. The results indicate that experimental testing remains critical for accurate erosion assessment, while CFD provides valuable insights into erosion patterns and influencing factors. Trends suggest that screen erosion is influenced by factors such as particle concentration, flow velocity, and base pipe hole configurations, highlighting the importance of choosing an optimized screen design for each well application. This study provides a unique combination of experimental testing and CFD analysis to evaluate erosion in sand control screens, offering a more comprehensive understanding of erosion mechanisms. The findings contribute to the industry by validating a computational erosion prediction model that can be used while also identifying the limitations of both the model and current screen gap measurement techniques. This research enhances predictive capabilities for sand screen performance.