Abstract
Sand control screens in oil and gas wells are susceptible to erosional wear when producing at high flow rates with fine sand particles entrained in the fluid. This study combines laboratory experiments and computational fluid dynamics (CFD) modeling to quantify erosion in wire-wrapped and premium mesh screens under aggressive conditions. Erosion tests were performed using a slurry loop with approach velocities of 1.2-2.5 m·s-1 and fine sand (median diameter 80-150 μm), simulating realistic near-screen flow in high-rate completions while remaining within typical laboratory ranges reported in industry studies (e.g., SwRI rigs up to 1.07 m·s-1 and recent coupon tests at 0.37-0.61 m·s-1). Erosion was assessed via optical microscopy for gap widening, maximum particle passed (MPP), and filter cut point (FCP), following protocols aligned with API 19SS and ISO 17824 standards. A CFD model employing the Discrete Phase Model (DPM) with an empirical erosion correlation was calibrated against experimental data to capture localized particle impingement and turbulent effects near the screen surface. Results show erosion rate increases nonlinearly with velocity and fines content, with localized wear at wire edges and mesh openings often concentrated at impact angles of 25-45°. The calibrated model predicts screen life with reasonable accuracy for field conditions.