Erosion of filter media is a significant threat to efficiency because it affects the ratio between downtimes and production rates. The ConocoPhillips investigation was part of a wide-ranging study of sand control screen erosion and results showed that plain or twilled weave filter meshes that are conventionally deployed in well pipes are not capable of handling the local pore velocities. The risk of premature production breakdowns can only be countered by reducing flow rates.







Real and virtual structure of the filter configuration. Image: GKD

In supplementary CFD modelling of flow paths and the distribution of pore velocities, it was proved that the flow-dependent multiplier term is higher not by a factor of 2 or 3 but, even at just medium flow rates, by a factor of 63. KPZ meshes are capable of standing up to such pore velocities long-term because of the higher volume porosity of their construction, which reduces flow velocity by around 30%. Along with high mechanical robustness, this type of woven wire mesh is capable of sustaining high daily production.