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KPZ mesh in oil and gas exploration: higher flow rates and longer life cycles

Groundbreaking results from an experimental study and CFD simulations on sand control screen erosion

A major oil and gas exploration and production company has investigated the erosion behaviour of conventional filter media used in well pipes in the framework of a comprehensive study of sand control screen erosion. The results show that the plain or twilled weave filter meshes conventionally deployed in the well are not capable of handling the local pore velocities in the well. So far, the risk of premature production breakdowns could only be countered by reducing flow rates. In supplementary CFD modelling of flow paths and the distribution of pore velocities, GKD – GEBR. KUFFERATH AG was able to prove that – in contrast to previous assumptions – 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. The only filter media capable of standing up to such pore velocities in the long run are KPZ meshes, which, thanks to the higher volume porosity of their construction, reduce flow velocity by around 30 percent. Also featuring high mechanical robustness, this type of woven wire mesh is therefore capable of facilitating sustainably higher daily production rates than any other mesh type that could be deployed in this sector.

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