In oil and gas industry, sand can be carried with oil and gas, when producing from unconsolidated sandstone reservoirs. The existence of sand particles with fluids flow can lead to severe damages to production system’s components. Therefore, sand control techniques are needed to prevent potential damages. Standalone sand screens (SAS) are widely used because they can provide reliable sand control with low cost and low complexity. However, SAS application can become disadvantageous because of mechanical erosion due to sand particle impingement. The experimental investigation of sand screens erosion is challenging, as the measurements are to be carried out for a representative SAS material and geometry at laboratory-scale simulated conditions. The simulated conditions should mimic the real flow conditions, which involve many interrelated parameters. Some of these parameters are related to the entrained sand particles (i.e., particle shape, size and, concentration) while other parameters are related to the flow characteristics (i.e., flow velocity and fluid properties). In this review, the key factors influencing sand screens erosion are described, and erosion mechanisms are highlighted. In addition, experimental results showing the effects of key parameters on SAS erosion are discussed and evaluated. Also, challenges associated with previous studies, along with a proposed outlook to overcome those challenges, are presented. It has been found that the limitations of the previous studies are related to test setup and flow direction, particle–particle interaction, and particle–fluid interaction considerations. This review highlighted noticeable research gaps in sand screens erosion measurements that can be considered in future.

This research explores discrete element method analysis to investigate the wear of NiTi Sand Screens in comparison to traditional materials. The study utilized Altair EDEM v2022.2 software and employed Oka and Archard models to simulate the wear behavior of Nitinol, a well-established Shape Memory Alloy (SMA). The mechanical properties considered include Poisson’s ratio, solid density, shear modulus, and Young modulus. Results indicate significantly higher wear values and deformations with the Oka model compared to negligible wear with the Archard model. The Oka model’s emphasis on impact as the primary wear mechanism, supported by high normal cumulative energy, better represents sand screen wear phenomena. Additionally, this study indicates that factors such as particle size distribution and normal and tangential cumulative contact energy hold potential as predictors of wear response and characteristics. The Oka model demonstrated that NiTi exhibited reduced wear losses compared to SUS630 and Cr–Mn white cast iron, both of which are recognized for their high toughness when subjected to an impact load. Experimental analysis validated the simulation findings with morphological and graphical erosion plots. The limitation of observing the shape memory effect through DEM (discrete element method) simulation was acknowledged. Recommendations include characterizing post-wear microstructural changes, exploring the influence of temperature on wear behavior, and further research to refine wear models and understand SMA sand screen responses.

Production of sand from oil and gas wells necessitates the application of techniques for sand control. Sand screens are widely used. However, they are susceptible to failures, often stemming from improper selection and design. This study reviews existing selection criteria and identifies the causes of failures. It has been concluded that, sand screens selection should not rely on a single method but should consider a comprehensive combination of factors. This paper presents comparative analyses among various sand screen types. Also, it compares different materials used in sand screens, such as expandable, ceramics, metallic alloys, polymers, and shape memory materials, in terms of their performance and susceptibility to failure. These comprehensive comparisons can greatly assist in the optimized selection process for sand screens.