I would be very cautious about using PSD from cuttings and also SWCs. It is no surprise that these are giving a finer PSD than analogues. In your case, I would go more by analogues, - particularly if you can show that the reservoir sands and depositional environment is similar to yours.
When selecting sand screens and doing screen sizing, very much focus has traditionally been given to sand retention testing. Rule of thumbs have been used to determine critical sand production (like 0.12 lb/ft2) without focusing on what needs to be achieved. To make this simple, the screen should retain sand to prevent critical sand production to surface (or into the completion). At the same time, the screen must allow flow-back of mud and fines from the drilling phase.
Critical sand rate varies form case to case, but in a normal oil producer, fairly large initial sand production is acceptable as long as the coarse fraction is retained. A simple conservative indication is to use the D10 value, but more aggressive testing indicates that D5 is more than sufficient to start retaining the sand and build up a natural sand pack. A larger slot opening may lead to higher initial sand production, but as soon as a natural sand pack starts building up on the sand screen, this sand production stops.
The other element which often tend to be forgotten is the minimum slot opening. 200um is in the low end and requires properly conditioned mud or a clean brine as completion fluid. Dissolving fluids should also be considered in this case. A larger screen size like 250 um will be more robust with respect to particle flow back. In the case of very high permeable formation or very high solids content in the mud, even a larger minimum slot opening could be considered. If the screen size is too small, a low permeable layer may build up on the screen resulting in a high differential pressure. This could result in hot spotting and screen erosion and is probably a more common reason for screen failure than too large screen sizing.
Best regards, - Lasse Hermansson and Terje Moen, Ridge AS