Summary Most offshore oil wells use flow-control safety valves that are either actively controlled from the surface or passively actuated by pressure changes. In this paper, we propose a passive, thermally-actuated safety valve that adds redundancy to well systems and significantly increases well safety. We use quasistatic thermal modeling, validated with experimental downhole data, to identify and characterize a suitable temperature regime for shape memory alloy actuation. We develop a complete loading and shut-in procedure with the new valve that is consistent with current practice in artificial lift. Finally, through a true-scale stainless-steel prototype, we demonstrate essential manufacturability and successful valve closure in accordance with predictions.

Gas-lifted oil wells are susceptible to failure through malfunction of gas lift valves (GLV). One failure mode occurs when the GLV check valve fails and product passes into the well annulus, potentially reaching the wellhead. This is a growing concern as offshore wells are drilled thousands of meters below the ocean floor in extreme temperature and pressure conditions and repair and monitoring become difficult. The authors have previously developed a thermally-actuated safety valve to prevent product backflow into the annulus in the event of check valve failure. The safety valve uses shape memory alloy (SMA) wires to translate a temperature change into a displacement and, based on commercially available SMA wire material properties, requires a 6°C temperature change to fully actuate. In some wells, however, check valve failure may result in less than 6°C temperature change. In this paper a new concept is developed to sharpen the austenitic phase change in SMA actuators. The concept has broad practical implications because it will allow thermally-activated devices, such as fluid control valves, to become much more precise, i.e., translating a small temperature change into a large displacement. The new concept uses the fact that SMA transition temperatures are stress dependent. By specifically controlling stress in the wire, the temperature difference required for austenitic transition can be decreased. This is achieved with a negative-differential spring — a spring that exerts a decreasing amount of force as it is displaced. The concept is tested experimentally by conductively and electrically heating SMA wires connected to a negative-differential spring. Results show a 2.9°C-5°C reductions, respectively, in the temperature difference required for austenitic transition.

Gas-lifted oil wells are susceptible to failure through malfunction of gas lift valve assemblies (GLV). One failure mode occurs when the GLV check valve fails and product passes into the well annulus, potentially reaching the wellhead. This is a growing concern as offshore wells are drilled thousands of meters below the ocean floor in extreme temperature and pressure conditions, and repair and monitoring become difficult. Currently no safeguard exists in the GLV to prevent product passage in the event of check valve failure. In this paper a design and operational procedures are proposed for a thermally-actuated positive-locking safety valve to seal the GLV in the event of check valve failure. A thermal model of the well and GLV system is developed and compared to well data to verify feasibility of a thermally-actuated safety valve. A 3× scale prototype safety valve is built and tested under simulated failure scenarios and well start-up scenarios. Realistic well temperatures in the range of 20C to 70C are used. Results demonstrate valve closure in response to simulated check valve failure and valve opening during simulated well start-up.Copyright © 2011 by ASME