Inflatable production packer with pressure relief valve assembly

Abstract

A downhole tool includes an inner mandrel having an inner mandrel bore that extends axially-therethrough. The downhole tool also includes a first valve configured to move between a first position and a second position. The downhole tool also includes an inflatable element configured to inflate and expand radially-outward and into contact with a surrounding tubular in response to the first valve moving to the second position, which permits a fluid in the inner mandrel bore to flow into the inflatable element. The downhole tool also includes a second valve configured to vent some of the fluid within the inflatable element to an exterior of the downhole tool in response to the fluid reaching a second valve pressure threshold.

What is claimed is: 
     
         1 . A downhole tool, comprising:
 an inner mandrel having an inner mandrel bore that extends axially-therethrough; a first valve configured to move between a first position and a second position;   an inflatable element configured to inflate and expand radially-outward and into contact with a surrounding tubular in response to the first valve moving to the second position, which permits a fluid in the inner mandrel bore to flow into the inflatable element; and   a second valve configured to vent some of the fluid within the inflatable element to an exterior of the downhole tool in response to the fluid reaching a second valve pressure threshold.   
     
     
         2 . The downhole tool of  claim 1 , wherein the downhole tool comprises an inflatable production packer (IPP). 
     
     
         3 . The downhole tool of  claim 1 , wherein the inner mandrel defines an inflation port that provides a path of fluid communication between the inner mandrel bore and an annulus within the downhole tool. 
     
     
         4 . The downhole tool of  claim 3 , wherein the annulus is positioned radially-outward from the inner mandrel bore, wherein the first valve is positioned at least partially within the annulus, and wherein the inflatable element is in fluid communication with the annulus. 
     
     
         5 . The downhole tool of  claim 3 , wherein the first valve prevents fluid communication between the inner mandrel bore and the annulus in the first position, and wherein the first valve permits fluid communication between the inner mandrel bore and the annulus in the second position. 
     
     
         6 . The downhole tool of  claim 1 , further comprising a crossover positioned below the inflatable element, wherein the crossover defines a crossover bore that provides a path of fluid communication between the inflatable element and the exterior of the downhole tool. 
     
     
         7 . The downhole tool of  claim 6 , wherein the second valve is positioned within the crossover bore. 
     
     
         8 . The downhole tool of  claim 6 , wherein the second valve comprises a pressure relief valve. 
     
     
         9 . The downhole tool of  claim 6 , wherein the crossover bore comprises:
 a first portion having a central longitudinal axis that is parallel to a central longitudinal axis of the inner mandrel; and   a second portion having a central longitudinal axis that is not parallel to the central longitudinal axis of the inner mandrel.   
     
     
         10 . The downhole tool of  claim 9 , wherein the second valve is located within the first portion. 
     
     
         11 . An inflatable production packer (IPP), comprising:
 an inner mandrel having an inner mandrel bore that extends axially-therethrough, wherein the inner mandrel defines an inflation port that provides a path of fluid communication between the inner mandrel bore and an annulus within the downhole tool, and wherein the annulus is positioned radially-outward from the inner mandrel bore;   a first valve positioned within the annulus, wherein the first valve is configured to move between a first position and a second position, wherein the first valve in the first position prevents fluid communication between the inner mandrel bore and the annulus, wherein the first valve in the second position permits fluid communication between the inner mandrel bore and the annulus;   an inflatable element in fluid communication with the annulus, wherein the inflatable element inflates and expands radially-outward and into contact with a surrounding tubular in response to the first valve moving to the second position, which permits a fluid in the inner mandrel bore to flow through the inflation port and the annulus and into the inflatable element;   a crossover positioned below the inflatable element, wherein the crossover defines a crossover bore that provides a path of fluid communication between the inflatable element and an exterior of the IPP; and   a second valve positioned within the crossover bore, wherein the second valve comprises a pressure relief valve that is configured to vent some of the fluid within the inflatable element to the exterior of the IPP in response to the fluid reaching a second valve pressure threshold.   
     
     
         12 . The inflatable production packer of  claim 11 , further comprising a spring positioned within the annulus, wherein the spring is positioned below the first valve, wherein the spring exerts a force on the first valve that biases the first valve toward the first position. 
     
     
         13 . The inflatable production packer of  claim 12 , wherein the first valve is in the first position in response to a pressure of the fluid in the inner mandrel bore being less than a first valve pressure threshold such that the force exerted on the first valve by the spring is greater than an opposing force exerted by the first valve by the fluid, and wherein the first valve is in the second position in response to the pressure of the fluid in the inner mandrel bore being greater than the first valve pressure threshold such that the force exerted on the first valve by the spring is less than the opposing force exerted by the first valve by the fluid. 
     
     
         14 . The inflatable production packer of  claim 11 , wherein a pressure of the fluid in the inner mandrel bore is decreased to below the first pressure threshold after the inflatable element inflates, which causes the first valve to move from the second position to the first position, thereby trapping a portion of the fluid in the annulus and the inflatable element at a first temperature and a first pressure. 
     
     
         15 . The inflatable production packer of  claim 14 , wherein the trapped portion of the fluid increases to a second temperature due to a surrounding environment in a wellbore, which causes the pressure of the trapped portion of the fluid to increase to the second valve pressure threshold, and wherein the second valve pressure threshold is greater than the first pressure. 
     
     
         16 . A method for operating an inflatable production packer (IPP) in a wellbore, the method comprising:
 running the IPP into the wellbore in a run-in position;   actuating the IPP from the run-in position to an inflation position by increasing a pressure of a fluid in a bore of the IPP, which actuates a first valve in the IPP from a first position to a second position and causes an inflatable element of the IPP to inflate and expand radially-outward and into contact with a surrounding tubular; and   actuating the IPP from the inflation position to a set position by decreasing the pressure in the bore of the IPP, which actuates the first valve from the second position to the first position and traps a portion of the fluid in the inflatable element,   wherein the IPP comprises a second valve that is configured vent some of the trapped portion of the fluid to an exterior of the IPP in response to the fluid reaching a second valve pressure threshold.   
     
     
         17 . The method of  claim 16 , wherein the trapped portion of the fluid has a first pressure and a first temperature when the IPP actuates to the set position, and wherein the trapped portion of the fluid increases to a second temperature due to a surrounding environment in the wellbore, which causes the pressure of the trapped portion of the fluid to increase to the second valve pressure threshold. 
     
     
         18 . The method of  claim 17 , wherein the first pressure is from about 3,500 kPa to about 10,350 kPa. 
     
     
         19 . The method of  claim 17 , wherein the second valve pressure threshold is from about 6,900 kPa to about 13,800 kPa. 
     
     
         20 . A method for operating an inflatable packer in a wellbore, the method comprising:
 running the inflatable packer into the wellbore;   actuating the inflatable packer, which causes an inflatable element of the inflatable packer to inflate and expand radially-outward upon application of a first pressure;   setting the inflatable packer when the first pressure reaches a second pressure; and   reducing a portion of the second pressure when the second pressure reaches a third pressure, wherein the third pressure is greater than the second pressure.