Modular downhole tool systems with integrated hydraulic-electric actuation and intelligent flow control for coiled tubing operations
A system includes a downhole tool string having a downhole well tool configured to perform one or more downhole well operations of a well system, and at least one modular actuator module mechanically coupled to the downhole well tool. The at least one modular actuator module is configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular actuator modules. In addition, the at least one modular actuator module is configured to provide on-command actuation for the downhole well tool based on control signals received from a surface processing system located at a surface location of the well system to enable the downhole well tool to perform the one or more downhole well operations of the well system.
1 . A downhole tool string, comprising:
a downhole well tool configured to perform one or more downhole well operations of a well system; and
at least one modular actuator module mechanically coupled to the downhole well tool,
wherein the at least one modular actuator module is configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular actuator modules,
wherein the at least one modular actuator module comprises:
modular actuator electronic control components configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular actuator electronic control components; and
modular hydraulic components configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular hydraulic components, and
wherein the at least one modular actuator module is configured to provide on-command actuation for the downhole well tool based on control signals received from a surface processing system located at a surface location of the well system to enable the downhole well tool to perform the one or more downhole well operations of the well system.
2 . The downhole tool string of claim 1 , wherein the at least one modular actuator module is configured to provide both pressure control and mechanical shifting actuation for the downhole well tool.
3 . The downhole tool string of claim 1 , comprising a plurality of modular actuator modules mechanically coupled to the downhole well tool and stacked along an axial length of the downhole well tool.
4 . The downhole tool string of claim 3 , wherein the plurality of modular actuator modules are configured to directly or indirectly interact with each other during performance of the one or more downhole well operations.
5 . The downhole tool string of claim 1 , wherein the modular hydraulic components comprise a bi-directional hydraulic pump and a motor, the bi-directional hydraulic pump configured to be actuated by the motor.
6 . The downhole tool string of claim 1 , wherein the at least one modular actuator module comprises an orienting mechanism configured to adjust a direction and/or inclination of at least one modular hydraulic component of the modular hydraulic components of the at least one modular actuator module relative to a target external to the downhole well tool.
7 . The downhole tool string of claim 1 , wherein the at least one modular actuator module is directly mechanically coupled to at least one specialized tank configured to provide one or more additives into a flow path relative to the downhole well tool.
8 . The downhole tool string of claim 1 , wherein the at least one modular actuator module is directly mechanically coupled to at least one accumulator tank within which pressure charge may be stored with nitrogen/hydraulics, and which may be actuated by the at least one modular actuator module to release high-velocity jets of fluid from the downhole well tool.
9 . The downhole tool string of claim 1 , wherein the at least one modular actuator module is directly mechanically coupled to at least one drawdown tank that has pressure drawn down, which may be opened up to create a vacuum relative to the downhole well tool.
10 . The downhole tool string of claim 1 , wherein the at least one modular actuator module is directly mechanically coupled to a valve assembly configured to be actuated by the at least one modular actuator module to provide one or more fluids relative to the downhole well tool on-command.
11 . A downhole well tool, comprising:
at least one modular actuator module mechanically coupled to the downhole well tool,
wherein the at least one modular actuator module is configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular actuator modules,
wherein the at least one modular actuator module comprises:
modular actuator electronic control components configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular actuator electronic control components; and
modular hydraulic components configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular hydraulic components, and
wherein the at least one modular actuator module is configured to provide on-command actuation for the downhole well tool based on control signals received from a surface processing system located at a surface location of a well system to enable the downhole well tool to perform one or more downhole well operations of the well system.
12 . The downhole well tool of claim 11 , wherein the at least one modular actuator module is configured to provide both pressure control and mechanical shifting actuation for the downhole well tool.
13 . The downhole well tool of claim 11 , comprising a plurality of modular actuator modules mechanically coupled to the downhole well tool and stacked along an axial length of the downhole well tool.
14 . The downhole well tool of claim 13 , wherein the plurality of modular actuator modules are configured to directly or indirectly interact with each other during performance of the one or more downhole well operations.
15 . The downhole well tool of claim 11 , wherein the modular hydraulic components comprise a bi-directional hydraulic pump and a motor, the bi-directional hydraulic pump configured to be actuated by the motor.
16 . The downhole well tool of claim 11 , wherein the at least one modular actuator module comprises an orienting mechanism configured to adjust a direction and/or inclination of at least one modular hydraulic component of the modular hydraulic components of the at least one modular actuator module relative to a target external to the downhole well tool.
17 . A downhole tool string, comprising:
a downhole well tool configured to perform one or more downhole well operations of a well system; and
a plurality of modular actuator modules mechanically coupled to the downhole well tool and stacked along an axial length of the downhole well tool,
wherein each modular actuator module of the plurality of modular actuator modules is configured to be removably decoupled from the downhole well tool to enable interchangeability with other modular actuator modules,
wherein at least one modular actuator module of the plurality of modular actuator modules comprises a bi-directional hydraulic pump configured to be actuated by a motor of the at least one modular actuator module, and
wherein each modular actuator module of the plurality of modular actuator modules is configured to provide both pressure control and mechanical shifting actuation for the downhole well tool based on control signals received from a surface processing system located at a surface location of the well system to enable the downhole well tool to perform the one or more downhole well operations of the well system.