Methods and systems using electrically powered linear actuators

Abstract

An actuation system includes an electric motor coupled to a gearing system, at least two actuating rods, and a common load carrier. A first end of each of the actuating rods are coupled to a first end of each of at least two output shafts of the gearing system. The actuating rods independently extend through at least two through-holes in the common load carrier. An output rod is coupled to and extends from a first end of the common load carrier opposite the gearing system.

Description

Attorney Docket No.; 18954-212WO1METHODS AND SYSTEMS USING ELECTRICALLY POWERED LINEAR ACTUATORSBACKGROUND

[0001] Linear actuators convert energy into linear motion. Actuators may be characterized by their energy source, such as compressed fluid (hydraulic), compressed gas (pneumatic), or electricity. Actuator applications requiring large actuation forces, such as for blow-out preventers (BOPs), typically use hydraulic actuators, as hydraulic power may offer the highest power density and the greatest force amplification compared to other energy sources. Hydraulic actuators typically require hydraulic communication lines, integrated connection components and housings, which may complicate installation and maintenance.BRIEF SUMMARY

[0002] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0003] Embodiments disclosed herein relate generally to electrically powered linear actuators, their applications, and components.

[0004] In one aspect, embodiments disclosed herein relate to actuation systems that include an electric motor coupled to a gearing system, at least two actuating rods, and a common load carrier. A first end of each of the actuating rods may be coupled to a first end of each of at least two output shafts of the gearing system. The actuating rods may independently extend through at least two through-holes in the common load carrier. An output rod may be coupled to and extend from a first end of the common load carrier opposite the gearing system.

[0005] In another aspect, embodiments disclosed herein relate to methods of linearly actuating a component. The methods may include initiating operation of an electric motor, rotating an output shaft of the electric motor, wherein an end of the output shaft is inAttorney Docket No.; 18954-212WO1 rotational communication with one or more gears of a gearing system, operating the gearing system, wherein the gearing system comprises at least two output shafts, rotating at least two actuating rods with the gearing system, wherein a first end of each of the at least two actuating rods may be coupled to an end of each of the at least two output shafts, and moving a common load carrier along a linear plane. The actuating rods may extend through at least two through-holes of the common load carrier, and the rotation of the actuating rods may linearly move the common load carrier. The output rod may be connected to the component being actuated, e.g., a BOP ram or a valve closure element.

[0006] In yet another aspect, embodiments disclosed herein relate to methods of operating a blowout preventer (BOP) capable of shearing. The methods may include installing an actuation system on a bonnet door of a ram chamber of the BOP. The actuation system may include an electric motor coupled to a gearing system, at least two actuating rods, wherein a first end of each of the actuating rods may be coupled to a first end of at least two output shafts of the gearing system, and a common load carrier, wherein the actuating rods may independently extend through at least two through-holes in the common load carrier. The methods may further include rotating the actuating rods with the gearing system by operating the electric motor, and moving the common load carrier along a linear plane, wherein the rotation of the actuating rods linearly moves the common load carrier.

[0007] Other aspects and advantages of the claimed subject matter will be apparent from the following description and the appended claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a diagram showing a cross-sectional view of a linear actuator system in accordance with one or more embodiments.

[0009] FIGs. 2A and 2B show simplified diagrams of perspective views of a linear actuator system in accordance with one or more embodiments.

[0010] FIG. 3 shows a cross-sectional partial view of a common load carrier according to embodiments of the present disclosure.Attorney Docket No.; 18954-212WO1

[0011] FIG. 4 shows a cross-sectional view of a common load carrier according to embodiments of the present disclosure.

[0012] FIG. 5 is a computer system in accordance with one or more embodiments.

[0013] FIG. 6 is block flow diagram of a method in accordance with one or more embodiments.

[0014] FIG. 7 is block flow diagram of a method in accordance with one or more embodiments.

[0015] FIG. 8 shows an example of an output rod connected to a ram block according to embodiments of the present disclosure.

[0016] FIG. 9 shows an example of a blow out prevention system including an electronic actuation system in accordance with one or more embodiments.DETAILED DESCRIPTION OF THE INVENTION

[0017] In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description.

[0018] Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before,” “after,” “single,” and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements.Attorney Docket No.; 18954-212WO1

[0019] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. For example, a bearing may include any number of bearings without limitation.

[0020] Terms such as “approximately,” “substantially,” etc., mean that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

[0021] In the following description of FIGs. 1-9, any component described with regard to a figure, in various embodiments disclosed herein, may be equivalent to one or more like- named components described with regard to any other figure. For brevity, descriptions of these components will not be repeated with regard to each figure. Thus, each and every embodiment of the components of each figure is incorporated by reference and assumed to be optionally present within every other figure having one or more like-named components. Additionally, in accordance with various embodiments disclosed herein, any description of the components of a figure is to be interpreted as an optional embodiment which may be implemented in addition to, in conjunction with, or in place of the embodiments described with regard to a corresponding like-named component in any other figure.

[0022] Embodiments disclosed herein relate generally to actuation systems, such as electrically powered linear actuators, and methods of actuating a component. The actuation system of one or more embodiments may be adapted to an existing mechanical configuration. Actuation systems according to embodiments of the present disclosure may be used for high power actuation applications, such as with BOPs. For example, embodiments disclosed herein include systems and methods for integrating an electric linear actuator to a BOP (e.g., to a bonnet door of a BOP). An actuation system in accordance with one or more embodiments can be used to actuate rams in a BOP. In such embodiments, the actuation system may be connected to a bonnet door of the BOP, such as between existing bolts to the bonnet door.

[0023] However, actuation systems according to embodiments of the present disclosure may be used in other applications, e.g., valve actuators, any other actuator that converts rotary motion to linear motion, any other actuator that would benefit from compactnessAttorney Docket No.; 18954-212WO1 and shock load mitigation, or any combination thereof. For example, an actuation system according to embodiments of the present disclosure may be connected to a closure element of a valve (e.g., a plug, disc, gate, or wedge, depending on the type of valve) to linearly move the closure element between open and closed positions.

[0024] ACTUATION SYSTEM

[0025] In one aspect, embodiments disclosed herein relate to an actuation system. Actuation systems according to embodiments of the present disclosure may include a linear actuator that is capable of moving a component along a linear plane. The actuation system of one or more embodiments may be electrically powered. Electrically powered linear actuators according to embodiments of the present disclosure may use a compact, power dense electric motor to create a highly reliable, shock load resistant, and simple system.

[0026] The actuation system of one or more embodiments may include an electric motor coupled to a gearing system, at least two actuating rods, and a common load carrier. The electric motor may be coupled to the gearing system such that the electric motor powers two or more gears in the gearing system for rotary motion. For example, the electric motor may include a motor shaft that is coupled to an input location in the gearing system. The motor shaft may initiate and / or perpetuate rotation of the at least two gears of the gearing system. A first end of each of the at least two actuating rods may be coupled to gears in the gearing system. In one or more embodiments, the actuating rods may be output shafts of the gearing system (integrally formed as the same component). In some embodiments, the gearing system may have separate output shafts that are connected to the actuating rods of the linear actuator. The gearing system may be in rotational communication with one or more components of the linear actuator. For example, rotation of the at least two gears may initiate and / or propagate rotation of at least one actuating rod of linear actuator. In some embodiments, the linear actuator includes two actuating rods in rotational communication with the gearing system.

[0027] Additionally, in one or more embodiments, the electric motor may have an axis parallel with an actuating rod of the linear actuator. In such embodiments, the input shaft to the gearbox is parallel to the actuating rods and / or output shafts of the gearbox.

[0028] The electric motor transfers power to the actuating rods via a gearing system. In one or more embodiments, the electric motor includes at least one output shaft, which may also form the input shaft of the gearing system (where the motor output shaft and theAttorney Docket No.; 18954-212WO1 gearing system input shaft may be the same component but labeled differently depending on which system is being referred to), or which may be connected to a separate gearing system input shaft. Additionally, the gearing system may include at least two output shafts, which may form the actuating rods (where the gearing system output shafts and the actuating rods may be the same components but labeled differently depending on which system is being referred to), or which may be connected to separate actuating rod components. The electric motor may be coupled to the gearing system via an output shaft of the electric motor such that the electric motor powers a rotation of the output shaft and initiates movement of at least two gears of the gearing system. The gearing system may include a plurality of interworking gears that are configured to transfer power from an electric motor to the at least two actuating rods via the output shaft of the electric motor. The output shaft of the electric motor, the output shafts of the gearing system, or any combination thereof may be provided in a parallel configuration (e.g., on parallel axes) with the actuating rods. A high motor input torque generated by the electric motor may enable use of a single motor, resulting in a simpler control system for operating the actuation system.

[0029] The gearing system may include a gearbox that houses the gears. An arrangement of the at least two gears of the gearing system may enable the two output shafts of the gearing system to be mechanically synchronized (e.g., moving at the same time), rotationally synchronized (e.g., moving at the same rotational speed), or both. The gearing technology may include one or more technologies known to those skilled in the art, such as well known gearing technology that is optimized for achieving a high torque and reduction ratio in a compact space. Such gearing technology may include, but is not limited to systems of differently sized gears. Further, multiple solutions exist in the industry to interface each linear actuating rod with the gearing system output shafts.

[0030] The at least two actuating rods may each independently extend through at least two holes in a common load carrier. In one or more embodiments, more than two linear actuating rods and a corresponding number of output shafts of a gearing system may be used. For example, three or more, four or more, five or more, or six or more actuating rods and a corresponding number of output shafts of the gearing system (e.g., three or more, four or more, five or more, or six or more output shafts) may be used. In such instances, each of the actuating rods may extend through a corresponding hole in the common loadAttorney Docket No.; 18954-212WO1 carrier. Each actuating rod may be a threaded rod. The threaded rods may include threads extending at least a portion of the length of the threaded rod. As a non-limiting example, the threads of the threaded rod may extend the entire length of the actuating rod.

[0031] The at least two actuating rods may be connected at a first end to the output shafts of the gearing system. As described above, an alternative embodiment may have the output shafts of the gearing system form the actuating rods. The at least two actuating rods may be connected at a second end (opposite the first end) to a component housing. In one or more embodiments, the second ends of the linear actuating rods may be coupled (e.g., mounted) to a component housing by inserting the second ends of the linear actuating rods into receiving cavities in the component housing. Radial bearings or bushings may be provided between each of the linear actuating rod second end and receiving cavity in the component housing. The second end of the actuating rods may be rotatably connected to the receiving cavities to allow rotation of the rods’ second ends relative to the component housing.

[0032] The at least two actuating rods may be located in an actuation zone of the actuation system. The actuating rods may extend from a first end of the actuation zone to a second, opposite, end of the actuation zone. In some embodiments, the actuation zone extends from the output shafts of the gearing system to the second end of the actuating rods (e.g., the component housing, when present). The actuation zone may include the actuating rods extending through a common load carrier. The actuating rods and the common load carrier may be disposed in an actuation zone of the actuation system. In a unactuated state, the common load carrier body may be proximate to the gearing system. In an actuated state, the common load carrier body may be proximate to the second end of the actuation zone such that the common load carrier body is moved linearly upon actuation of the at least one actuating rod.

[0033] The actuation zone may include at least one bearing positioned around each of the actuating rods, proximate their first ends. The at least one bearing may be located between a gearbox of the gearing system and a first end of the common load carrier. The first end of the common load carrier may face the gearing system and may be proximate to the gearing system when in the unactuated state.

[0034] In one or more embodiments, the at least one bearing includes mirrored thrust bearings. The mirrored thrust bearings may include a pair of thrust bearings positionedAttorney Docket No.; 18954-212WO1 around each actuating rod. Each pair of thrust bearings may include an outer thrust bearing positioned proximate a gearbox of the gearing system and an inner thrust bearing positioned on an opposite side of the outer thrust bearing from the gearbox. The inner thrust bearing may be held in a mirrored position, interior to the outer thrust bearing. By mirroring the thrust bearings, the mirrored thrust bearings may be capable of withstanding opened and closed forces (i.e., from fully actuated to unactuated positions), thereby allowing a relatively small radial bearing or bushing on the second end of the actuating rods mounted to the component housing. Depending on the force requirements, it may be possible to design the system with thrust bearings on both ends of the threaded actuating rods instead of in a mirrored arrangement. In such a case, the radial bearings or bushings on the component housing would be replaced with a set of thrust bearings.

[0035] The at least two actuating rods and the at least two holes in the common load carrier may each be linear. In some embodiments, the at least two actuating rods and the at least two holes in the common load carrier are threaded.

[0036] The threads of the actuating rods, the threads present along the inner surface of holes in the common load carrier, or both may be any type of thread known to those skilled in the art. As a non-limiting example, the threads of the actuating rods, the threads of the holes in the common load carrier, or both have a shape selected from the group consisting of right hand threads, left hand threads, taper threads, v-shaped threads, metric or international threads, square threads, seller threads, British standard threads, acme threads, knuckle threads, buttress threads, worm threads, single threads, multi threads, among others known to those skilled in the art.

[0037] As a non-limiting example, threads of one or more embodiments may isolate the gearbox from shock loads when the threads (e.g., square threads) are used in combination with thrust bearings. The phrase “square threads” may broadly refer to the threads on the threaded holes of the common load carrier according to embodiments of the present disclosure that are perpendicular or near perpendicular to the threaded shaft of the actuating rods, and may include, e.g., threads having a generally square-shaped cross-sectional profile. Due to the simple and robust nature of square threads, smaller sizing can advantageously be accepted as well. As such, with shock loads isolated from the gearbox, a more compact and reliable gearbox system can be achieved.Attorney Docket No.; 18954-212WO1

[0038] When the common load carrier is assembled in an actuation system, the first end of the common load carrier may face in an axial direction toward the gearing system, while the second end of the common load carrier (opposite the first end) may face in the opposite axial direction. An output rod may extend axially from the second end of the common load carrier. The output rod may be coupled to or integrally formed with the common load carrier. For example, the output rod may be threadedly coupled to the common load carrier, where the second end of the common load carrier may include a threaded hole and the output rod may include a first end having threads such that the output rod is threadedly coupled to the common load carrier. In some embodiments, the output rod may be fixedly coupled to the common load carrier (e.g,. welded). The second end of the common load carrier is opposite to the first end of the common load carrier. The first end of the common load carrier may have a surface that is parallel to a gearbox of the gearing system.

[0039] The common load carrier, in combination with the threaded actuating rods, may be configured to move along a linear plane that is parallel to the axis of the output shaft of the electric motor. The second end of the output shaft may be on a parallel axis to the axis of the output shaft of the electric motor. For example, the actuation system may be mounted to a housing (e.g., a BOP bonnet door) such that the common load carrier body is located on a same linear plane as the component being actuated. In such embodiments, the movement of the common load carrier including the output shaft may actuate the component along the same linear plane as the common load carrier. According to embodiments of the present disclosure, the output rod may be connected at a second end to the common load carrier, and at a first end (opposite the second end) to a component being actuated. For example, in embodiments where the actuation system is used to actuate BOP rams, the first end of the output rod may be connected to a ram block in the BOP. In embodiments where the actuation system is used to actuate a valve, the first end of the output rod may be connected to the closure element of the valve.

[0040] In some embodiments, the threaded holes of the common load carrier each independently include a central cavity comprising floating inserts. In one or more embodiments, the floating insert may be made of an anti-galling material, such as bronze. The floating insert design may reduce cost because the entire load carrier does not need to be made of the anti-galling materials, which can be costly and potentially difficult to obtainAttorney Docket No.; 18954-212WO1 in large sizes. Further, the system may simplify maintenance effort because only the floating insert needs to be replaced instead of the entire common load carrier.

[0041] The floating insert may interface with the common load carrier body via a spline, key, or other means known in the industry to prevent rotation of the insert relative to the common load carrier body. The floating inserts may be axially enclosed in the central cavity by a shoulder of the common load carrier on one end and a lock ring on an opposite end. The floating insert may be threaded along its interior surface and interface with the common load carrier at an opposite non-threaded surface. The threaded surface may be configured to receive the threads of the actuating rod. The threaded surfaces of the floating inserts may allow the common load carrier to move along an axial plane (e.g., on a parallel axis to the axis of the actuating rods).

[0042] As a non-limiting example, the floating insert may be axially enclosed by a shoulder on one end and a threaded lock ring on the other end, which enables the system to have equal open and close force capacity while still maintaining a simple design. The shoulder may or may not be integral to the common load carrier body. Additionally, in cases where the shoulder is integral to the common load carrier body, this design may have an inherent increase in capacity to withstand axial loading.

[0043] By using bearing configurations disclosed herein, bearing-mounted actuation systems may be provided with a smaller and / or narrower mounting profile as compared to conventionally mounted actuation systems, which may also provide corresponding size and weight reductions. Advantageously, the actuation system in accordance with one or more embodiments may have a reduced weight as compared to conventionally mounted actuation systems.

[0044] The actuation system may be capable of being adapted to an existing mechanical configuration. A non-limiting example of an electrically powered actuation system in accordance with one or more embodiments of the present disclosure may be as shown in FIG. 1, which shows a cross-sectional view of the actuation system. The actuation system as shown in FIG. 1 may be mounted to a BOP system between an existing BOP bolt structure 130. The actuation system includes a motor and gearing housing 103 that encloses electric motor 102 and gearing system 104. Electric motor 102 includes output shaft 106 having an end that is included in gearing system 104. The output shaft 106 may be asAttorney Docket No.; 18954-212WO1 described previously and promote the rotational motion of one or more gears in gearing system 104.

[0045] Gearing system 104 may include output shafts 119 coupled to actuating rods 114 of actuation zone 110. Actuation zone 110 includes mirrored thrust bearings 120. On each of the actuating rods 114, a first bearing 122 is disposed proximate to the gearbox of gearing system 104. A second bearing 124 is mirrored to the first bearing 122 and is disposed proximate to a first end of actuating rods 114.

[0046] In FIG. 1, actuating rods 114 extend in a linear plane 116 that is parallel to output shaft 106 of electric motor 102. Actuating rods 114 extend through common load carrier 117. Output rod 126 is coupled to the common load carrier 117 at an end that is opposite the end that faces second bearings 124. A second end 118 of actuating rods 114 (opposite first ends coupled to output shafts of the gearing system 104) is coupled to a component housing 112. The second end 118 of actuating rods 114 may be coupled to component housing 112 as described previously. As shown in FIG. 1, output rod 126 extends through component housing 112 in the actuated state such that one or more components in the component housing 112 is actuated. For example, the component housing may be a valve housing, and the output rod may extend through the valve housing and be connected to a closure element in the valve.

[0047] FIG. 2A shows an example of an electrically powered actuation system 200 in accordance with one or more embodiments. FIG. 2B shows a different view of the actuation system 200 shown in FIG. 2A. The actuation system is shown in the actuated state in FIG. 2 A is shown in the unactuated state in FIG. 2B.

[0048] In the embodiment shown in FIG. 2A, the actuation system includes an actuation zone 210 connected to a housing 212 of the component being actuated. Upon actuation, output rod 226 extends through the housing 212. Housing 212 may be a BOP bonnet door such that the actuation system is coupled between existing bonnet door bolts 230 used to secure the bonnet door to a ram chamber. In FIG. 2A, the actuation system includes a gearbox 240 that may include the electric motor and the gearing system of the actuation system.

[0049] FIG. 2B shows a different view of the actuation system of FIG. 2A. For example, FIG. 2B shows an internal view of actuation zone 210 and gearbox 240 of FIG. 2 A. In FIG. 2B, electric motor 202 is coupled to gearing system 204. Mirrored thrust bearingsAttorney Docket No.; 18954-212WO1220 are positioned at an end of each of two actuating rods 214. Actuating rods 214 extend through common load carrier 205. Output rod 226 may be coupled to and extend from a surface of common load carrier 205 opposite a surface facing the thrust bearings 220. Output rod 226 extends through a wall of the housing 212. The actuation system shown in FIG. 2B may fit into pre-existing systems, such as a BOP system, between bonnet door bolts 230.

[0050] In FIGs. 1-2A, the common load carrier including an output rod is shown in the actuated state, and in FIG. 2B, the common load carrier and connected output rod are shown in the unactuated state. In the embodiments shown in each of FIGs. 1-2B, the actuation system includes an actuation zone connected to a housing of the component being actuated. For example, in embodiments where the actuation zone is used to actuate rams in a BOP, the actuation zone may be connected to a bonnet door of the BOP, e.g., between existing bolts to the bonnet door.

[0051] In one or more embodiments, housing 112 and / or 212 as shown in FIGs. 1 and 2A- 2B is a BOP bonnet door. The bonnet door may be mounted to a BOP body via the bonnet door bolts 230, where the bonnet door may be removed to access the interior of the BOP. Multiple bonnet doors may be provided on a BOP to access multiple interior locations of the BOP, e.g., to access multiple rams. According to embodiments of the present disclosure, actuation systems according to embodiments of the present disclosure may be connected to a bonnet door of a BOP ram chamber, where the output rod of the actuation system may extend through the bonnet door and connect to a ram block. As known to those of ordinary skill in the art, ram blocks are positioned around a central bore extending through a BOP and may be actuated to move into the central bore to seal and close off the central bore and / or shear through a tubular within the central bore, depending on the type of rams being actuated.

[0052] For example, FIG. 8 shows an example of the output rod 226 from the actuation system in FIGs. 2A-B connected to a ram block 250. As shown, the output rod 226 includes a threaded end 232 at one axial end of the output rod for connection to the common load carrier 205 and a connecting end 234 at an opposite axial end for connection to the component being actuated, which in the embodiment in FIG. 8 is a ram block 250. When the actuation system 200 is installed on a bonnet door 212 of a BOP, the output rod 226 may extend from the common load carrier 205, through the bonnet door 212, andAttorney Docket No.; 18954-212WO1 connect to the ram block 250 at the connecting end 234. In the embodiment shown, the connecting end 234 may have an irregular shape that fits within and interlocks with a correspondingly shaped receiving cavity formed in the ram block 250. However, other connecting features may be used to connect the connecting end of the output rod to a ram block (e.g., corresponding threaded surfaces, bolts, welding, etc.). With such configuration, when a ram block needs to be accessed (e.g., for replacement or maintenance), the bonnet door 212 (along with the connected actuation system 200) may be removed from the BOP and the ram block 250 may be accessed.

[0053] In FIGs. 1-2B, the gearing arrangement within each of these actuation systems may enable the two output shafts to be mechanically synchronized. The gearing technology used in each actuation system reflects well known gearing technology in the industry that is optimized for achieving a high torque and reduction ratio in a compact space, including but not limited to systems of differently sized gears. As one of ordinary skill in the art may appreciate, multiple solutions exist in the industry to interface each actuating rod with the gearing system output shafts.

[0054] FIGs. 3 and 4 each depict cross-sectional views of holes in a common load carrier in accordance with one or more embodiments. For example, each of FIGs. 3 and 4 show cross-sectional views of a common load carrier having floating inserts inserted within through-holes formed through the common load carrier body. Advantageously, the common load carriers shown in FIGs. 3-4 may enable the floating insert to equally withstand open and close loads from the actuation system, or at the very least, an inherently high close load.

[0055] Specifically, FIG. 3 depicts a cross-sectional diagram of half of a single through- hole of the common load carrier in accordance with one or more embodiments. As shown in FIG. 3, a common load carrier (e.g., carrier 302) is capable of housing floating insert 306. Floating insert 306 may interface with an inner surface of common load carrier 302 via a spline 304. Floating insert 306 and spline 304 are held in an inner central cavity 312 formed around the through-hole of common load carrier 302 via a shoulder 314 and lock key 310. Lock key 310 may be a locking ring having an annular body with a threaded outer surface that threadably connects to an inner threaded surface of the common load carrier 302, e.g., inner threaded surface 307 formed along a partial axial length of the inner central cavity 312, as shown in FIG. 3. As shown in FIG. 3, shoulder 314 is formed by the bodyAttorney Docket No.; 18954-212WO1 of the common load carrier 302. In some embodiments, the shoulder may be formed by a wear plate fixed to or formed in the common load carrier body.

[0056] In some embodiments, a second lock key may form the shoulder. For example, some embodiments, a lock key may be provided on each axial end of the inner central cavity, including a first lock key 310 threadedly connected within a first axial end of the inner central cavity and a second lock key threadedly connected within an opposite, second axial end of the inner central cavity, where the floating insert 306 is held axially between and interfaces the first and second lock keys.

[0057] Floating insert 306 and common load carrier 302 may be made of the same or different material. In some embodiments, the floating insert 306 (with or without spline 304) is more readily accessible and replaceable via locking and unlocking of lock key 310 as compared to traditional actuators. Such access may improve the lifetime of electrically powered actuation systems in accordance with one or more embodiments.

[0058] An actuating rod 320 may have a threaded outer surface that threadably engages with the threaded inner surface 308 of the floating insert 306. As the actuating rod 320 is rotated via a connected gearing system, the rotationally fixed floating insert 306 (and connected common load carrier) translates linearly along the rotating actuating rods 320.

[0059] FIG. 4 depicts a cross-sectional diagram of two through-holes of a common load carrier 402 in accordance with one or more embodiments. Actuating rods 414a, 414b extend through holes of common load carrier 402 containing threaded floating inserts 406. Actuating rods 414a, 414b are drawn with straight lines for simplicity, but have a threaded outer surface along their entire length (or along at least 80% of their length) with a thread configuration corresponding to that of the threaded inner surface of the floating insert 406, e.g., using square threads. While only depicted around actuating rod 414a, it may be appreciated that actuating rod 414b is inserted through a through hole with the same configuration of floating insert 406 and key 410 to achieve mechanical synchronization and rotation of actuating rods 414a, 414b. In other embodiments, threaded actuating rods may be threaded through holes in a common load carrier, where the holes have threaded inner surfaces that engage with the actuating rods and that are integrally formed in the common load carrier (without a separate insert).

[0060] Additionally, FIG. 4 includes output rod 426 connected through a central hole 434 of the common load carrier 402. Output rod 426 is coupled to common load carrier 402Attorney Docket No.; 18954-212WO1 via a threaded end 432. As shown in FIG. 4, the outer surface of threaded end 432 and the inner surface of central hole 434 may each be threaded using a thread configuration that engages and connects the output rod to the common load carrier. In one or more embodiments, the output rod 426 may have a stopping feature such as a nut, shoulder, and / or a non-threaded portion adjacent the threaded end 432, where the stopping feature may prevent the output rod 426 from moving through the central hole 434 past the threaded end 432.

[0061] One or more components of an actuation system (e.g., an electric motor, gearing system, actuating rods, among others) may be in electronic communication with a computer system. For example, one or more components of an actuation system may include a sensor component (e.g., a temperature sensor, torque sensor, encoder, resolver, position sensors, among other sensor types) that is configured to transmit data to a computer system.

[0062] FIG. 5 depicts a block diagram of a computer system 502 used to provide computational functionalities associated with described algorithms, methods, functions, processes, flows, and procedures as described in this disclosure, according to one or more embodiments. The illustrated computer 502 is intended to encompass any computing device such as a server, desktop computer, laptop / notebook computer, wireless data port, smart phone, personal data assistant (PDA), tablet computing device, one or more processors within these devices, or any other suitable processing device, including both physical or virtual instances (or both) of the computing device. Additionally, the computer 502 may include an input device, such as a keypad, keyboard, touch screen, or other device that can accept user information, and an output device that conveys information associated with the operation of the computer 502, including digital data, visual, or audio information (or a combination of information), or a GUI.

[0063] At a high level, the computer 502 is an electronic computing device operable to receive, transmit, process, store, or manage data and information associated with the described subject matter (e.g., for operating an electric motor of an actuation system to actuate a linear actuator). According to some implementations, the computer 502 may also include or be communicably coupled with an application server, e-mail server, web server, caching server, streaming data server, business intelligence (BI) server, or other server (or a combination of servers).Attorney Docket No.; 18954-212WO1

[0064] The computer 502 can receive requests over network 530 from a client application (for example, executing on another computer 502 and responding to the received requests by processing the said requests in an appropriate software application. In addition, requests may also be sent to the computer 502 from internal users (for example, from a command console or by other appropriate access method), external or third-parties, other automated applications, as well as any other appropriate entities, individuals, systems, or computers.

[0065] Each of the components of the computer 502 can communicate using a system bus503. In some implementations, any or all of the components of the computer 502, both hardware or software (or a combination of hardware and software), may interface with each other or the interface 504 (or a combination of both) over the system bus 503 using an application programming interface (API) 512 or a service layer 513 (or a combination of the API 512 and service layer 513. The API 512 may include specifications for routines, data structures, and object classes. The service layer 513 provides software services to the computer 502 or other components (whether or not illustrated) that are communicably coupled to the computer 502. The functionality of the computer 502 may be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer 513, provide reusable, defined business functionalities through a defined interface. The computer 502 may further include one or more applications 507 (an algorithmic software engine) for providing functionality according to particular needs, desires, or particular implementations of the computer 502, particularly with respect to functionality described in this disclosure.

[0066] The computer 502 includes one or more interface(s) 504. The interface 504 is used by the computer 502 for communicating with other systems in a distributed environment that are connected to the network 530. Generally, the interface 504 includes logic encoded in software or hardware (or a combination of software and hardware) and operable to communicate with the network 530. More specifically, the interface 504 may include software supporting one or more communication protocols associated with communications such that the network 530 or interface's hardware is operable to communicate physical signals within and outside of the illustrated computer 502.

[0067] The computer 502 includes at least one processor 505. Generally, the processor 505 executes instructions and manipulates data to perform the operations of the computerAttorney Docket No.; 18954-212WO1502 and any algorithms, methods, functions, processes, flows, and procedures as described in the instant disclosure.

[0068] The computer 502 also includes at least one memory 506 that holds data for the computer 502 or other components (or a combination of both) that can be connected to the network 530. For example, memory 506 can be a database storing data consistent with this disclosure.

[0069] There may be any number of computers 502 associated with, or external to, a computer system containing computer 502, wherein each computer 502 communicates over network 530. Further, the term “client,” “user,” and other appropriate terminology may be used interchangeably as appropriate without departing from the scope of this disclosure. Moreover, this disclosure contemplates that many users may use one computer 502, or that one user may use multiple computers 502.

[0070] ELECTRONIC BOP

[0071] According to embodiments of the present disclosure, an electrically powered actuation system, as described herein, may be used in a BOP system, such as a BOP system capable of shearing according to industry requirements, a boltless BOP, a BOP with bolts, or any combination thereof. The smaller mounting profile of actuation systems described herein (relative to traditional actuators) may be mounted to standard BOP doors, between an existing bolt pattern of bolts used to connect the bonnet door to the BOP body (bonnet- to-BOP bolt pattern), such as in a BOP bonnet system. Bonnet doors to a BOP may be used to access rams inside the BOP. As a non-limiting example, the BOP bonnet system may be provided on an electrically actuated BOP, e.g., having a configuration as shown in FIG. 9 and described in further detail below.

[0072] For example, the actuation zone of an actuation system may be coupled to a BOP bonnet door. The BOP bonnet door may be coupled to an end of the actuation zone that is opposite to the location of the gearing system. In such embodiments, the output rod coupled to the common load carrier body may be capable of extending through the BOP bonnet door (i.e., existing BOP structure) upon operation of the actuation system.

[0073] According to embodiments of the present disclosure, a BOP bonnet system, such as provided on an electric BOP, may include at least one electric motor, a gearing system, and at least two actuating rods that are collectively mounted to the BOP bonnet door. The BOP bonnet system may include the actuation systems as shown in FIGs. 1-2B. TheAttorney Docket No.; 18954-212WO1 configurations shown in FIGs. 1-2B use one electric motor and two actuating rods, where the two actuating rods drive a common load carrier that has an output rod fixed to and extending from an opposite side of the common load carrier. However, other configurations using more or less of these components may be envisioned to drive a common load carrier to actuate a BOP ram and operate the BOP.

[0074] Actuation systems according to embodiments disclosed herein may use square threads for threaded components (e.g., actuating rods and common load carrier holes (or hole inserts)) to allow for a more compact configuration. Square threads have a generally rectangular cross-sectional profile, where the thread flanks (side walls) extend substantially perpendicularly to the threaded wall. The square-like profile of square threads may not transmit radial forces and thus allows for higher efficiency in linear force transmission. By using actuation systems having a relatively smaller footprint (e.g., using square threads) the output rod and dual threaded actuating rods may interface directly with the bonnet door of a BOP and fit within its existing bonnet-to-BOP bolt pattern. This arrangement results in a highly compact solution from both a width and length standpoint regardless of whether the BOP is boltless. A more compact version of the actuation system may reduce weight, simplify handling, and allow retrofitting of the actuation system to existing BOPs. Additionally, protecting the gearbox from shock loads with a simple, robust square thread screw can result in a higher reliability system.

[0075] FIG. 9 shows an example of an electric BOP stack 802 having multiple rams. An actuation system according to embodiments of the present disclosure is mounted to the bonnet door of each of the multiple rams for electrically actuating the rams of the BOP 802. For example, in the embodiment shown, actuation systems 810a, 810b according to embodiments disclosed herein are mounted to the bonnet doors 812 of ram chambers at opposite sides of the electric BOP housing 804. Rams are positioned within the ram chambers such that a ram block (e.g.,. ram block 250 shown in FIG. 8) of each ram is positioned to interface with a central bore extending axially through the BOP stack 802. The bonnet doors to each of the rams may be bolted to the BOP housing 804 using bonnet door bolts 830. Each of the actuation systems may be connected to the bonnet doors between the bonnet door bolts 830, such that the bonnet door bolts 830 for each bonnet door 812 surrounds the mounting footprint of each actuation system 810a, 810b. In the embodiment shown, the bonnet door bolts 830 are provided around opposite lateral sidesAttorney Docket No.; 18954-212WO1 of the actuation system mounting footprint. However, in some embodiments, bonnet door bolts may be provided around all sides or a different combination of sides of an actuation system mounting footprint.

[0076] Each actuation system may include a motor and gearing housing 803 that encloses an electric motor (e.g., motor 102 in FIG. 1) and gearing system (e.g., gearing system 104 in FIG. 1) and an actuation zone 805 that includes actuating rods (e.g., actuating rods 214 in FIG. 2B), a common load carrier (e.g., 204 in FIG. 2B), and an output rod (e.g., 226 in FIGs. 2A-B and 8) assembled together as described herein. As described above, the output rod (e.g., output rod 226 in FIGs. 2A-B and 8) from each actuation system 810a, 810b may extend from a common load carrier (e.g., common load carrier 205 in FIG. 2B) in the actuation system, through the connected bonnet door 812, and connect at a connecting end to a ram block (e.g., ram block 250 in FIG. 8) of the BOP ram. The electric motors of the actuation systems 810a, 810b may be operated to electrically actuate the output rods of the actuation systems, thereby pushing the connected ram blocks into the electric BOP’s central bore to seal the central bore.

[0077] According to various implementations, the central bore of a BOP stack may or may not have a tubular therein. Further, an electric BOP may have multiple rams of different types (e.g., shear, pipe, and / or blind rams) in an axially stacked configuration, where selected ram type(s) may be actuated via an actuation system according to embodiments disclosed herein to seal the central bore depending on whether a tubular is in the central bore (e.g., shear and / or pipe rams may be actuated when a tubular is present and blind rams may be actuated when a tubular is not present).

[0078] For example, actuation systems according to embodiments of the present disclosure may be included in an electric BOP as a full scale, shear ram actuator. As a non-limiting example, the shear ram actuator may be rated to shear at the same force a hydraulically- actuated shear ram actuator can deliver while also shearing at a faster speed than hydraulically actuated rams. By using actuation systems according to embodiments of the present disclosure, the actuation system may provide necessary shear force and faster shear speed in a relatively smaller, more compact space, such that the actuation system may be mounted between existing mounting bolts on the BOP.

[0079] Actuation systems according to embodiments of the present disclosure may also (or alternatively) be used to actuate other types of BOP rams, such as pipe rams (having aAttorney Docket No.; 18954-212WO1 semi-circular groove that seals around the outer diameter of a tubular in the BOP without cutting the tubular), variable bore rams (rams capable of sealing around a range of tubular sizes), and / or blind rams (having flat interfacing surfaces that close together to seal the opening through the BOP when no tubulars are present).

[0080] An actuation system according to embodiments of the present disclosure may be sized for retrofits to existing subsurface (e.g., subsea) BOP stacks while also remaining compact enough to enable the BOP bonnet doors to swing open so that maintenance on the rams can be performed just as it is conventionally.

[0081] Electrically-powered actuation systems according to embodiments of the present disclosure may be used with electrification of all electric BOP actuators, including annular BOP, LMRP and wellhead connectors, and choke & kill valve actuators. For example, electrically-powered actuation systems according to embodiments of the present disclosure may be used with full-scale, marinized versions of all BOP functions for a BOP stack.

[0082] In one or more embodiments, an electric BOP or BOP bonnet system is compatible with broadly accepted well control technology combined with proven components. For example, conventional wellbore wetted components and key aspects of conventional surface and subsurface (e.g., subsea) control systems may be used with electric BOPs. As such, the electric BOP may be designed to incorporate the same ram blocks, BOP body, connector system, and elastomer sealing technology conventionally utilized in the oil and gas industry. Surface and subsurface control systems may also remain the same as in operation today with the exception that these systems will be adapted to communicate with the electric BOP’s motor, drive, gearbox and battery systems, e.g., using one or more computer systems such as described with FIG. 5. The electric motor and drivetrain (e.g., including a gearing system, common load carrier, and actuating rods) of the electric BOP may be designed to accommodate the combination of high force, high shock load, and minimized space challenges experienced in the oil and gas industry.

[0083] The electric BOP system of one or more embodiments relies on an electrical power source, such as batteries and / or a volt alternating current power source (e.g., 120 VAC power source), and an electric motor of the actuation system. The electrical power source and the electric motor are able to provide the electric BOP’s rated peak performance irrespective of depth. In contrast, conventionally multiplexed control (MUX) BOP systems rely on accumulator bottles for stored energy to complete a shear, whichAttorney Docket No.; 18954-212WO1 astronomically increases the number of bottles required when higher shear forces are required along with deeper depths.

[0084] Advantageously, the electric BOP does not require hydraulic fluid, and thus cannot vent hydraulic fluid to a local environment (e.g., a sea for subsea operations). Such advantages may allow for drilling in environmentally sensitive areas where regulatory bodies have prohibited such projects due to environmental regulations. In addition to performance and reliability enhancements, the elimination of hydraulic components generates significant weight savings, which can result in the reduction of wellhead fatigue and the ability for smaller vessels to execute plug and abandonment (P / A) operations.

[0085] METHOD OF LINEARLY ACTUATING A COMPONENT

[0086] In another aspect, embodiments herein relate to a method of linearly actuating a component. The method of actuating a component may be as shown in FIG. 6. In some embodiments, the method includes providing an actuation system as described previously herein.

[0087] In block 602, the method includes initiating operation of an electric motor. Electric motor operation may be initiated by transmitting a signal from a computer system, which may be as described previously herein. In some embodiments, the electric motor is in electronic communication with a sensor of a component to be actuated. For example, the electric motor may receive a signal from the sensor of the component to be actuated such that operation of the electric motor is initiated upon receipt of the signal. Such signals may include, for example, a position of a ram from a position sensor in an electric BOP.

[0088] In some embodiments, the method includes monitoring a component to be actuated. For example, when the component to be actuated is a BOP ram, the method may include monitoring downhole pressure changes, pressure changes within one or more components of the BOP, temperature changes, fluid changes or any combination thereof. In another example, when the component to be actuated is a valve closure element, the method may include monitoring the position of the valve closure element (e.g., between the open and closed position). Monitoring the component may include monitoring one or more sensors (e.g., pressure, temperature, torque, fluid level, position, pH, among others) of the component. Monitoring the component may include transmitting data from the one or more sensors to a computer system located at a surface location.Attorney Docket No.; 18954-212WO1

[0089] In another non-limiting example, when a method of actuating a component includes an actuation system as described previously, electrical continuity / system functionality checks may be completed in an almost instantaneous fashion. Electrical continuity checks and signature tests may evaluate and / or monitor key parameters, such as torque, temperature, position, time etc., thereby resulting in a robust real-time condition monitoring program for the actuation system.

[0090] In block 604, the method includes rotating an output shaft of the electric motor, wherein an end of the output shaft is in rotational communication with one or more gears of a gearing system. The electric motor and the gearing system may be as described previously.

[0091] In block 606, method 600 includes operating the gearing system including at least two output shafts. Operating the gearing system may include promoting rotation of or within the at least two output shafts. The two output shafts of the gearing system may be coupled to a first end of at least two actuating rods such that operation of the gearing system initiates the rotation of the at least two actuating rods as shown in block 608 of method 600.

[0092] The rotation of the actuating rods may move a common load carrier along a linear plane as shown in block 610. The actuating rods, the common load carrier, or both may be as described previously. For example, the actuating rods and the holes of the common load carrier used in method 600 may be threaded. In some embodiments, each of at least two actuating rods extend through each of at least two holes of the common load carrier. The rotation of the at least two actuating rods may initiate and / or perpetuate the linear movement of the common load carrier.

[0093] In some embodiments, the electric motor has an axis that is parallel with the actuating rods. In such embodiments, the common load carrier may move in a linear motion that is on a plane that is parallel to the output shaft of the electric motor. The output shaft of the electric motor may be positioned offset from but parallel to the output shafts of the gearing system. In such embodiments, the common load carrier may move in a linear motion that is on a plane that is parallel to the output shafts of the gearing system.

[0094] In some embodiments, the method of actuating a component may include rotating the actuating rods in a synchronized manner. By rotating the linear actuator rods in the synchronized manner, the actuating rods may act in concert to translate a common loadAttorney Docket No.; 18954-212WO1 carrier back and forth along the actuating rods. For example, the actuating rods may be threaded through threaded holes in a common load carrier.

[0095] The common load carrier may also include another threaded hole, through which an output rod may be threadedly connected. The threaded hole for the output rod may be centrally located between the threaded holes for the linear actuator rods. The threaded hole for the output rod may be a through-hole (extending entirely through the common load carrier) or may be a blind hole (extending partially through the common load carrier). In one or more embodiments, the output rod may have a threaded end that threadedly connects to the threaded hole and an unthreaded body that does not fit through the threaded hole. The common load carrier may be a single, integrated body, which may move back and forth within the interior of the linear actuator portion. As the common load carrier is translated forward and backward along the actuating rods (e.g., via the synchronized actuating rod rotation discussed above), between a fully-actuated state (as shown in FIGs. 1 and 2A-2B) and a fully unactuated state (e.g., a start position), the connected output rod is also translated back and forth.

[0096] METHOD OF OPERATING A BOP

[0097] In another aspect, embodiments herein relate to a method of operating a blowout preventer (BOP). The method may be as shown in FIG. 7. Method 700 of FIG. 7 may include one or more steps of a method of FIG. 6 described previously.

[0098] In one or more embodiments, method 700 includes installing an actuation system on a bonnet door of a body of the BOP as shown in block 702. The actuation system, the BOP, or both may be as described previously herein. The installing may include positioning the actuation system between an existing bolt pattern of bolts on the bonnet door of the BOP. Accordingly, by providing actuation systems with a mounting footprint small enough to fit between an existing BOP bolt pattern, actuation systems according to embodiments of the present disclosure may be used to retrofit existing BOPs. The installing may include aligning the linear motion of the output rod of the common load carrier with an inlet on the BOP bonnet door. The existing bolt pattern of the BOP may connect the bonnet door to the BOP body (e.g., to an end of a ram chamber of the BOP).

[0099] In block 704, method 700 includes rotating at least two actuating rods with the gearing system by operating the electric motor. A first end of each of the at least two actuating rods are coupled to an end of each of the at least two output shafts of the gearingAttorney Docket No.; 18954-212WO1 system. Method 700 also includes moving a common load carrier along a linear plane as shown in block 706.

[0100] In some embodiments, method 700 may include initiating, using a computer system, a sensor, or combinations thereof, operation of the electric motor. Method 700 may include monitoring, using a computer system, one or more parameters of the BOP, one or more downhole parameters, or combinations thereof. The monitoring may be performed when the BOP is disposed in a well.

[0101] In some embodiments, pre-deployment tests can be performed. With regards to predeployment testing, hydraulic soak tests, which typically take 2-3 days can be replaced with electrical continuity / system functionality checks that can be completed in an almost instantaneous fashion. Electrical continuity checks and signature tests for key parameters, such as torque, temperature, position, time etc. result in a robust real-time condition monitoring program for the BOP throughout the well construction process.

[0102] The method may include providing sufficient torque via operation of the actuation system to enable an emergency disconnect sequence of the BOP. In some embodiments, the method includes controlling ram closure on the BOP with the actuation system. For example, micro-testing and / or soft stops on a ram of the BOP may be initiated. In some embodiments, the BOP may be partially closed, a soft stop of the BOP may be initiated to measure a parameter of the BOP, or any combinations thereof.

[0103] Embodiments herein may be capable of providing a fully electrified BOP system referred to as an electric BOP. Such electric BOPs may be used in subsea operations (at the sea floor) or on land operations (at the surface). In doing so, all hydraulic systems may be replaced with electric actuation systems disclosed herein to generate a step change in the reliability, operational efficiency, and performance of traditional BOP systems. Electric BOPs in accordance with one or more embodiments may leverage field-proven wellbore wetted components while integrating motor / drive technology into the latest version of surface and subsea control systems. Electric subsea and surface BOP stacks according to embodiments disclosed herein serve both floating and fixed offshore rigs as well as land rigs. The end result is that the oil and gas industry is able to provide energy to BOP operations in a more safe, environmentally friendly, and economical manner than previously possible with a greater degree of operational certainty in the process.Attorney Docket No.; 18954-212WO1

[0104] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. Further, it would be apparent to one of ordinary skill that the subject matter of the dependent claims of one or more embodiments may be combined with other dependent claims.

Claims

Attorney Docket No.; 18954-212WO1CLAIMSWhat is claimed is:

1. An actuation system, comprising: an electric motor coupled to a gearing system; at least two actuating rods, wherein a first end of each of the at least two actuating rods are coupled to a first end of each of at least two output shafts of the gearing system; a common load carrier, wherein the at least two actuating rods independently extend through at least two through-holes in the common load carrier; and an output rod coupled to and extending from a first end of the common load carrier opposite the gearing system.

2. The actuation system of claim 1, wherein the at least two actuating rods and the at least two through-holes in the common load carrier are threaded with square threads.

3. The actuation system of claim 1, wherein the first end of the common load carrier comprises a threaded hole and the output rod comprises a first end having threads, and wherein the output rod is threadedly coupled to the common load carrier via the threaded hole.

4. The actuation system of any one of claims 1 to 3, wherein: at least one bearing is disposed around the first end of each of the actuating rods.

5. The actuation system of claim 4, wherein the at least one bearing comprises mirrored thrust bearings.

6. The actuation system of any one of claims 1 to 3, wherein the electric motor is coupled to the gearing system via an output shaft of the electric motor such that the electric motor powers a rotation of the output shaft and initiates movement of at least two gears of the gearing system.

7. The actuation system of claim 6, wherein an arrangement of the at least two gears of the gearing system enables the two output shafts of the gearing system to be mechanically synchronized.Attorney Docket No.; 18954-212WO18. The actuation system of any one of claims 1 to 3, wherein the actuation system is mounted to a component housing.

9. The actuation system of claim 8, wherein a second end of each of the actuating rods are mounted to a component housing, and wherein radial bearings or bushings are provided between the second end of each of the actuating rods and each of at least two receiving cavities located in the component housing.

10. The actuation system of claim 8, wherein the component is a ram in a blow out preventer (BOP).

11. The actuation system of claim 8, wherein the component is a closure element in a valve, and wherein the component housing is a valve housing.

12. The actuation system of any one of claims 1 to 3, wherein the threaded through-holes of the common load carrier each independently comprise a central cavity containing a floating insert.

13. The actuation system of claim 12, wherein the floating insert interfaces with the common load carrier in the central cavity via a spline and / or a key.

14. The actuation system of claim 12, wherein the floating insert is axially enclosed in the central cavity by a shoulder of the common load carrier on one end and a lock ring on an opposite end.

15. A method of linearly actuating a component, the method comprising: initiating operation of an electric motor; rotating an output shaft of the electric motor, wherein an end of the output shaft is in rotational communication with one or more gears of a gearing system; operating the gearing system, wherein the gearing system comprises at least two output shafts; rotating at least two actuating rods with the gearing system, wherein a first end of each of the at least two actuating rods is coupled to an end of each of the at least two output shafts; and moving a common load carrier along a linear plane, wherein:Attorney Docket No.; 18954-212WO1 the at least two actuating rods extend through at least two through-holes of the common load carrier, and the rotation of the at least two actuating rods linearly moves the common load carrier.

16. The method of claim 15, wherein the at least two actuating rods and the through-holes of the common load carrier are threaded with square threads.

17. The method of claim 15 or 16, wherein the electric motor has an axis that is parallel with the at least two actuating rods.

18. A method of operating a blowout preventer (BOP) capable of shearing, the method comprising: installing an actuation system on a bonnet door of a ram chamber of the BOP, wherein the actuation system comprises: an electric motor coupled to a gearing system; at least two actuating rods, wherein a first end of each of the at least two actuating rods are coupled to a first end of at least two output shafts of the gearing system; and a common load carrier, wherein the at least two actuating rods independently extend through at least two through-holes in the common load carrier; rotating the at least two actuating rods with the gearing system by operating the electric motor; and moving the common load carrier along a linear plane, wherein the rotation of the at least two actuating rods linearly moves the common load carrier.

19. The method of claim 18, wherein the installing comprises installing the actuation system between an existing bolt pattern of bolts on the bonnet door connecting the bonnet door to the ram chamber.

20. The method of claim 18 or 19, further comprising: monitoring, using a computer system, one or more parameters of the BOP when disposed in a well; and initiating, using the computer system, operation of the electric motor.

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