Electric BOP Bonnet With Roller Screw Actuation for Reliable Pressure Control
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Solution Overview
Problem
Current blowout preventer (BOP) systems rely on hydraulic control, which can fail in deep and challenging environments, leading to costly downtime and operational inefficiencies.
Innovation Solution
Implementing an electric BOP system with a main body, ram cavity, opposing ram blocks, and electric bonnets equipped with a housing, guide piston, connecting rod, electric motor, gearbox assembly, and roller screw assembly to convert rotary motion into linear motion, actuating the ram blocks for sealing or shearing tubular strings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic control systems are used in BOP equipment, then operational capability is maintained, but system reliability deteriorates in deep and challenging environments due to potential hydraulic failures
Solution Approach 1:
The patent replaces the hydraulic control system with an electric control system using a linear actuator. The linear actuator converts rotational motion from an electric motor into linear motion to directly actuate the ram blocks, eliminating hydraulic fluid, hoses, and associated components. This substitution improves reliability by removing hydraulic failure points while reducing overall system complexity.
Solution Approach 2:
The invention extracts and removes the hydraulic control system from the BOP equipment, replacing it with an electric actuation system. By taking out the hydraulic components (fluid reservoir, pumps, valves, hoses), the patent eliminates the sources of hydraulic failure and reduces maintenance requirements, thereby improving system reliability in challenging environments.
2Reliability
If electric motors with gearbox assemblies and roller screw assemblies are used to actuate ram blocks, then reliability is improved by eliminating hydraulic failures, but device complexity increases due to additional mechanical components
Solution Approach 1:
The patent substitutes an electric motor-driven linear actuator system for the hydraulic actuation system. The linear actuator integrates a motor, gearbox, and roller screw mechanism into a single compact unit that directly drives the ram blocks. This integration improves reliability by eliminating hydraulic fluid leaks and contamination issues while the compact design actually reduces overall mechanical complexity compared to distributed hydraulic components.
Solution Approach 2:
The invention merges the motor, gearbox assembly, and roller screw mechanism into an integrated linear actuator unit. This consolidation improves reliability by reducing the number of connection points and potential failure modes associated with separate hydraulic and mechanical components. The integrated design also simplifies installation and maintenance, offsetting the apparent increase in mechanical complexity.
3Ease of operation
If linear actuators with roller screw assemblies are used to convert rotary motion to linear motion, then ease of operation is improved, but weight of moving object increases due to additional actuation mechanisms
Solution Approach 1:
The patent replaces complex hydraulic actuation mechanisms with an electric linear actuator that uses a roller screw assembly for motion conversion. The roller screw provides high mechanical efficiency and precise control with reduced friction compared to traditional screw mechanisms. While the actuator adds some weight, it eliminates the need for heavy hydraulic reservoirs, pumps, and hoses, resulting in a net weight reduction and improved ease of operation through electric control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The electric BOP system enhances reliability, efficiency, and reduces operating costs by eliminating hydraulic failures, while providing compact and lightweight pressure control equipment.
Implementation Method 1
a roller screw assembly disposed in the rear housing, the roller screw assembly having a first end and a second end, wherein the first end of the roller screw assembly is connected to the gearbox assembly, and wherein the second end of the roller screw assembly is connected to the guide piston, wherein rotation of the motor shaft of the electric motor transmits rotary motion to the gearbox assembly, wherein the gearbox assembly transforms the rotary motion into linear motion using the roller screw assembly
Data Source
AI summary
An electric bonnet includes a housing; a guide piston disposed in the housing; an electric motor having a motor shaft; a rear housing connected to the housing; a gearbox assembly disposed in the rear housing, the gearbox assembly being coupled to the motor shaft of the electric motor; and a roller screw assembly disposed in the rear housing. A first end of the roller screw assembly is connected to the gearbox assembly, and a second end of the roller screw assembly is connected to the guide piston. Rotation of the motor shaft of the electric motor transmits rotary motion to the gearbox assembly, which transforms the rotary motion into linear motion using the roller screw assembly. The linear motion of the roller screw assembly actuates the guide piston.