Fleetwide Performance Optimization Case Study: Reducing Variability Through BOP Digital Pressure Testing and Well Barrier Verification

When the operator introduced a new rig into the region, they quickly identified a performance gap in Blowout Preventer (BOP) testing. Rigs with several years of experience using IPT Global’s digital pressure testing consistently delivered faster and more reliable results. This new rig had not yet adopted the standardized digital workflow required to achieve comparable performance.

The operator’s objective was to bring the new rig up to mature BOP testing performance as quickly as possible while maintaining verifiable well barrier integrity. Achieving this required shifting from variable manual processes to a consistent, documented digital pressure testing approach that reduced risk, minimized inefficiencies, and supported better operational decisions across the fleet.

IPT Global partnered with the operator to embed its digital pressure testing technology, provide hands-on coaching, and establish standardized workflows. The result was a rapid improvement in safety and efficiency, with 210 documented pressure tests and significant reductions in critical path time early in the campaign.

The Challenge: Inconsistent BOP Testing and Well Barrier Verification

Each well is unique, making direct comparisons in well barrier testing difficult. BOP testing provided the most practical benchmark because of its central role in safety and operational efficiency. The operator sought two outcomes: absolute confidence in barrier integrity and a reduction in high-pressure test times to minimize operational exposure and risk.

In addition, they wanted a consistent, documented pressure testing practice across the fleet, along with improved transparency between onshore support engineers and offshore execution teams. This was essential to minimize invisible lost communication time during a compressed drilling program.

The Solution: IPT Global’s Digital Pressure Testing Across Operations

Our solution delivers accuracy, efficiency, and consistent assurance across every pressure test. 

• Advanced technology: Thermal Compensated Leak Detection (TCLD) applies physics based, in-house algorithms with more stringent pass and fail criteria than typical operators or regulatory standards 
• Collaboration: IPT Global, the drilling contractor, and the operator work in close alignment to streamline procedures and optimize operational performance 
• User-friendly tools: SureTec software provides digital pressure testing, automated approvals, auditable documentation report, and clear barrier schematics that simplify planning and execution
• Data-driven approach: IPT Global’s dataset of more than 300,000 pressure tests benchmarks performance and identify actionable improvements

How We Delivered

Adopting new technology requires the right expertise and support. IPT Global ensures customers maximize the value of our tools through a unique blend of operational experience and data science. Our team combines direct rig experience with specialized software and analytics knowledge, applying technical excellence with practical execution.

IPT Global deployed field coaches to train crews in real operating conditions and ensure consistent, effective use of the software. Once training was complete, our 24/7 Real-Time Operations Center provided continuous support for planning, execution and oversight. IPT Global also supported the operator by embedding advisors within the wells team and providing real time visibility across rigs, shore bases, and headquarters.

A key component of the solution was IPT Global’s verification matrix, developed alongside drilling engineers as they designed the test plan. The matrix provides assurance that every valve and component is tested to the correct pressure. Presented in a clear matrix format, it enables easy identification of optimization opportunities, such as removing unnecessary test steps and ensuring each barrier element is tested in the most efficient sequence.

All 210 pressure tests executed through the wells campaign were documented in standardized format, inclusive of all formation integrity tests (FIT) / Leak off tests (LOT), BOP tests, inflow tests and completions testing.

Technology in Action

Within IPT Global’s SureTec software, pressure data can be captured from existing infrastructure such as cement units, IWOCS or ROV systems and automatically integrates into the platform. Post-test, digital approval removes the inefficiencies of chasing wet signatures or waiting for email confirmations. IPT connectivity bridges the gap between offshore execution and onshore approval, giving onshore teams real-time transparency into critical wellbore barrier verification. Each test is compiled into an auditable documentation report that can be shared with regulators and incorporated into end-of-well reporting. 

A function that sets IPT Global’s SureTec technology apart is its ability to generate surface and wellbore barrier schematics, providing offshore teams with clear, visual representations of the well configuration. For years, describing well configurations relied on complex plans and written instructions. IPT streamlines this by automatically importing data from industry-standard well planning software and offering drag-and-drop options. Primary and secondary barriers can be assigned, making it easy to visualize which barrier envelope is being tested at each stage, reducing confusion and enhancing operational efficiency offshore. 

Results: Reduced BOP Test Time with Verifiable Well Barrier Integrity

Figure 1. Reduction in total BOP test duration across the campaign from 14 hours to six hours achieved early and sustained through subsequent tests.

The most significant achievement was the reduction of the overall BOP test sequence from approximately 14 hours to just six hours, and this was achieved after only three BOP tests out of the 14 completed during the campaign. These improvements were driven by a combination of IPT Global’s technology, coaching and the visual clarity provided by our software.

At the core of this success was our Thermal Compensated Leak Detection, which reduced individual BOP test steps from 17 minutes to eight minutes, delivering more than a 50 percent saving per step. These gains were further supported by optimized test planning through our verification matrix and barrier schematics, as well as efficiency improvements achieved through crew training and real-time operational support.

Figure 2. Breakdown of 210 documented pressure tests across the drilling and completion lifecycle, illustrating range of tests captured in standardized reports.

All tests were documented in easy-to-audit reports, ensuring compliance and transparency. While the time savings highlighted here focus on BOP digital pressure testing, the campaign included 210 documented pressure tests covering the full cycle of drilling and completing these wells.

Importantly, IPT Global’s field coaches were removed from the rig after initial training, with the offshore crew fully supported remotely by our 24-7 Real-Time Operations Center. This demonstrated that tool adoption and consistent high performance were embedded in the crew and sustained throughout the campaign.

Conclusion: Advancing Well Barrier Integrity Through Standardized Digital Pressure Testing

IPT Global provides confidence in every test for every well by applying stringent in-house criteria, delivering faster results than traditional methods, and working collaboratively with customers to drive operational safety and efficiency. Our software ensures information flows seamlessly to the right people at the right time, while barrier schematics allow safe planning and execution ahead of operations. All of this is supported by real-time oversight from our Operations Center.

Looking ahead, IPT Global will continue to advance continuous improvement and software integrations to make our solutions even more accessible and valuable for end users.