In offshore drilling, BOP testing is a critical component of well barrier assurance. However, inconsistent processes across rigs can lead to incorrect line-ups, missed tests, and operational risk. This case study examines how the IPT Global Service Delivery Team supported an operator to improve BOP testing performance across a five-rig fleet in the Gulf of Mexico using SureTec® PressureTesting.
Across a five-rig fleet operating in the Gulf of America, incorrect line-ups (sometimes known as misalignments) during BOP tests occurred up to 60% of the time. The potential of executing BOP pressure tests with these errors increased safety risk and decreased operational efficiencies. The difference across rigs wasn’t equipment or operator. It was the consistency of the application of the well barrier assurance testing process by rig crews. The operator requested IPT Global’s support across the fleet to ensure a common baseline performance level was maintained across the rigs.
In offshore drilling operations, performance gaps between similar rigs working together with the same operator are common. Crew experience, familiarity with procedures, and operational maturity all vary. What doesn’t vary, however, is the consequence of a missed well barrier test. Incorrect line-ups undetected during BOP testing can leave critical components untested, create regulatory and environmental exposure, and compound into costly rig downtime.
To help establish a standardized approach, the IPT Global Real-Time Operations Center (RTOC) conducted a fleet-wide analysis of all BOP pressure tests over the course of one year. The results illustrate both the scale of the problem and the value of a consistent, technology-backed assurance framework, regardless of individual rig performance.
A fleet-wide analysis of 76 BOP pressure tests highlights both the scale of incorrect line-ups and the impact on offshore drilling performance.
When results are broken down by rig, the variance is stark and highlights a critical point: performance is driven by the consistent application of robust processes and assurance.
| Rig | No. of BOP Tests | Tests with Incorrect Line-ups | Missed Incorrect Line-ups Detected by RTOC | Lost Time (min) |
| Rig A | 17 | 59% | 5 tests (29%) | 270 |
| Rig B | 18 | 56% | 3 tests (17%) | 165 |
| Rig C | 8 | 13% | — | 5 |
| Rig D | 20 | 5% | — | 8 |
| Rig E | 13 | 0% | — | 0 |
The rigs with the lowest incorrect line-up rates share a common thread: a standardized, familiar process developed or supported by the IPT Global Service Delivery Team. Rig C operates with a full-time IPT Global Field Advisor supporting BOP testing execution and well barrier assurance processes embedded with the crew. The one incorrect line-up it recorded during the year was caught immediately by that IPT Global team member. Rig D had IPT Global Field Advisors on location for an extended period who helped build simplified, consistent test plans; the crew became deeply familiar with those plans, and the data reflects it. Rig E recorded zero incorrect line-ups across all 13 tests.
Rigs A and B tell a different story. Rig A recorded a total of 15 incorrect line-ups during BOP testing operations. This was the highest in the fleet and impacted 59% of its BOP tests, with the frequency trending upward as the year progressed. Rig A’s crew had recently been blended from two different drilling contractors, introducing unfamiliarity. IPT Global Field Advisors were not present onboard for BOP testing, though the IPT Global Service Delivery Team remotely identified five incorrect line-ups that were undetected by rig personnel. This accounted for three and a half hours of intervention time that would otherwise have resulted in undetected deviations.
Rig B showed a persistent failure at a specific test step with incorrect line-ups occurring in 56% of all tests, traceable to an incorrect cementer line-up that went uncorrected over multiple test cycles.
This is not a story about which rigs have better crews or stronger safety cultures. It is a demonstration of what happens when a standardized well barrier assurance and BOP testing process is applied consistently across a fleet, and what happens when it isn’t.
Every rig has its own dynamics: crew experience, contractor mix, familiarity with test plans, and operational culture and tempo. IPT Global does not override these dynamics. Instead, the SureTec PressureTesting software provides a standardized well barrier assurance framework for BOP testing, combining real-time monitoring, structured verification processes, and field expertise that operates independently of them.
Where a rig is already performing well, this approach reinforces and documents the behavior. Where performance is inconsistent, it identifies deviations early, before they become compliance events, safety incidents, or compounding downtime.
The data makes this clear. The eight incorrect line-ups missed by onboard crew but detected through real-time monitoring and structured BOP testing verification via PressureTesting and the IPT Global RTOC were identified through a consistent, structured process combining volume benchmarking, step-by-step checklist verification, and direct communication protocols, applied consistently and independently of rig floor activity.
Operators managing multiple assets simultaneously in offshore drilling operations face these same challenges at a larger scale. Performance varies, crews turn over, and experience levels differ. While a fleet-wide assurance program like SureTec PressureTesting does not remove these variables, it does establish a consistent baseline, ensuring performance gaps do not go undetected.
The rigs that performed best were not immune to incorrect line-ups. They were simply better equipped through familiarity, simplified plans, and consistent oversight to prevent or catch them early. IPT Global’s role is to extend that level of performance across the entire fleet, not just to those that have benefited from time and continuity.
A standardized approach to well barrier assurance is not a substitute for good rig culture. It is the mechanism that ensures good practice is applied consistently, regardless of where any individual rig sits on the performance curve.
Looking to improve BOP testing performance or strengthen your well barrier assurance processes? Contact IPT Global to implement a standardized, pressure testing and real-time monitoring framework across your offshore drilling fleet.
Subsea blowout preventer (BOP) soak testing is a long-standing part of pre-deployment programs. However, it remains one of the least consistently executed aspects of BOP control system evaluation. While teams perform the test routinely, they often overlook insight into stabilized pressure behavior.
Once a subsea BOP stack is deployed offshore, limited access significantly increases the cost of uncertainty. In 2023, IPT Global collaborated with Seadrill on an article published by Drilling Contractor examining the operational value of standardizing BOP soak testing and proposing a structured framework aligned with the American Petroleum Institute’s (API) Standard 53.
A subsea BOP soak test is a pressure stabilization procedure. Rigs perform it during pre-deployment testing to evaluate the integrity of the BOP control system under sustained pressure conditions. Unlike dynamic testing, soak testing allows pressures to stabilize and the system to settle into equilibrium.
During this stabilized period is when that behavior often emerges. Gradual pressure decay or inconsistent regulator response become apparent once transient effects dissipate. These conditions are not always obvious but can directly influence stack readiness and long-term system reliability.
Identifying these issues before deployment allows for investigation with limited operational impact. When teams do not identify these behaviors, they often surface during operations. At that stage, troubleshooting options are fewer and consequences are more costly.
Despite the importance of well control assurance, subsea BOP soak testing still varies across rigs, fleets, and regions. Common differences include test duration, applied pressure, acceptance criteria, and documentation practices.
In practice, this variability rarely reflects a lack of focus on safety. In IPT Global’s experience supporting pre-deployment testing, variability most often reflects legacy practices, differing OEM guidance, and misaligned acceptance thresholds. Over time, these inconsistencies make results difficult to compare and increase reliance on interpretation rather than data-driven evidence.
Standardizing subsea BOP soak testing does not mean removing operational judgment or imposing rigid procedures across all systems. Instead, it establishes a shared baseline that supports clearer execution and more consistent interpretation of results.
In the article, we discussed the operational value of more structured subsea BOP soak testing, aligned with API Standard 53. The intent was to reduce unnecessary variability while preserving flexibility across different BOP configurations.
Soak testing offers a rare opportunity to observe control system behavior once transient pressure effects have stabilized. When teams miss or inconsistently execute that opportunity, they overlook meaningful indicators of system health. API Standard 53 already serves as the foundation for subsea BOP equipment system requirements. Expanding guidance to clearly address soak testing would strengthen consistency while preserving flexibility across different system designs and operating environments.
Digital pressure data enables teams to review stabilization trends directly, revealing gradual decay, irregular stabilization, and repeatable anomalies across tests.
With IPT Global’s Equipment Health Monitoring HealthAnalytics software and Monitoring service, digital diagnostics capture high-resolution pressure behavior during soak testing, enabling objective, contextual evaluation of subtle trends. Engineers in IPT Global’s Real-Time Operations Center (RTOC) monitor test data in real time and support decision-making during pre-deployment activities.
Together, our HealthAnalytics and Monitoring modules strengthen engineering judgment rather than replace it. Objective data provides a common reference point, improves alignment between operators, drilling contractors, and OEMs, and supports more confident decisions related to deployment readiness and pre-deployment assurance.
Subsea BOP soak testing delivers value through how teams evaluate results and act on them. Programs that consistently derive data-driven insight approach soak testing as part of a broader assurance process.
As subsea systems continue to increase in complexity, the ability to reduce uncertainty before deployment becomes increasingly important. Subsea BOP soak testing remains one of the few opportunities to observe control system behavior under stabilized pressure conditions.
Through the SureTec® Equipment Health Monitoring solution, IPT Global applies a consistent, data-driven approach to subsea BOP soak testing during pre-deployment operations. By focusing on how control systems behave under stabilized pressure conditions, teams gain clearer insight into system performance before deployment decisions are made.
As subsea systems continue to grow in complexity, the way soak testing is executed and interpreted matters more than ever. Aligning practices with API Standard 53 provides a common framework for evaluating control system behavior, reducing unnecessary variability, and strengthening well control assurance across fleets. When teams pair that framework with objective pressure data and structured evaluation, soak testing becomes less about confirming pressure holds and more about understanding what the system is communicating before it goes offshore.
Looking ahead, IPT Global continues to advance digital software integrations that support consistent application of subsea BOP testing practices and ongoing improvement across the testing lifecycle.
For additional context, read the full article published in Drilling Contractor: Standardizing subsea BOP soak testing: overview of value and recommended best practices – Drilling Contractor by Patrick Hillard and Leonard Childers, IPT Global; and Ahmed Omar, Seadrill
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 SureTec® PressureTesting solution consistently delivered faster and more reliable results. The new rig had not yet adopted the standardized digital pressure testing 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 implement its PressureTesting solution, provide hands-on coaching, and establish standardized workflows. The result was a rapid improvement in safety and efficiency, with 210 documented pressure tests over the course of 14 months and significant reductions in critical path time early in the campaign.
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.
IPT Global’s leading digital pressure testing software delivers accuracy, efficiency, and consistent assurance across every pressure test.
Adopting new technology requires the right expertise and support. IPT Global ensures customers maximize the value of our solutions 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 (RTOC) 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 PressureTesting TestPlanner module – a verification matrix developed alongside drilling engineers as they designed the test plan. TestPlanner 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.
Within the PressureTesting solution, pressure data can be captured from existing infrastructure such as cement units, IWOCS, or ROV systems and automatically integrated into the SureTec platform. The PressureTesting DigitalApprovals module removes the inefficiencies of chasing post-test wet signatures or waiting for email confirmations. Our RemoteView module bridges the gap between offshore execution and onshore approval, giving onshore teams real-time transparency into critical wellbore barrier verification. And with the ComplianceReporting module, 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 platform apart is its WellSchematic solution, which provides the ability to generate wellbore and 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 Global streamlines this by automatically importing data from industry-standard well planning software and offering drag-and-drop options. Through the BarrierManagement module, 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.
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 solutions.
At the core of this success was our Thermally 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 TestPlanner, which optimized test planning through our verification matrix, WellSchematic, and BarrierManagement, 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 focuses 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 (RTOC). This demonstrated that solution adoption and consistent high performance were embedded in the crew and sustained throughout the campaign.
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 WellSchematic and BarrierManagement allow safe planning and execution ahead of operations. All of this is supported by real-time oversight from our RTOC.
Looking ahead, IPT Global will continue to advance well assurance intelligence and software integrations to make our solutions even more accessible and valuable for end users.
Managed Pressure Drilling (MPD) systems operate under demanding conditions, where small deviations in pressure or hydraulic behavior can escalate into equipment failure, unplanned non-productive time (NPT), and increased well control risk. Traditional well control equipment testing often depends on manual interpretation, delayed reporting, and limited visibility into early degradation trends.
In this analysis of MPD equipment failure, we examine how a major offshore operator used MPD control system data and IPT Global’s Equipment Health Monitoring solution to identify the deviation pattern that preceded a Slimline Annular (SLA) element failure. The analysis shows how automated MPD failure analysis and equipment health workflows can reveal early indicators of annular wear long before visible damage.
The operator experienced an unexpected failure of the Slimline Annular (SLA) element on the Integrated Rise Joint (IRJ) after less than two months of deployment and only 13 closures. During retrieval, the rig team discovered large pieces of degraded rubber in the trip tank and on top of the wear bushing.
The failure resulted in more than 250 hours of NPT. While the root cause was established through a lengthy investigation by the Original Equipment Manufacturer (OEM), the operator wanted to determine whether early indicators were present in the MPD control system data and if digital analysis could have detected the problem sooner.
This case raises two key questions for the operator:
Figure 1. IPT Global’s MPD Equipment Health Monitoring dashboard enabled the operator to analyze annular pressure response trends and identify early signs of Slimline Annular (SLA) element degradation ahead of failure.
During a technology review, the operator approached IPT Global to evaluate whether digital real-time and MPD integrity management analytics could better support early detection of equipment degradation. They tested whether IPT Global’s Equipment Health Monitoring HealthAnalytics module could analyze MPD control data without context, manual tagging, or event descriptions.
To create a blind test, the operator provided a set of sanitized CSV files from the Transocean drillship MPD system; the files contained only raw time-series data from the SLA subsystem. Using this data set, IPT Global evaluated whether HealthAnalytics could pinpoint the failure window and detect the signal patterns that occurred beforehand.
IPT Global prepared the files, reformatted them, and ingested them into the Equipment Health Monitoring system. This software uses model-driven workflows designed for well control equipment testing, MPD failure analysis, and condition-based monitoring. It evaluates pressure response, hydraulic behavior, and closure performance to identify changes that indicate abnormal equipment performance or early-stage degradation.
Within minutes of data ingestion, the system flagged unusual pressure and hydraulic patterns inconsistent with expected annular behavior. IPT Global engineers ran multiple analysis modes over the next 48 to 72 hours to validate the signal patterns. Ultimately, the results consistently pointed to the same failure window later confirmed by the operator and the OEM.
Key outcomes
The analysis identified a distinct deviation in the annular element’s pressure and hydraulic response with progressive wear. Importantly, this pattern was detectable days before the failure became visible.
“With IPT Global’s Equipment Health Monitoring, we saw in two days what took months to uncover,” said the operator’s Senior Advisor of Rig Systems. “That’s the kind of insight that changes how you think about equipment monitoring.”
Figure 2. IPT Global’s MPD integrity workflows support proactive, data-driven condition monitoring that reduces NPT and improves equipment assurance.
This case demonstrates how digital MPD integrity management testing can improve operational reliability and reduce NPT. By tracking baseline trends and small deviations, operators can detect MPD equipment wear early and improve maintenance and risk decisions.
IPT Global continues to expand its condition-based monitoring and predictive analytics for MPD systems, strengthening well control readiness, accelerating fault detection, and supporting a more proactive approach to equipment assurance.
Blowout preventer (BOP) testing is a critical-path operation in drilling programs, but for this major onshore operator it had become a persistent bottleneck. Average test durations exceeded six hours per BOP test, increasing non-productive time (NPT) and creating schedule challenges.
Beyond timing, the operator’s legacy methods, including circular chart recorders and outdated digital systems, made improving BOP testing efficiency increasingly difficult. These outdated tools often failed to capture complete assurance data, leaving quality issues undetected and complicating BOP testing compliance with API Standard 53.
The operator needed a digital solution to reduce BOP test time, improve BOP testing accuracy, and provide complete traceability across its rig fleet while supporting safer and more reliable well operations.
To address these challenges, the operator implemented IPT Global’s SureTec platform and its PressureTesting digital solution, designed to improve BOP testing workflows across its onshore rig fleet. Third-party testing companies used SureTec laptops at the rig site, while IPT Global’s Real-Time Operations Center (RTOC) in Houston provided remote technical support as needed. The solution’s high-resolution, real-time pressure data replaced manual readings and outdated tools to eliminate uncertainty and mitigate human error.
Automated validation and digital reporting streamlined the entire process, producing faster, more accurate, and fully verifiable results.
By digitizing and automating pressure test workflows with PressureTesting, the operator achieved a measurable step-change in operational efficiency. The solution replaced manual data capture and outdated systems with precise, real-time pressure data and automated validation tools. This transformation directly translated into faster test cycles, reduced rig downtime, and measurable gains in BOP testing efficiency.
Figure 1. Comparative performance summary showing substantial reductions in test time and enhanced API Standard 53 Compliance after implementing IPT Global’s SureTec PressureTesting solution.
IPT Global’s SureTec Impact
This performance represents a best-in-class reduction in test duration, significantly cutting overall BOP testing duration and improving rig uptime.
Figure 2. Single-test performance metrics recorded by IPT Global’s PressureTesting solution, showing how digital time tracking isolates each stage of the BOP test cycle.
The charts below indicate a decreasing trend over a 4-year period for Total Test Time, Line-Up Time, and Rig Ops Time as a result of optimized BOP testing and learnings from the implementation of PressureTesting. The continued improvement is indicative of the ongoing value and effectiveness of IPT Global’s digital solutions.
Figure 3. Visualization of improving year-over-year BOP test time trends across the operator’s onshore rig fleet, highlighting the reliability and optimization achieved through IPT Global’s SureTec PressureTesting digital workflows.
Consistent, verifiable test data and analysis is critical for maintaining compliance and preventing quality issues. With PressureTesting, the operator gained full traceability into every test event, allowing early identification of irregularities and ensuring that every BOP test aligned with API Standard 53 requirements.
IPT Global’s SureTec Impact
The chart below compares average BOP critical path test times for rigs under state and federal regulations. Despite longer federal hold requirements, SureTec’s PressureTesting maintained shorter average times and tighter variability, demonstrating consistent performance under all compliance conditions.
Figure 4. Average BOP test durations under state and federal regulatory conditions, highlighting reduced test time variability and improved consistency with IPT Global’s SureTec PressureTesting.
SureTec’s centralized digital test records allowed the operator to monitor trends, analyze test performance, and make real-time data-driven decisions faster than ever before. Over time, this capability improved its well integrity management program and established a culture of continuous improvement across rigs and over multiple years of operation.
IPT Global’s SureTec Impact
What began as an effort to reduce BOP test time resulted in a transformation of the operator’s BOP testing workflow. With SureTec PressureTesting, the operator not only achieved faster testing but also improved quality control, regulatory compliance, and data visibility, which improved well integrity management across its entire rig fleet.
Today, IPT Global’s SureTec PressureTesting solution is setting the benchmark for improving BOP testing efficiency and helping operators reduce BOP test time across both onshore and offshore environments. The digital solution continues to set the standard for BOP testing accuracy and assurance, enabling operators worldwide to improve efficiency in BOP testing operations.
In this Drilling Contractor article, IPT Global and Seadrill examine why subsea blowout preventer (BOP) soak testing remains inconsistently executed across rigs and regions, despite its role in pre-deployment assurance. Differences in test duration, pressure levels, and acceptance criteria often stem from legacy practices and varying OEM guidance rather than a lack of focus on safety.
The authors propose a framework aligned with API Standard 53 to establish a shared testing baseline, paired with digital pressure data to catch subtle issues, like gradual decay or irregular regulator response, before deployment, when troubleshooting is far more difficult. IPT Global’s SureTec® Equipment Health Monitoring solution and Real-Time Operations Center (RTOC) support this kind of objective, data-driven evaluation during pre-deployment testing.
Read the full article: Standardizing subsea BOP soak testing: overview of value and recommended best practices by Patrick Hillard and Leonard Childers, IPT Global; and Ahmed Omar, Seadrill