Using Monitoring Data to Predict Failures and Minimize Downtime
June 25th, 2025
How real-time analytics are transforming offshore efficiency and equipment reliability
Unexpected equipment failures can cost offshore teams millions in downtime, repairs, and safety risks. But with real-time monitoring systems and intelligent BOP test data analysis, companies are shifting from reactive maintenance to predictive strategies. In this blog, we explore how teams use monitoring data to identify warning signs, prevent failures, and boost operational efficiency backed by real examples from the field.
In this blog we’ll dive into how monitoring data, paired with digital BOP testing software and remote digital pressure testing, is enabling predictive maintenance across offshore drilling operations. You'll see how BOP engineers and operations teams use advanced analytics and real-time monitoring to stay ahead of issues, reduce unplanned downtime, and improve performance at every level.
1. From Reactive to Predictive: A Shift in Offshore Maintenance Culture
Traditionally, equipment failures in offshore environments were addressed only after something broke. Today, thanks to real-time monitoring systems and machine learning, operators can take a proactive approach.
Here’s how predictive maintenance is applied:
Sensor-driven data collection: Pressure, temperature, and vibration sensors constantly stream real-time data from key equipment.
Anomaly detection: AI algorithms flag unusual patterns, indicating a component may be nearing failure.
Automated alerts: Teams are notified early, allowing for preventive action before the issue escalates.
2. BOP Test Data: The Untapped Goldmine
Every BOP test generates valuable operational data, but many teams still underutilize it. With the right BOP testing software, that data becomes a strategic asset.
Benefits of leveraging BOP test data analysis:
Failure trend identification: Spot recurring issues across similar components or units.
Performance benchmarking: Compare results across rigs or time periods to detect declining performance.
Automated compliance reporting: Reduce manual logging and human error while meeting regulatory standards.
By combining BOP tracking with smart analytics, companies can better plan maintenance schedules, reducing unexpected repairs and increasing digital BOP testing efficiency.
3. Real-Time Monitoring in Action: Field Examples That Show Results
Predictive insights aren’t just theoretical—they’re actively preventing failures in the field. Here are real-world examples of how Aquila’s real-time monitoring systems and BOP tracking tools are supporting offshore teams in identifying issues early and minimizing downtime:
Example 1: Solenoid manifold regulator issue caught before deployment
During daily rounds before BOP deployment, the RTOC identified an anomaly with the solenoid manifold regulators on both pods, which were seeking set pressure. The onboard FSE was promptly notified.
“Aquila RTOC quickly recognized a shift in HPU pump cycle frequency and depletion rate. Upon notification of the increased pump frequency, the rig team monitored and investigated, discovering that the annular regulator was venting back to the tank. By carefully analyzing pressure trends, the leaking solenoid valves were repaired before BOP deployment.”
By addressing the issue before deployment, the team avoided a potential critical failure during subsea operations.
Example 2: Subsea issue detected mid-operation
During a routine operation while the BOP was deployed subsea, the RTOC identified a shift in pump cycle frequency and depletion rate. It was also noted that no BOP functions had been performed in the last 12 hours.
“The Aquila FSE and subsea team onboard were notified. The ROV unit was mobilized and during inspection, the yellow riser recoil valve was found to have an external leak. The yellow riser recoil valve was placed in the vent position, and the depletion rate returned to normal.”
This event demonstrates the value of continuous real-time monitoring—even in moments of operational “quiet”—to catch anomalies and maintain system integrity.
Conclusion
Monitoring data is no longer just a byproduct of offshore operations—it’s a powerful tool for prediction, prevention, and performance. With the right combination of BOP testing software, digital BOP testing services, and real-time monitoring systems, offshore teams can catch problems before they become failures. Whether it's reducing downtime, improving safety, or increasing the lifespan of critical equipment, predictive maintenance driven by data is the future of BOP engineering and offshore efficiency.
