Using Monitoring Data to Predict Failures and Minimize Downtime
December 10th, 2025
How real-time analytics are improving offshore efficiency and equipment reliability
Unexpected equipment failures can lead to significant downtime, repairs, and safety concerns. With real-time monitoring systems and structured BOP test data analysis, offshore teams are gradually shifting from reactive maintenance to more preventive, data-informed strategies. In this blog, we explore how monitoring data helps identify early warning signs, support decision-making, and improve operational efficiency, including examples observed in offshore operations.
In this blog, we examine how monitoring data—combined with digital BOP testing software and remote digital pressure testing—supports more consistent maintenance planning across offshore drilling operations. We highlight how BOP engineers and operations personnel use real-time analytics to anticipate issues earlier, reduce unplanned downtime, and enhance overall equipment performance.
1. From Reactive to Predictive: An Evolving Approach to Offshore Maintenance
Traditionally, offshore teams addressed equipment failures after the issue had already occurred. Today, real-time monitoring systems and data analytics allow a more preventive approach, helping teams respond earlier and with more context.
How predictive maintenance is applied:
Sensor-driven data collection: Pressure, temperature, and vibration sensors provide continuous data from key equipment.
Anomaly detection: AI tools and pattern-recognition models highlight irregular trends that may indicate emerging issues.
Structured alerts: Teams receive early notifications, allowing technical personnel to investigate conditions that could progress into failures.
This shift does not replace engineering expertise—it complements it with consistent, data-supported insight.
2. BOP Test Data: A Valuable and Often Underused Resource
Each BOP test generates detailed operational information, but much of this data has traditionally been underutilized. With dedicated BOP testing software, that information becomes easier to interpret and apply to maintenance planning.
Benefits of a structured BOP test data analysis approach:
Identifying recurring trends: Helps highlight repeated issues across similar components or equipment units.
Performance comparison: Supports benchmarking across rigs, time periods, or operating conditions.
More reliable reporting: Reduces manual entries and supports consistent documentation for compliance requirements.
When BOP tracking is combined with digital analytics, teams can better plan maintenance intervals, helping reduce unexpected repairs and improving digital BOP testing efficiency.
3. Real-Time Monitoring in Action: Examples from Offshore Operations
Predictive insights are being applied daily in real offshore environments. Below are examples of how Aquila’s real-time monitoring systems and BOP tracking tools have supported teams in identifying anomalies early and reducing operational impact.
Example 1: Solenoid manifold regulator issue detected before deployment
During daily monitoring prior to BOP deployment, the RTOC identified deviations in the solenoid manifold regulators on both pods, which appeared to be seeking set pressure. The onboard FSE was notified.
“Aquila RTOC observed a change in HPU pump cycle frequency and depletion rate. After the notification, the rig team monitored the behavior and found that the annular regulator was venting back to tank. By reviewing the pressure trends, the leaking solenoid valves were repaired before BOP deployment.”
Detecting the issue early helped the team address it before subsea operations, reducing the likelihood of unplanned interventions.
Example 2: Subsea issue identified during operations
While the BOP was deployed subsea, the RTOC detected a shift in pump cycle frequency and depletion rate, even though no BOP functions had been performed in the previous 12 hours.
“The Aquila FSE and the subsea team were notified. The ROV was mobilized and, during inspection, the yellow riser recoil valve was found with an external leak. The valve was placed in the vent position, and the depletion rate returned to expected levels.”
This example highlights how continuous real-time monitoring supports system integrity, even when operations appear stable.
Conclusion
Monitoring data has become an essential input for preventive maintenance in offshore environments. Predictive maintenance does not eliminate failures, but it helps teams act earlier and with clearer context—strengthening reliability and improving operational efficiency across BOP engineering and pressure-control workflows.
Teams looking to enhance their monitoring and testing programs can explore how Aquila’s real-time monitoring and digital BOP testing software contribute to more informed and proactive offshore operations.
