May 22nd, 2025
How Real-Time Monitoring and Digital Testing Saved Offshore Operations
Top 5 BOP Failures We’ve Prevented—and How We Caught Them in Time
When it comes to subsea safety, Blowout Preventer (BOP) failures are among the most critical risks operators face. At Aquila Engineering, our Remote Technical Operations Center (RTOC) uses real-time monitoring systems and digital BOP testing software to detect anomalies early, allowing our teams to respond before issues escalate. In this blog, we reveal five real BOP failures our team prevented in the field—and the technology and expertise that made it possible.
We’ll explore how Aquila Engineering’s real-time BOP monitoring and digital BOP testing services helped offshore teams detect and resolve serious BOP issues before they caused operational delays or safety incidents. These examples highlight the value of proactive BOP engineering, remote digital pressure testing, and efficient BOP test data analysis. Whether you're an operator, BOP engineer, or drilling supervisor, you'll see how early detection and smarter data can transform offshore reliability.
1. Surface Accumulator Leak Prevented Through Early Flow Detection
During routine monitoring, our RTOC flagged a sudden change in pump cycle frequency and surface flowmeter data following the operation of several failsafe valves. Our alert enabled the rig to quickly identify a leaking surface accumulator bottle and replace the bladder before further system impact.
Thanks to the combination of digital BOP testing software and sharp BOP engineering insights, the problem was resolved efficiently preventing downtime and ensuring continued compliance.
2. Hidden Leak in Annular Regulator Caught via Pump Cycling Pattern
Over several hours, the RTOC detected that the HPU pumps were cycling more frequently, even though the fluid depletion rate remained under 1 GPH. While subtle, our BOP test data analysis identified the pattern as abnormal.
The issue turned out to be a slow leak from the annular regulator venting back to the tank—something that would have otherwise gone unnoticed for longer. This case exemplifies how BOP tracking and real-time monitoring systemsreduce uncertainty and empower rigs to act on developing issues before they worsen.
3. Diverter Supply Regulator Failure Detected Through Behavioral Trends
After a series of BOP valve functions, our monitoring software detected unusual pump behavior. Collaboration between the onboard Aquila FSE and rig team led to the discovery of a faulty diverter supply regulator.
Using remote digital pressure testing tools, we reduced troubleshooting time and enabled a targeted repair. The rig avoided extended non-productive time, reinforcing the value of digital BOP testing efficiency in day-to-day operations.
4. Erratic Diverter Panel Regulator Performance Uncovered
Multiple valve functions triggered noticeable fluctuations in both depletion rate and pump cycle frequency. Our RTOC flagged the behavior and followed up with a deeper pressure trend analysis. The diverter panel regulator was found to be the root cause.
This case highlights how real-time BOP test monitoring and remote digital pressure testing not only aid in early detection but also streamline communication between engineering teams and operators—boosting both speed and accuracy.
5. POD Stack Stinger Leaks Identified After LMRP Relatch
Immediately after relatching the LMRP to the lower stack, the RTOC noticed a change in depletion and cycle rates. Working with our BOP engineers on site, we identified leaks in the blue and yellow POD stinger extend functions.
To maintain safe operations, the stingers were safely vented, and an official Statement of Fact was issued to ensure regulatory compliance. This example showcases how BOP testing companies can support safe decisions even during complex subsea operations through real-time visibility and compliance-focused data analysis.
Conclusion: Why Operators Trust Aquila Engineering for BOP Integrity
Every second counts when it comes to BOP integrity and that’s exactly where Aquila Engineering makes the difference. More than just a technology provider, we act as a trusted partner to offshore operators, combining cutting-edge digital BOP testing tools, real-time monitoring systems, and hands-on engineering expertise to prevent failures before they happen.
The five cases shared here aren’t just success stories, they’re proof of how Aquila’s proactive approach, powered by our Remote Technical Operations Center (RTOC), enables rigs to stay ahead of issues, optimize safety, and meet compliance standards with confidence.
At Aquila, we’re not just delivering data - we’re delivering insight, action, and peace of mind. Whether you're upgrading your BOP program or building a more resilient offshore operation, we’re here to support you every step of the way.
Let’s redefine what’s possible in BOP assurance together.
Explore our custom solutions and real-time offshore support at www.aquila-engineer.com