The Main Challenges in Pressure Testing Digitalization — and How to Overcome Them
December 3rd, 2025
How Operators Can Move from Circular Charts to Digital BOP Testing With Confidence
As pressure testing evolves, many operators are shifting from paper-based workflows and circular charts to digital BOP testing systems. But the transition is not simple. We will explore the biggest challenges companies face when digitalizing pressure testing processes — and how Aquila’s approach helps teams achieve measurable results in efficiency, data quality, and well integrity assurance.
In this blog, we look at the evolving landscape of pressure testing digitalization across offshore operations. As BOP engineers, well integrity teams, and drilling contractors adopt digital BOP testing software, new challenges appear. We separated two common challenges leaders face today, and the tested-on-the-field strategies that help overcome them.
1. Ensuring Data Accuracy and Compliance Across Digital Workflows
For decades, pressure tests relied on circular charts, handwritten notes, and manual sign offs. Moving to digital platforms introduces new expectations for accuracy, consistency, and compliance.
Key challenges include:
Maintaining consistent data quality across multiple rigs and shifts.
Interpreting BOP pressure test data without human bias or inconsistent annotations.
Ensuring traceability for BOP testing audits and regulatory reviews.
Managing different testing types — BOP function tests, and pressure stabilization phases — within a single workflow.
How to overcome it:
Adopt digital BOP testing software designed to standardize BOP pressure test procedures.
Use real-time monitoring systems that automatically record pressure curves, hold times, chart anomalies, and stabilization periods.
Centralize test results in a secure platform that supports bop test data analysis and digital signatures.
How Aquila helps:
Aquila Digital Pressure Testing offers an integrated approach for data capture, automated validation, and secure reporting — reducing manual interpretation errors and supporting audit-ready documentation with proven performance.
2. Managing Cybersecurity Risks in Digital Pressure Testing Systems
As rigs adopt BOP digital assurance, well integrity software, and remote operations, cybersecurity becomes critical.
Pressure-testing data flows now include surface systems, rig networks, cloud environments, and operational technologies — and each layer requires proper protection.
Common cybersecurity concerns:
Exposure of rig networks to cyber threats to the oil and gas industry.
Protecting real-time monitoring data from tampering.
Safeguarding communication between offshore assets and onshore centers like RTM drilling hubs.
Ensuring compliance with internal security policies while enabling digital workflows.
How to overcome it:
Choose pressure testing solutions built with cybersecurity for oil rigs and oil and gas cyber security standards in mind.
Implement data and network security controls across offshore and onshore nodes.
Use platforms designed to mitigate common vulnerabilities found in older or stand-alone systems.
Incorporate continuous monitoring and logging across all BOP testing data flows.
How Aquila helps:
Aquila’s digital ecosystem supports oil & gas cybersecurity standards with secure cloud environments, encrypted data flows, and role-based access — all aligned with the needs of subsea solutions in oil and gas operations.
Conclusion
Digital pressure testing is no longer optional for operators who want to improve reliability, reduce non-productive time, and support audit readiness. By addressing challenges in compliance and cybersecurity companies can build a more consistent and data-driven approach to BOP testing.
Aquila delivers a new approach to digital BOP testing — with secure data flows, structured procedures, and real-time monitoring tools that provide measurable results for well integrity teams, drilling contractors, and BOP engineers.
