WELL CONTROL READINESS
Figure 2 (above): The BOP Reliability Systems Soak Test dashboard uses pressure
trend identification algorithm technology, which in this case identified a leak in the
subsea manifold regulator fluid circuit within a minute of function actuation. Figure
3 (right): Upon visual inspection, confirmation was made identifying an SPM valve
with a failed seal plate while at maximum operating pressure.

annual reports, the cumulative average
BOP pulls hovered around the low 30s
annually for the represented BOP stacks.

It’s clear there is a marked improvement in
these figures when juxtaposed with data
from preceding years.

Data from 2020 and 2021 present an
even more encouraging narrative: The
number of stack pulls averaged in the low
20s. Many BOP experts acknowledge the
pivotal role of the rigorous soak tests con-
ducted prior to deployment. Although this
isn’t a normalized metric, it points toward
enhanced reliability performance.

The inference? The industry is lean-
ing into the lessons learned and making
strides in equipment reliability perfor-
mance. Considering this positive trend,
coupled with industrywide knowledge
sharing, there has been clear progress in
the pursuit of zero NPT.

State of industry practices
Current industry practices regarding
BOP soak testing exhibit significant varia-
tions in frequency, methodology and test
duration. Many equipment owners and
operators conduct these tests regularly
22 before deployment, while others perform
them both before and after deployment.

Additionally, there’s no standardized time-
frame for these tests, with durations rang-
ing from minutes to days.

The complexity of these tests also varies,
from two-step tests to procedures with 15 or
more steps. Factors influencing the testing
methodology include stack configuration,
contractual agreements, deployment dura-
tion estimates, maintenance planning, con-
dition-based maintenance program matu-
rity, crew proficiency and digital monitor-
ing capabilities. Despite these differences,
“boots-on-the-ground” inspections remain
the most common means of leak detection.

There is also significant promise shown
in the latest digital trend recognition algo-
rithms. For example, a proactive subsea
team, along with a specialized team of
remote BOP analysts, have been able to
identify system anomalies within min-
utes of pressure stabilization and pinpoint
critical components within each fluid cir-
cuit (Figures 2-4). This can significantly
reduce troubleshooting and fault-finding
efforts during an already stressful, fast-
paced pre-deployment period.

Standardization challenges
Differences in BOP design and opera-
tional philosophies among major OEMs
also contribute to variations in soak test-
ing practices. Each OEM has testing proce-
dures tailored to their BOP designs, leading
to a wide array of testing methodologies.

For instance, OEMs have freedom regard-
ing the rated pressure of the operating
chambers in their BOPs. These rated pres-
sures can vary from a few hundred psi up
to 5,000 psi or more. The soak tests must
accommodate these differences that exist
not only between different OEMs but also
in different models of operators within
each OEM.

SEPTEMBER/OCTOBER 2023 • DRILLING CONTRACTOR