Improving hydraulic system reliability

Client: Global independent energy company

Asset type: Drillship

Location: Americas

Scope of work: Real-time monitoring (RTM) services in support of 21-day test approval

Summary of event: Rig subsea personnel, in partnership with ModuSpec surveyors, utilised ModuSpec RTM services to systematically identify potential hydraulic system leaks and equipment deficiencies. The objective of this collaborative effort focused on ensuring the integrity of the BOP hydraulic control systems, to maintain operational safety and compliance with industry standards.

How we helped: Utilising our RTM diagnostic tools, our RTM specialists were able to identify irregularities in pressure trends that are common identifiers of possible hydraulic system leaks and/or issues. Our specialists detected multiple anomalies not identified by the primary visual inspection or by a third-party digital pressure testing provider, which had initially passed the soak tests. These false-positive results could have led to undetected system vulnerabilities, which were later confirmed by rig personnel upon notification. Additionally, RTM specialists assisted in ensuring that the test met the preset criteria, determining whether the soak test passed or failed.

Key findings:

• Test 6: (Drilling contractor’s procedure): The third-party digital pressure testing vendor passed the test with an 11 psi drop over 30 minutes. However, RTM data showed a 60-psi pressure loss. Subsequent inspection revealed a leak on the opposite pod’s pod select valve.
• Test 6A: The third-party digital pressure testing vendor again passed the test, but ModuSpec recorded a 60 psi drop in 30 minutes. Further analysis identified regulator cycling behaviour that drew on the pod supply/HPU pressure, indicative of leaks. Investigations confirmed leaks in the middle inner kill and middle outer kill open circuits.

Value to client: By identifying and addressing hydraulic control system leaks before BOP deployment, ModuSpec’s RTM services help proactively mitigate operational risk and avoid potential downtime events. Early detection ensures that system integrity is validated prior to well operations, reducing the likelihood of mid-operation failures that could require riser retrieval and BOP recovery – activities that carry significant safety risks, logistical complexity, and cost. 

This proactive approach not only minimises exposure to unplanned interventions but also enhances personnel safety and operational continuity. Through RTM monitoring and independent oversight, we enable clients to maintain control system readiness, improve safety assurance, and remain ahead of costly disruptions.

We provided critical oversight that uncovered significant hydraulic system leaks missed by traditional methods. This case reinforces the importance of independent RTM validation in ensuring BOP control system integrity and highlights the value of data-driven insights in offshore safety assurance. A soak test case was created via ModuSpec RTM’s case management system and findings/solutions were documented and saved.

Strategic or commercial impact:

1. Enhanced risk mitigation: The RTM system enabled early detection of hydraulic control system leaks that were not identified through conventional means or by third-party testers. This significantly reduced the risk of BOP malfunction during critical operations, directly contributing to well control and environmental safety.
2. Independent verification & regulatory confidence: By independently identifying failed components despite third-party pass results, ModuSpec RTM strengthened operator confidence and audit readiness. This impartial oversight aligns with regulatory expectations for technology qualification and continuous system assurance 12.
3. Reduced NPT and cost avoidance: Undetected failures – had they progressed into operational downtime – could have resulted in substantial non-productive time (NPT), deferred production, or emergency interventions. RTM insights facilitated targeted maintenance, reducing unnecessary component replacements and costly downtime.
4. Increased accountability among vendors: The discrepancies identified between ModuSpec RTM data and the third-party digital pressure testing vendor test results highlight RTM's role in improving service quality and accountability – driving improved vendor performance, transparency, and contract enforcement.
5. Strategic differentiator in service offering: The successful use of RTM in this scenario demonstrates a clear operational and safety advantage that ModuSpec can market to clients. It positions RTM not only as a compliance or monitoring tool, but as a commercially valuable safeguard that reduces liability and increases operational assurance.