August 16th, 2024
Ensuring BOP Reliability
Your Guide to Effective Soak Testing
At Aquila Engineering, we’re committed to maximizing the reliability and safety of your BOP systems.
Our expert guidance and innovative solutions help you ensure that your Blowout Preventer (BOP) performs flawlessly when it counts the most.
One of the key methods we emphasize is soak testing- a critical process to verify the integrity of your BOP system pre-deployment. Here’s a guide to help you navigate this essential testing phase with confidence.
What is Soak Testing?
Soak testing is designed to evaluate the pressure integrity of your BOP control system by monitoring how well it maintains pressure over time. This process is crucial for confirming that the system will perform reliably during drilling and emergency operations, with no hidden leaks or weaknesses.
Setting Criteria for Successful Soak Tests
When it comes to passing a soak test, there isn’t a one-size-fits-all solution. Aquila Engineering is actively working with industry leaders and API to establish robust standards for soak testing.
Many operators and contractors have set additional guidelines for acceptable pressure decay over a measured time. These guidelines may range from 50 psi/hour to 30 psi/30 minutes or less. An acceptable decay rate may depend on the system or circuit being tested and the volume of the test system.
It is important however to correlate an acceptable pressure decay with a leak rate which can be used to calculate pump run times. Will your “acceptable” leak rate result in your HPU pumps running every 3-4 hours to keep up with this pressure decay?
Select a rate that aligns with your system’s specifications and operational requirements. Always consult with the equipment manufacturer for their recommended criteria.
Testing Conditions: Offline vs. Online
Offline Testing: This isolates the BOP from its main control systems, and provides BOP control from a test or auxiliary system which may not contain full MUX pod transducer readbacks
Online Testing: Conducting tests with the main control systems active and ensures a more realistic evaluation of how the system performs in real-world conditions.
You also have the choice between testing the entire accumulator system versus a single accumulator bank:
Entire System: Testing on a larger volume can artificially hide issues. A 120-psi pressure decay testing with 12 accumulator bottles may only appear as a 15-psi decay performing the same test with 96 accumulator bottles online.
Single Bank/Row: Allows for more focused testing and makes it easier for personnel to identify if a problem exists Measuring and Monitoring Tools.
Charts and Gauges: Provide minimally useful manual readings and may lack detailed insights.
Transducers with Software: Our advanced solutions, like Aquila’s DPT (Digital Pressure Testing) suite, offer continuous monitoring with precise data, helping you spot issues early and accurately.
Aquila’s Expert Tips for Effective Soak Testing
Minimize Test Volume: Test with the smallest practical volume to detect issues more sensitively. Smaller volumes make it easier to identify leaks and pressure drops.
Full System Control: Test with a control system that provides complete control and readback. This is essential for detecting leaks and understanding system performance in detail.
Separate Emergency Circuit Tests: Test emergency systems like DMAS and acoustic controls independently to ensure they are fully operational under test conditions.
Utilize Continuous Monitoring Systems: Leverage our advanced DPT digital pressure testing suite for a detailed, real-time view of your system’s performance, making troubleshooting more efficient.
Engage the Right Personnel: Ensure you have skilled personnel to visually inspect for leaks and analyze results. Their expertise is crucial for identifying potential issues, even when visual signs are minimal.
Consider Environmental Factors: Aim for optimal conditions, if possible, but be prepared to account for environmental variables that could impact testing results.
In Summary
At Aquila Engineering, we believe that thorough soak testing is vital to ensuring the safety and reliability of your BOP systems. By following these guidelines and utilizing our cutting-edge solutions, you can approach your testing process with confidence, knowing that your system is ready to perform when it matters most.