Double Stack BOP Refurbishment & Recertification
Background
A client required a full five-year refurbishment and recertification of a critical double-stack Blowout Preventer (BOP) system to maintain operational safety and ensure compliance with offshore drilling regulations. The BOP is a vital component of well control, and any degradation in performance could result in operational downtime or environmental risk. The refurbishment was to be completed within a tight schedule, with zero compromise on quality or compliance.
The Project
Hydrus undertook the project at its certified refurbishment facility, beginning with the complete disassembly of the double-stack BOP system. Major components, including ram blocks, bonnet assemblies, hydraulic circuits, control systems, and sealing elements, were meticulously inspected and assessed using non-destructive testing (NDT) methods. Each component was evaluated against original equipment manufacturer (OEM) specifications and industry standards.
Worn or damaged parts were refurbished or replaced as necessary, with replacement components sourced to match OEM criteria. Skilled technicians reassembled the BOP in accordance with the original manufacturing tolerances, applying rigorous quality checks at every stage.
The system was then subjected to a comprehensive testing programme. This included hydrostatic pressure testing to validate sealing integrity, and full functional testing of hydraulic and mechanical operations to confirm proper actuation and performance under simulated field conditions.
Throughout the process, Hydrus maintained clear documentation and traceability. A complete package of certification documents, including NDT reports, pressure test results, materials traceability records, and recertification approvals, was compiled for client review and regulatory filing.
The Results
The double-stack BOP was successfully refurbished and recertified within the agreed timeframe. The asset was returned to service with extended operational life, assured performance, and full regulatory compliance. The project strengthened the client’s safety-critical infrastructure and reinforced Hydrus’s reputation for precision, quality, and delivery in high-stakes offshore environments.
