Free bop (blowout preventer) inspection checklist

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Free BOP blowout preventer inspection checklist (PDF-ready). Covers API 53 pressure testing, ram function, annular preventer, accumulator and control system.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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Benefits of using this bop (blowout preventer) inspection checklist

• Well control assurance: systematic inspection and testing of every BOP component confirms the stack can seal the wellbore under maximum anticipated surface pressure conditions.
• API 53 compliance: documented pressure tests, function tests and inspection results demonstrate compliance with the API 53 standard required by petroleum regulators worldwide.
• Catastrophic risk reduction: identifying degraded ram rubbers, weak accumulator charges, faulty control pod signals or leaking seals before they prevent the BOP from closing during a well control event.
• Operational continuity: proactive detection of BOP issues during routine inspections prevents unplanned rig shutdowns for emergency BOP maintenance, which can cost hundreds of thousands of dollars per day in rig downtime.
• Regulatory readiness: complete BOP inspection and test records are among the first documents requested during regulatory audits, incident investigations and permit applications.
• Environmental protection: ensuring the BOP stack functions as designed prevents uncontrolled releases of hydrocarbons to the environment, protecting marine ecosystems, groundwater and surrounding communities.

How to use this bop (blowout preventer) inspection checklist

1. Review the well programme, BOP stack configuration and API 53 testing requirements. Confirm the BOP has been installed and nippled up correctly before commencing the inspection.: Obtain the well programme document specifying the BOP stack configuration, rated working pressure, ram sizes and API 53 testing schedule. Confirm the BOP has been installed on the wellhead with the correct connector type and that all flanges, studs and ring gaskets are correctly made up. Review the previous BOP test results and any outstanding defect reports. Confirm the test pump and pressure recording equipment are calibrated and functional.
2. Visually inspect the entire BOP stack: check ram bodies, annular housing, flanges, studs, hydraulic hoses, choke and kill lines, and the control system for external damage, leaks or corrosion.: Walk around the BOP stack and inspect every visible component. Check ram bodies and bonnets for cracks, corrosion or hydraulic leaks. Inspect the annular preventer housing for damage. Check all flange faces and stud bolts for corrosion, cross-threading or insufficient make-up. Inspect all hydraulic hoses and rigid lines for chafing, external damage, corrosion and secure clamping. Check choke and kill line valves for leaks. Note any items requiring immediate attention before pressure testing.
3. Function-test each BOP element: close and open each ram (pipe ram, blind ram, shear ram) and the annular preventer. Verify position indicators, closing times and control system response from all control stations.: Operate each ram from the driller control panel and verify it closes and opens fully within the specified time. Confirm ram position indicators (mechanical or electronic) correctly display the open and closed states. Close the annular preventer on pipe and verify sealing. Test operation from the remote panel and any secondary control stations. For subsea BOPs, test operation from both control pods. Measure and record closing times for each element. Verify accumulator pressure recovery after each operation cycle.
4. Perform pressure testing per API 53: conduct low-pressure test (200-300 psi, 5-minute hold) followed by high-pressure test (rated working pressure, 5-minute minimum hold) on each ram, annular, choke line, kill line and wellhead connector.: Install the test plug or test tool in the wellbore. Pump up to the low-pressure test value (200 to 300 psi) and hold for 5 minutes. Monitor the pressure chart for any decline. A pressure drop indicates a leak that must be investigated and rectified before proceeding. After a successful low-pressure test, pump up to the rated working pressure of the element being tested and hold for a minimum of 5 minutes (some operators require 10 minutes). Record the test pressure, hold time and any observed pressure drop on the chart recorder. Repeat for each ram, the annular preventer, choke line valves, kill line valves and the wellhead connector. API 53 permits a maximum pressure drop during the test as specified in the standard.
5. Inspect the accumulator system: check pre-charge nitrogen pressure on each bottle, verify total usable volume and closure time per API 53. Check hydraulic fluid level, condition and pump performance.: Measure the pre-charge nitrogen pressure on each accumulator bottle using a calibrated charging rig (typically 1,000 psi pre-charge for 3,000 psi systems). Record each bottle pressure. Calculate the total usable accumulator volume and verify it meets the API 53 requirement (sufficient to close all BOPs plus reserves with pumps off). Time the closure of the annular and one set of rams with accumulator pressure only and verify it meets the specification. Check hydraulic fluid level in the reservoir and inspect for contamination, discolouration or water ingress. Test pump output pressure and volume.
6. Test emergency and backup activation systems. Document all test results, defect findings and corrective actions. Obtain sign-off from the drilling superintendent or well control authority.: Test the emergency disconnect system (EDS) where applicable, verifying the shear rams close and the LMRP disconnects cleanly (subsea BOPs may use a simulated test). Test autoshear and deadman backup functions as applicable. Test acoustic or ROV backup activation systems if fitted. Document every test result on the BOP test record form including test pressures, hold times, pressure drops, function test times, accumulator pre-charge pressures and defect findings. Create corrective actions for any failures with assigned responsibility and due dates. Obtain sign-off from the drilling superintendent, company representative and regulatory inspector if required.

In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.

Frequently asked questions

What does API 53 require for BOP pressure testing?

API 53 requires BOP pressure testing at initial installation, before drilling out each casing shoe, every 14 days during drilling operations, and after any BOP repair or component replacement. Each test consists of a low-pressure test (200 to 300 psi for 5 minutes) followed by a high-pressure test at the rated working pressure (minimum 5-minute hold). All rams, the annular preventer, choke line, kill line and wellhead connector must be tested individually. Pressure must be held steady for the required duration with any drop investigated and rectified before operations continue. All test results must be documented on a chart recorder or electronic data logger.

How often should a BOP be inspected and tested?

BOPs must be pressure tested at initial installation, before drilling out each casing shoe, every 14 days during active drilling and after any repair or component replacement. Function tests (closing and opening all rams and the annular preventer) should be performed at least weekly. Accumulator pre-charge pressures should be checked during each pressure test. Visual inspections of the stack should be performed daily during drilling operations. For BOPs in storage or between wells, a full inspection and test must be completed before deployment to the next well.

What is the difference between a ram BOP and an annular preventer?

A ram BOP uses steel ram blocks that close horizontally across the wellbore to seal around the drill pipe (pipe rams), seal the open hole (blind rams) or shear through the drill pipe and seal (shear rams). Ram BOPs provide the highest pressure rating and sealing reliability. An annular preventer uses a doughnut-shaped rubber packing element that closes around any size pipe or closes on open hole by squeezing inward from all sides. The annular preventer is more versatile (it seals on any pipe size) but has a lower pressure rating than ram BOPs and its packing element wears faster. A complete BOP stack typically includes both types, with the annular preventer on top and multiple ram BOPs below.

What are the consequences of failing a BOP pressure test?

Failing a BOP pressure test means the BOP stack cannot reliably seal the wellbore at the required pressure, which is a well control safety issue. Operations must stop until the failure is investigated, the cause is identified and the component is repaired or replaced. The BOP must then be retested successfully before drilling operations can resume. Common causes of failed tests include degraded ram rubbers, worn annular packing elements, damaged ring gaskets, leaking choke or kill valves, and loose flange connections. A pressure test failure during operations can result in several days of non-productive rig time while repairs are completed.

Is this BOP inspection checklist free to download?

Yes. This BOP inspection checklist is completely free to download and use. Open the template in your browser and print or save as PDF. No account or sign-up is required. If you want to digitise inspections with automatic scheduling, photo capture and compliance dashboards, MapTrack can help. Book a free demo to see how it works for your operation.