Free BOP (blowout preventer) inspection checklist

• The MapTrack BOP (blowout preventer) inspection checklist contains 40 checks across 8 sections. Sections covered: Ram BOP - Visual Inspection, Annular Preventer, Hydraulic Control System, Function Test Results (record times in seconds), Accumulator System, Choke & Kill Manifold, Pressure Testing (record psi & hold time), Emergency & Backup Systems.
• Ram-type BOPs: inspect ram rubbers and ram blocks for wear, damage and correct sizing, verify each ram (pipe ram, blind ram, shear ram) opens and closes fully, check ram indicators and position feedback.
• Annular preventer: inspect annular packing element for wear, extrusion and deterioration, verify annular closes on pipe and open hole, check closing pressure and opening pressure.
• BOP control system: inspect hydraulic accumulators (check pre-charge nitrogen pressure), verify accumulator volume and response time per API 53, test all control stations (driller panel, remote panel, subsea control pods if applicable).

Learn more about maintenance and work orders in MapTrack.

• 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.

• Ram-type BOPs: inspect ram rubbers and ram blocks for wear, damage and correct sizing, verify each ram (pipe ram, blind ram, shear ram) opens and closes fully, check ram indicators and position feedback.
• Annular preventer: inspect annular packing element for wear, extrusion and deterioration, verify annular closes on pipe and open hole, check closing pressure and opening pressure.
• BOP control system: inspect hydraulic accumulators (check pre-charge nitrogen pressure), verify accumulator volume and response time per API 53, test all control stations (driller panel, remote panel, subsea control pods if applicable).
• Pressure testing: perform low-pressure test (200 to 300 psi for 5 minutes) and high-pressure test (to rated working pressure for 5 minutes minimum) on each ram, annular preventer, choke line, kill line and wellhead connector per API 53.
• Choke and kill lines: inspect choke and kill valves for leaks and correct operation, verify choke manifold valve positions, inspect flexible hoses and rigid lines for external damage and corrosion.
• Wellhead and connectors: inspect wellhead housing and BOP connector (flange or collet connector), verify stud and nut condition, check ring gaskets for damage, verify connector lockdown mechanism.
• Hydraulic system: check hydraulic fluid level and condition (colour, contamination), inspect hydraulic hoses and fittings for leaks, verify pump output pressure and volume.
• Emergency systems: test emergency disconnect system (EDS) where applicable, test autoshear or deadman functions (subsea BOPs), test acoustic or ROV backup activation systems.
• Documentation: record all pressure test results (test pressure, hold time, observed pressure drop), function test results, defect findings, corrective actions and inspector details.

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.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• API Standard 53 (Blowout Prevention Equipment Systems for Drilling Wells)
• API Specification 16A (Specification for Drill-through Equipment)
• API RP 53 (Recommended Practice for BOP Equipment Systems)
• NOPSEMA Well Integrity requirements (Australian offshore petroleum)
• AS 4076 - Blowout Prevention Equipment Systems for Drilling Wells
• WHS Regulations 2011, Chapter 5 - Plant and Structures

• Model WHS Regulations (Safe Work Australia)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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