Even a well-maintained ram BOP can experience operational problems. This troubleshooting guide is based on CAMTOP’s field service experience with WU-series ram BOPs deployed globally across onshore and offshore drilling programs.

⚠️ Critical Safety Rule: Never attempt to open a BOP or perform repairs while the BOP is under wellbore pressure.

Common Failure Modes at a Glance

# Symptom Most Likely Cause
1 Ram seal leaks during pressure test Worn/damaged ram packing
2 BOP closes too slowly (>30 seconds) Low hydraulic pressure; undersized accumulators
3 Rams will not fully close Manual lock not retracted; ram obstruction
4 Hydraulic pressure drops after closing Internal hydraulic leak; piston seal failure
5 External hydraulic fluid leak Damaged bonnet seal or hydraulic fitting
6 Manual lock binds or will not engage Misalignment; corrosion; cross-threading
7 Top seal / body seal leaks Damaged top seal assembly
8 BOP body leaks at flange joint Damaged ring gasket; improper bolt torque

Issue 1: Ram Seal Leaks During Pressure Test

Diagnostic: Check whether the leak is from the ram face seal or the bonnet seal. Inspect ram packing visually for extrusion, tearing, or chemical degradation. Confirm the correct pipe OD is in the bore.

Fix: Replace ram packing with new CAMTOP OEM softgoods kit. Always use genuine CAMTOP OEM softgoods — third-party packing may not meet dimensional specifications for the WU-series.

Issue 2: BOP Closes Too Slowly

Diagnostic: Check hydraulic control unit pressure at the BOP (not just at the control unit). Check accumulator pre-charge pressure. Check for restrictions in hydraulic closing lines.

Fix: Increase control unit pump output pressure. Re-charge or replace accumulators. Replace kinked/restricted hydraulic hoses.

Issue 3: Rams Will Not Fully Close

First check: Are manual lock screws fully retracted? A partially engaged lock screw will mechanically prevent full ram closure.

Fix: Back out manual lock screws completely, clear bore obstruction, or verify correct ram assembly is installed.

Issue 4: Hydraulic Pressure Drops After Closing

Fix: Replace hydraulic cylinder piston seals (CAMTOP cylinder seal kit). If manual locks are available, engage them to mechanically maintain closure while investigating.

Issue 5: External Hydraulic Fluid Leak

Leak Location Likely Cause Fix
Bonnet face Bonnet face seal O-ring damaged Replace bonnet face seal; re-torque bonnet bolts
Hydraulic cylinder end cap End cap O-ring damaged Replace cylinder end cap seals
Hydraulic port fittings Loose fitting; damaged thread or O-ring Tighten fitting; replace O-ring seal

Experiencing a BOP problem not covered here? CAMTOP’s field service team provides 24/7 remote technical support: sales@cposl.com | +86.21.58432768 | www.camtop-oilfieldtools.com/