Free wellhead inspection checklist

What is a wellhead inspection checklist?

A wellhead inspection checklist is a structured form used to verify the mechanical integrity, pressure containment and operational readiness of wellhead equipment on oil and gas production or drilling sites. The wellhead is the surface termination of a well bore and includes the casing head, tubing head, Christmas tree valves, flanges, seals and associated fittings. Because wellheads operate under high pressure and often in corrosive environments, routine inspection is critical to preventing uncontrolled releases, leaks and equipment failures. This checklist is aligned with API Specification 6A (Wellhead and Tree Equipment), which defines the design, material, testing and marking requirements for wellhead components. It covers visual inspection of all flanges, ring gaskets, stud bolts and nuts, valve operation and seat testing, pressure gauge verification, corrosion monitoring, cathodic protection status, BOP (blowout preventer) connection points, wellhead cellar condition and safety system function tests. In Australia, wellhead equipment also falls under state petroleum regulations and the Safety Case regime administered by NOPSEMA (National Offshore Petroleum Safety and Environmental Management Authority) for offshore operations or state regulators for onshore wells. A standardised inspection checklist ensures that every wellhead receives consistent scrutiny, that findings are recorded for regulatory reporting and that defects are tracked through to corrective action, supporting both API 6A compliance and local safety case requirements.

Learn more about maintenance and work orders in MapTrack.

Benefits of digitising forms in MapTrack

When you digitise wellhead checklists in MapTrack, you get:

• Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
• Automatically get alerts when faults are identified.
• Link every form digitally as a PDF to the relevant asset, location or person.
• Receive a digital PDF copy with every submission to your email.
• Ability to share forms digitally.
• Build conditional logic (show or hide questions based on answers).
• Take pictures or attach photos. Not possible with a paper-based form.
• Electronic signatures.
• Edit forms later without reprinting.
• Restrict permissions (who can view, complete or approve).
• Build forms with AI (describe what you need and MapTrack suggests the form).
• Trigger work orders automatically when a fault is logged during an inspection.
• Track service intervals by hours, kilometres or calendar date in one place.
• Attach supplier invoices and parts receipts to each maintenance record.

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What to include in a wellhead inspection checklist

This wellhead inspection checklist covers 10 key areas:

• Well identification: well name or number, field name, pad or platform location, wellhead asset ID, date, inspector name and competency reference.
• Casing head and tubing head: visual condition, corrosion, erosion, mechanical damage, casing hanger lockdown screws torqued, casing annulus pressure readings.
• Flanges and ring gaskets: flange faces clean and undamaged, ring gasket type and material correct per API 6A, no visible leaks at flange joints, stud bolts and nuts present, correctly torqued and not corroded.
• Christmas tree valves: each valve operates fully open and fully closed, handwheels or actuators functional, valve position indicators correct, no external leaks, bonnet bolts secure.
• Pressure gauges: tubing pressure, casing pressure and annulus pressure gauges readable, calibration in-date, isolation valves functional.
• Choke and flow control: choke bean or adjustable choke condition, no erosion at choke body, flow path aligned to production requirements.
• BOP connection points (if applicable): BOP flange condition, stud holes aligned, ring groove undamaged, flange protectors in place when BOP not installed.
• Corrosion and cathodic protection: external corrosion rating (none / surface / pitting / severe), cathodic protection system status (sacrificial anodes or impressed current), CP test point readings if accessible.
• Wellhead cellar: cellar clean and drained, no standing fluids, cellar walls structurally sound, no hydrocarbon accumulation.
• Safety systems: surface safety valve (SSV) function test, emergency shutdown (ESD) valve response, fire loop or fusible plug condition, SCADA communication confirmed.

How often should you complete this checklist?

Wellhead inspections should follow a tiered schedule based on risk and regulatory requirements. A basic visual inspection (leak checks, pressure readings, valve position confirmation) should be performed during every routine well visit, which may be daily, weekly or monthly depending on the field operating philosophy. A comprehensive wellhead inspection covering all checklist items, including valve operation, flange bolting checks and corrosion assessment, should be performed at least every six months for production wellheads and before and after every drilling or workover campaign. Safety system function tests (SSV, ESD) are typically required quarterly or as specified in the facility safety case. Australian state petroleum regulations and NOPSEMA guidance generally require operators to maintain a written scheme of examination and inspection for pressure-containing equipment, with intervals justified by a risk-based assessment. Always refer to the operator integrity management plan, API 6A and any applicable state or Commonwealth legislation.

Applicable regulatory standards

This template aligns with the following regulations and standards:

• API Specification 6A - Wellhead and Tree Equipment (design, material, testing and marking requirements)
• API Recommended Practice 14B - Design, Installation, Repair and Operation of Subsurface Safety Valve Systems
• NOPSEMA Safety Case Guidelines (offshore petroleum operations in Australian Commonwealth waters)
• Relevant state Petroleum Acts and Regulations (e.g. Petroleum and Gas (Production and Safety) Act 2004, QLD; Petroleum Act 1998, VIC)
• WHS Regulations 2011, Chapter 5 - Plant and Structures

Related resources

More maintenance templates and guides:

• Pipeline inspection checklist
• Pressure vessel inspection checklist
• Storage tank inspection checklist
• Equipment maintenance log
• Air compressor inspection checklist
• Inspections and audits
• Maintenance and work orders
• Oil and gas asset tracking
• Pricing