FMEA and FMECA PDF

HSE
Health & Safety

Executive
Completion component reliability

Failure mode identification
Prepared by IDM Engineering

for the Health and Safety Executive
OFFSHORE TECHNOLOGY REPORT

2001/061
HSE
Health & Safety
Executive
Completion component reliability

Failure mode identification
IDM Engineering
Torridon House
73-75 Regent Quay
Aberdeen
AB11 5AR
United Kingdom
HSE BOOKS
Crown copyright 2002
Applications for reproduction should be made in writing to:
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First published 2002
ISBN 0 7176 2244 4
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This report is made available by the Health and Safety

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been supported by funds provided by the Executive.
Neither the Executive, nor the contractors concerned
assume any liability for the reports nor do they
necessarily reflect the views or policy of the Executive.
ii
EXECUTIVE SUMMARY
A study has been undertaken on behalf of the HSE by IDM Engineering Ltd, to determine the
credible failure modes and their direct effects as associated with typical single and dual
completion gas lift designs as utilised in the UK North Sea. The study has been undertaken with
the understanding that both wellhead configurations would be analysed under normal operating
conditions. No consideration was given for any installation, workover or abandonment activities
in connection with the wells.
To ensure that a typical wellhead and tree arrangement was modelled, vendor information in the
form of general arrangement drawings and associated information was reviewed from various
manufacturers. A representative single and dual completion model was generated from this
information in conjunction with the expertise associated within the project team.
In order to identify the key components and seal arrangements that required consideration
during the FMECA, the primary gas path was charted for both representative models. Each
model was then broken up into zones to help facilitate the FMECA. Primary, secondary and
tertiary barriers (where appropriate) were then identified.
With the aid of zone specific drawings the FMECA was carried out for each representative
model. The FMECA was carried out up to the side pocket mandrels in the production tubing for
completeness, however, the main focus of the study was above the dual bore upper packer
separating the upper and lower A annulus.
The results of the FMECA for the single and dual completion model are detailed in Appendix F
& E respectively.
Both FMECAs highlighted failure modes with the potential to leak injection gas to the
atmosphere. Further leak sources were identified arising from component/sealing arrangement
failures. These failures could in turn, cause injection gas to leak into the B annulus and C
annulus (single completion only).
iii
iv
CONTENTS
1. OBJECTIVE .............................................................................................................. 1
2. INTRODUCTION ...................................................................................................... 2
2.1. BACKGROUND ................................................................................................2
2.2. GAS LIFT ..........................................................................................................2
2.3. SINGLE AND DUAL COMPLETION GAS LIFT MODELS ..............................3
3. REPRESENTATIVE MODELS................................................................................. 5
3.1. MODEL DESCRIPTION ...................................................................................5
3.2. OPERATING PARAMETERS ..........................................................................6
3.3. MODEL BOUNDARIES ....................................................................................6
3.3.1. Dual Completion Model Boundaries ...................................................6
3.3.2. Single Completion Model Boundaries.................................................7
3.3.3. General Model Boundaries...................................................................7
4. METHODOLOGY ..................................................................................................... 8
4.1. ASSUMPTIONS ................................................................................................8
4.2. APPROACH......................................................................................................8
4.2.1. Representative Model Identification....................................................8
4.2.2. FMECA ....................................................................................................9
5. RESULTS ............................................................................................................... 12
5.1. DUAL COMPLETION FMECA .......................................................................12
5.2. SINGLE COMPLETION FMECA ....................................................................12
6. ACKNOWLEDGEMENTS....................................................................................... 13
7. REFERENCE LIST................................................................................................. 14
8. BIBLIOGRAPHY ..................................................................................................... 16
9. GLOSSARY OF TERMS ........................................................................................ 18
10. FIGURES ................................................................................................................ 19
APPENDIX A - PRIMARY GAS PATHS, WETTED CONTAINMENT ZONES,

PRIMARY AND SECONDARY BARRIERS DUAL COMPLETION. .............................. 23
APPENDIX B - PRIMARY GAS PATHS, WETTED CONTAINMENT ZONES,

PRIMARY AND SECONDARY BARRIERS SINGLE COMPLETION. .......................... 30
APPENDIX C - SEAL DESCRIPTIONS DUAL COMPLETION..................................... 35
APPENDIX D - SEAL DESCRIPTIONS SINGLE COMPLETION ................................. 48
APPENDIX E - DUAL COMPLETION FMECA RESULTS ............................................ 58
v
APPENDIX F - SINGLE COMPLETION FMECA RESULTS....................................... 146
APPENDIX G - DUAL COMPLETION MODEL DRAWINGS ...................................... 217
APPENDIX H - SINGLE COMPLETION MO DEL DRAWINGS ................................... 239
vi
1. OBJECTIVE
The objective of this study is to identify the failure modes that can lead to leakage of gas from
representative single and dual completion gas lift wells.
1
2. INTRODUCTION
2.1. BACKGROUND
As part of normal offshore oil and gas operations gas can be injected into the production tubing
of a well to assist in the recovery of the hydrocarbon fluids. A normal feature of this process is
the mass of pressurised hydrocarbon gas that resides in the well annulus. The well annulus
differs from typical topside process plant in that it does not have a means to vent or blowdown
its inventory of gas in an emergency, only to contain the gas within the annulus its self. The
mass of pressurised gas is typically in the range of 0.5 to 12 metric tonnes. The gas represents a
considerable hazard to platform personnel through fire and explosion. Of ultimate interest is the
magnitude of this risk. It must be noted that the hazard is created as a function of injecting gas
into the well annulus. The hazard does not originate directly from the reservoir. Many
continuous gas lift wells, will cease to flow if the supply of compressed gas from topside
compression is lost.
This study has been commissioned to identify typical failure modes associated with typical gas
lift configurations. Ultimately a representative frequency of gas leakage from a typical gas lift
well can be established.
The purpose of this study is to develop a representative single and dual completion gas lift well
and to identify typical failure modes associated with the equipment that is used in the well
configuration.
Results from this report will be used in future studies to identify failure and/or leakage rates for
equipment used in these types of wells.
2.2. GAS LIFT
Artificial lift is a commonly used methodology for enhancing reservoir recovery rates, gas lift
being by far the most utilised technique. The principle of gas lift is to simply supplement the
natural flow process of hydrocarbon fluids by adding additional gas into the produced fluid to
reduce the hydrostatic head component and hence, the back pressure on the formation.
There are essentially two different methods of gas lift, which are utilised offshore to enhance or
stimulate wells to ensure recover well fluids:
Continuous Gas Lift

Intermittent Gas Lift
Continuous gas lift is essential for wells, which under normal operating conditions would not
flow. This is due to an ageing well which is off plateau, as a result the reservoir pressure having
dropped considerably and/or increased viscosity of the hydrocarbon fluids.
The injection gas is normally supplied in a closed loop system, the gas is fed from the gas
separation, compression and drying (if necessary) process facilities to the well as required.
2
The lift gas is normally injected down the annulus and into the production tubing through the
side pocket mandrels. In certain circumstances, the gas is supplied via annulus tubing into the
lower well annulus and injected into the production tubing string as before.
The other less common concept is the intermittent gas lift system. This is used to produce low
volumes of liquid (<350 stb/d) from wells with low Bottom Hole Flow Pressure (BHFP) (<0.1
psi/ft). In this case, the liquid is produced in slugs by periodically opening a motorized flowline
valve and allowing the gas accumulated in the annulus to suddenly expand through the side
pocket mandrels to surface, bringing the accumulated liquids with it. A standing valve is often
used to prevent the gas from flowing into the formation.
2.3. SINGLE AND DUAL COMPLETION GAS LIFT MODELS
The models used in this study will assume that continuous gas lift is required to maintain the
flow of hydrocarbons under normal operating conditions.
There are four basic configurations of gas lift well used in the UK sector of the North Sea,
principally:
Single Completion
Dual Completion
Single Tree Dual-String Completion
Concentric Completion
In the first, and simpler configuration (Figure 1), gas is routed through a wellhead annular valve
and into the A annulus. The gas passes through the annulus downhole safety valve (DHSV)
located in the dual bore upper packer. The lower packer prevents gas from flowing further down
the annulus. Gas is injected into the production tubing at various depths between upper and
lower packers via the side packer mandrels. In this configuration the A annulus is completely
filled with gas from the tubing hanger to the lower side pocket mandrel. There is a facility for
isolating the upper and lower A annulus by closing the annulus DHSV.
The more complex dual completion (Figure 2) routes the gas through an annulus wing valve
mounted on the Christmas tree, down through the upper and lower master valves, and into the
annulus pipe work via an in line DHSV, to a point directly below the dual bore upper packer.
Gas is injected into the production tubing at various depths between upper and lower packers
via the side pocket mandrels. In this configuration and, under normal operation only the lower
A annulus space between the upper and lower packers is filled with gas. The upper A
annulus contains completion fluid.
(1)
The single tree dual-string completion is essentially a hybrid between the single and dual
completion designs. Similarly to the dual completion, annulus tubing is utilised to inject the gas
into the lower well annulus below the dual bore upper packer. This removes the inventory of gas
that would normally reside under the tubing hanger in a typical single completion design. The
gas itself would still be injected via the A annulus.
(1)(2)
The concentric design, which also uses a single tress essentially, is a modified single
completion design. Lift gas is injected through the tubing spool and down the annulus created
by the addit ional casing string within the production casing.
3
In order to represent the most onerous circumstances offshore, the single and dual completions
models are considered further in this study.
4
3. REPRESENTATIVE MODELS
3.1. MODEL DESCRIPTION
(7)
It is recognised that there are no standard representations of single or dual completion gas lift
wells. As a consequence there are many configurations in terms of well layout and equipment
design. Despite this, the general function of using gas to reduce the hydrostatic head on the
production tubing and promote a flow of well fluids remains the same. The variations in
configuration and design originate from three key areas.
1. Variability in basic design between the equipment manufacturers.

2. Variability of manufacturers design due to specification by operators.
3. Variability due to combining manufacturers equipment for the completion.
(4)
It is not the intent of this study to represent all permutations of well equipment and layout. It is
the intent to establish the associated failure modes with typical equipment configurations,
layouts and operating conditions.
To establish a representative model an industry-recognised standard has been applied to provide

a common guideline. We consider that the same standard would be applied to the majority of
completions found offshore. This results in a consistent link between a specific North Sea gas
lift well and the representative model of one.
The representative models for the single and dual completion models were developed from the
review of a variety of general arrangement drawings, taking into account the various
considerations discussed above.
Figure 1 represents a schematic of the single completion considered for this study, the following
features were considered:
Gas is injected through the connection to one of the A annulus valves.

The annular valve adjacent to the gas injection point is automated (fail closed), and
linked accordingly to the ESD system.
A none active-wing valve on the tree have been included for the annulus.
A compact wellhead design was considered as opposed to separate tubing spools.
9 5/8 casing is utilised for the production casing with a 7 liner downhole.
The production wing valve and upper master valve are automated (fail closed), and
linked accordingly to the ESD system.
Tie down bolts have been utilised for the tubing hanger to tubing spool.
A dual bore upper packer is utlised to separate the upper and lower annulus, with the
annulus DHSV installed within the packer body.
Figure 2 represents a schematic of the dual completion considered for this study, the following
features were considered:
None active-wing valves on the tree have been included for both annulus and
production.
A compact wellhead design was considered as opposed to separate tubing spools.
9 5/8 casing is utilised for the production casing with a 7 liner downhole.
A VR plug was modelled in the A annulus to model a particular case where there is
maintenance of an annular valve.
5
Both the annulus and production wing valves and upper master valves are automated
(fail closed), and linked accordingly to the ESD system.
Tie down bolts have been utilised for the tubing hanger to tubing spool.
A dual bore upper packer is utlised to separate the upper and lower annulus.
API standard 6A (seventeenth edition) has been used as the basis in the development of the
representative models.
The primary gas paths for the dual completion and single completion were then determined, key
items providing boundaries for each zone were described using consistent terminology.
(8) to (13)
In order to facilitate the FMECA, the schematic drawings were split down into general
area zones (see glossary) were described by linking these items in pairs (Appendix A & B).
Drawings were then generated for each zone for the dual completion detailing all major
components identified in Appendix A to facilitate the FMECA (Appendix G). Only the
drawings of the major differences between the dual and single models were generated for the
single completion arrangement as a result of duplication of similar components (Appendix H).
In order to distinguish between the different types of polymeric/elastomeric sealing

arrangements, for each zone the seals were colour coded according to the following regime.
Red Primary Active Seal

Blue Secondary Active Seal
Black Passive Seal
It should be noted that all metal to metal, threaded connections and components were
considered but not highlighted on the drawings in the same way as the sealing arrangements
above.
3.2. OPERATING PAR AMETERS
The model considers dry gas composed of 95% Methane and the balance being a combination
of Ethane and Propane. Gas well entry temperature is assumed circa 82C with an entry
pressure of 1500 psi.
The model represents the normal continuous producing condition. Well intervention, work-over,
inspection, test, maintenance operations, and any non-normal well conditions, including
initiating events that do not originate from the well model, do not form part of this study.
3.3. MODEL BOUNDARIES
3.3.1. Dual Completion Model Boundaries
The boundaries of the dual completion model are defined by:
The gas line check valve.

Tree assembly including all major valves up to secondary (and where applicable
tertiary) seal barriers.
Well head up to the secondary seal barriers.
6
Annulus assembly up to the side pocket mandrels.
Secondary seal barriers.
Production tubing up to the production wing valve.
3.3.2. Single Completion Model Boundaries
The boundaries of the single completion model are defined by:
The gas line check valve.

Well head up to the secondary seal barriers.
Annulus assembly up to the side pocket mandrels.
Secondary seal barriers.
Production tubing up to the production wing valve.
3.3.3. General Model Boundaries
The boundaries include some downhole components. This was because all secondary and
tertiary barriers were considered. Failure of some primary barriers downhole, result in annulus
spaces around the wellhead becoming wetted by gas. Subsequent barrier failure can then result
in loss of containment topsides.
7
4. METHODOLOGY
4.1. ASSUMPTIONS
The model assumes the following points: -
The production/operations group is responsible for well integrity under normal

operating conditions.
The individuals working on or around wellhead equipment are competent to do so.
The operator ensures suitable training and supervision (as appropriate) to all individuals
operating on or around the wellhead.
A permit to work system is in place, applied and operating satisfactorily.
The inspection function is effective in identifying non-normal events or situations.
Maintenance brings the equipment into the As Good As New (AGAN) condition.
The requirements of DCR Well examination Legislation are being effectively applied.
The initial suitability of the equipment is correct in terms of its design limits, and
capability to withstand any reasonably foreseeable non-normal events.
The well is performing within its specified operational parameters.
All seals and containment components are suitable for typical gas lift tree ratings ie
(3,000, 5,000, 6000 psi etc).
Lockdown bolts are used rather than a lockdown ring for the tubing hanger on both
models.
Gas lift is utilised to maintain continuous production.
Equipment is compatible with the well fluids.
Major accident events, misuse or negligence are not considered.
(6)
The downhole safety valves utilised in the single and dual completions are considered
to be tubing retrievable and not wireline retrievable.
4.2. APPROACH
4.2.1. Representative Model Identification
Initially the primary gas routing was established, from the point at which the gas enters the tree,
to a point where the gas and the well fluids leaves the tree.
8
The primary gas paths for the dual completion and single completion were then determined, key
items was described using a consistent terminology (Section 3).
General area zones were described by linking these items into pairs. In order to ensure that the
FMECA remains focused consideration has to be given to all sources of leakage; therefore there
was a degree of overlap when looking at each zone in turn. This is highlighted in the FMECA
results (Appendix E & F) in italics and ensures that there are no working joints (see glossary).
(14) to (18
Further examination of drawings was then undertaken to describe the primary, secondary
and tertiary barriers (see glossary) as described in Appendix A & B. Once the location of the
key mechanical joints and seals was complete, a description of each joint configuration and type
was made.
(3)(5)
Seal descriptions and details of the following segments are described in Appendix C & D
inclusive.
Primary gas paths.

Components.
Wetted containment zones.
Primary, Secondary and where applicable tertiary barriers.
Mechanical joints.
Seal configurations.
All elastomeric/polymeric seals were categorised into the following types as a result of sealing
arrangements being very different between manufacturers, even though the type of seal is
similar.
Compression
Parallel
Face
The preparation work was complete and the FMECA could commence.
4.2.2. FMECA
(19)
The FMECA was conducted in general accordance with BS 5760 part 5 (1991). Taking each
zone in turn, the mechanical joints forming the barriers between the well fluids and atmosphere,
(primary, secondary and tertiary) were examined in terms of their configuration, components
and function. Using engineering knowledge and experience, the credible failure modes, their
causes and their effect where discussed and recorded as appropriate.
4.2.2.1. Description Of FMECA Structure
A sample FMECA worksheet is detailed in Figure 3. The worksheet is made up of several

columns holding all the pertinent information discussed during the FMECA, a description of
each column is detailed below.
System This is a defined set of components or an assembly that forms part of the overall gas
lift well. The systems have been broken down and referenced as zones.
9
Sub system - The sub systems are the major component assemblies associated with each
zone. It is the sub systems that are subjected to the FMECA.
Function The function of each sub system is described in terms of its primary or foremost
role. There can be more than one function for each sub system.
Failure This provides an outline as to where the credible failures are likely to occur within
the sub system. This FMECA has focused on the mechanical joints and seal assemblies of the
sub systems. For example bonnet seal failure leads to one consideration as to the ways in
which the seal can fail.
Cause This outlines the most likely reasons leading to failure. There can be several effects
originating from a single cause. In the example of the bonnet seal then as one example, the
bolts may be incorrectly installed.
Effect Provides a description as to what is likely to occur to the mechanical joints and seal
assemblies if the cause manifests itself. In the example of bolts being incorrectly installed, there
may be several effects, depending upon either over tightening or under tightening the bolts.
Symptoms What evidence of the effect will exist? Would the symptom reveal the failure
immediately or over a period of time? Would it be visible or audible to an operator? Or would
the failure remain unrevealed perhaps for many years?
For example where a joint has been incorrectly made perhaps using wrong materia ls or
techniques, then it may remain undetected. The integrity of the joint is not to the design intent
and it may remain as a weak point that we are not aware of until failure occurs (if it occurs at
all).
Mitigation Prior to ranking the probability of occurrence, the normal or usual practices of
design, construction, installation, commissioning and operations need to be considered. Only the
primary mitigating factors are recorded. For example the use of ISO 9001 as a quality assurance
standard requires that many aspects of design, manufacture, inspection and test are considered
and formally managed. This does not guarantee that failures will not occur, but does provide
confidence that the probability of occurrence should be reduced. The integrity and effectiveness
of such standards, systems and procedures has not been considered.
4.2.2.2. Criticality Analysis
Using a qualitative approach, each failure consequence was ranked in terms of its local effect.
A single barrier primary seal failure that would result in a direct loss of containment is ranked as
a high criticality. Conversely, failure of a primary barrier that results in a secondary barrier
becoming wetted is considered to be less critical. The consequence is ranked at one of five
levels.
5 Full cross sectional area failure of a major barrier (seals or components) leading directly to
loss of containment.
4 Full cross sectional area failure of a minor barrier (seals or components) leading directly to
loss of containment.
3 Major seal failure, leading to loss of primary containment that should be detectable by an
operator or the F&G systems if a subsequent seal fails and containment is lost.
10
2 Part seal failure, leading to a loss of primary containment that is unlikely to be detectable by
an operator or the F&G systems if subsequent seals fail.
1 Minor Seal failure, (perished, weeping) leading to a loss of primary containment that would
wet the secondary barriers or cause a fugitive emission to atmosphere.
Using a qualitative approach, each failure was ranked in terms of its probability of occurrence,
when considering all assumptions of the model. The probability is ranked at one of five levels.
1 Highly improbable, not considered to be realistic.
2 Improbable, a rare one off event.
3 Possible, known to have occurred previously.
4 Probable, has been experienced on more than one occasion.
5 Frequent, is a normal or regular occurrence for the situation.
The criticality of each failure mode and effect was then detailed in the criticality section of
Figure 3 in the format consequence.probability. This enables the screening of the less critical
events and sets the seen for any future leak frequency analysis.
11
5. RESULTS
5.1. DUAL COMPLETION FMECA
The results of the FMECA for the dual completion model are detailed in Appendix E.
It can be noted that even though the dual completion zone drawings (Appendix G) cover zones
1 to 20, the FMECA only covered down to the side pocket mandrels in the production tubing.
This was carried out for completeness, the study was only concerned with any leakage in above
the dual bore upper packer. The results dictated that even though the original focus was purely
on the leakage of injection gas below the tubing hanger in the upper A annulus. There were
some expected failure modes leading to potential leaks to atmosphere from the xmas tree and
the wellhead configuration. Certain failure modes dictated leakage of injection gas into the B
annulus providing additional potential leak sources to atmosphere.
5.2. SINGLE COMPLETION FMECA
The results of the FMECA for the single completion model are detailed in Appendix F.
It was noted that even though the equipment was simpler in construction than that of the dual
completion, there were obvious similarities in the designs. As a result of this only the zones,
which were significantly different between the two completion designs, were completed
(Appendix H). Similarly to the dual completion the FMECA only covered down to the side
pocket mandrels in the production tubing, again for completeness. The single completion
pressurises both the upper and lower annulus as a result of injecting directly into the A annulus
under normal operating conditions. The results highlighted that certain components/sealing
arrangements in the dual completion model were secondary barriers, in the single completion
model the same items became primary barriers. The same as the dual completion, there were
some expected failure modes leading to potential leaks to atmosphere from the xmas tree and
the wellhead configuration. Certain failure modes dictated that injection gas could not only leak
into the B annulus but also the C annulus providing additional potential leak sources to
atmosphere.
12
6. ACKNOWLEDGEMENTS
The authors would like to acknowledge the individuals who contributed to this study:
Dr M Croft of The Robert Gordon University, Mr. J Da Costa of Hancoss Ltd. and
Mr H Hopper of Subsea Well Technology Ltd.
13
7. REFERENCE LIST
1. BLOWOUT RISK ANALYSIS OF GAS-LIFT COMPLETIONS

Society of Petroleum Engineers Paper
Report no.: SPE 20916, D D Grassick, P S Kallos, S Dean and S D J King, May 1992
2. DOWN HOLE SAFETY VALVE FOR CONCENTRIC COMPLETION

Report No,: SPE 16536/1, J L Geyelin., 1987
3. THE IMPORTANCE OF CORRECT RUNNING AND HANDLING PROCEDURES FOR

PREMIUM TUBULAR GOODS
Report No,: SPE 16107, D E Walstad and D W Crawford, March 1987
4. PROCEDURES AND PRACTICES OF DUAL-COMPLETION DESIGN IN ABU DHABI

Society of Petroleum En gineers Paper
Report No,: SPE 17983, R F Gabort & G J Ghnelm, February 1997
5. EVALUATION OF PREMIUM TAPERED THREADED CONNECTIONS USING

FINITE ELEMENT ANALYSIS AND FULL-SCALE TESTING
Report No,: SPE 23904, A Hilbert & I A Kalli, February 1992
6. RADICAL SOLUTIONS REQUIRED: COMPLETIONS WITHOUT PACKERS AND

DOWNHOLE SAFETY VALVES CAN BE SAFE
Report No,: SPE 56934, C J Durham & C A Oaveley, September 1999
7. RISK ANALYSIS OF SINGLE AND DUAL-STRING GAS-LIFT COMPLETIONS

Report No,: SPE 19281, D Grassick, P S Kallos, I J A Jardine & F J Doogan, 1990
8. Y BLOCK XMAS TREE & WELLHEAD LAYOUT, GAS LIFT SYSTEM

FMC
Drawing No.: SD-4333-65
9. XMAS TREE & WELLHEAD LAYOUT, GAS LIFT SYSTEM

FMC
Drawing No.: SD-4333-70
10. SECTIONAL LAYOUT PLATFORM, WELLHEAD AND TREE ASSEMBLY

FMC
Drawing No.: DL-0931
11. WELLHEAD DUAL COMPLETION

FMC
Drawing No.: SK-1587
14
12. WELLHEAD AND XMAS TREE, STANDARD COMPLETION
Cooper Cameron
Drawing No.: SK-177568-01
13. PLATFORM DRILLED PRODUCTION WELLHEAD ASSEMBLY DRAWING

Cooper Cameron
Drawing No.: LO-021811-01
14. CAMERON API GATE VALVES

Cooper Cameron
1997
15. 1999-2000 CAMERON CATELOG

Cooper Cameron
1999
16. CAMERON MBO ULTIBOWL WELLHEAD SYSTEM

Cooper Cameron
1998
17. SSMC WELLHEAD SYSTEM

Cooper Cameron
1998
18. CAMERON CONVENTIONAL SURFACE WELLHEADS

Cooper Cameron
1998
19. RELIABILITY OF SYSTEMS, EQUIPMENT AND COMPONENTS. GUIDE TO

FAILURE MODES, EFFECTS AND CRITICALITY ANALYSIS (FMEA AND FMECA)
British Standards Institue
Document No.: BS 5760 part 5, 1991.
15
8. BIBLIOGRAPHY
1. COMPLETION DESIGN MANUAL

BP Exploration
Vol 1, & 2
2. BP Exploration, Forties Artificial Lift Project, Shallow Gas Lift Course, 1989.
3. IN SITU MACHINING AND REPAIR OF CAMERON FC STYLE XMAS TREES

Society of Petroleum Engineers
Drawing No.: SPE 19274/1, Bryne D, Terry Dr P
4. SHORT COURSE ON GAS LIFT PRINCIPLES AND EQUIPMENT.

Camco Training Department
Study Guide, 1991
5. COMPLETION PRODUCTS
Halliburton
Second Edition.
6. MSC DRILLING ENGINEERING, MODULE 9, COMPLETION TECHNOLOGY.

The Robert Gordon University
7. WELL ENGINEERING DISTANCE LEARNING PACKAGE WELLHEADS

Shell Expro
Version 1.00
8. WELL ENGINEERING DISTANCE LEARNING PACKAGE COMPLETIONS

Shell Expro
Version 1.00
9. WELL SERVICES CO-ORDINATOR COMPETENCE COURSE, MODULE 1

Shell Expro
Version 3, Jan 1996
10. PRODUCTION OPERATIONS WELL SERVICES GUIDE, ASPECTS OF WELL

COMPLETION DESIGN,
Shell International Exploration and Production B.V
Document No.: EP 95-1811, Vol 2, Nov 1995.
11. SPECIFICATION FOR WELLHEAD AND CHRISTMAS TREE EQUIPMENT

American Petroleum Institute
Document No.: API 6A 17th Ed , Nov 1999.
12. VAM CATALOG

Sumitomo Metals
No. 940
13. SUMITOMO PRODUCTS FOR THE OIL AND GAS INDUSTRIES.

Sumitomo Metals
16
14. HIGH ALLOY OCTG, NEW SM SERIES
Sumitomo Metals
15. TUBULAR CONNECTION DATA BOOK

Weatherford
1992
17
9. GLOSSARY OF TERMS
Term Description
Primary Barrier Equipment or sealing arrangement providing
containment, which is in direct contact with either gas
or hydrocarbon fluids, under normal operating
conditions.
Secondary Barrier Equipment or sealing arrangement providing
containment, in the event of a primary barrier failure
under normal operating conditions.
Tertiary Barrier Equipment or sealing arrangement providing
containment, in the event of a primary and secondary
barrie r failure under normal operating conditions.
Zone Each model is broken down into discrete manageable
areas (zones) so that a detailed FMECA can be carried
out.
Working Joint A joint or section, which defines the boundary of a
zone. If the joint or section is not included within the
adjacent zone, the FMECA would have not considered
all permutations.
18
10. FIGURES
CONTENTS
Page
Figure 1 Single Completion Gas Lift Well Schematic .......................................................... 20

Figure 2 Dual Completion Gas Lift Well Schematic ............................................................ 21
Figure 3 Sample FMECA Worksheet.................................................................................. 22
19
Figure 1 Single Completion Gas Lift Well Schematic
20
Figure 2 Dual Completion Gas Lift Well Schematic
21
SYSTEM SUB-SYSTEM FUNCTION FAILURE CAUSE EFFECT SYMPTOMS MITIGATION CRITICALITY
Figure 3 Sample FMECA Worksheet
22
APPENDIX A
PRIMARY GAS PATHS, WETTED CONTAINMENT ZONES,

PRIMARY AND SECONDARY BARRIERS DUAL COMPLETION
23
MAJOR COMPONENTS OF THE DUAL COMPLETION MODEL USING A DUAL
BLOCK TREE ARRANGEMENT.
Primary gas path
1.1 Gas line check valve

1.2 Annulus wing valve
1.3 Annulus upper master valve
1.4 Annulus lower master valve
1.5 Annulus bore tubing hanger
1.6 Annulus tubing & annulus tubing nipples
1.7 Annulus downhole safety valve
1.8 Annulus tubing
1.9 Annulus bore dual bore upper packer
1.10 Lower well annulus
1.11 Side Pocket Mandrels
1.12 Production tubing
1.13 Production bore dual bore upper packer
1.15 Production downhole safety valve
1.16 Production tubing and nipples
1.17 Production bore tubing hanger
1.18 Production lower master valve
1.19 Production upper master valve
1.20 Production wing valve
HYDROCARBON (WETTED) CONTAINMENT ZONES (WELL IN PRODUCTION)
Zone 1.1 1.2
Primary barrier components:
Gas check valve

Connecting pipework
Annulus wing valve
Secondary barrier components None
Zone 1.2 1.3
Annulus wing valve

Annulus non-active wing valve,
Annulus bore,
Annulus upper master valve,
Annulus swab valve,
Chemical injection valve.
24
Secondary barrier components:
Tree cap
Zone 1.3 1.4
Annulus upper master valve

Annulus bore
Annulus lower master valve
Zone 1.4 1.5
Annulus lower master valve,

Annulus bore,
Annulus bore tubing hanger
Tubing spool to tree outer flange seal,

Tubing spool downhole chemical injection line,
Tubing spool downhole chemical injection point packing gland & tertiary outer block
assembly,
Tubing hanger tie down bolts and seals,
Tubing spool downhole safety valve control packing gland & tertiary outlet block
assembly,
Tubing spool to tubing hanger seal,
Tubing hanger downhole safety valve control upper packing gland,
Tubing hanger downhole chemical injection point upper packing gland.
Tubing spool downhole safety valve control line.
Zone 1.5 1.6
Annulus bore Tubing hanger,

Annulus tubing & annulus tubing nipples
Secondary barrier components
Production casing,
Production casing hanger seal to tubing spool,
Upper annulus tubing spool inner valve,
Upper annulus tubing spool outer valve,
Upper annulus tubing spool monitor and vent assembly,
25
VR plug & tertiary valve(s),
Tubing hanger seal to tubing spool,
Tubing spool downhole safety valve control line,
Tubing hanger downhole safety valve control line lower packing gland,
Tubing hanger downhole chemical injection line lower packing gland,
(Possible connection between tubing spool and casing spool.)
B and C casing spool valves and associated equipment form tertiary barriers, and require
primary and secondary failures before being subjected to gas. This would require a triple
jeopardy event to realise a leak to the wellhead areas. These barriers are not considered
further.
Zone 1.6 1.7
Annulus tubing & annulus tubing nipples

Annulus downhole safety valve.
Secondary Barrier Components - As per details for zone 1.5 1.6
Zone 1.7 1.8
Annulus downhole safety valve

Annulus tubing.
Zone 1.8 1.9
Annulus tubing
Annulus bore dual bore upper packer.
Zone 1.9 1.11
Annulus bore dual bore upper packer

Lower well annulus - 9 5/8 Casing
Side Pocket Mandrels
Chemical Injection line
Secondary barrier components-
B annulus (bore of intermediate casing)

Intermediate casing hanger to casing spool seal
26
Production casing hanger seal to the casing spool
B annulus valve & upper annulus spool monitor and vent assembly
VR plug
Tertiary Barrier Components:
C annulus
Tertiary valve(s)
Zone 1.11 1.12
Side Pocket Mandrels

Production tubing
Secondary barrier components Not applicable gas already in annulus as function of gas lift.
Zone 1.12 1.13
Production tubing,
Production bore dual bore upper packer
Secondary barrier components Not applicable gas already in annulus as function of gas lift.
Zone 1.13 1.14
Production bore dual bore upper packer,

Production tubing.
Secondary barrier components As per details for zone 1.5 1.6
Zone 1.14 1.15
Production tubing,
Production downhole safety valve
Zone 1.15 1.16
Production downhole safety valve,

Production tubing and nipples.
27
Zone 1.16 1.17
Production tubing and nipples,

Production bore tubing hanger.
Zone 1.17 1.18
Production bore tubing hanger,

Production bore,
Production lower master valve.

Tubing spool downhole chemical injection line packing gland & tertiary outer block
assembly,
assembly,
Tubing hanger downhole safety valve control packing gland,
Tubing hanger downhole chemical injection point packing gland,
Zone 1.18 1.19
Production lower master valve,

Production bore,
Production upper master valve.
Zone 1.19 1.20
Production upper master valve,

Production bore,
SWAB valve,
Chemical injection valve,
Production wing valve,
Production non-active wing valve.
28
Tree cap
29
APPENDIX B
PRIMARY GAS PATHS, WETTED CONTAINMENT ZONES,

PRIMARY AND SECONDARY BARRIERS SINGLE
COMPLETION
30
MAJOR COMPONENTS OF THE SINGLE COMPLETION MODEL USING A SINGLE
BLOCK TREE ARRANGEMENT
Primary gas path
2.1 Gas line check valve

2.2 Tubing spool side valve
2.3 Upper well annulus
2.4 Annulus downhole safety valve in the dual bore packer
2.5 Lower well annulus
2.6 Side Pocket Mandrels
2.7 Lower production tubing
2.9 Upper production tubing
2.10 Production downhole safety valve
2.13 Production lower master valve
2.14 Production upper master valve
2.15 Production wing valve
HYDROCARBON (WETTED) CONTAINMENT ZONES (WELL IN PRODUCTION)
Zone 2.1 2.2
Gas check valve,

Connecting pipework,
Tubing spool side valve.
Zone 2.2 2.3
Tubing spool side valve,

Tubing spool to casing hanger seal,
Production tubing to tubing hanger seal,
Upper well annulus,
Tubing hanger body,
Production tubing,
Upper annulus tubing spool and monitoring assembly.
31
Tubing hanger tie down bolts,

Tubing hanger down hole safety valve control line upper packing gland,
Tubing hanger down hole chemical injection line upper packing gland,
Tubing hanger downhole safety valve control packing gland & tertiary block assembly,
Tubing hanger downhole chemical injection packing gland & tertiary block assembly,
Zone 2.3 2.4
Upper well annulus,

Annulus downhole safety valve,
Production tubing,
Secondary barrier components -
B Annulus Casing,
B Annulus Tubing Spool Valves,
B annulus tubing spool to casing hanger seal.
Zone 2.4 2.6

Dual bore upper packer,
Lower well annulus (9 5/8"),
Side Pocket Mandrels (SPM),
Chemical Injection Line.
B annulus (bore of intermediate casing),

Intermediate casing hanger to casing spool seal,
Tertiary seal is the C annulus,
Production casing hanger seal to the casing spool,
B annulus valve & upper annulus spool monitor and vent assembly.
Zone 2.6 2.8
Side packer mandrels,

Lower production tubing,
Production bore dual bore upper packer
32
Not Applicable (gas already in annulus as a function of gas lift)
Zone 2.8 2.9

Upper production tubing.
Zone 2.9 2.10
Upper production tubing,

Production downhole safety valve.
Zone 2.10 2.11

Zone 2.11 2.12

Tubing hanger.
33
Zone 2.12 2.13
Tubing hanger,
Production bore,

assembly,
assembly,
Tubing hanger downhole safety valve control packing gland,
Tubing hanger downhole chemical injection point packing gland.
Zone 2.13 2.14
Production lower master valve

Production bore,
Production upper master valve
Zone 2.14 2.15

Production bore,
SWAB valve,
Chemical injection valve
Production wing valve
Tree Cap
34
APPENDIX C
SEAL DESCRIPTIONS DUAL COMPLETION
35
SEAL DESCRIPTIONS FOR EACH ZONE - DUAL COMPLETION
Zone 1.1 1.2
Primary barrier components: -
Gas check valve,

Annulus wing valve.
1.0 Gas Check Valve (Fail Closed) - (open)

1.1 Bonnet Seal (compression, bolts)
1.2 Ring gasket (compression, bolts)
2.0 Connecting Pipework

2.1 Ring Gasket (compression, bolts)
3.0 Annulus Wing Valve (Fail Closed) Floating Gate (open)

3.2 Stem Seal (parallel, screw cap)
3.3 Grease fitting (compression screw thread)
Secondary barrier components: None
Zone 1.2 1.3
Annulus wing valve,

Annulus non-active wing valve,
Annulus bore,
Annulus swab valve,
Chemical injection valve.
1.0 Annulus Wing Valve (Fail Closed) Floating Gate (open)

2.0 Annulus Bore

2.1 Tree Block
3.0 Annulus Upper Master Valve (Fail Closed) Floating Gate (open)
4.0 Annulus SWAB Valve (Manual) Floating Gate (closed)

4.1 Gate Seal (face, pressure)
4.2 Seat Seal (face, pressure)
36
4.4 Back Seat (face, pressure) - ineffective
4.5 Stem seal (grease fitting secondary barrier)
5.0 Chemical Injection Valve (open)

5.1 Single Cartridge Dual Check Valve (metal to metal nose joint, threaded)
5.2 CI Valve - Bonnet Assembly (screw cap, threaded)
5.3 CI Valve - Stem packing
5.4 CI Valve - Ring Gasket (compression, bolts)
6.0 Annulus non-active wing va lve (Manual) Floating Gate (closed)

Secondary barrier components: Tree cap
7.0 Tree Cap

7.1 Tree Cap (parallel, screw cap)
7.2 Test Port (compression, screw threads)
Zone 1.3 1.4

Annulus bore,
Annulus lower master valve.
1.0 Annulus Upper Master Valve (Fail Closed) Floating Gate (open)
2.1 Annulus Bore

2.1 Tree Body
3.0 Annulus Lower Master Valve (Manual) Floating Gate (open)

Zone 1.4 1.5
Annulus lower master valve,

Annulus bore,
Annulus bore tubing hanger.
37
1.0 Annulus Lower Master Valve (Manual) Floating Gate (open)
2.0 Annulus Bore

2.1 Tree Body
2.2 Bore Sleeve (parallel, main fixing bolts for tree)

3.1 Hanger Body

assembly,
assembly,
Tubing hanger downhole safety valve control upper packing gland,
Tubing hanger downhole chemical injection point upper packing gland,
4.0 Tubing spool to tree outer flange seal

4.1 Ring Gasket (compression, main fixing bolts for tree)
5.0 Tubing spool downhole chemical injection line

5.1 Chemical Injection Line Integrity
6.0 Tubing spool downhole chemical injection point packing gland & tertiary outer block
assembly
6.1 Packing Gland (tertiary seal - outer block assembly seal (compression, bolts), Gland to
Line Seal)
6.2 Gland to Tubing Spool Seal
7.0 Tubing hanger tie down bolts and seals

7.1 Bolt Seals (Compression, screw)
8.0 Tubing spool downhole safety valve control packing gland & tertiary outlet block
assembly
Line Seal)
9.0 Tubing spool to tubing hanger seal

9.1 Tubing spool annulus Seal (parallel, lockdown)
10.0 Tubing hanger downhole safety valve control line upper packing gland
10.1 Tubing hanger downhole safety valve control line upper packing gland (compression,
screw)
38
11.0 Tubing hanger downhole chemical injection line upper packing gland
11.1 Tubing hanger downhole chemical injection point upper packing gland (compression,
screw)
12.0 Tubing spool downhole safety valve control line

12.1 Downhole safety valve control line Integrity
Zone 1.5 1.6
Annulus bore - tubing hanger,

Annulus tubing & annulus tubing nipples.

1.1 Tubing Hanger Body
1.2 Premium Tapered Tubing Connection

2.1 Tubing
2.2 Annulus Tubing Nipples
Production casing,
Production casing hanger seal to tubing spool,
Upper annulus tubing spool inner valve,
Upper annulus tubing spool outer valve,
VR plug & tertiary valve(s),
Tubing hanger seal to tubing spool,
(Possible connection between tubing spool and casing spool).
B and C casing spool valves and associated equipment form tertiary barriers, and require
primary and secondary failures before being subjected to gas. This would require a triple
jeopardy event to realise a leak to the wellhead areas. These barriers are not considered further.
3.0 Production casing

3.1 Production Pipe
3.2 Premium Casing Threads
4.0 Production casing hanger seal to tubing spool

4.1 Production casing hanger seal to casing spool (parallel, lockdown)
5.0 Upper annulus tubing spool inner valve (Manual) (open) well producing, open
valves to take a sample
39
5.4 Grease fitting (compression, screw thread)
6.0 Upper annulus tubing spool monitor and vent assembly

6.2 Needle Valve (compression, screw)
7.0 VR plug & tertiary valve(s)

7.1 VR Plug (parallel, screw) (tertiary seal manual gate valves)
8.0 Tubing hanger seal to tubing spool



11.0 Tubing hanger downhole safety valve control line lower packing gland
11.1 Tubing hanger downhole safety valve control line lower packing gland (compression,
screw)
12.0 Tubing hanger downhole chemical injection line lower packing gland
12.1 Tubing hanger downhole chemical injection point lower packing gland (compression,
screw)
Zone 1.6 1.7
Annulus tubing & annulus tubing nipples,

Annulus downhole safety valve.

1.1 Annulus Tubing
2.0 Annulus downhole safety valve (ADHSV Fail Closed) - (open)

2.1 Premium tapered tubing connection
2.2 Valve body
2.3 Valve piston/control line seal
Secondary barrier components:- As per details for zone 1.5 1.6
Zone 1.7 1.8

Annulus tubing.
40
1.0 Annulus downhole safety valve (ADHSV Fail Closed) - (open)
1.2 Valve body
2.0 Annulus Tubing

2.1 Annulus Tubing
Secondary barrier components: - As per details for zone 1.5 1.6
Zone 1.8 1.9
Annulus tubing,
Annulus bore dual bore upper packer,
Dual bore upper packer chemical injection line upper packing gland.
1.0 Annulus Tubing

1.1 Annulus Tubing
1.2 Premium Tapered Tubin g Connection

2.1 Packer body
Secondary barrier components: - As per details for zone 1.5 1.6

4.0 Dual bore upper packer chemical injection line upper packing gland
4.1 Dual bore upper packer chemical injection point upper packing gland (compression,
screw)
Zone 1.9 1.11
Annulus bore dual bore upper packer,

Chemical injection line,
Lower well annulus,
Side Pocket Mandrels.

1.1 Packer body
2.0 Lower well annulus 9 5/8 Casing

2.1 Annulus Tubing
41
3.0 Side Pocket Mandrels (SPM)

3.1 SPM body
3.2 Orifice Valve (parallel)
4.0 Chemical Injection Line

4.1 Chemical Injection Line pipe
4.2 Chemical injection line connection at bottom of dual bore upper packer
Secondary barrier components: -
B annulus (bore of intermediate casing)

Intermediate casing hanger to casing spool seal
Tertiary seal is the C annulus
Production casing hanger seal to the casing spool
B annulus valve & upper annulus spool monitor and vent assembly
VR plug & tertiary valve(s)
Zone 1.11 1.12
Side Pocket Mandrels,

Production tubing..

1.1 SPM body

2.1 Production Tubing
Not applicable gas already in annulus as function of gas lift.
Zone 1.12 1.13
Production tubing,
Production bore dual bore upper packer.

1.1 Tubing

2.1 Packer body
42
Not applicable gas already in annulus as function of gas lift.
Zone 1.13 1.14

Production tubing.

1.1 Packer body

2.1 Tubing
Zone 1.14 1.15
Production tubing,

1.1 Tubing
2.0 Production downhole safety valve (Fail Closed) - (open)

2.2 Valve body
Zone 1.15 1.16


1.2 Valve body
43
2.2 Production Tubing Nipples
Zone 1.16 1.17

Production bore tubing hanger.

1.2 Production Tubing Nipples

Zone 1.17 1.18
Production bore tubing hanger,

Production bore,

2.0 Production bore

2.2 Tree Body
3.0 Production Lower Master Valve (Manual) Floating Gate (open)


Tubing spool downhole chemical injection line packing gland & tertiary outer block
assembly,
44
assembly,
Tubing hanger downhole safety valve control line upper packing gland,
Tubing hanger downhole chemical injection point upper packing gland,


6.0 Tubing spool downhole chemical injection line packing gland & tertiary outer block
assembly
Line Seal)

assembly
Line Seal)

9.1 Tubing spool production Seal (parallel, lockdown)
10.1 Tubing hanger downhole safety valve control upper packing gland (compression,
screw)
screw)

Zone 1.18 1.19
Production lower master valve,

Production bore,
Production upper master valve.
1.0 Production lower master valve (Manual) Floating Gate (open)

45
2.0 Production bore

2.1 Tree Body
3.0 Production upper master valve (Fail Closed) Floating Gate (open)
Zone 1.19 1.20
Production upper master valve,

Production bore,
Swab valve,
Chemical injection point,
Production wing valve,
1.0 Production Wing Valve (Fail Closed) Floating Gate (open)

2.0 Production Bore

2.1 Tree Block
3.0 Production Upper Master Valve (Fail Closed) Floating Gate (open)
4.0 Production SWAB Valve (Manual) Floating Gate (closed)


6.0 Production non-active wing valve (Manual) Floating Gate (closed)

46
Tree cap.
7.0 Tree Cap

47
APPENDIX D
SEAL DESCRIPTIONS SINGLE COMPLETION
48
SEAL DESCRIPTIONS FOR EACH ZONE - SINGLE COMPLETION
Zone 2.1 2.2
Gas check valve,

1.0 Gas Check Valve (Fail Closed) - (open)

1.2 Ring gasket (compression, bolts)
2.0 Connecting Pipework

3.0 Tubing Spool Side Valve (Fail Closed) Floating Gate (open)
Zone 2.2 2.3

Tubing spool to casing hanger seal,
Production tubing to tubing hanger seal,
Upper well annulus,
Tubing hanger body,
Production tubing,
Upper annulus tubing spool and monitoring assembly.
1.0 Tubing Spool Side Valve (Fail Closed) Floating Gate (open)

3.0 Tubing spool to casing hanger seal

3.1 Tubing spool to casing hanger seal (parallel, lockdown)
49
4.0 Production tubing to tubing hanger seal
4.1 Premium Threaded Connection
5.0 Upper well annulus

5.1 Tubing
6.0 Tubing hanger body

6.1 Hanger body
7.0 Tubing hanger downhole safety valve control line lower packing gland (x2)
7.1 Tubing hanger downhole safety valve control line lower packing gland (compression,
screw)
8.0 Tubing hanger downhole chemical injection line lower packing gland
8.1 Tubing hanger downhole chemical injection line lower packing gland (compression,
screw)



12.0 Tubing spool side valve (Manual) (open) well producing, open valves to take a
sample
13.0 Upper annulus tubing spool and monitoring assembly

Tubing hanger tie down bolts,

Tubing hanger downhole safety valve control line upper packing gland,
Tubing hanger downhole chemical injection line upper packing gland,
Tubing hanger downhole safety valve control packing gland & tertiary block assembly,
Tubing hanger downhole chemical injection packing gland & tertiary block assembly,
14.0 Tubing hanger tie down bolts

50
screw)
screw)

18.0 Tubing hanger downhole safety valve control packing gland & tertiary block assembly
Line Seal)
19.0 Tubing hanger downhole chemical injection packing gland & tertiary block assembly
Line Seal)


Zone 2.3 2.4
Upper well annulus,

Production tubing,
1.0 Upper well annulus production casing

2.0 Annulus downhole safety valve (Fail Closed) - (open)

2.1 Valve Body
2.2 Valve piston / control line seal (parallel)

Secondary barrier components -
B Annulus Casing,
B Annulus Tubing Spool Valves,
B annulus tubing spool to casing hanger seal.
51
4.0 Intermediate Casing B Annulus
4.1 Intermediate Casing
5.0 B Annulus Tubing Spool Valves (Manual) (open) well producing, open valves to take
a sample
6.0 Upper annulus tubing spool monitor and vent assembly

7.0 B annulus tubing spool to casing hanger seal

7.1 Tubing spool to casing hanger seal (parallel, lockdown)
Zone 2.4 2.6

Lower well annulus (9 5/8"),
Side Pocket Mandrels (SPM),
Chemical Injection Line.
1.0 Annulus downhole safety valve in the dual bore packer (Fail Closed) - (open)
1.1 Valve Body
2.0 Dual bore upper packer

2.1 Packer body
3.0 Lower well annulus (9 5/8")


4.1 SPM body
5.0 Chemical Injection Line

5.1 Chemical Injection Line pipe
5.2 Chemical injection line connection at bottom of dual bore upper packer
52
B annulus (bore of intermediate casing),

Intermediate casing hanger to casing spool seal,
Tertiary seal is the C annulus,
Production casing hanger seal to the casing spool,
B annulus valve & upper annulus spool monitor and vent assembly.
Zone 2.6 2.8
Side packer mandrels,

Lower production tubing,
Dual bore upper packer

1.1 SPM body
2.0 Lower production tubing

2.1 Tubing
3.0 Dual bore upper packer

3.1 Packer body
Zone 2.8 2.9

Upper production tubing.

1.1 Packer body

2.1 Tubing
53
Zone 2.9 2.10
Upper production tubing,


1.1 Tubing

2.1 Valve Body
Zone 2.10 2.11


1.1 Valve Body

2.1 Tubing
Zone 2.11 2.12

Tubing hanger.

1.1 Tubing
54
2.0 Tubing hanger
Zone 2.12 2.13
Tubing hanger,
Production bore,
1.0 Tubing hanger

2.0 Production bore

2.2 Tree Body
3.0 Production Lower Master Valve (Manual) Floating Gate (open)


assembly,
Tubing spool downhole safety valve control line packing gland & tertiary outlet block
assembly,
Tubing hanger downhole safety valve control line packing gland,
Tubing hanger downhole chemical injection point packing gland.


6.0 Tubing spool downhole chemical injection point packing gland & tertiary outer block
assembly
Line Seal)
55
assembly
8.1 Packing Gland (tertia ry seal - outer block assembly seal (compression, bolts), Gland to
Line Seal)

screw)
11.0 Tubing hanger downhole chemical injection point upper packing gland
screw)

Zone 2.13 2.14
Production lower master valve

Production bore,
1.0 Production lower master valve (Manual) Floating Gate (open)

2.0 Production bore

2.1 Tree Body
3.0 Production upper master valve (Fail Closed) Floating Gate (open)
Zone 2.14 2.15

Production bore,
56
SWAB valve,
Chemical injection valve
Production wing valve
1.0 Production Wing Valve (Fail Closed) Floating Gate (open)

2.0 Production Bore

2.1 Tree Block
3.0 Production Upper Master Valve (Fail Closed) Floating Gate (open)
4.0 Production SWAB Valve (Manual) Floating Gate (closed)


Tree cap
7.0 Tree Cap

57
APPENDIX E
58
Designers and
Material specification of manufacturers to have
To contain the gas
seal incompatible with ISO quality systems in
1. Gas Check Valve - within the tree on loss of Bonnet seal leakage Seal incorrectly Gradually leaking over
Zone 1.1 to 1.2 body causing place. Offshore 2.2
Primary Barrier pressurisation in the (metal to metal joint) specified time
differential cell to be supervisors checks and
upstream pipework.
setup. balances i.e. permit to
work system etc.
Designers and
Dimensions, chemical
manufacturers to have
To contain the gas and mechanical
ISO quality systems in
1. Gas Check Valve - within the tree on loss of Bonnet seal leakage Wrong seal taken from properties similar to
Zone 1.1 to 1.2 N one place. Offshore 2.2
Primary Barrier pressurisation in the (metal to metal joint) stores actual specification,
supervisors checks and
upstream pipework. therefore no immediate
balances i.e. permit to
effect.
work system etc.
To contain the gas Tree has been operating

1. Gas Check Valve - within the tree on loss of Bonnet seal leakage Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.1 to 1.2 None. 2.2
Primary Barrier pressurisation in the (metal to metal joint) specified specified in design initial teething problems
upstream pipework. have been ironed out.
Employ competent
individuals and
appropriate supervision
To contain the gas
is available.
1. Gas Check Valve - within the tree on loss of Bonnet seal leakage Seal incorrectly
Zone 1.1 to 1.2 Effective seal not made Gas leak around seal 2.1
Primary Barrier pressurisation in the (metal to metal joint) installed
upstream pipework.
Pressure tested after
envelope broken.
To contain the gas Employ competent

Bolts installed
1. Gas Check Valve - within the tree on loss of Bonnet seal leakage Sealing arrangement individuals and
Zone 1.1 to 1.2 incorrectly - bolts Joint integrity reduced 3.3
Primary Barrier pressurisation in the (metal to metal joint) unevenly energised appropriate supervision
unevenly tensioned
upstream pipework. is available.
Designers and
To contain the gas
Bolts installed ISO quality systems in
1. Gas Check Valve - within the tree on loss of Bonnet seal leakage
Zone 1.1 to 1.2 incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
Primary Barrier pressurisation in the (metal to metal joint)
grade of bolt fitted supervisors checks and
upstream pipework.
work system etc.
59

Bolts installed
1. Gas Check Valve - within the tree on loss of Bonnet seal leakage Seal distortion leading to individuals and
Zone 1.1 to 1.2 incorrectly - bonnet over Joint integrity reduced 2.3
Primary Barrier pressurisation in the (metal to metal joint) progressive leakage. appropriate supervision
tensioned
Employ competent
individuals and
To contain the gas
Bolts installed appropriate supervision
1. Gas Check Valve - within the tree on loss of Bonnet seal leakage Instantaneous leak from
Zone 1.1 to 1.2 incorrectly - bonnet Joint integrity reduced is available. 2.3
Primary Barrier pressurisation in the (metal to metal joint) bonnet
under tensioned
upstream pipework.
envelope broken.
To contain the gas

Possible detection by
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Bolts loosen off in
Zone 1.1 to 1.2 Partial leakage of gas Gas release plant operators and/or 2.3
Primary Barrier pressurisation in the Seal service
F&G system
upstream pipework.
To contain the gas

Catastrophic failure of Appropriate support for
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Excessive vibration on
Zone 1.1 to 1.2 Fatigue failure of bolts one or more bolts after a piping as per pipe stress 3.3
Primary Barrier pressurisation in the Seal pipework
period of time. analysis.
upstream pipework.
To contain the gas

Thermal/mechanical Catastrophic failure of Appropriate piping
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Displacement from
Zone 1.1 to 1.2 gradients induce fatigue one or more bolts after a design as per pipe stress 3.3
Primary Barrier pressurisation in the Seal normal relative position
on bolts period of time. analysis.
upstream pipework.
Designers and
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Wrong seal taken from properties similar to
Zone 1.1 to 1.2 None place. Offshore 2.2
Primary Barrier pressurisation in the Seal stores actual specification,
effect.
work system etc.
Designers and
To contain the gas
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Seal incorrectly Gradually increasing
Primary Barrier pressurisation in the Seal specified leak over time.
upstream pipework.
work system etc.
60

1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.1 to 1.2 None 2.2
Primary Barrier pressurisation in the Seal specified specified in design initial teething problems
Employ competent
individuals and
To contain the gas
is available.
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Seal incorrectly
Zone 1.1 to 1.2 Effective seal not made Gas leakage around seal 2.1
Primary Barrier pressurisation in the Seal installed
upstream pipework.
envelope broken.

Bolts installed
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Sealing arrangement individuals and
Primary Barrier pressurisation in the Seal unevenly energised appropriate supervision
unevenly tensioned
Designers and
To contain the gas
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket
Zone 1.1 to 1.2 incorrectly - incorrect Joint integrity reduced None place. Offshore 3.2
Primary Barrier pressurisation in the Seal
upstream pipework.
work system etc.

Bolts installed
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Seal distortion leading to individuals and
Primary Barrier pressurisation in the Seal progressive leakage. appropriate supervision
tensioned
Employ competent
individuals and
To contain the gas
1. Gas Check Valve - within the tree on loss of Failure of Ring Gasket Instantaneous leak from
Primary Barrier pressurisation in the Seal bonnet
under tensioned
upstream pipework.
envelope broken.
To contain the gas

2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Bolts loosen off in
- Primary Barrier pressurisation in the Seal service
F&G system
upstream pipework.
61
To contain the gas

2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Excessive vibration on
- Primary Barrier pressurisation in the Seal pipework
upstream pipework.
To contain the gas

2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Displacement from
- Primary Barrier pressurisation in the Seal normal relative position
upstream pipework.
Designers and
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Wrong seal taken from properties similar to
- Primary Barrier pressurisation in the Seal stores actual specification,
effect.
work system etc.
Designers and
To contain the gas
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Seal incorrectly Gradually increasing
- Primary Barrier pressurisation in the Seal specified leak over time.
upstream pipework.
work system etc.

2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Seal incorrectly Seal incorrectly in excess of 6 months,
- Primary Barrier pressurisation in the Seal specified specified in design initial teething problems
Employ competent
individuals and
To contain the gas
is available.
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Seal incorrectly
- Primary Barrier pressurisation in the Seal installed
upstream pipework.
envelope broken.

Bolts installed
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Sealing arrangement individuals and
- Primary Barrier pressurisation in the Seal unevenly energised appropriate supervision
unevenly tensioned
62
Designers and
To contain the gas
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket
- Primary Barrier pressurisation in the Seal
upstream pipework.
work system etc.

Bolts installed
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Seal distortion leading to individuals and
- Primary Barrier pressurisation in the Seal progressive leakage. appropriate supervision
tensioned
Employ competent
individuals and
To contain the gas
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Instantaneous leak from
- Primary Barrier pressurisation in the Seal bonnet
under tensioned
upstream pipework.
envelope broken.
Designers and
To contain the gas
within the tree on loss of
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage Seal incorrectly Gradually leaking over
- Primary Barrier upstream pipework and (metal to metal joint) specified time
or on activation of
platform ESD
work system etc.
Designers and
To contain the gas Dimensions, chemical
within the tree on loss of and mechanical
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage Wrong seal taken from properties similar to
- Primary Barrier upstream pipework and (metal to metal joint) stores actual specification,
or on activation of therefore no immediate
platform ESD effect.
work system etc.
To contain the gas

within the tree on loss of Tree has been operating
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage Seal incorrectly Seal incorrectly in excess of 6 months,
- Primary Barrier upstream pipework and (metal to metal joint) specified specified in design initial teething problems
or on activation of have been ironed out.
platform ESD
63
Employ competent
individuals and
To contain the gas
is available.
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage Seal incorrectly
Zone 1.1 to 1.2 Effective seal not made Gas leak around seal 2.1
- Primary Barrier upstream pipework and (metal to metal joint) installed
or on activation of
platform ESD
envelope broken.
To contain the gas

within the tree on loss of Employ competent
Bolts installed
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage Sealing arrangement individuals and
- Primary Barrier upstream pipework and (metal to metal joint) unevenly energised appropriate supervision
unevenly tensioned
or on activation of is available.
platform ESD
Designers and
To contain the gas
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage
Zone 1.1 to 1.2 incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
- Primary Barrier upstream pipework and (metal to metal joint)
or on activation of
platform ESD
work system etc.
To contain the gas

Bolts installed
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage Seal distortion leading to individuals and
- Primary Barrier upstream pipework and (metal to metal joint) progressive leakage. appropriate supervision
tensioned
platform ESD
Employ competent
To contain the gas
individuals and
3. Annulus Wing Valve pressurisation in the Bonnet seal leakage Instantaneous leak from
- Primary Barrier upstream pipework and (metal to metal joint) bonnet
under tensioned
or on activation of
platform ESD
envelope broken.
To contain the gas

Perform maintenance
and inspection in
3. Annulus Wing Valve pressurisation in the Gas leaks from actuator
Zone 1.1 to 1.2 Stem Seal Leak Wear and Tear Loss of full seal accordance with 2.4
- Primary Barrier upstream pipework and housing
manufacturers
or on activation of
requirements.
platform ESD
64
To contain the gas

Perform maintenance
and inspection in
Zone 1.1 to 1.2 Stem Seal Leak Packing not set correctlyLoss of full seal accordance with 2.4
manufacturers
or on activation of
requirements.
platform ESD
To contain the gas

Perform maintenance
and inspection in
Zone 1.1 to 1.2 Stem Seal Leak Wrong packing fitted Loss of full seal accordance with 2.4
manufacturers
or on activation of
requirements.
platform ESD
To contain the gas

Fitter backs off
3. Annulus Wing Valve pressurisation in the Audible evidence of gas
Zone 1.1 to 1.2 Grease fitting Leakage assembly rather than Partial leak Using competent fitters 3.3
- Primary Barrier upstream pipework and release
just the cap
or on activation of
platform ESD
To contain the gas

Removal or backing off
of plug during routine
Zone 1.1 to 1.2 Grease fitting Leakage greasing/lubricating Partial leak Using competent fitters 3.3
removes inner check
or on activation of
valve
platform ESD
Designers and
To contain the gas
1. Annulus Wing Valve pressurisation in the Seal incorrectly Gradually leaking over
Zone 1.2 to 1.3 Bonnet Seal Leakage body causing place. Offshore 2.2
- Primary Barrier upstream pipework and specified time
or on activation of
platform ESD
work system etc.
Designers and
1. Annulus Wing Valve pressurisation in the Wrong seal taken from properties similar to
Zone 1.2 to 1.3 Bonnet Seal Leakage None place. Offshore 2.2
- Primary Barrier upstream pipework and stores actual specification,
work system etc.
65
To contain the gas

1. Annulus Wing Valve pressurisation in the Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 Bonnet Seal Leakage None. 2.2
- Primary Barrier upstream pipework and specified specified in design initial teething problems
platform ESD
Employ competent
individuals and
To contain the gas
is available.
1. Annulus Wing Valve pressurisation in the Seal incorrectly
Zone 1.2 to 1.3 Bonnet Seal Leakage Effective seal not made Gas leak around seal 2.1
- Primary Barrier upstream pipework and installed
or on activation of
platform ESD
envelope broken.
To contain the gas

Bolts installed
1. Annulus Wing Valve pressurisation in the Sealing arrangement individuals and
Zone 1.2 to 1.3 Bonnet Seal Leakage incorrectly - bolts Joint integrity reduced 3.3
- Primary Barrier upstream pipework and unevenly energised appropriate supervision
unevenly tensioned
platform ESD
Designers and
To contain the gas
1. Annulus Wing Valve pressurisation in the
Zone 1.2 to 1.3 Bonnet Seal Leakage incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
- Primary Barrier upstream pipework and
or on activation of
platform ESD
work system etc.
To contain the gas

Bolts installed
1. Annulus Wing Valve pressurisation in the Seal distortion leading individuals and
Zone 1.2 to 1.3 Bonnet Seal Leakage incorrectly - bonnet Joint integrity reduced 2.3
- Primary Barrier upstream pipework and to progressive leakage. appropriate supervision
over tensioned
platform ESD
Employ competent
To contain the gas
individuals and
1. Annulus Wing Valve pressurisation in the Instantaneous leak from
Zone 1.2 to 1.3 Bonnet Seal Leakage incorrectly - bonnet Joint integrity reduced is available. 2.3
- Primary Barrier upstream pipework and bonnet
under tensioned
or on activation of
platform ESD
envelope broken.
66
To contain the gas

Perform maintenance
and inspection in
Zone 1.2 to 1.3 Stem Seal Leakage Wear and Tear Loss of full seal accordance with 2.4
manufacturers
or on activation of
requirements.
platform ESD
To contain the gas

Perform maintenance
and inspection in
1. Annulus Wing Valve pressurisation in the Packing not set Gas leaks from actuator
Zone 1.2 to 1.3 Stem Seal Leakage Loss of full seal accordance with 2.4
- Primary Barrier upstream pipework and correctly housing
manufacturers
or on activation of
requirements.
platform ESD
To contain the gas

Perform maintenance
and inspection in
Zone 1.2 to 1.3 Stem Seal Leakage Wrong packing fitted Loss of full seal accordance with 2.4
manufacturers
or on activation of
requirements.
platform ESD
To contain the gas

Fitter backs off
Zone 1.2 to 1.3 Grease fitting leakage assembly rather than Partial leak Using competent fitters 3.3
just the cap
or on activation of
platform ESD
To contain the gas

of plug during routine
Zone 1.2 to 1.3 Grease fitting leakage greasing/lubricating Partial leak Using competent fitters 3.3
removes inner check
or on activation of
valve
platform ESD
Slag
Designers and
inclusion/laminations,
2. Annulus Bore - To maintain annulus Stress raisers and crack manufacturers to have
Zone 1.2 to 1.3 Tree block failure Manufacturing defect cold laps and other 1.2
Primary Barrier pressure integrity initiators ISO quality systems in
geometric imperfections
place.
in the forged block.
67
Designers and
To contain the gas
3. Annulus Upper seal incompatible with ISO quality systems in
pressurisation in the Seal incorrectly Gradually leaking over
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage body causing place. Offshore 2.2
upstream pipework and specified time
Barrier differential cell to be supervisors checks and
or on activation of
platform ESD
work system etc.
Designers and
3. Annulus Upper ISO quality systems in
pressurisation in the Wrong seal taken from properties similar to
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage None place. Offshore 2.2
upstream pipework and stores actual specification,
Barrier supervisors checks and
work system etc.
To contain the gas

3. Annulus Upper
pressurisation in the Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage None. 2.2
upstream pipework and specified specified in design initial teething problems
Barrier
platform ESD
Employ competent
individuals and
To contain the gas
3. Annulus Upper is available.
pressurisation in the Seal incorrectly
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage Effective seal not made Gas leak around seal 2.1
upstream pipework and installed
Barrier
or on activation of
platform ESD
envelope broken.
To contain the gas

3. Annulus Upper Bolts installed
pressurisation in the Sealing arrangement individuals and
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage incorrectly - bolts Joint integrity reduced 3.3
upstream pipework and unevenly energised appropriate supervision
Barrier unevenly tensioned
platform ESD
68
Designers and
To contain the gas
3. Annulus Upper Bolts installed ISO quality systems in
pressurisation in the
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
upstream pipework and
Barrier grade of bolt fitted supervisors checks and
or on activation of
platform ESD
work system etc.
To contain the gas

pressurisation in the Seal distortion leading to individuals and
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage incorrectly - bonnet over Joint integrity reduced 2.3
upstream pipework and progressive leakage. appropriate supervision
Barrier tensioned
platform ESD
Employ competent
To contain the gas
individuals and
3. Annulus Upper Bolts installed appropriate supervision
pressurisation in the Instantaneous leak from
Zone 1.2 to 1.3 Master Valve - Primary Bonnet Seal Leakage incorrectly - bonnet Joint integrity reduced is available. 2.3
upstream pipework and bonnet
Barrier under tensioned
or on activation of
platform ESD
envelope broken.
To contain the gas

Perform maintenance
3. Annulus Upper and inspection in
pressurisation in the Gas leaks from actuator
Zone 1.2 to 1.3 Master Valve - Primary Stem Seal Leak Wear and Tear Loss of full seal accordance with 2.4
upstream pipework and housing
Barrier manufacturers
or on activation of
requirements.
platform ESD
To contain the gas

Perform maintenance
Zone 1.2 to 1.3 Master Valve - Primary Stem Seal Leak Packing not set correctlyLoss of full seal accordance with 2.4
or on activation of
requirements.
platform ESD
To contain the gas

Perform maintenance
Zone 1.2 to 1.3 Master Valve - Primary Stem Seal Leak Wrong packing fitted Loss of full seal accordance with 2.4
or on activation of
requirements.
platform ESD
69
To contain the gas

3. Annulus Upper Fitter backs off
pressurisation in the Audible evidence of gas
Zone 1.2 to 1.3 Master Valve - Primary Grease fitting Leakage assembly rather than Partial leak Using competent fitters 3.3
upstream pipework and release
Barrier just the cap
or on activation of
platform ESD
To contain the gas

3. Annulus Upper of plug during routine
Zone 1.2 to 1.3 Master Valve - Primary Grease fitting Leakage greasing/lubricating Partial leak Using competent fitters 3.3
Barrier removes inner check
or on activation of
valve
platform ESD
Pressure testing at
manufactures to ensure
integrity of gate/seat.
Provides isolation of
Maintenance and
annulus from tree cap
4. Annulus SWAB Poor seal between gate Gate/seat scored or Gas passing into upper Pressurised gas under inspection by
Zone 1.2 to 1.3 other than under any 1.5
Valve - Primary Barrier and seat damaged bore under tree cap tree cap manufacturer including
well intervention
periodic testing
conditions
offshore.
Tree cap is a secondary

barrier
Designers and
Provides isolation of Material specification of manufacturers to have
annulus from tree cap seal incompatible with ISO quality systems in
4. Annulus SWAB Poor seal between seat Seal incorrectly Gradually leaking over
Zone 1.2 to 1.3 other than under any body causing place. Offshore 1.1
Valve - Primary Barrier seal and valve body specified time
well intervention differential cell to be supervisors checks and
conditions setup. balances i.e. permit to
work system etc.
Designers and
Provides isolation of manufacturers to have
and mechanical
annulus from tree cap ISO quality systems in
4. Annulus SWAB Poor seal between seat Wrong seal taken from properties similar to Gradually increasing
Zone 1.2 to 1.3 other than under any place. Offshore 1.2
Valve - Primary Barrier seal and valve body stores actual specification, leak over time.
well intervention supervisors checks and
therefore no immediate
conditions balances i.e. permit to
effect.
work system etc.
70
Tree has been operating
4. Annulus SWAB Poor seal between seat Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 other than under any None. 1.2
Valve - Primary Barrier seal and valve body specified specified in design initial teething problems
well intervention
have been ironed out.
conditions
Employ competent
individuals and
Provides isolation of appropriate supervision
annulus from tree cap is available.
4. Annulus SWAB Poor seal between seat Seal incorrectly
Zone 1.2 to 1.3 other than under any Effective seal not made Gas leak around seal 1.1
Valve - Primary Barrier seal and valve body installed
well intervention
conditions
envelope broken.
Designers and
Provides isolation of Material specification of manufacturers to have
annulus from tree cap seal incompatible with ISO quality systems in
4. Annulus SWAB Bonnet seal leakage Seal incorrectly Gradually leaking over
Zone 1.2 to 1.3 other than under any body causing place. Offshore 2.2
Valve - Primary Barrier (metal to metal joint) specified time
well intervention differential cell to be supervisors checks and
conditions setup. balances i.e. permit to
work system etc.
Designers and
and mechanical
annulus from tree cap ISO quality systems in
4. Annulus SWAB Bonnet seal leakage Wrong seal taken from properties similar to
Zone 1.2 to 1.3 other than under any None place. Offshore 2.2
Valve - Primary Barrier (metal to metal joint) stores actual specification,
well intervention supervisors checks and
effect.
work system etc.
4. Annulus SWAB Bonnet seal leakage Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 other than under any None. 2.2
Valve - Primary Barrier (metal to metal joint) specified specified in design initial teething problems
well intervention
conditions
Employ competent
individuals and
Provides isolation of appropriate supervision
annulus from tree cap is available.
4. Annulus SWAB Bonnet seal leakage Seal incorrectly
Zone 1.2 to 1.3 other than under any Effective seal not made Gas leak around seal 2.1
Valve - Primary Barrier (metal to metal joint) installed
well intervention
conditions
envelope broken.
71
Employ competent
annulus from tree cap Bolts installed
4. Annulus SWAB Bonnet seal leakage Sealing arrangement individuals and
Zone 1.2 to 1.3 other than under any incorrectly - bolts Joint integrity reduced 3.3
Valve - Primary Barrier (metal to metal joint) unevenly energised appropriate supervision
well intervention unevenly tensioned
is available.
conditions
Designers and
annulus from tree cap Bolts installed ISO quality systems in
4. Annulus SWAB Bonnet seal leakage
Zone 1.2 to 1.3 other than under any incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
Valve - Primary Barrier (metal to metal joint)
well intervention grade of bolt fitted supervisors checks and
work system etc.
Employ competent
annulus from tree cap Bolts installed
4. Annulus SWAB Bonnet seal leakage Seal distortion leading to individuals and
Zone 1.2 to 1.3 other than under any incorrectly - bonnet over Joint integrity reduced 2.3
Valve - Primary Barrier (metal to metal joint) progressive leakage. appropriate supervision
well intervention tensioned
is available.
conditions
Employ competent
Provides isolation of individuals and
annulus from tree cap Bolts installed appropriate supervision
4. Annulus SWAB Bonnet seal leakage Instantaneous leak from
Zone 1.2 to 1.3 other than under any incorrectly - bonnet Joint integrity reduced is available. 2.3
Valve - Primary Barrier (metal to metal joint) bonnet
well intervention under tensioned
conditions Pressure tested after
envelope broken.
Provides isolation of Perform maintenance

annulus from tree cap and inspection in
4. Annulus SWAB Gas leaks from handle
Zone 1.2 to 1.3 other than under any Stem seal leakage Wear and Tear Loss of full seal accordance with 2.4
Valve - Primary Barrier assembly
well intervention manufacturers
conditions requirements.

Zone 1.2 to 1.3 other than under any Stem seal leakage Packing not set correctlyLoss of full seal accordance with 2.4

Zone 1.2 to 1.3 other than under any Stem seal leakage Wrong packing fitted Loss of full seal accordance with 2.4
72
Cartridge nose seal Employ competent
To provide a controlled
5. Chemical Injection failure, annulus gas Cartridge not fully Gas leakage around individuals and
Zone 1.2 to 1.3 entry point for chemical None. 1.1
Valve - Primary Barrier leakage past cartridge tightened cartridge walls appropriate supervision
injection
wall is available.
Designers and
To provide a controlled seal incompatible with ISO quality systems in
5. Chemical Injection Seal incorrectly Gradually leaking over
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal body causing place. Offshore 2.2
Valve - Primary Barrier specified time
injection differential cell to be supervisors checks and
work system etc.
Designers and
and mechanical
To provide a controlled ISO quality systems in
5. Chemical Injection Wrong seal taken from properties similar to
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal None place. Offshore 2.2
Valve - Primary Barrier stores actual specification,
injection supervisors checks and
effect.
work system etc.

5. Chemical Injection Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal None. 2.2
Valve - Primary Barrier specified specified in design initial teething problems
injection
Employ competent
individuals and
To provide a controlled is available.
5. Chemical Injection Seal incorrectly
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal Effective seal not made Gas leak around seal 2.1
Valve - Primary Barrier installed
injection

envelope broken.
Employ competent
To provide a controlled Bolts installed
5. Chemical Injection Sealing arrangement individuals and
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal incorrectly - bolts Joint integrity reduced 3.3
Valve - Primary Barrier unevenly energised appropriate supervision
injection unevenly tensioned
is available.
73
Designers and
To provide a controlled Bolts installed ISO quality systems in
5. Chemical Injection
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
Valve - Primary Barrier
injection grade of bolt fitted supervisors checks and
work system etc.
Employ competent
5. Chemical Injection Seal distortion leading to individuals and
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal incorrectly - bonnet over Joint integrity reduced 2.3
Valve - Primary Barrier progressive leakage. appropriate supervision
injection tensioned
is available.
Employ competent
individuals and
To provide a controlled Bolts installed appropriate supervision
5. Chemical Injection Instantaneous leak from
Zone 1.2 to 1.3 entry point for chemical Failure of bonnet seal incorrectly - bonnet Joint integrity reduced is available. 2.3
Valve - Primary Barrier bonnet
injection under tensioned
envelope broken.
To provide a controlled Possible detection by

5. Chemical Injection Failure of Ring Gasket Bolts loosen off in
Zone 1.2 to 1.3 entry point for chemical Partial leakage of gas Gas release plant operators and/or 2.3
Valve - Primary Barrier Seal service
injection F&G system
To provide a controlled Catastrophic failure of Appropriate support for

5. Chemical Injection Failure of Ring Gasket Excessive vibration on
Zone 1.2 to 1.3 entry point for chemical Fatigue failure of bolts one or more bolts after a piping as per pipe stress 3.3
Valve - Primary Barrier Seal pipework
injection period of time. analysis.
To provide a controlled Thermal/mechanical Catastrophic failure of Appropriate piping

5. Chemical Injection Failure of Ring Gasket Displacement from
Zone 1.2 to 1.3 entry point for chemical gradients induce fatigue one or more bolts after a design as per pipe stress 3.3
Valve - Primary Barrier Seal normal relative position
injection on bolts period of time. analysis.
Designers and
and mechanical
To provide a controlled ISO quality systems in
5. Chemical Injection Failure of Ring Gasket Wrong seal taken from properties similar to
Zone 1.2 to 1.3 entry point for chemical None place. Offshore 2.2
Valve - Primary Barrier Seal stores actual specification,
injection supervisors checks and
effect.
work system etc.
74
Designers and
To provide a controlled seal incompatible with ISO quality systems in
5. Chemical Injection Failure of Ring Gasket Seal incorrectly Gradually increasing
Zone 1.2 to 1.3 entry point for chemical body causing place. Offshore 2.2
Valve - Primary Barrier Seal specified leak over time.
injection differential cell to be supervisors checks and
work system etc.

5. Chemical Injection Failure of Ring Gasket Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 entry point for chemical None 2.2
Valve - Primary Barrier Seal specified specified in design initial teething problems
injection
Employ competent
individuals and
To provide a controlled is available.
5. Chemical Injection Failure of Ring Gasket Seal incorrectly
Zone 1.2 to 1.3 entry point for chemical Effective seal not made Gas leakage around seal 2.1
Valve - Primary Barrier Seal installed
injection

envelope broken.
Employ competent
5. Chemical Injection Failure of Ring Gasket Sealing arrangement individuals and
Zone 1.2 to 1.3 entry point for chemical incorrectly - bolts Joint integrity reduced 3.3
Valve - Primary Barrier Seal unevenly energised appropriate supervision
injection unevenly tensioned
is available.
Designers and
To provide a controlled Bolts installed ISO quality systems in
5. Chemical Injection Failure of Ring Gasket
Zone 1.2 to 1.3 entry point for chemical incorrectly - incorrect Joint integrity reduced None place. Offshore 3.2
Valve - Primary Barrier Seal
injection grade of bolt fitted supervisors checks and
work system etc.
Employ competent
5. Chemical Injection Failure of Ring Gasket Seal distortion leading to individuals and
Zone 1.2 to 1.3 entry point for chemical incorrectly - bonnet over Joint integrity reduced 2.3
Valve - Primary Barrier Seal progressive leakage. appropriate supervision
injection tensioned
is available.
75
Employ competent
individuals and
To provide a controlled Bolts installed appropriate supervision
5. Chemical Injection Failure of Ring Gasket Instantaneous leak from
Zone 1.2 to 1.3 entry point for chemical incorrectly - bonnet Joint integrity reduced is available. 2.3
Valve - Primary Barrier Seal bonnet
injection under tensioned
envelope broken.
Perform maintenance
To provide a controlled and inspection in
5. Chemical Injection Gas leaks from handle
Zone 1.2 to 1.3 entry point for chemical Stem seal leakage Wear and Tear Loss of full seal accordance with 2.4
injection manufacturers
requirements.
Perform maintenance
Zone 1.2 to 1.3 entry point for chemical Stem seal leakage Packing not set correctlyLoss of full seal accordance with 2.4
requirements.
Perform maintenance
Zone 1.2 to 1.3 entry point for chemical Stem seal leakage Wrong packing fitted Loss of full seal accordance with 2.4
requirements.
Pressure testing at
manufactures to ensure
integrity of gate/seat.
Maintenance and
6. Annulus non-active To provide a facility for
Poor seal between gate Gate/seat scored or Gas passing into upper Pressurised gas under inspection by
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into 1.5
and seat damaged bore under tree cap tree cap manufacturer including
Barrier the annulus.
periodic testing
offshore.
Tree cap is a secondary

barrier
76
Designers and
6. Annulus non-active To provide a facility for seal incompatible with ISO quality systems in
Poor seal between seat Seal incorrectly Gradually leaking over
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into body causing place. Offshore 1.1
seal and valve body specified time
Barrier the annulus. differential cell to be supervisors checks and
work system etc.
Designers and
and mechanical
6. Annulus non-active To provide a facility for ISO quality systems in
Poor seal between seat Wrong seal taken from properties similar to Gradually increasing
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into place. Offshore 1.2
seal and valve body stores actual specification, leak over time.
Barrier the annulus. supervisors checks and
effect.
work system etc.

Poor seal between seat Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into None. 1.2
seal and valve body specified specified in design initial teething problems
Employ competent
individuals and
6. Annulus non-active To provide a facility for is available.
Poor seal between seat Seal incorrectly
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Effective seal not made Gas leak around seal 1.1
seal and valve body installed

envelope broken.
Designers and
Bonnet seal leakage Seal incorrectly Gradually leaking over
(metal to metal joint) specified time
work system etc.
Designers and
and mechanical
Bonnet seal leakage Wrong seal taken from properties similar to
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into None place. Offshore 2.2
(metal to metal joint) stores actual specification,
effect.
work system etc.
77

Bonnet seal leakage Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into None. 2.2
(metal to metal joint) specified specified in design initial teething problems
Employ competent
individuals and
Bonnet seal leakage Seal incorrectly
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Effective seal not made Gas leak around seal 2.1
(metal to metal joint) installed

envelope broken.
Employ competent
6. Annulus non-active To provide a facility for Bolts installed
Bonnet seal leakage Sealing arrangement individuals and
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - bolts Joint integrity reduced 3.3
(metal to metal joint) unevenly energised appropriate supervision
Barrier the annulus. unevenly tensioned
is available.
Designers and
6. Annulus non-active To provide a facility for Bolts installed ISO quality systems in
Bonnet seal leakage
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
(metal to metal joint)
Barrier the annulus. grade of bolt fitted supervisors checks and
work system etc.
Employ competent
Bonnet seal leakage Seal distortion leading to individuals and
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - bonnet over Joint integrity reduced 2.3
(metal to metal joint) progressive leakage. appropriate supervision
Barrier the annulus. tensioned
is available.
Employ competent
individuals and
6. Annulus non-active To provide a facility for Bolts installed appropriate supervision
Bonnet seal leakage Instantaneous leak from
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - bonnet Joint integrity reduced is available. 2.3
(metal to metal joint) bonnet
Barrier the annulus. under tensioned
envelope broken.
Perform maintenance
6. Annulus non-active To provide a facility for and inspection in
Gas leaks from handle
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Stem seal leakage Wear and Tear Loss of full seal accordance with 2.4
assembly
Barrier the annulus. manufacturers
requirements.
78
Perform maintenance
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Stem seal leakage Packing not set correctlyLoss of full seal accordance with 2.4
assembly
requirements.
Perform maintenance
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Stem seal leakage Wrong packing fitted Loss of full seal accordance with 2.4
assembly
requirements.
6. Annulus non-active To provide a facility for Possible detection by

Failure of Ring Gasket Bolts loosen off in
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Partial leakage of gas Gas release plant operators and/or 2.3
Seal service
Barrier the annulus. F&G system
6. Annulus non-active To provide a facility for Catastrophic failure of Appropriate support for
Failure of Ring Gasket Excessive vibration on
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Fatigue failure of bolts one or more bolts after a piping as per pipe stress 3.3
Seal pipework
Barrier the annulus. period of time. analysis.
6. Annulus non-active To provide a facility for Thermal/mechanical Catastrophic failure of Appropriate piping
Failure of Ring Gasket Displacement from
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into gradients induce fatigue one or more bolts after a design as per pipe stress 3.3
Seal normal relative position
Barrier the annulus. on bolts period of time. analysis.
Designers and
and mechanical
Failure of Ring Gasket Wrong seal taken from properties similar to
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into None place. Offshore 2.2
Seal stores actual specification,
effect.
work system etc.
Designers and
Failure of Ring Gasket Seal incorrectly Gradually increasing
Seal specified leak over time.
work system etc.

Failure of Ring Gasket Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into None 2.2
Seal specified specified in design initial teething problems
79
Employ competent
individuals and
Failure of Ring Gasket Seal incorrectly
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into Effective seal not made Gas leakage around seal 2.1
Seal installed

envelope broken.
Employ competent
Failure of Ring Gasket Sealing arrangement individuals and
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - bolts Joint integrity reduced 3.3
Seal unevenly energised appropriate supervision
Barrier the annulus. unevenly tensioned
is available.
Designers and
6. Annulus non-active To provide a facility for Bolts installed ISO quality systems in
Failure of Ring Gasket
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - incorrect Joint integrity reduced None place. Offshore 3.2
Seal
Barrier the annulus. grade of bolt fitted supervisors checks and
work system etc.
Employ competent
Failure of Ring Gasket Seal distortion leading to individuals and
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - bonnet over Joint integrity reduced 2.3
Seal progressive leakage. appropriate supervision
Barrier the annulus. tensioned
is available.
Employ competent
individuals and
6. Annulus non-active To provide a facility for Bolts installed appropriate supervision
Failure of Ring Gasket Instantaneous leak from
Zone 1.2 to 1.3 wing valve - Primary injecting kill fluid into incorrectly - bonnet Joint integrity reduced is available. 2.3
Seal bonnet
Barrier the annulus. under tensioned
envelope broken.
On failure of primary
To provide a removable barrier (gate on SWAB)
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Bolts loosen off in
Barrier allow well intervention primary barriers. Tree service
F&G system
activities Cap Annulus Bore Seal
passing.
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Excessive vibration on
Zone 1.2 to 1.3 Fatigue of bolts one or more bolts after a piping as per pipe stress 3.3
Barrier allow well intervention primary barriers. Tree pipework
passing.
80
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Displacement from
Barrier allow well intervention primary barriers. Tree normal relative position
passing.
Designers and
On failure of primary Dimensions, chemical
To provide a removable barrier (gate on SWAB) and mechanical
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Wrong seal taken from properties similar to
Barrier allow well intervention primary barriers. Tree stores actual specification,
activities Cap Annulus Bore Seal therefore no immediate
passing. effect.
work system etc.
Designers and
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal incorrectly Gradually increasing
Barrier allow well intervention primary barriers. Tree specified leak over time.
passing.
work system etc.
To provide a removable barrier (gate on SWAB) Tree has been operating
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal incorrectly Seal incorrectly in excess of 6 months,
Barrier allow well intervention primary barriers. Tree specified specified in design initial teething problems
activities Cap Annulus Bore Seal have been ironed out.
passing.
Employ competent
individuals and
is available.
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal incorrectly
Barrier allow well intervention primary barriers. Tree installed
passing.
envelope broken.
To provide a removable barrier (gate on SWAB) Employ competent
Bolts installed
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Sealing arrangement individuals and
Barrier allow well intervention primary barriers. Tree unevenly energised appropriate supervision
unevenly tensioned
activities Cap Annulus Bore Seal is available.
passing.
81
Designers and
7. Tree Cap - Secondary secondary barrier to all tree cap seals are
Barrier allow well intervention primary barriers. Tree
passing.
work system etc.
Bolts installed
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal distortion leading to individuals and
Barrier allow well intervention primary barriers. Tree progressive leakage. appropriate supervision
tensioned
activities Cap Annulus Bore Seal is available.
passing.
Employ competent
individuals and
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Instantaneous leak from
Barrier allow well intervention primary barriers. Tree bonnet
under tensioned
passing.
envelope broken.
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Bolts loosen off in
Barrier allow well intervention primary barriers. Tree service
F&G system
activities Cap Bonnet Seal
passing.
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Excessive vibration on
Zone 1.2 to 1.3 Fatigue of bolts one or more bolts after a piping as per pipe stress 3.3
Barrier allow well intervention primary barriers. Tree pipework
passing.
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Displacement from
Barrier allow well intervention primary barriers. Tree normal relative position
passing.
82
Designers and
On failure of primary Dimensions, chemical
To provide a removable barrier (gate on SWAB) and mechanical
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Wrong seal taken from properties similar to
Barrier allow well intervention primary barriers. Tree stores actual specification,
activities Cap Bonnet Seal therefore no immediate
passing. effect.
work system etc.
Designers and
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal incorrectly Gradually increasing
Barrier allow well intervention primary barriers. Tree specified leak over time.
passing.
work system etc.
To provide a removable barrier (gate on SWAB) Tree has been operating
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal incorrectly Seal incorrectly in excess of 6 months,
Barrier allow well intervention primary barriers. Tree specified specified in design initial teething problems
activities Cap Bonnet Seal have been ironed out.
passing.
Employ competent
individuals and
is available.
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal incorrectly
Barrier allow well intervention primary barriers. Tree installed
passing.
envelope broken.
Bolts installed
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Sealing arrangement individuals and
Barrier allow well intervention primary barriers. Tree unevenly energised appropriate supervision
unevenly tensioned
activities Cap Bonnet Seal is available.
passing.
Designers and
Barrier allow well intervention primary barriers. Tree
passing.
work system etc.
83
Bolts installed
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Seal distortion leading to individuals and
Barrier allow well intervention primary barriers. Tree progressive leakage. appropriate supervision
tensioned
activities Cap Bonnet Seal is available.
passing.
Employ competent
individuals and
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Instantaneous leak from
Barrier allow well intervention primary barriers. Tree bonnet
under tensioned
passing.
envelope broken.
Careful installation of
On failure of primary tree cap.
To provide a removable
barrier (gate on SWAB) Scoring and/or nipping
7. Tree Cap - Secondary secondary barrier to Damage of o-ring on Gas leakage from the
Zone 1.2 to 1.3 all tree cap seals are of o-ring breaking down 2.4
Barrier allow well intervention installation of cap tree cap retainer ring.
primary barriers. Tree seal integrity
activities
Cap Plug Seal passing. Pressure test of tree cap
on tree assembly.
Inspect and dress
polished bore prior to
To provide a removable installation.
barrier (gate on SWAB) Damage to polished
7. Tree Cap - Secondary secondary barrier to Gas leakage from the
Zone 1.2 to 1.3 all tree cap seals are bore on installation of Scoring of polished bore 2.3
Barrier allow well intervention tree cap retainer ring.
primary barriers. Tree tree cap
activities
Cap Plug Seal passing.
Pressure test of tree cap
on tree assembly.
Designers and
On failure of primary place. Offshore
barrier (gate on SWAB) supervisors checks and
7. Tree Cap - Secondary secondary barrier to Gas leakage from the
Zone 1.2 to 1.3 all tree cap seals are Incorrect o-ring used Inadequate seal balances. 2.2
Barrier allow well intervention tree cap retainer ring.
primary barriers. Tree
activities

on tree assembly.
84
Designers and
On failure of primary place. Offshore
To provide a removable Gradual deteriation of
barrier (gate on SWAB) supervisors checks and
7. Tree Cap - Secondary secondary barrier to Ageing of o-ring prior seal, causing increasing Gas leakage from the
Zone 1.2 to 1.3 all tree cap seals are balances. 2.2
Barrier allow well intervention to installation leakage over a period of tree cap retainer ring.
primary barriers. Tree
activities time

on tree assembly.
Use of go/no go gauges
during manufacture.
No visible symptoms.
Reduced thread to Designers and
thread contact surface manufacturers to have
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Thread cut out of
Zone 1.2 to 1.3 (seal maintained by Degraded mechanical ISO quality systems in 3.3
Barrier allow well intervention primary barriers. Test tolerance
excessive PTFE for joint, since joint relies place. Offshore
activities Valve-Tree Cap crewed
example) more on excessive supervisors checks and
seal interface passing.
sealant than intimate balances.
thread contact.
Use of competent fitters

during manufacture.
Designers and
To provide a removable barrier (gate on SWAB) Component will only
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Thread cut out of Either male or female mate for a proportion of
Zone 1.2 to 1.3 ISO quality systems in 3.3
Barrier allow well intervention primary barriers. Test tolerance threads are cut oversize the threads (rather than
place. Offshore
activities Valve-Tree Cap crewed full length engagement)
balances.

Excessive torque
required to install. Use of competent fitters
and effective
supervision.
Zone 1.2 to 1.3 Cross threads Ineffective seal Fitting improperly 1.3
Barrier allow well intervention primary barriers. Test
aligned.
Suitable pressure
testing.
Leaking joint.
85
Joint difficult to make
up.

On failure of primary Excessive torque and effective
To provide a removable barrier (gate on SWAB) required to install. supervision.
7. Tree Cap - Secondary secondary barrier to all tree cap seals are Improperly mated
Zone 1.2 to 1.3 Damaged threads 1.3
Barrier allow well intervention primary barriers. Test threads
seal interface passing. Fitting improperly Suitable pressure
aligned. testing.
Leaking joint
On failure of primary Perform maintenance

barrier (gate on SWAB) and inspection in
7. Tree Cap - Secondary secondary barrier to Gas leaks from actuator
Zone 1.2 to 1.3 all tree cap seals are Wear and Tear Loss of full seal accordance with 2.4
Barrier allow well intervention housing
primary barriers. Valve manufacturers
activities
Stem packing passing. requirements.

Zone 1.2 to 1.3 all tree cap seals are Packing not set correctly Loss of full seal accordance with 2.4
activities

Zone 1.2 to 1.3 all tree cap seals are Wrong packing fitted Loss of full seal accordance with 2.4
activities
86
Designers and
To contain the gas
1. Annulus Upper seal incompatible with ISO quality systems in
pressurisation in the Seal incorrectly Gradually leaking over
upstream pipework and specified time
or on activation of
platform ESD
work system etc.
Designers and
1. Annulus Upper ISO quality systems in
pressurisation in the Wrong seal taken from properties similar to
upstream pipework and stores actual specification,
work system etc.
To contain the gas

1. Annulus Upper
pressurisation in the Seal incorrectly Seal incorrectly in excess of 6 months,
upstream pipework and specified specified in design initial teething problems
Barrier
platform ESD
Employ competent
individuals and
To contain the gas
1. Annulus Upper is available.
pressurisation in the Seal incorrectly
Barrier
or on activation of
platform ESD
envelope broken.
To contain the gas

upstream pipework and unevenly energised appropriate supervision
platform ESD
87
Designers and
To contain the gas
1. Annulus Upper Bolts installed ISO quality systems in
or on activation of
platform ESD
work system etc.
To contain the gas

pressurisation in the Seal distortion leading individuals and
Zone 1.3 to 1.4 Master Valve - Primary Bonnet Seal Leakage incorrectly - bonnet Joint integrity reduced 2.3
upstream pipework and to progressive leakage. appropriate supervision
Barrier over tensioned
platform ESD
Employ competent
To contain the gas
individuals and
1. Annulus Upper Bolts installed appropriate supervision
pressurisation in the Instantaneous leak from
or on activation of
platform ESD
envelope broken.
To contain the gas

Perform maintenance
or on activation of
requirements.
platform ESD
To contain the gas

Perform maintenance
pressurisation in the Packing not set Gas leaks from actuator
Zone 1.3 to 1.4 Master Valve - Primary Stem Seal Leak Loss of full seal accordance with 2.4
upstream pipework and correctly housing
or on activation of
requirements.
platform ESD
To contain the gas

Perform maintenance
or on activation of
requirements.
platform ESD
88
To contain the gas

1. Annulus Upper Individual back off
pressurisation in the Leakage from grease Audible evidence of gas
Zone 1.3 to 1.4 Master Valve - Primary assembly rather than Partial leak Using competent fitters 3.3
upstream pipework and fitting release
or on activation of
platform ESD
To contain the gas

1. Annulus Upper of plug during routine
pressurisation in the Leakage from grease Audible evidence of gas
Zone 1.3 to 1.4 Master Valve - Primary greasing/lubricating Partial leak Using competent fitters 3.3
upstream pipework and fitting release
or on activation of
valve
platform ESD
Slag
Designers and
place.
Designers and
To contain the gas
3. Annulus Lower seal incompatible with ISO quality systems in
within the tree on loss of Seal incorrectly Gradually leaking over
pressurisation in the specified time
upstream pipework
work system etc.
Designers and
3. Annulus Lower ISO quality systems in
within the tree on loss of Wrong seal taken from properties similar to
pressurisation in the stores actual specification,
upstream pipework therefore no immediate
effect.
work system etc.

3. Annulus Lower
within the tree on loss of Seal incorrectly Seal incorrectly in excess of 6 months,
pressurisation in the specified specified in design initial teething problems
Barrier
upstream pipework have been ironed out.
89
Employ competent
individuals and
To contain the gas
3. Annulus Lower is available.
within the tree on loss of Seal incorrectly
pressurisation in the installed
Barrier
upstream pipework
envelope broken.

3. Annulus Lower Bolts installed
within the tree on loss of Sealing arrangement individuals and
pressurisation in the unevenly energised appropriate supervision
upstream pipework is available.
Designers and
To contain the gas
3. Annulus Lower Bolts installed ISO quality systems in
upstream pipework
work system etc.

within the tree on loss of Seal distortion leading to individuals and
Zone 1.3 to 1.4 Master Valve - Primary Bonnet Seal Leakage incorrectly - bonnet over Joint integrity reduced 2.3
pressurisation in the progressive leakage. appropriate supervision
Barrier tensioned
Employ competent
individuals and
To contain the gas
3. Annulus Lower Bolts installed appropriate supervision
within the tree on loss of Instantaneous leak from
pressurisation in the bonnet
upstream pipework
envelope broken.
Perform maintenance
To contain the gas
3. Annulus Lower and inspection in
within the tree on loss of Gas leaks from handle
pressurisation in the assembly
upstream pipework
requirements.
Perform maintenance
To contain the gas
Zone 1.3 to 1.4 Master Valve - Primary Stem Seal Leak Packing not set correctlyLoss of full seal accordance with 2.4
upstream pipework
requirements.
90
Perform maintenance
To contain the gas
upstream pipework
requirements.
To contain the gas

3. Annulus Lower Individual back off
within the tree on loss of Leakage from grease Audible evidence of gas
pressurisation in the fitting release
upstream pipework

To contain the gas
3. Annulus Lower of plug during routine
upstream pipework
valve
Designers and
To contain the gas
1. Annulus Lower seal incompatible with ISO quality systems in
within the tree on loss of Seal incorrectly Gradually leaking over
pressurisation in the specified time
upstream pipework
work system etc.
Designers and
1. Annulus Lower ISO quality systems in
within the tree on loss of Wrong seal taken from properties similar to
pressurisation in the stores actual specification,
upstream pipework therefore no immediate
effect.
work system etc.

1. Annulus Lower
within the tree on loss of Seal incorrectly Seal incorrectly in excess of 6 months,
pressurisation in the specified specified in design initial teething problems
Barrier
upstream pipework have been ironed out.
Employ competent
individuals and
To contain the gas
1. Annulus Lower is available.
within the tree on loss of Seal incorrectly
pressurisation in the installed
Barrier
upstream pipework
envelope broken.
91

within the tree on loss of Sealing arrangement individuals and
pressurisation in the unevenly energised appropriate supervision
Designers and
To contain the gas
1. Annulus Lower Bolts installed ISO quality systems in
upstream pipework
work system etc.

within the tree on loss of Seal distortion leading individuals and
Zone 1.4 to 1.5 Master Valve - Primary Bonnet Seal Leakage incorrectly - bonnet Joint integrity reduced 2.3
pressurisation in the to progressive leakage. appropriate supervision
Employ competent
individuals and
To contain the gas
1. Annulus Lower Bolts installed appropriate supervision
within the tree on loss of Instantaneous leak from
pressurisation in the bonnet
upstream pipework
envelope broken.
Perform maintenance
To contain the gas
upstream pipework
requirements.
Perform maintenance
To contain the gas
within the tree on loss of Packing not set Gas leaks from handle
Zone 1.4 to 1.5 Master Valve - Primary Stem Seal Leak Loss of full seal accordance with 2.4
pressurisation in the correctly assembly
upstream pipework
requirements.
Perform maintenance
To contain the gas
upstream pipework
requirements.
92
To contain the gas

1. Annulus Lower Individual back off
upstream pipework

To contain the gas
1. Annulus Lower of plug during routine
upstream pipework
valve
Slag
Designers and
place.
Confirmed by pressure
testing and established
installation procedures.
During installation of Leakage into xmas Potential leakage from
2. Annulus Bore - To maintain annulus Annulus bore sleeve
Zone 1.4 to 1.5 tree the seals become tree/upper tubing hanger tied own bolts or tree 2.3
Primary Barrier pressure integrity seal failure
damaged cavity body gasket.
Competent individuals
and appropriate
supervision
Confirmed by pressure
testing and established
installation procedures.
Due to incorrect Leakage into xmas Potential leakage from
2. Annulus Bore - To maintain annulus Annulus bore sleeve
Zone 1.4 to 1.5 installation seals fail to tree/upper tubing hanger tied own bolts or tree 2.3
Primary Barrier pressure integrity seal failure
energise cavity body gasket.
Competent individuals
and appropriate
supervision
Slag
Designers and
To provide a continuous inclusion/laminations,
3. Annulus bore tubing Stress raisers and crack manufacturers to have
Zone 1.4 to 1.5 bore between the tree Annulus bore failure Manufacturing defect cold laps and other 1.1
hanger - Primary Barrier initiators ISO quality systems in
and the annulus tubing geometric imperfections
place.
93
Leakage of gas past
threaded connection
consequently Instrument monitor
pressurising the upper A facility on upper A
annulus. annulus.
Failure due to threads
To provide a sealed
3. Annulus bore tubing Failure of seal (metal to being out with
Zone 1.4 to 1.5 mechanical joint Ineffective seal 2.2
hanger - Primary Barrier metal) manufacturing
between components
tolerances
Additional loading on Pressure in upper A
the dual bore upper annulus monitored by
packer (hydrostatic plant operators.
head, weight of tubing
and gas lift pressure)
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
3. Annulus bore tubing Failure of seal (metal to
Zone 1.4 to 1.5 mechanical joint Galling on seal face Ineffective seal 2.2
hanger - Primary Barrier metal)
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
3. Annulus bore tubing Failure of seal (metal to Insufficient make up
hanger - Primary Barrier metal) torque
between components
94
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
3. Annulus bore tubing Failure of seal (metal to Excessive loading on Seal integrity reduced or
Zone 1.4 to 1.5 mechanical joint 2.2
hanger - Primary Barrier metal) seal arrangement failed
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
3. Annulus bore tubing Failure of threaded Jumping out or
Zone 1.4 to 1.5 mechanical joint Joint opens 2.2
hanger - Primary Barrier connection 'unzipping' of the thread
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
3. Annulus bore tubing Failure of threaded Joint integrity reduced
Zone 1.4 to 1.5 mechanical joint Shearing of threads 2.2
hanger - Primary Barrier connection or failed
between components
4. Tubing spool to tree Provide seal between Thermal/mechanical Catastrophic failure of Appropriate piping
Leakage of gas around Displacement from
Zone 1.4 to 1.5 outer flange seal - the tree and the spool gradients induce fatigue one or more bolts after a design as per pipe stress 2.3
seal normal relative position
Secondary Barrier interface on bolts period of time. analysis.
95
Designers and
and mechanical
4. Tubing spool to tree Provide seal between ISO quality systems in
Leakage of gas around Wrong seal taken from properties similar to
Zone 1.4 to 1.5 outer flange seal - the tree and the spool None place. Offshore 1.2
seal stores actual specification,
Secondary Barrier interface supervisors checks and
effect.
work system etc.
Designers and
4. Tubing spool to tree Provide seal between seal incompatible with ISO quality systems in
Leakage of gas around Seal incorrectly Gradually increasing
Zone 1.4 to 1.5 outer flange seal - the tree and the spool body causing place. Offshore 1.2
seal specified leak over time.
Secondary Barrier interface differential cell to be supervisors checks and
work system etc.

4. Tubing spool to tree Provide seal between
Leakage of gas around Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.4 to 1.5 outer flange seal - the tree and the spool None 1.2
seal specified specified in design initial teething problems
Secondary Barrier interface
Employ competent
individuals and
4. Tubing spool to tree Provide seal between is available.
Leakage of gas around Seal incorrectly
Zone 1.4 to 1.5 outer flange seal - the tree and the spool Effective seal not made Gas leakage around seal 1.1
seal installed

envelope broken.
Pump Labouring
(audible)
Regular checks of pump
pressure injection rates
by plant operators.
5. Tubing spool Rupture of chemical Significant reduction or
Provide a conduit for Pressurisation of void
downhole chemical injection line - between Pipework damaged cessation of dosing rate
Zone 1.4 to 1.5 chemical injection into between tree and tubing 1.2
injection line - tubing spool and tree during installation of chemicals.
production bore spool with chemicals.
Secondary Barrier cavity
Competent fitters and
appropriate installation
procedures.
Potential leakage from
ring gasket and tie down
bolts.
96
Designers and
6. Tubing spool manufacturers to have
downhole chemical ISO quality systems in
injection line packing place. Offshore
To provide a seal Gradual deteriation of
gland - Secondary supervisors checks and
between the chemical seal, causing increasing Leakage around seal
Zone 1.4 to 1.5 Barrier Leakage around seal Ageing of seal balances. 2.2
injection line and the leakage over a period of increasing over time.
gland bore time
Outer block assembly -
Tertiary Barrier
Pressure test of
complete assembly.
6. Tubing spool Employ competent
downhole chemical individuals and
injection line packing appropriate supervision
To provide a seal
gland - Secondary is available.
between the chemical Seal incorrectly
Zone 1.4 to 1.5 Barrier Leakage around seal Effective seal not made Gas leakage around seal 1.1
injection line and the installed
gland bore
Tertiary Barrier Pressure tested after
envelope broken.
6. Tubing spool
downhole chemical Designers and
injection line packing manufacturers to have
To provide a seal and mechanical
gland - Secondary ISO quality systems in
between the chemical Wrong seal taken from properties similar to
Zone 1.4 to 1.5 Barrier Leakage around seal None place. Offshore 1.2
injection line and the stores actual specification,
gland bore therefore no immediate
Outer block assembly - balances i.e. permit to
effect.
Tertiary Barrier work system etc.
6. Tubing spool
injection line packing Material specification of manufacturers to have
To provide a seal
gland - Secondary seal incompatible with ISO quality systems in
between the chemical Seal incorrectly Gradually increasing
Zone 1.4 to 1.5 Barrier Leakage around seal body causing place. Offshore 1.2
injection line and the specified leak over time.
gland bore
Outer block assembly - setup. balances i.e. permit to
6. Tubing spool
downhole chemical
injection line packing
To provide a seal Tree has been operating
gland - Secondary
between the chemical Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.4 to 1.5 Barrier Leakage around seal None 1.2
injection line and the specified specified in design initial teething problems
gland bore have been ironed out.
Tertiary Barrier
97
6. Tubing spool Employ competent
downhole chemical individuals and
injection line packing appropriate supervision
gland - Secondary To provide a seal is available.
Seal incorrectly
Zone 1.4 to 1.5 Barrier between the gland body Leakage around seal Effective seal not made Gas leakage around seal 1.1
installed
and the tubing spool
envelope broken.
6. Tubing spool
injection line packing manufacturers to have
and mechanical
gland - Secondary To provide a seal ISO quality systems in
Wrong seal taken from properties similar to
Zone 1.4 to 1.5 Barrier between the gland body Leakage around seal None place. Offshore 1.2
stores actual specification,
and the tubing spool supervisors checks and
Outer block assembly - balances i.e. permit to
effect.
6. Tubing spool
injection line packing Material specification of manufacturers to have
gland - Secondary To provide a seal seal incompatible with ISO quality systems in
Seal incorrectly Gradually increasing
Zone 1.4 to 1.5 Barrier between the gland body Leakage around seal body causing place. Offshore 1.2
specified leak over time.
and the tubing spool differential cell to be supervisors checks and
Outer block assembly - setup. balances i.e. permit to
6. Tubing spool
downhole chemical
gland - Secondary To provide a seal
Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.4 to 1.5 Barrier between the gland body Leakage around seal None 1.2
specified specified in design initial teething problems
Tertiary Barrier
Designers and
6. Tubing spool manufacturers to have
downhole chemical ISO quality systems in
injection line packing place. Offshore
Gradual deteriation of
gland - Secondary To provide a seal supervisors checks and
seal, causing increasing Leakage around seal
Zone 1.4 to 1.5 Barrier between the gland body Leakage around seal Ageing of seal balances. 2.2
leakage over a period of increasing over time.
time
Tertiary Barrier
Pressure test of
complete assembly.
98
Designers and
Leakage around seal
place. Offshore
To provide a secondary Gradual deteriation of increasing over time.
7. Tubing hanger tie supervisors checks and
barrier between the seal, causing increasing
Zone 1.4 to 1.5 down bolts and seals - Leakage around seal Ageing of seal balances. 2.2
casing spool and the tie leakage over a period of Casing hanger may drop
Secondary Barrier
down bolts time as a result of seal
deteriation.
Pressure test of
complete assembly.
Designers and
8. Tubing spool ISO quality systems in
downhole safety valve place. Offshore
To provide a seal Gradual deteriation of
control packing gland - supervisors checks and
between the DHSV seal, causing increasing Leakage around seal
Zone 1.4 to 1.5 Secondary Barrier Leakage around seal Ageing of seal balances. 2.2
control line and the leakage over a period of increasing over time.
gland bore time
Outlet block assembly -
Tertiary Barrier
Pressure test of
complete assembly.
8. Tubing spool Designers and

downhole safety valve manufacturers to have
control packing gland - ISO quality systems in
between the DHSV Wrong seal taken from properties similar to
Zone 1.4 to 1.5 Secondary Barrier Leakage around seal None place. Offshore 1.2
control line and the stores actual specification,
Outlet block assembly - balances i.e. permit to
effect.

downhole safety valve Material specification of manufacturers to have
To provide a seal
control packing gland - seal incompatible with ISO quality systems in
between the DHSV Seal incorrectly Gradually increasing
Zone 1.4 to 1.5 Secondary Barrier Leakage around seal body causing place. Offshore 1.2
control line and the specified leak over time.
gland bore
Outlet block assembly - setup. balances i.e. permit to
8. Tubing spool
downhole safety valve
To provide a seal Tree has been operating
control packing gland -
between the DHSV Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.4 to 1.5 Secondary Barrier Leakage around seal None 1.2
control line and the specified specified in design initial teething problems
gland bore have been ironed out.
Tertiary Barrier
99
Employ competent
8. Tubing spool individuals and
downhole safety valve appropriate supervision
To provide a seal
control packing gland - is available.
between the DHSV Seal incorrectly
Zone 1.4 to 1.5 Secondary Barrier Leakage around seal Effective seal not made Gas leakage around seal 1.1
control line and the installed
gland bore
envelope broken.
Designers and
control packing gland - To provide a seal supervisors checks and
Zone 1.4 to 1.5 Secondary Barrier between the gland body Leakage around seal Ageing of seal balances. 2.2
time
Tertiary Barrier
Pressure test of
complete assembly.

and mechanical
control packing gland - To provide a seal ISO quality systems in
Zone 1.4 to 1.5 Secondary Barrier between the gland body Leakage around seal None place. Offshore 1.2
effect.

downhole safety valve Material specification of manufacturers to have
control packing gland - To provide a seal seal incompatible with ISO quality systems in
Zone 1.4 to 1.5 Secondary Barrier between the gland body Leakage around seal body causing place. Offshore 1.2
8. Tubing spool
control packing gland - To provide a seal
Zone 1.4 to 1.5 Secondary Barrier between the gland body Leakage around seal None 1.2
Tertiary Barrier
100
Employ competent
control packing gland - To provide a seal is available.
Seal incorrectly
Zone 1.4 to 1.5 Secondary Barrier between the gland body Leakage around seal Effective seal not made Gas leakage around seal 1.1
installed
envelope broken.
Pressure build up in the Instrument monitor
upper A annulus. facility on upper A
annulus.
9. Tubing spool to To provide a seal
Over a period of time
Zone 1.4 to 1.5 tubing hanger seal - between the tubing Leakage around seal Seal loses energisation 1.3
seal has compressed
Secondary Barrier hanger and tubing spool Tertiary barriers
provided by annular Pressure in upper A
valves, VR plug and annulus monitored by
instrumentation fittings plant operators.
Employ competent
individuals and
9. Tubing spool to To provide a seal is available.
Seal incorrectly
Zone 1.4 to 1.5 tubing hanger seal - between the tubing Leakage around seal Effective seal not made Gas leakage around seal 1.1
installed
Secondary Barrier hanger and tubing spool

envelope broken.
Designers and
and mechanical
9. Tubing spool to To provide a seal ISO quality systems in
Zone 1.4 to 1.5 tubing hanger seal - between the tubing Leakage around seal None place. Offshore 1.2
Secondary Barrier hanger and tubing spool supervisors checks and
effect.
work system etc.
Designers and
9. Tubing spool to To provide a seal seal incompatible with ISO quality systems in
Zone 1.4 to 1.5 tubing hanger seal - between the tubing Leakage around seal body causing place. Offshore 1.2
Secondary Barrier hanger and tubing spool differential cell to be supervisors checks and
work system etc.

9. Tubing spool to To provide a seal
Zone 1.4 to 1.5 tubing hanger seal - between the tubing Leakage around seal None 1.2
101
Designers and
place. Offshore
9. Tubing spool to To provide a seal supervisors checks and
Zone 1.4 to 1.5 tubing hanger seal - between the tubing Leakage around seal Ageing of seal balances. 2.2
time
Pressure test of
complete assembly.
during manufacture.
10. Tubing hanger Loss of integrity of Reduced thread to Designers and

Provide a seal between
downhole safety valve packing gland body thread contact surface manufacturers to have
the DHSV control line Thread cut out of
Zone 1.4 to 1.5 control line upper thread causing trapped (seal maintained by Degraded mechanical ISO quality systems in 3.3
and the tubing hanger tolerance
packing gland - pressure to leak into excessive PTFE for joint, since joint relies place. Offshore
body
Secondary Barrier upper annulus example) more on excessive supervisors checks and
thread contact.

during manufacture.
10. Tubing hanger Loss of integrity of Designers and

Provide a seal between Component will only
downhole safety valve packing gland body manufacturers to have
the DHSV control line Thread cut out of Either male or female mate for a proportion of
Zone 1.4 to 1.5 control line upper thread causing trapped ISO quality systems in 3.3
and the tubing hanger tolerance threads are cut oversize the threads (rather than
packing gland - pressure to leak into place. Offshore
body full length engagement)
Secondary Barrier upper annulus supervisors checks and
balances.

Excessive torque
required to install.
and effective
10. Tubing hanger Loss of integrity of
Provide a seal between supervision.
downhole safety valve packing gland body
the DHSV control line
Zone 1.4 to 1.5 control line upper thread causing trapped Cross threads Ineffective seal Fitting improperly 1.3
and the tubing hanger
packing gland - pressure to leak into aligned.
body
Secondary Barrier upper annulus
Suitable pressure
testing.
Leaking joint.
102
up.

Excessive torque and effective
Provide a seal between required to install. supervision.
downhole safety valve packing gland body
the DHSV control line Improperly mated
Zone 1.4 to 1.5 control line upper thread causing trapped Damaged threads 1.3
and the tubing hanger threads
packing gland - pressure to leak into
body
Fitting improperly Suitable pressure
aligned. testing.
Leaking joint
Loss of integrity of
10. Tubing hanger annulus.
Provide a seal between packing gland
the DHSV control line compression fitting Leakage of gas into
Zone 1.4 to 1.5 control line upper Incorrect joint make-up 1.3
and the tubing hanger causing trapped pressure upper A annulus
packing gland - Tertiary barriers
body to leak into upper
Secondary Barrier provided by annular Pressure in upper A
annulus
during manufacture.
11. Tubing hanger Loss of integrity of Reduced thread to Designers and

downhole chemical packing gland body thread contact surface manufacturers to have
the Chemical Injection Thread cut out of
Zone 1.4 to 1.5 injection line upper thread causing trapped (seal maintained by Degraded mechanical ISO quality systems in 3.3
line and the tubing tolerance
packing gland - pressure to leak into excessive PTFE for joint, since joint relies place. Offshore
hanger body
Secondary Barrier upper annulus example) more on excessive supervisors checks and
thread contact.
103
during manufacture.
11. Tubing hanger Loss of integrity of Designers and

downhole chemical packing gland body manufacturers to have
the Chemical Injection Thread cut out of Either male or female mate for a proportion of
Zone 1.4 to 1.5 injection line upper thread causing trapped ISO quality systems in 3.3
line and the tubing tolerance threads are cut oversize the threads (rather than
packing gland - pressure to leak into place. Offshore
hanger body full length engagement)
Secondary Barrier upper annulus supervisors checks and
balances.

Excessive torque
and effective
downhole chemical packing gland body
the Chemical Injection
Zone 1.4 to 1.5 injection line upper thread causing trapped Cross threads Ineffective seal Fitting improperly 1.3
line and the tubing
packing gland - pressure to leak into aligned.
hanger body
Suitable pressure
testing.
Leaking joint.
up.

downhole chemical packing gland body
the Chemical Injection Improperly mated
Zone 1.4 to 1.5 injection line upper thread causing trapped Damaged threads 1.3
line and the tubing threads
packing gland - pressure to leak into
hanger body
aligned. testing.
Leaking joint
11. Tubing hanger annulus.
Provide a seal between packing gland
downhole chemical
the Chemical Injection compression fitting Leakage of gas into
Zone 1.4 to 1.5 injection line upper Incorrect joint make-up 1.3
line and the tubing causing trapped pressure upper A annulus
packing gland - Tertiary barriers
hanger body to leak into upper
Secondary Barrier provided by annular Pressure in upper A
annulus
104
Pump Labouring
(audible)
by plant operators.
12. Tubing spool Provide a conduit for Rupture of down hole Pressurisation of void Significant reduction or
downhole safety valve the hydraulic fluid for safety valve control line Pipework damaged between tree and tubing cessation of dosing rate
Zone 1.4 to 1.5 1.2
control line - Secondary control of the down hole - between tubing spool during installation spool with hydraulic of chemicals.
Barrier safety valves and tree cavity fluid.
procedures.
ring gasket and tie down
bolts.
Slag
To provide a continuous Designers and
1. Annulus bore tubing inclusion/laminations,
bore between the tubing Stress raisers and crack manufacturers to have
Zone 1.5 to 1.6 hanger - Primary Annulus bore failure Manufacturing defect cold laps and other 1.1
hanger and the annulus initiators ISO quality systems in
Barrier geometric imperfections
tubing place.
Leakage of gas past

threaded connection
annulus. annulus.
1. Annulus bore tubing To provide a sealed
Failure of seal (metal to being out with
Zone 1.5 to 1.6 hanger - Primary mechanical joint Ineffective seal 2.2
metal) manufacturing
Barrier between components
tolerances
Leakage of gas past

threaded connection
annulus. annulus.
Failure of seal (metal to
Zone 1.5 to 1.6 hanger - Primary mechanical joint Galling on seal face Ineffective seal 2.2
metal)
105
Leakage of gas past
threaded connection
annulus. annulus.
Failure of seal (metal to Insufficient make up
Zone 1.5 to 1.6 hanger - Primary mechanical joint Ineffective seal 2.2
metal) torque
Leakage of gas past

threaded connection
annulus. annulus.
Failure of seal (metal to Excessive loading on Seal integrity reduced
Zone 1.5 to 1.6 hanger - Primary mechanical joint 2.2
metal) seal arrangement or failed
Leakage of gas past

threaded connection
annulus. annulus.
Failure of threaded Jumping out or
Zone 1.5 to 1.6 hanger - Primary mechanical joint Joint opens 2.2
connection 'unzipping' of the thread
106
Leakage of gas past
threaded connection
annulus. annulus.
Failure of threaded Joint integrity reduced
Zone 1.5 to 1.6 hanger - Primary mechanical joint Shearing of threads 2.2
connection or failed
Leakage of gas into the

upper A annulus.
Designers and
2. Annulus tubing & Provide location and
Nipple body integrity Stress raisers and crack manufacturers to have
Zone 1.5 to 1.6 annulus tubing nipples - hang-off for well Manufacturing defect 2.2
failure initiators Additional loading on ISO quality systems in
Primary Barrier intervention equipment
the dual bore upper place.
packer (hydrostatic

upper A annulus.
Annulus tubing will Designers and

2. Annulus tubing &
provide a conduit for the Stress raisers and crack manufacturers to have
Zone 1.5 to 1.6 annulus tubing nipples - Annulus tubing ruptures Manufacturing defect 2.2
gas to be injected into initiators Additional loading on ISO quality systems in
Primary Barrier
the production bore. the dual bore upper place.
packer (hydrostatic
Leakage of gas past

threaded connection
annulus. annulus.
2. Annulus tubing & To provide a sealed
Zone 1.5 to 1.6 annulus tubing nipples - mechanical joint Ineffective seal 2.2
Primary Barrier between components
tolerances
107
Leakage of gas past
threaded connection
annulus. annulus.
Zone 1.5 to 1.6 annulus tubing nipples - mechanical joint Galling on seal face Ineffective seal 2.2
metal)
Leakage of gas past

threaded connection
annulus. annulus.
metal) torque
Leakage of gas past

threaded connection
annulus. annulus.
Failure of seal (metal to Excessive loading on Seal integrity reduced or
Zone 1.5 to 1.6 annulus tubing nipples - mechanical joint 2.2
metal) seal arrangement failed
108
Leakage of gas past
threaded connection
annulus. annulus.
Zone 1.5 to 1.6 annulus tubing nipples - mechanical joint Joint opens 2.2
Leakage of gas past

threaded connection
annulus. annulus.
Zone 1.5 to 1.6 annulus tubing nipples - mechanical joint Shearing of threads 2.2
Degradation of
Produce corrosion Optimisation of material
components over time.
To protect the formation products which are a design and selection
3. Production casing - to the top of the pay Production casing split Corrosion (where water source of debris and can
Zone 1.5 to 1.6 1.3
Secondary Barrier zone and the 9 5/8" or parted is present) under certain situations
casing apply a pressure to
This less applicable to
mating surfaces Injection of inhibitors
13% Cr Alloys.
Deep pits and cavities. Optimisation of material
design and selection
To protect the formation
3. Production casing - to the top of the pay Production casing split Corrosion (where water
Zone 1.5 to 1.6 Localised corrosion 4.3
Secondary Barrier zone and the 9 5/8" or parted is present) If equipment is left for
casing an extended period of Good corrosion
time full wall management strategy
perforation can occur. and execution.
109
Gas lift pressure leakage
into the B annulus,
consequently annular
valves on B annulus
To protect the formation
become primary barrier.
3. Production casing - to the top of the pay Production casing split
Zone 1.5 to 1.6 Incorrect casing design Casing could part Correct casing design 3.3
Secondary Barrier zone and the 9 5/8" or parted
casing
B annulus is rated to a
lower pressure than the
A annulus.
into the B annulus,
valves on B annulus
Design and
manufacturers quality
assurance in accordance
13% Cr steels with ISO and
To protect the formation B annulus is rated to a
Embrittlement during vulnerable to temper equivalent.
3. Production casing - to the top of the pay Production casing split lower pressure than the
Zone 1.5 to 1.6 manufacturing process Embrittlement under 2.3
Secondary Barrier zone and the 9 5/8" or parted A annulus.
(high alloy steels) incorrect welding and
casing
heat treatment regimes.
Plant operators would
monitor annulus
Loss of ductility
pressure.
resulting in a greater
sensitivity to cracking
under normal well
conditions (thermal
loading).
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
3. Production casing - Failure of seal (metal to being out with
Secondary Barrier metal) manufacturing
between components
tolerances
110
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
3. Production casing - Failure of seal (metal to
Secondary Barrier metal)
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
3. Production casing - Failure of seal (metal to Insufficient make up
Secondary Barrier metal) torque
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
3. Production casing - Failure of seal (metal to Excessive loading on Seal integrity reduced or
Secondary Barrier metal) seal arrangement failed
between components
111
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
3. Production casing - Failure of threaded Jumping out or
Secondary Barrier connection 'unzipping' of the thread
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
3. Production casing - Failure of threaded Joint integrity reduced
Secondary Barrier connection or failed
between components
Pressure build up in the
Instrument monitor
B annulus.
facility on B annulus.
4. Production casing
To provide a seal
hanger seal to tubing Over a period of time
Zone 1.5 to 1.6 between the casing Leakage around seal Seal loses energisation 3.3
spool - Secondary seal has compressed
hanger and casing spool Secondary barriers
Barrier Pressure in B annulus
provided by annular
monitored by plant
valves and
operators.
instrumentation fittings
Employ competent
individuals and
To provide a seal is available.
hanger seal to tubing Seal incorrectly
Zone 1.5 to 1.6 between the casing Leakage around seal Effective seal not made Gas leakage around seal 1.1
spool - Secondary installed
hanger and casing spool
Barrier
envelope broken.
112
Designers and
4. Production casing and mechanical
To provide a seal ISO quality systems in
hanger seal to tubing Wrong seal taken from properties similar to
Zone 1.5 to 1.6 between the casing Leakage around seal None place. Offshore 1.2
spool - Secondary stores actual specification,
hanger and casing spool supervisors checks and
Barrier therefore no immediate
effect.
work system etc.
Designers and
To provide a seal seal incompatible with ISO quality systems in
hanger seal to tubing Seal incorrectly Gradually increasing
Zone 1.5 to 1.6 between the casing Leakage around seal body causing place. Offshore 1.2
spool - Secondary specified leak over time.
hanger and casing spool differential cell to be supervisors checks and
Barrier
work system etc.
4. Production casing Tree has been operating

To provide a seal
hanger seal to tubing Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.5 to 1.6 between the casing Leakage around seal None 1.2
spool - Secondary specified specified in design initial teething problems
Barrier have been ironed out.
Designers and
Leakage around seal
place. Offshore
4. Production casing Gradual deteriation of increasing over time
To provide a seal supervisors checks and
hanger seal to tubing seal, causing increasing
Zone 1.5 to 1.6 between the casing Leakage around seal Ageing of seal balances. 2.2
spool - Secondary leakage over a period of Casing hanger may drop
Barrier time as a result of seal
deteriation.
Pressure test of
complete assembly.
Designers and
To provide a facility to Material specification of manufacturers to have
5. Upper annulus tubing
isolate the A,B or C Bonnet seal leakage seal incompatible with ISO quality systems in
spool inner and outer Seal incorrectly Gradually leaking over
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 body causing place. Offshore 2.2
valves - Secondary specified time
instrumentation monitor valves differential cell to be supervisors checks and
Barrier
annular pressures setup. balances i.e. permit to
work system etc.
113
Designers and
To provide a facility to manufacturers to have
5. Upper annulus tubing and mechanical
isolate the A,B or C Bonnet seal leakage ISO quality systems in
spool inner and outer Wrong seal taken from properties similar to
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 None place. Offshore 2.2
valves - Secondary stores actual specification,
instrumentation monitor valves supervisors checks and
Barrier therefore no immediate
annular pressures balances i.e. permit to
effect.
work system etc.
To provide a facility to
5. Upper annulus tubing Tree has been operating
isolate the A,B or C Bonnet seal leakage
spool inner and outer Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 None. 2.2
valves - Secondary specified specified in design initial teething problems
instrumentation monitor valves
Barrier have been ironed out.
annular pressures
Employ competent
individuals and
To provide a facility to appropriate supervision
isolate the A,B or C Bonnet seal leakage is available.
spool inner and outer Seal incorrectly
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 Effective seal not made Gas leak around seal 2.1
valves - Secondary installed
instrumentation monitor valves
Barrier
annular pressures
envelope broken.
5. Upper annulus tubing Employ competent
isolate the A,B or C Bonnet seal leakage Bolts installed
spool inner and outer Sealing arrangement individuals and
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 incorrectly - bolts Joint integrity reduced 3.3
valves - Secondary unevenly energised appropriate supervision
instrumentation monitor valves unevenly tensioned
Barrier is available.
annular pressures
Designers and
To provide a facility to manufacturers to have
isolate the A,B or C Bonnet seal leakage Bolts installed ISO quality systems in
spool inner and outer
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
valves - Secondary
instrumentation monitor valves grade of bolt fitted supervisors checks and
Barrier
annular pressures balances i.e. permit to
work system etc.
5. Upper annulus tubing Employ competent
isolate the A,B or C Bonnet seal leakage Bolts installed
spool inner and outer Seal distortion leading to individuals and
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 incorrectly - bonnet over Joint integrity reduced 2.3
valves - Secondary progressive leakage. appropriate supervision
instrumentation monitor valves tensioned
Barrier is available.
annular pressures
114
Employ competent
To provide a facility to individuals and
isolate the A,B or C Bonnet seal leakage Bolts installed appropriate supervision
spool inner and outer Instantaneous leak from
Zone 1.5 to 1.6 annulus and with (metal to metal joint) - 2 incorrectly - bonnet Joint integrity reduced is available. 2.3
valves - Secondary bonnet
instrumentation monitor valves under tensioned
Barrier
annular pressures Pressure tested after
envelope broken.
To provide a facility to Perform maintenance

isolate the A,B or C and inspection in
spool inner and outer Stem Seal Leak - 2 Gas leaks from handle
Zone 1.5 to 1.6 annulus and with Wear and Tear Loss of full seal accordance with 2.4
valves - Secondary valves assembly
instrumentation monitor manufacturers
Barrier
annular pressures requirements.

Zone 1.5 to 1.6 annulus and with Packing not set correctlyLoss of full seal accordance with 2.4
Barrier

Zone 1.5 to 1.6 annulus and with Wrong packing fitted Loss of full seal accordance with 2.4
Barrier
isolate the A,B or C Fitter backs off
spool inner and outer Audible evidence of gas
Zone 1.5 to 1.6 annulus and with Grease fitting Leakage assembly rather than Partial leak Using competent fitters 3.3
valves - Secondary release
instrumentation monitor just the cap
Barrier
annular pressures
To provide a facility to Removal or backing off

isolate the A,B or C of plug during routine
spool inner and outer Audible evidence of gas
Zone 1.5 to 1.6 annulus and with Grease fitting Leakage greasing/lubricating Partial leak Using competent fitters 3.3
valves - Secondary release
instrumentation monitor removes inner check
Barrier
annular pressures valve
6. Upper annulus tubing To provide a facility for Cartridge nose seal Employ competent
spool monitor and vent pressure monitoring failure, annulus gas Cartridge not fully Gas leakage around individuals and
assembly - Secondary equipment to be linked leakage past cartridge tightened cartridge walls appropriate supervision
Barrier to the A annulus wall is available.
115
Designers and
6. Upper annulus tubing To provide a facility for
spool monitor and vent pressure monitoring Seal incorrectly Gradually leaking over
Zone 1.5 to 1.6 Failure of bonnet seal body causing place. Offshore 2.2
assembly - Secondary equipment to be linked specified time
Barrier to the A annulus
work system etc.
Designers and
6. Upper annulus tubing To provide a facility for and mechanical
spool monitor and vent pressure monitoring Wrong seal taken from properties similar to
Zone 1.5 to 1.6 Failure of bonnet seal None place. Offshore 2.2
assembly - Secondary equipment to be linked stores actual specification,
Barrier to the A annulus therefore no immediate
effect.
work system etc.
6. Upper annulus tubing To provide a facility for Tree has been operating
spool monitor and vent pressure monitoring Seal incorrectly Seal incorrectly in excess of 6 months,
Zone 1.5 to 1.6 Failure of bonnet seal None. 2.2
assembly - Secondary equipment to be linked specified specified in design initial teething problems
Barrier to the A annulus have been ironed out.
Employ competent
individuals and
is available.
spool monitor and vent pressure monitoring Seal incorrectly
Zone 1.5 to 1.6 Failure of bonnet seal Effective seal not made Gas leak around seal 2.1
assembly - Secondary equipment to be linked installed
envelope broken.
6. Upper annulus tubing To provide a facility for Employ competent

Bolts installed
spool monitor and vent pressure monitoring Sealing arrangement individuals and
Zone 1.5 to 1.6 Failure of bonnet seal incorrectly - bolts Joint integrity reduced 3.3
assembly - Secondary equipment to be linked unevenly energised appropriate supervision
unevenly tensioned
Barrier to the A annulus is available.
Designers and
spool monitor and vent pressure monitoring
Zone 1.5 to 1.6 Failure of bonnet seal incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
assembly - Secondary equipment to be linked
work system etc.
116

Bolts installed
spool monitor and vent pressure monitoring Seal distortion leading to individuals and
Zone 1.5 to 1.6 Failure of bonnet seal incorrectly - bonnet over Joint integrity reduced 2.3
assembly - Secondary equipment to be linked progressive leakage. appropriate supervision
tensioned
Employ competent
individuals and
spool monitor and vent pressure monitoring Instantaneous leak from
Zone 1.5 to 1.6 Failure of bonnet seal incorrectly - bonnet Joint integrity reduced is available. 2.3
assembly - Secondary equipment to be linked bonnet
under tensioned
envelope broken.

spool monitor and vent pressure monitoring Failure of Ring Gasket Bolts loosen off in
assembly - Secondary equipment to be linked Seal service
F&G system

spool monitor and vent pressure monitoring Failure of Ring Gasket Excessive vibration on
assembly - Secondary equipment to be linked Seal pipework

spool monitor and vent pressure monitoring Failure of Ring Gasket Displacement from
assembly - Secondary equipment to be linked Seal normal relative position
Designers and
spool monitor and vent pressure monitoring Failure of Ring Gasket Wrong seal taken from properties similar to
assembly - Secondary equipment to be linked Seal stores actual specification,
Barrier to the A annulus therefore no immediate
effect.
work system etc.
Designers and
spool monitor and vent pressure monitoring Failure of Ring Gasket Seal incorrectly Gradually increasing
assembly - Secondary equipment to be linked Seal specified leak over time.
work system etc.
117
6. Upper annulus tubing To provide a facility for Tree has been operating
spool monitor and vent pressure monitoring Failure of Ring Gasket Seal incorrectly Seal incorrectly in excess of 6 months,
assembly - Secondary equipment to be linked Seal specified specified in design initial teething problems
Barrier to the A annulus have been ironed out.
Employ competent
individuals and
is available.
spool monitor and vent pressure monitoring Failure of Ring Gasket Seal incorrectly
assembly - Secondary equipment to be linked Seal installed
envelope broken.

Bolts installed
spool monitor and vent pressure monitoring Failure of Ring Gasket Sealing arrangement individuals and
assembly - Secondary equipment to be linked Seal unevenly energised appropriate supervision
unevenly tensioned
Designers and
spool monitor and vent pressure monitoring Failure of Ring Gasket
assembly - Secondary equipment to be linked Seal
work system etc.

Bolts installed
spool monitor and vent pressure monitoring Failure of Ring Gasket Seal distortion leading to individuals and
assembly - Secondary equipment to be linked Seal progressive leakage. appropriate supervision
tensioned
Employ competent
individuals and
spool monitor and vent pressure monitoring Failure of Ring Gasket Instantaneous leak from
assembly - Secondary equipment to be linked Seal bonnet
under tensioned
envelope broken.
Perform maintenance
and inspection in
spool monitor and vent pressure monitoring Gas leaks from handle
Zone 1.5 to 1.6 Stem seal leakage Wear and Tear Loss of full seal accordance with 2.4
assembly - Secondary equipment to be linked assembly
manufacturers
requirements.
118
Perform maintenance
and inspection in
Zone 1.5 to 1.6 Stem seal leakage Packing not set correctlyLoss of full seal accordance with 2.4
manufacturers
requirements.
Perform maintenance
and inspection in
Zone 1.5 to 1.6 Stem seal leakage Wrong packing fitted Loss of full seal accordance with 2.4
manufacturers
requirements.
inner annular valve.
Correct torque applied
to VR plug in
Provides isolation in accordance with the
7. VR plug - Secondary
A,B or C annulus to manufacturers
Barrier VR plugs are generally
Zone 1.5 to 1.6 carry out maintenance Nose seal failure Debris on seal face Seal not seated correctly specification. 1.1
used for maintenance
on annular valves and
Tertiary valve(s) when one of the annular
fittings.
valves requires to be
removed and an
additional isolation is
required.
Leakage from upper A
annulus into inner
annular valve.
Provides isolation in
A,B or C annulus to
Barrier Failure of threaded Misalignment during Threads crossed causing
Zone 1.5 to 1.6 carry out maintenance VR plugs are generally Use of competent fitters.1.3
connection installation loss of integrity of joint
on annular valves and used for maintenance
Tertiary valve(s)
fittings. when one of the annular
removed and an
required.
Leakage from upper A
annulus into inner
annular valve.
Provides isolation in
A,B or C annulus to Galling of threads due
Barrier Failure of threaded
Zone 1.5 to 1.6 carry out maintenance to debris on threaded Loss of integrity of joint VR plugs are generally Use of competent fitters.1.3
connection
on annular valves and connections used for maintenance
Tertiary valve(s)
fittings. when one of the annular
removed and an
required.
119
Designers and
place. Offshore
8. Tubing hanger seal to To provide a seal supervisors checks and
Zone 1.5 to 1.6 tubing spool - between the tubing Leakage around seal Ageing of seal balances. 2.2
time
Pressure test of
complete assembly.
Designers and
and mechanical
8. Tubing hanger seal to To provide a seal ISO quality systems in
Zone 1.5 to 1.6 tubing spool - between the tubing Leakage around seal None place. Offshore 1.2
Secondary Barrier hanger and tubing spool supervisors checks and
effect.
work system etc.
Designers and
8. Tubing hanger seal to To provide a seal seal incompatible with ISO quality systems in
Zone 1.5 to 1.6 tubing spool - between the tubing Leakage around seal body causing place. Offshore 1.2
Secondary Barrier hanger and tubing spool differential cell to be supervisors checks and
work system etc.

8. Tubing hanger seal to To provide a seal
Zone 1.5 to 1.6 tubing spool - between the tubing Leakage around seal None 1.2
Employ competent
individuals and
8. Tubing hanger seal to To provide a seal is available.
Seal incorrectly
Zone 1.5 to 1.6 tubing spool - between the tubing Leakage around seal Effective seal not made Gas leakage around seal 1.1
installed

envelope broken.
120
Instrument monitor
B annulus.
8. Tubing hanger seal to To provide a seal
Over a period of time
Zone 1.5 to 1.6 tubing spool - between the tubing Leakage around seal Seal loses energisation 3.3
seal has compressed
Secondary Barrier hanger and tubing spool Secondary barriers
Pressure in B annulus
provided by annular
monitored by plant
valves and
operators.
Pump Labouring
pressure and injection
(audible) - increased
rates by plant operators.
9. Tubing spool Pressurisation of void injection rate
Provide a conduit for Rupture of chemical
downhole chemical Pipework damaged between tubing hanger
Zone 1.5 to 1.6 chemical injection into injection line - below 1.2
injection line - during installation and the dual bore upper
production bore tubing hanger
Secondary Barrier packer with chemicals.
Significant increase of
dosing rate of chemicals.
procedures.
pressure and injection
Pressurisation of void rates by plant operators.
10. Tubing spool Provide a conduit for
Rupture of down hole between tubing hanger Pump Labouring
downhole safety valve the hydraulic fluid for Pipework damaged
Zone 1.5 to 1.6 safety valve control line and the dual bore upper (audible) - increased 1.2
control line - Secondary control of the down hole during installation
- below tubing hanger packer with hydraulic injection rate
Barrier safety valves
fluid. Competent fitters and
procedures.
during manufacture.
Loss of integrity of No visible symptoms.

packing gland body
11. Tubing hanger thread causing trapped Reduced thread to Designers and
downhole safety valve pressure to leak into thread contact surface manufacturers to have
Zone 1.5 to 1.6 control line lower cavity between tree and (seal maintained by Degraded mechanical ISO quality systems in 3.3
packing gland - tubing hanger. excessive PTFE for joint, since joint relies place. Offshore
body
Secondary Barrier example) more on excessive supervisors checks and
On coincident failure of sealant than intimate balances.
upper packing gland. thread contact.
121
during manufacture.
packing gland body
11. Tubing hanger thread causing trapped Designers and
downhole safety valve pressure to leak into manufacturers to have
Zone 1.5 to 1.6 control line lower cavity between tree and ISO quality systems in 3.3
packing gland - tubing hanger. place. Offshore
Secondary Barrier supervisors checks and
On coincident failure of balances.
upper packing gland.

Excessive torque
Loss of integrity of required to install.
packing gland body
and effective
11. Tubing hanger thread causing trapped
downhole safety valve pressure to leak into
Zone 1.5 to 1.6 control line lower cavity between tree and Cross threads Ineffective seal Fitting improperly 1.3
and the tubing hanger
packing gland - tubing hanger. aligned.
body
Secondary Barrier
Suitable pressure
On coincident failure of
testing.
Leaking joint.
up.
packing gland body
Zone 1.5 to 1.6 control line lower cavity between tree and Damaged threads 1.3
packing gland - tubing hanger.
body
Secondary Barrier
aligned. testing.
Leaking joint
122
Leakage of gas past

threaded connection
consequently
Loss of integrity of pressurising the cavity Instrument monitor
packing gland body between tree and tubing facility on upper A
11. Tubing hanger thread causing trapped hanger annulus.
the DHSV control line Leakage of gas into
Zone 1.5 to 1.6 control line lower cavity between tree and Incorrect joint make-up 1.3
and the tubing hanger upper A annulus
packing gland - tubing hanger. Tertiary barriers
body
Secondary Barrier provided by tie down Pressure in upper A
On coincident failure of bolt arrangement, annulus monitored by
upper packing gland. chemical injection point, plant operators.
down hole safety valve
point, tubing hanger to
casing spool seal.

during manufacture.

packing gland body
downhole chemical pressure to leak into thread contact surface manufacturers to have
Zone 1.5 to 1.6 injection line lower cavity between tubing (seal maintained by Degraded mechanical ISO quality systems in 3.3
packing gland - hanger and tree. excessive PTFE for joint, since joint relies place. Offshore
hanger body
upper packing gland. thread contact.

during manufacture.
packing gland body
downhole chemical pressure to leak into manufacturers to have
Zone 1.5 to 1.6 injection line lower cavity between tubing ISO quality systems in 3.3
packing gland - hanger and tree. place. Offshore
123
Excessive torque
packing gland body
and effective
downhole chemical pressure to leak into
Zone 1.5 to 1.6 injection line lower cavity between tubing Cross threads Ineffective seal Fitting improperly 1.3
line and the tubing
packing gland - hanger and tree. aligned.
hanger body
Secondary Barrier
Suitable pressure
testing.
Leaking joint.
up.
packing gland body
Zone 1.5 to 1.6 injection line lower cavity between tubing Damaged threads 1.3
packing gland - hanger and tree.
hanger body
Secondary Barrier
aligned. testing.
Leaking joint
Leakage of gas past

threaded connection
consequently
Loss of integrity of pressurising the cavity
packing gland body between tree and tubing
12. Tubing hanger thread causing trapped hanger.
downhole chemical pressure to leak into Leakage of gas into
Zone 1.5 to 1.6 injection line lower cavity between tubing Incorrect joint make-up cavity between tubing None. 1.3
line and the tubing
packing gland - hanger and tree. hanger and tree. Tertiary barriers
hanger body
Secondary Barrier provided by tie down
On coincident failure of bolt arrangement,
upper packing gland. chemical injection point,
down hole safety valve
point, tubing hanger to
casing spool seal.
124
upper A annulus.
Designers and
1. Annulus tubing & Provide location and
Nipple body integrity Stress raisers and crack manufacturers to have
Zone 1.6 to 1.7 annulus tubing nipples - hang-off for well Manufacturing defect 2.2
failure initiators Additional loading on ISO quality systems in
Primary Barrier intervention equipment
packer (hydrostatic

upper A annulus.
Annulus tubing will
Designers and
1. Annulus tubing & provide a conduit for
Stress raisers and crack manufacturers to have
Zone 1.6 to 1.7 annulus tubing nipples - the gas to be injected Annulus tubing ruptures Manufacturing defect 2.2
initiators Additional loading on ISO quality systems in
Primary Barrier into the production
bore.
packer (hydrostatic
Leakage of gas past

threaded connection
annulus. annulus.
tolerances
Leakage of gas past

threaded connection
annulus. annulus.
Zone 1.6 to 1.7 annulus tubing nipples - mechanical joint Galling on seal face Ineffective seal 2.2
metal)
125
Leakage of gas past
threaded connection
annulus. annulus.
metal) torque
Leakage of gas past

threaded connection
annulus. annulus.
Zone 1.6 to 1.7 annulus tubing nipples - mechanical joint 2.2
Leakage of gas past

threaded connection
annulus. annulus.
Zone 1.6 to 1.7 annulus tubing nipples - mechanical joint Joint opens 2.2
126
Leakage of gas past
threaded connection
annulus. annulus.
Zone 1.6 to 1.7 annulus tubing nipples - mechanical joint Shearing of threads 2.2
Leakage of gas past

threaded connection
annulus. annulus.
To provide addition Failure due to threads
2. Annulus downhole
barrier between lower Failure of seal (metal to being out with
Zone 1.6 to 1.7 safety valve - Primary Ineffective seal 2.2
annulus and metal) manufacturing
Barrier
tree/wellhead tolerances
Leakage of gas past

threaded connection
annulus. annulus.
To provide addition
2. Annulus downhole
barrier between lower Failure of seal (metal to
Zone 1.6 to 1.7 safety valve - Primary Galling on seal face Ineffective seal 2.2
annulus and metal)
Barrier
tree/wellhead
127
Leakage of gas past
threaded connection
annulus. annulus.
To provide addition
2. Annulus downhole
barrier between lower Failure of seal (metal to Insufficient make up
annulus and metal) torque
Barrier
tree/wellhead
Leakage of gas past

threaded connection
annulus. annulus.
To provide addition
2. Annulus downhole
barrier between lower Failure of seal (metal to Excessive loading on Seal integrity reduced or
Zone 1.6 to 1.7 safety valve - Primary 2.2
annulus and metal) seal arrangement failed
Barrier
tree/wellhead
Leakage of gas past

threaded connection
annulus. annulus.
To provide addition
2. Annulus downhole
barrier between lower Failure of threaded Jumping out or
Zone 1.6 to 1.7 safety valve - Primary Joint opens 2.2
annulus and connection 'unzipping' of the thread
Barrier
tree/wellhead
128
Leakage of gas past
threaded connection
annulus. annulus.
To provide addition
2. Annulus downhole
barrier between lower Failure of threaded Joint integrity reduced
Zone 1.6 to 1.7 safety valve - Primary Shearing of threads 2.2
annulus and connection or failed
Barrier
tree/wellhead
Correct specification of
seals.
Gas leakage into upper
A annulus.
To provide addition
2. Annulus downhole Failure of two radially
barrier between lower Failure of housing DHSV housing loses
Zone 1.6 to 1.7 safety valve - Primary successive seals of the Manufacturers and 1.1
annulus and sealing arrangement integrity
Barrier component interface designers have a
tree/wellhead
A Annular valves suitable quality
become tertiary barriers. assurance system in
accordance with ISO or
equivalent.
A annulus.
To provide addition seals.
barrier between lower Failure of control line Leakage into the A Flapper closes if control
Zone 1.6 to 1.7 safety valve - Primary successive seals of the 2.1
annulus and housing annulus line ruptures
Barrier component interface
tree/wellhead
Periodic testing
A Annular valves
become tertiary barriers.
Leakage of gas past
threaded connection
annulus. annulus.
To provide addition Failure due to threads
1. Annulus downhole
barrier between lower Failure of seal (metal to being out with
annulus and metal) manufacturing
Barrier
tree/wellhead tolerances
129
Leakage of gas past
threaded connection
annulus. annulus.
To provide addition
1. Annulus downhole
barrier between lower Failure of seal (metal to
Zone 1.7 to 1.8 safety valve - Primary Galling on seal face Ineffective seal 2.2
annulus and metal)
Barrier
tree/wellhead
Leakage of gas past

threaded connection
annulus. annulus.
To provide addition
1. Annulus downhole
barrier between lower Failure of seal (metal to Insufficient make up
annulus and metal) torque
Barrier
tree/wellhead
Leakage of gas past

threaded connection
annulus. annulus.
To provide addition
1. Annulus downhole
barrier between lower Failure of seal (metal to Excessive loading on Seal integrity reduced
Zone 1.7 to 1.8 safety valve - Primary 2.2
annulus and metal) seal arrangement or failed
Barrier
tree/wellhead
130
Leakage of gas past
threaded connection
annulus. annulus.
To provide addition
1. Annulus downhole
barrier between lower Failure of seal (metal to Jumping out or
Zone 1.7 to 1.8 safety valve - Primary Joint opens 2.2
annulus and metal) 'unzipping' of the thread
Barrier
tree/wellhead
Leakage of gas past

threaded connection
annulus. annulus.
To provide addition
1. Annulus downhole
barrier between lower Failure of seal (metal to Joint integrity reduced
Zone 1.7 to 1.8 safety valve - Primary Shearing of threads 2.2
annulus and metal) or failed
Barrier
tree/wellhead
seals.
A annulus.
To provide addition
barrier between lower Failure of housing DHSV housing loses
Zone 1.7 to 1.8 safety valve - Primary successive seals of the Manufacturers and 1.1
annulus and sealing arrangement integrity
Barrier component interface designers have a
tree/wellhead A Annular valves
suitable quality
become tertiary
assurance system in
barriers.
equivalent.
A annulus.
To provide addition seals.
1. Annulus downhole Failure of two radially Flapper closes if control
barrier between lower Failure of control line Leakage into the A
Zone 1.7 to 1.8 safety valve - Primary successive seals of the line ruptures 2.1
annulus and housing annulus
tree/wellhead
Periodic testing
A Annular valves
become tertiary
barriers.
131
upper A annulus.
Annulus tubing will Designers and

2. Annulus Tubing - provide a conduit for the Stress raisers and crack manufacturers to have
Zone 1.7 to 1.8 Annulus tubing ruptures Manufacturing defect 2.2
Primary Barrier gas to be injected into initiators Additional loading on ISO quality systems in
the production bore. the dual bore upper place.
packer (hydrostatic
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
2. Annulus Tubing - Failure of seal (metal to being out with
Primary Barrier metal) manufacturing
between components
tolerances
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
2. Annulus Tubing - Failure of seal (metal to
Primary Barrier metal)
between components
132
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
2. Annulus Tubing - Failure of seal (metal to Insufficient make up
Primary Barrier metal) torque
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
2. Annulus Tubing - Failure of seal (metal to Excessive loading on Seal integrity reduced or
Primary Barrier metal) seal arrangement failed
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
2. Annulus Tubing - Failure of threaded Jumping out or
Primary Barrier connection 'unzipping' of the thread
between components
133
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
2. Annulus Tubing - Failure of threaded Joint integrity reduced
Primary Barrier connection or failed
between components

upper A annulus.
Annulus tubing will
Designers and
provide a conduit for
1. Annulus Tubing - Stress raisers and crack manufacturers to have
Zone 1.8 to 1.9 the gas to be injected Annulus tubing ruptures Manufacturing defect 2.2
Primary Barrier initiators Additional loading on ISO quality systems in
into the production
bore.
packer (hydrostatic
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
1. Annulus Tubing - Failure of seal (metal to being out with
Primary Barrier metal) manufacturing
between components
tolerances
134
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
1. Annulus Tubing - Failure of seal (metal to
Primary Barrier metal)
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
1. Annulus Tubing - Failure of seal (metal to Insufficient make up
Primary Barrier metal) torque
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
1. Annulus Tubing - Failure of seal (metal to Excessive loading on Seal integrity reduced or
Primary Barrier metal) seal arrangement failed
between components
135
Leakage of gas past
threaded connection
annulus. annulus.
To provide a sealed
1. Annulus Tubing - Failure of threaded Jumping out or
Primary Barrier connection 'unzipping' of the thread
between components
Leakage of gas past

threaded connection
annulus. annulus.
To provide a sealed
1. Annulus Tubing - Failure of threaded Joint integrity reduced
Primary Barrier connection or failed
between components
Periodic checks of upper
A annulus pressure.
Dual upper bore packer
2. Annulus bore dual Gas passing from lower
provides isolation Failure of the packer Upper A annulus
Zone 1.8 to 1.9 bore upper packer - Incorrectly set annulus to upper 2.2
between the upper and sealing element pressurise with gas.
Primary Barrier annulus
lower annulus Pressure testing when
packer was originally
installed.
A annulus pressure.
provides isolation Failure of the packer Deteriation of the Upper A annulus
Zone 1.8 to 1.9 bore upper packer - annulus to upper 2.2
between the upper and sealing element packer sealing element pressurise with gas.
installed.
Dual upper bore packer Expansion and
2. Annulus bore dual Packer to be designed
provides isolation Failure of the packer Design working loads Additional tensile loads contraction of annulus
Zone 1.8 to 1.9 bore upper packer - for all reasonably 2.3
between the upper and sealing element are exceeded imposed on packer tubing in the absence of
Primary Barrier foreseeable events.
lower annulus a slip joint.
136
A annulus pressure.
2. Annulus bore dual Deteriation of the Gas passing from lower
provides isolation Failure of the tubing Upper A annulus
Zone 1.8 to 1.9 bore upper packer - annulus upper bore annulus to upper 2.2
between the upper and annulus to packer seal pressurise with gas.
Primary Barrier tubing stab seal annulus
installed.
Dual upper bore packer Expansion and Tubing stab to be
2. Annulus bore dual
provides isolation Failure of the tubing Design working loads Additional tensile loads contraction of annulus designed for all
Zone 1.8 to 1.9 bore upper packer - 2.3
between the upper and annulus to packer seal are exceeded imposed on packer tubing in the absence of reasonably foreseeable
Primary Barrier
lower annulus a slip joint. events.
Pump Labouring
(audible)
by plant operators.
Rupture of chemical
3. Downhole chemical Provide a conduit for
injection line - between Pipework damaged Pressurisation of upper a Significant reduction or
Zone 1.8 to 1.9 injection line - chemical injection into 1.2
tubing hanger and dual during installation annulus with chemicals cessation of dosing rate
Secondary Barrier production bore
bore upper packer of chemicals.
procedures.
A annulus pressure
increase.
Loss of integrity of during manufacture.
packing gland body
thread causing trapped No visible symptoms.
pressure to leak up
4. Dual bore packer against the lower Reduced thread to Designers and
downhole chemical chemical injection line thread contact surface manufacturers to have
Zone 1.8 to 1.9 injection line upper packing gland. (seal maintained by Degraded mechanical ISO quality systems in 3.3
line and the dual bore tolerance
packing gland - excessive PTFE for joint, since joint relies place. Offshore
upper packer body
Secondary Barrier Coincident failure of example) more on excessive supervisors checks and
lower chemical injection sealant than intimate balances.
line packing gland in thread contact.
order to leak into lower
annulus.
137
Loss of integrity of during manufacture.
packing gland body
thread causing trapped
pressure to leak up
4. Dual bore packer against the lower Designers and
downhole chemical chemical injection line manufacturers to have
Zone 1.8 to 1.9 injection line upper packing gland. ISO quality systems in 3.3
line and the dual bore tolerance threads are cut oversize the threads (rather than
packing gland - place. Offshore
upper packer body full length engagement)
Secondary Barrier Coincident failure of supervisors checks and
lower chemical injection balances.
line packing gland in
annulus.
packing gland body Excessive torque
thread causing trapped required to install.
pressure to leak up
and effective
4. Dual bore packer against the lower
downhole chemical chemical injection line
Zone 1.8 to 1.9 injection line upper packing gland. Cross threads Ineffective seal Fitting improperly 1.3
line and the dual bore
packing gland - aligned.
upper packer body
Secondary Barrier Coincident failure of
Suitable pressure
lower chemical injection
testing.
order to leak into lower Leaking joint.
annulus.

up.
packing gland body
pressure to leak up
4. Dual bore packer against the lower
Zone 1.8 to 1.9 injection line upper packing gland. Damaged threads 1.3
line and the dual bore threads
packing gland -
upper packer body
Secondary Barrier Coincident failure of
lower chemical injection
aligned. testing.
annulus.
Leaking joint
138
Chemical injection line

subject to back pressure
from injection gas under
normal chemical
packing gland body
injection activities.
thread causing trapped Instrument monitor
Chemical injection
pressure to leak up facility on upper A
pressure will increase.
4. Dual bore packer against the lower annulus.
the Chemical Injection Leakage of gas into Chemical injection line
Zone 1.8 to 1.9 injection line upper packing gland. Incorrect joint make-up 1.3
line and the dual bore upper A annulus pressurised with
packing gland -
upper packer body injection gas when not
Secondary Barrier Coincident failure of Pressure in upper A
injecting chemicals.
lower chemical injection annulus monitored by
line packing gland in plant operators.
Tertiary barriers
annulus.
provided by annular
valves, VR plug and
Periodic checks of
upper A annulus
pressure.
provides isolation Failure of the packer Upper A annulus
Zone 1.9 to 1.11 bore upper packer - Incorrectly set annulus to upper 2.2
between the upper and sealing element pressurise with gas.
lower annulus
Pressure testing when
installed.
Periodic checks of
upper A annulus
pressure.
provides isolation Failure of the packer Deteriation of the Upper A annulus
Zone 1.9 to 1.11 bore upper packer - annulus to upper 2.2
between the upper and sealing element packer sealing element pressurise with gas.
lower annulus
installed.
Dual upper bore packer Expansion and
1. Annulus bore dual Packer to be designed
provides isolation Failure of the packer Design working loads Additional tensile loads contraction of annulus
Zone 1.9 to 1.11 bore upper packer - for all reasonably 2.3
between the upper and sealing element are exceeded imposed on packer tubing in the absence of
Primary Barrier foreseeable events.
lower annulus a slip joint.
Periodic checks of
upper A annulus
1. Annulus bore dual Deteriation of the Gas passing from lower pressure.
provides isolation Failure of the tubing Upper A annulus
Zone 1.9 to 1.11 bore upper packer - annulus upper bore annulus to upper 2.2
between the upper and annulus to packer seal pressurise with gas.
Primary Barrier tubing stab seal annulus Pressure testing when
lower annulus
installed.
139
Dual upper bore packer Expansion and Tubing stab to be
provides isolation Failure of the tubing Design working loads Additional tensile loads contraction of annulus designed for all
Zone 1.9 to 1.11 bore upper packer - 2.3
between the upper and annulus to packer seal are exceeded imposed on packer tubing in the absence of reasonably foreseeable
Primary Barrier
lower annulus a slip joint. events.
Degradation of
Produce corrosion Optimisation of material
components over time.
To provide a conduit for products which are a design and selection
2. Lower well annulus
the gas to be injected Lower annulus casing Corrosion (where water source of debris and can
Zone 1.9 to 1.11 (9 5/8") - Primary 1.3
into the production split or parted is present) under certain situations
Barrier
string apply a pressure to
This less applicable to
mating surfaces Injection of inhibitors
13% Cr Alloys.
Deep pits and cavities. Optimisation of material
design and selection
To provide a conduit for
the gas to be injected Lower annulus casing Corrosion (where water
Zone 1.9 to 1.11 (9 5/8") - Primary Localised corrosion 4.3
into the production split or parted is present) If equipment is left for
Barrier
string an extended period of Good corrosion
time full wall management strategy
perforation can occur. and execution.
into the B annulus,
valves on B annulus
To provide a conduit for
2. Lower well annulus become primary barrier.
the gas to be injected Lower annulus casing
Zone 1.9 to 1.11 (9 5/8") - Primary Incorrect casing design Casing could part Correct casing design 3.3
into the production split or parted
Barrier
string
A annulus.
into the B annulus,
valves on B annulus
Design and
13% Cr steels with ISO and
To provide a conduit for B annulus is rated to a
2. Lower well annulus Embrittlement during vulnerable to temper equivalent.
the gas to be injected Lower annulus casing lower pressure than the
Zone 1.9 to 1.11 (9 5/8") - Primary manufacturing process Embrittlement under 2.3
into the production split or parted A annulus.
Barrier (high alloy steels) incorrect welding and
string
heat treatment regimes.
monitor annulus
Loss of ductility
pressure.
under normal well
conditions (thermal
loading).
140
Leakage of gas past
threaded connection
annulus. annulus.
2. Lower well annulus To provide a sealed
Zone 1.9 to 1.11 (9 5/8") - Primary mechanical joint Ineffective seal 2.2
tolerances
Leakage of gas past

threaded connection
annulus. annulus.
Zone 1.9 to 1.11 (9 5/8") - Primary mechanical joint Galling on seal face Ineffective seal 2.2
metal)
Leakage of gas past

threaded connection
annulus. annulus.
metal) torque
141
Leakage of gas past
threaded connection
annulus. annulus.
Zone 1.9 to 1.11 (9 5/8") - Primary mechanical joint 2.2
Leakage of gas past

threaded connection
annulus. annulus.
Zone 1.9 to 1.11 (9 5/8") - Primary mechanical joint Joint opens 2.2
Leakage of gas past

threaded connection
annulus. annulus.
Zone 1.9 to 1.11 (9 5/8") - Primary mechanical joint Shearing of threads 2.2
Manufacturers and
designers quality
assurance scheme in
To provide a means of Gas is not injected at the Gas lift is not effective, accordance with ISO or
3. Side Pocket Mandrels Orifice valve fails to
Zone 1.9 to 1.11 injecting gas into the Incorrect set pressure right level in the if well is reliant on gas equivalent. 1.2
(SPM) - Primary Barrier open on demand
bore string production string lift well may not flow.
Orifice valves checked
before installation in
well.
142
Manufacturers and
Gas lift is not effective,
designers quality
if well is reliant on gas
assurance scheme in
lift well may not flow.
To provide a means of equivalent.
3. Side Pocket Mandrels Orifice valve fails to Orifice valve seized - Gas is not injected into
Zone 1.9 to 1.11 injecting gas into the 1.2
(SPM) - Primary Barrier open on demand closed the production string
bore string
Lower A annulus is
pressurised beyond
normal operating
conditions.
well.
Chemical injection
pipework and fittings
should be designed and
normal chemical
constructed for all
reasonably foreseeable
Chemical injection
Provide a conduit to events.
4. Chemical Injection Chemical injection line Operational loads pressure will increase.
Zone 1.9 to 1.11 inject chemicals into the Line could split 2.3
Line rupture exceeded
production tubing
Chemical injection
pressure should be
pressurised with
monitored by competent
injection gas when not
individuals.
Combination of
vibration and tension in
line due to slippage of
Provide a conduit to supports.
4. Chemical Injection Chemical injection line Operational loads Correct supporting
Zone 1.9 to 1.11 inject chemicals into the Fatigue 2.3
Line rupture exceeded arrangement.
production tubing
Pressure cyclic effects

from injecting.
143
Joint leakage at either
dual bore upper packer
or connection to
production tubing.
Chemical injection
Chemical injection line constructed for all
subject to back pressure reasonably foreseeable
Provide a conduit to from injection gas under events.
4. Chemical Injection Chemical injection line Operational loads
Zone 1.9 to 1.11 inject chemicals into the Incorrect installation normal chemical 2.3
Line rupture exceeded
production tubing injection activities.
Chemical injection
pressure will increase. Chemical injection
pressure should be
monitored by competent
individuals.
pressurised with
Due to residual liquids
from previous
operations.

Corrosion/materials
Provide a conduit to engineer to ensure
4. Chemical Injection Chemical injection line Operational loads normal chemical
Zone 1.9 to 1.11 inject chemicals into the Corrosion of fittings compatibility of 2.3
Line rupture exceeded injection activities.
production tubing materials with
Chemical injection
environment.

pressurised with
144
Upper chemical
injection line seal to
A annulus pressure.
takes lower A annulus
Lower seal between
Provide a conduit to Deteriation of the lower Gas passing from lower pressure. Coincidental
4. Chemical Injection chemical injection line
Zone 1.9 to 1.11 inject chemicals into the chemical injection line annulus to upper failure of upper 2.2
Line and dual bore upper
production tubing seal annulus chemical injection line
packer Pressure testing when
seal to dual bore upper
packer to upper A
installed.
annulus pressurise with
gas.
Lower seal between Expansion and Tubing stab to be

Provide a conduit to
4. Chemical Injection chemical injection line Design working loads Additional tensile loads contraction of annulus designed for all
Zone 1.9 to 1.11 inject chemicals into the 2.3
Line and dual bore upper are exceeded imposed on packer tubing in the absence of reasonably foreseeable
production tubing
packer a slip joint. events.
Failure of upper
chemical injection line
packer to upper A
A annulus pressure.
gas.
Upper seal between
Provide a conduit to Deteriation of the upper Gas passing from lower
4. Chemical Injection chemical injection line
Zone 1.9 to 1.11 inject chemicals into the chemical injection line annulus to upper 2.2
Line and dual bore upper
production tubing seal annulus
packer Pressure testing when
Failure of lower
installed.
packer to upper A
gas.
Upper seal between Expansion and Tubing stab to be
Provide a conduit to
4. Chemical Injection chemical injection line Design working loads Additional tensile loads contraction of annulus designed for all
Zone 1.9 to 1.11 inject chemicals into the 2.3
Line and dual bore upper are exceeded imposed on packer tubing in the absence of reasonably foreseeable
production tubing
145
APPENDIX F
SINGLE COMPLETION FMECA RESULTS
146
Designers and
To contain the gas Material specification manufacturers to have
within the A annulus of Bonnet seal leakage of seal incompatible ISO quality systems in
1. Gas Check Valve - Seal incorrectly Gradually leaking over
Zone 2.1 to 2.2 the wellhead on loss of with body causing place. Offshore 2.2
Primary Barrier (metal to metal joint) specified time supervisors checks and
pressurisation in the differential cell to be
upstream pipework. setup. balances i.e. permit to
work system etc.
Designers and
To contain the gas manufacturers to have
and mechanical
within the A annulus of ISO quality systems in
1. Gas Check Valve - Bonnet seal leakage Wrong seal taken from properties similar to place. Offshore
Zone 2.1 to 2.2 the wellhead on loss of actual specification, None 2.2
Primary Barrier (metal to metal joint) stores
pressurisation in the supervisors checks and
upstream pipework. balances i.e. permit to
effect.
work system etc.

within the A annulus of in excess of 6 months,
1. Gas Check Valve - Bonnet seal leakage Seal incorrectly Seal incorrectly
Zone 2.1 to 2.2 the wellhead on loss of None. initial teething 2.2
Primary Barrier (metal to metal joint) specified specified in design
pressurisation in the problems have been
upstream pipework. ironed out.
Employ competent
individuals and
To contain the gas appropriate supervision
within the A annulus of is available.
1. Gas Check Valve - Bonnet seal leakage Seal incorrectly
Zone 2.1 to 2.2 the wellhead on loss of (metal to metal joint) Effective seal not made Gas leak around seal 2.1
Primary Barrier installed
upstream pipework.
envelope broken.
To contain the gas

Employ competent
within the A annulus of Bonnet seal leakage Bolts installed
1. Gas Check Valve - Sealing arrangement individuals and
Zone 2.1 to 2.2 the wellhead on loss of incorrectly - bolts Joint integrity reduced 3.3
Primary Barrier (metal to metal joint) unevenly energised appropriate supervision
pressurisation in the unevenly tensioned
is available.
upstream pipework.
147
Designers and
within the A annulus of Bonnet seal leakage Bolts installed ISO quality systems in
1. Gas Check Valve -
Zone 2.1 to 2.2 the wellhead on loss of incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
Primary Barrier (metal to metal joint) supervisors checks and
pressurisation in the grade of bolt fitted
work system etc.
To contain the gas

Employ competent
within the A annulus of Bolts installed
1. Gas Check Valve - Bonnet seal leakage Seal distortion leading individuals and
Zone 2.1 to 2.2 the wellhead on loss of incorrectly - bonnet Joint integrity reduced to progressive leakage. appropriate supervision 2.3
Primary Barrier (metal to metal joint)
pressurisation in the over tensioned
is available.
upstream pipework.
Employ competent
To contain the gas individuals and
within the A annulus of Bolts installed appropriate supervision
1. Gas Check Valve - Bonnet seal leakage Instantaneous leak from
Zone 2.1 to 2.2 the wellhead on loss of (metal to metal joint) incorrectly - bonnet Joint integrity reduced is available. 2.3
Primary Barrier bonnet
pressurisation in the under tensioned
upstream pipework. Pressure tested after
envelope broken.
To contain the gas

within the A annulus of Possible detection by
1. Gas Check Valve - Failure of Ring Gasket Bolts loosen off in
Zone 2.1 to 2.2 the wellhead on loss of Seal Partial leakage of gas Gas release plant operators and/or 2.3
Primary Barrier service
pressurisation in the F&G system
upstream pipework.
To contain the gas

within the A annulus of Catastrophic failure of Appropriate support for
1. Gas Check Valve - Failure of Ring Gasket Excessive vibration on
Zone 2.1 to 2.2 the wellhead on loss of Fatigue failure of bolts one or more bolts after pipework piping as per pipe stress 3.3
Primary Barrier Seal
pressurisation in the a period of time. analysis.
upstream pipework.
148
To contain the gas

1. Gas Check Valve - within the A annulus of Failure of Ring Gasket Thermal/mechanical Catastrophic failure of Displacement from Appropriate piping
Zone 2.1 to 2.2 the wellhead on loss of gradients induce fatigue one or more bolts after design as per pipe stress 3.3
Primary Barrier Seal normal relative position
pressurisation in the on bolts a period of time. analysis.
upstream pipework.
Designers and
and mechanical
within the A annulus of ISO quality systems in
1. Gas Check Valve - Failure of Ring Gasket Wrong seal taken from properties similar to
Zone 2.1 to 2.2 the wellhead on loss of None place. Offshore 2.2
Primary Barrier Seal stores actual specification,
pressurisation in the supervisors checks and
effect.
work system etc.
Designers and
To contain the gas Material specification manufacturers to have
within the A annulus of of seal incompatible ISO quality systems in
1. Gas Check Valve - Failure of Ring Gasket Seal incorrectly Gradually increasing
Zone 2.1 to 2.2 the wellhead on loss of Seal with body causing place. Offshore 2.2
Primary Barrier specified leak over time.
pressurisation in the differential cell to be supervisors checks and
work syst em etc.

within the A annulus of in excess of 6 months,
1. Gas Check Valve - Failure of Ring Gasket Seal incorrectly Seal incorrectly
Zone 2.1 to 2.2 Primary Barrier the wellhead on loss of Seal specified specified in design None initial teething 2.2
pressurisation in the problems have been
Employ competent
individuals and
within the A annulus of is available.
1. Gas Check Valve - Failure of Ring Gasket Seal incorrectly Gas leakage around
Zone 2.1 to 2.2 the wellhead on loss of Effective seal not made 2.1
Primary Barrier Seal installed seal
upstream pipework.
envelope broken.
149
To contain the gas

Employ competent
1. Gas Check Valve - within the A annulus of Failure of Ring Gasket Bolts installed Sealing arrangement individuals and
Zone 2.1 to 2.2 the wellhead on loss of incorrectly - bolts Joint integrity reduced 3.3
Primary Barrier Seal unevenly energised appropriate supervision
pressurisation in the unevenly tensioned
is available.
upstream pipework.
Designers and
within the A annulus of Bolts installed ISO quality systems in
1. Gas Check Valve - Failure of Ring Gasket
Zone 2.1 to 2.2 the wellhead on loss of incorrectly - incorrect Joint integrity reduced None place. Offshore 3.2
Primary Barrier Seal
pressurisation in the grade of bolt fitted supervisors checks and
work system etc.
To contain the gas

Employ competent
within the A annulus of Bolts installed
1. Gas Check Valve - Failure of Ring Gasket Seal distortion leading individuals and
Zone 2.1 to 2.2 the wellhead on loss of Seal incorrectly - bonnet Joint integrity reduced to progressive leakage. 2.3
Primary Barrier appropriate supervision
pressurisation in the over tensioned
is available.
upstream pipework.
Employ competent
1. Gas Check Valve - within the A annulus of Failure of Ring Gasket Bolts installed Instantaneous leak from
Zone 2.1 to 2.2 the wellhead on loss of incorrectly - bonnet Joint integrity reduced is available. 2.3
Primary Barrier Seal bonnet
pressurisation in the under tensioned
envelope broken.
To contain the gas

2. Connecting within the A annulus of Possible detection by
Failure of Ring Gasket Bolts loosen off in
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of Partial leakage of gas Gas release plant operators and/or 2.3
Seal service
Barrier pressurisation in the F&G system
upstream pipework.
150
To contain the gas

2. Connecting within the A annulus of Failure of Ring Gasket Catastrophic failure of Appropriate support for
Excessive vibration on
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of Fatigue failure of bolts one or more bolts after piping as per pipe stress 3.3
Seal pipework
Barrier pressurisation in the a period of time. analysis.
upstream pipework.
To contain the gas

2. Connecting within the A annulus of Thermal/mechanical Catastrophic failure of Appropriate piping
Failure of Ring Gasket Displacement from
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of gradients induce fatigue one or more bolts after design as per pipe stress 3.3
Seal normal relative position
Barrier pressurisation in the on bolts a period of time. analysis.
upstream pipework.
Designers and
and mechanical
2. Connecting within the A annulus of ISO quality systems in
Failure of Ring Gasket Wrong seal taken from properties similar to
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of Seal None place. Offshore 2.2
Barrier pressurisation in the supervisors checks and
effect.
work system etc.
Designers and
To contain the gas Material specification manufact urers to have
2. Connecting within the A annulus of Failure of Ring Gasket Seal incorrectly of seal incompatible ISO quality systems in
Gradually increasing
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of with body causing place. Offshore 2.2
Seal specified leak over time. supervisors checks and
Barrier pressurisation in the differential cell to be
work system etc.

2. Connecting within the A annulus of in excess of 6 months,
Failure of Ring Gasket Seal incorrectly Seal incorrectly
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of None initial teething 2.2
Seal specified specified in design
Barrier pressurisation in the problems have been
151
Employ competent
individuals and
2. Connect ing within the A annulus of Failure of Ring Gasket Seal incorrectly is available.
Gas leakage around
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of Effective seal not made 2.1
Seal installed seal
Barrier pressurisation in the
upstream pipework.
envelope broken.
To contain the gas

Employ competent
2. Connecting within the A annulus of Bolts installed
Failure of Ring Gasket Sealing arrangement individuals and
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of incorrectly - bolts Joint integrity reduced unevenly energised
Seal appropriate supervision 3.3
Barrier pressurisation in the unevenly tensioned
is available.
upstream pipework.
Designers and
2. Connecting within the A annulus of Bolts installed ISO quality systems in
Failure of Ring Gasket
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of Seal incorrectly - incorrect Joint integrity reduced None place. Offshore 3.2
Barrier pressurisation in the grade of bolt fitted supervisors checks and
work system etc.
To contain the gas

Employ competent
2. Connecting within the A annulus of Bolts installed
Failure of Ring Gasket Seal distortion leading individuals and
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of Seal incorrectly - bonnet Joint integrity reduced to progressive leakage. 2.3
Barrier pressurisation in the over tensioned
is available.
upstream pipework.
Employ competent
2. Connecting within the A annulus of Bolts installed appropriate supervision
Failure of Ring Gasket Instantaneous leak from is available.
Zone 2.1 to 2.2 Pipework - Primary the wellhead on loss of incorrectly - bonnet Joint integrity reduced 2.3
Seal bonnet
Barrier pressurisation in the under tensioned
envelope broken.
152
To contain the gas Designers and

within the A annulus of Material specification manufacturers to have
the wellhead on loss of of seal incompatible ISO quality systems in
3. Tubing Spool Side Bonnet seal leakage Seal incorrectly Gradually leaking over
Zone 2.1 to 2.2 pressurisation in the with body causing place. Offshore 2.2
Valve - Primary Barrier upstream pipework and (metal to metal joint) specified time supervisors checks and
differential cell to be
or on activation of setup. balances i.e. permit to
platform ESD work system etc.

within the A annulus of manufacturers to have
and mechanical
the wellhead on loss of ISO quality systems in
3. Tubing Spool Side pressurisation in the Bonnet seal leakage Wrong seal taken from properties similar to place. Offshore
Zone 2.1 to 2.2 actual specification, None 2.2
Valve - Primary Barrier (metal to metal joint) stores
upstream pipework and supervisors checks and
or on activation of balances i.e. permit to
effect.
To contain the gas

within the A annulus of Tree has been operating
the wellhead on loss of in excess of 6 months,
3. Tubing Spool Side Bonnet seal leakage Seal incorrectly Seal incorrectly
Zone 2.1 to 2.2 pressurisation in the None. initial teething 2.2
Valve - Primary Barrier (metal to metal joint) specified specified in design
upstream pipework and problems have been
or on activation of ironed out.
platform ESD
Employ competent
within the A annulus of appropriate supervision
the wellhead on loss of is available.
3. Tubing Spool Side Bonnet seal leakage Seal incorrectly
Zone 2.1 to 2.2 pressurisation in the Effective seal not made Gas leak around seal 2.1
Valve - Primary Barrier (metal to metal joint) installed
or on activation of
platform ESD Pressure tested after
envelope broken.
153
To contain the gas

within the A annulus of
Employ competent
the wellhead on loss of Bolts installed
3. Tubing Spool Side Bonnet seal leakage Sealing arrangement individuals and
Zone 2.1 to 2.2 pressurisation in the incorrectly - bolts Joint integrity reduced 3.3
Valve - Primary Barrier upstream pipework and (metal to metal joint) unevenly energised appropriate supervision
unevenly tensioned
is available.
or on activation of
platform ESD

the wellhead on loss of Bolts installed ISO quality systems in
3. Tubing Spool Side pressurisation in the Bonnet seal leakage place. Offshore
Zone 2.1 to 2.2 incorrectly - incorrect Joint integrity reduced None. 3.2
Valve - Primary Barrier (metal to metal joint)
upstream pipework and grade of bolt fitted supervisors checks and
To contain the gas

the wellhead on loss of Employ competent
Bolts installed
3. Tubing Spool Side Bonnet seal leakage Seal distortion leading individuals and
Zone 2.1 to 2.2 pressurisation in the incorrectly - bonnet Joint integrity reduced 2.3
Valve - Primary Barrier (metal to metal joint) to progressive leakage. appropriate supervision
upstream pipework and over tensioned
platform ESD

within the A annulus of individuals and
the wellhead on loss of Bolts installed appropriate supervision
3. Tubing Spool Side Bonnet seal leakage Instantaneous leak from
Zone 2.1 to 2.2 pressurisation in the incorrectly - bonnet Joint integrity reduced is available. 2.3
Valve - Primary Barrier (metal to metal joint) bonnet
upstream pipework and under tensioned
or on activation of Pressure tested after
platform ESD envelope broken.
154
To contain the gas

within the A annulus of Perform maintenance
the wellhead on loss of
3. Tubing Spool Side Gas leaks from actuator and inspection in
Zone 2.1 to 2.2 pressurisation in the Stem Seal Leak Wear and Tear Loss of full seal accordance with 2.4
Valve - Primary Barrier upstream pipework and housing
manufacturers
or on activation of requirements.
platform ESD
To contain the gas

the wellhead on loss of and inspection in
3. Tubing Spool Side pressurisation in the Packing not set Gas leaks from actuator
Zone 2.1 to 2.2 Stem Seal Leak Loss of full seal accordance with 2.4
Valve - Primary Barrier correctly housing
upstream pipework and manufacturers
platform ESD
To contain the gas

the wellhead on loss of and inspection in
3. Tubing Spool Side Gas leaks from actuator
Zone 2.1 to 2.2 pressurisation in the Stem Seal Leak Wrong packing fitted Loss of full seal accordance with 2.4
Valve - Primary Barrier housing
upstream pipework and manufacturers
platform ESD
To contain the gas

the wellhead on loss of Fitter backs off
3. Tubing Spool Side Audible evidence of
Zone 2.1 to 2.2 pressurisation in the Grease fitting Leakage assembly rather than Partial leak Using competent fitters 3.3
Valve - Primary Barrier gas release
upstream pipework and just the cap
or on activation of
platform ESD
155
To contain the gas

within the A annulus of Removal or backing off
the wellhead on loss of of plug during routine
3. Tubing Spool Side Audible evidence of
Zone 2.1 to 2.2 pressurisation in the Grease fitting Leakage greasing/lubricating Partial leak Using competent fitters 3.3
Valve - Primary Barrier upstream pipework and gas release
removes inner check
or on activation of valve
platform ESD

within the A annulus of Material specification manufacturers to have
1. Tubing Spool Side the wellhead on loss of of seal incompatible ISO quality systems in
pressurisation in the Seal incorrectly Gradually leaking over place. Offshore
Zone 2.2 to 2.3 Valve - Primary Bonnet Seal Leakage with body causing 2.2
specified time
Barrier upstream pipework and differential cell to be supervisors checks and
or on activation of setup. balances i.e. permit to

and mechanical
1. Tubing Spool Side the wellhead on loss of ISO quality systems in
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Bonnet Seal Leakage None place. Offshore 2.2
Barrier upstream pipework and supervisors checks and
effect.
To contain the gas

within the A annulus of Tree has been
1. Tubing Spool Side the wellhead on loss of operating in excess of 6
Seal incorrectly Seal incorrectly
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Bonnet Seal Leakage None. months, initial teething 2.2
specified specified in design
Barrier upstream pipework and problems have been
or on activation of ironed out.
platform ESD
156
Employ competent
within the A annulus of appropriate supervision
1. Tubing Spool Side the wellhead on loss of is available.
Seal incorrectly
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Bonnet Seal Leakage Effective seal not made Gas leak around seal 2.1
Barrier
or on activation of
platform ESD Pressure tested after
envelope broken.
To contain the gas

the wellhead on loss of Employ competent
1. Tubing Spool Side Bolts installed
Zone 2.2 to 2.3 Valve - Primary Bonnet Seal Leakage incorrectly - bolts Joint integrity reduced 3.3
unevenly energised appropriate supervision
Barrier upstream pipework and unevenly tensioned
is available.
or on activation of
platform ESD

1. Tubing Spool Side the wellhead on loss of Bolts installed ISO quality systems in
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Bonnet Seal Leakage incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
Barrier upstream pipework and grade of bolt fitted supervisors checks and
To contain the gas

Employ competent
1. Tubing Spool Side the wellhead on loss of Bolts installed
Seal distortion leading individuals and
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Bonnet Seal Leakage incorrectly - bonnet Joint integrity reduced 2.3
to progressive leakage. appropriate supervision
Barrier upstream pipework and over tensioned
platform ESD
157

within the A annulus of individuals and
1. Tubing Spool Side the wellhead on loss of Bolts installed appropriate supervision
Instantaneous leak from
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Bonnet Seal Leakage incorrectly - bonnet Joint integrity reduced is available. 2.3
or on activation of Pressure tested after
platform ESD envelope broken.
To contain the gas

1. Tubing Spool Side the wellhead on loss of and inspection in
pressurisation in the Stem Seal Leakage Gas leaks from
Zone 2.2 to 2.3 Valve - Primary Wear and Tear Loss of full seal accordance with 2.4
actuator housing
Barrier upstream pipework and manufacturers
platform ESD
To contain the gas

Packing not set Gas leaks from
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Stem Seal Leakage Loss of full seal accordance with 2.4
correctly actuator housing
platform ESD
To contain the gas

Gas leaks from
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Stem Seal Leakage Wrong packing fitted Loss of full seal accordance with 2.4
actuator housing
platform ESD
158
To contain the gas

1. Tubing Spool Side the wellhead on loss of Fitter backs off
Audible evidence of gas
Zone 2.2 to 2.3 Valve - Primary pressurisation in the Grease fitting leakage assembly rather than Partial leak Using competent fitters 3.3
or on activation of
platform ESD
To contain the gas

within the A annulus of Removal or backing off
1. Tubing Spool Side the wellhead on loss of of plug during routine
Zone 2.2 to 2.3 Valve - Primary Grease fitting leakage greasing/lubricating Partial leak Using competent fitters 3.3
release
Barrier upstream pipework and removes inner check
or on activation of valve
platform ESD

cavity between tree and
tubing hanger.
2. Tubing spool to To provide a seal Over a period of time Secondary barriers

Seal fails to remain
Zone 2.2 to 2.3 tubing hanger seal - between the tubing Leakage around seal seal is permanent None. 1.3
energised provided by tie down
Primary Barrier hanger and tubing spool deformed
bolt arrangement,
chemical injection
point, downhole safety
valve point, tubing
hanger to casing spool
seal.
Employ competent
individuals and
Seal incorrectly Gas leakage around
Zone 2.2 to 2.3 tubing hanger seal - between the tubing Leakage around seal Effective seal not made 1.1
installed seal
Primary Barrier hanger and tubing spool

envelope broken.
159
Designers and
and mechanical
Zone 2.2 to 2.3 tubing hanger seal - between the tubing Leakage around seal None place. Offshore 1.2
Primary Barrier hanger and tubing spool supervisors checks and
effect.
work system etc.
Designers and
Material specification manufacturers to have
2. Tubing spool to To provide a seal of seal incompatible ISO quality systems in
Seal incorrectly Gradually increasing place. Offshore
Zone 2.2 to 2.3 tubing hanger seal - between the tubing Leakage around seal with body causing 1.2
Primary Barrier hanger and tubing spool differential cell to be supervisors checks and
work system etc.

2. Tubing spool to To provide a seal in excess of 6 months,
Zone 2.2 to 2.3 tubing hanger seal - between the tubing Leakage around seal None initial teething 1.2
Primary Barrier hanger and tubing spool problems have been
ironed out.
Designers and
place. Offshore
Gradual determination
of seal, causing Leakage around seal
Zone 2.2 to 2.3 tubing hanger seal - between the tubing Leakage around seal Ageing of seal balances. 2.2
increasing leakage over increasing over time.
Primary Barrier hanger and tubing spool
a period of time
Pressure test of
complete assembly.
160
B annulus.
Instrument monitor
3. Tubing spool to To provide a seal Over a period of time Secondary barriers
Zone 2.2 to 2.3 Casing Hanger Seal - between the casing Leakage around seal seal is permanently provided by tie down 3.3
energised
Primary Barrier hanger and casing spool deformed bolt arrangement,
chemical injection
monitored by plant
operators.
valve point, tubing
seal.
Employ competent
individuals and
Zone 2.2 to 2.3 Casing Hanger Seal - between the casing Leakage around seal Effective seal not made 1.1
installed seal
Primary Barrier hanger and casing spool

envelope broken.
Designers and
and mechanical
Zone 2.2 to 2.3 Casing Hanger Seal - between the casing Leakage around seal None place. Offshore 1.2
Primary Barrier hanger and casing spool supervisors checks and
effect.
work system etc.
Designers and
3. Tubing spool to To provide a seal of seal incompatible ISO quality systems in
Zone 2.2 to 2.3 Casing Hanger Seal - between the casing Leakage around seal with body causing place. Offshore 1.2
Primary Barrier hanger and casing spool differential cell to be supervisors checks and
work system etc.
161

3. Tubing spool to To provide a seal in excess of 6 months,
Zone 2.2 to 2.3 Casing Hanger Seal - between the casing Leakage around seal None initial teething 1.2
Primary Barrier hanger and casing spool problems have been
ironed out.
Designers and
Leakage around seal
place. Offshore
Gradual determination increasing over time.
of seal, causing
Zone 2.2 to 2.3 Casing Hanger Seal - between the casing Leakage around seal Ageing of seal balances. 2.2
increasing leakage over Casing hanger may
Primary Barrier hanger and casing spool
a period of time drop as a result of seal
determination.
Pressure test of
complete assembly.
Leakage of gas past

threaded connection
consequently
pressurising the cavity
between tree and tubing
hanger.
4. Production Tubing toTo provide a sealed
Failure of seal (metal tobeing out with
Zone 2.2 to 2.3 Tubing Hanger Seal - mechanical joint Ineffective seal None. 2.2
metal) manufacturing Secondary barriers
tolerances provided by tie down
bolt arrangement,
chemical injection
valve point, tubing
seal.
162
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3 Tubing Hanger Seal - mechanical joint Galling on seal face Ineffective seal None. 2.2
metal) Secondary barriers
provided by tie down
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
4. Production Tubing to To provide a sealed
Failure of seal (metal toInsufficient make up
Zone 2.2 to 2.3 Tubing Hanger Seal - mechanical joint Ineffective seal None. 2.2
metal) torque Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
163
Leakage of gas past

threaded connection
consequently
hanger.
Failure of seal (metal toExcessive loading on Seal integrity reduced
Zone 2.2 to 2.3 Tubing Hanger Seal - mechanical joint None. 2.2
metal) seal arrangement or failed Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3 Tubing Hanger Seal - mechanical joint
connection 'unzipping' of the threadJoint opens Secondary barriers
None. 2.2
bolt arrangement,
chemical injection
valve point, tubing
seal.
164
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3 Tubing Hanger Seal - mechanical joint Shearing of threads None. 2.2
connection or failed Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
Slag
To provide containment inclusion/laminations, Designers and
5. Upper Well annulus - for hydrocarbon gas to Stress raisers and crack cold laps and other manufacturers to have
Zone 2.2 to 2.3 Primary Barrier be injected into Casing Spool failure Manufacturing defect initiators ISO quality systems in 1.2
geometric
production bore imperfections in the place.
forged block.
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
5. Upper Well annulus - Failure of seal (metal tobeing out with
Zone 2.2 to 2.3 mechanical joint Ineffective seal None. 2.2
Primary Barrier metal) manufacturing Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
165
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
5. Upper Well annulus - Failure of seal (metal to
Zone 2.2 to 2.3 mechanical joint Galling on seal face Ineffective seal None. 2.2
Primary Barrier metal) Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
5. Upper Well annulus - Failure of seal (metal toInsufficient make up
Primary Barrier metal) torque Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
166
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
5. Upper Well annulus - Failure of seal (metal toExcessive loading on Seal integrity reduced
Zone 2.2 to 2.3 mechanical joint None. 2.2
Primary Barrier metal) seal arrangement or failed Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
5. Upper Well annulus - Failure of threaded Jumping out or
Zone 2.2 to 2.3 mechanical joint
Primary Barrier connection 'unzipping' of the threadJoint opens Secondary barriers
None. 2.2
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
167
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
5. Upper Well annulus - Failure of threaded Joint integrity reduced
Zone 2.2 to 2.3 mechanical joint Shearing of threads None. 2.2
Primary Barrier connection or failed Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
Slag
To provide a inclusion/laminations, Designers and
6. Tubing hanger body continuous bore Stress raisers and crack cold laps and other manufacturers to have
Zone 2.2 to 2.3 - Primary Barrier between the tree and Production bore failure Manufacturing defect initiators ISO quality systems in 1.1
geometric
the production tubing imperfections in the place.
forged block.

during manufacture.
packing gland body
pressure to leak up to Designers and
7. Tubing hanger Reduced thread to
Provide a seal between upper packing gland. manufacturers to have
downhole safety valve thread contact surface
Zone 2.2 to 2.3 control line lower (seal maintained by Degraded mechanical ISO quality systems in 3.3
and the tubing hanger Coincident failure of tolerance
packing gland (x2) - excessive PTFE for joint, since joint relies place. Offshore
body upper packing gland more on excessive supervisors checks and
Primary Barrier example)
would lead to trapped balances.
sealant than intimate
pressure leaking into
thread contact.
cavity between tubing
hanger and tree.
168

during manufacture.
packing gland body
pressure to leak up to
7. Tubing hanger Designers and
Provide a seal between upper packing gland. Component will only
Zone 2.2 to 2.3 control line lower ISO quality systems in 3.3
and the tubing hanger Coincident failure of tolerance threads are cut oversize the threads (rather than
packing gland (x2) - place. Offshore
body upper packing gland full length engagement)
Primary Barrier supervisors checks and
hanger and tree.
Excessive torque
packing gland body
thread causing trapped Use of competent fitters
pressure to leak up to and effective
7. Tubing hanger supervision.
Provide a seal between upper packing gland.
Zone 2.2 to 2.3 control line lower Cross threads Ineffective seal Fitting improperly 1.3
and the tubing hanger Coincident failure of
packing gland (x2) - aligned.
body upper packing gland
Primary Barrier Suitable pressure
would lead to trapped
pressure leaking into testing.
Leaking joint.
hanger and tree.

up.
packing gland body
pressure to leak up to Excessive torque and effective
7. Tubing hanger required to install. supervision.
Zone 2.2 to 2.3 control line lower Damaged threads 1.3
and the tubing hanger Coincident failure of threads
packing gland (x2) -
body upper packing gland
Primary Barrier Fitting improperly Suitable pressure
pressure leaking into aligned. testing.
hanger and tree.
Leaking joint
169
Leakage of gas past

threaded connection
Loss of integrity of consequently
packing gland body pressurising the cavity
thread causing trapped between tree and tubing
pressure to leak up to hanger.
7. Tubing hanger
downhole safety valve Leakage of gas into
Zone 2.2 to 2.3 control line lower Incorrect joint make-up cavity between tubing None. 1.3
and the tubing hanger Coincident failure of Secondary barriers
packing gland (x2) - hanger and tree.
body upper packing gland provided by tie down
Primary Barrier
would lead to trapped bolt arrangement,
pressure leaking into chemical injection
cavity between tubing point, downhole safety
hanger and tree. valve point, tubing
seal.

during manufacture.
packing gland body
pressure to leak up to Designers and
8. Tubing hanger Reduced thread to
Provide a seal between upper packing gland. manufacturers to have
downhole chemical thread contact surface
Zone 2.2 to 2.3 injection line lower (seal maintained by Degraded mechanical ISO quality systems in 3.3
line and the tubing Coincident failure of tolerance
packing gland - excessive PTFE for joint, since joint relies place. Offshore
hanger body upper packing gland more on excessive supervisors checks and
Primary Barrier example)
sealant than intimate
thread contact.
hanger and tree.
170

during manufacture.
packing gland body
pressure to leak up to
8. Tubing hanger Designers and
Provide a seal between upper packing gland. Component will only
downhole chemical manufacturers to have
Zone 2.2 to 2.3 injection line lower ISO quality systems in 3.3
line and the tubing Coincident failure of tolerance threads are cut oversize the threads (rather than
packing gland - place. Offshore
hanger body upper packing gland full length engagement)
Primary Barrier supervisors checks and
hanger and tree.
Excessive torque
packing gland body
pressure to leak up to and effective
8. Tubing hanger supervision.
downhole chemical
Zone 2.2 to 2.3 injection line lower Cross threads Ineffective seal Fitting improperly 1.3
line and the tubing Coincident failure of
packing gland - aligned.
hanger body upper packing gland
Primary Barrier Suitable pressure
pressure leaking into testing.
Leaking joint.
hanger and tree.

up.
packing gland body
pressure to leak up to Excessive torque and effective
8. Tubing hanger required to install. supervision.
downhole chemical
Zone 2.2 to 2.3 injection line lower Damaged threads 1.3
line and the tubing Coincident failure of threads
packing gland -
hanger body upper packing gland
Primary Barrier Fitting improperly Suitable pressure
pressure leaking into aligned. testing.
hanger and tree.
Leaking joint
171
Leakage of gas past

threaded connection
Loss of integrity of consequently
packing gland body pressurising the cavity
thread causing trapped between tree and tubing
pressure to leak up to hanger.
8. Tubing hanger
downhole chemical Leakage of gas into
Zone 2.2 to 2.3 injection line lower Incorrect joint make-up cavity between tubing None. 1.3
line and the tubing Coincident failure of Secondary barriers
hanger body upper packing gland provided by tie down
Primary Barrier
would lead to trapped bolt arrangement,
pressure leaking into chemical injection
cavity between tubing point, downhole safety
hanger and tree. valve point, tubing
seal.
Regular checks of
Pump Labouring
pump pressure and
injection rates by plant
Pressurisation of void injection rate
9. Tubing spool operators.
Provide a conduit for Rupture of chemical between the tubing
downhole chemical Pipework damaged
Zone 2.2 to 2.3 chemical injection into injection line - below hanger and the dual 1.2
injection line - Primary during installation
production bore tubing hanger bore upper packer with
Barrier Significant increase of
chemicals.
dosing rate of
chemicals.
procedures.
Regular checks of
pump pressure and
Pressurisation of void
10. Tubing spool Provide a conduit for operators.
Rupture of down hole between the tubing Pump Labouring
downhole safety valve hydraulic fluid for Pipework damaged
Zone 2.2 to 2.3 safety valve control line hanger and the dual (audible) - increased 1.2
control line - Primary control of the down during installation
- below tubing hanger bore upper packer with injection rate
Barrier hole safety valves
hydraulic fluid
procedures.
172

production tubing
Production tubing will
Designers and
11. Production tubing - provide a conduit for Production tubing Stress raisers and crack manufacturers to have 1.2
Zone 2.2 to 2.3 the hydrocarbon fluid Manufacturing defect
primary barrier ruptures initiators No credible effect, ISO quality systems in
to the topsides process
since gas pressure place.
plant.
should be higher than
hydrocarbon fluids.

production tubing Use of competent fitters
Failure due to threads and effective
To provide a sealed supervision.
11. Production tubing - Failure of seal (metal tobeing out with
primary barrier metal) manufacturing No credible effect,
between components
tolerances since gas pressure Suitable pressure
should be higher than testing.
hydrocarbon fluids.

and effective
11. Production tubing - Failure of seal (metal to
primary barrier metal) No credible effect,
between components
since gas pressure Suitable pressure
hydrocarbon fluids.

and effective
To provide a sealed
11. Production tubing - Failure of seal (metal toInsufficient make up supervision.
primary barrier metal) torque No credible effect,
between components since gas pressure Suitable pressure
hydrocarbon fluids.
173

and effective
To provide a sealed
11. Production tubing - Failure of seal (metal toExcessive loading on Seal integrity reduced supervision.
primary barrier metal) seal arrangement or failed No credible effect,
between components Suitable pressure
since gas pressure
hydrocarbon fluids.

and effective
11. Production tubing - Failure of threaded Jumping out or
primary barrier connection 'unzipping' of the thread No credible effect,
between components
hydrocarbon fluids.

and effective
11. Production tubing - Failure of threaded Joint integrity reduced
primary barrier connection or failed No credible effect,
between components
hydrocarbon fluids.
Designers and
Material specification manufact urers to have
isolate the A,B or C
12. Annulus Tubing of seal incompatible ISO quality systems in
annulus and with Bonnet seal leakage Seal incorrectly Gradually leaking over
Zone 2.2 to 2.3 Spool Valves - Primary with body causing place. Offshore 2.2
instrumentation (metal to metal joint) specified time
monitor annular
pressures
work system etc.
174
Designers and
To provide a facility to Dimensions, chemical
isolate the A,B or C and mechanical
12. Annulus Tubing ISO quality systems in
annulus and with Bonnet seal leakage Wrong seal taken from properties similar to
Zone 2.2 to 2.3 Spool Valves - Primary instrumentation None place. Offshore 2.2
(metal to metal joint) stores actual specification,
monitor annular therefore no immediate
pressures effect.
work system etc.
12. Annulus Tubing in excess of 6 months,
annulus and with Bonnet seal leakage Seal incorrectly Seal incorrectly
Zone 2.2 to 2.3 Spool Valves - Primary None. initial teething 2.2
instrumentation (metal to metal joint) specified specified in design
Barrier problems have been
monitor annular
ironed out.
pressures
Employ competent
individuals and
isolate the A,B or C appropriate supervision
12. Annulus Tubing is available.
annulus and with Bonnet seal leakage Seal incorrectly
Zone 2.2 to 2.3 Spool Valves - Primary Effective seal not made Gas leak around seal 2.1
instrumentation (metal to metal joint) installed
Barrier monitor annular
pressures
envelope broken.
isolate the A,B or C Employ competent
12. Annulus Tubing Bolts installed
Bonnet seal leakage Sealing arrangement individuals and
Zone 2.2 to 2.3 Spool Valves - Primary annulus and with incorrectly - bolts Joint integrity reduced unevenly energised 3.3
instrumentation (metal to metal joint) appropriate supervision
monitor annular is available.
pressures
Designers and
12. Annulus Tubing Bolts installed ISO quality systems in
annulus and with Bonnet seal leakage
Zone 2.2 to 2.3 Spool Valves - Primary instrumentation incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
(metal to metal joint)
monitor annular
pressures
work system etc.
175
isolate the A,B or C Employ competent
12. Annulus Tubing Bolts installed
annulus and with Bonnet seal leakage Seal distortion leading individuals and
Zone 2.2 to 2.3 Spool Valves - Primary incorrectly - bonnet Joint integrity reduced 2.3
instrumentation (metal to metal joint) to progressive leakage. appropriate supervision
pressures
Employ competent
individuals and
12. Annulus Tubing Bolts installed appropriate supervision
annulus and with Bonnet seal leakage Instantaneous leak from
Zone 2.2 to 2.3 Spool Valves - Primary incorrectly - bonnet Joint integrity reduced is available. 2.3
instrumentation (metal to metal joint) bonnet
monitor annular
pressures
envelope broken.
Perform maintenance
12. Annulus Tubing and inspection in
Zone 2.2 to 2.3 Spool Valves - Primary annulus and with Stem Seal Leak Wear and Tear Loss of full seal accordance with 2.4
instrumentat ion assembly
monitor annular
requirements.
pressures
Perform maintenance
12. Annulus Tubing isolate the A,B or C
annulus and with Packing not set Gas leaks from handle and inspection in
Zone 2.2 to 2.3 Spool Valves - Primary Stem Seal Leak Loss of full seal accordance with 2.4
instrumentation correctly assembly
monitor annular
requirements.
pressures
Perform maintenance
12. Annulus Tubing and inspection in
annulus and with Gas leaks from handle
Zone 2.2 to 2.3 Spool Valves - Primary Stem Seal Leak Wrong packing fitted Loss of full seal accordance with 2.4
instrumentation assembly
monitor annular
requirements.
pressures
176
12. Annulus Tubing isolate the A,B or C Fitter backs off
annulus and with Audible evidence of
Zone 2.2 to 2.3 Spool Valves - Primary Grease fitting Leakage assembly rather than Partial leak Using competent fitters 3.3
instrumentation gas release
monitor annular
pressures
12. Annulus Tubing of plug during routine
annulus and with Audible evidence of
Zone 2.2 to 2.3 Spool Valves - Primary Grease fitting Leakage greasing/lubricating Partial leak Using competent fitters 3.3
monitor annular
valve
pressures
13. Upper annulus To provide a facility for Cartridge nose seal Employ competent
tubing spool monitor pressure monitoring failure, annulus gas Cartridge not fully Gas leakage around individuals and
and vent assembly - equipment to be linked leakage past cartridge tightened cartridge walls appropriate supervision
Primary Barrier to the A annulus wall is available.
Designers and
13. Upper annulus To provide a facility for
of seal incompatible ISO quality systems in
tubing spool monitor pressure monitoring Seal incorrectly Gradually leaking over
Zone 2.2 to 2.3 Failure of bonnet seal with body causing place. Offshore 2.2
and vent assembly - equipment to be linked specified time
Primary Barrier to the A annulus
work system etc.
Designers and
13. Upper annulus To provide a facility for and mechanical
tubing spool monitor pressure monitoring Wrong seal taken from properties similar to
Zone 2.2 to 2.3 Failure of bonnet seal None place. Offshore 2.2
and vent assembly - equipment to be linked stores actual specification,
Primary Barrier to the A annulus therefore no immediate
effect.
work system etc.
177

tubing spool monitor pressure monitoring
Zone 2.2 to 2.3 Failure of bonnet seal None. initial teething 2.2
and vent assembly - equipment to be linked specified specified in design
problems have been
ironed out.
Employ competent
individuals and
is available.
tubing spool monitor pressure monitoring Seal incorrectly
and vent assembly - equipment to be linked installed
envelope broken.
13. Upper annulus To provide a facility for Employ competent

Bolts installed
tubing spool monitor pressure monitoring Sealing arrangement individuals and
Zone 2.2 to 2.3 Failure of bonnet seal incorrectly - bolts Joint integrity reduced unevenly energised
and vent assembly - equipment to be linked appropriate supervision 3.3
unevenly tensioned
Primary Barrier to the A annulus is available.
Designers and
13. Upper annulus To provide a facility for ISO quality systems in
Bolts installed
tubing spool monitor pressure monitoring place. Offshore
Zone 2.2 to 2.3 Failure of bonnet seal incorrectly - incorrect Joint integrity reduced None. 3.2
and vent assembly - equipment to be linked
work system etc.

Bolts installed
tubing spool monitor pressure monitoring Seal distortion leading individuals and
Zone 2.2 to 2.3 incorrectly - bonnet
and vent assembly - equipment to be linked Failure of bonnet seal Joint integrity reduced to progressive leakage. appropriate supervision 2.3
over tensioned
178
Employ competent
individuals and
tubing spool monitor pressure monitoring Instantaneous leak from
Zone 2.2 to 2.3 Failure of bonnet seal incorrectly - bonnet Joint integrity reduced is available. 2.3
and vent assembly - equipment to be linked bonnet
under tensioned
envelope broken.

tubing spool monitor pressure monitoring Failure of Ring Gasket Bolts loosen off in
and vent assembly - equipment to be linked Seal service
F&G system

tubing spool monitor pressure monitoring Failure of Ring Gasket Excessive vibration on
Zone 2.2 to 2.3 Fatigue failure of bolts one or more bolts after piping as per pipe stress 3.3
and vent assembly - equipment to be linked Seal pipework
a period of time. analysis.

tubing spool monitor pressure monitoring Failure of Ring Gasket Displacement from
Zone 2.2 to 2.3 gradients induce fatigue one or more bolts after design as per pipe stress 3.3
and vent assembly - equipment to be linked Seal normal relative position
on bolts a period of time. analysis.
Designers and
13. Upper annulus To provide a facility for and mechanical
tubing spool monitor pressure monitoring Failure of Ring Gasket Wrong seal taken from properties similar to place. Offshore
Zone 2.2 to 2.3 actual specification, None 2.2
and vent assembly - equipment to be linked Seal stores
Primary Barrier to the A annulus therefore no immediate
effect.
work system etc.
179
Designers and
tubing spool monitor pressure monitoring Failure of Ring Gasket Seal incorrectly Gradually increasing
Zone 2.2 to 2.3 with body causing place. Offshore 2.2
and vent assembly - equipment to be linked Seal specified leak over time. supervisors checks and
work system etc.

in excess of 6 months,
tubing spool monitor pressure monitoring Failure of Ring Gasket Seal incorrectly Seal incorrectly
Zone 2.2 to 2.3 None initial teething 2.2
and vent assembly - equipment to be linked Seal specified specified in design
problems have been
ironed out.
Employ competent
individuals and
13. Upper annulus To provide a facility for is available.
tubing spool monitor pressure monitoring Failure of Ring Gasket Seal incorrectly Gas leakage around
Zone 2.2 to 2.3 Effective seal not made 2.1
and vent assembly - equipment to be linked Seal installed seal
envelope broken.
13. Upper annulus To provide a facility for Emplo y competent

Bolts installed
tubing spool monitor pressure monitoring Failure of Ring Gasket Sealing arrangement individuals and
Zone 2.2 to 2.3 incorrectly - bolts Joint integrity reduced unevenly energised
and vent assembly - equipment to be linked Seal appropriate supervision 3.3
unevenly tensioned
Designers and
13. Upper annulus To provide a facility for ISO quality systems in
Bolts installed
tubing spool monitor pressure monitoring Failure of Ring Gasket
and vent assembly - equipment to be linked Seal
Primary Barrier to the A annulus balances i.e. permit to
work system etc.
180

Bolts installed
tubing spool monitor pressure monitoring Failure of Ring Gasket Seal distortion leading individuals and
Zone 2.2 to 2.3 incorrectly - bonnet Joint integrity reduced 2.3
and vent assembly - equipment to be linked Seal to progressive leakage. appropriate supervision
over tensioned
Employ competent
individuals and
tubing spool monitor pressure monitoring Failure of Ring Gasket Instantaneous leak from
and vent assembly - equipment to be linked Seal bonnet
under tensioned
envelope broken.
Perform maintenance
and inspection in
tubing spool monitor pressure monitoring Gas leaks from handle
Zone 2.2 to 2.3 accordance with
and vent assembly - equipment to be linked Stem seal leakage Wear and Tear Loss of full seal assembly 2.4
manufacturers
requirements.
Perform maintenance
and inspection in
tubing spool monitor pressure monitoring Packing not set Gas leaks from handle
and vent assembly - equipment to be linked Stem seal leakage correctly Loss of full seal assembly 2.4
manufacturers
requirements.
Perform maintenance
and inspection in
tubing spool monitor pressure monitoring Gas leaks from handle
and vent assembly - equipment to be linked Stem seal leakage Wrong packing fitted Loss of full seal assembly 2.4
manufacturers
requirements.
Designers and
Leakage around seal place. Offshore
To provide a secondary Gradual determination increasing over time.
14. Tubing hanger tie supervisors checks and
barrier between the of seal, causing
Zone 2.2 to 2.3 down bolts and seals - balances.
casing spool and the tie Leakage around seal Ageing of seal increasing leakage over Casing hanger may 2.2
Secondary Barrier
down bolts a period of time drop as a result of seal
determination.
Pressure test of
complete assembly.
181

during manufacture.

packing gland body
downhole safety valve pressure to leak into thread contact surface manufacturers to have
Zone 2.2 to 2.3 the DHSV control line cavity between tubing Thread cut out of Degraded mechanical ISO quality systems in 3.3
control line upper (seal maintained by
body
lower packing gland. thread contact.

during manufacture.
packing gland body
Provide a seal between pressure to leak into Component will only manufacturers to have
the DHSV control line Thread cut out of Either male or female mate for a proportion of ISO quality systems in
Zone 2.2 to 2.3 control line upper cavity between tubing 3.3
lower packing gland.
Excessive torque
packing gland body
and effective
Zone 2.2 to 2.3 control line upper Fitting improperly
and the tubing hanger cavity between tubing Cross threads Ineffective seal 1.3
body
Secondary Barrier
Suitable pressure
testing.
Leaking joint.
182
up.
packing gland body
15. Tubing hanger Excessive torque and effective
Provide a seal between thread causing trapped required to install. supervision.
downhole safety valve pressure to leak into Improperly mated
Zone 2.2 to 2.3 control line upper cavity between tubing Damaged threads 1.3
body
Secondary Barrier
aligned. testing.
Leaking joint
Leakage of gas past

threaded connection
consequently
packing gland body
15. Tubin g hanger hanger.
Provide a seal between thread causing trapped
downhole safety valve pressure to leak into Leakage of gas into
Zone 2.2 to 2.3 control line upper cavity between tubing Incorrect joint make-up cavity between tubing None. 1.3
and the tubing hanger Secondary barriers
packing gland - hanger and tree. hanger and tree.
body provided by tie down
Secondary Barrier
bolt arrangement,
chemical injection
valve point, tubing
seal.
183

during manufacture.

packing gland body
downhole chemical pressure to leak into thread contact surface manufacturers to have
Zone 2.2 to 2.3 the Chemical Injection cavity between tubing Thread cut out of Degraded mechanical ISO quality systems in 3.3
injection line upper (seal maintained by
hanger body
lower packing gland. thread contact.

during manufacture.
packing gland body
Provide a seal between pressure to leak into Component will only manufacturers to have
downhole chemical
the Chemical Injection Thread cut out of Either male or female mate for a proportion of ISO quality systems in
Zone 2.2 to 2.3 injection line up per cavity between tubing 3.3
Excessive torque
packing gland body
and effective
Provide a seal bet ween supervision.
Zone 2.2 to 2.3 injection line upper cavity between tubing Cross threads Ineffective seal Fitting improperly 1.3
line and the tubing
hanger body
Secondary Barrier
Suitable pressure
testing.
Leaking joint.
184
up.
packing gland body
16. Tubing hanger Excessive torque and effective
Provide a seal between thread causing trapped required to install. supervision.
downhole chemical pressure to leak into Improperly mated
Zone 2.2 to 2.3 injection line upper cavity between tubing Damaged threads 1.3
hanger body
Secondary Barrier
aligned. testing.
Leaking joint
Leakage of gas past

threaded connection
consequently
packing gland body
16. Tubing hanger hanger.
Provide a seal between thread causing trapped
downhole chemical pressure to leak into Leakage of gas into
Zone 2.2 to 2.3 injection line upper cavity between tubing Incorrect joint make-up cavity between tubing None. 1.3
line and the tubing Secondary barriers
packing gland - hanger and tree. hanger and tree.
hanger body provided by tie down
Secondary Barrier
bolt arrangement,
chemical injection
valve point, tubing
seal.
17. Tubing spool to tree Provide seal between Thermal/mechanical Catastrophic failure of Appropriate piping
Leakage of gas around Displacement from
Zone 2.2 to 2.3 outer flange seal - the tree and the spool gradients induce fatigue one or more bolts after design as per pipe stress 2.3
seal normal relative position
Secondary Barrier interface on bolts a period of time. analysis.
185
Designers and
and mechanical
17. Tubing spool to tree Provide seal between ISO quality systems in
Leakage of gas around Wrong seal taken from properties similar to
Zone 2.2 to 2.3 outer flange seal - the tree and the spool None place. Offshore 1.2
seal stores actual specification,
Secondary Barrier interface supervisors checks and
effect.
work system etc.
Designers and
17. Tubing spool to tree Provide seal between of seal incompatible ISO quality systems in
Leakage of gas around Seal incorrectly Gradually increasing place. Offshore
Zone 2.2 to 2.3 outer flange seal - the tree and the spool with body causing 1.2
seal specified leak over time.
Secondary Barrier interface differential cell to be supervisors checks and
work system etc.

17. Tubing spool to tree Provide seal between in excess of 6 months,
Leakage of gas around Seal incorrectly Seal incorrectly
Zone 2.2 to 2.3 outer flange seal - the tree and the spool None initial teething 1.2
seal specified specified in design
Secondary Barrier interface problems have been
ironed out.
Employ competent
individuals and
17. Tubing spool to tree Provide seal between is available.
Leakage of gas around Seal incorrectly Gas leakage around
Zone 2.2 to 2.3 outer flange seal - the tree and the spool Effectiv e seal not made 1.1
seal installed seal

envelope broken.
Designers and
To provide a seal Gradual determination
control packing gland - between the DHSV supervisors checks and
of seal, causing Leakage around seal
Zone 2.2 to 2.3 Secondary Barrier Leakage around seal Ageing of seal balances. 2.2
control line and the increasing leakage over increasing over time.
gland bore a period of time
Tertiary Barrier
Pressure test of
complete assembly.
186

control packing gland - ISO quality systems in
between the DHSV Wrong seal taken from properties similar to
Zone 2.2 to 2.3 Secondary Barrier Leakage around seal None place. Offshore 1.2
control line and the stores actual specification,
effect.

downhole safety valve Material specification manufacturers to have
control packing gland - To provide a seal of seal incompatible ISO quality systems in
Secondary Barrier between the DHSV Seal incorrectly Gradually increasing place. Offshore
Zone 2.2 to 2.3 Leakage around seal with body causing 1.2
control line and the specified leak over time.
gland bore
18. Tubing spool

downhole safety valve Tree has been operating
control packing gland - To provide a seal in excess of 6 months,
between the DHSV Seal incorrectly Seal incorrectly
Zone 2.2 to 2.3 Secondary Barrier Leakage around seal None initial teething 1.2
control line and the specified specified in design
problems have been
Outlet block assembly - gland bore ironed out.
Tertiary Barrier
Employ competent
Secondary Barrier between the DHSV Seal incorrectly Gas leakage around
Zone 2.2 to 2.3 Leakage around seal Effective seal not made 1.1
control line and the installed seal
gland bore
envelope broken.
187
Designers and
Gradual determination
control packing gland - To provide a seal Leakage around seal
of seal, causing
Zone 2.2 to 2.3 Secondary Barrier between the gland body Leakage around seal Ageing of seal balances. 2.2
a period of time
Tertiary Barrier
Pressure test of
complete assembly .

and mechanical
control packing gland - To provide a seal ISO quality systems in
Zone 2.2 to 2.3 Secondary Barrier between the gland body Leakage around seal None place. Offshore 1.2
effect.

downhole safety valve Material specification manufacturers to have
control packing gland - To provide a seal of seal incompatible ISO quality systems in
Zone 2.2 to 2.3 Secondary Barrier between the gland body Leakage around seal with body causing place. Offshore 1.2
18. Tubing spool

downhole safety valve Tree has been operating
control packing gland - To provide a seal in excess of 6 months,
Zone 2.2 to 2.3 Secondary Barrier between the gland body Leakage around seal None initial teething 1.2
and the tubing spool problems have been
Outlet block assembly - ironed out.
Tertiary Barrier
188
Employ competent
downhole safety valve appropriat e supervision
Zone 2.2 to 2.3 Secondary Barrier between the gland body Leakage around seal Effective seal not made 1.1
installed seal
envelope broken.
Designers and
19. Tubing spool
downhole chemical
place. Offshore
gland - Secondary To provide a seal Gradual determination
Barrier between the chemical of seal, causing Leakage around seal
Zone 2.2 to 2.3 Leakage around seal Ageing of seal balances. 2.2
injection line and the increasing leakage over increasing over time.
Outer block assembly - gland bore a period of time
Tertiary Barrier
Pressure test of
complete assembly.
19. Tubing spool
Employ competent
downhole chemical
individuals and
is available.
Barrier between the chemical Seal incorrectly Gas leakage around
Zone 2.2 to 2.3 Leakage around seal Effective seal not made 1.1
injection line and the installed seal
Outer block assembly - gland bore
Tertiary Barrier
envelope broken.
19. Tubing spool

injection line packing Dimensions, chemical
gland - Secondary To provide a seal and mechanical
Barrier between the chemical Leakage around seal Wrong seal taken from properties similar to
injection line and the stores actual specification,
Outer block assembly - gland bore therefore no immediate
Tertiary Barrier effect.
work system etc.
189
19. Tubing spool
Barrier between the chemical Leakage around seal Seal incorrectly Gradually increasing
Zone 2.2 to 2.3 with body causing place. Offshore 1.2
injection line and the specified leak over time. supervisors checks and
Tertiary Barrier
work system etc.
19. Tubing spool

downhole chemical
gland - Secondary Tree has been operating
To provide a seal
Barrier between the chemical Seal incorrectly Seal incorrectly
Zone 2.2 to 2.3 Leakage around seal None initial teething 1.2
injection line and the specified specified in design
problems have been
Tertiary Barrier ironed out.
19. Tubing spool

Employ competent
downhole chemical
individuals and
gland - Secondary
To provide a seal is available.
Barrier Seal incorrectly Gas leakage around
Zone 2.2 to 2.3 between the gland body Leakage around seal Effective seal not made 1.1
installed seal
Tertiary Barrier
envelope broken.
19. Tubing spool

downhole chemical
Designers and
injection line packing Dimensions, chemical
gland - Secondary and mechanical
To provide a seal ISO quality systems in
Barrier Wrong seal taken from properties similar to
Zone 2.2 to 2.3 between the gland body Leakage around seal None place. Offshore 1.2
Outer block assembly - therefore no immediate
Tertiary Barrier effect.
work system etc.
190
19. Tubing spool
gland - Secondary
To provide a seal of seal incompatible ISO quality systems in
Barrier Seal incorrectly Gradually increasing
Zone 2.2 to 2.3 between the gland body Leakage around seal with body causing place. Offshore 1.2
specified leak over time. supervisors checks and
and the tubing spool differential cell to be
Tertiary Barrier
work system etc.
19. Tubing spool

downhole chemical
gland - Secondary Tree has been operating
To provide a seal in excess of 6 months,
Barrier Seal incorrectly Seal incorrectly
Zone 2.2 to 2.3 between the gland body Leakage around seal None initial teething 1.2
and the tubing spool problems have been
Tertiary Barrier ironed out.
Designers and
19. Tubing spool
downhole chemical
place. Offshore
gland - Secondary Gradual determination
To provide a seal supervisors checks and
Barrier of seal, causing Leakage around seal
Zone 2.2 to 2.3 between the gland body Leakage around seal Ageing of seal balances. 2.2
Outer block assembly - a period of time
Tertiary Barrier
Pressure test of
complete assembly.
Pump Labouring
(audible)
Regular checks of
pump pressure injection
rates by plant operators.
20. Tubing spool Rupture of chemical Pressurisation of void Significant reduction or
Provide a conduit for
Zone 2.2 to 2.3 downhole chemical injection line - between Pipework damaged between the tree and cessation of dosing rate 1.2
chemical injection into
injection line - tubing spool and tree during installation tubing spool with of chemicals.
production bore
Secondary Barrier cavity chemicals.
procedures.
ring gasket and tie
down bolts.
191
Regular checks of
pump pressure and
21. Tubing spool Provide a conduit for Rupture of down hole Pressurisation of void operators.
Pump Labouring
Zone 2.2 to 2.3 downhole safety valve hydraulic fluid for safety valve control line Pipework damaged between the tree and 1.2
control line - Secondary control of the down - between tubing spool during installation tubing spool with
injection rate
Barrier hole safety valves and tree cavity hydraulic fluid
procedures.
Slag
To provide containment inclusion/laminations, Designers and
1. Upper Well annulus - for hydrocarbon gas to Stress raisers and crackcold laps and other manufacturers to have
Zone 2.3 to 2.4 Primary Barrier be injected into Casing Spool failure Manufacturing defect initiators geometric ISO quality systems in 1.2
production bore imperfections in the place.
forged block.
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
1. Upper Well annulus - Failure of seal (metal being out with
Primary Barrier to metal) manufacturing Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
192
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
1. Upper Well annulus - Failure of seal (metal
Zone 2.3 to 2.4 mechanical joint Galling on seal face Ineffective seal None. 2.2
Primary Barrier to metal) Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
1. Upper Well annulus - Failure of seal (metal Insufficient make up
Primary Barrier to metal) torque Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
193
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
1. Upper Well annulus - Failure of seal (metal Excessive loading on Seal integrity reduced
Zone 2.3 to 2.4 mechanical joint None. 2.2
Primary Barrier to metal) seal arrangement or failed Secondary barriers
between components
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed Jumping out or
1. Upper Well annulus - Failure of threaded
Zone 2.3 to 2.4 mechanical joint 'unzipping' of the Joint opens None. 2.2
Primary Barrier connection Secondary barriers
between components thread
bolt arrangement,
chemical injection
valve point, tubing
seal.
194
Leakage of gas past

threaded connection
consequently
hanger.
To provide a sealed
1. Upper Well annulus - Failure of threaded Joint integrity reduced
Zone 2.3 to 2.4 mechanical joint Shearing of threads None. 2.2
Primary Barrier connection or failed Secondary barriers
between components
bolt arra ngement,
chemical injection
valve point, tubing
seal.
Failure due to threads No credible effect, gas

2. Annulus downhole
To provide addition Failure of seal (metal tobeing out with already present in both
Zone 2.3 to 2.4 safety valve - Primary Ineffective seal Not Applicable 2.2
barrier in A annulus metal) manufacturing upper and lower A
Barrier
tolerances annulus.
No credible effect, gas

2. Annulus downhole
To provide addition Failure of seal (metal to already present in both
Zone 2.3 to 2.4 safety valve - Primary Galling on seal face Ineffective seal Not Applicable 2.2
barrier in A annulus metal) upper and lower A
Barrier
annulus.
2. Annulus downhole
To provide addition Failure of seal (metal toInsufficient make up already present in both
barrier in A annulus metal) torque upper and lower A
Barrier
annulus.
2. Annulus downhole
To provide addition Failure of seal (metal toExcessive loading on Seal integrity reduced already present in both
Zone 2.3 to 2.4 safety valve - Primary Not Applicable 2.2
barrier in A annulus metal) seal arrangement or failed upper and lower A
Barrier
annulus.

2. Annulus downhole
To provide addition Failure of threaded Jumping out or already present in both
Zone 2.3 to 2.4 safety valve - Primary Joint opens Not Applicable 2.2
barrier in A annulus connection 'unzipping' of the thread upper and lower A
Barrier
annulus.

2. Annulus downhole
To provide addition Failure of threaded Joint integrity reduced already present in both
Zone 2.3 to 2.4 safety valve - Primary Shearing of threads Not Applicable 2.2
barrier in A annulus connection or failed upper and lower A
Barrier
annulus.
195
seals.

To provide addition Failure of housing DHSV housing loses already present in both
barrier in A annulus sealing arrangement integrity upper and lower A Manufacturers and
annulus. designers have suitable
quality assurance
system in accordance
with ISO or equivalent.
Upper A annulus
already pressurised Correct specification of
with gas, therefore seals.
To provide addition Failure of control line Leakage into the A pressure of gas
barrier in A annulus housing annulus potentially higher than
Barrier component interface hydrocarbon fluid
inhibiting the leak into Periodic testing
the upper A annulus.

production tubing
Production tubing will
Designers and
provide a conduit for
3. Production tubing - Production tubing Stress raisers and crack manufacturers to have
Zone 2.3 to 2.4 the hydrocarbon fluid ruptures Manufacturing defect 1.2
primary barrier initiators No credible effect, ISO quality systems in
to the topsides process
since gas pressure place.
plant.
should be higher than
hydrocarbon fluids.

Failure due to threads and effective
To provide a sealed
3. Production tubing - Failure of seal (metal tobeing out with supervision.
primary barrier metal) manufacturing No credible effect,
tolerances since gas pressure
hydrocarbon fluids.
196

and effective
To provide a sealed
3. Production tubing - Failure of seal (metal to supervision.
primary barrier metal) No credible effect,
since gas pressure
hydrocarbon fluids.

and effective
3. Production tubing - Failure of seal (metal toInsufficient make up
primary barrier metal) torque No credible effect,
between components
hydrocarbon fluids.

and effective
3. Production tubing - Failure of seal (metal toExcessive loading on Seal integrity reduced
primary barrier metal) seal arrangement or failed No credible effect,
between components
hydrocarbon fluids.

and effective
To provide a sealed
3. Production tubing - Failure of threaded Jumping out or supervision.
primary barrier connection 'unzipping' of the thread No credible effect,
between components since gas pressure Suitable pressure
hydrocarbon fluids.
197

and effective
To provide a sealed
3. Production tubing - Failure of threaded Joint integrity reduced supervision.
primary barrier connection or failed No credible effect,
since gas pressure
hydrocarbon fluids.
Produce corrosion Degradation of Optimisation of

products which are a components over time. material design and
To give additional
source of debris and selection
4. B Annulus Casing - protection to the Production casing split Corrosion (where water
Zone 2.3 to 2.4 can under certain 1.3
secondary barrier formation to the top of or parted is present)
the pay zone. situations apply a
pressure to mating This less applicable to
surfaces 13% Cr Alloys. Injection of inhibitors
Optimisation of
Deep pits and cavities.
material design and
selection
To give additional
4. B Annulus Casing - protection to the Production casing split Corrosion (where water
Zone 2.3 to 2.4 Localised corrosion 4.3
secondary barrier formation to the top of or parted is present) If equipment is left for
the pay zone. an extended period of
Good corrosion
time full wall
management strategy
perforation can occur.
and execution.
Gas lift pressure
leakage into the C
annulus, consequently
annular valves on C
To give additional annulus become
4. B Annulus Casing - protection to the Production casing split primary barrier.
Zone 2.3 to 2.4 secondary barrier formation to the top of or parted Incorrect casing design Casing could part Correct casing design 3.3
the pay zone.
C annulus is rated to a
B annulus.
198
Gas lift pressure
Design and
leakage into the C
annular valves on C
Precipitation of with ISO and
To give additional annulus become
Embrittlement during Chromium Carbides equivalent.
4. B Annulus Casing - protection to the Production casing split primary barrier.
Zone 2.3 to 2.4 manufacturing process under incorrect welding 2.3
secondary barrier formation to the top of or parted
(high alloy steels) and heat treatment
the pay zone.
regimes.
monitor annulus
pressure.
B annulus.
Gas lift pressure

leakage into the C
Instrument monitor
annular valves on C facility on B & C
Failure due to threads annulus become annulus.
To provide a sealed
4. B Annulus Casing - Failure of seal (metal tobeing out with primary barrier.
secondary barrier metal) manufacturing
between components
tolerances
Pressure in B and C
annulus monitored by
lower pressure than the plant operators.
B annulus.
Gas lift pressure

leakage into the C
Instrument monitor
annulus become annulus.
To provide a sealed
4. B Annulus Casing - Failure of seal (metal to primary barrier.
secondary barrier metal)
between components
Pressure in B and C
B annulus.
199
Gas lift pressure
leakage into the C
Instrument monitor
To provide a sealed
4. B Annulus Casing - Failure of seal (metal toInsufficient make up primary barrier.
secondary barrier metal) torque
between components
Pressure in B and C
B annulus.
Gas lift pressure

leakage into the C
Instrument monitor
To provide a sealed
4. B Annulus Casing - Failure of seal (metal toExcessive loading on Seal integrity reduced primary barrier.
secondary barrier metal) seal arrangement or failed
between components
Pressure in B and C
B annulus.
Gas lift pressure

leakage into the C
Instrument monitor
To provide a sealed
4. B Annulus Casing - Failure of threaded Jumping out or primary barrier.
secondary barrier connection 'unzipping' of the thread
between components
Pressure in B and C
B annulus.
200
Gas lift pressure
leakage into the C
Instrument monitor
To provide a sealed
4. B Annulus Casing - Failure of threaded Joint integrity reduced primary barrier.
secondary barrier connection or failed
between components
Pressure in B and C
B annulus.
Designers and
isolate the B annulus
5. B Annulus Tubing of seal incompatible ISO quality systems in
and with Bonnet seal leakage Seal incorrectly Gradually leaking over
Zone 2.3 to 2.4 Spool Valves - with body causing place. Offshore 2.2
instrumentation (metal to metal joint) specified time
Secondary Barrier differential cell to be supervisors checks and
monitor annular
pressures
work system etc.
Designers and
To provide a facility to Dimensions, chemical
isolate the B annulus and mechanical
5. B Annulus Tubing ISO quality systems in
and with Bonnet seal leakage Wrong seal taken from properties similar to
Zone 2.3 to 2.4 Spool Valves - None place. Offshore 2.2
instrumentation (metal to metal joint) stores actual specification,
monitor annular therefore no immediate
pressures effect.
work system etc.
5. B Annulus Tubing in excess of 6 months,
and with Bonnet seal leakage Seal incorrectly Seal incorrectly
Zone 2.3 to 2.4 Spool Valves - None. initial teething 2.2
instrumentation (metal to metal joint) specified specified in design
Secondary Barrier problems have been
monitor annular
ironed out.
pressures
201
Employ competent
To provide a facility to individuals and
5. B Annulus Tubing is available.
and with Bonnet seal leakage Seal incorrectly
Zone 2.3 to 2.4 Spool Valves - Effective seal not made Gas leak around seal 2.1
instrumentation (metal to metal joint) installed
Secondary Barrier monitor annular
pressures
envelope broken.
isolate the B annulus Employ competent
5. B Annulus Tubing Bolts installed
and with Bonnet seal leakage Sealing arrangement individuals and
Zone 2.3 to 2.4 Spool Valves - incorrectly - bolts Joint integrity reduced unevenly energised
instrumentation (metal to metal joint) appropriate supervision 3.3
Secondary Barrier unevenly tensioned
pressures
Designers and
5. B Annulus Tubing Bolts installed ISO quality systems in
and with Bonnet seal leakage
Zone 2.3 to 2.4 Spool Valves - incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
instrumentation (metal to metal joint)
Secondary Barrier grade of bolt fitted supervisors checks and
monitor annular
pressures
work system etc.
isolate the B annulus Employ competent
5. B Annulus Tubing Bolts installed
and with Bonnet seal leakage Seal distortion leading individuals and
Zone 2.3 to 2.4 Spool Valves - incorrectly - bonnet Joint integrity reduced to progressive leakage. 2.3
instrumentation (metal to metal joint) appropriate supervision
Secondary Barrier over tensioned
pressures
Employ competent
individuals and
5. B Annulus Tubing Bolts installed appropriate supervision
and with Bonnet seal leakage Instantaneous leak from is available.
Zone 2.3 to 2.4 Spool Valves - instrumentation incorrectly - bonnet Joint integrity reduced 2.3
(metal to metal joint) bonnet
Secondary Barrier under tensioned
monitor annular
pressures
envelope broken.
202
Perform maintenance
5. B Annulus Tubing isolate the B annulus
and with Gas leaks from handle and inspection in
Zone 2.3 to 2.4 Spool Valves - Stem Seal Leak Wear and Tear Loss of full seal accordance with 2.4
Secondary Barrier manufacturers
monitor annular
requirements.
pressures
Perform maintenance
5. B Annulus Tubing and in spection in
and with Packing not set Gas leaks from handle
Zone 2.3 to 2.4 Spool Valves - Stem Seal Leak Loss of full seal accordance with 2.4
instrumentation correctly assembly
monitor annular
requirements.
pressures
Perform maintenance
5. B Annulus Tubing and inspection in
and with Gas leaks from handle
Zone 2.3 to 2.4 Spool Valves - Stem Seal Leak Wrong packing fitted Loss of full seal accordance with 2.4
monitor annular
requirements.
pressures
isolat e the B annulus
5. B Annulus Tubing Fitter backs off
and with Audible evidence of
Zone 2.3 to 2.4 Spool Valves - Grease fitting Leakage assembly rather than Partial leak Using competent fitters 3.3
Secondary Barrier just the cap
monitor annular
pressures
5. B Annulus Tubing of plug during routine
and with Audible evidence of
Zone 2.3 to 2.4 Spool Valves - Grease fitting Leakage greasing/lubricating Partial leak Using competent fitters 3.3
Secondary Barrier removes inner check
monitor annular
valve
pressures
6. Upper annulus tubing To provide a facility for Cartridge nose seal Employ competent
spool monitor and vent pressure monitoring failure, annulus gas Cartridge not fully Gas leakage around individuals and
assembly - Secondary equipment to be linked leakage past cartridge tightened cartridge walls appropriate supervision
Barrier to the B annulus wall is available.
203
Designers and
spool monitor and vent pressure monitoring Seal incorrectly Gradually leaking over
Zone 2.3 to 2.4 Failure of bonnet seal with body causing place. Offshore 2.2
assembly - Secondary equipment to be linked specified time supervisors checks and
Barrier to the B annulus
work system etc.
Designers and
spool monitor and vent pressure monitoring Wrong seal taken from properties similar to place. Offshore
Zone 2.3 to 2.4 Failure of bonnet seal actual specification, None 2.2
assembly - Secondary equipment to be linked stores
Barrier to the B annulus therefore no immediate
effect.
work system etc.

spool monitor and vent pressure monitoring Seal incorrectly Seal incorrectly
Zone 2.3 to 2.4 initial teething
assembly - Secondary equipment to be linked Failure of bonnet seal specified specified in design None. 2.2
problems have been
ironed out.
Employ competent
individuals and
is available.
spool monitor and vent pressure monitoring Seal incorrectly
assembly - Secondary equipment to be linked installed
envelope broken.

Bolts installed
spool monitor and vent pressure monitoring Sealing arrangement individuals and
Zone 2.3 to 2.4 Failure of bonnet seal incorrectly - bolts Joint integrity reduced unevenly energised 3.3
assembly - Secondary equipment to be linked appropriate supervision
unevenly tensioned
Barrier to the B annulus is available.
204
Designers and
Zone 2.3 to 2.4 spool monitor and vent pressure monitoring Failure of bonnet seal incorrectly - incorrect Joint integrity reduced None. place. Offshore 3.2
assembly - Secondary equipment to be linked supervisors checks and
grade of bolt fitted
work system etc.

Bolts installed
spool monitor and vent pressure monitoring Seal distortion leading individuals and
Zone 2.3 to 2.4 incorrectly - bonnet
assembly - Secondary equipment to be linked Failure of bonnet seal Joint integrity reduced to progressive leakage. appropriate supervision 2.3
over tensioned
Employ competent
individuals and
6. Upper annulus tubing To provide a facility for appropriat e supervision
Bolts installed
spool monitor and vent pressure monitoring Instantaneous leak from is available.
Zone 2.3 to 2.4 Failure of bonnet seal incorrectly - bonnet Joint integrity reduced 2.3
assembly - Secondary equipment to be linked bonnet
under tensioned
envelope broken.

spool monitor and vent pressure monitoring Failure of Ring Gasket Bolts loosen off in
assembly - Secondary equipment to be linked Seal service
F&G system

spool monitor and vent pressure monitoring Failure of Ring Gasket Excessive vibration on
Zone 2.3 to 2.4 assembly - Secondary equipment to be linked Seal Fatigue failure of bolts one or more bolts after pipework piping as per pipe stress 3.3
a period of time. analysis.

spool monitor and vent pressure monitoring Failure of Ring Gasket Displacement from
Zone 2.3 to 2.4 gradients induce fatigue one or more bolts after design as per pipe stress 3.3
assembly - Secondary equipment to be linked Seal normal relative position
on bolts a period of time. analysis.
205
Designers and
spool monitor and vent pressure monitoring Failure of Ring Gasket Wrong seal taken from properties similar to
assembly - Secondary equipment to be linked Seal stores actual specification,
Barrier to the B annulus therefore no immediate
effect.
work system etc.
Designers and
6. Upper annulus tubing To provide a facility for ISO quality systems in
of seal incompatible
spool monitor and vent pressure monitoring Failure of Ring Gasket Seal incorrectly Gradually increasing place. Offshore
Zone 2.3 to 2.4 with body causing 2.2
assembly - Secondary equipment to be linked Seal specified leak over time.
work system etc.

spool monitor and vent pressure monitoring Failure of Ring Gasket Seal incorrectly Seal incorrectly
Zone 2.3 to 2.4 None initial teething 2.2
assembly - Secondary equipment to be linked Seal specified specified in design
problems have been
ironed out.
Employ competent
individuals and
is available.
spool monitor and vent pressure monitoring Failure of Ring Gasket Seal incorrectly Gas leakage around
Zone 2.3 to 2.4 Effective seal not made 2.1
assembly - Secondary equipment to be linked Seal installed seal
envelope broken.

Bolts installed
spool monitor and vent pressure monitoring Failure of Ring Gasket Sealing arrangement individuals and
Zone 2.3 to 2.4 incorrectly - bolts Joint integrity reduced unevenly energised 3.3
assembly - Secondary equipment to be linked Seal appropriate supervision
unevenly tensioned
206
Designers and
spool monitor and vent pressure monitoring Failure of Ring Gasket
assembly - Secondary equipment to be linked Seal supervisors checks and
grade of bolt fitted
work system etc.

Bolts installed
spool monitor and vent pressure monitoring Failure of Ring Gasket Seal distortion leading individuals and
Zone 2.3 to 2.4 incorrectly - bonnet Joint integrity reduced to progressive leakage. appropriate supervision 2.3
assembly - Secondary equipment to be linked Seal
over tensioned
Employ competent
individuals and
6. Upper annulus tubing To provide a facility for appropriate supervision
Bolts installed
spool monitor and vent pressure monitoring Failure of Ring Gasket Instantaneous leak from is available.
Zone 2.3 to 2.4 incorrectly - bonnet Joint integrity reduced 2.3
assembly - Secondary equipment to be linked Seal bonnet
under tensioned
envelope broken.
Perform maintenance
and inspection in
assembly - Secondary equipment to be linked Stem seal leakage Wear and Tear Loss of full seal assembly 2.4
manufacturers
requirements.

B annulus.
Instrument monitor
7. B annulus tubing To provide a seal Over a period of time Secondary barriers
Zone 2.3 to 2.4 spool to casing hanger between the casing Leakage around seal seal is permanently provided by tie down 3.3
energised
seal - Primary Barrier hanger and casing spool deformed bolt arrangement,
chemical injection
monitored by plant
valve point, tubing operators.
seal.
207
Employ competent
individuals and
7. B annulus tubing To provide a seal is available.
Zone 2.3 to 2.4 spool to casing hanger between the casing Leakage around seal Effective seal not made 1.1
installed seal
seal - Primary Barrier hanger and casing spool

envelope broken.
Designers and
and mechanical
7. B annulus tubing To provide a seal ISO quality systems in
Wrong seal taken from properties similar to place. Offshore
Zone 2.3 to 2.4 spool to casing hanger between the casing Leakage around seal actual specification, None 1.2
stores
seal - Primary Barrier hanger and casing spool supervisors checks and
effect.
work system etc.
Designers and
7. B annulus tubing To provide a seal of seal incompatible ISO quality systems in
Zone 2.3 to 2.4 spool to casing hanger between the casing Leakage around seal with body causing place. Offshore 1.2
seal - Primary Barrier hanger and casing spool differential cell to be supervisors checks and
work system etc.

7. B annulus tubing To provide a seal in excess of 6 months,
Zone 2.3 to 2.4 spool to casing hanger between the casing Leakage around seal None initial teething 1.2
seal - Primary Barrier hanger and casing spool problems have been
ironed out.
Designers and
Leakage around seal
place. Offshore
Gradual determination increasing over time.
7. B annulus tubing To provide a seal supervisors checks and
of seal, causing
Zone 2.3 to 2.4 spool to casing hanger between the casing Leakage around seal Ageing of seal balances. 2.2
increasing leakage over Casing hanger may
seal - Primary Barrier hanger and casing spool
a period of time drop as a result of seal
determination.
Pressure test of
complete assembly.
208
Failure due to threads No credible effect, gas

1. Annulus downhole
To provide addition Failure of seal (metal being out with already present in both
barrier in A annulus to metal) manufacturing upper and lower A
Barrier
tolerances annulus.

1. Annulus downhole
To provide addition Failure of seal (metal already present in both
Zone 2.4 to 2.6 safety valve - Primary Galling on seal face Ineffective seal Not Applicable 2.2
barrier in A annulus to metal) upper and lower A
Barrier
annulus.
1. Annulus downhole
To provide addition Failure of seal (metal Insufficient make up already present in both Not Applicable
barrier in A annulus to metal) torque upper and lower A
Barrier
annulus.

1. Annulus downhole
To provide addition Failure of seal (metal Excessive loading on Seal integrity reduced already present in both
Zone 2.4 to 2.6 safety valve - Primary Not Applicable 2.2
barrier in A annulus to metal) seal arrangement or failed upper and lower A
Barrier
annulus.

1. Annulus downhole Jumping out or
To provide addition Failure of threaded already present in both
Zone 2.4 to 2.6 safety valve - Primary 'unzipping' of the Joint opens Not Applicable 2.2
barrier in A annulus connection upper and lower A
Barrier thread
annulus.
1. Annulus downhole
To provide addition Failure of threaded Joint integrity reduced already present in both
Zone 2.4 to 2.6 safety valve - Primary Shearing of threads Not Applicable 2.2
barrier in A annulus connection or failed upper and lower A
Barrier
annulus.
seals.

To provide addition Failure of housing DHSV housing loses already present in both
barrier in A annulus sealing arrangement integrity upper and lower A Manufacturers and
annulus. designers have suitable
quality assurance
system in accordance
with ISO or equivalent.
209
Upper A annulus
already pressurised Correct specification of
with gas, therefore seals.
To provide addition Failure of control line Leakage into the A pressure of gas
barrier in A annulus housing annulus potentially higher than
hydrocarbon fluid
inhibiting the leak into Periodic testing
the upper A annulus.
Periodic checks of
upper A annulus
pressure.
Dual upper bore packer No credible effect, gas
provides isolation Failure of the packer already present in both
Zone 2.4 to 2.6 bore upper packer - Incorrectly set None. 2.2
between the upper and sealing element upper and lower A
Primary Barrier
lower annulus annulus.
installed.
Periodic checks of
upper A annulus
pressure.
provides isolation Failure of the packer Determination of the already present in both
Zone 2.4 to 2.6 bore upper packer -
between the upper and sealing element packer sealing element None. upper and lower A 2.2
Primary Barrier
installed.
Periodic checks of
upper A annulus
pressure.
2. Annulus bore dual Determination of the
provides isolation Failure of the tubing already present in both
Zone 2.4 to 2.6 bore upper packer - annulus upper bore None. 2.2
between the upper and annulus to packer seal upper and lower A
Primary Barrier tubing stab seal
installed.
Produce corrosion Degradation of Optimisation of
products which are a components over time. material design and
To provide a conduit
3. Lower well annulus source of debris and selection
for the gas to be Lower annulus casing Corrosion (where water
Zone 2.4 to 2.6 (9 5/8") - Primary can under certain 1.3
injected into the split or parted is present)
Barrier situations apply a
production string
pressure to mating This less applicable to
surfaces 13% Cr Alloys. Injection of inhibitors
210
Optimisation of
Deep pits and cavities.
material design and
selection
for the gas to be Lower annulus casing Corrosion (where water
Zone 2.4 to 2.6 (9 5 /8") - Primary Localised corrosion 4.3
injected into the split or parted is present) If equipment is left for
Barrier
production string an extended period of
Good corrosion
time full wall
management strategy
perforation can occur.
and execution.
Gas lift pressure
leakage into the B
annular valves on B
To provide a conduit annulus become
for the gas to be Lower annulus casing primary barrier.
Zone 2.4 to 2.6 (9 5/8") - Primary Incorrect casing design Casing could part Correct casing design 3.3
injected into the split or parted
Barrier
production string
A annulus.
Gas lift pressure

leakage into the B
annular valves on B
annulus become
primary barrier. Design and
Precipitation of with ISO and
3. Lower well annulus Embrittlement during Chromium Carbides B annulus is rated to a equivalent.
for the gas to be Lower annulus casing
Zone 2.4 to 2.6 (9 5/8") - Primary manufacturing process under incorrect welding lower pressure than the 2.3
injected into the split or parted
Barrier (high alloy steels) and heat treatment A annulus.
production string
regimes.
monitor annulus
Loss of ductility pressure.
under normal well
conditions (thermal
loading).
211
Leakage of gas past

threaded connection
pressurising the upper facility on upper A
A annulus. annulus.
Failure of seal (metal tobeing out with
tolerances
Leakage of gas past

threaded connection
A annulus. annulus.
Zone 2.4 to 2.6 (9 5/8") - Primary mechanical joint Galling on seal face Ineffective seal 2.2
metal)
Leakage of gas past

threaded connection
A annulus. annulus.
Failure of seal (metal toInsufficient make up
metal) torque
212
Leakage of gas past

threaded connection
A annulus. annulus.
Failure of seal (metal toExcessive loading on Seal integrity reduced
Zone 2.4 to 2.6 (9 5/8") - Primary mechanical joint 2.2
metal) seal arrangement or failed
Leakage of gas past

threaded connection
A annulus. annulus.
Zone 2.4 to 2.6 (9 5/8") - Primary mechanical joint Joint opens 2.2
Leakage of gas past

threaded connection
A annulus. annulus.
Zone 2.4 to 2.6 (9 5/8") - Primary mechanical joint Shearing of threads 2.2
213
Manufacturers and
designers quality
assurance scheme in
4. Side Pocket To provide a means of Gas is not injected at Gas lift is not effective, equivalent.
Orifice valve fails to
Zone 2.4 to 2.6 Mandrels (SPM) - injecting gas into the Incorrect set pressure the right level in the if well is reliant on gas 1.2
open on demand
Primary Barrier bore string production string lift well may not flow.

well.
Manufacturers and
Gas lift is not effective,
designers quality
if well is reliant on gas
assurance scheme in
lift well may not flow.
4. Side Pocket To provide a means of equivalent.
Orifice valve fails to Orifice valve seized - Gas is not injected into
Zone 2.4 to 2.6 Mandrels (SPM) - injecting gas into the 1.2
open on demand closed the production string
Primary Barrier bore string
Lower A annulus is
pressurised beyond
normal operating
conditions.
well.

Chemical injection
subject to backpressure
from injection gas
under normal chemical
constructed for all
reasonably foreseeable
Chemical injection
5. Chemical Injection Provide a conduit to events.
Chemical injection line Operational loads pressure will increase.
Zone 2.4 to 2.6 Line primary barrier inject chemicals into Line could split 2.3
rupture exceeded
the production tubing
Chemical injection
pressure should be
pressurised with
monitored by
competent individuals.
Combination of
vibration and tension in
line due to slippage of
5. Chemical Injection Provide a conduit to supports.
Chemical injection line Operational loads Correct supporting
Zone 2.4 to 2.6 Line primary barrier inject chemicals into Fatigue 2.3
rupture exceeded arrangement.
Pressure cyclic effects

from injecting.
214
Joint leakage at either

or connection to
production tubing.
Chemical injection
Chemical injection line constructed for all
subject to backpressure reasonably foreseeable
5. Chemical Injection Provide a conduit to from injection gas events.
Chemical injection line Operational loads
Zone 2.4 to 2.6 Line primary barrier inject chemicals into Incorrect installation under normal chemical 2.3
rupture exceeded
the production tubing inject ion activities.
Chemical injection
pressure will increase. Chemical injection
pressure should be
monitored by
competent individuals.
pressurised with
Due to residual liquids

from previous
operations.

subject to backpressure
Corrosion/materials
from injection gas
5. Chemical Injection Provide a conduit to engineer to ensure
Chemical injection line Operational loads under normal chemical
Zone 2.4 to 2.6 Line primary barrier inject chemicals into Corrosion of fittings compatibility of 2.3
rupture exceeded injection activities.
the production tubing materials with
Chemical injection
environment.

pressurised with
215
Upper chemical
injection line seal to Periodic checks of
dual bore upper packer upper A annulus
takes lower A annulus pressure.
Lower seal between
5. Chemical Injection Provide a conduit to Determination of the Gas passing from lower pressure. Coincidental
Zone 2.4 to 2.6 chemical injection line 2.2
Line primary barrier inject chemicals into lower chemical annulus to upper failure of upper
and dual bore upper
the production tubing injection line seal annulus chemical injection line
packer
seal to dual bore upper Pressure testing when
packer to upper A packer was originally
annulus pressurise with installed.
gas.
Lower seal between Expansion and Tubing stab to be

5. Chemical Injection Provide a conduit to
chemical injection line Design working loads Additional tensile loads contraction of annulus designed for all
Zone 2.4 to 2.6 Line primary barrier inject chemicals into 2.3
and dual bore upper are exceeded imposed on packer tubing in the absence of reasonably foreseeable
Failure of upper
packer to upper A Periodic checks of
annulus pressurise with upper A annulus
gas. pressure.
Upper seal between
5. Chemical Injection Provide a conduit to Determination of the Gas passing from lower
Zone 2.4 to 2.6 Line primary barrier inject chemicals into upper chemical annulus to upper 2.2
and dual bore upper
the production tubing injection line seal annulus
packer Failure of lower Pressure testing when
chemical injection line packer was originally
seal to dual bore upper installed.
packer to upper A
gas.
Upper seal between Expansion and Tubing stab to be

5. Chemical Injection Provide a conduit to
chemical injection line Design working loads Additional tensile loads contraction of annulus designed for all
Zone 2.4 to 2.6 Line primary barrier inject chemicals into
and dual bore upper are exceeded imposed on packer tubing in the absence of reasonably foreseeable 2.3
216
APPENDIX G
DUAL COMPLETION MODEL DRAWINGS
217
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APPENDIX H
SINGLE COMPLETION MODEL DRAWINGS
239
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Printed and published by the Health and Safety Executive

C0.35 01/02
ISBN 0-7176-2244-4
OTO 2001/061
35.00 9 780717 622443

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HSE

Health & Safety

Completion component reliability

Prepared by IDM Engineering

OFFSHORE TECHNOLOGY REPORT

Completion component reliability

First published 2002

ISBN 0 7176 2244 4

All rights reserved. No part of this publication may be

This report is made available by the Health and Safety

9. GLOSSARY OF TERMS ........................................................................................ 18

10. FIGURES ................................................................................................................ 19

APPENDIX A - PRIMARY GAS PATHS, WETTED CONTAINMENT ZONES,

APPENDIX B - PRIMARY GAS PATHS, WETTED CONTAINMENT ZONES,

APPENDIX C - SEAL DESCRIPTIONS DUAL COMPLETION..................................... 35

APPENDIX D - SEAL DESCRIPTIONS SINGLE COMPLETION ................................. 48

APPENDIX E - DUAL COMPLETION FMECA RESULTS ............................................ 58

APPENDIX G - DUAL COMPLETION MODEL DRAWINGS ...................................... 217

APPENDIX H - SINGLE COMPLETION MO DEL DRAWINGS ................................... 239

2.2. GAS LIFT

Continuous Gas Lift

2.3. SINGLE AND DUAL COMPLETION GAS LIFT MODELS

3.1. MODEL DESCRIPTION

1. Variability in basic design between the equipment manufacturers.

To establish a representative model an industry-recognised standard has been applied to provide

Gas is injected through the connection to one of the A annulus valves.

In order to distinguish between the different types of polymeric/elastomeric sealing

Red Primary Active Seal

3.2. OPERATING PAR AMETERS

3.3. MODEL BOUNDARIES

3.3.1. Dual Completion Model Boundaries

The boundaries of the dual completion model are defined by:

The gas line check valve.

3.3.2. Single Completion Model Boundaries

The boundaries of the single completion model are defined by:

The gas line check valve.

3.3.3. General Model Boundaries

The model assumes the following points: -

The production/operations group is responsible for well integrity under normal

The individuals working on or around wellhead equipment are competent to do so.

A permit to work system is in place, applied and operating satisfactorily.

The inspection function is effective in identifying non-normal events or situations.

The well is performing within its specified operational parameters.

Gas lift is utilised to maintain continuous production.

Equipment is compatible with the well fluids.

Major accident events, misuse or negligence are not considered.

4.2.1. Representative Model Identification

Primary gas paths.

4.2.2.1. Description Of FMECA Structure

A sample FMECA worksheet is detailed in Figure 3. The worksheet is made up of several

4.2.2.2. Criticality Analysis

1 Highly improbable, not considered to be realistic.

2 Improbable, a rare one off event.

3 Possible, known to have occurred previously.

4 Probable, has been experienced on more than one occasion.

5 Frequent, is a normal or regular occurrence for the situation.

5.1. DUAL COMPLETION FMECA

5.2. SINGLE COMPLETION FMECA

1. BLOWOUT RISK ANALYSIS OF GAS-LIFT COMPLETIONS

2. DOWN HOLE SAFETY VALVE FOR CONCENTRIC COMPLETION

3. THE IMPORTANCE OF CORRECT RUNNING AND HANDLING PROCEDURES FOR

4. PROCEDURES AND PRACTICES OF DUAL-COMPLETION DESIGN IN ABU DHABI

5. EVALUATION OF PREMIUM TAPERED THREADED CONNECTIONS USING