Oto 01061

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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written permission of the copyright owner.
This report is made available by the Health and Safety

Executive as part of a series of reports of work which has
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.
3.3.2.
3.3.3.
4.
Dual Completion Model Boundaries ...................................................6

Single Completion Model Boundaries.................................................7
General Model Boundaries...................................................................7
METHODOLOGY ..................................................................................................... 8
4.1.
ASSUMPTIONS ................................................................................................8
4.2.
APPROACH......................................................................................................8
4.2.1.
4.2.2.
Representative Model Identification....................................................8

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
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.
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.
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.
In order to represent the most onerous circumstances offshore, the single and dual completions
models are considered further in this study.
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.
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.
3.3.1.
MODEL BOUNDARIES
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.
3.3.2.
Annulus assembly up to the side pocket mandrels.

Secondary seal barriers.
Production tubing up to the production wing valve.
Single Completion Model Boundaries
The boundaries of the single completion model are defined by:
3.3.3.
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.
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.
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)
4.2.
4.2.1.
The downhole safety valves utilised in the single and dual completions are considered
to be tubing retrievable and not wireline retrievable.
APPROACH
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.
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.
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
Primary Barrier
Secondary Barrier
Tertiary Barrier
Zone
Working Joint
Description
Equipment or sealing arrangement providing
containment, which is in direct contact with either gas
or hydrocarbon fluids, under normal operating
conditions.
containment, in the event of a primary barrier failure
under normal operating conditions.
containment, in the event of a primary and secondary
barrie r failure under normal operating conditions.
Each model is broken down into discrete manageable
areas (zones) so that a detailed FMECA can be carried
out.
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
Figure 3 Sample FMECA Worksheet
22
SYMPTOMS
MITIGATION
CRITICALITY
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
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
Gas line check valve

Annulus wing valve
Annulus upper master valve
Annulus lower master valve
Annulus bore tubing hanger
Annulus tubing & annulus tubing nipples
Annulus downhole safety valve
Annulus tubing
Annulus bore dual bore upper packer
Lower well annulus
Side Pocket Mandrels
Production tubing
Production bore dual bore upper packer
Production tubing
Production downhole safety valve
Production tubing and nipples
Production bore tubing hanger
Production lower master valve
Production upper master valve
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,
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,

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 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

Lower well annulus - 9 5/8 Casing
Chemical Injection line
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


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

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
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
Gas line check valve

Tubing spool side valve
Upper well annulus
Annulus downhole safety valve in the dual bore packer
Lower well annulus
Lower production tubing
Upper production tubing
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,
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,
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 bore,

Zone 2.14 2.15

Production bore,
SWAB valve,
Chemical injection 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
1.1
1.2
Gas Check Valve (Fail Closed) - (open)

Bonnet Seal (compression, bolts)
Ring gasket (compression, bolts)
2.0
2.1
Connecting Pipework
Ring Gasket (compression, bolts)
3.0
3.1
3.2
3.3
Annulus Wing Valve (Fail Closed) Floating Gate (open)

Stem Seal (parallel, screw cap)
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
1.1
1.2
1.3
1.4
Annulus Wing Valve (Fail Closed) Floating Gate (open)

2.0
2.1
Annulus Bore
Tree Block
3.0
3.1
3.2
3.3
Annulus Upper Master Valve (Fail Closed) Floating Gate (open)

4.0
4.1
4.2
4.3
Annulus SWAB Valve (Manual) Floating Gate (closed)

Gate Seal (face, pressure)
Seat Seal (face, pressure)
36
4.4
4.5
Back Seat (face, pressure) - ineffective

Stem seal (grease fitting secondary barrier)
5.0
5.1
5.2
5.3
5.4
Chemical Injection Valve (open)

Single Cartridge Dual Check Valve (metal to metal nose joint, threaded)
CI Valve - Bonnet Assembly (screw cap, threaded)
CI Valve - Stem packing
CI Valve - Ring Gasket (compression, bolts)
6.0
6.1
6.2
6.3
6.4
6.5
Annulus non-active wing va lve (Manual) Floating Gate (closed)

Secondary barrier components: Tree cap

7.0
7.1
7.2
Tree Cap
Tree Cap (parallel, screw cap)
Test Port (compression, screw threads)
Zone 1.3 1.4


Annulus bore,
Annulus lower master valve.
1.0
1.1
1.2
1.3
Annulus Upper Master Valve (Fail Closed) Floating Gate (open)

2.1
2.1
Annulus Bore
Tree Body
3.0
3.1
3.2
3.3
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
1.1
1.2
1.3
Annulus Lower Master Valve (Manual) Floating Gate (open)

2.0
2.1
2.2
Annulus Bore
Tree Body
Bore Sleeve (parallel, main fixing bolts for tree)
3.0
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
4.1
Tubing spool to tree outer flange seal

Ring Gasket (compression, main fixing bolts for tree)
5.0
5.1
Tubing spool downhole chemical injection line

Chemical Injection Line Integrity
6.0
6.2
assembly
Packing Gland (tertiary seal - outer block assembly seal (compression, bolts), Gland to
Line Seal)
Gland to Tubing Spool Seal
7.0
7.1
Tubing hanger tie down bolts and seals

Bolt Seals (Compression, screw)
8.0
8.2
assembly
Line Seal)
9.0
9.1
Tubing spool to tubing hanger seal

Tubing spool annulus Seal (parallel, lockdown)
10.0
10.1
Tubing hanger downhole safety valve control line upper packing gland
Tubing hanger downhole safety valve control line upper packing gland (compression,
screw)
6.1
8.1
38
11.0
11.1
Tubing hanger downhole chemical injection line upper packing gland

Tubing hanger downhole chemical injection point upper packing gland (compression,
screw)
12.0
12.1
Tubing spool downhole safety valve control line

Downhole safety valve control line Integrity
Zone 1.5 1.6

Annulus bore - tubing hanger,

Annulus tubing & annulus tubing nipples.
1.0
1.1
1.2

Tubing Hanger Body
Premium Tapered Tubing Connection
2.0
2.1
2.2
2.3

Tubing
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
3.1
3.2
Production casing
Production Pipe
Premium Casing Threads
4.0
4.1
Production casing hanger seal to tubing spool

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
5.1
39
5.2
5.3
5.4

Grease fitting (compression, screw thread)
6.0
6.1
6.2
Upper annulus tubing spool monitor and vent assembly

Needle Valve (compression, screw)
7.0
7.1
VR plug & tertiary valve(s)

VR Plug (parallel, screw) (tertiary seal manual gate valves)
8.0
8.1
Tubing hanger seal to tubing spool

9.0
9.1

10.0
10.1

11.0
11.1
Tubing hanger downhole safety valve control line lower packing gland
Tubing hanger downhole safety valve control line lower packing gland (compression,
screw)
12.0
12.1
Tubing hanger downhole chemical injection line lower packing gland

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.
1.0
1.1
1.2
1.3

Annulus Tubing
2.0
2.1
2.2
2.3
Annulus downhole safety valve (ADHSV Fail Closed) - (open)

Premium tapered tubing connection
Valve body
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
1.1
1.2
1.3
Annulus downhole safety valve (ADHSV Fail Closed) - (open)

Valve body
2.0
2.1
2.2
Annulus Tubing
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
1.1
1.2
Annulus Tubing
Annulus Tubing
Premium Tapered Tubin g Connection
2.0
2.1
2.2

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

3.0
3.1

4.0
4.1
Dual bore upper packer chemical injection line upper packing gland
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.
1.0
1.1
1.2

Packer body
2.0
2.1
Lower well annulus 9 5/8 Casing

Annulus Tubing
41
2.2
2.3

Production casing
3.0
3.1
3.2
Side Pocket Mandrels (SPM)

SPM body
Orifice Valve (parallel)
4.0
4.1
4.2
Chemical Injection Line

Chemical Injection Line pipe
Chemical injection line connection at bottom of dual bore upper packer
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..
1.0
1.1
1.2

SPM body
2.0
2.1
2.2
Production tubing
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.
1.0
1.1
1.2
Production tubing
Tubing
2.0
2.1

Packer body
42
2.2

Not applicable gas already in annulus as function of gas lift.
Zone 1.13 1.14

Production tubing.
1.0
1.1
1.2

Packer body
2.0
2.1
2.2
Production tubing
Tubing

Zone 1.14 1.15
Production tubing,
1.0
1.1
1.2
Production tubing
Tubing
2.0
2.1
2.2
2.3
Production downhole safety valve (Fail Closed) - (open)

Valve body

Zone 1.15 1.16
1.0
1.1
1.2
1.3

Valve body
43
2.0
2.1
2.2
2.3

Production Tubing
Production Tubing Nipples

Zone 1.16 1.17

Production bore tubing hanger.
1.0
1.1
1.2
1.3

Production Tubing
Production Tubing Nipples
2.0
2.1
2.2

Tubing Hanger Body

Zone 1.17 1.18
Production bore tubing hanger,

Production bore,
1.0
1.1
1.2

Tubing Hanger Body
2.0
2.1
2.2
Production bore
Tree Body
3.0
3.1
3.2
3.3
Production Lower Master Valve (Manual) Floating Gate (open)


assembly,
44
assembly,
Tubing hanger downhole safety valve control line upper packing gland,
Tubing hanger downhole chemical injection point upper packing gland,
4.0
4.1

5.0
5.1

6.0
6.2
assembly
Line Seal)
7.0
7.1

8.0
8.2
assembly
Line Seal)
9.0
9.1

Tubing spool production Seal (parallel, lockdown)
10.0
10.1
Tubing hanger downhole safety valve control upper packing gland (compression,
screw)
11.0
11.1

screw)
12.0
12.1

6.1
8.1
Zone 1.18 1.19

1.0
1.1
1.2
Production lower master valve,

Production bore,
Production upper master valve.
Production lower master valve (Manual) Floating Gate (open)
45
1.3
2.0
2.1
Production bore
Tree Body
3.0
3.1
3.2
3.3
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
1.1
1.2
1.3
1.4
Production Wing Valve (Fail Closed) Floating Gate (open)

2.0
2.1
Production Bore
Tree Block
3.0
3.1
3.2
3.3
Production Upper Master Valve (Fail Closed) Floating Gate (open)

4.0
4.1
4.2
4.3
4.4
4.5
Production SWAB Valve (Manual) Floating Gate (closed)

5.0
5.1
5.2
5.3
5.4

6.0
6.1
6.2
Production non-active wing valve (Manual) Floating Gate (closed)

46
6.3
6.4
6.5

7.0
7.1
7.2
Tree cap.
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
1.1
1.2
Gas Check Valve (Fail Closed) - (open)

Ring gasket (compression, bolts)
2.0
2.1
Connecting Pipework
3.0
3.1
3.2
3.3
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
1.1
1.2
1.3
Tubing Spool Side Valve (Fail Closed) Floating Gate (open)

2.0
2.1

3.0
3.1
Tubing spool to casing hanger seal

Tubing spool to casing hanger seal (parallel, lockdown)
49
4.0
4.1
Production tubing to tubing hanger seal

Premium Threaded Connection
5.0
5.1
5.2
Upper well annulus

Tubing
6.0
6.1
Tubing hanger body

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

Tubing hanger downhole chemical injection line lower packing gland (compression,
screw)
9.0
9.1

10.0
10.1

11.0
11.1
11.2
Production tubing
Production tubing
12.0
12.1
12.2
12.3
12.4
Tubing spool side valve (Manual) (open) well producing, open

sample
13.0
13.1
13.2
Upper annulus tubing spool and monitoring assembly

valves to take a
14.0
14.1
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,
Tubing hanger tie down bolts
50
15.0
15.1
screw)
16.0
16.1

screw)
17.0
17.1

18.0
18.1
Tubing hanger downhole safety valve control packing gland & tertiary block assembly
Line Seal)
18.2
19.0
19.1
19.2
Tubing hanger downhole chemical injection packing gland & tertiary block assembly
Line Seal)
20.0
20.1

21.0
21.1

Zone 2.3 2.4

Upper well annulus,

Production tubing,
1.0
1.1
1.2
Upper well annulus production casing

Production casing
2.0
2.1
2.2
2.3
Annulus downhole safety valve (Fail Closed) - (open)

Valve Body
Valve piston / control line seal (parallel)
3.0
3.1
3.2
Production tubing
Production Tubing
B Annulus Casing,
B Annulus Tubing Spool Valves,
B annulus tubing spool to casing hanger seal.
51
4.0
4.1
4.2
Intermediate Casing B Annulus

Intermediate Casing
5.0
5.1
5.2
5.3
5.4
B Annulus Tubing Spool Valves (Manual) (open) well producing, open valves to take
a sample
6.0
6.1
6.2
Upper annulus tubing spool monitor and vent assembly

7.0
7.1
B annulus tubing spool to casing hanger seal

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
1.1
1.2
1.3
Annulus downhole safety valve in the dual bore packer (Fail Closed) - (open)
Valve Body
2.0
2.1
2.2
Dual bore upper packer

Packer body
3.0
3.1
3.2
Lower well annulus (9 5/8")

Production casing
4.0
4.1
4.2

SPM body
5.0
5.1
5.2
Chemical Injection Line

Chemical Injection Line pipe
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,
1.0
1.1
1.2

SPM body
2.0
2.1
2.2
Lower production tubing

Tubing
3.0
3.1
3.2

Packer body
Zone 2.8 2.9


Upper production tubing.
1.0
1.1
1.2

Packer body
2.0
2.1
2.2

Tubing
53
Zone 2.9 2.10

Upper production tubing,

1.0
1.1
1.2

Tubing
2.0
2.1
2.2
2.3

Valve Body
Zone 2.10 2.11


1.0
1.1
1.2
1.3

Valve Body
2.0
2.1
2.2
2.3

Tubing
Zone 2.11 2.12

1.0
1.1
1.2
1.3

Tubing hanger.
Tubing
54
2.0
2.1
2.2
Tubing hanger
Tubing Hanger Body
Zone 2.12 2.13

Tubing hanger,
Production bore,
1.0
1.1
1.2
Tubing hanger
Tubing Hanger Body
2.0
2.1
2.2
Production bore
Tree Body
3.0
3.1
3.2
3.3
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.
4.0
4.1

5.0
5.1

6.0
assembly
Line Seal)
6.1
6.2
55
7.0
7.1

8.0
8.2
assembly
Packing Gland (tertia ry seal - outer block assembly seal (compression, bolts), Gland to
Line Seal)
9.0
9.1

10.0
10.1
screw)
11.0
11.1
Tubing hanger downhole chemical injection point upper packing gland

screw)
12.0
12.1

8.1
Zone 2.13 2.14


Production bore,
1.0
1.1
1.2
1.3
Production lower master valve (Manual) Floating Gate (open)

2.0
2.1
Production bore
Tree Body
3.0
3.1
3.2
3.3
Production upper master valve (Fail Closed) Floating Gate (open)


Zone 2.14 2.15

Production bore,
56
SWAB valve,
Chemical injection valve
1.0
1.1
1.2
1.3
1.4
Production Wing Valve (Fail Closed) Floating Gate (open)

2.0
2.1
Production Bore
Tree Block
3.0
3.1
3.2
3.3
Production Upper Master Valve (Fail Closed) Floating Gate (open)

4.0
4.1
4.2
4.3
4.4
4.5
Production SWAB Valve (Manual) Floating Gate (closed)

5.0
5.1
5.2
5.3
5.4

7.0
7.1
7.2
Tree cap
Tree Cap
57
APPENDIX E
58
SYSTEM
Zone 1.1 to 1.2
SUB-SYSTEM
FUNCTION
1. Gas Check Valve Primary Barrier
FAILURE
CAUSE
EFFECT
SYMPTOMS
To contain the gas

within the tree on loss of Bonnet seal leakage
pressurisation in the
(metal to metal joint)
upstream pipework.
Seal incorrectly
specified
Material specification of
seal incompatible with
Gradually leaking over
body causing
time
differential cell to be
setup.
Designers and
manufacturers to have
ISO quality systems in
place. Offshore
2.2
supervisors checks and
balances i.e. permit to
work system etc.
Tree has been operating
in excess of 6 months,
2.2
initial teething problems
have been ironed out.
Zone 1.1 to 1.2
To contain the gas

upstream pipework.
Dimensions, chemical
and mechanical
Wrong seal taken from properties similar to
N one
stores
actual specification,
therefore no immediate
effect.
Zone 1.1 to 1.2
To contain the gas

upstream pipework.
Seal incorrectly
specified
Zone 1.1 to 1.2
To contain the gas

upstream pipework.
Seal incorrectly
specified in design
None.
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
appropriate supervision
is available.
Seal incorrectly
installed
Effective seal not made Gas leak around seal
2.1
Pressure tested after
envelope broken.
Zone 1.1 to 1.2
Zone 1.1 to 1.2
To contain the gas

upstream pipework.
To contain the gas

upstream pipework.
Bolts installed
incorrectly - bolts
unevenly tensioned
Bolts installed
incorrectly - incorrect
grade of bolt fitted
59
Joint integrity reduced
Sealing arrangement
unevenly energised
Joint integrity reduced None.
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.1 to 1.2
To contain the gas

upstream pipework.
To contain the gas

upstream pipework.
Zone 1.1 to 1.2
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
Bolts installed
Seal distortion leading to individuals and
incorrectly - bonnet over Joint integrity reduced
2.3
progressive leakage.
tensioned
is available.
Bolts installed
incorrectly - bonnet
under tensioned
Employ competent
individuals and
Instantaneous leak from
is available.
2.3
bonnet
envelope broken.
Zone 1.1 to 1.2
To contain the gas

within the tree on loss of Failure of Ring Gasket Bolts loosen off in
Seal
service
upstream pipework.
Zone 1.1 to 1.2
To contain the gas

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

Thermal/mechanical
Appropriate piping
Displacement from
gradients induce fatigue one or more bolts after a
design as per pipe stress 3.3
Seal
normal relative position
on bolts
period of time.
analysis.
upstream pipework.
To contain the gas

within the tree on loss of Failure of Ring Gasket Wrong seal taken from
Seal
stores
upstream pipework.
and mechanical
properties similar to
None
effect.
Designers and
place. Offshore
2.2
work system etc.
To contain the gas

within the tree on loss of Failure of Ring Gasket Seal incorrectly
Seal
specified
upstream pipework.
Gradually increasing
body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.1 to 1.2
Zone 1.1 to 1.2
60
Partial leakage of gas
Gas release
Possible detection by
plant operators and/or
F&G system
2.3
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.1 to 1.2
To contain the gas

Seal
specified
upstream pipework.
Zone 1.1 to 1.2
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Seal incorrectly
specified in design
None

2.2
Employ competent
individuals and
is available.
To contain the gas

Seal
installed
upstream pipework.
Effective seal not made Gas leakage around seal
2.1
envelope broken.
Zone 1.1 to 1.2
To contain the gas

Bolts installed
incorrectly - bolts
Seal
unevenly tensioned
upstream pipework.
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Joint integrity reduced None
Designers and
place. Offshore
3.2
work system etc.
Zone 1.1 to 1.2
To contain the gas

Bolts installed
Seal
upstream pipework.
Zone 1.1 to 1.2
To contain the gas

Employ competent
Bolts installed
2.3
Seal
tensioned
upstream pipework.
is available.
To contain the gas

Bolts installed
Seal
under tensioned
upstream pipework.
Zone 1.1 to 1.2
Zone 1.1 to 1.2
To contain the gas

2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Bolts loosen off in
- Primary Barrier
Seal
service
upstream pipework.
61
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Gas release
F&G system
2.3
SYSTEM
SUB-SYSTEM
Zone 1.1 to 1.2
To contain the gas

2. Connecting Pipework within the tree on loss of Failure of Ring Gasket
- Primary Barrier
pipework
Seal
period of time.
analysis.
upstream pipework.
Zone 1.1 to 1.2
To contain the gas

Thermal/mechanical
Appropriate piping
Displacement from
- Primary Barrier
Seal
on bolts
period of time.
analysis.
upstream pipework.
Zone 1.1 to 1.2
To contain the gas
and mechanical
2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Wrong seal taken from properties similar to
None
- Primary Barrier
Seal
stores
upstream pipework.
effect.
Zone 1.1 to 1.2
To contain the gas

2. Connecting Pipework within the tree on loss of Failure of Ring Gasket Seal incorrectly
- Primary Barrier
Seal
specified
upstream pipework.
body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.1 to 1.2
To contain the gas

- Primary Barrier
Seal
specified
upstream pipework.
Seal incorrectly
specified in design

2.2
Zone 1.1 to 1.2
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
None
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.
To contain the gas

- Primary Barrier
Seal
installed
upstream pipework.
2.1
envelope broken.
Zone 1.1 to 1.2
To contain the gas

Bolts installed
incorrectly - bolts
- Primary Barrier
Seal
unevenly tensioned
upstream pipework.
62
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
Zone 1.1 to 1.2
To contain the gas

Bolts installed
- Primary Barrier
Seal
upstream pipework.
Zone 1.1 to 1.2
To contain the gas

Employ competent
Bolts installed
2.3
- Primary Barrier
Seal
tensioned
upstream pipework.
is available.
Zone 1.1 to 1.2
FUNCTION
FAILURE
CAUSE
EFFECT
To contain the gas

Bolts installed
- Primary Barrier
Seal
under tensioned
upstream pipework.
SYMPTOMS
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.1 to 1.2
To contain the gas

within the tree on loss of
3. Annulus Wing Valve pressurisation in the
Bonnet seal leakage
- Primary Barrier
upstream pipework and (metal to metal joint)
or on activation of
platform ESD
Seal incorrectly
specified
Zone 1.1 to 1.2
To contain the gas

Bonnet seal leakage
- Primary Barrier
or on activation of
platform ESD
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.1 to 1.2
To contain the gas

Bonnet seal leakage
- Primary Barrier
or on activation of
platform ESD
Seal incorrectly
specified

2.2
body causing
time
setup.
Seal incorrectly
specified in design
63
None.
SYSTEM
SUB-SYSTEM
Zone 1.1 to 1.2
CAUSE
EFFECT
To contain the gas

Bonnet seal leakage
- Primary Barrier
or on activation of
platform ESD
Seal incorrectly
installed
Zone 1.1 to 1.2
To contain the gas

Bonnet seal leakage
- Primary Barrier
or on activation of
platform ESD
Bolts installed
incorrectly - bolts
unevenly tensioned
Zone 1.1 to 1.2
To contain the gas

Bonnet seal leakage
- Primary Barrier
or on activation of
platform ESD
Bolts installed
Zone 1.1 to 1.2
To contain the gas

Bonnet seal leakage
- Primary Barrier
or on activation of
platform ESD
Employ competent
Bolts installed
2.3
tensioned
is available.
Zone 1.1 to 1.2
To contain the gas

Bonnet seal leakage
- Primary Barrier
or on activation of
platform ESD
Zone 1.1 to 1.2
FUNCTION
FAILURE
To contain the gas

Stem Seal Leak
- Primary Barrier
upstream pipework and
or on activation of
platform ESD
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
Bolts installed
under tensioned
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Wear and Tear
Loss of full seal
64
Perform maintenance
and inspection in
Gas leaks from actuator
accordance with
housing
manufacturers
requirements.
2.4
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
Zone 1.1 to 1.2
To contain the gas

Stem Seal Leak
- Primary Barrier
or on activation of
platform ESD
Zone 1.1 to 1.2
To contain the gas

Stem Seal Leak
- Primary Barrier
or on activation of
platform ESD
Zone 1.1 to 1.2
To contain the gas

Fitter backs off
Grease fitting Leakage assembly rather than
- Primary Barrier
just the cap
or on activation of
platform ESD
Zone 1.1 to 1.2
To contain the gas

Grease fitting Leakage
- Primary Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
Seal incorrectly
specified
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
and mechanical
None
stores
effect.
MITIGATION
CRITICALITY
Packing not set correctlyLoss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Wrong packing fitted
Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Partial leak
Audible evidence of gas

Using competent fitters 3.3
release
Removal or backing off

of plug during routine
greasing/lubricating
Partial leak
removes inner check
valve

release
body causing
time
setup.
65
Designers and
place. Offshore
2.2
work system etc.
Designers and
place. Offshore
2.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
Seal incorrectly
installed
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
Bolts installed
incorrectly - bolts
unevenly tensioned
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

Bonnet Seal Leakage
- Primary Barrier
or on activation of
platform ESD
CRITICALITY
Seal incorrectly
specified
Seal incorrectly
specified in design
None.

2.2
Employ competent
individuals and
is available.
2.1
envelope broken.
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Bolts installed
Designers and
place. Offshore
3.2
work system etc.
Bolts installed
over tensioned
Employ competent
Seal distortion leading individuals and
2.3
to progressive leakage. appropriate supervision
is available.
Bolts installed
under tensioned
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
66
SYSTEM
SUB-SYSTEM
FUNCTION
EFFECT
SYMPTOMS
Zone 1.2 to 1.3
To contain the gas

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

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

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

Grease fitting leakage
- Primary Barrier
or on activation of
platform ESD
Fitter backs off

assembly rather than
just the cap
Partial leak

release
Zone 1.2 to 1.3
To contain the gas

- Primary Barrier
or on activation of
platform ESD

Partial leak
removes inner check
valve

release
Zone 1.2 to 1.3
2. Annulus Bore Primary Barrier
To maintain annulus
pressure integrity
FAILURE
Tree block failure
CAUSE
Wear and Tear
Packing not set

correctly
Manufacturing defect
67
Slag
inclusion/laminations,
Stress raisers and crack
cold laps and other
initiators
geometric imperfections
in the forged block.
MITIGATION
CRITICALITY
Designers and
1.2
place.
SYSTEM
SUB-SYSTEM
CAUSE
EFFECT
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Master Valve - Primary
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Seal incorrectly
specified
body causing
time
setup.
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Seal incorrectly
specified

2.2
Zone 1.2 to 1.3
Zone 1.2 to 1.3
FUNCTION
FAILURE
Seal incorrectly
specified in design
SYMPTOMS
None.
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.
To contain the gas

3. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Seal incorrectly
installed
To contain the gas

3. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Bolts installed
incorrectly - bolts
unevenly tensioned
2.1
envelope broken.
68
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Bolts installed
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Employ competent
Bolts installed
2.3
tensioned
is available.
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Stem Seal Leak
Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Stem Seal Leak
Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Stem Seal Leak
Barrier
or on activation of
platform ESD
CAUSE
EFFECT
Bolts installed
under tensioned
SYMPTOMS
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Wear and Tear
69
Loss of full seal
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Fitter backs off
just the cap
Barrier
or on activation of
platform ESD
Zone 1.2 to 1.3
To contain the gas

3. Annulus Upper
Barrier
or on activation of
platform ESD
MITIGATION
CRITICALITY
Partial leak

release

Partial leak
removes inner check
valve

release
Pressure testing at
manufactures to ensure
integrity of gate/seat.
Zone 1.2 to 1.3
Provides isolation of
annulus from tree cap
4. Annulus SWAB
other than under any
Valve - Primary Barrier
well intervention
conditions
Poor seal between gate Gate/seat scored or

and seat
damaged
Gas passing into upper Pressurised gas under

bore under tree cap
tree cap
Maintenance and
inspection by
1.5
manufacturer including
periodic testing
offshore.
Tree cap is a secondary

barrier
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Poor seal between seat Seal incorrectly

seal and valve body
specified
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
and mechanical
Poor seal between seat Wrong seal taken from properties similar to
seal and valve body
stores
leak over time.
effect.
body causing
time
setup.
70
Designers and
place. Offshore
1.1
work system etc.
Designers and
place. Offshore
1.2
work system etc.
SYSTEM
SUB-SYSTEM
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Zone 1.2 to 1.3
FUNCTION
4. Annulus SWAB
well intervention
conditions
FAILURE
CAUSE

seal and valve body
specified
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Seal incorrectly
specified in design
None.

1.2
Employ competent
individuals and
is available.

seal and valve body
installed
1.1
envelope broken.
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
body causing
time
setup.
Designers and
place. Offshore
2.2
work system etc.
Bonnet seal leakage

Seal incorrectly
specified
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Bonnet seal leakage

and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Bonnet seal leakage

Seal incorrectly
specified

2.2
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Bonnet seal leakage

Seal incorrectly
specified in design
None.
Employ competent
individuals and
is available.
Seal incorrectly
installed
2.1
envelope broken.
71
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Bonnet seal leakage

Bolts installed
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Bonnet seal leakage

Employ competent
Bolts installed
2.3
tensioned
is available.
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
Zone 1.2 to 1.3
4. Annulus SWAB
well intervention
conditions
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
Bonnet seal leakage

Bolts installed
incorrectly - bolts
unevenly tensioned
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Bonnet seal leakage

Bolts installed
under tensioned
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Stem seal leakage
Stem seal leakage
Stem seal leakage
Wear and Tear
Loss of full seal
72
Loss of full seal
Gas leaks from handle

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
SYSTEM
SUB-SYSTEM
CAUSE
EFFECT
SYMPTOMS
MITIGATION
Zone 1.2 to 1.3
Cartridge nose seal

To provide a controlled
failure, annulus gas
5. Chemical Injection
entry point for chemical
leakage past cartridge
injection
wall
Cartridge not fully

tightened
Gas leakage around

cartridge walls
None.
Employ competent
individuals and
1.1
is available.
entry point for chemical Failure of bonnet seal
injection
Seal incorrectly
specified
body causing
time
setup.
Zone 1.2 to 1.3
injection
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.2 to 1.3
injection
Seal incorrectly
specified

2.2
Zone 1.2 to 1.3
Zone 1.2 to 1.3
FUNCTION
FAILURE
injection
Seal incorrectly
specified in design
None.
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.
Seal incorrectly
installed
2.1
envelope broken.
Zone 1.2 to 1.3
injection
Bolts installed
incorrectly - bolts
unevenly tensioned
73
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Zone 1.2 to 1.3
injection
Bolts installed
Zone 1.2 to 1.3
injection
Employ competent
Bolts installed
2.3
tensioned
is available.
Zone 1.2 to 1.3
injection
Bolts installed
under tensioned
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.2 to 1.3
Failure of Ring Gasket Bolts loosen off in
Seal
service
injection
Zone 1.2 to 1.3
Failure of Ring Gasket
Seal
pipework
injection
period of time.
analysis.
Zone 1.2 to 1.3
Thermal/mechanical
Appropriate piping
Displacement from
Seal
injection
on bolts
period of time.
analysis.
Zone 1.2 to 1.3
and mechanical
Failure of Ring Gasket Wrong seal taken from properties similar to
None
Seal
stores
injection
effect.
74
Gas release
F&G system
2.3
Designers and
place. Offshore
2.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
Zone 1.2 to 1.3
Failure of Ring Gasket Seal incorrectly
Seal
specified
injection
body causing
leak over time.
setup.
Zone 1.2 to 1.3
Seal
specified
injection
Seal incorrectly
specified in design
Zone 1.2 to 1.3
None
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
2.2
Employ competent
individuals and
is available.
Seal
installed
injection
2.1
envelope broken.
Zone 1.2 to 1.3
Bolts installed
incorrectly - bolts
Seal
injection
unevenly tensioned
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Zone 1.2 to 1.3
Bolts installed
Seal
injection
Zone 1.2 to 1.3
Employ competent
Bolts installed
2.3
Seal
injection
tensioned
is available.
75
SYSTEM
Zone 1.2 to 1.3
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Bolts installed
Seal
injection
under tensioned
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.2 to 1.3
entry point for chemical Stem seal leakage
injection
Zone 1.2 to 1.3
injection
Zone 1.2 to 1.3
injection

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
Wear and Tear
Loss of full seal
Loss of full seal
Pressure testing at
manufactures to ensure
integrity of gate/seat.
Zone 1.2 to 1.3
6. Annulus non-active
wing valve - Primary
Barrier
To provide a facility for

Poor seal between gate Gate/seat scored or
injecting kill fluid into
and seat
damaged
the annulus.
Gas passing into upper Pressurised gas under

bore under tree cap
tree cap
Maintenance and
inspection by
1.5
manufacturer including
periodic testing
offshore.
Tree cap is a secondary

barrier
76
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
body causing
time
setup.
MITIGATION
CRITICALITY
Designers and
place. Offshore
1.1
work system etc.
Barrier

seal and valve body
specified
the annulus.
Zone 1.2 to 1.3
Barrier
and mechanical
Poor seal between seat Wrong seal taken from properties similar to
seal and valve body
stores
leak over time.
the annulus.
effect.
Designers and
place. Offshore
1.2
work system etc.
Zone 1.2 to 1.3
Barrier

seal and valve body
specified
the annulus.

1.2
Zone 1.2 to 1.3
Zone 1.2 to 1.3
Barrier
Seal incorrectly
specified in design
None.
Employ competent
individuals and
is available.

seal and valve body
installed
the annulus.
1.1
envelope broken.
Zone 1.2 to 1.3
Zone 1.2 to 1.3
Barrier
Barrier
body causing
time
setup.

Bonnet seal leakage
the annulus.
Seal incorrectly
specified

Bonnet seal leakage
the annulus.
and mechanical
None
stores
effect.
77
Designers and
place. Offshore
2.2
work system etc.
Designers and
place. Offshore
2.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.2 to 1.3
Barrier

Bonnet seal leakage
the annulus.
Zone 1.2 to 1.3
Barrier
FAILURE

Bonnet seal leakage
the annulus.
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Seal incorrectly
specified
Seal incorrectly
specified in design
None.

2.2
Employ competent
individuals and
is available.
Seal incorrectly
installed
2.1
envelope broken.
Zone 1.2 to 1.3
Barrier

Bonnet seal leakage
the annulus.
Bolts installed
incorrectly - bolts
unevenly tensioned
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Zone 1.2 to 1.3
Barrier

Bonnet seal leakage
the annulus.
Bolts installed
Zone 1.2 to 1.3
Barrier

Bonnet seal leakage
the annulus.
Employ competent
Bolts installed
2.3
tensioned
is available.
Zone 1.2 to 1.3
Barrier

Bonnet seal leakage
the annulus.
Bolts installed
under tensioned
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.2 to 1.3
Barrier

injecting kill fluid into Stem seal leakage
the annulus.
Wear and Tear
Loss of full seal
78

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.2 to 1.3
Barrier

the annulus.
Zone 1.2 to 1.3
Barrier

the annulus.
Zone 1.2 to 1.3
Barrier

Seal
service
the annulus.
Zone 1.2 to 1.3
Barrier

Seal
pipework
the annulus.
period of time.
analysis.
Zone 1.2 to 1.3
Barrier

Thermal/mechanical
Appropriate piping
Displacement from
Seal
the annulus.
on bolts
period of time.
analysis.
Barrier
and mechanical
None
Seal
stores
the annulus.
effect.
Zone 1.2 to 1.3
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
Loss of full seal

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
Gas release
F&G system
2.3
Zone 1.2 to 1.3
Barrier

Seal
specified
the annulus.
body causing
leak over time.
setup.
Zone 1.2 to 1.3
Barrier

Seal
specified
the annulus.
Seal incorrectly
specified in design
79
None
Designers and
place. Offshore
2.2
work system etc.
Designers and
place. Offshore
2.2
work system etc.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
Zone 1.2 to 1.3
Barrier

Seal
installed
the annulus.
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
Zone 1.2 to 1.3
Barrier

Bolts installed
incorrectly - bolts
Seal
the annulus.
unevenly tensioned
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Zone 1.2 to 1.3
Barrier

Bolts installed
Seal
the annulus.
Zone 1.2 to 1.3
Barrier
Employ competent
Bolts installed
2.3
Seal
the annulus.
tensioned
is available.
Zone 1.2 to 1.3
Barrier

Bolts installed
Seal
the annulus.
under tensioned
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.2 to 1.3
To provide a removable
7. Tree Cap - Secondary secondary barrier to
Barrier
allow well intervention
activities
On failure of primary
barrier (gate on SWAB)
all tree cap seals are
Bolts loosen off in
primary barriers. Tree service
Cap Annulus Bore Seal
passing.
Zone 1.2 to 1.3
Barrier
activities
Fatigue of bolts
primary barriers. Tree
passing.
one or more bolts after a
pipework
period of time.
analysis.
80
Gas release
F&G system
2.3
SYSTEM
SUB-SYSTEM
Zone 1.2 to 1.3
Barrier
activities
Thermal/mechanical
Appropriate piping
Displacement from
on bolts
period of time.
analysis.
passing.
Zone 1.2 to 1.3
Barrier
activities
Wrong seal taken from
primary barriers. Tree stores
passing.
Zone 1.2 to 1.3
To provide a removable barrier (gate on SWAB)
Seal incorrectly
Barrier
allow well intervention primary barriers. Tree specified
activities
passing.
Zone 1.2 to 1.3
Barrier
activities
Zone 1.2 to 1.3
Seal incorrectly
allow well intervention primary barriers. Tree installed
Barrier
activities
passing.
Zone 1.2 to 1.3
FUNCTION
Barrier
activities
FAILURE
CAUSE
EFFECT
Seal incorrectly
primary barriers. Tree specified
passing.
SYMPTOMS
MITIGATION
CRITICALITY
and mechanical
None
effect.
Designers and
place. Offshore
2.2
work system etc.
body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work system etc.
Seal incorrectly
specified in design

2.2
None
Employ competent
individuals and
is available.
2.1
envelope broken.
Bolts installed
incorrectly - bolts
unevenly tensioned
passing.
81
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
Zone 1.2 to 1.3
Barrier
activities
Bolts installed
passing.
Zone 1.2 to 1.3
Barrier
activities
Employ competent
Bolts installed
2.3
tensioned
is available.
passing.
Zone 1.2 to 1.3
Bolts installed
Barrier
allow well intervention primary barriers. Tree
under tensioned
activities
passing.
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.2 to 1.3
Barrier
activities
Bolts loosen off in
primary barriers. Tree service
Cap Bonnet Seal
passing.
Zone 1.2 to 1.3
Barrier
activities
Fatigue of bolts
Cap Bonnet Seal
passing.
one or more bolts after a
pipework
period of time.
analysis.
Zone 1.2 to 1.3
Barrier
activities
Thermal/mechanical
Appropriate piping
Displacement from
on bolts
period of time.
analysis.
Cap Bonnet Seal
passing.
82
Gas release
F&G system
2.3
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
Zone 1.2 to 1.3
Barrier
activities
Zone 1.2 to 1.3
Seal incorrectly
Barrier
allow well intervention primary barriers. Tree specified
activities
Cap Bonnet Seal
passing.
Zone 1.2 to 1.3
Barrier
activities
Zone 1.2 to 1.3
Seal incorrectly
allow well intervention primary barriers. Tree installed
Barrier
activities
Cap Bonnet Seal
passing.
EFFECT
primary barriers. Tree stores
Cap Bonnet Seal
passing.
Seal incorrectly
primary barriers. Tree specified
Cap Bonnet Seal
passing.
SYMPTOMS
MITIGATION
CRITICALITY
and mechanical
None
effect.
Designers and
place. Offshore
2.2
work system etc.
body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work system etc.
Seal incorrectly
specified in design

2.2
None
Employ competent
individuals and
is available.
2.1
envelope broken.
Bolts installed
incorrectly - bolts
unevenly tensioned
Cap Bonnet Seal
passing.
Zone 1.2 to 1.3
Barrier
activities
Zone 1.2 to 1.3
Bolts installed
Barrier
allow well intervention primary barriers. Tree
activities
Cap Bonnet Seal
passing.
83
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
SYSTEM
SUB-SYSTEM
Zone 1.2 to 1.3
Barrier
activities
Employ competent
Bolts installed
2.3
tensioned
Cap Bonnet Seal
is available.
passing.
Zone 1.2 to 1.3
Barrier
activities
Bolts installed
under tensioned
Cap Bonnet Seal
passing.
Zone 1.2 to 1.3
Zone 1.2 to 1.3
Zone 1.2 to 1.3
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Careful installation of
tree cap.
Damage of o-ring on
Barrier
installation of cap
activities
Cap Plug Seal passing.
Scoring and/or nipping

Gas leakage from the
of o-ring breaking down
tree cap retainer ring.
seal integrity
barrier (gate on SWAB) Damage to polished
bore on installation of
Barrier
primary barriers. Tree tree cap
activities
Scoring of polished bore
Incorrect o-ring used
Barrier
activities
Inadequate seal
2.4
Pressure test of tree cap
on tree assembly.
Inspect and dress
polished bore prior to
installation.


2.3
on tree assembly.
Designers and
place. Offshore
balances.
2.2

on tree assembly.
84
CRITICALITY
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.2 to 1.3
Ageing of o-ring prior
Barrier
to installation
activities
SYMPTOMS
Gradual deteriation of
seal, causing increasing Gas leakage from the
leakage over a period of tree cap retainer ring.
time
MITIGATION
CRITICALITY
Designers and
place. Offshore
balances.
2.2

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

during manufacture.
Zone 1.2 to 1.3
Barrier
activities
Thread cut out of
primary barriers. Test tolerance
Designers and
Component will only
Either male or female mate for a proportion of
threads are cut oversize the threads (rather than
place. Offshore
full length engagement)
balances.
Zone 1.2 to 1.3
Excessive torque
required to install.
Cross threads
Barrier
allow well intervention primary barriers. Test
activities
Ineffective seal

and effective
supervision.
1.3
Fitting improperly
aligned.
Suitable pressure
testing.
Leaking joint.
85
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.2 to 1.3
Damaged threads
Barrier
allow well intervention primary barriers. Test
activities
SYMPTOMS
Joint difficult to make
up.
Excessive torque
MITIGATION
CRITICALITY

and effective
supervision.
Improperly mated
threads
1.3
Fitting improperly
aligned.
Suitable pressure
testing.
Leaking joint
Zone 1.2 to 1.3
Wear and Tear
Barrier
primary barriers. Valve
activities
Stem packing passing.
Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
Zone 1.2 to 1.3
Packing not set correctly Loss of full seal
Barrier
activities
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Zone 1.2 to 1.3
Barrier
activities
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
86
Loss of full seal
2.4
SYSTEM
SUB-SYSTEM
CAUSE
EFFECT
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Seal incorrectly
specified
body causing
time
setup.
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Seal incorrectly
specified

2.2
Zone 1.3 to 1.4
Zone 1.3 to 1.4
FUNCTION
FAILURE
Seal incorrectly
specified in design
SYMPTOMS
None.
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Seal incorrectly
installed
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Bolts installed
incorrectly - bolts
unevenly tensioned
2.1
envelope broken.
87
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Bolts installed
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Bolts installed
over tensioned
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Bonnet Seal Leakage
Barrier
or on activation of
platform ESD
Bolts installed
under tensioned
SYMPTOMS
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
2.3
is available.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Stem Seal Leak
Barrier
or on activation of
platform ESD
Wear and Tear
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Stem Seal Leak
Barrier
or on activation of
platform ESD
Packing not set

correctly
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Stem Seal Leak
Barrier
or on activation of
platform ESD
88
Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
SYSTEM
SUB-SYSTEM
CAUSE
EFFECT
SYMPTOMS
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Leakage from grease
upstream pipework and fitting
Barrier
or on activation of
platform ESD
Individual back off

just the cap
Partial leak

release
Zone 1.3 to 1.4
To contain the gas

1. Annulus Upper
Leakage from grease
upstream pipework and fitting
Barrier
or on activation of
platform ESD

Partial leak
removes inner check
valve

release
Zone 1.3 to 1.4
FUNCTION
To maintain annulus
pressure integrity
FAILURE
Tree block failure
MITIGATION
CRITICALITY
Slag
cold laps and other
initiators
Designers and
1.2
place.
body causing
time
setup.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Seal incorrectly
specified
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Seal incorrectly
specified

2.2
Seal incorrectly
specified in design
89
None.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
CAUSE
EFFECT
SYMPTOMS
Seal incorrectly
installed
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Bolts installed
incorrectly - bolts
unevenly tensioned
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Bolts installed
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Employ competent
Bolts installed
2.3
tensioned
is available.
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Stem Seal Leak
Barrier
upstream pipework
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Stem Seal Leak
Barrier
upstream pipework
Bolts installed
under tensioned
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Wear and Tear
Loss of full seal
90

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.3 to 1.4
To contain the gas

3. Annulus Lower
Stem Seal Leak
Barrier
upstream pipework
Zone 1.3 to 1.4
Zone 1.3 to 1.4
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Loss of full seal

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
To contain the gas

3. Annulus Lower
within the tree on loss of Leakage from grease
fitting
Barrier
upstream pipework
Individual back off

just the cap
Partial leak

release
To contain the gas

3. Annulus Lower
fitting
Barrier
upstream pipework

Partial leak
removes inner check
valve

release
body causing
time
setup.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Seal incorrectly
specified
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Seal incorrectly
specified

2.2
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Seal incorrectly
specified in design
None.
Employ competent
individuals and
is available.
Seal incorrectly
installed
2.1
envelope broken.
91
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Bolts installed
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Bolts installed
over tensioned
Employ competent
2.3
is available.
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Bonnet Seal Leakage
Barrier
upstream pipework
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Stem Seal Leak
Barrier
upstream pipework
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Stem Seal Leak
Barrier
upstream pipework
Zone 1.4 to 1.5
To contain the gas

1. Annulus Lower
Stem Seal Leak
Barrier
upstream pipework
CAUSE
EFFECT
SYMPTOMS
MITIGATION
Bolts installed
incorrectly - bolts
unevenly tensioned
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Bolts installed
under tensioned
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Loss of full seal
Wear and Tear
Packing not set

correctly
Loss of full seal
92
Loss of full seal

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
SYSTEM
SUB-SYSTEM
Zone 1.4 to 1.5
Zone 1.4 to 1.5
Zone 1.4 to 1.5
CAUSE
EFFECT
SYMPTOMS
To contain the gas

1. Annulus Lower
fitting
Barrier
upstream pipework
Individual back off

just the cap
Partial leak

release
To contain the gas

1. Annulus Lower
fitting
Barrier
upstream pipework

Partial leak
removes inner check
valve

release
FUNCTION
To maintain annulus
pressure integrity
FAILURE
Tree block failure
Slag
cold laps and other
initiators
MITIGATION
CRITICALITY
Designers and
1.2
place.
Confirmed by pressure
testing and established
installation procedures.
Zone 1.4 to 1.5
To maintain annulus
pressure integrity
Annulus bore sleeve

seal failure
During installation of
tree the seals become
damaged
Leakage into xmas

Potential leakage from
tree/upper tubing hanger tied own bolts or tree
cavity
body gasket.
2.3
Competent individuals
and appropriate
supervision
Confirmed by pressure
testing and established
installation procedures.
Zone 1.4 to 1.5
To maintain annulus
pressure integrity
Annulus bore sleeve

seal failure
Due to incorrect
Leakage into xmas
installation seals fail to tree/upper tubing hanger tied own bolts or tree
energise
cavity
body gasket.
2.3
Competent individuals
and appropriate
supervision
Zone 1.4 to 1.5
To provide a continuous
3. Annulus bore tubing
bore between the tree Annulus bore failure
hanger - Primary Barrier
and the annulus tubing
93
Slag
cold laps and other
initiators
Designers and
1.1
place.
SYSTEM
Zone 1.4 to 1.5
SUB-SYSTEM
FUNCTION
To provide a sealed
mechanical joint
between components
FAILURE
CAUSE
EFFECT
Failure due to threads

Failure of seal (metal to being out with
metal)
manufacturing
tolerances
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
pressurising the upper A facility on upper A
annulus.
annulus.
Ineffective seal
2.2
Additional loading on
the dual bore upper
packer (hydrostatic
head, weight of tubing
and gas lift pressure)
Pressure in upper A
annulus monitored by
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.4 to 1.5
To provide a sealed
mechanical joint
between components
Failure of seal (metal to

Galling on seal face
metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.4 to 1.5
To provide a sealed
mechanical joint
between components
Failure of seal (metal to Insufficient make up

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
94
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.4 to 1.5
To provide a sealed
mechanical joint
between components
Failure of seal (metal to Excessive loading on

metal)
seal arrangement
Seal integrity reduced or

failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.4 to 1.5
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Jumping out or
Joint opens
'unzipping' of the thread
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.4 to 1.5
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Zone 1.4 to 1.5
4. Tubing spool to tree Provide seal between

outer flange seal the tree and the spool
Secondary Barrier
interface
Pressure in upper A
plant operators.
Thermal/mechanical
Appropriate piping
Leakage of gas around
Displacement from
seal
on bolts
period of time.
analysis.
95
SYSTEM
Zone 1.4 to 1.5
SUB-SYSTEM
FUNCTION

Secondary Barrier
interface
FAILURE
CAUSE
EFFECT
SYMPTOMS
and mechanical
Leakage of gas around Wrong seal taken from properties similar to
None
seal
stores
effect.
Zone 1.4 to 1.5

Secondary Barrier
interface
Leakage of gas around Seal incorrectly

seal
specified
body causing
leak over time.
setup.
Zone 1.4 to 1.5

Secondary Barrier
interface

seal
specified
Seal incorrectly
specified in design
Zone 1.4 to 1.5

Secondary Barrier
interface
None
MITIGATION
CRITICALITY
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.
1.2
Employ competent
individuals and
is available.

seal
installed
1.1
envelope broken.
Pump Labouring
(audible)
Zone 1.4 to 1.5
5. Tubing spool
downhole chemical
injection line Secondary Barrier
Rupture of chemical
Provide a conduit for
injection line - between Pipework damaged
chemical injection into
tubing spool and tree
during installation
production bore
cavity
Significant reduction or
Pressurisation of void
cessation of dosing rate
between tree and tubing
of chemicals.
spool with chemicals.

ring gasket and tie down
bolts.
96
Regular checks of pump

pressure injection rates
by plant operators.
1.2
Competent fitters and
appropriate installation
procedures.
SYSTEM
SUB-SYSTEM
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
injection line packing
gland - Secondary
Barrier
Outer block assembly Tertiary Barrier
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
FUNCTION
To provide a seal
between the chemical
injection line and the
gland bore
To provide a seal
gland bore
FAILURE
Leakage around seal
Leakage around seal
CAUSE
EFFECT
SYMPTOMS
Ageing of seal
seal, causing increasing Leakage around seal
leakage over a period of increasing over time.
time
MITIGATION
CRITICALITY
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Employ competent
individuals and
is available.
Seal incorrectly
installed
1.1
envelope broken.
To provide a seal
gland bore
To provide a seal
gland bore
To provide a seal
gland bore
Leakage around seal
and mechanical
None
stores
effect.
Leakage around seal
Seal incorrectly
specified
body causing
leak over time.
setup.
Leakage around seal
Seal incorrectly
specified
Seal incorrectly
specified in design
97
None
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.

1.2
SYSTEM
Zone 1.4 to 1.5
SUB-SYSTEM
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
FUNCTION
FAILURE
To provide a seal
between the gland body Leakage around seal
and the tubing spool
CAUSE
EFFECT
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
1.1
Seal incorrectly
installed
SYMPTOMS
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier

envelope broken.
To provide a seal
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
and mechanical
None
stores
effect.
To provide a seal
Seal incorrectly
specified
body causing
leak over time.
setup.
To provide a seal
Seal incorrectly
specified
Seal incorrectly
specified in design
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
None
Zone 1.4 to 1.5
6. Tubing spool
downhole chemical
gland - Secondary
Barrier
To provide a seal
time
Ageing of seal
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.

1.2
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
98
SYSTEM
Zone 1.4 to 1.5
Zone 1.4 to 1.5
SUB-SYSTEM
FUNCTION
7. Tubing hanger tie

down bolts and seals Secondary Barrier
To provide a secondary
barrier between the
Leakage around seal
casing spool and the tie
down bolts
8. Tubing spool
downhole safety valve
To provide a seal
control packing gland between the DHSV
Secondary Barrier
control line and the
gland bore
Outlet block assembly Tertiary Barrier
FAILURE
Leakage around seal
CAUSE
EFFECT
SYMPTOMS
Ageing of seal
Leakage around seal

Gradual deteriation of increasing over time.
seal, causing increasing
leakage over a period of Casing hanger may drop
as a result of seal
time
deteriation.
time
Ageing of seal
MITIGATION
CRITICALITY
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Zone 1.4 to 1.5
8. Tubing spool
To provide a seal
Secondary Barrier
gland bore
Zone 1.4 to 1.5
8. Tubing spool
To provide a seal
Secondary Barrier
gland bore
Zone 1.4 to 1.5
8. Tubing spool
To provide a seal
Secondary Barrier
gland bore
Leakage around seal
and mechanical
None
stores
effect.
Leakage around seal
Seal incorrectly
specified
body causing
leak over time.
setup.
Leakage around seal
Seal incorrectly
specified
Seal incorrectly
specified in design
99
None
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.

1.2
SYSTEM
SUB-SYSTEM
Zone 1.4 to 1.5
8. Tubing spool
To provide a seal
Secondary Barrier
gland bore
Zone 1.4 to 1.5
FUNCTION
FAILURE
CAUSE
Leakage around seal
Seal incorrectly
installed
8. Tubing spool
control packing gland - To provide a seal
Secondary Barrier
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
1.1
time
Ageing of seal

envelope broken.
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Zone 1.4 to 1.5
8. Tubing spool
Secondary Barrier
Zone 1.4 to 1.5
8. Tubing spool
Secondary Barrier
Zone 1.4 to 1.5
8. Tubing spool
Secondary Barrier
and mechanical
None
stores
effect.
Designers and
place. Offshore
1.2
work system etc.
Seal incorrectly
specified
body causing
leak over time.
setup.
Designers and
place. Offshore
1.2
work system etc.
Seal incorrectly
specified
Seal incorrectly
specified in design

1.2
100
None
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.4 to 1.5
8. Tubing spool
Secondary Barrier
Seal incorrectly
installed
Zone 1.4 to 1.5
9. Tubing spool to
tubing hanger seal Secondary Barrier
To provide a seal
Leakage around seal
between the tubing
hanger and tubing spool
Seal loses energisation
Zone 1.4 to 1.5
9. Tubing spool to
To provide a seal
Leakage around seal
between the tubing
Seal incorrectly
installed
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
1.1
envelope broken.
Pressure build up in the Instrument monitor
upper A annulus.
facility on upper A
annulus.
Over a period of time
seal has compressed
1.3
Tertiary barriers
provided by annular
Pressure in upper A
valves, VR plug and
instrumentation fittings plant operators.
Employ competent
individuals and
is available.
1.1
envelope broken.
Zone 1.4 to 1.5
9. Tubing spool to
To provide a seal
Leakage around seal
between the tubing
and mechanical
None
stores
effect.
Zone 1.4 to 1.5
9. Tubing spool to
To provide a seal
between the tubing
Leakage around seal
Seal incorrectly
specified
body causing
leak over time.
setup.
Zone 1.4 to 1.5
9. Tubing spool to
To provide a seal
between the tubing
Leakage around seal
Seal incorrectly
specified
Seal incorrectly
specified in design
101
None
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.
1.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.4 to 1.5
9. Tubing spool to
To provide a seal
between the tubing
Leakage around seal
CAUSE
EFFECT
SYMPTOMS
Ageing of seal
time
MITIGATION
CRITICALITY
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
during manufacture.
Zone 1.4 to 1.5
10. Tubing hanger

control line upper
packing gland Secondary Barrier
Loss of integrity of
Provide a seal between
packing gland body
the DHSV control line
Thread cut out of
thread causing trapped
and the tubing hanger
tolerance
pressure to leak into
body
upper annulus
Reduced thread to
(seal maintained by
excessive PTFE for
example)
Degraded mechanical
more on excessive
thread contact.
Designers and
place. Offshore
balances.

during manufacture.
Zone 1.4 to 1.5
10. Tubing hanger

control line upper
packing gland body
Thread cut out of
tolerance
body
upper annulus
Designers and
Component will only
place. Offshore
balances.

Excessive torque
Zone 1.4 to 1.5
10. Tubing hanger

control line upper
packing gland body
thread causing trapped Cross threads
body
upper annulus
Ineffective seal
1.3
Fitting improperly
aligned.
Leaking joint.
102

and effective
supervision.
Suitable pressure
testing.
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.4 to 1.5
10. Tubing hanger

control line upper
packing gland body
thread causing trapped Damaged threads
body
upper annulus
Zone 1.4 to 1.5
10. Tubing hanger

control line upper

body
FAILURE
CAUSE
EFFECT
SYMPTOMS
up.
Excessive torque
MITIGATION

and effective
supervision.
Improperly mated
threads
1.3
Fitting improperly
aligned.
packing gland
Leakage of gas into
compression fitting
Incorrect joint make-up
causing trapped pressure
upper A annulus
to leak into upper
annulus
CRITICALITY
Suitable pressure
testing.
Leaking joint
upper A annulus.
facility on upper A
annulus.
1.3
Tertiary barriers
provided by annular
Pressure in upper A
valves, VR plug and
during manufacture.
Zone 1.4 to 1.5
11. Tubing hanger

downhole chemical
injection line upper
packing gland body
the Chemical Injection
Thread cut out of
line and the tubing
tolerance
hanger body
upper annulus
Reduced thread to
(seal maintained by
excessive PTFE for
example)
Degraded mechanical
more on excessive
thread contact.
Designers and
place. Offshore
balances.
103
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.4 to 1.5
11. Tubing hanger

downhole chemical
packing gland body
Thread cut out of
line and the tubing
tolerance
hanger body
upper annulus
SYMPTOMS
MITIGATION
CRITICALITY
during manufacture.
Designers and
Component will only
place. Offshore
balances.

Excessive torque
Zone 1.4 to 1.5
11. Tubing hanger

downhole chemical
packing gland body
thread causing trapped Cross threads
line and the tubing
hanger body
upper annulus
Ineffective seal

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.
up.
Zone 1.4 to 1.5
Zone 1.4 to 1.5
11. Tubing hanger

downhole chemical
11. Tubing hanger

downhole chemical
packing gland body
thread causing trapped Damaged threads
line and the tubing
hanger body
upper annulus

line and the tubing
hanger body
Excessive torque
Improperly mated
threads
packing gland
compression fitting
Leakage of gas into
causing trapped pressure
upper A annulus
to leak into upper
annulus
104

and effective
supervision.
1.3
Fitting improperly
aligned.
Suitable pressure
testing.
Leaking joint
upper A annulus.
facility on upper A
annulus.
1.3
Tertiary barriers
provided by annular
Pressure in upper A
valves, VR plug and
SYSTEM
Zone 1.4 to 1.5
SUB-SYSTEM
12. Tubing spool

control line - Secondary
Barrier
FUNCTION
FAILURE
CAUSE
EFFECT

Rupture of down hole
the hydraulic fluid for safety valve control line Pipework damaged
control of the down hole - between tubing spool during installation
safety valves
and tree cavity
SYMPTOMS
Pump Labouring
(audible)
Pressurisation of void Significant reduction or

between tree and tubing cessation of dosing rate
spool with hydraulic
of chemicals.
fluid.
ring gasket and tie down
bolts.
Zone 1.5 to 1.6
Zone 1.5 to 1.6
To provide a continuous
bore between the tubing
hanger - Primary
Annulus bore failure
hanger and the annulus
Barrier
tubing
1. Annulus bore tubing To provide a sealed

hanger - Primary
mechanical joint
Barrier
between components
Slag
cold laps and other
initiators

Ineffective seal
manufacturing
metal)
tolerances
MITIGATION
CRITICALITY

by plant operators.
1.2
procedures.
Designers and
1.1
place.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.5 to 1.6

hanger - Primary
mechanical joint
Barrier
between components

metal)
2.2
Ineffective seal
the dual bore upper
packer (hydrostatic
105
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.5 to 1.6

hanger - Primary
mechanical joint
Barrier
between components

metal)
torque
2.2
Ineffective seal
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.5 to 1.6

hanger - Primary
mechanical joint
Barrier
between components

metal)
seal arrangement
Seal integrity reduced

or failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.5 to 1.6

hanger - Primary
mechanical joint
Barrier
between components
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
106
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.5 to 1.6

hanger - Primary
mechanical joint
Barrier
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas into the

upper A annulus.
Zone 1.5 to 1.6
2. Annulus tubing &

Provide location and
Nipple body integrity
annulus tubing nipples - hang-off for well
failure
Primary Barrier
intervention equipment

initiators
the dual bore upper
packer (hydrostatic
Designers and
2.2
place.

upper A annulus.
Zone 1.5 to 1.6
Zone 1.5 to 1.6
Annulus tubing will

2. Annulus tubing &
provide a conduit for the
annulus tubing nipples Annulus tubing ruptures Manufacturing defect
gas to be injected into
Primary Barrier
the production bore.
2. Annulus tubing &

To provide a sealed
annulus tubing nipples - mechanical joint
Primary Barrier
between components

manufacturing
metal)
tolerances
107

initiators
the dual bore upper
packer (hydrostatic
Designers and
2.2
place.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
2. Annulus tubing &

To provide a sealed
between components
Primary Barrier

metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
2. Annulus tubing &

To provide a sealed
Primary Barrier
between components

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.5 to 1.6
2. Annulus tubing &

To provide a sealed
Primary Barrier
between components

metal)
seal arrangement

failed
2.2
the dual bore upper
packer (hydrostatic
108
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
2. Annulus tubing &

To provide a sealed
between components
Primary Barrier
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
2. Annulus tubing &

To provide a sealed
Primary Barrier
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Zone 1.5 to 1.6
Zone 1.5 to 1.6
3. Production casing Secondary Barrier
To protect the formation

to the top of the pay
Production casing split Corrosion (where water
zone and the 9 5/8"
or parted
is present)
casing
Degradation of
Produce corrosion
components over time.
products which are a
source of debris and can
under certain situations
apply a pressure to
This less applicable to
mating surfaces
13% Cr Alloys.
Deep pits and cavities.

Localised corrosion
zone and the 9 5/8"
or parted
is present)
casing
109
If equipment is left for

an extended period of
time full wall
perforation can occur.
Pressure in upper A
plant operators.
Optimisation of material
design and selection
1.3
Injection of inhibitors
4.3
Good corrosion
management strategy
and execution.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.5 to 1.6

Production casing split
Incorrect casing design Casing could part
zone and the 9 5/8"
or parted
casing
SYMPTOMS
MITIGATION
Gas lift pressure leakage
into the B annulus,
consequently annular
valves on B annulus
become primary barrier.
Correct casing design
B annulus is rated to a
lower pressure than the
A annulus.
into the B annulus,
valves on B annulus
Zone 1.5 to 1.6
13% Cr steels
Embrittlement during vulnerable to temper
manufacturing process Embrittlement under
zone and the 9 5/8"
or parted
A annulus.
(high alloy steels)
incorrect welding and
casing
heat treatment regimes.
Loss of ductility
resulting in a greater
sensitivity to cracking
under normal well
conditions (thermal
loading).
Zone 1.5 to 1.6
To provide a sealed
mechanical joint
between components

metal)
manufacturing
tolerances
110
CRITICALITY
3.3
Design and
manufacturers quality
assurance in accordance
with ISO and
equivalent.
2.3
Plant operators would
monitor annulus
pressure.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
To provide a sealed
mechanical joint
between components

metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
To provide a sealed
mechanical joint
between components

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.5 to 1.6
To provide a sealed
mechanical joint
between components

metal)
seal arrangement

failed
2.2
the dual bore upper
packer (hydrostatic
111
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.5 to 1.6
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Pressure build up in the

Instrument monitor
B annulus.
facility on B annulus.
Zone 1.5 to 1.6
4. Production casing
hanger seal to tubing
spool - Secondary
Barrier
To provide a seal
Leakage around seal
between the casing
hanger and casing spool
Zone 1.5 to 1.6
spool - Secondary
Barrier
To provide a seal
between the casing
Leakage around seal
Seal incorrectly
installed

seal has compressed
3.3
Secondary barriers
Pressure in B annulus
provided by annular
monitored by plant
valves and
operators.
instrumentation fittings
Employ competent
individuals and
is available.
1.1
envelope broken.
112
SYSTEM
SUB-SYSTEM
Zone 1.5 to 1.6
spool - Secondary
Barrier
FUNCTION
FAILURE
To provide a seal
between the casing
Leakage around seal
CAUSE
EFFECT
SYMPTOMS
and mechanical
None
stores
effect.
Zone 1.5 to 1.6
spool - Secondary
Barrier
To provide a seal
Leakage around seal
between the casing
Seal incorrectly
specified
body causing
leak over time.
setup.
Zone 1.5 to 1.6
spool - Secondary
Barrier
To provide a seal
between the casing
Leakage around seal
Seal incorrectly
specified
Seal incorrectly
specified in design
Zone 1.5 to 1.6
spool - Secondary
Barrier
To provide a seal
between the casing
Leakage around seal
None
Leakage around seal

Gradual deteriation of increasing over time
seal, causing increasing
leakage over a period of Casing hanger may drop
as a result of seal
time
deteriation.
Ageing of seal
MITIGATION
CRITICALITY
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.
1.2
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Zone 1.5 to 1.6
To provide a facility to
5. Upper annulus tubing
isolate the A,B or C
Bonnet seal leakage
spool inner and outer
Seal incorrectly
annulus and with
(metal to metal joint) - 2
valves - Secondary
specified
instrumentation monitor valves
Barrier
annular pressures
body causing
time
setup.
113
Designers and
place. Offshore
2.2
work system etc.
SYSTEM
SUB-SYSTEM
Zone 1.5 to 1.6
Bonnet seal leakage
annulus and with
valves - Secondary
stores
Barrier
annular pressures
and mechanical
None
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.5 to 1.6
Bonnet seal leakage
Seal incorrectly
annulus and with
valves - Secondary
specified
Barrier
annular pressures
Seal incorrectly
specified in design

2.2
Zone 1.5 to 1.6
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
None.
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
Bonnet seal leakage
Seal incorrectly
annulus and with
valves - Secondary
installed
Barrier
annular pressures
2.1
envelope broken.
Zone 1.5 to 1.6
Bolts installed
Bonnet seal leakage
(metal to metal joint) - 2 incorrectly - bolts
annulus and with
valves - Secondary
unevenly tensioned
Barrier
annular pressures
Zone 1.5 to 1.6
Bonnet seal leakage
Bolts installed
annulus and with
(metal to metal joint) - 2 incorrectly - incorrect
valves - Secondary
Barrier
annular pressures
Zone 1.5 to 1.6
Employ competent
Bonnet seal leakage
Bolts installed
(metal to metal joint) - 2 incorrectly - bonnet over Joint integrity reduced
2.3
annulus and with
valves - Secondary
tensioned
Barrier
is available.
annular pressures
114
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.5 to 1.6
Bonnet seal leakage
Bolts installed
annulus and with
(metal to metal joint) - 2 incorrectly - bonnet
valves - Secondary
under tensioned
Barrier
annular pressures
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.5 to 1.6
Stem Seal Leak - 2
annulus and with
valves - Secondary
valves
instrumentation monitor
Barrier
annular pressures
Zone 1.5 to 1.6
Stem Seal Leak - 2
annulus and with
valves - Secondary
valves
Barrier
annular pressures
Zone 1.5 to 1.6
Stem Seal Leak - 2
annulus and with
valves - Secondary
valves
Barrier
annular pressures
Zone 1.5 to 1.6
Fitter backs off
annulus and with
valves - Secondary
just the cap
Barrier
annular pressures
Zone 1.5 to 1.6
annulus and with
valves - Secondary
Barrier
annular pressures

Partial leak
removes inner check
valve

release
Zone 1.5 to 1.6
6. Upper annulus tubing To provide a facility for

spool monitor and vent pressure monitoring
assembly - Secondary equipment to be linked
Barrier
to the A annulus
Cartridge not fully

tightened
None.
Cartridge nose seal

leakage past cartridge
wall

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
Loss of full seal

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
Partial leak

release
Wear and Tear
Loss of full seal
115
Gas leakage around

cartridge walls
Employ competent
individuals and
1.1
is available.
SYSTEM
SUB-SYSTEM
Zone 1.5 to 1.6
CAUSE
EFFECT

Failure of bonnet seal
Barrier
to the A annulus
Seal incorrectly
specified
body causing
time
setup.
Zone 1.5 to 1.6

Barrier
to the A annulus
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.5 to 1.6

Barrier
to the A annulus
Seal incorrectly
specified

2.2
Zone 1.5 to 1.6
FUNCTION
FAILURE

Barrier
to the A annulus
Seal incorrectly
specified in design
SYMPTOMS
None.
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.
Seal incorrectly
installed
2.1
envelope broken.
Zone 1.5 to 1.6

Barrier
to the A annulus
Zone 1.5 to 1.6

Barrier
to the A annulus
Bolts installed
incorrectly - bolts
unevenly tensioned
Bolts installed
116
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.5 to 1.6

Barrier
to the A annulus
Zone 1.5 to 1.6

Barrier
to the A annulus
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
Bolts installed
2.3
tensioned
is available.
Bolts installed
under tensioned
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Zone 1.5 to 1.6

assembly - Secondary equipment to be linked Seal
service
Barrier
to the A annulus
Zone 1.5 to 1.6

pipework
period of time.
analysis.
Barrier
to the A annulus
Zone 1.5 to 1.6

Thermal/mechanical
Appropriate piping
Displacement from
on bolts
period of time.
analysis.
Barrier
to the A annulus
Zone 1.5 to 1.6

Failure of Ring Gasket Wrong seal taken from
stores
Barrier
to the A annulus
and mechanical
None
effect.
Designers and
place. Offshore
2.2
work system etc.

specified
Barrier
to the A annulus
body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work system etc.
Zone 1.5 to 1.6
117
Gas release
F&G system
2.3
SYSTEM
SUB-SYSTEM
Zone 1.5 to 1.6

specified
Barrier
to the A annulus
Zone 1.5 to 1.6
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Seal incorrectly
specified in design
None

2.2
Employ competent
individuals and
is available.

installed
Barrier
to the A annulus
2.1
envelope broken.
Zone 1.5 to 1.6

Bolts installed
incorrectly - bolts
unevenly tensioned
Barrier
to the A annulus
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Zone 1.5 to 1.6

Bolts installed
Barrier
to the A annulus
Zone 1.5 to 1.6

Employ competent
Bolts installed
2.3
tensioned
Barrier
to the A annulus
is available.
Zone 1.5 to 1.6

Bolts installed
under tensioned
Barrier
to the A annulus
Zone 1.5 to 1.6

Stem seal leakage
Barrier
to the A annulus
Wear and Tear
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Loss of full seal
118

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.5 to 1.6

Stem seal leakage
Barrier
to the A annulus
Zone 1.5 to 1.6

Stem seal leakage
Barrier
to the A annulus
CAUSE
EFFECT
Loss of full seal
SYMPTOMS
MITIGATION
CRITICALITY

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

assembly
Perform maintenance
and inspection in
accordance with
manufacturers
requirements.
2.4

inner annular valve.
Zone 1.5 to 1.6
Provides isolation in
7. VR plug - Secondary
A,B or C annulus to
Barrier
carry out maintenance
on annular valves and
Tertiary valve(s)
fittings.
Nose seal failure
Debris on seal face
Zone 1.5 to 1.6
A,B or C annulus to
Barrier
Tertiary valve(s)
fittings.
Failure of threaded
connection
Misalignment during
installation
Zone 1.5 to 1.6
A,B or C annulus to
Barrier
Tertiary valve(s)
fittings.
Failure of threaded
connection
Galling of threads due

to debris on threaded
connections
119
Correct torque applied

to VR plug in
accordance with the
manufacturers
VR plugs are generally
Seal not seated correctly
1.1
specification.
used for maintenance
when one of the annular
valves requires to be
removed and an
additional isolation is
required.
Leakage from upper A
annulus into inner
annular valve.
Threads crossed causing

VR plugs are generally Use of competent fitters.1.3
loss of integrity of joint
removed and an
required.
Leakage from upper A
annulus into inner
annular valve.
Loss of integrity of joint VR plugs are generally Use of competent fitters.1.3

removed and an
required.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
Zone 1.5 to 1.6
8. Tubing hanger seal to To provide a seal

tubing spool between the tubing
Leakage around seal
Secondary Barrier
CAUSE
EFFECT
SYMPTOMS
Ageing of seal
time
MITIGATION
CRITICALITY
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Zone 1.5 to 1.6

Leakage around seal
Secondary Barrier
and mechanical
None
stores
effect.
Zone 1.5 to 1.6

Leakage around seal
Secondary Barrier
Seal incorrectly
specified
body causing
leak over time.
setup.
Zone 1.5 to 1.6

Leakage around seal
Secondary Barrier
Seal incorrectly
specified
Seal incorrectly
specified in design
Zone 1.5 to 1.6

Leakage around seal
Secondary Barrier
None
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.
1.2
Employ competent
individuals and
is available.
Seal incorrectly
installed
1.1
envelope broken.
120
SYSTEM
SUB-SYSTEM
Zone 1.5 to 1.6
CAUSE
EFFECT

Leakage around seal
Secondary Barrier

seal has compressed
9. Tubing spool
downhole chemical

Rupture of chemical
chemical injection into injection line - below
production bore
tubing hanger
Pipework damaged
during installation
Zone 1.5 to 1.6
10. Tubing spool

control line - Secondary
Barrier

the hydraulic fluid for
Pipework damaged
safety valve control line
control of the down hole
during installation
- below tubing hanger
safety valves
Zone 1.5 to 1.6
packing gland body
11. Tubing hanger
Thread cut out of
control line lower
cavity between tree and
tolerance
packing gland tubing hanger.
body
Secondary Barrier
On coincident failure of
upper packing gland.
Zone 1.5 to 1.6
FUNCTION
FAILURE
between tubing hanger
and the dual bore upper
packer with chemicals.
SYMPTOMS
MITIGATION
Instrument monitor
B annulus.
3.3
Secondary barriers
provided by annular
monitored by plant
valves and
operators.
Pump Labouring
pressure and injection
(audible) - increased
rates by plant operators.
injection rate
1.2

Significant increase of
dosing rate of chemicals.
procedures.
pressure and injection
between tubing hanger Pump Labouring
and the dual bore upper (audible) - increased
1.2
packer with hydraulic injection rate
fluid.
procedures.
during manufacture.
Reduced thread to
(seal maintained by
excessive PTFE for
example)
Degraded mechanical
more on excessive
thread contact.
Designers and
place. Offshore
balances.
121
CRITICALITY
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.5 to 1.6
packing gland body
11. Tubing hanger
Thread cut out of
control line lower
tolerance
body
Secondary Barrier
SYMPTOMS
MITIGATION
CRITICALITY
during manufacture.
Designers and
Component will only
place. Offshore
balances.
Zone 1.5 to 1.6
Excessive torque
packing gland body
11. Tubing hanger
cavity between tree and Cross threads
control line lower
tubing hanger.
packing gland body
Secondary Barrier
Ineffective seal

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.
up.
Zone 1.5 to 1.6
packing gland body
11. Tubing hanger
cavity between tree and Damaged threads
control line lower
body
Secondary Barrier
Excessive torque
Improperly mated
threads
1.3
Fitting improperly
aligned.
Leaking joint
122

and effective
supervision.
Suitable pressure
testing.
SYSTEM
Zone 1.5 to 1.6
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
packing gland body
11. Tubing hanger
Leakage of gas into
cavity between tree and Incorrect joint make-up
control line lower
upper A annulus
tubing hanger.
packing gland body
Secondary Barrier
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
pressurising the cavity Instrument monitor
between tree and tubing facility on upper A
hanger
annulus.
1.3
Tertiary barriers
provided by tie down
Pressure in upper A
bolt arrangement,
chemical injection point, plant operators.
down hole safety valve
point, tubing hanger to
casing spool seal.
during manufacture.
Zone 1.5 to 1.6
12. Tubing hanger

downhole chemical
injection line lower
packing gland body
Thread cut out of
cavity between tubing
line and the tubing
tolerance
hanger and tree.
hanger body
Reduced thread to
(seal maintained by
excessive PTFE for
example)
Degraded mechanical
more on excessive
thread contact.
Designers and
place. Offshore
balances.

during manufacture.
Zone 1.5 to 1.6
12. Tubing hanger

downhole chemical
packing gland body
Thread cut out of
line and the tubing
tolerance
hanger and tree.
hanger body
Designers and
Component will only
place. Offshore
balances.
123
SYSTEM
Zone 1.5 to 1.6
SUB-SYSTEM
12. Tubing hanger

downhole chemical
FUNCTION
FAILURE
CAUSE
EFFECT
packing gland body
cavity between tubing Cross threads
line and the tubing
hanger and tree.
hanger body
Ineffective seal
SYMPTOMS
Excessive torque
MITIGATION
CRITICALITY

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.
up.
Zone 1.5 to 1.6
12. Tubing hanger

downhole chemical
packing gland body
cavity between tubing Damaged threads
line and the tubing
hanger and tree.
hanger body
Excessive torque

and effective
supervision.
Improperly mated
threads
1.3
Fitting improperly
aligned.
Suitable pressure
testing.
Leaking joint
Zone 1.5 to 1.6
12. Tubing hanger

downhole chemical
packing gland body
Leakage of gas into
cavity between tubing Incorrect joint make-up cavity between tubing
line and the tubing
hanger and tree.
hanger and tree.
hanger body
124
Leakage of gas past

threaded connection
consequently
pressurising the cavity
hanger.
None.
Tertiary barriers
bolt arrangement,
chemical injection point,
down hole safety valve
point, tubing hanger to
casing spool seal.
1.3
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

upper A annulus.
Zone 1.6 to 1.7
1. Annulus tubing &

Provide location and
Nipple body integrity
annulus tubing nipples - hang-off for well
failure
Primary Barrier
intervention equipment

initiators
the dual bore upper
packer (hydrostatic
Designers and
2.2
place.

upper A annulus.
Zone 1.6 to 1.7
Zone 1.6 to 1.7
Annulus tubing will

1. Annulus tubing &
provide a conduit for
annulus tubing nipples - the gas to be injected
Primary Barrier
into the production
bore.
1. Annulus tubing &

To provide a sealed
Primary Barrier
between components
Annulus tubing ruptures Manufacturing defect

metal)
manufacturing
tolerances

initiators
the dual bore upper
packer (hydrostatic
Designers and
2.2
place.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.6 to 1.7
1. Annulus tubing &

To provide a sealed
Primary Barrier
between components

metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
125
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.6 to 1.7
1. Annulus tubing &

To provide a sealed
Primary Barrier
between components

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.6 to 1.7
1. Annulus tubing &

To provide a sealed
Primary Barrier
between components

metal)
seal arrangement

failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.6 to 1.7
1. Annulus tubing &

To provide a sealed
Primary Barrier
between components
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
126
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.6 to 1.7
1. Annulus tubing &

To provide a sealed
Primary Barrier
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Zone 1.6 to 1.7
Zone 1.6 to 1.7
2. Annulus downhole
safety valve - Primary
Barrier
2. Annulus downhole
Barrier
To provide addition
barrier between lower
annulus and
tree/wellhead
To provide addition
annulus and
tree/wellhead

metal)
manufacturing
tolerances
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
127
Pressure in upper A
plant operators.
SYSTEM
Zone 1.6 to 1.7
Zone 1.6 to 1.7
Zone 1.6 to 1.7
SUB-SYSTEM
2. Annulus downhole
Barrier
2. Annulus downhole
Barrier
2. Annulus downhole
Barrier
FUNCTION
To provide addition
annulus and
tree/wellhead
To provide addition
annulus and
tree/wellhead
To provide addition
annulus and
tree/wellhead
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
metal)
seal arrangement

failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
128
Pressure in upper A
plant operators.
SYSTEM
Zone 1.6 to 1.7
SUB-SYSTEM
2. Annulus downhole
Barrier
FUNCTION
To provide addition
annulus and
tree/wellhead
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Correct specification of
seals.
Zone 1.6 to 1.7
2. Annulus downhole
Barrier
To provide addition
annulus and
tree/wellhead
Zone 1.6 to 1.7
2. Annulus downhole
Barrier
To provide addition
annulus and
tree/wellhead
Gas leakage into upper

A annulus.
Failure of housing
sealing arrangement
Failure of two radially

DHSV housing loses
successive seals of the
integrity
component interface
Failure of control line

housing

Leakage into the A
annulus
component interface
Manufacturers and
1.1
designers have a
A Annular valves
suitable quality
become tertiary barriers. assurance system in
accordance with ISO or
equivalent.
A annulus.
seals.
Flapper closes if control
line ruptures
2.1
Periodic testing
A Annular valves
become tertiary barriers.
Zone 1.7 to 1.8
1. Annulus downhole
Barrier
To provide addition
annulus and
tree/wellhead

Ineffective seal
manufacturing
metal)
tolerances
129
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
SYSTEM
Zone 1.7 to 1.8
Zone 1.7 to 1.8
Zone 1.7 to 1.8
SUB-SYSTEM
1. Annulus downhole
Barrier
1. Annulus downhole
Barrier
1. Annulus downhole
Barrier
FUNCTION
To provide addition
annulus and
tree/wellhead
To provide addition
annulus and
tree/wellhead
To provide addition
annulus and
tree/wellhead
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
metal)
2.2
Ineffective seal
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
metal)
torque
2.2
Ineffective seal
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
metal)
seal arrangement

or failed
2.2
the dual bore upper
packer (hydrostatic
130
Pressure in upper A
plant operators.
SYSTEM
Zone 1.7 to 1.8
Zone 1.7 to 1.8
SUB-SYSTEM
1. Annulus downhole
Barrier
1. Annulus downhole
Barrier
FUNCTION
To provide addition
annulus and
tree/wellhead
To provide addition
annulus and
tree/wellhead
FAILURE
CAUSE
EFFECT
SYMPTOMS
1. Annulus downhole
Barrier
To provide addition
annulus and
tree/wellhead
CRITICALITY
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Failure of seal (metal to Jumping out or
Joint opens
metal)
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Shearing of threads
metal)

or failed
2.2
the dual bore upper
packer (hydrostatic
A annulus.
Zone 1.7 to 1.8
MITIGATION
Failure of housing
sealing arrangement

DHSV housing loses
integrity
component interface
A Annular valves
become tertiary
barriers.
Pressure in upper A
plant operators.
seals.
1.1
Manufacturers and
designers have a
suitable quality
assurance system in
equivalent.

A annulus.
Zone 1.7 to 1.8
1. Annulus downhole
Barrier
To provide addition
annulus and
tree/wellhead

housing

Leakage into the A
annulus
component interface
Flapper closes if control

line ruptures
A Annular valves
become tertiary
barriers.
131
seals.
2.1
Periodic testing
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

upper A annulus.
Zone 1.7 to 1.8
Zone 1.7 to 1.8
2. Annulus Tubing Primary Barrier
Annulus tubing will

provide a conduit for the
gas to be injected into
the production bore.
To provide a sealed
mechanical joint
between components

manufacturing
metal)
tolerances

initiators
the dual bore upper
packer (hydrostatic
Designers and
2.2
place.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.7 to 1.8
To provide a sealed
mechanical joint
between components

metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
132
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.7 to 1.8
To provide a sealed
mechanical joint
between components

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.7 to 1.8
To provide a sealed
mechanical joint
between components

metal)
seal arrangement

failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.7 to 1.8
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
133
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.7 to 1.8
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.

upper A annulus.
Zone 1.8 to 1.9
Zone 1.8 to 1.9
Annulus tubing will

the gas to be injected
into the production
bore.
To provide a sealed
mechanical joint
between components

metal)
manufacturing
tolerances
134

initiators
the dual bore upper
packer (hydrostatic
Designers and
2.2
place.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.8 to 1.9
To provide a sealed
mechanical joint
between components

metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.8 to 1.9
To provide a sealed
mechanical joint
between components

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.8 to 1.9
To provide a sealed
mechanical joint
between components

metal)
seal arrangement

failed
2.2
the dual bore upper
packer (hydrostatic
135
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.8 to 1.9
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.8 to 1.9
To provide a sealed
mechanical joint
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Periodic checks of upper

A annulus pressure.
Zone 1.8 to 1.9
Zone 1.8 to 1.9
Zone 1.8 to 1.9
2. Annulus bore dual

bore upper packer Primary Barrier
Dual upper bore packer

provides isolation
Failure of the packer
between the upper and sealing element
lower annulus
Incorrectly set


provides isolation
lower annulus
Gas passing from lower

Deteriation of the
Upper A annulus
annulus to upper
packer sealing element
pressurise with gas.
annulus


provides isolation
lower annulus
Design working loads

are exceeded

Upper A annulus
annulus to upper
annulus
136
2.2
Pressure testing when
packer was originally
installed.
A annulus pressure.
2.2
installed.
Expansion and
Packer to be designed
Additional tensile loads contraction of annulus
for all reasonably
imposed on packer
tubing in the absence of
foreseeable events.
a slip joint.
2.3
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.8 to 1.9


Zone 1.8 to 1.9
FAILURE
CAUSE
EFFECT
SYMPTOMS

provides isolation
Failure of the tubing
between the upper and annulus to packer seal
lower annulus
Deteriation of the
annulus upper bore
tubing stab seal

Upper A annulus
annulus to upper
annulus

provides isolation
lower annulus

are exceeded
Expansion and
imposed on packer
a slip joint.
Pump Labouring
(audible)
Zone 1.8 to 1.9
Rupture of chemical
3. Downhole chemical Provide a conduit for
injection line chemical injection into
tubing hanger and dual during installation
Secondary Barrier
production bore
bore upper packer
Pressurisation of upper a Significant reduction or

annulus with chemicals cessation of dosing rate
of chemicals.
A annulus pressure
increase.
Zone 1.8 to 1.9
4. Dual bore packer

downhole chemical
packing gland body
pressure to leak up
against the lower
chemical injection line
Thread cut out of
packing gland.
line and the dual bore
tolerance
upper packer body
Coincident failure of
lower chemical injection
line packing gland in
order to leak into lower
annulus.
MITIGATION
CRITICALITY
A annulus pressure.
2.2
installed.
Tubing stab to be
designed for all
2.3
reasonably foreseeable
events.
by plant operators.
1.2
procedures.
during manufacture.
Reduced thread to
(seal maintained by
excessive PTFE for
example)
Degraded mechanical
more on excessive
thread contact.
Designers and
place. Offshore
balances.
137
SYSTEM
Zone 1.8 to 1.9
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
4. Dual bore packer

downhole chemical
packing gland body
pressure to leak up
against the lower
Thread cut out of
packing gland.
tolerance
upper packer body
annulus.
SYMPTOMS
MITIGATION
CRITICALITY
during manufacture.
Designers and
Component will only
place. Offshore
balances.
Zone 1.8 to 1.9
Zone 1.8 to 1.9
4. Dual bore packer

downhole chemical
4. Dual bore packer

downhole chemical
packing gland body
pressure to leak up
against the lower
packing gland.
Cross threads
upper packer body
annulus.
Excessive torque
Ineffective seal

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.
packing gland body
pressure to leak up
against the lower
packing gland.
Damaged threads
upper packer body
annulus.

up.
Excessive torque
Improperly mated
threads
1.3
Fitting improperly
aligned.
Leaking joint
138

and effective
supervision.
Suitable pressure
testing.
SYSTEM
Zone 1.8 to 1.9
Zone 1.9 to 1.11
Zone 1.9 to 1.11
Zone 1.9 to 1.11
Zone 1.9 to 1.11
SUB-SYSTEM
4. Dual bore packer

downhole chemical
FUNCTION
FAILURE
CAUSE
EFFECT
packing gland body
pressure to leak up
against the lower
Leakage of gas into
packing gland.
upper A annulus
upper packer body
annulus.
SYMPTOMS
Chemical injection line

pressurised with
injection gas when not
Pressure in upper A
injecting chemicals.
plant operators.
1.3
Tertiary barriers
provided by annular
valves, VR plug and
Periodic checks of
upper A annulus
pressure.
Incorrectly set

provides isolation
lower annulus

Deteriation of the
Upper A annulus
annulus to upper
packer sealing element
annulus


provides isolation
lower annulus

are exceeded


Deteriation of the
provides isolation
annulus upper bore
tubing stab seal
lower annulus

CRITICALITY

subject to back pressure
from injection gas under
normal chemical
injection activities.
Instrument monitor
Chemical injection
facility on upper A
pressure will increase.
annulus.

provides isolation
lower annulus

MITIGATION

Upper A annulus
annulus to upper
annulus
2.2
installed.
Periodic checks of
upper A annulus
pressure.
2.2
installed.
139
Expansion and
Packer to be designed
for all reasonably
imposed on packer
foreseeable events.
a slip joint.

Upper A annulus
annulus to upper
annulus
2.3
Periodic checks of
upper A annulus
pressure.
2.2
installed.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 1.9 to 1.11


provides isolation
between the upper and annulus to packer seal are exceeded
lower annulus
Zone 1.9 to 1.11
To provide a conduit for

2. Lower well annulus
Lower annulus casing
(9 5/8") - Primary
into the production
split or parted
Barrier
string
SYMPTOMS
Expansion and
imposed on packer
a slip joint.
Degradation of
Produce corrosion
components over time.
Corrosion (where water source of debris and can
under certain situations
is present)
apply a pressure to
mating surfaces
13% Cr Alloys.
Zone 1.9 to 1.11

(9 5/8") - Primary
into the production
split or parted
Barrier
string
Corrosion (where water

Localised corrosion
is present)
Zone 1.9 to 1.11

(9 5/8") - Primary
into the production
split or parted
Barrier
string
Zone 1.9 to 1.11
13% Cr steels
Embrittlement during vulnerable to temper
manufacturing process Embrittlement under
A annulus.
(high alloy steels)
incorrect welding and
heat treatment regimes.
Loss of ductility
under normal well
conditions (thermal
loading).
140
CRITICALITY
Tubing stab to be
designed for all
2.3
events.
1.3

an extended period of Good corrosion
time full wall
management strategy
perforation can occur. and execution.
into the B annulus,
valves on B annulus
A annulus.
into the B annulus,
valves on B annulus

(9 5/8") - Primary
into the production
split or parted
Barrier
string
MITIGATION
4.3
3.3
Design and
with ISO and
equivalent.
2.3
monitor annulus
pressure.
SYSTEM
Zone 1.9 to 1.11
SUB-SYSTEM
FUNCTION
2. Lower well annulus To provide a sealed

(9 5/8") - Primary
mechanical joint
between components
Barrier
FAILURE
CAUSE
EFFECT

metal)
manufacturing
tolerances
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.9 to 1.11

(9 5/8") - Primary
mechanical joint
Barrier
between components

metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.9 to 1.11

(9 5/8") - Primary
mechanical joint
Barrier
between components

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
141
Pressure in upper A
plant operators.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.9 to 1.11

(9 5/8") - Primary
mechanical joint
between components
Barrier

metal)
seal arrangement

failed
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
annulus.
Zone 1.9 to 1.11

(9 5/8") - Primary
mechanical joint
Barrier
between components
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
Pressure in upper A
plant operators.
Leakage of gas past

threaded connection
Instrument monitor
consequently
annulus.
annulus.
Zone 1.9 to 1.11

(9 5/8") - Primary
mechanical joint
Barrier
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
Zone 1.9 to 1.11
To provide a means of
3. Side Pocket Mandrels
Orifice valve fails to
injecting gas into the
(SPM) - Primary Barrier
open on demand
bore string
Incorrect set pressure
142
Pressure in upper A
plant operators.
Manufacturers and
designers quality
assurance scheme in
Gas is not injected at the Gas lift is not effective, accordance with ISO or
1.2
right level in the
if well is reliant on gas equivalent.
production string
lift well may not flow.
Orifice valves checked
before installation in
well.
SYSTEM
SUB-SYSTEM
Zone 1.9 to 1.11
3. Side Pocket Mandrels
(SPM) - Primary Barrier
open on demand
bore string
Zone 1.9 to 1.11
Line
FUNCTION
FAILURE
CAUSE
EFFECT
Orifice valve seized closed
Provide a conduit to
Chemical injection line Operational loads
inject chemicals into the
rupture
exceeded
production tubing
MITIGATION
CRITICALITY
Manufacturers and
Gas lift is not effective,
designers quality
if well is reliant on gas
assurance scheme in
equivalent.
Gas is not injected into
1.2
the production string
Lower A annulus is
pressurised beyond
normal operating
conditions.
well.
Line could split
SYMPTOMS

Chemical injection
pipework and fittings
should be designed and
normal chemical
constructed for all
Chemical injection
events.
2.3
Chemical injection
pressure should be
pressurised with
monitored by competent
individuals.
Zone 1.9 to 1.11
Line
rupture
exceeded
production tubing
Combination of
vibration and tension in
line due to slippage of
supports.
Fatigue
Pressure cyclic effects
from injecting.
143
Correct supporting
arrangement.
2.3
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 1.9 to 1.11
Line
rupture
exceeded
production tubing
Zone 1.9 to 1.11
Line
FAILURE
CAUSE
EFFECT
rupture
exceeded
production tubing
Incorrect installation
Corrosion of fittings
SYMPTOMS
MITIGATION
CRITICALITY
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
from injection gas under events.
normal chemical
2.3
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
engineer to ensure
normal chemical
compatibility of
materials with
Chemical injection
environment.

pressurised with
144
2.3
SYSTEM
Zone 1.9 to 1.11
Zone 1.9 to 1.11
Zone 1.9 to 1.11
Zone 1.9 to 1.11
SUB-SYSTEM
FUNCTION
Line
Upper chemical
injection line seal to
takes lower A annulus
Lower seal between
Deteriation of the lower Gas passing from lower pressure. Coincidental
chemical injection line annulus to upper
failure of upper
and dual bore upper
production tubing
seal
annulus
packer
seal to dual bore upper
packer to upper A
annulus pressurise with
gas.
Line
Line
Line
FAILURE
CAUSE
EFFECT
Lower seal between

chemical injection line Design working loads
and dual bore upper
are exceeded
production tubing
packer
Expansion and
imposed on packer
a slip joint.
Upper seal between

Deteriation of the upper Gas passing from lower
chemical injection line annulus to upper
and dual bore upper
production tubing
seal
annulus
packer
Upper seal between

chemical injection line Design working loads
and dual bore upper
are exceeded
production tubing
packer
145
SYMPTOMS
MITIGATION
CRITICALITY

A annulus pressure.
2.2
installed.
Tubing stab to be
designed for all
2.3
events.
Failure of upper
packer to upper A
A annulus pressure.
gas.
2.2
Failure of lower
installed.
packer to upper A
gas.
Expansion and
imposed on packer
a slip joint.
Tubing stab to be
designed for all
2.3
events.
APPENDIX F
SINGLE COMPLETION FMECA RESULTS
146
SYSTEM
Zone 2.1 to 2.2
Zone 2.1 to 2.2
Zone 2.1 to 2.2
Zone 2.1 to 2.2
SUB-SYSTEM
FUNCTION
CAUSE
EFFECT
To contain the gas

within the A annulus of Bonnet seal leakage
the wellhead on loss of
upstream pipework.
Seal incorrectly
specified
Material specification
of seal incompatible
with body causing
time
setup.
To contain the gas

within the A annulus of
Bonnet seal leakage
upstream pipework.
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
To contain the gas

Bonnet seal leakage
upstream pipework.
Seal incorrectly
specified

initial teething
2.2
problems have been
ironed out.
FAILURE
To contain the gas

Bonnet seal leakage
the wellhead on loss of (metal to metal joint)
upstream pipework.
Seal incorrectly
specified in design
SYMPTOMS
None.
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.
Seal incorrectly
installed
2.1
envelope broken.
Zone 2.1 to 2.2
To contain the gas

upstream pipework.
Bolts installed
incorrectly - bolts
unevenly tensioned
147
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 2.1 to 2.2
To contain the gas

upstream pipework.
Bolts installed
incorrectly - incorrect Joint integrity reduced None.
Zone 2.1 to 2.2
To contain the gas

Bonnet seal leakage
upstream pipework.
Bolts installed
over tensioned
To contain the gas

Bonnet seal leakage
the wellhead on loss of (metal to metal joint)
upstream pipework.
Zone 2.1 to 2.2
Zone 2.1 to 2.2
Zone 2.1 to 2.2
FAILURE
CAUSE
EFFECT
Bolts installed
under tensioned
SYMPTOMS
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
Joint integrity reduced to progressive leakage. appropriate supervision 2.3
is available.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
To contain the gas

the wellhead on loss of Seal
service
upstream pipework.
To contain the gas

Fatigue failure of bolts one or more bolts after pipework
Seal
a period of time.
analysis.
upstream pipework.
148
Gas release
plant operators and/or 2.3
F&G system
SYSTEM
Zone 2.1 to 2.2
Zone 2.1 to 2.2
Zone 2.1 to 2.2
Zone 2.1 to 2.2
Zone 2.1 to 2.2
SUB-SYSTEM
FUNCTION
To contain the gas

Appropriate piping
within the A annulus of Failure of Ring Gasket Thermal/mechanical Catastrophic failure of Displacement from
gradients induce fatigue one or more bolts after
Seal
on bolts
a period of time.
analysis.
upstream pipework.
To contain the gas

Seal
stores
upstream pipework.
and mechanical
None
effect.
Designers and
place. Offshore
2.2
work system etc.
To contain the gas

specified
upstream pipework.
with body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work syst em etc.
To contain the gas

specified
upstream pipework.
Seal incorrectly
specified in design

initial teething
2.2
problems have been
ironed out.
FAILURE
CAUSE
EFFECT
To contain the gas

Seal
installed
upstream pipework.
Effective seal not made
SYMPTOMS
None
Gas leakage around

seal
MITIGATION
Employ competent
individuals and
is available.
2.1
envelope broken.
149
CRITICALITY
SYSTEM
SUB-SYSTEM
FUNCTION
To contain the gas

within the A annulus of Failure of Ring Gasket Bolts installed
incorrectly - bolts
Seal
unevenly tensioned
upstream pipework.
Zone 2.1 to 2.2
To contain the gas

Bolts installed
incorrectly - incorrect Joint integrity reduced None
Seal
upstream pipework.
Zone 2.1 to 2.2
To contain the gas

Bolts installed
over tensioned
upstream pipework.
To contain the gas

within the A annulus of Failure of Ring Gasket Bolts installed
Seal
under tensioned
upstream pipework.
Zone 2.1 to 2.2
Zone 2.1 to 2.2
Zone 2.1 to 2.2
2. Connecting
Pipework - Primary
Barrier
FAILURE
CAUSE
To contain the gas

Seal
service
upstream pipework.
150
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Employ competent
Joint integrity reduced to progressive leakage.
2.3
is available.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Gas release
F&G system
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 2.1 to 2.2
2. Connecting
Pipework - Primary
Barrier
To contain the gas

within the A annulus of Failure of Ring Gasket
Fatigue failure of bolts one or more bolts after
Seal
pipework
a period of time.
analysis.
upstream pipework.
Zone 2.1 to 2.2
2. Connecting
Pipework - Primary
Barrier
To contain the gas

Thermal/mechanical Catastrophic failure of
Appropriate piping
Displacement from
Seal
on bolts
a period of time.
analysis.
upstream pipework.
2. Connecting
Pipework - Primary
Barrier
To contain the gas

stores
upstream pipework.
and mechanical
None
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.1 to 2.2
2. Connecting
Pipework - Primary
Barrier
To contain the gas

within the A annulus of Failure of Ring Gasket Seal incorrectly
Seal
specified
upstream pipework.
with body causing
leak over time.
setup.
Designers and
manufact urers to have
place. Offshore
2.2
work system etc.
Zone 2.1 to 2.2
2. Connecting
Pipework - Primary
Barrier
To contain the gas

Seal
specified
upstream pipework.
Seal incorrectly
specified in design

initial teething
2.2
problems have been
ironed out.
Zone 2.1 to 2.2
FAILURE
CAUSE
EFFECT
151
SYMPTOMS
None
MITIGATION
CRITICALITY
SYSTEM
Zone 2.1 to 2.2
SUB-SYSTEM
2. Connect ing
Pipework - Primary
Barrier
FUNCTION
FAILURE
CAUSE
EFFECT
To contain the gas

within the A annulus of Failure of Ring Gasket Seal incorrectly
Seal
installed
upstream pipework.
SYMPTOMS
Gas leakage around

seal
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
2. Connecting
Pipework - Primary
Barrier
To contain the gas

Bolts installed
incorrectly - bolts
Seal
unevenly tensioned
upstream pipework.
Zone 2.1 to 2.2
2. Connecting
Pipework - Primary
Barrier
To contain the gas

Bolts installed
upstream pipework.
Zone 2.1 to 2.2
2. Connecting
Pipework - Primary
Barrier
To contain the gas

Bolts installed
over tensioned
upstream pipework.
2. Connecting
Pipework - Primary
Barrier
To contain the gas

Bolts installed
Seal
under tensioned
upstream pipework.
Zone 2.1 to 2.2
Zone 2.1 to 2.2
152
Sealing arrangement
Joint integrity reduced unevenly energised
Employ competent
individuals and
appropriate supervision 3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Employ competent
2.3
is available.
Employ competent
individuals and
Instantaneous leak from is available.
2.3
bonnet
envelope broken.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 2.1 to 2.2
To contain the gas

3. Tubing Spool Side
Bonnet seal leakage
Valve - Primary Barrier upstream pipework and (metal to metal joint)
or on activation of
platform ESD
Seal incorrectly
specified
with body causing
time
setup.
Zone 2.1 to 2.2
To contain the gas

3. Tubing Spool Side pressurisation in the
Bonnet seal leakage
or on activation of
platform ESD
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.1 to 2.2
To contain the gas

Bonnet seal leakage
or on activation of
platform ESD
Seal incorrectly
specified

initial teething
2.2
problems have been
ironed out.
Zone 2.1 to 2.2
To contain the gas

Bonnet seal leakage
or on activation of
platform ESD
Seal incorrectly
specified in design
SYMPTOMS
None.
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.
Seal incorrectly
installed
2.1
envelope broken.
153
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 2.1 to 2.2
To contain the gas

Bonnet seal leakage
Valve - Primary Barrier upstream pipework and (metal to metal joint)
or on activation of
platform ESD
Bolts installed
incorrectly - bolts
unevenly tensioned
Sealing arrangement
unevenly energised
Zone 2.1 to 2.2
To contain the gas

Bonnet seal leakage
or on activation of
platform ESD
Bolts installed
Zone 2.1 to 2.2
To contain the gas

Bonnet seal leakage
or on activation of
platform ESD
Bolts installed
over tensioned
Zone 2.1 to 2.2
To contain the gas

Bonnet seal leakage
or on activation of
platform ESD
Bolts installed
under tensioned
SYMPTOMS
MITIGATION
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Employ competent
2.3
is available.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
154
CRITICALITY
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
Zone 2.1 to 2.2
To contain the gas

Stem Seal Leak
Valve - Primary Barrier upstream pipework and
or on activation of
platform ESD
Wear and Tear
Zone 2.1 to 2.2
To contain the gas

Stem Seal Leak
or on activation of
platform ESD
Packing not set

correctly
Zone 2.1 to 2.2
To contain the gas

Stem Seal Leak
or on activation of
platform ESD
Zone 2.1 to 2.2
To contain the gas

Fitter backs off
just the cap
or on activation of
platform ESD
Loss of full seal
Perform maintenance
Gas leaks from actuator and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
Wrong packing fitted Loss of full seal
Perform maintenance
and inspection in
accordance with
housing
manufacturers
requirements.
2.4
155
Partial leak
Audible evidence of
gas release
MITIGATION
CRITICALITY
SYSTEM
SUB-SYSTEM
Zone 2.1 to 2.2
To contain the gas

Valve - Primary Barrier upstream pipework and
or on activation of
platform ESD
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
FUNCTION
FAILURE
CAUSE
EFFECT

Partial leak
removes inner check
valve
SYMPTOMS
MITIGATION
CRITICALITY
Audible evidence of
gas release

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD
Seal incorrectly
specified

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD
Seal incorrectly
specified
Tree has been

operating in excess of 6
months, initial teething 2.2
problems have been
ironed out.
with body causing
time
setup.
Seal incorrectly
specified in design
156
None.
Designers and
place. Offshore
2.2
work system etc.
SYSTEM
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD
Seal incorrectly
installed

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD
Bolts installed
incorrectly - bolts
unevenly tensioned

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD
Bolts installed

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD
Bolts installed
over tensioned
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
157
Sealing arrangement
unevenly energised
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
Employ competent
2.3
is available.
SYSTEM
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
FAILURE

Valve - Primary
Barrier
To contain the gas

Bonnet Seal Leakage
or on activation of
platform ESD

Valve - Primary
Barrier
To contain the gas

pressurisation in the Stem Seal Leakage
or on activation of
platform ESD

Valve - Primary
Barrier
To contain the gas

Stem Seal Leakage
or on activation of
platform ESD

Valve - Primary
Barrier
To contain the gas

pressurisation in the Stem Seal Leakage
or on activation of
platform ESD
CAUSE
EFFECT
Bolts installed
under tensioned
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Wear and Tear
Gas leaks from

actuator housing
Perform maintenance
and inspection in
accordance with
2.4
manufacturers
requirements.
Loss of full seal
Gas leaks from

actuator housing
Perform maintenance
and inspection in
accordance with
2.4
manufacturers
requirements.
Loss of full seal
Gas leaks from

actuator housing
Perform maintenance
and inspection in
2.4
accordance with
manufacturers
requirements.
Loss of full seal
Packing not set

correctly
158
SYSTEM
Zone 2.2 to 2.3
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS

Valve - Primary
Barrier
To contain the gas

Fitter backs off
Grease fitting leakage assembly rather than
just the cap
or on activation of
platform ESD

Valve - Primary
Barrier
To contain the gas

or on activation of
platform ESD
MITIGATION
CRITICALITY
Partial leak

release

greasing/lubricating Partial leak
removes inner check
valve

release

tubing hanger.
Zone 2.2 to 2.3
Zone 2.2 to 2.3
2. Tubing spool to
tubing hanger seal Primary Barrier
2. Tubing spool to
To provide a seal
between the tubing
Leakage around seal
To provide a seal
between the tubing
Leakage around seal
Seal fails to remain

energised
Seal incorrectly
installed
Over a period of time Secondary barriers

seal is permanent
None.
deformed
bolt arrangement,
chemical injection
point, downhole safety
valve point, tubing
hanger to casing spool
seal.
Gas leakage around

seal
Employ competent
individuals and
is available.
1.1
envelope broken.
159
1.3
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
2. Tubing spool to
FUNCTION
FAILURE
To provide a seal
Leakage around seal
between the tubing
CAUSE
EFFECT
SYMPTOMS
and mechanical
None
stores
effect.
Zone 2.2 to 2.3
2. Tubing spool to
To provide a seal
between the tubing
Leakage around seal
Seal incorrectly
specified
with body causing
leak over time.
setup.
Zone 2.2 to 2.3
2. Tubing spool to
To provide a seal
between the tubing
Leakage around seal
Seal incorrectly
specified
Seal incorrectly
specified in design
Zone 2.2 to 2.3
2. Tubing spool to
To provide a seal
between the tubing
Leakage around seal
None
Gradual determination
of seal, causing
Leakage around seal
increasing leakage over increasing over time.
a period of time
Ageing of seal
MITIGATION
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.

initial teething
1.2
problems have been
ironed out.
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
160
CRITICALITY
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

B annulus.
Instrument monitor
Zone 2.2 to 2.3
Zone 2.2 to 2.3
3. Tubing spool to
Casing Hanger Seal Primary Barrier
3. Tubing spool to
To provide a seal
between the casing
Leakage around seal
To provide a seal
between the casing
Leakage around seal

energised
Seal incorrectly
installed

seal is permanently
deformed
bolt arrangement,
chemical injection
monitored by plant
operators.
valve point, tubing
seal.
Gas leakage around

seal
3.3
Employ competent
individuals and
is available.
1.1
envelope broken.
Zone 2.2 to 2.3
Zone 2.2 to 2.3
3. Tubing spool to
3. Tubing spool to
To provide a seal
between the casing
Leakage around seal
To provide a seal
between the casing
Leakage around seal
and mechanical
None
stores
effect.
with body causing
leak over time.
setup.
Seal incorrectly
specified
161
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 2.2 to 2.3
3. Tubing spool to
To provide a seal
between the casing
Leakage around seal
Zone 2.2 to 2.3
3. Tubing spool to
FAILURE
To provide a seal
between the casing
Leakage around seal
CAUSE
EFFECT
Seal incorrectly
specified
Seal incorrectly
specified in design
SYMPTOMS
MITIGATION
None

initial teething
1.2
problems have been
ironed out.
Leakage around seal

Gradual determination increasing over time.
of seal, causing
increasing leakage over Casing hanger may
a period of time
drop as a result of seal
determination.
Ageing of seal
CRITICALITY
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
4. Production Tubing toTo provide a sealed

Tubing Hanger Seal - mechanical joint
Primary Barrier
between components

Failure of seal (metal tobeing out with
metal)
manufacturing
tolerances
162
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
None.
2.2
None.
2.2
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3

Primary Barrier
between components

metal)
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
4. Production Tubing to To provide a sealed

Primary Barrier
between components
Failure of seal (metal toInsufficient make up

metal)
torque
163
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3

Primary Barrier
between components
Failure of seal (metal toExcessive loading on

metal)
seal arrangement

None.
or failed
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
2.2
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3

Primary Barrier
between components
Failure of threaded
connection
Jumping out or
'unzipping' of the threadJoint opens
164
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3

Primary Barrier
between components
Zone 2.2 to 2.3
To provide containment
5. Upper Well annulus - for hydrocarbon gas to
Casing Spool failure
Primary Barrier
be injected into
production bore
Failure of threaded
connection
Shearing of threads

None.
or failed
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
Slag
Stress raisers and crack cold laps and other
initiators
geometric
imperfections in the
forged block.
2.2
Designers and
place.
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
To provide a sealed
5. Upper Well annulus mechanical joint
Primary Barrier
between components

metal)
manufacturing
tolerances
165
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
None.
2.2
None.
2.2
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
To provide a sealed
Primary Barrier
between components

metal)
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
To provide a sealed
Primary Barrier
between components

metal)
torque
166
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
To provide a sealed
Primary Barrier
between components

metal)
seal arrangement

None.
or failed
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
2.2
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
To provide a sealed
Primary Barrier
between components
Failure of threaded
connection
Jumping out or
'unzipping' of the threadJoint opens
167
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.2 to 2.3
To provide a sealed
Primary Barrier
between components
Zone 2.2 to 2.3
To provide a
6. Tubing hanger body continuous bore
- Primary Barrier
between the tree and Production bore failure Manufacturing defect
the production tubing
Zone 2.2 to 2.3
packing gland body
pressure to leak up to
7. Tubing hanger
Provide a seal between upper packing gland.
Thread cut out of
control line lower
and the tubing hanger Coincident failure of tolerance
packing gland (x2) body
upper packing gland
Primary Barrier
would lead to trapped
pressure leaking into
hanger and tree.
Failure of threaded
connection
Shearing of threads

None.
or failed
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
Slag
Stress raisers and crack cold laps and other
initiators
geometric
forged block.
2.2
Designers and
place.

during manufacture.
Reduced thread to
(seal maintained by
Degraded mechanical
excessive PTFE for
more on excessive
example)
thread contact.
Designers and
place. Offshore
balances.
168
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

during manufacture.
packing gland body
7. Tubing hanger
Thread cut out of
control line lower
and the tubing hanger Coincident failure of tolerance
upper packing gland
Primary Barrier
hanger and tree.
Designers and
Component will only
place. Offshore
balances.
Zone 2.2 to 2.3
packing gland body
7. Tubing hanger
control line lower
Cross threads
and the tubing hanger Coincident failure of
upper packing gland
Primary Barrier
hanger and tree.
Excessive torque
Ineffective seal

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.

up.
Zone 2.2 to 2.3
packing gland body
7. Tubing hanger
control line lower
Damaged threads
upper packing gland
Primary Barrier
hanger and tree.
Excessive torque

and effective
supervision.
Improperly mated
threads
1.3
Fitting improperly
aligned.
Leaking joint
169
Suitable pressure
testing.
SYSTEM
Zone 2.2 to 2.3
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
packing gland body
7. Tubing hanger
Leakage of gas into
control line lower
Incorrect joint make-up cavity between tubing
packing gland (x2) hanger and tree.
body
upper packing gland
Primary Barrier
hanger and tree.
8. Tubing hanger
downhole chemical
packing gland Primary Barrier
SYMPTOMS
MITIGATION
CRITICALITY
None.
1.3
Leakage of gas past

threaded connection
consequently
hanger.
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.

during manufacture.
packing gland body
Thread cut out of
line and the tubing
Coincident failure of tolerance
hanger body
upper packing gland
hanger and tree.
Reduced thread to
(seal maintained by
Degraded mechanical
excessive PTFE for
more on excessive
example)
thread contact.
Designers and
place. Offshore
balances.
170
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
8. Tubing hanger
downhole chemical
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

during manufacture.
packing gland body
Thread cut out of
line and the tubing
Coincident failure of tolerance
hanger body
upper packing gland
hanger and tree.
Designers and
Component will only
place. Offshore
balances.
Zone 2.2 to 2.3
8. Tubing hanger
downhole chemical
packing gland body
Cross threads
line and the tubing
hanger body
upper packing gland
hanger and tree.
Excessive torque
Ineffective seal

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.

up.
Zone 2.2 to 2.3
8. Tubing hanger
downhole chemical
packing gland body
Damaged threads
line and the tubing
hanger body
upper packing gland
hanger and tree.
Excessive torque

and effective
supervision.
Improperly mated
threads
1.3
Fitting improperly
aligned.
Leaking joint
171
Suitable pressure
testing.
SYSTEM
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
SUB-SYSTEM
8. Tubing hanger
downhole chemical
FUNCTION
FAILURE
EFFECT
packing gland body
Leakage of gas into
Incorrect joint make-up cavity between tubing
line and the tubing
hanger and tree.
hanger body
upper packing gland
hanger and tree.
9. Tubing spool
Provide a conduit for Rupture of chemical
downhole chemical
chemical injection into injection line - below
injection line - Primary
production bore
tubing hanger
Barrier
10. Tubing spool

control line - Primary
Barrier
CAUSE

hydraulic fluid for
control of the down
hole safety valves
Pipework damaged
during installation

Pipework damaged
safety valve control line
during installation
- below tubing hanger
172
SYMPTOMS
MITIGATION
CRITICALITY
None.
1.3
Leakage of gas past

threaded connection
consequently
hanger.
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
Pump Labouring
Pressurisation of void injection rate
between the tubing
hanger and the dual
bore upper packer with
Significant increase of
chemicals.
dosing rate of
chemicals.
between the tubing
Pump Labouring
hanger and the dual
bore upper packer with injection rate
hydraulic fluid
Regular checks of
pump pressure and
injection rates by plant
operators.
1.2
procedures.
Regular checks of
pump pressure and
operators.
1.2
procedures.
SYSTEM
SUB-SYSTEM
Zone 2.2 to 2.3
Production tubing will

11. Production tubing - provide a conduit for Production tubing
the hydrocarbon fluid
primary barrier
ruptures
to the topsides process
plant.
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
FUNCTION
To provide a sealed
11. Production tubing mechanical joint
primary barrier
between components
To provide a sealed
primary barrier
between components
To provide a sealed
primary barrier
between components
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

production tubing
Designers and
manufacturers to have 1.2
No credible effect,
initiators
since gas pressure
place.
should be higher than
hydrocarbon fluids.

metal)
manufacturing
tolerances

metal)

metal)
torque
173
Ineffective seal

production tubing
and effective
supervision.
1.2
No credible effect,
since gas pressure
Suitable pressure
should be higher than testing.
hydrocarbon fluids.
Ineffective seal

production tubing
and effective
supervision.
1.2
No credible effect,
since gas pressure
Suitable pressure
hydrocarbon fluids.
Ineffective seal

production tubing
and effective
supervision.
1.2
No credible effect,
since gas pressure
Suitable pressure
hydrocarbon fluids.
SYSTEM
Zone 2.2 to 2.3
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
To provide a sealed
primary barrier
between components
To provide a sealed
primary barrier
between components
FAILURE
CAUSE
EFFECT

metal)
seal arrangement
Failure of threaded
connection
Zone 2.2 to 2.3
To provide a sealed
primary barrier
between components
Zone 2.2 to 2.3
12. Annulus Tubing
annulus and with
Bonnet seal leakage
Spool Valves - Primary
instrumentation
Barrier
monitor annular
pressures
Failure of threaded
connection
SYMPTOMS
MITIGATION
CRITICALITY

production tubing
and effective
supervision.
1.2
No credible effect,
or failed
Suitable pressure
since gas pressure
hydrocarbon fluids.
Jumping out or
Joint opens

production tubing
and effective
supervision.
1.2
No credible effect,
since gas pressure
Suitable pressure
hydrocarbon fluids.
Shearing of threads

production tubing
and effective
supervision.
1.2
or failed
No credible effect,
since gas pressure
Suitable pressure
hydrocarbon fluids.
Seal incorrectly
specified
with body causing
time
setup.
174
Designers and
manufact urers to have
place. Offshore
2.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 2.2 to 2.3
12. Annulus Tubing
annulus and with
Bonnet seal leakage
Spool Valves - Primary instrumentation
Barrier
monitor annular
pressures
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.2 to 2.3
12. Annulus Tubing
annulus and with
Bonnet seal leakage
instrumentation
Barrier
monitor annular
pressures
Seal incorrectly
specified

initial teething
2.2
problems have been
ironed out.
Zone 2.2 to 2.3
12. Annulus Tubing
annulus and with
Bonnet seal leakage
instrumentation
Barrier
monitor annular
pressures
Seal incorrectly
installed
Zone 2.2 to 2.3
12. Annulus Tubing
Bonnet seal leakage
Spool Valves - Primary annulus and with
instrumentation
Barrier
monitor annular
pressures
Bolts installed
incorrectly - bolts
unevenly tensioned
Zone 2.2 to 2.3
12. Annulus Tubing
annulus and with
Bonnet seal leakage
Spool Valves - Primary instrumentation
Barrier
monitor annular
pressures
Seal incorrectly
specified in design
SYMPTOMS
None.
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
Sealing arrangement
Bolts installed
175
Employ competent
individuals and
3.3
is available.
Designers and
place. Offshore
3.2
work system etc.
SYSTEM
SUB-SYSTEM
Zone 2.2 to 2.3
12. Annulus Tubing
Bonnet seal leakage
annulus and with
instrumentation
Barrier
monitor annular
pressures
Zone 2.2 to 2.3
12. Annulus Tubing
annulus and with
Bonnet seal leakage
instrumentation
Barrier
monitor annular
pressures
Zone 2.2 to 2.3
FUNCTION
FAILURE
12. Annulus Tubing
Spool Valves - Primary annulus and with
Stem Seal Leak
instrumentat ion
Barrier
monitor annular
pressures
CAUSE
EFFECT
SYMPTOMS
Bolts installed
over tensioned
Employ competent
2.3
is available.
Bolts installed
under tensioned
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Stem Seal Leak
12. Annulus Tubing
annulus and with
Stem Seal Leak
instrumentation
Barrier
monitor annular
pressures
CRITICALITY
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Loss of full seal
Perform maintenance
and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Loss of full seal
Perform maintenance
Gas leaks from handle and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Perform maintenance
and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Wear and Tear
12. Annulus Tubing
annulus and with
instrumentation
Barrier
monitor annular
pressures
MITIGATION
Packing not set

correctly
176
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
Zone 2.2 to 2.3
12. Annulus Tubing
Fitter backs off
annulus and with
instrumentation
Barrier
just the cap
monitor annular
pressures
Zone 2.2 to 2.3
12. Annulus Tubing
annulus and with
instrumentation
Barrier
monitor annular
pressures
Zone 2.2 to 2.3
13. Upper annulus

tubing spool monitor
and vent assembly Primary Barrier
CRITICALITY
Partial leak
Audible evidence of
gas release

Partial leak
removes inner check
valve
Audible evidence of
gas release
None.
Employ competent
individuals and
1.1
is available.
To provide a facility for Cartridge nose seal

pressure monitoring
Cartridge not fully
equipment to be linked leakage past cartridge tightened
to the A annulus
wall
Gas leakage around

cartridge walls
Designers and
place. Offshore
2.2
work system etc.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
Seal incorrectly
specified
equipment to be linked
to the A annulus
with body causing
time
setup.
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
stores
to the A annulus
and mechanical
None
effect.
177
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 2.2 to 2.3
13. Upper annulus


Seal incorrectly
pressure monitoring
specified
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus

FAILURE
CAUSE
EFFECT
Seal incorrectly
specified in design
SYMPTOMS
MITIGATION
CRITICALITY
None.

initial teething
2.2
problems have been
ironed out.
Employ competent
individuals and
is available.

Seal incorrectly
pressure monitoring
installed
to the A annulus
2.1
envelope broken.
Zone 2.2 to 2.3
13. Upper annulus


Bolts installed
pressure monitoring
incorrectly - bolts
Failure
of
bonnet
seal
unevenly tensioned
to the A annulus
Sealing arrangement
Zone 2.2 to 2.3
13. Upper annulus


Bolts installed
pressure monitoring
Failure of bonnet seal incorrectly - incorrect Joint integrity reduced None.
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus


Bolts installed
pressure monitoring
equipment to be linked Failure of bonnet seal
over tensioned
to the A annulus
178
Employ competent
individuals and
is available.
Designers and
place. Offshore
3.2
work system etc.
Employ competent
is available.
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 2.2 to 2.3
13. Upper annulus


Bolts installed
pressure monitoring
Failure of bonnet seal incorrectly - bonnet
under tensioned
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
equipment to be linked Seal
service
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
one or more bolts after
Fatigue
failure
of
bolts
pipework
a period of time.
analysis.
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus


Appropriate piping
pressure monitoring
Displacement from
on bolts
a period of time.
analysis.
to the A annulus
13. Upper annulus

and mechanical
pressure monitoring
None
stores
to the A annulus
effect.
Zone 2.2 to 2.3
FAILURE
CAUSE
EFFECT
179
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Gas release
F&G system
Designers and
place. Offshore
2.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
specified
to the A annulus
with body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
specified
to the A annulus
Seal incorrectly
specified in design

initial teething
2.2
problems have been
ironed out.
Zone 2.2 to 2.3
13. Upper annulus

FAILURE
CAUSE
EFFECT

pressure monitoring
installed
to the A annulus
SYMPTOMS
None
Gas leakage around

seal
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
Zone 2.2 to 2.3
Zone 2.2 to 2.3
13. Upper annulus

13. Upper annulus


Bolts installed
pressure monitoring
incorrectly - bolts
unevenly tensioned
to the A annulus
Sealing arrangement

Bolts installed
pressure monitoring
to the A annulus
180
Emplo y competent
individuals and
is available.
Designers and
place. Offshore
3.2
work system etc.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Zone 2.2 to 2.3
13. Upper annulus


Bolts installed
pressure monitoring
over tensioned
to the A annulus
13. Upper annulus


Bolts installed
pressure monitoring
under tensioned
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
equipment to be linked Stem seal leakage
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
to the A annulus
Zone 2.2 to 2.3
13. Upper annulus


pressure monitoring
to the A annulus
Zone 2.2 to 2.3
Zone 2.2 to 2.3
To provide a secondary
14. Tubing hanger tie
barrier between the
down bolts and seals casing spool and the tie Leakage around seal
Secondary Barrier
down bolts
SYMPTOMS
MITIGATION
CRITICALITY
Employ competent
2.3
is available.
Employ competent
individuals and
is available.
2.3
bonnet
envelope broken.
Loss of full seal
Perform maintenance
and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Loss of full seal
Perform maintenance
and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Perform maintenance
and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Wear and Tear
Packing not set

correctly
Leakage around seal

of seal, causing
a period of time
determination.
Ageing of seal
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
181
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

during manufacture.
Zone 2.2 to 2.3
packing gland body
15. Tubing hanger
the DHSV control line cavity between tubing Thread cut out of
control line upper
tolerance
packing gland hanger and tree.
body
Secondary Barrier
lower packing gland.
Reduced thread to
Degraded mechanical
(seal maintained by
excessive PTFE for
example)
more on excessive
thread contact.
Designers and
place. Offshore
balances.

during manufacture.
Zone 2.2 to 2.3
packing gland body
15. Tubing hanger
Provide a seal between pressure to leak into
Thread cut out of
control line upper
tolerance
body
Secondary Barrier
Designers and
Component will only manufacturers to have
Either male or female mate for a proportion of ISO quality systems in
3.3
place. Offshore
balances.
Zone 2.2 to 2.3
Excessive torque
packing gland body
15. Tubing hanger
control line upper
and the tubing hanger cavity between tubing Cross threads
body
Secondary Barrier
Ineffective seal

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.
182
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
Zone 2.2 to 2.3
packing gland body
15. Tubing hanger
Provide a seal between thread causing trapped
control line upper
body
Secondary Barrier
EFFECT
SYMPTOMS
MITIGATION
up.
Excessive torque
CRITICALITY

and effective
supervision.
Improperly mated
threads
1.3
Fitting improperly
aligned.
Suitable pressure
testing.
Leaking joint
Leakage of gas past
threaded connection
consequently
hanger.
Zone 2.2 to 2.3
packing gland body
15. Tubin g hanger
Leakage of gas into
control line upper
None.
Secondary barriers
hanger and tree.
body
provided
by
tie
down
Secondary Barrier
bolt arrangement,
chemical injection
valve point, tubing
seal.
183
1.3
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY

during manufacture.
Zone 2.2 to 2.3
16. Tubing hanger

downhole chemical
packing gland body
the Chemical Injection cavity between tubing Thread cut out of
line and the tubing
tolerance
hanger and tree.
hanger body
Reduced thread to
Degraded mechanical
(seal maintained by
excessive PTFE for
example)
more on excessive
thread contact.
Designers and
place. Offshore
balances.

during manufacture.
Zone 2.2 to 2.3
16. Tubing hanger

downhole chemical
injection line up per
packing gland body
Provide a seal between pressure to leak into
Thread cut out of
line and the tubing
tolerance
hanger and tree.
hanger body
Designers and
Component will only manufacturers to have
Either male or female mate for a proportion of ISO quality systems in
3.3
place. Offshore
balances.
Zone 2.2 to 2.3
16. Tubing hanger

downhole chemical
Excessive torque
packing gland body
Provide a seal bet ween
cavity between tubing Cross threads
line and the tubing
hanger and tree.
hanger body
Ineffective seal

and effective
supervision.
Fitting improperly
aligned.
1.3
Suitable pressure
testing.
Leaking joint.
184
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
16. Tubing hanger

downhole chemical
FUNCTION
FAILURE
CAUSE
EFFECT
packing gland body
line and the tubing
hanger and tree.
hanger body
SYMPTOMS
MITIGATION
up.
Excessive torque

and effective
supervision.
Improperly mated
threads
1.3
Fitting improperly
aligned.
CRITICALITY
Suitable pressure
testing.
Leaking joint
Leakage of gas past
threaded connection
consequently
hanger.
packing gland body
Leakage of gas into
None.
line and the tubing
Secondary barriers
hanger and tree.
hanger and tree.
hanger body
bolt arrangement,
chemical injection
valve point, tubing
seal.
Zone 2.2 to 2.3
16. Tubing hanger

downhole chemical
Zone 2.2 to 2.3

Secondary Barrier
interface
1.3

Appropriate piping
Leakage of gas around
Displacement from
seal
on bolts
a period of time.
analysis.
185
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION

Secondary Barrier
interface
FAILURE
CAUSE
EFFECT
SYMPTOMS
and mechanical
Leakage of gas around Wrong seal taken from properties similar to
None
seal
stores
effect.
Zone 2.2 to 2.3

Secondary Barrier
interface

seal
specified
with body causing
leak over time.
setup.
Zone 2.2 to 2.3

Secondary Barrier
interface

seal
specified
Seal incorrectly
specified in design
Zone 2.2 to 2.3

Secondary Barrier
interface

seal
installed
Effectiv e seal not made
None
Gas leakage around

seal
MITIGATION
CRITICALITY
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.

initial teething
1.2
problems have been
ironed out.
Employ competent
individuals and
is available.
1.1
envelope broken.
Zone 2.2 to 2.3
18. Tubing spool

To provide a seal
control packing gland - between the DHSV
Secondary Barrier
gland bore
Leakage around seal
of seal, causing
Leakage around seal
a period of time
Ageing of seal
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
186
SYSTEM
SUB-SYSTEM
Zone 2.2 to 2.3
18. Tubing spool

To provide a seal
Secondary Barrier
gland bore
Zone 2.2 to 2.3
18. Tubing spool

between the DHSV
Secondary Barrier
gland bore
Zone 2.2 to 2.3
FUNCTION
18. Tubing spool

between the DHSV
Secondary Barrier
Outlet block assembly - gland bore
FAILURE
CAUSE
EFFECT
SYMPTOMS
Leakage around seal
and mechanical
None
stores
effect.
Leakage around seal
Seal incorrectly
specified
with body causing
leak over time.
setup.
Leakage around seal
Seal incorrectly
specified
Seal incorrectly
specified in design
None
MITIGATION
CRITICALITY
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
1.2
work system etc.

initial teething
1.2
problems have been
ironed out.
Tertiary Barrier
Zone 2.2 to 2.3
18. Tubing spool

between the DHSV
Secondary Barrier
gland bore
Leakage around seal
Seal incorrectly
installed
Gas leakage around

seal
Employ competent
individuals and
is available.
1.1
envelope broken.
187
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
FAILURE
18. Tubing spool

Secondary Barrier
CAUSE
EFFECT
SYMPTOMS
Leakage around seal
of seal, causing
a period of time
Ageing of seal
MITIGATION
CRITICALITY
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly .
Zone 2.2 to 2.3
18. Tubing spool

Secondary Barrier
Zone 2.2 to 2.3
18. Tubing spool

Secondary Barrier
Zone 2.2 to 2.3
18. Tubing spool

Secondary Barrier
and mechanical
None
stores
effect.
Designers and
place. Offshore
1.2
work system etc.
Seal incorrectly
specified
with body causing
leak over time.
setup.
Designers and
place. Offshore
1.2
work system etc.
Seal incorrectly
specified
Seal incorrectly
specified in design

1.2
initial teething
problems have been
ironed out.
188
None
SYSTEM
SUB-SYSTEM
Zone 2.2 to 2.3
18. Tubing spool

Secondary Barrier
Zone 2.2 to 2.3
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
FUNCTION
To provide a seal
Outer block assembly - gland bore
Tertiary Barrier
FAILURE
Leakage around seal
CAUSE
EFFECT
Seal incorrectly
installed
SYMPTOMS
Gas leakage around

seal
MITIGATION
CRITICALITY
Employ competent
individuals and
appropriat e supervision
is available.
1.1
envelope broken.
of seal, causing
Leakage around seal
a period of time
Ageing of seal
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Zone 2.2 to 2.3
Zone 2.2 to 2.3
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
To provide a seal
Leakage around seal
Tertiary Barrier
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
To provide a seal
between the chemical Leakage around seal
Tertiary Barrier
Seal incorrectly
installed
Gas leakage around

seal
Employ competent
individuals and
is available.
1.1
envelope broken.
and mechanical
None
stores
effect.
189
Designers and
place. Offshore
1.2
work system etc.
SYSTEM
Zone 2.2 to 2.3
Zone 2.2 to 2.3
Zone 2.2 to 2.3
SUB-SYSTEM
FAILURE
To provide a seal
between the chemical Leakage around seal
Tertiary Barrier
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
To provide a seal
Leakage around seal
Tertiary Barrier
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
Zone 2.2 to 2.3
FUNCTION
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
To provide a seal
CAUSE
EFFECT
Seal incorrectly
specified
with body causing
leak over time.
setup.
Designers and
place. Offshore
1.2
work system etc.
Seal incorrectly
specified
Seal incorrectly
specified in design

initial teething
1.2
problems have been
ironed out.
Seal incorrectly
installed
SYMPTOMS
None
Gas leakage around

seal
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
1.1
envelope broken.
To provide a seal
and mechanical
None
stores
effect.
190
Designers and
place. Offshore
1.2
work system etc.
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
19. Tubing spool
downhole chemical
gland - Secondary
Barrier
Zone 2.2 to 2.3
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
Zone 2.2 to 2.3
19. Tubing spool

downhole chemical
gland - Secondary
Barrier
FUNCTION
FAILURE
CAUSE
EFFECT
To provide a seal
Seal incorrectly
specified
with body causing
leak over time.
setup.
Designers and
place. Offshore
1.2
work system etc.
To provide a seal
Seal incorrectly
specified
Seal incorrectly
specified in design

initial teething
1.2
problems have been
ironed out.
To provide a seal
SYMPTOMS
None
of seal, causing
Leakage around seal
a period of time
Ageing of seal
MITIGATION
CRITICALITY
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
Pump Labouring
(audible)
Zone 2.2 to 2.3
20. Tubing spool

downhole chemical
Rupture of chemical
chemical injection into
tubing spool and tree during installation
production bore
cavity
Pressurisation of void Significant reduction or

between the tree and cessation of dosing rate
tubing spool with
of chemicals.
chemicals.
ring gasket and tie
down bolts.
191
Regular checks of
pump pressure injection
1.2
procedures.
SYSTEM
Zone 2.2 to 2.3
SUB-SYSTEM
FUNCTION
21. Tubing spool

downhole safety valve hydraulic fluid for
control line - Secondary control of the down
Barrier
hole safety valves
FAILURE
CAUSE
EFFECT

safety valve control line Pipework damaged
- between tubing spool during installation
and tree cavity
SYMPTOMS
Pump Labouring
between the tree and
tubing spool with
injection rate
hydraulic fluid
MITIGATION
CRITICALITY
Regular checks of
pump pressure and
operators.
1.2
procedures.
Zone 2.3 to 2.4
To provide containment
1. Upper Well annulus - for hydrocarbon gas to
Casing Spool failure
Primary Barrier
be injected into
production bore
Slag
Stress raisers and crackcold laps and other
Manufacturing defect initiators
geometric
forged block.
Designers and
place.
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.3 to 2.4
To provide a sealed
Primary Barrier
between components

Failure of seal (metal being out with
Ineffective seal
to metal)
manufacturing
tolerances
192
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.3 to 2.4
To provide a sealed
Primary Barrier
between components
Failure of seal (metal

to metal)
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.3 to 2.4
To provide a sealed
Primary Barrier
between components
Failure of seal (metal Insufficient make up

to metal)
torque
193
Ineffective seal
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.3 to 2.4
To provide a sealed
Primary Barrier
between components
Failure of seal (metal Excessive loading on

to metal)
seal arrangement

None.
or failed
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
2.2
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.3 to 2.4
To provide a sealed
Primary Barrier
between components
Failure of threaded
connection
Jumping out or
'unzipping' of the
thread
Joint opens
194
Secondary barriers
bolt arrangement,
chemical injection
valve point, tubing
seal.
None.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
consequently
hanger.
Zone 2.3 to 2.4
To provide a sealed
Primary Barrier
between components
Failure of threaded
connection
Zone 2.3 to 2.4
2. Annulus downhole
To provide addition
barrier in A annulus
Barrier

metal)
manufacturing
tolerances
Ineffective seal
No credible effect, gas

already present in both
Not Applicable
upper and lower A
annulus.
2.2
Zone 2.3 to 2.4
2. Annulus downhole
To provide addition
Barrier

metal)
Ineffective seal

Not Applicable
upper and lower A
annulus.
2.2
Zone 2.3 to 2.4
2. Annulus downhole
To provide addition
Barrier

metal)
torque
Ineffective seal

Not Applicable
upper and lower A
annulus.
2.2
Zone 2.3 to 2.4
2. Annulus downhole
To provide addition
Barrier

metal)
seal arrangement

Seal integrity reduced already present in both
Not Applicable
or failed
upper and lower A
annulus.
2.2
Zone 2.3 to 2.4
2. Annulus downhole
To provide addition
Barrier
Failure of threaded
connection
Jumping out or
Joint opens

Not Applicable
upper and lower A
annulus.
2.2
Zone 2.3 to 2.4
2. Annulus downhole
To provide addition
Barrier
Failure of threaded
connection
Shearing of threads

Joint integrity reduced already present in both
Not Applicable
or failed
upper and lower A
annulus.
2.2
Shearing of threads
195

None.
or failed
Secondary barriers
bolt arra ngement,
chemical injection
valve point, tubing
seal.
2.2
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
seals.
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
2. Annulus downhole
To provide addition
Barrier
2. Annulus downhole
To provide addition
Barrier
Failure of housing
sealing arrangement

Leakage into the A
housing
annulus
component interface
Production tubing will

3. Production tubing Production tubing
the hydrocarbon fluid ruptures
primary barrier
to the topsides process
plant.
To provide a sealed
primary barrier
between components

DHSV housing loses
integrity
component interface

1.1
upper and lower A
Manufacturers and
annulus.
designers have suitable
quality assurance
system in accordance
with ISO or equivalent.
Upper A annulus
already pressurised
seals.
with gas, therefore
pressure of gas
2.1
potentially higher than
hydrocarbon fluid
inhibiting the leak into Periodic testing
the upper A annulus.

production tubing

metal)
manufacturing
tolerances
196
Designers and
1.2
initiators
No credible effect,
since gas pressure
place.
should be higher than
hydrocarbon fluids.
Ineffective seal

production tubing
and effective
supervision.
1.2
No credible effect,
Suitable pressure
since gas pressure
hydrocarbon fluids.
SYSTEM
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
SUB-SYSTEM
FUNCTION
To provide a sealed
primary barrier
between components
To provide a sealed
primary barrier
between components
To provide a sealed
primary barrier
between components
To provide a sealed
primary barrier
between components
FAILURE
CAUSE
EFFECT
SYMPTOMS
Ineffective seal

production tubing
and effective
supervision.
1.2
No credible effect,
Suitable pressure
since gas pressure
hydrocarbon fluids.

metal)
torque
Ineffective seal

production tubing
and effective
supervision.
1.2
No credible effect,
since gas pressure
Suitable pressure
hydrocarbon fluids.

metal)
seal arrangement

production tubing
and effective
supervision.
1.2
or failed
No credible effect,
since gas pressure
Suitable pressure
hydrocarbon fluids.

metal)
Failure of threaded
connection
Jumping out or
Joint opens
197
MITIGATION
CRITICALITY

production tubing
and effective
supervision.
1.2
No credible effect,
since gas pressure
Suitable pressure
hydrocarbon fluids.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Shearing of threads

production tubing
and effective
supervision.
1.2
No credible effect,
or failed
Suitable pressure
since gas pressure
hydrocarbon fluids.
Zone 2.3 to 2.4
To provide a sealed
primary barrier
between components
Zone 2.3 to 2.4
Produce corrosion
To give additional
source of debris and
4. B Annulus Casing - protection to the
can under certain
secondary barrier
formation to the top of or parted
is present)
situations apply a
the pay zone.
pressure to mating
surfaces
Failure of threaded
connection
SYMPTOMS
Zone 2.3 to 2.4
To give additional
Localised corrosion
secondary barrier
is present)
the pay zone.
To give additional
secondary barrier
the pay zone.
1.3
13% Cr Alloys.
Optimisation of
material design and
selection

Good corrosion
time full wall
management strategy
and execution.
Gas lift pressure
leakage into the C
annulus, consequently
annular valves on C
annulus become
primary barrier.
C annulus is rated to a
B annulus.
198
CRITICALITY
Degradation of
Optimisation of
components over time. material design and
selection
Zone 2.3 to 2.4
MITIGATION
4.3
3.3
SYSTEM
Zone 2.3 to 2.4
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
Precipitation of
To give additional
Embrittlement during Chromium Carbides
manufacturing process under incorrect welding
secondary barrier
(high alloy steels)
and heat treatment
the pay zone.
regimes.
SYMPTOMS
Gas lift pressure
leakage into the C
annular valves on C
annulus become
primary barrier.
MITIGATION
CRITICALITY
Design and
with ISO and
equivalent.
2.3

monitor annulus
pressure.
B annulus.
Zone 2.3 to 2.4
Zone 2.3 to 2.4
To provide a sealed
4. B Annulus Casing mechanical joint
secondary barrier
between components
To provide a sealed
secondary barrier
between components

metal)
manufacturing
tolerances

metal)
Ineffective seal
Gas lift pressure

leakage into the C
Instrument monitor
facility on B & C
annular valves on C
annulus.
annulus become
primary barrier.
Pressure in B and C
lower pressure than the plant operators.
B annulus.
Ineffective seal
Gas lift pressure

leakage into the C
Instrument monitor
facility on B & C
annular valves on C
annulus.
annulus become
primary barrier.
Pressure in B and C
B annulus.
199
2.2
2.2
SYSTEM
Zone 2.3 to 2.4
SUB-SYSTEM
FUNCTION
To provide a sealed
secondary barrier
between components
FAILURE
CAUSE
EFFECT

metal)
torque
Ineffective seal
SYMPTOMS
MITIGATION
Gas lift pressure

leakage into the C
Instrument monitor
facility on B & C
annular valves on C
annulus.
annulus become
primary barrier.
CRITICALITY
2.2
Pressure in B and C
B annulus.
Zone 2.3 to 2.4
To provide a sealed
secondary barrier
between components

metal)
seal arrangement
Gas lift pressure

leakage into the C
Instrument monitor
facility on B & C
annular valves on C
annulus.
annulus become
Seal integrity reduced primary barrier.
or failed
2.2
Pressure in B and C
B annulus.
Zone 2.3 to 2.4
To provide a sealed
secondary barrier
between components
Failure of threaded
connection
Jumping out or
Joint opens
Gas lift pressure

leakage into the C
Instrument monitor
facility on B & C
annular valves on C
annulus.
annulus become
primary barrier.
Pressure in B and C
B annulus.
200
2.2
SYSTEM
Zone 2.3 to 2.4
SUB-SYSTEM
FUNCTION
To provide a sealed
secondary barrier
between components
FAILURE
Failure of threaded
connection
CAUSE
EFFECT
Shearing of threads
SYMPTOMS
MITIGATION
Gas lift pressure

leakage into the C
Instrument monitor
facility on B & C
annular valves on C
annulus.
annulus become
Joint integrity reduced primary barrier.
or failed
CRITICALITY
2.2
Pressure in B and C
B annulus.
Designers and
place. Offshore
2.2
work system etc.
5. B Annulus Tubing
Spool Valves Secondary Barrier
isolate the B annulus
and with
Bonnet seal leakage
instrumentation
monitor annular
pressures
Seal incorrectly
specified
Zone 2.3 to 2.4
5. B Annulus Tubing
and with
Bonnet seal leakage
instrumentation
monitor annular
pressures
and mechanical
None
stores
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.3 to 2.4
5. B Annulus Tubing
and with
Bonnet seal leakage
instrumentation
monitor annular
pressures
Seal incorrectly
specified

initial teething
2.2
problems have been
ironed out.
Zone 2.3 to 2.4
with body causing
time
setup.
Seal incorrectly
specified in design
201
None.
SYSTEM
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
5. B Annulus Tubing
and with
Bonnet seal leakage
instrumentation
monitor annular
pressures
Seal incorrectly
installed
5. B Annulus Tubing
and with
Bonnet seal leakage
instrumentation
monitor annular
pressures
Bolts installed
incorrectly - bolts
unevenly tensioned
5. B Annulus Tubing
and with
Bonnet seal leakage
instrumentation
monitor annular
pressures
Bolts installed
5. B Annulus Tubing
Bonnet seal leakage
and with
instrumentation
monitor annular
pressures
Bolts installed
over tensioned
5. B Annulus Tubing
and with
Bonnet seal leakage
instrumentation
monitor annular
pressures
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
Bolts installed
under tensioned
Sealing arrangement
Employ competent
individuals and
is available.
Designers and
place. Offshore
3.2
work system etc.
Employ competent
2.3
is available.
Employ competent
individuals and
2.3
bonnet
envelope broken.
202
SYSTEM
SUB-SYSTEM
FUNCTION
5. B Annulus Tubing
and with
Stem Seal Leak
instrumentation
monitor annular
pressures
Wear and Tear
5. B Annulus Tubing
and with
Stem Seal Leak
instrumentation
monitor annular
pressures
Packing not set

correctly
5. B Annulus Tubing
and with
Stem Seal Leak
instrumentation
monitor annular
pressures
5. B Annulus Tubing
isolat e the B annulus
Fitter backs off
and with
instrumentation
just the cap
monitor annular
pressures
Zone 2.3 to 2.4
5. B Annulus Tubing
and with
instrumentation
monitor annular
pressures
Zone 2.3 to 2.4
6. Upper annulus tubing To provide a facility for Cartridge nose seal

Cartridge not fully
assembly - Secondary equipment to be linked leakage past cartridge tightened
Barrier
to the B annulus
wall
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
Zone 2.3 to 2.4
FAILURE
CAUSE
EFFECT
SYMPTOMS
Loss of full seal
Perform maintenance
Gas leaks from handle and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Loss of full seal
Perform maintenance
and in spection in
accordance with
assembly
manufacturers
requirements.
2.4
Loss of full seal
Perform maintenance
and inspection in
accordance with
assembly
manufacturers
requirements.
2.4
Partial leak
Audible evidence of
gas release

Partial leak
removes inner check
valve
Audible evidence of
gas release
None.
Employ competent
individuals and
1.1
is available.
203
Gas leakage around

cartridge walls
MITIGATION
CRITICALITY
SYSTEM
SUB-SYSTEM
Zone 2.3 to 2.4

Seal incorrectly
specified
Barrier
to the B annulus
Zone 2.3 to 2.4
and mechanical
None
stores
Barrier
to the B annulus
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.3 to 2.4

Seal incorrectly
assembly - Secondary equipment to be linked Failure of bonnet seal specified
Barrier
to the B annulus

initial teething
2.2
problems have been
ironed out.
Zone 2.3 to 2.4
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
with body causing
time
setup.
Seal incorrectly
specified in design
None.
MITIGATION
CRITICALITY
Designers and
place. Offshore
2.2
work system etc.
Employ competent
individuals and
is available.

Seal incorrectly
installed
Barrier
to the B annulus
2.1
envelope broken.
Zone 2.3 to 2.4

Bolts installed
Failure of bonnet seal incorrectly - bolts
unevenly tensioned
Barrier
to the B annulus
204
Sealing arrangement
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
Zone 2.3 to 2.4

Bolts installed
Failure of bonnet seal incorrectly - incorrect Joint integrity reduced None.
Barrier
to the B annulus
Zone 2.3 to 2.4

Bolts installed
assembly - Secondary equipment to be linked Failure of bonnet seal
over tensioned
Barrier
to the B annulus
Zone 2.3 to 2.4

Bolts installed
Failure of bonnet seal incorrectly - bonnet
under tensioned
Barrier
to the B annulus
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
is available.
Employ competent
individuals and
appropriat e supervision
2.3
bonnet
envelope broken.
Zone 2.3 to 2.4

service
Barrier
to the B annulus
Zone 2.3 to 2.4

Fatigue failure of bolts one or more bolts after pipework
a period of time.
analysis.
Barrier
to the B annulus
Zone 2.3 to 2.4

Appropriate piping
Displacement from
on bolts
a period of time.
analysis.
Barrier
to the B annulus
205
Gas release
F&G system
SYSTEM
SUB-SYSTEM
Zone 2.3 to 2.4

stores
Barrier
to the B annulus
and mechanical
None
effect.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.3 to 2.4

specified
Barrier
to the B annulus
with body causing
leak over time.
setup.
Designers and
place. Offshore
2.2
work system etc.
Zone 2.3 to 2.4

specified
Barrier
to the B annulus
Seal incorrectly
specified in design

initial teething
2.2
problems have been
ironed out.
Zone 2.3 to 2.4
FUNCTION
FAILURE
CAUSE
EFFECT

installed
Barrier
to the B annulus
SYMPTOMS
None
Gas leakage around

seal
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
2.1
envelope broken.
Zone 2.3 to 2.4

Bolts installed
incorrectly - bolts
Seal
unevenly tensioned
Barrier
to the B annulus
206
Sealing arrangement
Employ competent
individuals and
3.3
is available.
SYSTEM
SUB-SYSTEM
Zone 2.3 to 2.4

Bolts installed
Barrier
to the B annulus
Zone 2.3 to 2.4

Bolts installed
over tensioned
Barrier
to the B annulus
Zone 2.3 to 2.4

Bolts installed
under tensioned
Barrier
to the B annulus
Zone 2.3 to 2.4
FUNCTION
FAILURE

assembly - Secondary equipment to be linked Stem seal leakage
Barrier
to the B annulus
CAUSE
EFFECT
Wear and Tear
SYMPTOMS
MITIGATION
CRITICALITY
Designers and
place. Offshore
3.2
work system etc.
Employ competent
is available.
Employ competent
individuals and
2.3
bonnet
envelope broken.
Loss of full seal
Perform maintenance
and inspection in
accordance with
assembly
manufacturers
requirements.
2.4

B annulus.
Instrument monitor
Zone 2.3 to 2.4
7. B annulus tubing
To provide a seal
spool to casing hanger between the casing
Leakage around seal
seal - Primary Barrier hanger and casing spool

energised
207

seal is permanently
deformed
bolt arrangement,
chemical injection
monitored by plant
operators.
valve point, tubing
seal.
3.3
SYSTEM
Zone 2.3 to 2.4
SUB-SYSTEM
FUNCTION
FAILURE
7. B annulus tubing
To provide a seal
Leakage around seal
CAUSE
EFFECT
Seal incorrectly
installed
SYMPTOMS
Gas leakage around

seal
MITIGATION
CRITICALITY
Employ competent
individuals and
is available.
1.1
envelope broken.
Zone 2.3 to 2.4
7. B annulus tubing
To provide a seal
Leakage around seal
Zone 2.3 to 2.4
7. B annulus tubing
To provide a seal
Leakage around seal
Zone 2.3 to 2.4
7. B annulus tubing
To provide a seal
Leakage around seal
Zone 2.3 to 2.4
7. B annulus tubing
To provide a seal
Leakage around seal
and mechanical
None
stores
effect.
Seal incorrectly
specified
Seal incorrectly
specified
with body causing
leak over time.
setup.
Designers and
place. Offshore
1.2
work system etc.
Seal incorrectly
specified in design

initial teething
1.2
problems have been
ironed out.
None
Leakage around seal

of seal, causing
a period of time
determination.
Ageing of seal
Designers and
place. Offshore
1.2
work system etc.
Designers and
place. Offshore
balances.
2.2
Pressure test of
complete assembly.
208
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Zone 2.4 to 2.6
1. Annulus downhole
To provide addition
Barrier

Failure of seal (metal being out with
Ineffective seal
to metal)
manufacturing
tolerances

Not Applicable
upper and lower A
annulus.
2.2
Zone 2.4 to 2.6
1. Annulus downhole
To provide addition
Barrier
Failure of seal (metal

to metal)
Ineffective seal

Not Applicable
upper and lower A
annulus.
2.2
Zone 2.4 to 2.6
1. Annulus downhole
To provide addition
Barrier
Failure of seal (metal Insufficient make up

to metal)
torque
Ineffective seal

already present in both Not Applicable
upper and lower A
annulus.
2.2
Zone 2.4 to 2.6
1. Annulus downhole
To provide addition
Barrier
Failure of seal (metal Excessive loading on

to metal)
seal arrangement

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

Not Applicable
upper and lower A
annulus.
2.2
Zone 2.4 to 2.6
1. Annulus downhole
To provide addition
Barrier
Failure of threaded
connection
Shearing of threads

Joint integrity reduced already present in both
Not Applicable
or failed
upper and lower A
annulus.
2.2
seals.
Zone 2.4 to 2.6
1. Annulus downhole
To provide addition
Barrier
Failure of housing
sealing arrangement

DHSV housing loses
integrity
component interface
209

1.1
upper and lower A
Manufacturers and
annulus.
designers have suitable
quality assurance
system in accordance
with ISO or equivalent.
SYSTEM
Zone 2.4 to 2.6
Zone 2.4 to 2.6
Zone 2.4 to 2.6
Zone 2.4 to 2.6
Zone 2.4 to 2.6
SUB-SYSTEM
FUNCTION
1. Annulus downhole
To provide addition
Barrier



FAILURE
CAUSE
EFFECT

Leakage into the A
housing
annulus
component interface

provides isolation
lower annulus
Incorrectly set

provides isolation
lower annulus
Determination of the
packer sealing element None.
None.

provides isolation
annulus upper bore
tubing stab seal
lower annulus
To provide a conduit
for the gas to be
(9 5/8") - Primary
injected into the
Barrier
production string
None.
Produce corrosion
source of debris and
Lower annulus casing Corrosion (where water
can under certain
split or parted
is present)
situations apply a
pressure to mating
surfaces
210
SYMPTOMS
MITIGATION
CRITICALITY
Upper A annulus
already pressurised
with gas, therefore
seals.
pressure of gas
2.1
potentially higher than
hydrocarbon fluid
inhibiting the leak into Periodic testing
the upper A annulus.

upper and lower A
annulus.

upper and lower A
annulus.

upper and lower A
annulus.
Periodic checks of
upper A annulus
pressure.
2.2
installed.
Periodic checks of
upper A annulus
pressure.
2.2
installed.
Periodic checks of
upper A annulus
pressure.
2.2
installed.
Degradation of
Optimisation of
components over time. material design and
selection
1.3
13% Cr Alloys.
SYSTEM
SUB-SYSTEM
Zone 2.4 to 2.6
for the gas to be
(9 5 /8") - Primary
injected into the
Barrier
production string
Zone 2.4 to 2.6
FUNCTION
for the gas to be
(9 5/8") - Primary
injected into the
Barrier
production string
FAILURE
CAUSE
EFFECT
Lower annulus casing Corrosion (where water

Localised corrosion
split or parted
is present)

split or parted
SYMPTOMS
MITIGATION
Optimisation of
material design and
selection
Good corrosion
time full wall
management strategy
and execution.
Gas lift pressure
leakage into the B
annular valves on B
annulus become
primary barrier.
CRITICALITY
4.3
3.3
A annulus.
Zone 2.4 to 2.6
for the gas to be
(9 5/8") - Primary
injected into the
Barrier
production string
Gas lift pressure

leakage into the B
annular valves on B
annulus become
primary barrier.
Design and
Precipitation of
with ISO and
Embrittlement during Chromium Carbides
B annulus is rated to a equivalent.
manufacturing process under incorrect welding lower pressure than the
2.3
split or parted
A annulus.
(high alloy steels)
and heat treatment
regimes.
monitor annulus
Loss of ductility
pressure.
under normal well
conditions (thermal
loading).
211
SYSTEM
Zone 2.4 to 2.6
SUB-SYSTEM
FUNCTION

(9 5/8") - Primary
mechanical joint
Barrier
between components
FAILURE
CAUSE
EFFECT

metal)
manufacturing
tolerances
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
Instrument monitor
consequently
pressurising the upper facility on upper A
A annulus.
annulus.
Ineffective seal
2.2
Additional loading on Pressure in upper A
the dual bore upper
packer (hydrostatic
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
A annulus.
Zone 2.4 to 2.6

(9 5/8") - Primary
mechanical joint
Barrier
between components

metal)
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
A annulus.
Zone 2.4 to 2.6

(9 5/8") - Primary
mechanical joint
Barrier
between components

metal)
torque
Ineffective seal
2.2
the dual bore upper
packer (hydrostatic
plant operators.
212
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Leakage of gas past

threaded connection
Instrument monitor
consequently
A annulus.
annulus.
Zone 2.4 to 2.6

(9 5/8") - Primary
mechanical joint
Barrier
between components

metal)
seal arrangement

or failed
2.2
the dual bore upper
packer (hydrostatic
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
A annulus.
Zone 2.4 to 2.6

(9 5/8") - Primary
mechanical joint
Barrier
between components
Failure of threaded
connection
Jumping out or
Joint opens
2.2
the dual bore upper
packer (hydrostatic
plant operators.
Leakage of gas past

threaded connection
consequently
Instrument monitor
annulus.
A annulus.
Zone 2.4 to 2.6

(9 5/8") - Primary
mechanical joint
Barrier
between components
Failure of threaded
connection
Shearing of threads

or failed
2.2
the dual bore upper
packer (hydrostatic
plant operators.
213
SYSTEM
SUB-SYSTEM
FUNCTION
Zone 2.4 to 2.6
4. Side Pocket
Mandrels (SPM) Primary Barrier
open on demand
bore string
Zone 2.4 to 2.6
Zone 2.4 to 2.6
4. Side Pocket
Mandrels (SPM) Primary Barrier
FAILURE
open on demand
bore string
CAUSE
EFFECT
Incorrect set pressure
Gas is not injected at

the right level in the
production string
Orifice valve seized closed
Gas is not injected into

the production string
SYMPTOMS
MITIGATION
CRITICALITY
Manufacturers and
designers quality
assurance scheme in
Gas lift is not effective, equivalent.
1.2
well.
Manufacturers and
Gas lift is not effective,
designers quality
assurance scheme in
equivalent.
1.2
Lower A annulus is
pressurised beyond
normal operating
conditions.
5. Chemical Injection Provide a conduit to

Line primary barrier inject chemicals into
rupture
exceeded
Line could split

subject to backpressure
from injection gas
under normal chemical
Chemical injection

well.
Chemical injection
constructed for all
events.
2.3
Chemical injection
pressure should be
pressurised with
monitored by
competent individuals.
Zone 2.4 to 2.6
Combination of
vibration and tension in
line due to slippage of
supports.

rupture
exceeded
Fatigue
Pressure cyclic effects
from injecting.
214
Correct supporting
arrangement.
2.3
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Joint leakage at either

or connection to
production tubing.
Zone 2.4 to 2.6

rupture
exceeded
Incorrect installation
Chemical injection
Chemical injection line constructed for all
subject to backpressure reasonably foreseeable
from injection gas
events.
2.3
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.
Zone 2.4 to 2.6

rupture
exceeded
Corrosion of fittings

subject to backpressure
from injection gas
Chemical injection

pressurised with
215
Corrosion/materials
engineer to ensure
compatibility of
materials with
environment.
2.3
SYSTEM
SUB-SYSTEM
FUNCTION
FAILURE
CAUSE
EFFECT
SYMPTOMS
MITIGATION
CRITICALITY
Upper chemical
Periodic checks of
injection line seal to
dual bore upper packer upper A annulus
takes lower A annulus pressure.
Gas passing from lower pressure. Coincidental
2.2
annulus to upper
failure of upper
annulus
seal to dual bore upper Pressure testing when
packer to upper A
annulus pressurise with installed.
gas.
Zone 2.4 to 2.6
Lower seal between

lower chemical
and dual bore upper
injection line seal
packer
Zone 2.4 to 2.6
Lower seal between

Expansion and
Tubing stab to be
chemical injection line Design working loads Additional tensile loads contraction of annulus designed for all
2.3
are exceeded
imposed on packer
and dual bore upper
tubing in the absence of reasonably foreseeable
packer
a slip joint.
events.
Zone 2.4 to 2.6
Zone 2.4 to 2.6
Upper seal between

upper chemical
and dual bore upper
injection line seal
packer
Failure of upper
packer to upper A
Periodic checks of
annulus pressurise with upper A annulus
gas.
pressure.
annulus to upper
annulus
2.2
Failure of lower
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
chemical injection line Design working loads Additional tensile loads contraction of annulus designed for all
and dual bore upper
are exceeded
imposed on packer
tubing in the absence of reasonably foreseeable 2.3
packer
a slip joint.
events.
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

Health & Safety

Completion component reliability

Crown copyright 2002

This report is made available by the Health and Safety

Dual Completion Model Boundaries ...................................................6

Representative Model Identification....................................................8

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

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

APPENDIX F - SINGLE COMPLETION FMECA RESULTS....................................... 146

Continuous Gas Lift

SINGLE AND DUAL COMPLETION GAS LIFT MODELS

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

Red Primary Active Seal

OPERATING PAR AMETERS

The boundaries of the dual completion model are defined by:

The gas line check valve.

Annulus assembly up to the side pocket mandrels.

The boundaries of the single completion model are defined by:

The gas line check valve.

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.

Representative Model Identification

Primary gas paths.

4.2.2.1. Description Of FMECA Structure

DUAL COMPLETION FMECA

SINGLE COMPLETION FMECA

12. WELLHEAD AND XMAS TREE, STANDARD COMPLETION

14. HIGH ALLOY OCTG, NEW SM SERIES

Figure 1 Single Completion Gas Lift Well Schematic

Figure 2 Dual Completion Gas Lift Well Schematic

Figure 3 Sample FMECA Worksheet

MAJOR COMPONENTS OF THE DUAL COMPLETION MODEL USING A DUAL

Primary gas path

Gas line check valve

HYDROCARBON (WETTED) CONTAINMENT ZONES (WELL IN PRODUCTION)

Gas check valve

Secondary barrier components None

Annulus wing valve

Secondary barrier components:

Zone 1.3 1.4

Annulus upper master valve

Secondary barrier components None

Annulus lower master valve,

Secondary barrier components:

Tubing spool to tree outer flange seal,

Zone 1.5 1.6

Annulus bore Tubing hanger,

Secondary barrier components

VR plug & tertiary valve(s),

Annulus tubing & annulus tubing nipples

Secondary Barrier Components - As per details for zone 1.5 1.6