Condabri Stuffing Box Failures

Incident date Summary

1/18/2014 Polish rod stuffing box passing gas.

1/18/2014 Polish rod stuffing box passing gas.

1/18/2014 Polish rod stuffing box leaking gas

1/18/2014 Polish rod stuffing box passing gas.

1/18/2014 Polish rod stuffing box passing gas.

1/18/2014 Polish rod stuffing box leaking gas

1/12/2014 CON034. Stuffing box dripping water out of drain tube.

1/12/2014 CON034. Stuffing box dripping water out of drain tube.

2/4/2014 At Condabri CON071, a gas leak from the from stuffing

box was detected. The investigation concluded that the
polished rod stuffing box was found to have insufficient
grease and the backing gland nut was loose. No
corrective actions were raised in OCIS.

2/21/2014 At Condabri CON076, a grease nipple in the stuffing

box was passing gas & water. Venting gas was heard.
Excess grease was cleaned up and the nipple was still
leaking. The investigation found that the ball inside the
grease nipple was sticking and not sealing properly.

7/29/2014 At Condabri CON129, water release from stuffing Box

at wellhead
 11/1/2014 At Condabri CON079, Found Stuffing Box leaking on
site inspection - approx. 300 L to surface - Shut Down
well & Isolate. The investigation determined that the
packing assembly had failed due not being greased or
adjusted frequently to maintain firmness of packing
onto the polished rod. The routine visits for this well
had been set at 2 weekly but had actually gone 4
weeks between visits.

2/18/2015 CNN068 stuffing box failied, arrived onsite to find it

passing water to grade. Well was overdue for
inspection, Lessons: more frequent visitation would
help decrease the chances of incident reoccurance.

At CNN018: Stuffing box was passing gas and forcing

grease out of drain, Shut in well and placed work
request to rectify.

4/24/2015 CON045 stuffing box leaking produced water to grade

At CNN143: Incorrect amount of packing rings in well

head stuffing box.

5/9/2015 At Condabri CNNO32 10,000 Litres produced water to

grade from failed stuffing box. Investigation found
polished rod worn by 1 mm.

19/05/2015 At Condabri North CNN009 After Well was bought on

line Operator has observed produced water passing to
grade from Stuffing box and shut well in.

5/29/2015 At CNN029 - CONDABRI NORTH - Passing Stuffing

Gland, water to grade
g Box Failures
Detail
Polish rod stuffing box passing gas.

Polish rod stuffing box passing gas thru tell tale hose.

Polish rod stuffing box leaking gas thru tell tale hose.

Polish rod stuffing box passing gas.

Polish rod stuffing box passing gas thru tell tale hose.

Polish rod stuffing box leaking gas thru tell tale hose.

CON034. When applying permit isolations it was

observed that the drain tube was dripping water
from the stuffing box packing.

CON034. When applying permit isolations it was

observed that the drain tube was dripping water
from the stuffing box packing.

CON 071 stuffing box was passing gas through the

collar around the polished rod on arrival at the lease
for a pump restart. An unknown amount of fluid had
also been passing whilst pump was running. Moisture
was noticed in the shaded area below some
pipework attached to the well head.

Conducting well reads and noticed that grease had

been oozing out of grease nipple and had built up
around the nipple itself. Upon further investigation I
heard a venting sound. Once cleaned off excess
grease nipple still passing.

While at well site CON129 it was observed that there

was process water coming out of the stuffing box at
the wellhead. This water was flowing down the pump
onto the lease pad.
CON079 - Found Stuffing Box leaking on site
inspection - approx. 300 L to surface - Greased 3
times & tighten up gland nut, still leaking - Contact
Mark Fulwood - Shut Down well & Isolate

CNN068 stuffing box failied, arrived onsite to find it

passing water to grade

While performing routine duties I have observed that

the Stuffing box was passing gas through the drain
from the packing.

CON045 discharging produced water to grade

through the stuffing box discharge tube. Water was
contained to well lease area

Whilst replacing the gland packing in the wellhead

stuffing box, found there to be 1 Yellow Kevlar
packing ring missing.

CNN032 stuffing box failed, arrived onsite to find it

passing produced water to grade.

Well site was bought online after some I&E

maintenance work and when pump was running it
was observed that produced water was passing to
grade via the stuffing box on the drive head.

Arrived on site to carry out routine inspection and

found that the stuffing box was leaking water to
grade (approx 100L)
 Incident Field
Incident date Reported Date Number Name
10/1/2014 10/1/2014 INC- Reedy
137273 Creek

10/29/2014 OBS- Reedy

304263 Creek

11/18/2014 11/18/2014 INC- Reedy

138416 Creek
1/12/2015 1/12/2015 INC- Reedy
139528 Creek

1/17/2015 OBS- Reedy

320180 Creek

2/3/2015 2/4/2015 INC- LNG

140012 Reedy
Creek
 2/7/2015 2/8/2015 INC- Combabul
140109 a

2/24/2015 2/24/2015 INC- Reedy

140434 Creek

3/27/2015 OBS- Reedy

336111 Creek

3/31/2015 OBS- LNG

336649 Reedy
Creek
351002.14
01.1257

6/8/2015 OBS- Reedy

353056 Creek
Operation
s

6/15/2015 6/15/2015 INC- Reedy

142536 Creek
Operation
s
6/26/2015 6/26/2015 INC- Reedy
142733 Creek
Operation
s
 Actual Potential
Highest Highest
Conseque Conseque
Summary Detail nce nce
At Combabula COM415, loss of 3.4 Other LOPC, A.12 Plant Piping, B.1 1 - Minor 1 - Minor
production water containment at Wellhead Onshore, C.12 Product
stuffing box on well head. The Quality
investigation determined the
possible causes to be the gland
packing has dried out after initial
installation to the time of first drive Production water loss of containment
head start up and could be prone to was found at wellhead. Leak was from
failure. drivehead stuffing box. An estimated
200 litres of water was released to
grade.

Wellhead was noted to have minor

leak 5 days earlier and was greased
which stopped the leak. Well was
visited 2 days prior and no leaking
was detected.

At Combabula COM372, Gas leak Small gas leak from drive head 1 - Minor 1 - Minor
from stuffing box stuffing box detected.

At Reedy Creek RCK089, Operator found 3-4000L of produced 1 - Minor 2 -

approximately 3-4000L of produced water and solids had gone to grade Moderate
water and solids went to grade as a from the stuffing box. Spill was half
result of stuffing box failure within the lease, half on rehabilitated
area.
At RCK030: Approximately 2-3000L
of a mixture of produced water and
solids went to grade due to solids.
Gas was also observed passing from
the hose on the stuffing box cap at
the time.
At COM235: Gas venting from
stuffing box tube.
COM 322 stuffing box failure
resulting in 3-4000L of produced
water going to grade
Operator was notified by WCS of 1 - Minor 2 -
water on the lease at RCK030, upon Moderate
further inspection it was found that
produced water and solids had gone
to grade (approximately 2-3000L). The
majority of the solids were contained
within the well lease. Gas was also
observed passing from the hose on
the stuffing box cap at the time. The
stuffing box had been inspected by a
Mechanical Technicial 3 days prior.
The stuffing box was found to be
leaking at the time of the inspecting,
so it was tightened and greased. The
stuffing box had been replaced 3
months prior to the incident. A
chemist had taken a sample 3 days
prior to the incident and noted that
the well had a high solids content.
This was reported to the field
supervisor.
Walk down of wellsite, revealed gas 1 - Minor 1 - Minor
venting from the rubber tube that
comes from the stuffing box.
Well shut down overnight on low 1 - Minor 2 -
production, BCCR tried to restart well Moderate
3 times, well failed to start. BCCR
notified Field Supervisor, who sent an
operator out to investigate. Operator
found the stuffing box had failed due
to high solids concentrations,
resulting in 3-4000L of produced
water to grade. The spill was
contained within the lease.
At COM349: Mechanical failure of
stuffing box seals resulting in
production fluids to grade. Minor
consequence < 2000 litres.
At COM370: Stuffing box failure
resulting in spill of solids and
produced water to grade
COM283 stuffing box packing
slightly passing water, stopped
when greased stuffing box. Work
request raised (11256034) to
replace packing.
COM284 Stuffing box slightly
passing water. stopped when
greased. Work Request raised
(11256217)
At Reedy Creek Operations -
Wellsite COM 209 - Leaking stuffing passing from the stuffing box.
box
At Reedy Creek COM117 a failure of Failure of stuffing box on well head at 1 - Minor 1 - Minor
stuffing box on well head at
COM117 and release of CSG water. water (est 800L). COM117 was
Visited site after learning well had 1 - Minor 1 - Minor
shut down 4 days prior with torque
issues. Access to site is restricted by
rain run-off currently. Found well
fluids had bypassed packers and
leaked to grade presumably around
the time of shutdown as the fluid had
evaporated and all that remained was
the solid residue.
Stuffing box failure at Com370 1 - Minor 1 - Minor
resulting in spill of solids and
produced to grade.
COM283 stuffing box packing slightly 1 - Minor 1 - Minor
passing water, stopped when greased
stuffing box. Work request raised
(11256034) to replace packing.
COM284 Stuffing box slightly passing 1 - Minor 1 - Minor
water. stopped when greased. Work
Request raised (11256217). Photo
attached.
Arrived at wellsite to find water 1 - Minor 1 - Minor
COM117 and release of muddy CSG
recently handed over by WCS with
latest reads on 7/6/15. Today is the
first site visit by a field operator since
handover.
Combabula wellsite COM117 was
found to have a stuffing box failure
resulting in approximately 500L of
solids and produced water going to
grade. Investigation: formation
material in production fluid abrasive
to standard packing seals. Standard
stuffing box assembly replaced with
Onyx version.
BCCR had identified that there was an 1 - Minor 2 -
issue at COM117 and requested an Moderate
Operator to investigate. A senior
operator went to the site to
investigate and found that
approximately 500L of solids and
produced water went to grade.
 Incident Type
Environmental, Process
Incident

Safety

Environmental
<Undefined>

Safety

Environmental, Process
Incident
<Undefined>

Environmental, Process
Incident

Other

Other

Environmental

Environmental, Process
Incident
Environmental
 Date of failure Well Tag
1 1/18/2014 _

2 1/18/2014 _

3 1/18/2014 _

4 1/18/2014 _

5 1/18/2014 _

6 1/18/2014 _

7 1/12/2014 CON034

8 2/4/2014 CON071

9 2/21/2014 CON076

10 7/29/2014 CON129

11 11/1/2014 CON079

12 2/18/2015 CNN068

13 _ CNN018

14 4/24/2015 CON045

15 _ CNN143

16 5/9/2015 CNN032
19/05/2015
17 CNN009

18 5/29/2015 CNN029

19 7/5/2015 CNN025

20 7/9/2015 CNN059

21 7/27/2015 CNN337

22 7/30/2015 CNN003

23 8/7/2015 CNN003

24 8/12/2015 CNN132

25 8/13/2015 CNN144

26 8/13/2015 CON193

27 8/13/2015 CNN043

28 8/30/2015 CON242
29 9/6/2015 COM205

30 9/8/2015 CON226

31 9/13/2015 CNN023

32 9/16/2015 CON086
 Failure Date
Well Tag
1 10/1/2014 COM415

2 10/29/2014 COM372

3 11/18/2014 RCK089

4 1/12/2015 RCK030

5 1/17/2015 COM235

6 2/4/2015 COM 322

7 2/8/2015 COM349

8 2/24/2015 COM370

9 3/27/2015 COM283

10 3/31/2015 COM284

11 6/8/2015 COM 209

12 6/15/2015 COM117

13 6/26/2015 COM117