Turnaround
The KPO Turnaround strategy is focused on optimisation of production and minimisation of cost by maximising intervals between turnarounds and through the reduction of actual turnaround durations. This must be achieved whilst ensuring safe, reliable continuous operations and regulatory compliance. Historically, all KPO Units had full field turnarounds every 3 years.
During 2023, an extensive technical review covering equipment maintenance strategies and regulatory сompliance led to the approval of extending the full field turnaround interval from three to four years, effective from 2022. The next full field turnaround is thus scheduled for 2026.
The turnaround strategy executed in 2024 aligned with previous years. Generally, a full field turnaround is a massive undertaking, creating a heavy workload for both KPO and contractor staff and equipment. KPO seizes opportunities to execute smaller shutdowns of individual production trains whenever possible to minimise peak workload during full field turnarounds and reduce HSE risks associated with concurrent activities.
In 2024, Unit 3 conducted individual train outages and a short full unit pit stop for scheduled maintenance from April to September. The scope included replacement of E108, E208 & E408 heat exchangers, routine preventive and maintenance work, and minor modifications.
Unit 2 conducted annual scheduled maintenance on injection compressors, covering minor inspections and PSV re-certification on compressors 360 A/B/C/D, as well as statutory maintenance, from 18 August through 29 September 2024.
KPO is the Operator of the Karachaganak oil and gas condensate field (KOGCF) which is located in North-West Kazakhstan and covers an area of over 280 km2. Karachaganak is a unique field with complex operating conditions, not in the least due to extreme continental climate. The field is some 1,600 m thick and very complex and unique with its top at a depth of around 3,500 m. The extracted hydrocarbons contain up to 4.5 % of highly toxic and corrosive hydrogen sulphide (H2S), as well as carbon dioxide (CO2) which can be highly corrosive in certain conditions. / GRI 2-1 /
According to the latest Reserves Re-Determination Report for the Karachaganak field (accepted by the RoK State Reserves Committee (GKZ) on 17.11.2017), it is estimated that the Karachaganak Field contains some 13.6 billion barrels of liquids and 59.4 trillion cubic feet of gas, of which approximately 16.1 % of liquids and 15.1 % of gas have been recovered as of 2024. / OG1 /
The Company invests heavily into the application of leading-edge technologies to maximize sustainable economic value and minimise environmental impact. The total investment in the development of the Karachaganak oil & gas condensate field since the signing of the FPSA in 1997 to 31.12.2024 has totalled over USD 32.8 bln. As of end 2024, 4,080 people worked in the KPO organisation.