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 was carried out covering all aspects associated with defining interval frequency such as Equipment Maintenance strategies and regulatory сompliance. The outcome of this review approved the implementation of an extended full field interval extension from 3 to 4 years commencing from 2022 onwards. This schedules the next full field turnaround to 2026.
The strategy for turnarounds executed in 2023 was in line with previous years. Generally, a full field Turnaround is a massive undertaking resulting in a huge workload for both KPO and contractor staff and equipment. KPO takes the opportunity to execute smaller shutdowns of the individual production trains wherever there is an opportunity window as this minimises the peak loading during full field turnarounds and reduces HSE risks related to concurrent activities at the units.
During 2023, Unit 3 conducted individual train outages and a short full unit pitstop for scheduled maintenance activities. These were carried out from May through to September: the scope in these outages covered E209 Heat exchanger replacement, routine P&M scope as well as minor modifications.
There was also a full field pitstop involving all Units for 24 hrs on 11th September 2023, which was necessary to conduct project tie-in work at KPC associated with KEP 1A 5th Injection Compressor scheduled start-up date in 2024.
Unit 2 conducted annual maintenance scheduled work on injection compressors. The work executed covered dry gas seal replacement on re-injection compressor 360C and minor inspection/PSV re-certification on compressors 360 A/B/D, as well as statutory maintenance within the period from 11 September through 30 October 2023.
NEXT FULL FIELD TURNAROUND IS PLANNED IN 2026.
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.
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 15.5 % of liquids and 14,5 % of gas have been recovered as of 2023.
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 31.12.2023 has totalled over USD 31.3 bln. As of end 2023, 4,080 people worked in the KPO organisation.