Asset Integrity and critical incident management

ASSET INTEGRITY

KPO monitors potential threats to its operations and mitigates Asset Integrity risks through its barrier management system. The Asset Integrity department together with the Units continuously assess the health status of the safety barriers to identify weaknesses, implement mitigating measures and establish plans to re-instate these barriers to its original design to prevent any major accident.

The Asset Integrity Management Framework is a set of processes to prevent major accident hazards and to raise Asset Integrity and Process Safety awareness amongst the KPO employees, contractors and subcontractors working at the Karachaganak field.

The Asset Integrity Framework Management System consists of the following key processes:

• Barrier Management – through the application of a structured process supported by the using of the Barrier Model tool;
• Asset Integrity Performance Analysis – through the use of Key Performance Indicators;
• Management of Change system for Brownfield Modifications – through the use of the Management of Change database;
• Asset Integrity Assurance – through the use of reviews, audits, verifications and assessments;
• Asset Integrity Improvement Culture initiatives – through the production of e-Learning modules on the Mechanical Isolation Procedure, Process Safety Fundamentals and the Barrier Model process.

In 2023, KPO Asset Integrity department has been working on further enhancement of the Barrier Model software at operational facilities/units in terms of their ownership of the BM and its and integration with other software applications. A Cumulative Risk Assessment methodology was developed and introduced to address these. Monthly BM review meetings with units were exercised. Training of newcomers has been continued.

In order to minimize asset integrity risks, we have set a number of 2023 of targets. The results of their implementation are presented further in the table.

Graph 1.Loss of Primary Containment at KPO by process facilities, 2021–2023 OG13

Within 2023, KPO has undertaken a number of activities addressing the key risks or barriers in the KPO asset integrity, including process containment and remediation of risks. Amongst those there were Process Containment remedial works and replacement of some items and inoperable equipment. 26 Barrier Model risks were resolved – 10 high risks, 14 medium and 2 low risks. The activities were focused on ensuring BM risk records have effective mitigations and BM Items have effective recovery plans in place. Training and coaching of operational staff in the use of Barrier Model application is ongoing.

In 2024, the following key activities are planned on Barrier Management process:

• Continue conducting Unit BM pre-meetings with Unit focal points and monthly Unit BM meetings as per 2024 schedule.
• Continue verification of the effectaiveness of mitigation measures and recovery plan implementation.
• Support BM integration for upcoming new projects.
• Continue staff training and awareness; organize BM roll-out sessions and BM e-learning for new-comers or staff new in their role.
• Support the closure of BM risks and recording the new Unit BM risks.
• Strengthen the barrier management process. Integrate BM risks identified from compliance assurance activities of key processes and risks associated with operational integrity critical processes.
• Promote, motivate and coach Units in the usage of BM Dashboard and Asset Integrity / Process Safety dashboards.
• Integrate Safety Critical Elements’ deferral / backlog into Barrier Model to enhance granularity of cumulative risks assessment.

Spills

In 2023, no cases of significant spills¹ were recorded at the territory of the Karachaganak field.

CRITICAL INCIDENT MANAGEMENT

In case of any incident, accident or emergency, KPO operates a robust three-level Emergency Response system used to trigger a prompt response, assessment of emergency scale, planning and implementation of actions to localize and eliminate emergency and its consequences. The system is graphically shown on figure 6.

Fig. 6.KPO emergency response system

In 2023, KPO continued training of Incident Management Team in accordance with the approved schedule.

Weekly, theoretical and practical trainings were carried out throughout 2023 with the involvement of KPO Civil Protection Units, namely:

• firefighting teams,
• gas rescue team,
• voluntary emergency-rescue team,
• medical units.

Totally, 43 drills have been conducted with the involvement of KPO Civil Protection Units at the training area.

Moreover, in 2023, KPO continued training of staff in civil protection via the e-learning system, as required by the RoK legislation.

In 2023, as part of ensuring the readiness of level I forces and resources, all Company’s hazardous production facilities conducted monthly emergency response drills with the involvement of the Facility Incident Command Team (ICT), emergency rescue teams and KPO and contractors’ personnel.

The total number of emergency response drills conducted in 2023 at KPO facilities for the purpose of exercising the actions of level I incident command teams and emergency rescue units amounted to 113 drills (114 in 2022).

Also, in accordance with the requirements of Order of the Minister of the RoK Emergency Response dated 16.07.2021 #349 “On approval of guidelines to develop Emergency Response Plan and conduct emergency response drills at hazardous production facilities” 13 emergency training exercises were conducted, of which 7 emergency training exercises were carried out with involvement of the II FIMC level.

In 2023, practical training was held for donning filter hood:

• AVON NH – 15, 1,677 people were trained in 50 classes,
• SCBA – 802 people were trained in 54 classes.

Graph 2.Emergency response drills completed in 2021–2023

The level II and III centres’ members took part in the following real mobilizations and drills, which allowed maintaining the readiness level:

Table 5.Level II and III drills conducted in 2023

Community preparedness

KPO maintains awareness of the community on the procedure for responding in case of emergency situation at the Karachaganak Field and along the export pipeline KATS and general fire safety requirements during fire hazard period.

In 2023, following the approved plan, 22 meetings were held for 184 people with the rural districts Akims and the community located around the Field to discuss such issues as: importance of the central monitoring station, village alarm stations and their intent, abidance by fire safety regulations during farming operations in fire hazard period.

21 meetings were held for 193 people from settlements located along the export pipeline KATS in the Indirborskiy, Makhambetskiy regions of Atyrau Oblast.

12 practical drills with activation of a single warning signal “Attention All” and use of the Village Alarm stations equipment were carried out to exercise joint actions of the rural districts Akimats and responsible people when managing evacuation of the community in case of threat from the field area, interaction with ECC Dispatcher. 133 people were involved during practical drills.

21 MEETINGS WERE HELD FOR 193 PEOPLE FROM SETTLEMENTS LOCATED ALONG THE EXPORT PIPELINE KATS IN THE INDIRBORSKIY, MAKHAMBETSKIY REGIONS OF ATYRAU OBLAST.

Additional C-40 sirens were installed in villages Priuralniy and Zharsuat for activation of single warning signal “Attention all” for coverage of the 100% villages population.

GSM block was installed at Dimitrovo village for remote activation of C-40 siren in this village.

To maintain constant readiness of village alarm stations, throughout the 2023, the Community Protection Specialist of the KPO Emergency Response Team jointly with contractor representatives carried out monthly testing of emergency alarm signals and public address systems, as well as the maintenance of this equipment. Such village alarm stations are installed in seven villages that are situated around the Field.