Asset Integrity

The key target of Asset Integrity is to prevent major incident hazards. As defined by the IOGP Standard no.456, Asset Integrity is achieved when facilities are structurally and mechanically sound, perform the processes and produce the products, for which they were designed.

KPO is committed to monitoring potential threats to its operations and continue working on mitigation of high risks through the safety barrier system. KPO’s Asset Integrity department continuously assess the ‘health status’ of the safety barriers to identify ‘holes in the barriers’ and to prevent any accidents.

The objective of KPO Asset Integrity is to prevent major incidents and reduce risks to people, environment, assets, and the Company’s reputation. In order to reduce the risk, we have defined barriers that relate to plant, people and processes, thus managing the major accident hazards to a level that is as low as reasonably practicable.

KPO Asset Integrity Management System is a set of measures to prevent major accident hazards and to raise hazard awareness amongst the KPO employees, all contractors and subcontractors working at the Karachaganak field.

Loss of Primary Containment (LOPC) is an unplanned or uncontrolled release of any material from primary containment, including non-toxic and non-flammable materials. The KPO 2020 Loss of Primary Containment Report provides for the analysis of the LOPC incidents that occurred during 2020 along with their defined recovery actions in terms of:

  • Root causes (in accordance with Incident Investigation Tap Root Methodology),
  • Level of compliance with Process Safety Fundamental rules,
  • Status of corrective actions,
  • Weeps & Seeps Leaks Register data.

Management and analysis of major accident hazards is the key to prevent or reduce the likelihood and severity of process safety events. Once a Process Safety event occurs, the investigation process is initiated with logging it in the KPO Synergi database. KPO investigation team analyse the root causes and develop recommendations and an action plan. Further implementation of actions is monitored via the Synergi database.

Statistical analysis for 2018-2020 shows that the number of LOPC events increased by 12% in 2020 against the 2019 performance, and the incidents severity was also increased. Only one Tier 2 Process Safety event occurred at KPC: gas leak at KPC Flash Gas Compressor building as shown on the graph.

Loss of Primary Containment at KPO by process facilities, 2018-2020

Note: For Process Safety Event definition (Tier-1/2/3), please refer to the International Standard IOGP 456.