2005 - KPO – Karachaganak Fourth Train Stabilisation & Sweetening Train, Kazakhstan
Summary
This project aimed to enhance the gas processing capacity at the Karachaganak field by adding a fourth train to stabilize and remove impurities such as hydrogen sulfide and carbon dioxide from the produced gas. The implementation of additional sweetening units was required to meet product specifications and improve plant efficiency.
Challanges
The integration of the fourth train into an existing operational facility posed significant challenges in terms of process optimization, maintenance planning, and risk management. The reliability of the new train had to be ensured while minimizing the impact on existing operations. Additionally, the sweetening process involved handling corrosive gases, which increased the risk of material degradation and equipment failure.
Solution
Performed a system-wide RAM study to evaluate availability impacts and optimize train configurations.
Developed an integrated maintenance and spare parts strategy to support the new train and ensure minimal disruptions.
Conducted a corrosion risk assessment (CRA) to develop material selection and inspection strategies for the new gas sweetening unit.
Led FMECA workshops to systematically analyze failure modes and implement targeted risk mitigation strategies.
