2006 - KPO – Karachaganak Field (Unit 2 Gas Re-Injection), Kazakhstan
Summary
The Karachaganak Field is one of the world’s largest gas and condensate reservoirs, requiring enhanced gas reinjection techniques to sustain production rates and maximize hydrocarbon recovery. The project involved the installation of high-pressure compressors to reinject produced gas back into the reservoir to maintain pressure and improve recovery efficiency.
Challanges
The key challenge was ensuring the high availability and reliability of the gas reinjection system. High -pressure compression equipment is prone to wear, and failures can lead to significant downtime, production losses, and costly maintenance interventions. Furthermore, ensuring compliance with strict reliability and safety standards was essential due to the high-pressure operating conditions.
Solution
Conducted a detailed RAM analysis to assess system performance and identify potential reliability bottlenecks.
Developed a preventive maintenance strategy for the high-pressure compressors to ensure continuous operations.
Designed a redundancy strategy using Reliability Block Diagrams (RBDs) to optimize reinjection system uptime.
Carried out a comprehensive FMECA study to identify critical failure modes and propose mitigation actions.
Ensured compliance with IEC 61511 through SIL assessments for the safety instrumented functions (SIFs) within the reinjection system.
