2010 - Eni, Karachaganak Phase II, Kazakhstan
Summary
The Karachaganak Phase II project was a major expansion of one of the world’s largest gas and condensate fields. The development focused on increasing production capacity, improving gas processing, and optimizing reinjection systems to maintain reservoir pressure.
Challanges
Operating in extreme weather conditions, with temperatures fluctuating from -40°C in winter to over 40°C in summer, posed significant challenges to equipment reliability. Additionally, the integration of high-pressure gas reinjection systems required rigorous safety and reliability assessments.
Solution
Conducted detailed RAM studies to model system availability and optimize maintenance schedules.
Performed functional safety assessments, ensuring compliance with IEC 61511 to mitigate risks associated with high-pressure gas reinjection.
Applied failure mode and effects analysis (FMECA) to identify critical components and improve operational resilience.
Developed a risk-based inspection (RBI) program to reduce unplanned downtime and extend equipment lifespan.
