As a contractor to the Republic of Kazakhstan, the Karachaganak Field is committed to executing all operations necessary to develop the field and produce petroleum in accordance with Good Oilfield Practice.
Following the completion of the Karachaganak Phase II Initial Programme in 2003, development efforts have included a continuous work programme. This encompasses drilling new development wells, performing workovers on existing wells, upgrading production facilities, and carrying out other essential projects to sustain high production levels.
Since 2014, to address challenges arising from increased gas-oil-ratio (GOR) that could constrain existing facilities, a series of Production Plateau Extension Projects (PEP) have been initiated. Key projects within this programme include:
KPC Gas De-bottlenecking (KGDBN) Project: This project aims to enhance the overall gas processing capacity at the Karachaganak Processing Complex (KPC) by expanding its gas handling capabilities.
4th Gas Reinjection Compressor (4IC) Project: This initiative is designed to increase the daily average volume of gas re-injected into the reservoir, thereby improving reservoir pressure support.
5th Trunkline and Gas Reinjection Wells Projects: These projects involve upgrading the gas injection network downstream of Unit 2 by installing a new trunk line and drilling new gas injection wells.
The PEP projects have progressed over time, with the 5th Trunkline and Gas Reinjection Wells Project beginning in December 2019 with the first of three new injection wells.
In March 2021, the KPC Gas De-bottlenecking (KGDBN) Project was successfully completed, and the plant was brought into production by the end of 2021. Similarly, the 4th Gas Reinjection Compressor (4IC) Project was finalized and operational by May 2022, with the final handover to Operations completed within 2022.
Karachaganak Expansion Project
The Karachaganak Field is further developing through the Karachaganak Expansion Project Phase 1 (KEP1), which is being implemented in stages. The KEP1 Project aims to sustain the stabilized liquid plateau by adding new wells, process facilities, and gas reinjection capabilities to manage the increasing GOR.
In December 2020, the Karachaganak Parent Companies authorized the KEP1A Project, marking a significant milestone in the field’s development. The KEP1A Project, the first phase of KEP1, includes the 5th Injection Compressor (5IC) and associated facilities. This phase utilizes the dehydration capacity added by the KGDBN Project to enhance gas reinjection and integrate new infrastructure with existing systems. Early works and temporary construction facilities were completed ahead of schedule in 2021, with engineering largely completed and major equipment orders placed in 2022. The compressor was delivered as planned, and vendor manufacturing and construction activities are ongoing.
On November 25, 2022, the Karachaganak Parent Companies and the Authorized Body (PSA LLP), supported by the Ministry of Energy of Kazakhstan, sanctioned the KEP1B Project. This second phase of KEP1 includes the 6th Injection Compressor, a gas dehydration unit, an expansion of the gathering network, and associated facilities. Like KEP1A, KEP1B aims to increase liquid recovery by optimizing existing facilities. Contracts for critical long-lead items were placed in 2022, and construction activities are set to begin in 2023. The project also prioritizes local content and provides job opportunities for Kazakhstani workers.
Additionally, the 6th Trunkline and 3 Injection Wells Project aims to maximize liquid recovery by expanding the field’s injection area. This project will re-distribute injection gas to the South West Frank area of the field, supporting pressure in nearby low GOR wells and improving reservoir management. The trunkline was completed in September 2021, with gas injection into the first new well expected later in 2023 and the remaining two wells to follow in early 2024.
