Asset Integrity

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

Implementation of the Asset Integrity Management System commenced in 2014, and is facilitated by the Asset Integrity Department. The following core tools are used in the process:

  1. Asset Integrity Barrier Model;
  2. Asset Integrity Key Performance Indicators (KPIs);
  3. Management of Change system for brownfield modifications;
  4. Process Safety Fundamentals campaign.

In 2018, the four asset integrity tools were further applied and developed.

KPO Asset Integrity Barrier Model

KPO Barrier Model is a database, which applies a widely used ‘Swiss Cheese’ model that provides a visual risk-oriented analysis of each KPO process facility. Today, the Barrier Model covers all significant risk areas and is notably used for decision-making.

Available on the KPO portal, the tool has involved over 200 users in 2018. Throughout 2018, the KPO Asset Integrity department has continuously upgraded the process of integration and interaction between all KPO departments to enable communication, escalation and follow-up of KPO’s significant risk issues.

APPLICATION OF THE ‘SWISS CHEESE’ MODEL

альтернативный текст

Overall 2018, KPO has identified 31 risks, 23 of which were reduced to the manageable level or eliminated.

In 2018, the Asset Integrity department has been working on a film to introduce an explanation of general principles applied in KPO Barrier Model with regard to process safety risk management. The aim of the film is to improve the Process Safety awareness of operations personnel that is one of the keys to preventing major accidents.

In 2019, the new Barrier Model software will be rolled out with increased functionality, thus enabling KPO to improve efficiency of the process with increasingly «live data» and reduce the response time to potential hazards.

Monitoring of Asset Integrity Performance

The objective of the KPO Asset Integrity KPIs is to identify and prevent events or conditions that could lead to higher level consequences. KPO monitors both lagging and leading indicators in line with relevant industry standards based on the API Recommended Practice API RP 754, OGP recommendations, ENI and Shell guidelines on the Asset Integrity KPI reporting. Properly defined and interpreted AI KPIs give KPO and its stakeholders confidence that the identified risks are being managed to prevent of major incidents.

The Asset Integrity KPIs are used to evaluate the conditions of the physical assets in terms of Process Safety and they provide the status of the following areas:

  1. Process Containment
  2. Safety Systems
  3. Static Equipment Integrity
  4. Alarm Management
  5. Ignition Control
  6. Maintenance Efficiency
  7. Well Integrity
  8. MOC Management
  9. Risk Management

A gap analysis of KPO Asset Integrity KPIs against the industry practice resulted in a revision of KPO Asset Integrity KPIs Scorecard as of March 2018. In line with AI KPI Scorecard a Process Safety Dashboard was developed to show the status of main KPIs graphically over time to identify trends and act on them.

Based on these KPIs, internal/external audits, and incidents, several projects were started or scaled up, such as the Alarm Rationalization project, material vulnerability checks and replacement and development of an enhanced Pre Startup Safety Review process.

The following results were achieved by the proactive use of KPIs in 2018:

  1. Despite the reduction of the Safety Critical Element (SCE) Work Orders backlog grace window from 28 days to 7 days, zero overdue SCE maintenance Work Orders were registered in the backlog for almost the whole year, showing a clear step up in SCE management;
  2. In 2018, Number of Tier 1 Loss of Primary Containment (LOPC) events decreased from two to one in comparison with the 2017 performance;
  3. A series of Gap Analyses in the Alarm Rationalisation Programme were completed for each Production Facility. The Alarm Rationalisation Methodology document (Phase I) was issued.

Loss of Primary Containment

Management and analysis of major accident hazards is the key to prevent or reduce the likelihood and severity of process safety events. Once a main Process Safety event occurs, an appropriate level investigation is carried out. The related data, findings, root causes and recommend actions are entered into the KPO Synergi database for further actions tracking and monitoring.

The statistical analysis for 2014-2017 shows that the number of Loss of Primary Containment (LOPC) events increased 30% in 2018 against the 2017 performance; however, the incidents severity reduced — only one Tier 1 and no Tier 2 Process Safety events were registered.

Loss of Primary Containment by process facilities, 2016-2018

Legend:

Process Safety Event Tier-1 refers to a number of Losses of Primary Containment events related to the process with greatest consequences (reportable to IOGP);

Process Safety Event Tier-2 refers to a number of Losses of Primary Containment events related to the process with lesser consequences (reportable to IOGP);

Process Safety Event Tier-3 refers to a number of other Losses of Primary Containment events related to the process. These events are not reportable to IOGP and are collected by Company for internal analysis and lessons learning.

Alarm Rationalisation Project

In 2017, KPO initiated the Alarm Rationalisation Project. The objective of this project is (1) to define consistent criteria for specifying process alarms and their priorities, (2) to apply these criteria in the existing assets of KPO, and (3) to implement the required changes to all relevant systems. All activities were split into three phases:

  • Phase I — Initial evaluation (completed): series of Gap Analysis were performed for each Production Facility (KPC, Unit-2, Unit-3, EOPS, Bolshoi Chagan and Atyrau Terminal), and an Alarm Rationalisation Methodology document (Phase I) was issued;
  • Phase II — Alarm Rationalization exercise (started in 2018, ongoing): a series of workshops based on the Phase I review;
  • Phase III — Implementation (planned for 2020): the outcome of the Rationalization exercise will be physically implemented in the existing automation systems by Maintenance department.

After completion, the Alarm Systems will be in full compliance with international standards (IEC 62682 & ANSI/ISA—18.2 — Management of Alarm Systems for the Process Industries). This prevents alarm flood and will enable the Control Room Operators to focus on critical alarms.

Management of Change

Based on internal and external reviews by the KPO Parent Companies, further improvements were implemented in the process of change management. Enhancements in efficiency, design reviews including official sign-off, and pre-startup checks were done to ensure robustness in any change before going live.

Process Safety Fundamentals campaign

Process Safety Fundamentals (PSF) are the learnings from significant Process Safety incidents in the O&G industry. KPO adopted the Shell PSF campaign materials and launched the campaign in August 2017.

The aim of the PSFs is to reduce the number of process safety incidents by putting extra emphasis on the routine on-site activities and requirements to reduce unsafe acts and conditions. The campaign was targeted at the frontline operations personnel both of KPO and contractors. To deliver this message, the Asset Integrity team conducted the roll-out presentations along with dissemination of visual materials (billboards, posters and plastic cards) across the field locations.

The Process Safety Fundamentals’ campaign achievements of 2018 year are the following:

  • PSF management roll out sessions were conducted for the contractors;
  • Six new PSF categories were added in the HSE Card, and ‘Best Process Safety card’ award category was introduced to the HSE Incentives programme;
  • PSF popup messages have been displayed on every KPO PC screen twice a week.

In 2019, further efforts will focus on embedding the Process Safety Fundamentals into our daily work including newcomers in projects implementation and increased maintenance activities.

KPO will continue building a process safety oriented culture and reinforcing a proactive approach to managing major accident hazards. The final objectives are:

  • to develop and lead the Asset Integrity and Process Safety activities as a joint effort of all KPO functions, able to avoid major accidents;
  • to establish and operate practical and effective Barrier Management principles that are understood, implemented and seen as the preferred choice by front-line users.