KPO Starts Gas Reinjection at Karachaganak Field, Kazakhstan

Karachaganak Petroleum Operating BV (KPO) has initiated formal gas‑reinjection operations for the KEP‑1B expansion project at the giant Karachaganak gas‑condensate field in north‑western Kazakhstan. The core of this expansion is the newly commissioned sixth gas‑injection compressor (6IC), which forms the heart of the reservoir pressure maintenance scheme.

Discovered in 1979, Karachaganak ranks among the world’s largest gas‑condensate fields, covering more than 280 square kilometres. Its initial hydrocarbon‑in‑place resource is estimated at 13.6 billion barrels of liquids and 59.4 trillion cubic feet of natural gas. Without continuous pressure support, reservoir pressure would gradually decline, condensate output would drop rapidly, and the plateau production period would be shortened significantly.

The KEP‑1B project received final sanction in November 2022. Project scope includes the new high‑pressure gas‑injection compressor train, a full gas dehydration unit, expansion of field gathering pipelines, reinjection network upgrade and supporting utility systems. The new gas‑injection compressor is designed to handle large‑volume produced gas and boost it to required reservoir injection pressure for reinjection back into the formation.

Before the 6IC went online, existing injection facilities were already running near full load. The addition of this gas‑injection compressor raises total gas‑processing capacity and lifts the maximum gas‑reinjection rate. By reinjecting surplus produced gas into the reservoir, operators stabilise downhole pressure, preserve condensate output and prolong the field’s production plateau.

Field engineers note that the gas‑injection compressor operates under severe service conditions: high suction flow rate, wide fluctuation of gas composition, and persistent high discharge pressure requirement. Stringent mechanical and performance acceptance tests were completed prior to hand‑over, including 72‑hour continuous full‑load running test to verify vibration, temperature, sealing and overall reliability for long‑term 24‑7 field operation.

KPO’s long‑term strategy for Karachaganak relies heavily on pressure‑maintenance via gas reinjection. The KEP‑1B expansion with the new gas‑injection compressor is a critical milestone. Moving forward, KPO will continue monitoring injection performance, optimise compressor operating parameters and evaluate further expansion options to maximise ultimate recovery of both natural gas and condensate resources from this giant field.