This document appears to be an internship presentation summarizing an internship at a production operations department from March 1-31. It includes sections on safety moments/rules, the history of the Kashagan project development, an introduction of the intern and internship program scope, the intern's work assignments and duties, and outcomes from the internship. The intern spent 17 active days with training, orientation, and working on tasks like understanding the flare system scope and performing control valve sizing calculations.

1. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
Title Directorate/Title Department : Production Operations
Student’s Name : Nartay Rabayev
Internship Period : 1 – 31 of March
Internship Presentation

2. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
CONTENT
2
1. Safety moments/ 12 Golden rules
2. Kashagan Project Development history
3. Intern General introduction
4. Internship Program Scope
5. Overall activities, roles and responsibilities in the company
6. Work Assignments of intern (Duties and Responsibilities)
7. Internship outcomes (Skills/Benefits)

3. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 3
BRIEF REVIEW
17 days(active) without holidays and
rest days:
1 day - Safety Training, getting
accesses to EDMS, Dep:O(folder),
Power BI, etc.
2 days – OPF Intro, writing notes (70
pages document)
1 day - PSBR 6, Safety rules
8 days – Flare system introduction
and understanding the scope of work
5 days for Control Valve sizing
calculations

4. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
Safety Moments
4

5. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 5
LIFE SAVING RULES # 1, 2, 3

6. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 6
LIFE SAVING RULES # 4, 5

7. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 7
LIFE SAVING RULES # 6, 7, 8

8. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 8
LIFE SAVING RULES # 9, 10

9. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
Kashagan Project Development
9
The North Caspian Project is the first major offshore oil and gas
development in Kazakhstan. It covers three fields: Kashagan,
Kairan and Aktoty.
The giant Kashagan field ranks as one of the largest oil
discoveries of the past four decades, with approximately 9-13
billion barrels (1-2 billion tones) of recoverable oil. The Kashagan
reservoir lies 80km offshore from the city of Atyrau in 3-4 meters
of water, and is more than 4km deep (4,200 meters).
In 2016, the first offshore oil in the history of Kazakhstan was
commercially produced from Kashagan. The Operator of the
project, North Caspian Operating Company N.V. (NCOC),
completed a major pipeline replacement project ahead of
schedule and on September 28 re-opened the first wells offshore.
The President of Kazakhstan, Nursultan Nazarbayev, honored the
project workers and veterans with a personal visit to Atyrau on
December 7, 2016.
The first million tones were exported in the first days of 2017,
and NCOC safely reached actual production levels of over
200,000 barrels per day in mid-2017.Given its scale and technical
complexity, the North Caspian project will be developed in
phases. The estimated cost of Kashagan Phase 1, which began
commercial production in 2016, is about US$55 billion.

10. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
Project Milestones
10
In 2017, NCOC and its shareholders marked the 20th anniversary
of the signing of the North Caspian Sea Production Sharing
Agreement (NCSPSA).
On November 18, 1997, in Washington DC, the Republic of
Kazakhstan and a consortium of the world's leading oil and gas
companies agreed on a legal framework that launched the
largest foreign direct investment project in the history of the
newly-independent country. The NCSPSA built on an earlier
agreement in December 1993 to conduct one of the largest 2D
seismic surveys ever undertaken in the industry. This historical
milestone falls on the Company's 1 Year of Commercial
Production marked in November 2017.
In 2018, the Consortium saw the celebration of the 25th
anniversary of the North Caspian Project commemorating the
establishment of an international consortium
KazakhstanCaspiShelf in December 1993 and the
commencement of seismic works on the Caspian Sea.
Project Challenges
The combined safety, engineering and logistics challenges in a harsh offshore
environment make Kashagan Phase 1 one of the largest and most complex
industrial projects currently being developed anywhere in the world.
Development of the Kashagan field represents a unique combination of
technical complexity and supply-chain coordination in a harsh offshore
environment where temperatures can drop below -30ºC in winter and rise to
+40ºC in summer
Because of its low salinity due to the inflow of fresh water from the Volga
River, shallow waters of only three to four meters, and subarctic temperatures,
this part of the Caspian freezes for nearly five months a year. Drifting ice and
ice scouring on the seabed put heavy restraints on construction, production
and logistics, calling for innovative technical solutions.
The Kashagan reservoir is located some 4,200 meters below the seabed and is
highly pressurized. The light crude oil from the Kashagan field has a high sour
gas content (H2S) and carbon dioxide (Co2). The particular challenge of
Kashagan is posed by the harsh operating environment, which requires many
more precautions and a much larger investment to manage the safety risks.
Located at the confluence of the Ural and Volga rivers, the North Caspian Sea
and its environment are characterized by rich and diverse flora and fauna with
60% of the species unique to the Caspian Sea. While the sturgeon is often
considered the most commercially valuable species, the Caspian Sea is also
home to seals, and its coastal wetlands attract a variety of birds, including
many of those listed in the Red Book of Kazakhstan. The Caspian Sea is also a
major migration route for birds flying from Asia to Siberia. Preserving this
sensitive environment in the northern part of the Caspian Sea and minimizing
impacts on the environment are key challenges in developing oil and gas
fields in this area.

11. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
PSBR 6
11
This process has been adopted for mandatory implementation in the NCOC.
N.V. by Managing Director and Senior Leadership Team (SLT)
Purpose: to prevent re-occurrence of major Process Safety Incidents that have
occurred in the industry by focusing on their main causes and key Barriers

12. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 12
PSBR 6. AVOID LIQUID RELEASE RELIEF TO
ATMOSPHERE
Purpose:
■ To manage the risk of harm to people due to release and ignition of flammable
hydrocarbons to atmosphere via vents and PSVs to atmosphere
What situations are covered?
■ Assets that have identified process Major Incident Hazards (MIH) as per NCOC
HSSE Risk Assessment Matrix (RAM) and that are used for producing, processing,
transporting or storing hydrocarbon liquid above its flash point.
Reference Standards:
1. Relief and Flare Philosophy (STN-00-Z15-R-YP-0004)
2. Pressure Relieving and Depressurizing Systems (API STD 521)
3. Process Isolation Philosophy (STN-00-Z15-R-YP-0003)
4. Drainage Philosophy (STN-00-Z15-R-YP-0005)
Major incidents in industry:
BP Texas City Isomerisation Unit Explosion, Texas, USA, March 23, 2005

13. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 13
Requirements of PSBR 6
1. Projects / Assets have an inventory of all atmospheric vents that have the potential to
release hydrocarbon liquid above its flash point.
2. Risk studies are performed to assess the risk of each of these vents. For identified
gaps, risk mitigation/ reduction measure(s) and remedial steps are identified, agreed
and in place (from cost and schedule perspective).
3. Demonstrate that Flare KO drum is adequately designed for the worst-case liquid
handling scenario. Essential load lists for onshore and offshore process equipment are
available and documented.
4. Adequacy of safeguards to prevent or to mitigate the risk of freezing of flare relief
systems, hydrate formation and potential for blockages and oxygen ingress has been
assessed and documented.
5. Philosophy of closed drain systems, including timing, sequencing, and ensuring
complete evacuation of fluids during from process equipment during emergencies is
available.
For more information, refer to Relief and Flare Philosophy (STN-00-Z15-R-YP-0004), section 4.

14. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 14
PSBR assessment methodology
A Major Accident Hazard is a source of danger that
has the potential to cause a major incident, whether
that involves multiple fatalities and/or significant
damage to plant, equipment or the environment.

15. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 15
NCOC Risk Assessment Matrix (RAM)

16. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
Intern’s Work Assignments
16
Inventory of Potential Vents Sources
Review Results (Additional details provided in Risk
Assessment Sheets)
Vent Description Source/ Location Potential Risk
Preliminary Risk
Assessment/ Risk Mitigation
Additional
Checks Required
Information
Available/ Required
RAM
Rank Status
Resid.
Risk
Ref Mandatory - Minimum Compliance (Higher Risk Vents)
06.On.
H.03
HP/LP Flare KO
Drums and Flare
A1-230-VN-003
(Intermediate LP
Flare KO Drum)
A1-230-VN-005
(Intermediate HP
Flare KO Drum)
A1-230-FC-001 (HP
Flare)
A1-230-FC-002 (LP
Flare)
A1-230-VN-001 (HP
Flare KO Drum)
A1-230-VN-002 (LP
Flare KO Drum)
A1-230-VN-006
(Intermediate HP
Flare KO Drum)
Potential spill to
the area (if Flare KO
Drum is not
properly sized).
Not known if Flare KO drum is
appropriately sized (considering all
of the possible liquid relieving
scenarios). Also consider overflow
drain/pumped flow from closed drain
into LP/HP Flare KO Drum(s). Flare
KO drum should hold the largest
liquid relief for at least 20 minutes
per API 520. Also need to ensure that
Flare KO Drum meets the following
DEP requirements:
Section 4.1 (DEP 80.45.10.10-Gen
(Jan 2009)
[1]: Maximum liquid level shall not
exceed the level where gas/liquid
separation can not be achieved (per
section 4.1.1. of DEP).
[2]: High Level Alarms-two
independent alarms via two separate
nozzles (level transmitters) with
adequate time allowed for operator
response. Minimum SIL-1 availability
per IPF classification per DEP
32.80.10.10-Gen.
[3]: Momentum criteria - rV2 shall
not exceed 105 lbf/ft2 for half open
pipe and 210 lbf/ft2 for
schoepentoeter. rV2 for outlet nozzle
shall not exceed 125 lbf/ft2.
Section 3.6.1 of DEP 80.45.10.10-Gen
(Jan 2009)
[4]: Minimum slope: 1:200 for sub
headers, 1:500 for main header in the
direction of KO drum.
Flare KO drum capacity
check needs to be made.
Two independent level
transmitters are
provided. High High
liquid level in the flare
KO drum to cause ESD1
for which action needs to
be confirmed. Also SIL
level and IPF
classification for level
transmitters to be
checked. Header slope
meets DEP requirements
both for flare and closed
drain system. See also
closed drum below.
Additional problem can
be that hydrates are
formed in the vessel due
to low temperature and
that outlets to pumps are
blocked. Need to check if
the pump capacity is
sufficient if the vessel has
a heater? Also,
pressure/fluid
communication/backflow
in the header/systems
(complete segregation
between various pressure
levels and types of
services need to be
carefully reviewed.
Refer to P&IDs:
KE01-A1-230-KD-R-HP-
0034-001.C06; 0034-
003.C06; 0034-004.C06;
0034-011.C06; KE01-A1-
550-PG-R-HP-0001-001-
C05; KE01-A1-550-PG-R-
HP-0001-003-C05 and
KE01-A1-550-PG-R-HP-
0201-001-C06; HP-0201-
003-C06; KE01-A1-550-
PO-R-HP-0001-001-C06;
KE01-A1-550-PO-R-HP-
0001-002-C05; KE01-A1-
550-PS-R-HP-0001-001-
C06; KE01-A1-550-PS-R-
HP-0002-001-P02; KE01-
A1-550-PS-R-HP-0201-
001-C05 and KE01-A1-
550-PZ-R-HP-0001-001-
C03.
For OPF, following
appendices to the Flare
Report and Basis of
Design:
KE01-A1-230-KD-R-RT-
1001-000 received:
APPENDIX II - LP FLARE
LOADS
APPENDIX III - HP FLARE
LOADS – COLD DRY
APPENDIX IV - HP FLARE
LOADS – WARM WET.
5B Open

17. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 17
FLARE SYSTEM

18. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 18
FLARE SYSTEM. K.O. DRUMS

19. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 19
FLARE SYSTEM. K.O. DRUMS

20. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 20
Checking for Capacity (Mechanical Datasheet)
HP Flare KO Drum
A1-230-VN-001 ( 155
𝑚3
)
LP Flare KO Drum
A1-230-VN-002 ( 155
𝑚3
)
Intermediate LP Flare
KO Drum A1-230-VN-
003 ( 92 𝑚3
)
Intermediate HP
Flare KO Drum A1-
230-VN-005 ( 127 𝑚3
)
Intermediate HP
Flare KO Drum A1-
230-VN-006 ( 92 𝑚3
)

21. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 21
KNOCK OUT DRUMS’ P&ID

22. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL
A1-230-VN-001 KO drum
22

23. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 23
HIGH-HIGH LIQUID LEVEL
■ We have extra 57 𝒎𝟑
after reaching HHLL, capacity for A1-230-VN-001 (155 𝑚3
-
57 𝑚3
=98 𝒎𝟑
).
■ We have to take into account the Pump-Out Capacity as well.
■ Units from which can be routed the gas/fluid to A1-230-VN-001(KO Drum):
UNIT 360 (Flash Gas Compressor)
UNIT 300/330 (Gas sweetening train 2)
A1-230-VN-005
A1-300-ZL-001 A/B
A1-300-VO-001
A1-190-VR-001
A1-550-VA-005

24. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 24
Flow Rates (from UNITS 300/330)

25. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 25
Flow Rates (from Dry Flare Header & OVERALL
CAPACITY CHECK)
■ A1-230-VN-005 (127 𝒎𝟑
)
3000-PSV-014A
3000-PSV-014B
A1-300-ZL-001A
A1-300-ZL-001B
96.00
SOUR HC GAS
VAPOUR
29.16
55.0
-6.3
15,601
1900-PSV-011
A1-190-VR-001
96.35
SOUR HC GAS
VAPOUR
23.00
87.3
38
33,667
Q(gas/vapour) =
(4.787+7.623+2.836+20.636+115.541+116.289+35000.191+4.3
14+13.463+4.9+93.845+99.311+276.779+296.306+1323+15.60
1+33.667) = 24640.1 * 0.02 (content of liquid)=
492.8 (kg/h 0.992 m3 / h )
Q(liquid) = 2530 (kg/h 5.1 m3 / h )
By API 520
a) A single contingency results in the flow of 25.2 kg/s (200,000
lb/h) of a fluid with a liquid density of 496.6 kg/m3
(31 lb/ft3) and a vapor density of 2.9 kg/m3 (0.18 lb/ft3), both at
flowing conditions.
Q (1st hour) = 6.092 m3/h +
127 m3 = 133.092 m3 – P/O Capacity (38.5
m3/h) = 94.592 m3
Q (2nd hour) = 6.092 m3/h +
94.592 m3 = 100.684 m3
NOTE: WE HAVE 1 HOUR 58 minutes until HHLL
98 m3
Pump Out Capacity
A1-200-VS-101/201/301
Inlet Separators

26. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 26
2nd Scenario (without P/O Capacity)
■ Q (1st hour) = 6.092 m3/h + 127 m3 = 133.092 m3
So, by proportion : 133.092 1 hour
98 x hour , x=0.74 hour
60 min 100 %
x min 74 % , x = 44.4 min
Outcome: WE HAVE 44 minutes 24 seconds until HHLL 98 m3

27. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 27
What is a Control Valve?
- To operate within operating envelope,
key process parameters (P, T, Flow, level)
are manipulated via a control loop
which uses control valve as a final element to
physically control the process parameter close
To the desired set-point.
- Control valve mainly consists of valve body,
Internal trim parts, actuator which provides power
to operate the valve, supply pressure regulators etc.

28. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 28
Valves Characteristics – Linear/Equal Percentage/
Quick-Opening

29. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 29
Quick Opening Type

30. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 30
Linear Type

31. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 31
Equal Percentage Type

32. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 32
Actuator type – Direct and Reverse Acting
Direct acting: Increasing the air pressure pushes the stem down
Reverse acting: Increasing air pressure pushes the stem up
Actuators: Pneumatic (Air), Electric, Spring, Manual

33. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 33
Control Valve Sizing – Key Criterions and Steps (ISA-75.01.01)

34. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 34
Background Information

35. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 35
Cv Valve coefficient definition
Cv is a relative measure of its efficiency at allowing fluid flow. The flow coefficient Cv is
the volume (in US gallons) of water at 60 °F that will flow per minute through a valve
with a pressure drop of 1 psi across the valve.
Units: (gallon/min)*1/ (psi)^0.5
: (m3/s)*1/ (Pa)^0.5

36. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 36
Control valve sizing – Liquids (Incompressible fluid)
Refer to Pages 100-104 of the Emersion hand-book for all steps.

37. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 37
LCV-035

38. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 38
LCV-035

39. Template:
IMP-Y03-FR-0002-000_A02
4/6/2023 INTERNAL 39
Excel calculations

40. Template:
IMP-Y03-FR-0002-000_A02