The Right Combination of Personnel & Process

The project consists of a $4.5 billion blue hydrogen clean energy complex to be built in Eastern Louisiana and the world’s largest instance of carbon capture.  The complex will produce 750MMscfd of blue hydrogen in Ascension Parish that will be delivered through 700+miles of pipelines.  The clean energy system will tie into 25 existing production facilities providing customers more than 1.6 billion cubic feet of hydrogen per day making it one of the largest producing hydrogen systems in the world.  With a 95% CO2 capture rate, it will be compressed to 1,750 psig and transported safely by pipeline 35 miles east of the new clean energy complex to multiple inland sequestration sites located along a pipeline corridor.  The complex will generate more than five metric tons per year (MTPY) of carbon dioxide which will be permanently sequestered in geologic pore space secured from the State of Louisiana approximately one mile below ground.  The clean energy complex will also produce 2.8 million metric tons per year of blue ammonia that will be transported around the world.  Injection facilities will be installed in shallow water (10ft).  Pipelines will be constructed in predominately swamp terrain (shallow water areas) and will have complex horizontal direction drills that will need to engineered.   

Keystone is providing engineering, design, hydraulic analysis, automation & controls, SCADA, project management, survey, procurement, permit support, project scheduling, project controls,  cathodic protection & AC mitigation, geotechnical investigations, environmental support, and right-of-way support for all pipelines (Hydrogen, CO2 Mainline, CO2Distribution Lines and Natural Gas), compressor stations, measurement and regulation facilities, CO2 injection facilities, and tie-in locations along the system. 

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Keystone provided project management, engineering, and design services to add a new offtake/delivery point at the existing Dewitt Central Facility. The project design of the new offtake/delivery point at the current facility pad involved 40Mbpd of unstabilized oil from the Eagle Ford asset. The design also provided constant flow with the existing stabilizer and utilized the existing Eagle Ford Pipeline pressure to provide the motive force.

The scope of the work associated with the new delivery point included a new incoming 12” lateral, 12” pig receiver, provisions for future booster pumps (preliminary sizing, space/footprint requirements, flanged tie-points, and I&E spares), dual/redundant free Water Knock Out packaged skids, interconnecting piping to available tie-points, interconnecting I&E back to the existing facility control system, sleeper/rack supports, and 480VAC power supply to switchrack.

Keystone designed the four-pile jacket substructures for the five six-megawatt wind turbines comprising the Block Island Wind Farm (BIWF) off the coast of Rhode Island. The project solidified its spot in history by being the first offshore wind farm to be constructed in North America and demonstrating that offshore wind energy is economically feasible in the US. During the project, Keystone was contracted under the US fabrication contractor and provided on-site engineering, construction support, load-out analysis, and sea fastening support for the structures.  

Keystone’s professional services for the BIWF included conceptual development of a post-piled jacket foundation and separate transition deck, detailed structural and electrical engineering design of foundations, bidding document prep, supplier identification, fabrication yard engineering services, on-site foundation fabrication, construction/installation support, and BSEE documentation prep.

The client recognized Keystone for providing exceptional service and expertise navigating the US regulations. Additionally, Keystone was awarded the prestigious Be Inspired Award for Offshore Innovation and received worldwide media attention for its role in the project.

Keystone leveraged the technology developed for the offshore oil and gas industry to meet the jacket foundation's complex design criteria. The iterative process optimized the jacket design and reduced the amount of steel needed for the substructure while ensuring more than 20 years of design life. As a result, the Block Island Wind Farm jackets are 15 percent lighter than a previous design used for the same wind turbine in the North Sea. The optimized design also reduced installation costs by more than 20 percent compared to traditional monopile construction and can survive hurricane-force winds.

Keystone assisted with a program for mitigation of the HAZOP high priority findings for various offshore platforms. The scope of work included trips offshore to verify the feasibility, detailed engineering and design, and the creation of work packages for the mitigation measures. Additionally, Keystone assisted with the quoting of long-lead equipment to mitigate HAZOP projects.

In 2017, the Petroleum Corporation of Jamaica was awarded an approximately $875,000 grant from the US Trade and Development Agency (USTDA) to develop a technical and economic feasibility study and implementation plan for a utility-scale offshore wind farm off the coast of Jamaica. This
study provided export opportunities for US suppliers. Keystone served as the prime contractor for the effort. The work scope included a detailed supply chain, infrastructure development plan, and logistical study for the construction of the wind farm.

The study also included creating a US supplier survey and register of US companies interested in exporting offshore wind-related products and services, as well as an estimation of the potential export value to US companies. The Terms of Reference (TOR) included the following: wind resource assessment, site selection study, wind turbine generator selection, foundation concept design study, logistics study for component delivery, local supply chain and infrastructure assessment, installation/implementation planning, US supply chain- supplier identification and register, stakeholder engagement, and regulatory/permitting review.