Upstream

The LLOG Exploration development of the Salamanca production facility comprises a floating production unit (FPU) which will be created from the refurbishment of a former Gulf of Mexico production facility that was previously decommissioned.  The FPU will serve as the collection point for production from the joint development of Leon discovery and Castile discovery, both located in the deepwater Gulf of Mexico in Keathley Canyon. The FPU will have a capacity of 60,000 barrels of oil per day and 40 million cubic feet of natural gas per day.  

By modifying a previously built production unit, the time and cost to refurbish the unit will be greatly reduced.  Additionally, the project has a significantly positive Environmental, Social, and Governance impact as it reuses an existing unit compared with abandonment of the unit, while also accomplishing approximately a 70% reduction in emissions impact compared to the construction of a new unit.  

The Milestone Construction Management Group will perform all topsides and hull construction management and the Inspection Group will perform all equipment packages/skids for the project.

Keystone provided fabrication and loadout engineering services for the Williams Gulfstar 1 FPS Topsides (approximately 8000 tons). Keystone performed the structural analysis for construction and loadout conditions. Engineer the loadout of the Topsides required design of a skidway, pulling/skidding, ballasting, and skidway load spreader systems. Keystone designed a project-specific skidding system which allowed the fabricator to skid the topisides with 60’ deck leg spacing on existing yard skidways that were set for a 69’ deck leg spacing. By utilizing the fabricators existing infrastructure loadspreader beams, and other items, Keystone’s solution reduced costs, saved time, and improved the overall efficiency of the project.

Lafayette-based Tarpon/JAB Energy Solutions sought out Keystone’s expertise to develop the East Zuhal Field, located off the coast of Sabah and the South China Sea. The scope involved the installation of a satellite drilling platform designed as a guyed wire monopod to accommodate four wells with a well test loop, equipped with a multiphase meter to measure bulk flow. Since the platform is to be unmanned, Keystone designed remote monitoring systems that require minimum manual intervention. The platform design provided for a variety of production equipment including a wellhead, production header, test loop, vent scrubber, vent boom, with CO2 Snuffer, open drain sump, instrument gas system, pig launcher, and safety/process control systems. The facility was outfitted with a crane, diesel generator, diesel tank, wash-down tank, wash-down pump, emergency shelter, wellheads enclosed by mudwalls, and a wellhead access platform.

Keystone provided support to allow for the pigging of a 14” OD subsea gas export pipeline spanning 42 miles from Mars TLP to West Delta 143. In the 11 years since last pigging, the line had accumulated asphaltenes in addition to retrograde condensate, both of which presented challenges to stabilizing liquid returns at WD-143. In coordination with vendor, Keystone provided equipment and platform interface for temporary condensate handling during Turnaround window.

Keystone provided civil, structural, mechanical, E&I engineering and detailed design for significant upgrades to accommodate offshore living quarters. These efforts involve extending the living quarters deck, including a freshwater skid, addition of new crane utilizing the existing pedestal, replacement of the primary generator, lift planning/analyses, and removal of existing equipment.

Additionally, Keystone provided engineering and design to support permanent quarters, lifeboats, and heliport modifications. These efforts involve platform integration of living quarters, installation of DEP compliant lifeboats and davits, demolition of existing portable buildings, demolition of existing helideck, relocation of existing air compressor skid, relocation of existing firewater monitors, relocation of existing IT telecom communication systems, fire and gas protection, electrical power, lighting, and instrumentation.

Keystone provided engineering and design services to support an increase in the offshore facility's production from brownfield and greenfield developments. The installation of a new pump module with three turbine-driven pumps and related ancillary equipment achieved an increase in production.

The scope of work included the following: turbine-driven pump module, bridge piping, fuel gas conditioning skid, control systems upgrade, MCC upgrade, chemical injection (DRA), custody transfer orifice meter for gas supply, and a new gas chromatograph skid for primary gas ultrasonic meters.

Additionally, Keystone provided project planning, procurement, and construction management services. This expansion allowed for a growth production of an additional 80-100K BOPD.