Keystone's history is rooted in upstream oil & gas with a wide range of experience from the design of offshore platforms/facilities to unconventional oil & gas developments in shale regions across the United States.
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 top sides with 60’ deck leg spacing on existing yard skidways that were set for a 69’ deck leg spacing. By utilizing the fabricators existing infrastructure load spreader 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.
Keystone led efforts to mitigate findings from HAZOP reviews. Keystone assisted at5 different locations and the review scope ranged from 10 to 90 items. Keystone was able to mitigate 65% of these findings without facility modifications, using additional analysis tools and process modelling. If modifications were necessary, Keystone worked to minimize the field scope for most to a coding change or addition of a monitoring point. For larger multi-discipline items, Keystone handled the design effort and coordinated installation with existing turnaround planning efforts.
Keystone provided multi-discipline engineering and design services for the installation of production equipment to accommodate new wells production in the Gulf of Mexico. The project involved new production equipment including a wellhead, flowline, four log/four slot manifold, production separator, and dehydration contactor/regen unit.
Keystone's scope of work included generating a process model to analyze the expected production from the new well as well as potential production from remote facilities and preparing a compliance package for BSEE submittal. Additionally, Keystone designed all interconnecting piping from the new equipment to the process tie-ins, designed structural modifications for the equipment as well as piping, and participated in the Facility HAZOP.
To support the Compressor Additions Project, Keystone provided project management, process, mechanical, electrical, instrument, C&A engineering and design, construction management, execution planning, and 3D laser scanning. The scope of work included evaluation of the compression system, addition of a new solar turbine compressor package, and two electric-driven VRU compressor packages. The purpose of the project was to minimize the downtime associated with the existing compressor shutdowns and provide 100% back-up during routine and scheduled maintenance.
Keystone provided front end engineering design (FEED) and detailed engineering design for a 30 MMSCFD Enhanced Oil Recovery Pilot in the Eagle Ford black oil area. The pilot area consists of two adjacent pads, with 21 injection wells separated by six buffer wells to monitor pressure and communication. The project scope included extending the well pad to accommodate gas injection and processing trains. The new processing train compresses, sweetens, and dehydrates gas utilized for fuel gas and flare purge with the remaining volume entering a header common with the injection compressor suction and gas lift pipeline.
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.
In an effort to revitalize an aging production field, Chevron tasked Keystone with developing a comprehensive design that could efficiently and effectively monetize reserves and production in the East Flank of bay Marchand. In phase 1 of the redevelopment project, Keystone optimized the well targeting, workovers and construction of new infrastructure. Phase 2 focused on further evaluation of both Greenfield and Brownfield project options developed in Phase 1 to handle production from approximately 50 new well sites. Keystone was directly involved in the creation of multiple concepts (Greenfield, Brownfield, and hybrid) that satisfied the overall project objectives. With collaboration between multiple Keystone offices, this Major Capital Project for Chevron highlighted our team’s capabilities. The level of detail required for cost estimates and schedules for each concept necessitated the creation of new estimating tools and a plethora of valuable data for future offshore projects.
Keystone employed its successful “design one, build many” approach to this significant wellsite development in the Utica shale. The Keystone project team began by standardizing several critical features into the wellsite design. Methods implemented allowed for strategic design automation in subsequent packages. The process resulted in earlier deliveries and several economic benefits realized by the owner of an E&P Company. The multi-well templates included piping and I&E designs used for field-wide deployment, process studies, and equipment validation.
Keystone provided project management, engineering, and design services for the West Karnes Gas Expansion Project. West Karnes Central Facility’s original processing capacity was 20 MBOPD liquid and 60 MMSCFD Gas. The production forecast for West Karnes indicated that liquid processing capacity was not a concern at the time. However, future compression requirements and the forecast gas throughput exceeded the original capacity of the gas train. The expansion increased the gas train capacity to 100 MMSCFD. The project elements included new gas cooler, two filter coalescers, dehydration system, fuel gas scrubber, and an amine plant.
Keystone’s scope included engineering and design services for the installation of new and relocation of existing equipment, demolition/abandonment, piping, civil/structural, and instrumentation and electrical design.
To support an increase in the water gathering infrastructure, Keystone provided the engineering, design, and analysis necessary to increase the throughput and capacity as well as mitigate corrosion and improve control. The scope of work included the redesign the pump suction headers to accommodate 75,000 BPD of throughput, the addition of a third water transfer pump with recommendations to increase the current capacity another 50%, replacement of process header piping with internally plastic coated piping to mitigate corrosion, and the addition of two connections to the discharge pump header.
Additionally, the scope included modifying the inlet headers from two separate pipelines with automated control valves and individual flow meters to allow for flow control into the facility as well as the modification of the existing control systems architecture to accommodate the additional valves and instrumentation.