Equipped for Any Project in Nearly Any Industry

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’s patented offshore wind turbine foundation design, the Inward Battered Guide Structure (IBGS), or “Twisted Jacket,” was featured in two US offshore wind projects that included an award up to $44 million in federal DOE grants in 2014. The grants intended to accelerate the deployment of US offshore wind by funding projects utilizing innovative technologies. Keystone’s foundation design featured in both award-winning fixed-bottom foundation projects: Atlantic City Windfarm (FACW) and Virginia Offshore Wind Technology Advancement Project (VOWTAP).

The project scope of work for VOWTAP included the conceptual design of the jacket and detailed design of the first fully coupled BLADED analysis and SACs post analysis, ULS and FLS completed.

Keystone’s work scope for FACW included providing engineering and design services to support a 25MW offshore wind farm project 2.8 miles off Atlantic City, New Jersey. The project involved the installation of six 4MW offshore wind turbine units, six of Keystone’s patented Inward Battered Guided Structure (IBGS) substructures and foundations, five inter-array submarine cables between the wind turbine units, one export submarine cable to shore, one upland power cable from shore to the onshore substation, one step-up transformer at the onshore substation connected to the upland cable, and modifications to the existing onshore substation to connect to the existing grid network. Additionally, the work scope included detailed design of the jackets, BOM/weight report, US fabrication assessment, installation analysis, and electrical system design.

Keystone provided engineering and design services to support Cape Wind, the first commercial and utility-sized offshore wind farm proposed in the US to reach an advanced stage of development. For the pioneering effort, Keystone worked with the US developer and a joint European engineering team for the detailed design of the monopile foundations. In addition to the foundation design engineering, Keystone served as the Professional Engineer of record for the State of Massachusetts. Although the project was never constructed, it was the first federally permitted offshore wind project in the US.

Keystone’s scope of work involved developing addition design load cases (DLCs) to check robustness for hurricane hazard, secondary steel conceptual and detailed design, and mechanical and electrical subsystems design. Additionally, the scope included the evaluation of the following: trans-Atlantic transportation support conditions, staging site requirements for monopile foundations related to us sites, and internal j-tubeless cabling and associated handling techniques.

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.

Keystone was one of four finalists in the UK Carbon Trust’s Offshore Wind Accelerator global foundation design competition to reduce the CAPEX of offshore wind turbine foundations. Keystone’s patented IBGS (Inward Battered Guide Structure), known as the “Twisted Jacket” in the offshore wind industry, proved to be 20% less expensive than traditional designs. Keystone’s jacket was the first of the winning concepts to be demonstrated. A Twisted Jacket prototype was built in Europe and become of the first structure installed Scottish territorial UK Round 3 waters.

Keystone’s scope of work included conceptual and detailed design of the substructure and foundation, which included structural engineering, electrical engineering, and drafting services for Keystone’s patented “Twisted Jacket”. Additionally, the scope included evaluation of European fabrication yards, design of fabrication cradle, fabrication support, design of guide structure transportation support and hydraulic tie-downs, development of installation Method Statement and Choreography, on-site construction support, and project management services.

Keystone provided a turnkey support package from conception to start-up for approximately $12MM TIC system to recapture and process landfill gas into pipeline quality natural gas. The project included the installation of an 8,000SCFM landfill well, H2S removal unit, compression, CO2 removal, dehydration, pipeline compression, and metering. Keystone specified and procured all equipment such as ASME vessels, blowers, coolers, heat exchangers, instrument air compressors, and tanks. Keystone’s scope encompassed all associated new foundations, buildings, site drainage, utility drops and interface, new MCC, switch gear, and VFD.

For the comprehensive effort, Keystone also handled procurement/expediting, project management, PLC & HMI programming, construction management, and on-site commissioning/start-up support. Keystone and subsidiary Milestone Project Services personnel managed the project through construction while concurrently developing PSM-compliant operating procedures and training client operations/maintenance personnel.

Keystone provided engineering and design support services for installing a meteorological tower for a 268MW offshore wind farm in Maryland. The structure included the construction as an intricate steel lattice tower approximately 330 feet (100.6 meters) in height. Additionally, the foundation is a Braced Caisson, a concept based on the Inward Battered Guide Structure (IBGS), commonly known as the “Twisted Jacket”, a patented solution by Keystone.

Keystone's scope of work included the following: conceptual and detailed design of the substructure and tower, electrical subsystems design, mechanical subsystems design, project management services, on-site fabrication support, bidding documentation prep, and installation strategy support.

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 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 facilities associated with the Centralized Storage, Keystone provided project management, engineering, and design FEED services. The scope included the installation of temporary storage and stabilization capabilities for the Eagle Ford Region to act as a surge for the Condensate Trunkline. Additionally, the project involved future expansion capabilities for an additional storage tank and vapor recovery to gather the flash gas. The stabilization capabilities were as necessary to get RVP to an acceptable level for production. The design criteria associated with the scope included a design storage capacity of 30,000 BBL and a design facility average flowrate of 120,000 BOPD.

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.

Keystone provided project management, engineering, and design services for the Lake Boeuf Grand Coteau Facility design to support the addition of two new wells and working over the existing Well #1. The new wells required a full facility to produce, separate, store, and sell the oil and gas production.

The scope of work for the new facility design included well flowline rated for SITP of the well (<10,000 psig) for Well #1, well flowline rated for SITP of the well (<15,000 psig) for Well #2 and #3, line heater with line heater fuel gas scrubber, slug catcher, HP and LP separator, fuel gas/instrument gas scrubber, oil heater treater, glycol dehydration package, amine unit for CO2 removal, dewpoint control unit, oil storage tanks, three 500 BBL water storage tanks, one spare storage (slop) tank, tank recirculation/offloading pump skid, HP flare scrubber and pump, LP and HP flare, and LP flare liquid blowcase.

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 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 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.

To revitalize an aging production field, an E&P company 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. 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 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.

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 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 project management, detailed design, and construction management to install a provisional replacement crane located off the coast of Brazil. The replacement crane used a dynamically positioned floatel for lift support.

Keystone coordinated with multiple parties and managed the construction of the removal, assembly, and reinstallation of the crane. The scope of work also included the cut and removal of an existing pedestal and planning, transportation, and sea fastening of both cranes.

As a significant effort to support a new Ethane Cracker, Keystone performed project management, engineering, and design for the $165MM expansion of an underground storage terminal in Sulphur, LA. The project's scope included installing a new brine pond, four ethylene transport pumps, ethylene dehydration system, CO2 Scrubber, flare system, and piping to the new wells at the underground storage facility. Additionally, Keystone executed the design of the associated meter stations and horizontal directional drill packages for the new Ethane & Ethylene pipelines.

Keystone provided project management, engineering, and design services for the significant expansion of a pipeline terminal, which included installing a new 80,000-barrel tank and additional rail offload for ethanol storage and a new eight-inch transfer line. The expansion of the existing ethanol rail offload included the addition of spaces for another 20 cars, including the all rail infrastructure with containment, safety equipment, and pump capacity up­grades. This expansion also allowed for the capability to provide products to an existing tank, the new 80,000-barrel tank, and provide flow to the latest transfer line.

Additionally, a second facility takes deliveries from the pipeline and includes storage for all the products (gasoline, diesel, and ethanol, etc.). This facility included the accommodations to fill transport trucks for delivery to customers using two separate additives, which provides the required lubricity additive for the ULSD and uses a VRU as the required vapor control unit for the truck loading area.

Scope of Work also included: composing performance specifications and assisting with the procurement of railcar expansion, storage tank, and electrical switchgear/MCC, four-bay truck loading station, four new buildings, six new tanks, VRU system for the terminal/truck loading, fire and gas safety system for the terminal, ethanol blend skid, evaluating utility systems, modifying containment and drainage systems, and specifying equipment including railcar offload pumps, transfer pumps, manifolds, and meters.

Keystone provided project management, engineering, design, and procurement support services for the detailed engineering and design of five facilities associated with the Delaware Basin Crude Pipeline, including brownfield modifications to four existing sites and one new greenfield site. The pipeline consists of 40 miles of 16" pipeline, 105 miles of 24" pipeline with a designed flow rate of 150,000 BOPD, and expansion capability up to 200,000 BOPD.

Keystone's scope of work included Coriolis meter additions, booster pump & mainline pump additions at three brownfield sites (18,000 total HP), greenfield pump station with one 200k BBL storage tank and provisions for five future tanks, and reinforced concrete foundations with above ground supports. The scope also included I&E tie-ins to new-build PLC & power infrastructure, MLV sites, pig launchers & receivers, 480VAC three-phase utility power drop, and communications (VSAT w/ cell phone backup).

Keystone provided project management, engineering, and design services at a greenfield and existing site in South Carolina for the installation of additional compressors. The project goal included increasing the overall pipeline capacity.

The brownfield compressor station expansion added new compressors to increase capacity from 150 MMSCFD to 300 MMSCFD. The scope of work included the installation of new separation vessels, coolers, and fuel gas coalescers. The greenfield site included installing a Solar Saturn turbine with centrifugal compressors for 175 MMSCFD with separation vessels, compression coolers, and fuel gas coalescers. Additionally, Keystone provided procurement, bidding, and permitting support services for this project.

Keystone provided multi-disciplined engineering and design services to install all piping, pig traps, meters, and infield pipelines associated with a greenfield 200 MMSCFD gas plant. The project scope of work included piping, foundations, controls, and power interconnect associated with pig receivers and ultrasonic meter skids on incoming 12” and 24” gas lines. Additionally, the scope included a Coriolis meter skid on 16” export NGL line, 16” and 20” residue gas export lines, and pig receiver at remote surface interconnect site.

The pipeline scope included crossing and code calculations, material selection, hydraulics, and interface with the surveyor to develop alignment sheets associated with 12” and 24” incoming gas lines, and 16” and 20” residue gas export pipelines between the new Cryo plant and nearby surface
sites.

Keystone provided project management, engineering, and design services for the detailed engineering design of the Orla Gas Gathering System located in West Texas and New Mexico. The project included installing a gas-gathering system to collect hydrocarbons from multiple Customer
Delivery Points. The scope of work involved installing a new 600 MMSCFD gas-gathering system, including 35 miles of 24" ANSI 600# gas pipeline, five surface meter/tie-in sites, and three surface receiving/metering sites. More specifically, all associated foundations, supports, piping, and I&E interconnects.

The pipeline scope of work included hydraulic calculations and material selection, API 1102 crossing calculations, HDD design, and interface with surveying for plat and alignment sheet development. Keystone also served as a primary interface between the client, third-party contractors, and all export pipeline operators. The receiving site was capable of 850 MMSCFD with a pipeline designed for 600 MMSCFD.

Keystone provided multi-discipline engineering and design services for a major project to install a $125MM new Alkylation Unit. The design basis of the new Alkylation Unit involved utilizing an existing decommissioned unit at another site. Nine pieces of equipment at that site were refurbished and reused for this project, including a refrigerant compressor and contactors, and six pressure vessels. One reboiler/heater, three towers, ten tanks, 11 heat exchangers, 21 drums, and 49 pumps were specified, purchased new, and installed. The additional connected electrical load required an expansion of the existing electrical substation including 800 new instruments.

Additionally, the project required new cooling towers and instrument air compressors since the existing facilities did not have adequate capacity. An existing LPG Truck Loading Rack required relocation and demolition to provide adequate spacing for the new unit.

To support an increase in the Sour Water System's capacity, Keystone provided project management, engineering, and design services for the FEL 3 and detailed design phases of the project. The new system design included a capacity of 120 GPM sour water charge and 40 GPM
turndown case.

The scope of work for the new Sour Water System Unit included sour water feed pumps, sour water feed/product exchangers, stripper tower, pump around pumps, overhead cooler, sour water reboiler, tempered water pumps, and a sump pump. Additionally, the new unit tied into steam, instrument air, and power systems.

Keystone provided project management and detailed engineering for the OSBL portion of restarting the coke conveyor unit at a refinery. Keystone’s scope included performing a 3D laser scan and assessing the existing structural steel and foundations which previously supported a 24” wide conveyor and providing detailed design for all necessary upgrades to support the installation of a new 36” wide conveyor in its place.

Additionally, Keystone provided detailed civil/structural design for a new coke crusher at the north end of the conveyor, as well as detailed electrical and instrumentation engineering.

Keystone provided engineering, design, and construction support for a significant process upgrade at the refinery. The multi-discipline project added new SulfaTreat technology designed to remove Hydrogen Sulfide (H2S) from the continuous flare system. A highly accelerated schedule was vital to meet newly issued federal regulations from the Environmental Protection Agency (EPA). The arduous 15-week project schedule showcased one of Keystone’s greatest strengths– the ability to be responsive and rapidly assemble an elite project team.

Keystone provided procurement support in addition to civil/structural, process/mechanical, electrical, instrumentation, and controls/automation engineering. The highly experienced team was able to engineer innovative solutions to save time and keep the project on schedule. The owner and the construction contractor commended Keystone for producing all deliverables on-time or early and doing so with a remarkably high level of quality.

Keystone performed multi-discipline engineering, project management, and design services to restart an ethylene cracker located in Sulphur, LA. Keystone’s scope involved moving propylene, CC4, and pyrolysis gasoline from the facility. Keystone designed a new railcar loadout system with a control building and truck loadout station to supplement the existing infrastructure.

The design featured two multi-product loadouts, four propylene loadouts, and one driver-interfaced truck loadout station. Keystone designed a new railway pipe rack that connects existing storage and transfer pumps to the new railcar loading stations and extends to the truck loading area. The facility design included a new control building, housing the PLC and HMI control systems, offices, break room, and washroom.

Additionally, the engineering scope included refurbishing/modifying the flare and relief systems, existing utilities, I&E, and interconnecting piping for new and existing equipment. Keystone performed PHA, LOPA, and SIL studies on all systems.

Keystone provided project management, engineering, and design services for the MDH Hydrotreater NOx Reduction Project for a refinery in Southeast, Louisiana. The project included the retrofitting of the reactor charge heater and the product fractionator heater, which are part of the middle distillate hydrotreater (MDH), to reduce NOx emissions.

The scope of this project included replacing existing burners with ultra-low NOx burners (ULNBs) for each heater, including necessary modifications to heater floor and burner fuel gas piping, adding convection coils to each heater, installing one new CEMS system, main fuel emergency shutdown skids and O2/combustible analyzers.

Keystone provided the project management, civil/structural design, and mechanical design for all Phase III and Phase IV activities. The Phase III scope also included enough documentation to prepare a total installed cost estimate of + 10%.

Keystone provided the loadout engineering for the Coelacanth Jacket. Weighing 32,000 tons and standing 1,218 feet tall with a base of 372 feet, the jacket is the third largest ever constructed. The jacket now supports a production facility in the Gulf of Mexico.

The Keystone team provided the engineering support and analysis needed to load the structure onto a barge for transport. The sheer size of the jacket required the use of the Heerema H851, the world’s largest cargo barge.

The Keystone team overcame many challenges to achieve a successful loading, including the design of additional load spreaders. The design allowed the fabricator to utilize existing yard skidway infrastructure and eliminated the need for barge skidway reinforcement, reducing project cost, and improved loading efficiency.

As part of a significant upgrade effort at the bulk terminal facility, Keystone provided engineering, design, automation programming, and on-site support. Keystone scope included the following: electrical load studies, specifications for electrical power system equipment, design of electrical and control systems for four new stacker gantry units and existing Krupp trailer-tripper unit, design of two complete substations, and design of electrical and control systems for reconfiguration of two existing yards, including cable tray, power systems, lighting, and grounding.

Additionally, the scope of work included electrical one-line diagrams for demolition and the new facility power distribution network, construction cost estimate and Primavera schedule, control philosophy and sequence of operations for the entire facility, and programming for all new PLCs and revise programming for all existing to remain PLCs.

Keystone provided civil/structural engineering and design services for the design of new fenders for a dock. Keystone's scope of work included developing the design basis for handling vessels at the dock and the development of mooring plans and requirements for the usage of vessels at the dock. Keystone produced a complete structural model using SACS software for the loading platform as well as the upriver and downriver dolphins and checked new fender reactions. Construction packages were designed and drafted for new mid fenders on the loading platform and upriver/downriver dolphins.

Keystone designed new breasting and mooring dolphins at four of the facility’s docks. The scope of work included site inspection of the marine terminal, structural design of new mooring/breasting Monopile, SACS Modeling, Optimoor Mooring arrangements, permitting requirements for new
structures to include correspondence with Corps of Engineers and all 3rd party agencies, review soils geotechnical data, and bathymetric/hydrographic surveys.

Additionally, Keystone’s work scope included surveying the existing docks to locate fender lines and existing marine structures, establish horizontal and vertical control at the site, coordinate with subcontractors, prepare permit drawings, layout drawings, structural drawings, and demolition plans.

Keystone provided civil/structural engineering and design services for the Dock Optimoor Analysis and Structural Assessment Project. Keystone’s scope of work included gathering drawings and information on existing structures and fenders, preliminary design basis and ship arrangement plans, and developing Optimoor models for the dock and run cases.

The project included three upriver/downriver breasting dolphins, a loading platform, and upriver/downriver mooring dolphins. The SACS models involved modeling dolphins using EDI SACS Marine Structural Analysis Program as well as modeling soil and piling. Additionally, the project scope included dynamics runs to develop dolphin spring, in place sizing to check dolphins with modified system spring, and check joints for API punching shear.

Keystone provided engineering design support services and developed a Phase II quality total installed cost estimate for the Dock Electrical Upgrade Project. The project goal included increasing reliability and improving maintenance at the refinery. Keystone's scope of work included installing new 5KV transformers for the dock and a new Main-Tie-Main (M-T-M) breaker system for the electrical feed to the refinery cooling water pumps.

Additionally, the scope involved the installation of two 5KV switch racks, the replacement of seven 480v motors on cooling water pumps with new 4160v motors, and the installation of new raceway and cable to interconnect all new equipment.

Keystone provided controls and automation engineering services for the PLC-Based Subsea Leak Detection project at two offshore facilities. The detection algorithms included meter-in/meter-out, conditional rate of change, and hydrostatic. The benefits of the PLC-based subsea leak detection include the following: can be installed in existing PLC/HMI or as a standalone PLC, configurable for any combinations of well/flowline alignment, configurable for multiple drill centers, alarms, and shutdown triggers available, and can be installed typically without downtime. Additional benefits include minimal subsea data required- pressures and valve statuses, user-configurable timers for all functions, automatic and manual inhibits and degrades, low processor overhead, and abort and abandon logs.

Keystone provided comprehensive automation support for multiple Host Facilities. Our team integrates third-party packaged subsea systems as part of a subsea tieback project, including subsea Master Control System (MCS), Subsea Leak Detection, MCC/VFD integration, corrosion monitoring, sand & pig detection, and MODU into the existing Host Facility Integrated Control and Safety System (ICSS).

Additionally, Keystone provided project management, interface coordination, integration, PLC/HMI programming, FAT/SIT testing, pre-commissioning, and start-up support. The deliverables included modified ICCS PLC programs, modified HMI application, revise/update Host Facility automation documentation, third-party integration, topsides FAT/SIT, and subsea FAT/SIT.

Keystone provided detailed engineering and design to replace existing DowTherm heating equipment for the deodorizer with new high-pressure steam equipment. The new equipment included the installation of a new 2500 KW high-pressure boiler and heater exchanger. Keystone’s scope of work included the evaluation of the process structure and the existing foundation in determining if upgrades are required to handle the new loading. The structural analysis concluded that both the structure and existing foundation are suitable to handle the new equipment with minimal modifications.

Additionally, the project included the design of intercoastal supporting steel for the heat exchanger, design support for pipe components, foundation modification details, ISOs, plan/section drawings, pipe stress analysis, and expansion joint evaluation.

Keystone provided project management, engineering, and design services for a New Change House at a food grade chemical manufacturing facility. The design included a new 40’x50’ metal building with a 4’ walkway on three sides, a divide for a men’s and woman’s side, and a dry and wet area with showers and restroom facilities. Keystone’s scope of work involved a complete drawing package that included plans for the site prep, plans and details for the foundation of the new building, plans and schedules for all mechanical and plumbing items, and plans and details for the layout of the exterior and interior building sections.

Keystone provided engineering and design services for the replacement of two existing filters and relocation of existing catalyst tanks in the Hydrogenation Unit. The project involved the construction and installation of an intermediate level mezzanine to support the drums and pumps that tie into the filters and tanks. Keystone’s scope of work included an analysis and design modifications of the support structure for the new filters and the relocated catalyst tanks. Additionally, the work scope included the following: surveying of the area for installation purposes of structural modifications and piping, creating an analysis model for the new intermediate mezzanine and overall existing structure, designing/analyzing steel and concrete connection details, creating drawings for modifications to the existing support structure, and creating drawings for the new mezzanine.

Keystone provided engineering, design, and project management to reroute the product delivery piping for packaging. The work scope included an engineering package to address the rerouting of product piping from the existing route to a new tie-in point that combines two product delivery streams. The complete package provided piping isometrics/tie-in details and support details along with a Bill of Materials for the new line.

Keystone provided engineering support to perform an existing mezzanine analysis to determine if it can support the new loading from a vertical accumulator vessel. The scope of work included a structural analysis model of the mezzanine with new loading from the vessel, determining if the mezzanine's structural integrity is sufficient to handle the additional loading, and drawings for modifications to the mezzanine to handle the new loading.

Keystone provided Phase II, III, and IV engineering and design services for a project to replace existing feedstock piping. The project goal was to evaluate three different options for routing and supporting the new pipe runs. For each option, Keystone provided a Total Installed Cost (TIC) estimate, total downtime, and future expansion needs.

Saving considerable costs and providing minimal downtime, the option chosen included a new elevated modular pipe rack located in the tank dike area. The rack design included vertical loops doubling as pipe bridges to accommodate pipe stress due to high-temperature service and to allow for equipment traffic in the tank farm. The rack modules, ranging from 40’-56’ in length, were fully welded in the shop and galvanized with the piping installed, steam traced, and insulated before shipping to the facility. Each module was lifted in place with piping jumpers welded between modules.

Keystone’s multi-discipline team received high praise for this project. The Client response below is an excellent reminder of how Keystone personnel always strive to exceed expectations.

“Very good project. Everything went well. Thanks to Keystone, the engineering was spot on.”

Keystone provided a FEED study and detailed engineering for replacing the 900lb steam header on two existing boilers at an alumina refinery. The project scope of work included detailed design piping and civil construction packages. Additionally, the construction packages included tie point drawings, demo drawings, and piping plans, elevations, and details.

Keystone provided detailed structural, instrument, electrical, and piping engineering and design services for the removal and replacement of an existing High-Pressure Carbamate Condenser. The scope of work included developing documents and drawings suitable for construction for the replacement of the existing condenser.

Keystone provided engineering and design services to evaluate the sizing and hydraulics of relief valves at a refinery in Northwest, Louisiana. The PSV assessment included 404 PSVs and 31 total Units. The scope of work included site visit per Unit for data collection, the design basis for applicable scope in each Unit, API 521 calculation for each PSV reviewed, a summary report including unit limitations, and an updated model of the relief system in Visual Flare.

Keystone provided front-end engineering design (FEED), detailed design, and procurement support services for the addition of lube oil additives to an existing mixing vessel. The project included laser scanning, evaluation of the tank (internals, mixer, and circulation rates), pipe supports, and PRV bladder calculation reports. The detailed design work scope involved installing a new 40-gallon storage and delivery unit and upgrading the current system with a new 70 GPM pump. Additionally, the work scope included installing new piping, spectacle blinds, additional product sampling points, associated foundations/curbing, associated controls for maximum operability/safety, and the relocation of an existing safety shower.