Construction Management

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.

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.

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 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, 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 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.