Downstream

Keystone provided project management, engineering, and design services to support the addition of a salt water disposal (SWD) well at the client’s facility in an effort to obtain increased saltwater injection capacity over the existing SWD well. Gas, crude oil, and minimal amounts of produced water were separated out and re-injected back into the bulk header flowing to the Central Facility.  Produced water was sent to a new tank battery and triplex pump to be re-injected into the newly drilled SWD #1 Well.  In addition to the necessary process equipment, the new facility required the construction of a limestone rock pad with truck access driveway, pollution containment berm, and 480V 3-Phelectrical site power.  

The scope of work for the new facility design included horizontal 3 phase separator with 10,000 BPD liquid handling capacity, one 400 BBL welded steel gun barrel tank, two 400 BBL welded steel water surge tanks, one 400 BBL welded steel crude oil storage tank, two oil recirculation/transfer pumps; 1,000 BPD, two water recirculation/transfer pumps; 1,000 BPD, two saltwater injection pumps; 8,000 BWPD; 150-200 HP, and two produced water filters.  

Keystone provided comprehensive instrumentation, electrical, and civil/structural design for a central delivery facility in Dewitt County, Texas to serve as a central receiving location for two incoming pipelines (12” and 16”) and provide delivery into one new 16”export pipeline. The facilities included: Pig launcher/receivers; slug catcher(3 tubes); separation and compression; NGL storage; flare design; liquid storage tanks (4 oil and 1 water); truck loading (NGL, Oil, and Water);electrical; instrument air compressor; fuel gas system and motor-driven VRU.

Installation of a 10,000BOPD Crude Oil Stabilization Unit at an Ohio terminal. Unit including a Natural Gas Liquid (NGL) compressor for process, NGL storage, and sales. Scope of work included specifying switchgear upgrades, size/specifying emergency MCC, size/specify electric generator and ATS, develop conceptual design with upgrade options, technical evaluation of equipment bids, development of construction scope and installation documentation, turnaround installation planning, and equipment alarm/status I/O development to DCS. Keystone provided a FEED Study, multi- discipline engineering and design, procurement, construction support, and on-site start-up and commissioning support.

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The project consists of a production facility to handle bulk product from 12 Wells.  The facility included Test Separators, Heater Treaters, Oil Storage Tanks, Produced Water Storage Tanks, Skim Oil System, Produced Water Transfer Pumps, Oil LACT Unit, Vapor Recovery Unit, Gas Dehydration, Gas Compression, and Vent/Relief System. The facility was powered from the local utility.  The facility was controlled by PLC.  Keystone is providing multi-discipline engineering and design services for the facility and pipeline interconnects.

Keystone provided project management, engineering, and design services to support replacement of existing substation and removal of field location switch racks. The project included engineering front end scope development, TIC development, bid evaluation, detailed design execution, and construction support. The project identified process unit electrical loads for power distribution replacement, specified substation equipment, incorporated a closed transition main tie main switchgear section, and implemented redundant A & B power feeds from primary 35KV substation yard. The substation building implemented a modular industrialized building design with vertical construction to accommodate space constraints. Electrical infrastructure within the building included LV switchgear, LV induction motors, power distribution, industrial UPS system, UPS power distribution, and DCS equipment space for upgrade of unit controls. The UPS power distribution consolidated and centralized existing unit UPS system. Cable tray systems, cabling, structural supports, foundations, and building were completely installed within an operating refinery. Final cutover and commissioning were performed during a planned turnaround outage.

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1,450 STPD Urea production facility in Louisiana. Project included the replacement of the urea reactor and HP stripper. Scoped included the rework of a 200ft tall structure to accommodate the removal and replacement of the vessels.  

The project consisted of the installation of three temporary steam boilers, one deaerator with BFW pumps, a blowdown vessel, CEMS units, demineralized water processing trailer and storage, wastewater storage, and transfer pumps. Approximately 10,000 linear feet of pipe was installed. Medium voltage, low voltage, and control power systems were installed. The systems were controlled via local PLCs on each piece of equipment and terminated at a central processing unit. A battery limit access platform was included in the scope. Keystone provided engineering and design services.

The project consisted of installing of a new Reactor, Air Preheater, Feedstock Preheater, Waste Heat Boiler, Cooling Water System, and Vent Scrubber at a carbon black facility. Process piping for reactor was tied into to the existing blower and bag filter systems. Reactor utility piping was interfaced with existing facility utility system piping systems at various locations throughout facility. Multi-level Structures were implemented with for support of associated utility and process piping requirements along with operations and maintenance access platforms to equipment and instrumentation. Project also included interface with pipe stress analysis and incorporation of stress requirements to Structural design. Keystone project execution team included Civil, Structural, Mechanical, Electrical, and Instrumentation engineering discipline support.

Keystone provided project management, engineering, design, procurement, and construction support for the rebuild and upgrade of biodiesel facility that experienced a major fire. The project included demo, redesign, and upgrade of a 5-level process structure with significant instrumentation and high pressure/temperature equipment. Additionally, a hydrogen recovery process was added to the system to reclaim spent hydrogen used in the biodiesel refining process. This required new process equipment, instrumentation, and electrical power to be expanded to a new location within site. Project included specification of control system replacement, instrumentation updates, electrical system wiring upgrades, heat trace system installation, and control system integration support with existing equipment onsite system.

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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 necessary to get RVP to an acceptable level for sales contract. 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.

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 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 an existing well. The new wells required a full facility to produce, separate, store, and sell the oil and gas production.

The scope of work for the newfacility design included well flowline rated for SITP of the existing well(<10,000 psig), well flowline rated for SITP of the new wells (<15,000psig),  line heater with line heater fuelgas scrubber, slug catcher, HP and LP separator, fuel gas/instrument gasscrubber, oil heater treater, glycol dehydration package, amine unit for CO2removal, dewpoint control unit, oil storage tanks, three-500 BBL water storagetanks, 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 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 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 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 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 addition of electrical substation and DCS control expansion including 800 new instruments. Additionally, the project implemented new cooling towers and instrument air compressors to expand existing facility utility infrastructure to support the process unit installation. An existing LPG Truck Loading Rack was demolished to create room for unit installation and a new LPG truck loading rack was engineered to support facility with safety interlock updates.

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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 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.

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, 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 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 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.

Keystone provided Phase II,III, and IV engineering and design services for a project to replace existingfeedstock piping. The project goal was to evaluate three different options for routingand supporting the new pipe runs. For each option, Keystone provided a totalinstalled cost 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.