Upstream

Greenfield design of a central facility with capacities of 70 MMscfd gas, 20,000 BOPD and 10,000 BWPD.  Facility included a gas train with Inlet Scrubbers, gas compression, gas cooling, H2S treating, filter coalescers, dehydration, and metering.  Liquids train included LP Separators, Oil Treaters, Vapor Recovery, Oil and Water Storage, LACT skids, Oil Pipeline Pumps and Truck Loading. Utilities includes Instrument Air, Fuel Gas, and High/Low Pressure Flare Systems.

Keystone provided front end engineering design  and detailed engineering design for a 30 MMSCFD EOR 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 thei injection compressor suction and gas lift pipeline.

Keystone provided multi-discipline engineering, design, and construction management services for the optimization of operations at the offshore field. The scope of work included pipeline modifications for bi-directional flow between additional fields and relocation of existing equipment.

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Keystone provided multi-disciplined engineering and design for the installation of a Solar Centaur 50 Compressor Skid, Gas Scrubber Skid, Gas Cooler installed on new elevated platform, Fuel Gas Skid, MCC Building, and deck extension for Engine Air Intake Filter. Keystone scope include structural design for deck extensions, intercostals, and pipe supports; interconnecting pipe design, electrical and instrumentation design, equipment specifications, and programming.

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Installation of a new pump module and three turbine-driven pumps at WD-143 to support increased production of an additional 80-100k BOPD. The scope of work included design and installation of 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 to SP-89E-B, and a new gas chromatograph skid for primary gas ultrasonic meters. Keystone multi-discipline engineering and design, project planning, procurement, and construction execution.

Additionally, Keystone provided engineering support for the pigging of a 14” OD subsea gas export pipeline spanning 42 miles. The line had accumulated asphaltenes in addition to retrograde condensate, both of which presented challenges to stabilizing liquid returns at the offshore facility. Keystone provided equipment and platform interface for temporary condensate handling during the turnaround.

Project to convert a drilling, separation, and compression facility to a full-production facility whereby oil and as can be directly exported to market from the platform, eliminating any reliance on other platforms. Bulk production will increase to 7 MMSCFD total gas, 1,800 BPD oil, and 5,000 BPD water. Upgrades include the addition of a line heater, heater treater, replacement of pipeline pumps, booster pumps, sump tank, and chemical tanks/skids (demulsifier and water treatment chemicals). Existing MCC was retrofitted for the pipeline pump replacement. Keystone provided detailed engineering and design services of the facility upgrades.

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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.

Design of a 60,000 BOPD greenfield spar-based floating production system in 4,000ft water in the Gulf of Mexico. Design included a three-level topside structure (approx. 8,000 tons). Keystone provided fabrication and loadout engineering services. Keystone performed a structural analysis for construction and loadout conditions. 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 topsides with 60’ deck leg spacing on existing yard skidways that were set for a 69’ deck leg spacing.

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Installation of a satellite drilling platform and 5km pipeline off the coast of Sabah in the South China Sea. The platform was designed as a guyed wire monopod platform to accommodate four wells with a well test loop and 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 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 mud walls, and a wellhead access platform.

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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 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 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 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.