Functional Safety

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.

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 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 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.