OIL & GAS DOWNSTREAM ASSET OPTIMISATION AND COMPLIANCE FOR PROCESS INDUSTRIES, STORAGE AND DISTRIBUTION
COSTAIN DOWNSTREAM SERVICES Cost effective and risk managed asset optimisation and compliance for process industries, storage and distribution. REFINERIES AND PROCESSING PLANTS Front End Solutions and Engineering Procurement and Construction Management Operations & Maintenance Support T&I Services Risk Based Integrity Management Engineering Term Services Functional Safety Assessment EPC AND PROJECT MANAGEMENT Costain has extensive EPC experience of working collaboratively with clients, suppliers and sub-contractors to deliver asset turnarounds, modification, improvement and replacement. We provide technical solutions and engineering services for off-sites, utilities, effluent treatment, power and tankage facilities. Costain manages fast track schedules on major projects by optimising: Design and supply packages for equipment and plant Use of local equipment suppliers, engineering, fabrication and construction services International procurement of specialist equipment and services Construction management and site supervision STORAGE AND DISTRIBUTION Tank and Pipeline Operations & Maintenance Jetty Maintenance and Integrity Assurance COMAH Compliance Assurance Tank Cleaning, Inspection, Engineering and Repair Accredited Process Safety Training Programme Accredited Confined Space Training FRONT END SOLUTIONS Option Identification and Screening Cost and Schedule Estimating Transport Modularisation and Constructability Risk Identification and Assessment Value Management/ Functional Analysis Layout Studies and Plot Plan Development PROCESS ENGINEERS TECHNOLOGY SPECIALISTS MACHINERY ENGINEERS TECHNICAL SAFETY AND ENVIRONMENTAL SPECIALISTS PLANT DESIGN AND LAYOUT MATERIALS ENGINEERS COST ESTIMATORS CONSTRUCTION SPECIALISTS Concept Evaluation and Selection Process and Energy Optimisation Technology Risk Management Environmental / BAT Assessment / Legislative Review Major Process Hazard Analysis and Coarse QRA ASSET INTEGRITY AND ASSET MANAGEMENT PLANNING VALUE ADDED ASSET MANAGEMENT TO PROVIDE COST EFFECTIVE REGULATORY COMPLIANCE: Condition monitoring beyond the normal inspection techniques to full evaluation of assets in use. INDUSTRIAL SERVICES Trained and qualified team offering high quality hazardous environment industrial cleaning and support services: T&I support services with teams of 200 people regularly provided Water jetting up to 2,750 bar Expertise in confined space working including the provision of rescue teams Hazardous and non-hazardous waste management in solid, liquid or sludge form Fleet of ADR compliant, low flash point, vacuumation vehicles Open and closed grit blasting, soda blasting Fire watchers, hole watchers and safety attendants Culvert cleaning, cleaning and de-silting of interceptors, pump and catch pits Tank bund cleaning API 570 inspection techniques to risk assess pipe layouts and using ultrasonic non-destructive pipe inspection. Extensive experience of tank inspections utilising EEMUA 159 Guidelines and associated risk assessments allowing us to optimise repairs and extend the operational life of tanks.
REFINING AND PROCESSING PLANTS STORAGE AND DISTRIBUTION CAPABILITIES Concept and Option Development Front End Services FEED Functional Safety Assessment EP(m) Risk Based Asset Management Term Services Technical Authority Assurance CAPABILITIES Operations & Maintenance COMAH Compliance Assurance Jetty Maintenance and Integrity Waste Management Integrity Management and Asset Management Plans Full Tank Cleaning, Inspect & Repair Capability Pipeline Engineering, Operations and Maintenance DOWNSTREAM ENGINEERING CAPABILITY STORAGE ASSET MANAGEMENT Fixed and floating roof tanks DCS & ESD system design Rotating equipment Pressure vessels Heat exchangers Cryogenic columns Instrumentation MECHANICAL PIPING INSTRUMENT ELECTRICAL CIVIL AND STRUCTURAL Smartplant SIL assessment PDMS & AutoCAD EEMUA 159, API 653 Vendor SAT & SAT TANK FARM MODIFICATIONS TANK FARM MANAGEMENT Management of aging assets Operations outsourcing CoMAH compliance Tank design, engineering and construction Civil engineering Tankage and pipework modifications Review, installation and upgrade of SIL rated control systems COST EFFECTIVE TANK ASSET MANAGEMENT Cleaning Inspection and report interpretation Fitness for Service review Repair engineering and on-site delivery EPC / EPC(m) Recommission Lining repair or replacement TANK TURNAROUND ENGINEERING SERVICES Costain has wide ranging experience of projects for the Oil refining industry, including: Revamps and expansions of existing facilities Engineering services as part of a site term agreement Acid gas removal and sulphur recovery Light and heavy ends fractionation Gasoline and diesel quality upgrading VOC abatement Lube oil refining OPERATIONS OF TANK FARMS, PIPELINES AND JETTIES Provisions of operatives trained and certified as competent on COMAH facilities Focus on Process Safety Management with accredited in-house training Asset Optimisation reviews including full Asset Management Planning HSE and EA operation compliance assurance RISK BASED INTEGRITY MANAGEMENT AND ENGINEERING Condition monitoring beyond the normal inspection techniques to full evaluation of assets in use API 570 inspection techniques to risk assess pipe layouts and using ultrasonic nondestructive inspection Tank inspections to EEMUA 159 Guidelines and associated risk assessments giving optimised repairs
NATIONAL REFINERY, STORAGE AND DISTRIBUTION PROJECT DELIVERY STANLOW OIL REFINERY A Term Services agreement covering significant front-end engineering and estimation of material and labour costs. Small to large detailed design packages, ±30% and ±10% estimates, procurement co-ordination and construction management. Projects ranged from 25 to 100,000 man hours. Major projects completed as part of the term services agreement include: Lube oil additive plant project Revamp of oil manufacturing plant Engineering design and construction supervision of HDS revamp Debottlenecking of an ethyl benzene unit CONOCOPHILLIPS TEESSIDE OIL TERMINAL VOC RECOVERY PROJECT Following the successful completion of the front end engineering design development (recognised as Best in Class by independent audit), Costain was awarded a follow-on contract for the engineering design, procurement, construction and commissioning of the VOC Recovery Project. Design and installation of facilities to collect 100% of the vapour displaced during ship loading (previously discharged direct to atmosphere) and to recover a minimum of 85% of the non-methane volatile organic compounds, significantly reducing the environmental discharges of hydrocarbons including benzene. OPA TANK TURNAROUNDS Costain manage the tank inspection and compliance programme for the OPA 150 tanks spread around 14 sites. Decommission Cleaning Lining removal if required Inspection and interpretation Risk based review Engineering and delivery of repairs and modifications Recommissioning OPA OPERATIONS Operation and maintenance of the Government Pipeline and Storage System 14 CoMAH sites and 2,000km of pipeline, plus jetties and road loading. Full local management and operative teams COMAH compliance programme Site improvement plans Competence management system Management of aging assets Pipe and tankage improvement projects Process safety training programme TOTAL LINDSEY OIL REFINERY Project management, engineering design and procurement. FLARE GAS RECOVERY Installation of a flare gas recovery compressor and auxiliary equipment on the refinery stage 1 and 2 flare systems. Reduces the requirement for the refinery to import natural gas as a fuel. FREON REPLACEMENT Replacement of refrigerant on the refinery s cryogenic unit. The new refrigeration package, which will use propane as a replacement for Freon, has been designed so that it can be manufactured off site in a modular format and installed with minimal disruption to production on site. TOTAL LINDSEY OIL REFINERY Provision of T&I support services for 2015 turnaround Industrial cleaning services Confined spaces and fire watchers Recruitment, verification and training Ramp up of 100 people for six week T&I Confined space entry
STANLOW OIL REFINERY OPA TANK TURNAROUNDS OPA OPERATIONS CONOCOPHILLIPS TEESSIDE OIL TERMINAL VOC RECOVERY PROJECT TOTAL LINDSEY OIL REFINERY ENGINEERING SERVICES UPSTREAM SUBSEA FLOATING TOPSIDES MIDSTREAM GAS PROCESSING GAS STORAGE TRANSMISSION & DISTRIBUTION LNG IMPORT DOWNSTREAM REFINERIES & PROCESSING PLANTS STORAGE & DISTRIBUTION WE DELIVER INTEGRATED SOLUTIONS ACROSS THE FULL ASSET LIFECYCLE. COSTAIN OIL & GAS PROJECT DELIVERY CENTRES 960 PEOPLE ACROSS PROCESS SECTORS Advisory & Concept Development Specialist Design 130 Aberdeen Programme Management Complex Project Delivery Technology Integration Asset Optimisation & Support 30 Teesside 170 Leeds 180 Immingham 450 Manchester Delivery Centre Head Office Maidenhead Manchester // Teesside // Aberdeen // London // Maidenhead // Immingham Connect with us: www.costain.com oilandgas@costain.com +44 (0) 161 910 3444