SHELL UK Limited

The location of the terminal at the start of the Thames estuary and in close proximity to the DP World shipping container terminal risked moored tankers drifting and damaging the asset when ships passed within close proximity.  The aim of the project was to remove the risk and provide redundancy for the asset.

The project replaced two existing Marine Loading Arms (MLA) with three new MLA’s complete with Emergency Release System (ERS  -  allows the MLA to decouple from the tanker in a drift scenario). Third party specialists supported with the creation of a drift study that allowed Fabri to align the parameters of the ERS decoupling positions with the expected drift speeds and the site ESD valves closure times to prevent surge.

In addition to the replacement arms the project identified an opportunity through local jetty/site pipework modifications to utilise an out of use line for the new third arm that significantly reduced the offload time of the tankers.

Fabri performed the complete project from cost benefit analysis / Feasibility study through to final commissioning of the new MLA’s and associated infrastructure.

• Full EPCM
• Compliance with Shell ODM process
• HAZOP & LOPA studies
• Process safety requirements design / compliance
• Mechanical, EC&I & Civil/Structural detailed design
• MLA & Automation systems upgrade specifications, FAT and SAT
• Commissioning and handover

Year / Budget

2017 - 2022 / £2,500,000

Project Managers

Michael Cummings (Fabri) / David Illik / Lina Lusadisu (Shell)

Joint Venture Project with Shell & ESSAR. The existing site pre blended Gas Oil (GO) tank T-1 was planned to be changed to Jet service and as such a new GO marker dye system was required to inject the marker into Derv at the loading gantries. To accommodate a new CAU was installed, new injection equipment and controllers, additive pumps and product pump PLC changes and new MCC switchgear. Complete project from concept to commissioning with the next phase of converting tank T-1 planned for 2021.

• Full EPCM
• Aggressive schedule to accommodate T-1 inspection
• Compliance with Shell ODM process
• HMRC compliance and approval
• HAZOP & LOPA studies
• Mechanical, EC&I & Civil/Structural detailed design
• Commissioning and handover

Year / Budget

2020 / £850K

Project Managers

Michael Cummings (Fabri) / Lina Lusadisu (Shell)

Reduction of time Jet road tankers require on the loading gantries by the introduction of a pre staging area that allow the tankers to confirm the tanker is empty before entering the loading gantry. An additional staging area after the loading gantry that allows the tanker to settle and sample following completion of the loading process. The new loading gantry arrangement facilitates an additional 100 trucks per day without the need to expand the existing site infrastructure (piping, pumping or number of loading gantries). Complete project from concept to commissioning.

• Full EPCM
• Compliance with Shell ODM process
• Design reviews
• Liaison with Highways England for increased road usage
• Mechanical, EC&I & Civil/Structural detailed design
• Commissioning and handover

Year / Budget

2019 / £600K

Project Managers

Michael Cummings (Fabri) / David Ilik(Shell)

Introduction of HMRC compliant Kerosene Marker Dye system at Shell Haven terminal requiring a containerised additive unit (C/W tank and pumps), dedicated kerosene loading gantry & injection and new dedicated slops system. Complete project from feasibility study through to commissioning.

• Full EPCM

• Compliance with Shell ODM process

• HMRC compliance and approval

• HAZOP

• Mechanical, EC&I & Civil/Structural detailed design

• Construction management and supervision

• Commissioning and handover

Year / Budget

2017 / £750K

Project Managers

Thomas Knight (Fabri) / Paul Comblain (Shell)

A project to determine the requirements for Remotely Operated Shut Off Valves (ROSOV) in accordance with HSE guidance and recommended practices.

• Identify / Assess and Select phases

• Review of site COMAH Safety Report against HSE guidance  HSG 244

• Implement Primary Criteria Assessments in accordance with
  HSG 244

• Implement Secondary Criteria Assessment in accordance with HSG 244

• Cost Benefit Analysis (CBA) for tank side ROSOV’s

Year / Budget

2015 – 2016 / £1 million

Project Manager

Andrew McCann (Fabri) / Chris Llewellyn (Shell)

Introduction of Shell V-Power grades into a joint venture site (Shell/BP) requiring new additive tankage, offloading and loading capabilities, modifications to the existing ethanol system and modifications to road loading gantries. Complete project from feasibility study through to commissioning.

• Full EPCM

• Compliance with Shell ODM process and BP CVP process

• Gap analysis of Shell DEP’s Vs BP ETP’s

• HAZOP & LOPA studies

• Mechanical, EC&I & Civil/Structural detailed design

• Construction management and supervision

• Commissioning and handover

Year / Budget

2016 / £1.1 million

Project Managers

Thomas Knight (Fabri) / Chris Llewellyn & Trevor Allinson (Shell)