SHELL UK Limited

It was identified during a site HEMP study that the road loading gantries at the terminal may not meet Shell’s fire protection requirements and may need to be fitted with a foam-water spray/deluge system.

The purpose of the project was:

• To determine if a fire protection system was required via a review of Shell documentation;
• If required, to identify what the system should be able to do and how the system should operate; and
• To propose options to satisfy these requirements.

Following detailed review, the requirement for gantry fire protection was identified within the loading bays containing spirt. As such Fabri developed the design for the agreed option to introduce a foam deluge systems for loading bays 1 to 5.

The design included utilisation of the existing Ethanol foam proportion system and extending the line to the loading bays. Local to the loading bays a new manifold was introduced that would allow selection from the control room to deluge foam on to the required gantry. Thus allowing deluged foam onto one bay at a time or up to a maximum three bays at any one time. 

Fabri performed the full project from conception through to final commissioning and handover inclusive of the following:

• Full ODM process from Identify and Assess through to Operate
• Compliance with Shell ODM process
• Mechanical, EC&I & Civil/Structural detailed design
• Commissioning and handover

Project Managers

Michael Cummings (Fabri) / Steve Taylor & Basil Manko (Shell)

Fabri Engineering Lead

Mech - David Burnett / EC&I - Kyle Anderson

Shell Kingsbury Terminal's control room contained most of the control PCs for the various systems required for the site to operate. These PCs, along with the CCTV PC systems, were kept in cabinets in the corner of the room. With site personnel constantly entering and exiting the room, the PCs were in an unfriendly environment where they could have come into contact with dirt and debris. The room is also not well cooled and ventilated, which could have caused these system PCs to overheat. The site VRU system (Vapour Recovery Unit) was also stored in another location under similar conditions.

The project therefore involved relocating these PC systems to the dedicated server room. This room contains other site systems such as the FuelFacs servers, so by moving the control PCs to the server room, the site systems will be located in the one location, which is also well cooled, clean and a much friendlier environment for these PCs. This server room is also locked via passcode adding another layer of security.

Additionally, the PC migration project provided an opportunity to upgrade the operator control station in the control room. This new infrastructure would provide operators with sit/stand desks, free-flow KVM switches and desk mounted monitors with individual audio feedback to provide operators with a more efficient and flexible working environment.

Cabling for all of the systems was first installed in position and then the PCs were moved to the server room individually. Once each system was moved, the system would be booted up and tested to ensure the system was in full working order before the next system was moved. This process reduced down time and disruption from the migration process.

Project Managers

Tom Knight (Fabri)/Matt Davis (Shell)

Fabri Engineering Lead

Rori Macpherson

The electrical infrastructure at Shell Haven Terminal included distribution equipment that was old and in some cases showing signs of deterioration and a difficulty to maintain. In addition, some of the infrastructure was largely to accommodate the old refinery equipment in the area and now had very few feeds from it.

An early stage study performed by Fabri proposed rationalisation and replacement of this older equipment and this was accepted by Shell as the project scope.

Early stage cable testing revealed that the cabling to the seven surface water interceptor pumps was nearing the end of its life and would need to be replaced as part of the project.

Also included in the project was the removal of the three surface water interceptor pump controllers with the new pump control to be included within the existing site SCADA.

An execution schedule for the project was developed by Fabri that ensured very few and short shutdowns of systems whilst the power infrastructure was swapped over to the new equipment.

Fabri performed all the engineering and design for the project as well as the procurement management and site commissioning.

Project Managers

Tom Knight (Fabri)/Lina Lusadisu (Shell)

Fabri Engineering Lead

Luke Patterson / Lewis Doherty

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

Budget

£2,500,000

Project Managers

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

Shell Haven Terminal had a legacy DCS system that included hardware no longer supported by the vendor or operating system. A combined replacement for this DCS and an additional smaller SCADA that was also in operation for some systems was required.

Little information and drawings were available on the existing DCS and SCADA systems and so Fabri had to perform site investigations and testing to establish how these operated. A more robust hardware configuration requirement was also developed to ensure redundancy and hot standby functionality. Fabri then developed a detailed specification to replicate the hardware requirements, existing systems operation and also included requested upgrades and changes to the operation made by Shell. This specification was used for pricing a new SCADA by SCADA vendors.

Fabri managed and supported the Shell selected SCADA vendor to ensure the package was compliant to the specification, graphics aligned to the Shell human factors standard and alarm management compliant to relevant standards. Fabri also organized and ran the graphic workshops and FAT which replicated all functionality of the new system.

An installation methodology was developed by Fabri to allow the terminal to keep running whilst the Installation was performed and systems cutover and tested from the old systems to the new.

Project Managers

Tom Knight (Fabri)/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

Budget

£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

Budget

£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

Budget

£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

Budget

£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

Budget

£1.1 million

Project Managers

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