Petrochemical

Yanbu, KSA

PETROCHEMICAL PLANT EXPANSION

Fabrication and installation support for a petrochemical plant expansion in Yanbu, delivering 3,000+ diameter-inches of piping and 200 tons of steel.

FabricationManpower

Overview

PROJECT OVERVIEW

Ranin International provided end-to-end fabrication and installation support for a major petrochemical plant expansion in Yanbu. The project delivered over 3,000 diameter-inches of piping spools and 200 tons of structural steel, from workshop fabrication through field erection and live plant tie-ins. All work was completed on schedule and within budget with 100% first-time radiographic acceptance.

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Details

KEY DETAILS

ClientINTERNATIONAL EPC CONTRACTOR

Year2024

Duration10 MONTHS

StatusIN PROGRESS

HIGHLIGHTS

3,000+ diameter-inches of piping spools fabricated in workshop and installed in the field

200 tons of structural steel fabricated, delivered, and erected on the project site

Seamless tie-in connections to existing live plant operations executed without production disruption

All welds passed first-time radiographic inspection with zero reject rate

Dedicated project management and planning team coordinating workshop and field activities

Completed within the original budget and on the contractual schedule without extensions

Comprehensive pre-commissioning including hydrostatic testing, flushing, and system punch list clearance

Full fabrication and installation data books compiled and delivered to client upon project closeout

Insights

PROJECT INSIGHTS

A detailed look at the challenges, methods, and outcomes that defined this project

FROM WORKSHOP TO FIELD: END-TO-END FABRICATION AND ERECTION

This expansion project demonstrated the advantages of having a single contractor manage both workshop fabrication and field installation. Over 3,000 diameter-inches of piping spools were fabricated in our Jubail workshop to project isometric drawings, alongside 200 tons of structural steel including pipe rack extensions, equipment supports, and access platforms. By controlling fabrication quality in the workshop, we ensured that every component arrived at the Yanbu site ready for immediate installation without the rework that often occurs when shop and field scopes are disconnected.

LIVE PLANT TIE-INS WITHOUT PRODUCTION DISRUPTION

The most critical phase of any brownfield expansion is the tie-in to existing live plant systems. Each connection point was pre-fabricated, pre-inspected, and staged in advance of the scheduled shutdown window. Our tie-in execution teams followed detailed isolation philosophies and risk assessments, with dedicated safety watchers and emergency response provisions in place throughout. Every tie-in was completed within the allocated window, enabling the plant to resume full production without delay.

STRUCTURAL STEEL ERECTION IN AN OPERATING FACILITY

Erecting 200 tons of structural steel within an operating petrochemical plant introduces constraints that do not exist on greenfield sites. Crane movements must be planned around active process equipment, hot work must be controlled near hydrocarbon systems, and ground-level access must be maintained for plant operations staff. Our erection crews coordinated daily with the client's operations team to schedule heavy lifts, manage temporary exclusion zones, and ensure that all structural connections were completed safely and within tolerance.

PRE-COMMISSIONING AND HANDOVER

Before handing over the expanded systems to the client's operations team, every new piping run and equipment installation underwent systematic pre-commissioning activities. Hydrostatic testing verified pressure integrity, chemical flushing removed construction debris from piping systems, and comprehensive system walkdowns generated punch lists that were systematically cleared. Full fabrication and installation data books, including weld logs, NDE reports, material test records, and as-built drawings, were compiled and delivered upon project closeout.

Scope

SCOPE OF WORK

Comprehensive delivery across all project phases

SHOP FABRICATION

Piping spool fabrication per isometric drawings in carbon steel, stainless steel, and alloy materials

Structural steel cutting, drilling, fitting, welding, and assembly to approved shop drawings

Equipment support frames, skid bases, and mounting structures fabricated to precise tolerances

Protective coating and preservation applied to all fabricated items prior to transport

Pre-shipment dimensional inspection and quality verification before release from workshop

FIELD INSTALLATION

Piping erection, fit-up, and field welding with continuous QC oversight at every joint

Structural steel erection including column splices, beam connections, and bracing installation

Equipment setting, leveling, grouting, and alignment to manufacturer tolerances

Field routing of small-bore piping, instrument tubing, and utility connections

Scaffold erection and dismantling to provide safe access for all field installation activities

TIE-IN & COMMISSIONING SUPPORT

Live plant tie-in planning including isolation philosophy, risk assessment, and execution procedures

Pre-fabrication and staging of all tie-in spools and fittings prior to scheduled shutdown windows

Hydrostatic testing, pneumatic leak testing, and flushing of all new and modified piping systems

Pre-commissioning support including system walkdowns, punch list generation, and deficiency resolution

Coordination with client operations team for safe startup and performance verification

PROJECT CONTROLS

Weekly progress reporting with schedule tracking, earned value analysis, and variance commentary

Material management covering procurement tracking, warehouse receipt, and controlled issuance

Quality documentation including weld logs, NDE reports, MTRs, and test certificates

Cost tracking and forecasting with monthly reporting against the approved project budget

Comprehensive project closeout data book compilation with all as-built records and certifications

NEOM INFRASTRUCTURE SUPPORT

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