Oil & Gas

Yanbu, KSA

REFINERY TURNAROUND PROJECT

Critical turnaround support for a major oil refinery in Yanbu, mobilizing 150+ certified welders and fitters within 10 days.

ManpowerFabrication

Overview

PROJECT OVERVIEW

Ranin International provided specialized welding, pipe fitting, and inspection teams for a major refinery turnaround in Yanbu. Over 150 certified tradesmen were deployed across multiple refinery units under an aggressive 45-day shutdown window. The project achieved zero safety incidents and 100% first-time radiographic weld acceptance.

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Details

KEY DETAILS

ClientNATIONAL REFINING COMPANY

Year2024

Duration45 DAYS

StatusCOMPLETED

HIGHLIGHTS

150+ specialized tradesmen mobilized and operational on site in under 10 days

All welders certified to ASME Section IX standards with 6G and 6GR qualifications

Turnaround completed within the planned 45-day shutdown window without schedule extension

Zero safety incidents recorded during the entire turnaround duration

100% first-time radiographic weld acceptance rate on all critical joints

Full as-built documentation, weld maps, and NDT reports delivered upon completion

Daily progress tracking with real-time resource reallocation to address emerging priorities

Successful tie-ins to live refinery systems executed under strict isolation protocols

Insights

PROJECT INSIGHTS

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

RAPID MOBILIZATION OF CERTIFIED TRADESMEN

The 10-day mobilization window required a highly organized deployment of 150+ tradesmen, all of whom needed active certifications before stepping onto a live refinery site. Our workforce management team coordinated the verification of 6G and 6GR welder qualifications, ASME Section IX procedure compliance, and site-specific safety inductions for every worker. Pre-deployment logistics including accommodation, transport, and PPE issuance were executed in parallel to ensure all crews were productive from day one.

EXECUTING PIPING MODIFICATIONS IN HYDROCARBON SERVICE

Modifying piping systems that carry high-temperature hydrocarbons requires flawless execution at every step. Each piping modification followed a controlled sequence: engineering review, material verification with Positive Material Identification, precision fit-up to isometric drawings, welding per qualified procedures, and full NDE inspection before the system was released for hydrostatic testing. Corroded pipe sections were systematically removed and replaced with new spools fabricated on site, maintaining process integrity throughout.

ACHIEVING ZERO-DEFECT WELD QUALITY

Every critical weld joint in the turnaround scope was subjected to radiographic testing, and the project achieved a 100% first-time acceptance rate. This outcome reflects the discipline built into every stage of the welding process: qualified weld procedures matched to each material and service condition, experienced welders selected for their proven track records, rigorous fit-up inspections prior to welding authorization, and real-time quality monitoring by our on-site QC inspectors.

CONFINED SPACE AND HOT WORK SAFETY MANAGEMENT

Refinery turnarounds involve extensive confined space entry and hot work operations, both of which are among the highest-risk activities in industrial maintenance. Our safety management protocols included atmospheric monitoring at all confined space entries, dedicated hole watchers, hot work permits with fire watch deployment, and emergency rescue provisions stationed at every active work front. The entire 45-day turnaround was completed with zero safety incidents.

Scope

SCOPE OF WORK

Comprehensive delivery across all project phases

WELDING & FABRICATION

Deployment of 6G and 6GR certified welders for all critical pressure-containing joints

On-site piping spool fabrication and precision field fit-up to isometric drawings

Alloy and stainless steel welding using GTAW (TIG) root and SMAW fill/cap processes

Fabrication of temporary and permanent supports, clamps, and bypass connections

Weld procedure qualification and welder performance qualification testing on site

PIPING MODIFICATIONS

Hot and cold tie-in connections to live process systems under strict isolation protocols

Line modifications including rerouting, size changes, and branch connection installations

Hydrostatic testing and pneumatic leak checks on all new and modified piping runs

Comprehensive flange management program with controlled bolt torquing and gasket replacement

Removal and replacement of corroded pipe sections in high-temperature hydrocarbon service

INSPECTION & QC

Full NDT coordination covering radiographic (RT), ultrasonic (UT), penetrant (PT), and magnetic particle (MT) testing

Dimensional inspection and fit-up checks at every stage prior to welding authorization

Weld mapping, joint tracking, and systematic documentation of all weld inspection results

Positive Material Identification (PMI) verification on all alloy piping and fittings

Final hydrostatic test witnessing and certification with client and third-party inspector

PROJECT MANAGEMENT

Daily progress tracking dashboards with earned value analysis and schedule forecasting

Resource planning and multi-shift scheduling to optimize workforce utilization

Client interface meetings, coordination with turnaround planners, and scope change management

Material management including receipt inspection, storage, and issuance tracking

Comprehensive closeout package with as-built drawings, test records, and data book compilation

HIGH-RISE CONSTRUCTION SUPPORT

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