Plant shutdown steel tie-ins, Jubail Industrial City
- Client
- Ghazal Petrochemicals
- Location
- Jubail Industrial City
- Year
- 2025
- Shutdown window
- 14 days
- Members replaced
- 18
- New frames
- 12
18 members cut out and 12 new frames installed inside a 14-day shutdown — zero day-over.
The challenge
A new pump skid needed steel modifications inside a 14-day plant shutdown. Eighteen existing members had to be cut out and twelve new frames erected while adjacent units stayed live, every hour beyond the window carried liquidated damages, and no hot work could start until line break certificates were signed.
Our approach
Every cut and frame was pre-fabricated and trial-assembled in the workshop so site work was removal, fit-up and bolting. We rehearsed the sequence in a mock-up yard, staged materials 40 m from the work face, and ran two shifts with permit-to-work, gas testing and fire watch on each. Cuts used cold methods where fire risk demanded, and survey checks ran after every frame so alignment errors never waited for the end.
The result
All tie-ins completed six hours inside the 14-day window — 18 members removed, 12 frames installed and surveyed, zero lost-time incidents across 9,700 safe man-hours at a peak crew of 28, and no extension to the shutdown was requested.
Scope delivered
- Workshop trial assembly of all new frames
- Line break confirmation & permit staging
- Cold cutting of 18 existing members
- Twelve new frames fitted & bolted
- Survey checks after every frame
- Two-shift execution with gas testing & fire watch
They finished six hours early and the units restarted on the hour we planned. The mock-up yard rehearsal was the difference.Shutdown coordinator · Ghazal Petrochemicals
