Tank farm pipe racks & access steel, Yanbu
- Client
- Nawah Energy Services
- Location
- Yanbu
- Year
- 2024
- Duration
- 9 weeks
- Steel installed
- 96 t
- Stair towers
- 2
96 t of racks, towers and platforms installed in nine weeks inside live tank-farm windows.
The challenge
New pipe racks and two stair towers had to thread through an operating tank farm. Hot work permits were restricted to gas-test windows, easterly winds regularly exceeded crane limits, and every lift had to avoid tank nozzles and fire-water lines running below.
Our approach
Steel was pre-assembled into transportable rack modules in Madinah so site work was bolting, not welding. Crews worked night-shift erection windows with exclusion zones over the tanks, tag lines on every module and a wind-speed trigger that stopped lifts at 10 m/s. Bracing was bolted and plumbed before the next rack bay went up, and platforms, ladders and handrails followed the day after each tower landed.
The result
Nine weeks from first setting-out to handover: 96 tonnes installed, all alignments within tolerance, zero lost-time injuries across 12,900 safe man-hours at a peak crew of 24, with no unplanned interruption to tank operations.
Scope delivered
- Rack modules pre-assembled in Madinah
- Night-shift erection inside exclusion zones
- Columns, beams & bracing bolted and plumbed
- Two access stair towers erected
- Platforms, ladders & handrails installed
- Survey report & as-built drawings
Night erection inside a live tank farm without one unplanned stop — their permit discipline is the reason we keep calling.Site manager · Nawah Energy Services