As part of the improvement work undertaken at the plant, a new Dew Point Control Unit (DPCU) and a Propane Refrigeration Unit have been installed, designed to address existing limitations in the handling of heavy hydrocarbon feed and higher acidity levels.
Sarens worked in collaboration with Wison Engineering Ltd. to lift 62 different modules, from pipe racks and equipment modules to fin fan coolers and large pipe spools with a diameter of 56 inches. In total, 124 precision lifts were carried out, with weights reaching up to 205 tons.
This project is part of Aramco's long-term strategy to increase NGL and ethane production and maximise the value of associated gas through high-efficiency liquid recovery plants.
The improvement works undertaken at the Shaybah NGL plant, located in the Rub' al-Khali (Empty Quarter) desert in Saudi Arabia, will have a clear impact on its production. The installation of a new Dew Point Control Unit (DPCU) and a Propane Refrigeration Unit will enable production levels to be restored to 2,400 MMSCFD from the current 1,800 MMSCFD (million standard cubic feet per day), ensuring that the plant remains one of the pillars supporting the region's energy system.
Sarens, world leader in heavy lifting, engineered transport and crane rental solutions, has been directly involved in the plant upgrade works on behalf of Saudi Aramco and in collaboration with Wison Engineering Ltd. To this end, their engineering team designed a single tailor-made lifting frame to handle 62 diverse modules, from pipe racks and equipment modules to fin fan coolers and large pipe spools with a diameter of 56 inches. In total, Sarens carried out 124 precision lifts, with weights reaching up to 205 tons.
To carry out these tasks, Sarens transported an LR1750 crane unit with a capacity of 750 tons and a CC2400 (400 tons) to Shaybah from its facilities in Jubail, more than 750 km away. To complete the assigned work, the cranes remained on site for approximately seven months, after taking three weeks to assemble and commission. During this time, both the machinery and Sarens' engineering team, made up of 16 highly qualified professionals, faced significant challenges, such as harsh weather conditions and the need to operate on a brownfield site at the plant.
The Dew Point Control Unit (DPCU) installed is crucial to the proper functioning of the plant, as it is responsible for removing heavy hydrocarbons and preventing the formation of solid hydrates in gas streams, which is a critical problem under high pressure and low temperature conditions, especially when cryogenic processes are used to recover NGL (Natural Gas Liquids), i.e. ethane, propane, butane and pentane separated from the gas in fractionation plants.
According to Solai Raja Periyakuruppan, Project Manager de Sarens, “executing this project in Shaybah, at the heart of the Rub’ al-Khali (Empty Quarter) desert, was an extraordinary challenge. The site is surrounded by towering red and golden sand dunes rising nearly 1000 feet, with wind speeds reaching 80 km/h and summer temperatures soaring up to 50°C at times. Despite these extreme conditions, our team delivered every lift with precision and safety at the forefront”.
This major refurbishment project at the Shaybah NGL plant is part of Saudi Aramco's long-term strategy to boost NGL and ethane production, thereby maximising the value of associated gas through high-efficiency liquid recovery plants. The project is also of paramount importance to the region, as it has contributed to boost local job creation.
Sarens has extensive experience internationally in the oil & gas sector. Together with McDermott, the company took part of the heavy lifting and load out operations at Jabel Ali as well as at Batam for Saudi Aramco’s Marjan Field Package 1, as well as the upgrade and improvement works of PT Pertamina refinery in Balikpapan, Indonesia. Also, for North Field Oil projects (Qatar Energy) Sarens was contracted by Seatrium to conduct the weighing, loadout and ballasting for two Bridges units, two Jackets and two Topsides utilizing up to 132 a/l for the Gallaf 2 project in Batam, Indonesia.
About Sarens
Sarens is the global leader and reference in crane rental, heavy lift and engineered transportation services. With state-of-the-art equipment, value engineering, one of the world's largest inventories of cranes, transporters and special rigging equipment, Sarens offers creative and intelligent solutions to today's heavy lifting and engineering transport challenges.
With more than 100 entities in 65 countries operating without borders, Sarens is an ideal partner for small to large-scale projects. Sarens currently employs 5,000 highly qualified professionals who are ready to serve the needs of any client worldwide and in all market sectors. https://www.sarens.com/