On-Stream Cold Welding & Coating for Yanbat Company
Yanbu, KSA
On-Stream Cold Welding & Coating for Yanbat Company
Status
Delivered
Project Type
Cold Welding & Coating
Commencement date
2024
Project description
Challenge:
Two live tanks containing a highly flammable (Client Category 5) product required structural repair in localized areas. Hot work was prohibited, and the work had to be executed without interrupting operations while managing ignition risk, static build-up, and strict permit controls. Our Solution.
Cold Welding (On-Stream Repair): Implemented a qualified cold repair system for defect arrest and reinforcement—avoiding heat, sparks, and hot work permits.
Hazard Controls: Continuous gas testing, bonding/grounding to prevent static, intrinsically safe tools, anti-static PPE, fire watch, and disciplined PTW/handover procedures.
Wet Abrasive Blasting: Performed water-assisted sandblasting to achieve the required surface profile while suppressing dust and eliminating ignition sources.
Coating Application: Applied an approved protective coating system immediately after surface preparation, ensuring adhesion and corrosion protection in service.
QA/QC & Documentation: Conducted surface-prep checks, environmental monitoring, and coating inspections; compiled a complete dossier with test records and as-built photos for client acceptance.
Results & Value
Safety: Completed with zero accidents or recordable incidents.
Continuity: Tanks remained in operation throughout the works—no unplanned downtime.
Schedule: Full scope completed on time, enabling the client to meet production targets.
Quality: Repairs and coating passed all acceptance criteria and were approved by client QA/QC.
This project demonstrates our capability to deliver safe, high-integrity, on-stream repairs in high-hazard environments, combining rigorous controls with efficient execution to protect people, assets, and production.
Two live tanks containing a highly flammable (Client Category 5) product required structural repair in localized areas. Hot work was prohibited, and the work had to be executed without interrupting operations while managing ignition risk, static build-up, and strict permit controls. Our Solution.
Cold Welding (On-Stream Repair): Implemented a qualified cold repair system for defect arrest and reinforcement—avoiding heat, sparks, and hot work permits.
Hazard Controls: Continuous gas testing, bonding/grounding to prevent static, intrinsically safe tools, anti-static PPE, fire watch, and disciplined PTW/handover procedures.
Wet Abrasive Blasting: Performed water-assisted sandblasting to achieve the required surface profile while suppressing dust and eliminating ignition sources.
Coating Application: Applied an approved protective coating system immediately after surface preparation, ensuring adhesion and corrosion protection in service.
QA/QC & Documentation: Conducted surface-prep checks, environmental monitoring, and coating inspections; compiled a complete dossier with test records and as-built photos for client acceptance.
Results & Value
Safety: Completed with zero accidents or recordable incidents.
Continuity: Tanks remained in operation throughout the works—no unplanned downtime.
Schedule: Full scope completed on time, enabling the client to meet production targets.
Quality: Repairs and coating passed all acceptance criteria and were approved by client QA/QC.
This project demonstrates our capability to deliver safe, high-integrity, on-stream repairs in high-hazard environments, combining rigorous controls with efficient execution to protect people, assets, and production.
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