Total Joint Integrity Assurance for a Major Petrochemical Complex

The Challenge

Petro Rabigh operates one of the world’s largest and most complex integrated refining and petrochemical facilities -processing 400,000 barrels/day of crude oil and more than 1.2 MTPA of ethane across 23 interlinked process plants. In 2015 the operator scheduled a Total Complex Shutdown (TCS)—the largest shutdown in Saudi Arabia that year. The entire facility needed to come offline safely, with thousands of critical bolted joints inspected, controlled, and reassembled to ensure a fully leak-free restart. The challenge was clear:

Manage joint integrity across multiple process units simultaneously

Maintain absolute safety in a high-density work environment

Minimise downtime during a rare, high-stakes turnaround

Deliver consistent, competent manpower and specialist equipment

Provide full traceability and documented assurance for every disturbed joint