Sarens Executes Complex Heavy Lifting for Saudi Aramco at Shaybah NGL Plant

Sarens successfully completed a major heavy lifting project for Saudi Aramco at the Shaybah NGL Plant in Saudi Arabia, working in collaboration with Wison Engineering Ltd. The project involved the installation of a new Dew Point Control Unit (DPCU) and a Propane Refrigeration Unit, designed to address existing limitations in handling heavy hydrocarbon feed and higher acidity levels. This upgrade restores the plant’s capacity from 1.800 MMSCFD back to 2.400 MMSCFD, supporting its critical role in the region’s energy infrastructure.

Operating in one of the most remote and challenging locations - the Rub’ al-Khali (Empty Quarter) desert - Sarens engineered 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 having a diameter of 56 inches. A total of 124 precision lifts were executed, with weights reaching up to 205 Tonnes.

To deliver these operations, Sarens deployed an LR1750 (750-Tonne) crane and a CC2400 (400-Tonne) crane, transported 750 km from Jubail to the Shaybah site. The cranes remained on-site for seven months, with a setup phase lasting three weeks. Despite harsh environmental conditions, limited space, and simultaneous operations inside a live brownfield, the Sarens team ensured seamless execution through meticulous planning and rigging arrangements.

The project team comprised 16 skilled crew members supported by dedicated engineers and project manager. All lifts were executed using slew-and-crawl operations, demonstrating Sarens’ ability to provide innovative and reliable solutions in complex environments.

“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”, said Project Manager Solai Raja Periyakaruppan.

Through this critical upgrade, Sarens has strengthened its position as a reliable partner for complex and high-value energy projects across the Middle East and globally.