Engineering Case Studies & Turnaround Success Track Record

Power & Utilities • Rabigh

14-Stage Boiler Feed Pump Re-Engineering (+350% MTBF)

Challenge: Chronic trips every 5 months due to severe cavitation, impeller erosion & shaft deflection.

Solution: Super Duplex impellers, ISO G1.0 balancing on 10T rig, API 682 Plan 53B dual seals & laser alignment.

Impact: Runtime extended to 24+ months, saving over $680,000 in unplanned outage losses.

+350%

Continuous Runtime

Increased from 5 to 24+ months

$680K+ Outage Loss Saved

Refining & Petrochemicals • Yanbu

Challenge: Critical 45-day TAR requiring bundle pulling, hydrojetting, retubing & 850 leak-free joints.

Solution: 120-man task force, mobile extractors, on-site retubing & ASME PCC-1 hydraulic torque tensioning.

Impact: Delivered 72 hours ahead of schedule with 180,000 safe hours and 100% leak-free startup.

0.00 LTI

180k Safe Work Hours

100% First-Pass Leak-Free Startup

72 Hours Ahead of Schedule

Petrochemicals • Jubail Industrial City

Challenge: Chronic hydrogen leakage across wet seals at 110 bar, causing gas flaring & high oil costs.

Solution: Converted to API 692 Tandem Dry Gas Seals with cleanroom helium lapping & 150-bar N2 dynamic testing.

Impact: Zero flaring achieved, $450,000 annual seal oil savings, and seamless 36-month run cycle.

$450K/yr

Seal Oil & Flaring Savings

API 692 DGS Conversion

Zero Flaring Milestone

Mining & Heavy Industry • Eastern Province

Challenge: Stator short halted primary ore mill; European OEM quoted a 6-month replacement lead time.

Solution: In-house Class H mica-glass diamond coils, dual-cycle VPI impregnation & 13.8kV Hi-Pot testing in Jeddah.

Impact: Fully commissioned on-site in 9 days, resuming 12,000 tons/day mineral processing.

9 Days

Turnaround vs 6-Mo OEM

6.6kV 3,500kW Rewind + VPI

12,000 T/Day Resumed