It is important to realize that when solving difficult issues, this can often lead to new innovations even within Project Management. All that you need is courage and collaboration and of course snorkels and fins!!.

1. INAUGURATION
CEREMONY
TECHNICAL CONFERENCE
FEBRUARY 1 - 2, 2017
SHERATON HOTEL
DAMMAM, SAUDI ARABIA
DIVING INTO INNOVATION:
COURAGE AND COLLABORATION SAVED
$ 200 MILLION AND A MEGA PROJECT
Abdulraheem F Al-Saeedi
Yanbu Aramco Sinopec Refining
Company (YASREF) Ltd.

2. WMK

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OUTLINE
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• Background
• Drivers to Solutions
• Story of the Solutions
• Engineering the Innovation
• Stakeholders Management
• Risk and Mitigation Measures
• Patent Application
• Success Factors
• Conclusion

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BACKGROUND
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• Build a 400 MBD Refinery Project
• Require Seawater cooling
• Build two Seawater Cooling Lines
• Tie-in to network is based on isolation / shutdown
availability

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BACKGROUND
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2.9 m
Line Size Comparison Valve Used in Construction

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BACKGROUND
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• The Supply line isolation was available and the Tie-in was completed
• The Return line isolation or shutdown was not possible due to the
major customer deferral of the planned shutdown
• The Return line Tie-in requires to be completed on-line or deferred by
one year for the planned shutdown
• The Refinery Start up date would be seriously impacted if the
complications of the Seawater Return line Tie- in was not resolved

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DRIVERS TO SOLUTIONS
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• Two Key Drivers
 Save the refinery start up date, planned for September 2014
 Avoid any costly interruption to the networks major customer

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THE STORY OF THE SOLUTIONS
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• Solution 1: Re-engineer the tie-in methodology and sequence to
Reduce the Shutdown Duration and attempt to secure a workable
window
 35 days → 14 days → 7 days
• Solution 2: Work in rerouting the impacted customers return line to
avail the workable window
• Solution 3: Hire a Hot tap contractor to perform the on-line tie-in
operation

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• Solution 4: Identify an outside of the box solution that will enable an
on-line connection
• Three major steps in finding and implementing the solution
1)Engineer a New &
innovative on-line Tie-in
methodology
3)Identify all risks along
with mitigation
measures
2)Engage the stakeholders
to be part of the solution
THE STORY OF THE SOLUTIONS

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ENGINEERING THE INNOVATION
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• Developed an initial concept based on joint discussions with the
stakeholders and utilizing previous project experience
• Identified two areas of the solution to complete the connection whilst
the network remains in service
 Engineer and Fabricate the Tee connection on site
 Find a method to cut the pipe from the inside of the tee connection

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• Appointed a Pipe manufacturer to detail design the connection
• Worked with out of Kingdom design offices to finalize a robust design
• Consulted with SMEs to seek specific recommendations
ENGINEERING THE INNOVATION

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ENGINEERING THE INNOVATION
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• Identify methods to cut from the inside of the tee connection
 The cutting could be done manually rather than by a machine
 Locate qualified divers who can perform the underwater cutting
operation
 Work with the Utility provider to obtain their recommendations
 Engaged local divers in the Yanbu area and prepared them for the
cutting operation

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ENGINEERING THE INNOVATION
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STAKEHOLDERS MANAGEMENT
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STAKEHOLDERS MANAGEMENT

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RISKS AND MITIGATION MEASURES
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• Develop a detailed Safe Work Method Statement and obtain the
stakeholders approval
• Itemized 12 construction activities to complete the work
• Identified all potential risks for each activity along with the associated
mitigation measures
 Anticipated a total of 66 potential risks
 Established 240 mitigation measures
• Incorporated some of the mitigations in the design
• Generated a specific work checklist to monitor all activities

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• Mitigation of vibration risks to the existing headers
RISKS AND MITIGATION MEASURES

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• Mitigation of weak points leakage
RISKS AND MITIGATION MEASURES

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• Mitigation of high temperature
RISKS AND MITIGATION MEASURES

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• Applied for the patent in Nov. 2014 in the US and Saudi Patent
Offices with the title :
Method and Apparatus for
Hot-Tap Tie in for Large Diameter Pipes
• Granted patent in Nov 2016 in both offices
 United States Patent No. 9,506,594
 Saudi Arabia Patent Application No. 114 36 0160
PATENT APPLICATION
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SUCCESS FACTORS
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• Strong Collaboration with Stakeholders
• Effective Stakeholder Management
• Proper identification and management of risks
• Employing expert and local talent
• The courage to undertake new concepts/solutions

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CONCLUSION
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Team Effort, Courage and Collaboration