Layer by layer, step by step – Building trust and excellence at Oman LNG

When you’re working on a site where pipes diameters range in size from a drinking straw to a dining table and often doing so 40 metres above the ground – it’s clear you’re not handling an ordinary assignment. At the Oman LNG facility in Sur, the KAEFER Oman Team has taken on a project that is extraordinary in both scale and complexity. And the numbers speak for themselves: over 700m² of insulation, 5,210m² of coating, 27,057m² of painting, and a staggering 152,854m³ of scaffolding. What began as a handful of services has grown into something huge, in every sense of the word.

It all started in February 2024, when the KAEFER Team first stepped onto the Oman LNG site. At the time, the scope was clearly defined: under a two-year Fabric Maintenance Contract (FMC), the team was tasked with delivering scaffolding, insulation, and painting services. But what followed went far beyond expectations. By showcasing their technical expertise, commitment, and collaborative spirit, KAEFER turned from a service provider into a trusted partner. Within the same year, the team not only earned a five-year shutdown agreement covering scaffolding, insulation, painting, and refractory work with Subcontractor named Bhawan Engineering company, but was also named the “third-best business partner for initiative and innovation”. A recognition for a team that had only just begun its journey on site. With this new level of trust came increased responsibility, and KAEFER Oman was ready to rise – layer by layer – to the challenge.

Layer upon layer

Working with one of Oman’s leading oil and gas companies comes with heightened expectations and Oman LNG is no exception. One of the most technically demanding aspects of the project was the coating work, which went far beyond what KAEFER Oman had previously managed. While most projects in the region require four layers of coating, the Oman LNG site demanded five. This wasn’t just an arbitrary requirement. The pipes at the facility are colour-coded based on their function:  water lines, for instance, must be coated in green, fire lines in red. That means the top layer isn’t simply protective. It’s also functional, serving as a visual indicator for safety and identification. It’s rare, technically advanced, and signals exceptionally high protection standards for the plant and its infrastructure.

KAEFER didn’t shy away from the challenge. Instead, the team embraced the complexity and once again proved their ability to adapt. With careful application, extensive planning, and meticulous attention to detail, KAEFER ensured that each layer was applied in the correct thickness and dried completely before the next one began. Because even the smallest flaw in a single layer can compromise the entire system. The team worked with pipe sizes ranging from 1.3 cm (1/2 inch)- roughly the width of a thick pen – to 2.1 metres (84 inch), about the size of a large dining table for eight. And as if that wasn’t enough, much of the work was carried out at heights of up to 40 metres. The conditions were demanding, but the team’s technical skill and continuous improvement mindset made it possible.

In line with KAEFER Oman’s commitment to investing in local talent, 21 Omani nationals are currently part of the KAEFER Oman LNG project workforce – 15 skilled workers and 6 staff members. Their expertise and engagement are a vital part of the project’s success.

Safety at every step

At KAEFER, safety isn’t a checkbox, it’s part of our culture. That principle was clearly visible throughout the work at Oman LNG. Every activity on site followed strict safety protocols, and the team implemented comprehensive Sphera safety training to minimise risks and ensure everyone on site remained safe. Sphera, KAEFER’s globally used digital tool for managing health, safety, and environmental (HSE) processes, played a key role in supporting safe and structured execution. This dedication to safety paid off. During the execution of the FMC contract, the team achieved 254,655 man-hours without a Lost-Time Injury (LTI). During the Train-3 major shutdown alone, another 152,625 man-hours were logged without incident. These achievements are not just statistics; they are a testament to the team’s daily commitment to smart, efficient, and safe work. And they didn’t go unnoticed.

Precision under pressure

While coating and insulation form a major part of the work, KAEFER Oman also handles highly specialised refractory services – the kind of work that can only be performed when the plant is shut down. Shutdown phases are notoriously short and demand flawless coordination. Every task must be planned in detail and executed with maximum efficiency, because a facility of this size simply cannot afford prolonged downtime.

That’s where KAEFER’s experience and agility truly shine. For one major shutdown, the site workforce was scaled up from 80 to 350 people: a major logistical effort that required LEAN planning and seamless coordination. The result? The shutdown project was completed on time, without a single health or safety incident. It was another powerful example of KAEFER’s ability to deliver under pressure and contribute to the ongoing success of the facility.

A partner in performance and progress

So, what exactly does KAEFER Oman’s work bring to the table for Oman LNG? In short: stability, reliability, and sustainability. By delivering high-quality maintenance, insulation, painting, coating and refractory services, KAEFER helps reduce unplanned downtime, prevent equipment failures, and keep operations running smoothly. This, in turn, helps Oman LNG maintain its position as a reliable global supplier in the energy sector. But the impact goes even further. KAEFER’s surface protection helps reduce emissions from pipe racks, while insulation installation minimises energy losses – directly supporting the facility’s environmental and sustainability goals.

Looking ahead – Building the future, layer by layer

From our first scaffold to five-layer coatings and complex shutdowns, every step KAEFER has taken at Oman LNG has been driven by precision, passion, and partnership.

As the energy industry continues to evolve, so does KAEFER Oman’s ambition. Layer by layer, challenge by challenge. Our ongoing commitment to innovation, strategic planning, and skilled execution positions us to meet Oman LNG’s future needs.

Looking ahead, KAEFER Oman stands ready to partner with clients and stakeholders as the industry moves forward. By continuing to deliver high-quality solutions and embracing new opportunities, we are helping to shape the future of energy in Oman – ensuring that our clients can count on us to achieve lasting progress.