{"id":14355,"date":"2025-05-30T07:24:40","date_gmt":"2025-05-30T07:24:40","guid":{"rendered":"https:\/\/roydadnaft.ir\/English\/?p=14355"},"modified":"2025-05-30T07:24:40","modified_gmt":"2025-05-30T07:24:40","slug":"overhauls-at-sp-refineries-boost-reliability-without-disrupting-supply","status":"publish","type":"post","link":"https:\/\/roydadnaft.ir\/English\/14355\/","title":{"rendered":"Overhauls at SP refineries boost reliability without disrupting supply"},"content":{"rendered":"

RoydadNaft – <\/a><\/span>\u00a0Major overhauls at South Pars gas refineries began in March with the goal of maintaining steady production and improving energy efficiency through domestic capabilities. These operations, supported by extensive manpower, new technology-based firms (NTBFs), and strict adherence to safety protocols, prepare the refineries to reliably supply gas through the winter.<\/p>\n

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As the country\u2019s largest natural gas processing complex, South Pars refineries play a vital role in meeting the energy needs of industries, power plants, and households. Producing over 70% of the nation\u2019s sweet gas, the complex holds a crucial position in Iran\u2019s energy security and economic growth. Therefore, maintaining operational readiness, efficiency, and safety requires the precise and regular execution of major maintenance programs. These overhauls serve not only as routine upkeep but also as strategic measures to enhance equipment reliability, minimize emergency shutdowns, improve unit efficiency, and prevent industrial accidents.<\/p>\n

Each year, overhaul operations are planned and carried out at South Pars\u2019s 13 gas refineries to reduce operational risks, extend equipment lifespan, improve performance, and ensure stable production during cold seasons. This year\u2019s maintenance began earlier than usual, starting at South Pars\u2019s ninth refinery (Phase 12). These efforts rely heavily on domestic expertise, cooperation with NTBFs, and full compliance with safety standards\u2014playing a key role in the country\u2019s steady gas supply.<\/p>\n

Coinciding with the start of these overhauls, the Petro Energy Information Network (Shana) visited the ninth refinery in Assaluyeh for an exclusive interview with the facility\u2019s management. The discussion covered the latest maintenance progress, daily gas production levels, collaboration with knowledge-based firms, and environmental initiatives. This report highlights key updates on this critical refinery\u2019s contribution to the national energy portfolio.<\/p>\n

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Continuous energy flow during maintenance<\/strong><\/p>\n

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Fereydoun Heidari, head of engineering and maintenance at South Pars Gas Complex, underscored the vital role the facility plays in the country\u2019s energy mix. \u201cWith 13 refineries and a central power plant, South Pars Gas Complex is indispensable for supplying a significant portion of the nation\u2019s energy. This necessitates precise planning, coordinated execution, and use of advanced technologies during overhaul processes,\u201d he said.<\/p>\n

Heidari explained that due to Iran\u2019s unique energy conditions, overhauls have shifted from seasonal schedules to cover both warm and cold seasons, preventing production halts and energy waste. \u201cCoordination across upstream and downstream sectors, dispatch centers, and regional and Tehran management is extensive and systematic to ensure uninterrupted gas flow to transmission lines during maintenance,\u201d he said.<\/p>\n

He noted that planning for 2025 overhaul activities began last November. After design, procurement, and coordination phases, work started on March 7 at the ninth refinery. The first phase lasted 13 days, followed by a second phase beginning May 16. On June 22, the seventh refinery became the third unit under maintenance. The overhaul of all 13 active refineries is scheduled to run through late October, covering about 198 calendar days.<\/p>\n

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Leveraging NTBFs, reducing downtime<\/strong><\/p>\n

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Heidari detailed the three-tier overhaul structure: \u201cmacro planning, refinery-level scheduling, and operational support. Spare parts supply, contractor services, and knowledge-based companies are key contributors to the support phase.\u201d Cooperation with knowledge-based firms has increased dramatically in recent years, allowing for the domestic production of many chemicals, sensitive equipment, catalysts, and specialized parts that were previously imported. Examples include advanced blowers, unique catalysts, and locally formulated chemicals.<\/p>\n

\u201cTo minimize downtime, we strategically schedule overhauls so units don\u2019t stop simultaneously, using other refineries\u2019 capacity to maintain production continuity,\u201d Heidari added. \u201cWe also employ advanced inspection and engineering methods to reduce shutdown time, increase accuracy, and enhance safety.\u201d<\/p>\n

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Sustainable development through efficiency, localization<\/strong><\/p>\n

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Heidari emphasized that all common spare parts for refinery overhauls are produced domestically. For critical parts affected by sanctions, localization efforts have been successful, ensuring supply independence. \u201cSouth Pars Gas Complex pursues sustainable development, efficiency gains, and reduced reliance on imports through precise planning, coordinated management, up-to-date technical knowledge, and domestic capabilities,\u201d he said.<\/p>\n

When spare parts shortages arise, corrective engineering modifications are implemented to maintain equipment availability, system reliability, and uninterrupted refinery output.<\/p>\n

Heidari highlighted the complex\u2019s strong workforce, noting that permanent staff possess high educational levels and technical expertise, supplemented by contractors from neighboring provinces. On average, over 700 personnel work on each overhaul phase.<\/p>\n

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Maintaining daily production during repairs<\/strong><\/p>\n

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Despite planned refinery shutdowns, Heidari said total daily production of about 600 million cubic meters remains stable through effective management.<\/p>\n

He also noted energy efficiency projects underway during maintenance, including optimizing turbine fuel use, reducing steam losses, repairing steam pipelines, and improving the centralized power plant\u2019s efficiency using advanced thermal cycles.<\/p>\n

Smart systems development has been a priority in recent years. \u201cWe have implemented smart control systems, industrial Internet of Things (IoT) devices, and online monitoring for critical equipment such as gas turbines,\u201d Heidari explained. \u201cThese AI-based technologies enable equipment optimization and predictive maintenance.\u201d<\/p>\n

Continuous and targeted training for all employees, contractors, experts, and managers is key to overhaul success. Prior to operations, all personnel complete theory and practical safety courses, ensuring full preparedness and improved safety and quality.<\/p>\n

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Ninth refinery produces about 80 mcm daily<\/strong><\/p>\n

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Hamid Khedri, manager of the ninth refinery, described the maintenance and production sustainability efforts for the cold season. \u201cTimely, targeted overhauls and preventive maintenance in electrical, instrumentation, and mechanical sectors prevent unplanned shutdowns. Our goal is to minimize downtime year-round,\u201d he said.<\/p>\n

Khedri noted energy optimization projects, including replacing 5,000 steam traps to prevent steam and condensate loss, achieving significant savings.<\/p>\n

The ninth refinery, consisting of three phases (A, B, and C), produces about 80 million cubic meters of sweet gas daily. Last year, it received approximately 29 billion cubic meters from wells, delivering 26.5 billion cubic meters after treatment to the sixth national pipeline. Production of condensates reached 26 million barrels, and 50,000 tons of sulfur were produced\u2014an important revenue source.<\/p>\n

Khedri highlighted the role of overhauls in maintaining equipment reliability. This year\u2019s maintenance began earlier than usual, and the planned three phases concluded without accidents.<\/p>\n

He announced the localization of a key piece of equipment: \u201cFeeder gearboxes, which had been out of service due to sanctions and lack of technical knowledge, are being redesigned, dismantled, and rebuilt with a knowledge-based company. The refinery has 12 gearboxes; two have been inactive for over 10 years, and the rest operated at high risk due to overdue maintenance. Manufacturing and technical drawings are complete, with full restoration expected by late August.\u201d<\/p>\n

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Reducing flare gas through environmental projects<\/strong><\/p>\n

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Khedri emphasized environmental efforts to reduce flare gas. \u201cWe have contracts to sell flare gas to a third party. After clearing legal and environmental hurdles, equipment is being installed. This project will greatly reduce flare gas waste,\u201d he said.<\/p>\n

Additional projects include a parallel system for sulfur recovery units to ensure continuous operation even if one unit shuts down. This project is 80% complete and expected to be operational within months.<\/p>\n

He praised staff performance during last winter\u2019s critical period, noting zero production disruptions despite challenges. \u201cOur dedicated and united team is a point of pride for refinery nine,\u201d he said.<\/p>\n

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Resolving long-standing technical challenges<\/strong><\/p>\n

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Alireza Hoquqi, operations manager at the ninth refinery, said the facility supplies about 7% of the country\u2019s gas. \u201cIt handles about 90 million cubic meters daily input and sends approximately 80 million cubic meters to the sixth national pipeline.\u201d<\/p>\n

He said the overhaul\u2019s ultimate goal is full readiness for reliable winter gas supply. \u201cAll identified issues have been programmed for resolution, aiming for a worry-free winter with stable production.\u201d<\/p>\n

Regarding energy optimization, Hoquqi highlighted resolving a multi-year technical problem with the emergency power system. \u201cDespite sanctions and expiration of permits for two emergency diesel generators, our engineers have solved the issue, enabling emergency power supply and rapid unit startup during outages.\u201d<\/p>\n

He praised the focus on knowledge-based companies and localization, supported by complex management and previous refinery leadership. \u201cThis policy has boosted equipment resilience and reduced foreign dependency. Examples include domestic manufacturing of heat exchangers, valves, and baskets.\u201d<\/p>\n

He applauded staff dedication amid challenges, noting their conscientious work across operations, maintenance, and engineering.<\/p>\n

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Over 3.4m safe work hours logged<\/strong><\/p>\n

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Heydar Vardiani, safety officer at the ninth refinery, explained the rigorous safety, health, and fitness protocols for overhaul personnel at the region\u2019s largest gas processing complex.<\/p>\n

Before deployment, roughly 300 day-shift and 60-70 night-shift workers complete eight-hour safety and site hazard training and must pass occupational health clearances. Those with medical issues face duty restrictions or denial of site access.<\/p>\n

Security units also vet workers for criminal records, substance abuse, and other requirements, starting preparations 20-30 days before official maintenance begins.<\/p>\n

Vardiani expressed pride in the high cooperation and dedication among workers. \u201cWe have logged over 3.4 million safe work hours without incidents. Many employees have worked three straight days on site, despite living 30-40 kilometers away,\u201d he said.<\/p>\n

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By Mojgan Faraji<\/strong><\/p>\n<\/div>\n<\/div>\n

Updated on