According to Tehran Oil Refining Company, Mahmoud Nikou outlined the importance of maintenance and major overhaul operations in ensuring stable production and achieving broader organizational goals. He said consistent preventive and predictive maintenance programs reduce unplanned shutdowns, improve the reliability of process units and help preserve operational capacity.

Nikou added that the maintenance division also contributes strategically to key objectives, including higher efficiency, lower operating costs, enhanced safety and protection of physical assets. He described major overhauls as a critical support arm for maintaining production and generating sustainable added value.

Maintaining Output During Overhauls

Nikou cited workforce shortages, aging equipment, constraints in procuring specialized parts, demanding operating conditions and the need to maintain stable production during overhaul activities as major challenges. He said addressing these issues requires precise planning and rapid decision-making.

He stressed the need for swift recruitment of qualified personnel, specialized training and timely supply of high-quality spare parts and equipment. To manage challenges, the company has adopted asset management-based approaches, prioritized critical equipment, localized parts, leveraged domestic capabilities and optimized overhaul schedules.

Nikou said temporary staff hired for the refinery’s tank overhaul project helped offset personnel shortages. Despite some coordination issues in the recruitment process, he said the overall benefits have been significant.

Digitalization Reshaping Refining Operations

Nikou highlighted the growing role of mechanized maintenance management systems, saying digital transformation has reshaped maintenance practices. The use of maintenance management platforms, online equipment condition monitoring, operational data analytics and artificial intelligence enables failure prediction and more precise decision-making.

He said rapid, data-driven decision-making based on internal information and awareness of environmental changes is now a key driver of profitability and production stability. This requires accelerated deployment of systems such as CMMS and ERP, along with AI-based decision-support frameworks.

Nikou said these technologies reduce unnecessary costs, extend equipment life, improve workforce productivity and pave the way for smart maintenance.

He emphasized the importance of balancing cost reductions with reliability. Preventive and predictive maintenance programs, he said, should be designed based on asset criticality, risk assessment and evaluation of maintenance effectiveness, gradually eliminating low-value activities while strengthening those that enhance reliability.

Skilled Workforce Remains Core Asset

Nikou described specialized human resources as the most valuable asset of the overhaul division, saying employee experience, technical skills and commitment directly influence maintenance quality and operational error reduction.

He said continuous training, knowledge transfer, succession planning and motivation initiatives are priorities for strengthening human capital. Targeted preventive maintenance and removal of low-impact activities, he added, improve resource optimization and efficiency.

He said identifying critical equipment and allocating resources to sensitive areas helps control costs while improving production stability and equipment safety.

Measuring Overhaul Success

Nikou said the success of major overhauls is assessed through indicators such as adherence to project schedules, minimal incidents and near-misses, fulfillment of HSE targets, cost control, avoidance of emergency repairs after startup and achievement of design capacity. Reduced unplanned shutdowns and increased equipment reliability are also key performance criteria.

HSE as an Integral Component

Nikou stressed that safety, health and environmental considerations are inseparable from overhaul operations. All activities, he said, are conducted through risk assessments, compliance with safety procedures and workforce training, with the primary goal of preventing incidents, protecting personnel and minimizing environmental impacts while sustaining stable production.

He cited predictive and preventive measures — including condition monitoring, proper lubrication, scheduled part replacements and operational process improvements — as essential strategies for extending asset life. Refurbishing worn equipment and upgrading outdated technologies, he said, also play a vital role.

Given the continuous nature of refinery operations, strict safety requirements, equipment complexity and the strategic importance of products, Nikou said maintenance management demands high precision, cross-unit coordination and emergency preparedness.

Asset Management Initiative Underway

Nikou said optimized asset management, resource protection and long-term value creation are central company objectives. In line with this strategy, he said the refinery established an asset management structure within the maintenance organization in 1404 (2025/26).

He said a task force for implementing the asset management system has been formed, involving departments including operations, technical services and engineering, maintenance, planning, risk and organizational excellence, finance, procurement and investment, commercial management, human capital development and HSE.

Nikou said the company is implementing the system based on ISO 55001:2024. Preventive and predictive programs for critical and high-risk equipment have been reviewed and optimized, and competency requirements for effective maintenance and operation are being defined.

He said the project is progressing with staff cooperation and management support. The system is expected to be ready for external audit by Mehr 1405 (September/October 2026). The ultimate goal, he said, is to establish an agile, intelligent, optimized and sustainable maintenance framework aligned with national refining industry objectives.