As the country’s 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’s sweet gas, the complex holds a crucial position in Iran’s 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.

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

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’s 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’s contribution to the national energy portfolio.

Continuous energy flow during maintenance

Fereydoun Heidari, head of engineering and maintenance at South Pars Gas Complex, underscored the vital role the facility plays in the country’s energy mix. “With 13 refineries and a central power plant, South Pars Gas Complex is indispensable for supplying a significant portion of the nation’s energy. This necessitates precise planning, coordinated execution, and use of advanced technologies during overhaul processes,” he said.

Heidari explained that due to Iran’s unique energy conditions, overhauls have shifted from seasonal schedules to cover both warm and cold seasons, preventing production halts and energy waste. “Coordination 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,” he said.

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.

Leveraging NTBFs, reducing downtime

Heidari detailed the three-tier overhaul structure: “macro planning, refinery-level scheduling, and operational support. Spare parts supply, contractor services, and knowledge-based companies are key contributors to the support phase.” 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.

“To minimize downtime, we strategically schedule overhauls so units don’t stop simultaneously, using other refineries’ capacity to maintain production continuity,” Heidari added. “We also employ advanced inspection and engineering methods to reduce shutdown time, increase accuracy, and enhance safety.”

Sustainable development through efficiency, localization

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. “South 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,” he said.

When spare parts shortages arise, corrective engineering modifications are implemented to maintain equipment availability, system reliability, and uninterrupted refinery output.

Heidari highlighted the complex’s 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.

Maintaining daily production during repairs

Despite planned refinery shutdowns, Heidari said total daily production of about 600 million cubic meters remains stable through effective management.

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’s efficiency using advanced thermal cycles.

Smart systems development has been a priority in recent years. “We have implemented smart control systems, industrial Internet of Things (IoT) devices, and online monitoring for critical equipment such as gas turbines,” Heidari explained. “These AI-based technologies enable equipment optimization and predictive maintenance.”

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.

Ninth refinery produces about 80 mcm daily

Hamid Khedri, manager of the ninth refinery, described the maintenance and production sustainability efforts for the cold season. “Timely, targeted overhauls and preventive maintenance in electrical, instrumentation, and mechanical sectors prevent unplanned shutdowns. Our goal is to minimize downtime year-round,” he said.

Khedri noted energy optimization projects, including replacing 5,000 steam traps to prevent steam and condensate loss, achieving significant savings.

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—an important revenue source.

Khedri highlighted the role of overhauls in maintaining equipment reliability. This year’s maintenance began earlier than usual, and the planned three phases concluded without accidents.

He announced the localization of a key piece of equipment: “Feeder 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.”

Reducing flare gas through environmental projects

Khedri emphasized environmental efforts to reduce flare gas. “We 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,” he said.

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.

He praised staff performance during last winter’s critical period, noting zero production disruptions despite challenges. “Our dedicated and united team is a point of pride for refinery nine,” he said.

Resolving long-standing technical challenges

Alireza Hoquqi, operations manager at the ninth refinery, said the facility supplies about 7% of the country’s gas. “It handles about 90 million cubic meters daily input and sends approximately 80 million cubic meters to the sixth national pipeline.”

He said the overhaul’s ultimate goal is full readiness for reliable winter gas supply. “All identified issues have been programmed for resolution, aiming for a worry-free winter with stable production.”

Regarding energy optimization, Hoquqi highlighted resolving a multi-year technical problem with the emergency power system. “Despite 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.”

He praised the focus on knowledge-based companies and localization, supported by complex management and previous refinery leadership. “This policy has boosted equipment resilience and reduced foreign dependency. Examples include domestic manufacturing of heat exchangers, valves, and baskets.”

He applauded staff dedication amid challenges, noting their conscientious work across operations, maintenance, and engineering.

Over 3.4m safe work hours logged

Heydar Vardiani, safety officer at the ninth refinery, explained the rigorous safety, health, and fitness protocols for overhaul personnel at the region’s largest gas processing complex.

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.

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

Vardiani expressed pride in the high cooperation and dedication among workers. “We 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,” he said.

By Mojgan Faraji