Located in the Khorasan Razavi province, the Khangiran Gas Refinery plays an indispensable role in Iran’s gas processing and energy supply. A long-standing symbol of resilience and self-sufficiency in the country’s gas industry, the refinery conducts planned annual overhauls to enhance reliability and guarantee a steady fuel supply during the cold season.

Spring 1404 marked a new season of effort and collaboration for the refinery. The overhaul project was carried out as scheduled with the extensive participation of skilled specialists — a large-scale operation completed through domestic capabilities and in cooperation with knowledge-based companies. It was accomplished without any incidents and in full compliance with safety and environmental standards. Precise time management, cost control, realistic contract adjustments, and the use of local workforce capacity were among the defining features of this year’s overhaul.

Beyond its technical scope, the overhaul has been recognized as a model of national management in utilizing domestic capabilities and local expertise. According to experts, the 1404 overhaul of  Khangiran Gas Refinery stands as a successful example of integrating science, experience, and commitment — where production stability, improved safety, and higher efficiency guided every decision.

To gain detailed insight into the technical and managerial aspects of the project, SHANA (Oil and Energy Information Network) conducted an exclusive interview with Nasser Nozari, the head of the refinery’s overhaul department. He explained how the maintenance was carried out with precision, highlighting the role of local personnel, the use of domestically made equipment, collaboration with knowledge-based companies, and effective risk management — making the project a replicable model for other refineries in Iran.

 What were the main achievements of the overhaul?

Overhauls are collective and step-by-step processes in which every single operation matters. Our goal was to ensure quality and production stability through consistency and careful planning. One of the key indicators at  Khangiran Refinery is conducting overhauls on schedule and at the required quality. We worked to shorten the duration of the overhaul while maintaining completeness and precision — directly reducing downtime and supporting maximum production.

This year’s overhaul achieved notable technical and operational results. The most important was increased production stability — not only maintaining it but reaching stable maximum output. Additionally, staff training, employment of local workers, and engagement with local service and repair companies were among the positive outcomes of this phase.

 How were costs managed during the overhaul?

Contract prices were reviewed and adjusted to reflect actual costs, with over 1,300 individual contracts examined and revised. Repair parts were supplied from domestic sources with suitable quality to reduce expenses. Regular coordination meetings were held for resource provision and logistics. Training sessions for both contractors and employer staff, and the formation of mixed teams of experienced and young workers, helped cut costs and enhance efficiency.

 What share of the workforce was local?

The overhaul team, including supervisors, was largely composed of skilled local professionals. Continuous training for contractor and employer staff — through both theoretical and field-based programs — improved technical knowledge and operational capabilities. This approach enabled the project to be completed with high quality and minimal safety risks.

 What safety and risk management measures were implemented?

We conducted industrial safety and health training, monitored workers’ health and safety in line with Social Security and Labor Organization regulations, and required technical and vocational certifications. Combining experienced and young workers, enforcing strict supervision, and providing targeted training to key personnel ensured top-level workplace safety.

 What results were achieved through cooperation with knowledge-based companies?

A large portion of the materials and spare parts required for the overhaul were supplied by domestic and knowledge-based companies. Many of these firms have been long-term partners and have developed strong expertise. Relying on local capacity not only led to financial savings but also helped expand regional employment and strengthen domestic industrial capability.

 What aspects of this overhaul can serve as a model for other refineries?

A successful overhaul requires precise planning, teamwork, and ongoing training. The project must be prioritized as the refinery’s top mission, with full coordination among human resources, technical, inspection, and safety departments. Effective materials procurement, preventive maintenance planning, and the use of control software for rotating and static equipment are key best practices that can be replicated elsewhere.

 Were environmental protection measures considered?

Although refinery overhauls may not appear directly related to environmental issues, comprehensive maintenance improves unit efficiency and reduces pollutant emissions. It also prevents gas and water waste — all of which contribute significantly to environmental protection.

 What were the main challenges of this overhaul?

Every project has challenges. Our responsibility was to manage them effectively — including contract management, supply of spare parts, scheduling, worker conditions, training levels, regional logistics, and health services. Through accurate planning and collective cooperation, we successfully completed the project with high safety and quality standards.

 In summary, what were the overall achievements of the 1404 overhaul?

The overhaul was a collective achievement — completed on schedule, safely, and with improved quality. Every phase followed detailed planning and teamwork, and most importantly, no incidents occurred. This round of maintenance prepared the refinery for stable and maximum production during the coming winter. Safety, quality, and efficiency were the defining accomplishments of the 1404 overhaul at  Khangiran Gas Refinery.

Interview by:

Mojgan Faraji