The ship loader, the plant’s only marine loading route for urea
shipments, showed abnormal vibration, corrosion and damage to key bolts,
prompting an immediate halt, said Mohammad-Mehdi Maleki, head of maintenance.
Maleki said engineers established a temporary loading route via hopper
and trailer at Pars Wharf, allowing exports to continue while the main unit was
taken offline for the first time in years. The original 43-day repair plan was
shortened through risk-based prioritisation to minimise disruption, he added.
Structural work included full washing and sandblasting, replacement of
corroded beams, refurbishment of cable rails and walkways, and complete
industrial repainting. Technicians also replaced 180 high-pressure bolts out of
480 despite restricted access and heavy corrosion, and inspected gearboxes and
belts.
Electrical teams installed composite ladders to replace metal units,
reorganised cable routes, renewed lighting systems and completed full checks of
electrical and instrumentation components to improve safety, especially during
night operations.
Maleki said the project required only one two-day extension and was
completed without accidents. The shutdown also enabled the overhaul of two main
export conveyors, preventing what he described as a potentially costly future
stoppage.
He said the refurbishment has significantly improved the reliability
of the export chain and provides a model for completing complex maintenance
projects under tight time constraints.