GAS TURBINE

MRPNR
Ci~OUP
GAS TURBINE
MGT-70 (MAP2A)
Foreword
Despite the existence of a wide variety of power generation methods, fossil power still
plays an outstanding role in the electricity market. Different types of gas and steam
turbines are the horsepower of industrial and developing economies all over the world.
MAPNA Turbine (TUGA) started its ambitious journey in 1999, during the country's market
boom. In the early years, the company built a concrete base for growth by developing
facilities and acquiring the knowledge required for manufacturing power turbines.
Since the start of manufacturing operations in early 2002, TUGA has continuously invested
in capacity development to respond to ever-increasing national and regional demands.
After a decade of successful production and delivery of more than 170 turbine units for
simple and combined cycles, today MAPNA Turbine is an undeniable player in the
power generation industry.
The company's technology has been acquired through successful cooperation with
well-known international partners, as well as through in-house developments and innovations.
TUGA heavy turbines for power generation are based on Siemens technology. As of the
end of 2011, they have accumulated an operational record of 2.5 million EOH.ln addition
to the power gas and steam turbines, the company is now producing a range of industrial
gas turbines and turbo-compressors.
In order to offer more value to customers, MAPNA,.TurbiJ1l e is <1eveloping its product and
service range by taking new strategies. The co mpany is. adding larger turbines with
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MAPNA Power Gas Turbine
Cost, durability and flexibility are major challenges in the power generation industry. The
quality of manufacturing, long life service, ability to fire with various types of fuels and
capability of use in simple and combined cycles are among the characteristics that the
MAPNA power gas turbine MGT-70 (MAP2A) can offer to tackle those challenges.
Large-volume, easy-maintenance combustion chambers besides hybrid and low NOx
burners lead to lower levels of pollutants, which helps alleviate any potential environmental
concerns.
Product Specifications*
~ Frequency
50 Hz
~ Gross power output
170MW
~ Gross efficiency
34.6%
~ Heatrate
10405 kJ/kWh
~ Design turbine inlet temperature
1090°C
~ Exhaust temperature
556°C
~ Exhaust mass flow
535 kg/s
~ Pressure radio
11.8
~ Number of compressor stages
16
~ Number/type of combustors
2/Silo type
~ NOx emission with natural gas
25 ppm
~ Overall dimensions
10.2m
~ Shipping weight
186 Mg
x
3.9m
x
3.7m
* In ISO conditions with natural gas
Advantages
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utilized in simple or combined cycle plants
Generator at the cold end
Central tie bolt rotor with internal air circulation around
No direct flame radiation on the turbine blades
Hybrid burners and large combustion chambers
Easy inspection of burners and turbine blades by means of manholes on combustion
chambers
Replaceable blades
Ability to use wide variety of fuel compositions
Fast start-up
Low emissions even in part-load condition due to DLN (dry low NOx) technology
High EOH inspection
Low cost maintenance
Grid stabilization
Extension of maintenance intervals
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Other Features
Flexible Rotor
The low-mass disk rotor of the gas turbine, whose self-centering disks (due to hirth facial
serrations) are jointed together with no torsion, possesses a high critical speed and is
internally cooled by extractions from the compressor to avoid deformation caused by
thermal stresses during start-up and load changes.
Efficient Compressor
The Inlet Guide Vanes direct the air flow to an efficient compressor which produces a
pressure ratio of more than 11.8 bar. The compressor blades can be removed and replaced without needing to dismantle the rotor. Anti-surge system with blow-off pipes,
which extract air from equal space intervals, prevents vibration and keeps the flow uniform.
Low NOx Combustors
The MAPNA gas turbine is flexible with fuel. Two large silo-type combustion chambers
with ceramic heat shields besides eight hybrid burners per each chamber with dry low
NOx technology result in high efficiency with less emission. The hybrid burners enable
the system to operate on premix and diffusion modes with both gas and oil. Manholes
allow personnel to directly inspect the hot-gas path components from burners to turbine
blades without lifting the cover.
Turbine Section
Cooling extractions from the compressor safeguard the first three stages of turbine
blades against the hot gas with high efficiency convection. There are oxidation and
corrosion protection coatings for freestanding moving blades.
Main Auxiliaries
Fuel System
A brilliant feature of the system is its dual-fuel design (gas and oil) with separate skids for
each fuel supply. The main parts of the fuel gas system are strainers and stop and control
valves, while those of the fuel oil system are the injection pump and duplex filters as
well as stop and control valves. A hydraulic oil system provides high-pressure hydraulic
oil to operate the control and emergency stop valves of the fuel systems. A purge water
system is used to prevent coking of fuel oil in the burners.
Air Intake
Air filtration provides a pollutant-free air with a suitable temperature at the engine inlet
and basically consists of anti-icing and three stages of filtration, as well as silencers.
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Exhaust
The exhaust duct vacates the flue to the environment or the entry of the steam
cycle. The main parts are the stack, silencer, pollutant measuring instruments, damping
system and its hydraulic actuator as well as the guillotine, which is used to separate the
HRSG from the exhaust system.
Lube and Lifting Oil System
The system performs heat dissipation and lubrication of the turbine and generator bearings.
It consists of an oil tank, pumps, pipes, flanges, filters, valves and cooler.
Instrumentation and Control
Important features of the turbine instrumentation and control are:
- Output power response to frequency variations in both primary and secondary (limits)
according to Droop.
- Automatic calculation of the turbine EOH in different conditions to determine the
proper maintenance/service regimen.
- Predictive control of IGV blades for providing a quick action to load variations during
frequency response and sudden load fluctuations, minimizing thermal stresses on gas
turbine hot parts.
- Automatic operation of start-up, stop, loading , fuel changeovers (gas to oil and vice
versa) and combustion mode transfer (diffusion to premix and vice versa).
- Provision of all required protective systems for the gas turbine and its auxiliaries.
- Provision of additional controllers that avoid approaching the axial compressor to
instability regions.
Units in Action
As the largest supplier of power plant equipment in the Middle East, we have a large
fleet of gas turbines installed and operating within Iran as well as in other countries. The
Damavand 2800-MW combined cycle power station is the largest plant in the region
constructed by MAPNA which includes 12 GTs of this type operating in one place since
2004. Tishreen and Jandar combined cycle blocks in Syria , as well as the AI-Sadir simple
cycle in Iraq are all among the plants abroad that use the MAPNA gas turbine.
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Services Offered After Sales
The hot gas path sections are the most likely to be damaged. However, the MAPNA gas
turbine's large combustion chamber avoids this as the long path of the hot gas to the first
blades prevents direct flame radiation. Moreover, such geometry enables the user to
inspect and easily clean combustion ashes from the turbine. In addition, the manholes
are of great importance within the inspection process.
Hot gas path and major inspections are normally performed at 33000 and 66000 EOH.
This interval may differ depending on the order. The MAPNA power GT is indeed an easily
maintained, tough and rugged machine during operation. With a proper maintenance
regimen, it can demonstrate a high level of reliability and availability. MAPNA Turbine
Company offers the following services to clients.
Provision of spare parts for the turbine and auxiliaries
Our reliable network of spare parts suppliers enables us to satisfy individual client demands,
including capital spares, as per order.
Fast-track supply of spares
Our spacious and fully-stocked warehouses allow us to supply spare parts at a moment's
notice. In addition, by providing consumable materials and strategic components from
our production line, we can quickly assist clients in case of unpredicted or sudden outages
and overhauls.
Long-term supply and support agreements
We offer long-term contracts for various types of support and service.
Supervision with installation and commissioning
Installation and commissioning of the turbine and auxiliaries are performed by skilled
personnel under our direct supervision. Personnel can also be made readily available on
and off the client site until the end of the guarantee period of the last unit in the power
plant.
Technical consultation services for end users
Our experienced and knowledgeable technical and engineering team is available for
consultation at any time.
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Training of end-user staff
We offer several training courses for new staff on site, such as general power plant
knowledge, operation, maintenance, and some special training, such as firefighting.
Performing inspections and overhauls
Our experienced maintenance personnel can perform turbine inspections and overhauls thoroughly.
Fabrication and repair of turbine special parts
Thanks to our state-of-the-art machineries and skilled manufacturing personnel, we can
provide fabrication and repair of special parts for our machines.
Execution of performance test
We have executed and assisted with performance tests for more than 60 units of turbine
by the end of 2011.
Research and Development
Customer needs and new markets are what drive our investment in research and development. MAPNA Turbine (TUGA) is now heading towards more diversity in products as well
as improving flexibility of the turbines for different applications and customer requirements.
This involves not only improving the power output and efficiency of the machines, but
also increasing product availability and component lifetime in order to reduce operation
and maintenance costs. Fuel and ambient conditions are important themes in our R&D.
Our turbines are installed in a variety of site environments, with different fuel composition
and operating conditions. We welcome the challenge involved in adapting our products
and services accordingly. Our research programs aim towards the goal of offering a diverse
portfolio that provides value for our customers.
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Head Office:
231 Mirdamad Ave. Tehran -I.R.lran.
P.O .Box: 15875-5643
Tel: +98 (21) 22908581-3
Fax: +98(21)22908654
Factory:
Fordis, Koraj - I.R.lran.
Post code : 31676-43594
Tel: +98 (26) 36183364
Fax: +98(26) 36612734
WNVV.mapnaturbine.com
info@mapnaturbine .com
The technical and other data contained in this document is
provided for information only and may not apply in all cases. The
required technical options and performance figures should therefore be specified in the contract. MAPNA reserves the right to
revise or change this information at any time without further notice.