NIAM

(PERSIAN ACRONYM FOR ‘MAPNA STANDARD DESIGN FOR POWER PLANTS’)

MAPNA Group is the first and largest general contractor of power plant projects in Middle East and West Asia. It is also the single major manufacturer of power plant main equipment and facilities and investor in private power plant projects across the nation. The Group provides ‘after sale services’ and ‘repair and maintenance’ in its products and services basket in response to ever-growing demand for electricity in the market and to support private projects. MAPNA Group’s wide spectrum of products and services opened international and regional markets in the Middle East to the Group thanks to competitive quality services, with only few examples to be mentioned here as projects underway or completed in Iraq, Syria, Oman, and Lebanon.
With over a total of 31,000 MW in electricity industry, MAPNA Group has a lion’s share in providing 45 per cent of nominal capacity of country’s power plants during past 20 years. In the same period, MAPNA has succeeded to indigenise cutting-edge technology in wide range of fields, notably design, procurement, manufacture of main facilities, construction, operation, and repair and maintenance of power plants and investing in power plant projects.
To attain industrial-level manufacturing, to shorten the time period, and to manufacture of adequate number of facilities in due time, many of world-renowned manufacturers in the electricity industry have standardized their products through applying prior experiences. As a worldwide prestigious company with about 150 years of experience in power generation, Siemens has developed its pre-engineered standard design of steam power plant called Varioplant and its gas turbine complex and its related equipment called Econopac. Italian Ansaldo Energia, also among the prestigious manufacturer worldwide, has developed its standard design for power block using VX4.2 and VX4.3A turbines, which has been called COPRA, an acronym of ‘Combined Brayton Rankine.

NIAM Credentials for standards includes basic design and other important gas and combined-cycle power plants, including P&ID (piping and instrumentation diagram), system and major equipment datasheet description, control system configuration and process and component control in power plant, single-line diagram (SLD) of whole components of the power plant, main equipment layout map and cable and pipeline routes, base design (and sometimes detailed) plan of power plant major buildings, signal list, electrical bar lists, general maps and credentials such as proposed technical standard, base design credentials, technical specification of coatings for pipeline, connections, ground systems coating, etc.
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Credentials are used by MAPNA staff as a reference for technical proposals made by employer, and are open to MAPNA engineering sections in early phases of the project; this provides engineering section a base for working out the credentials of the project through limited changes made into the reference.
NIAM has made an attempt to attract wide spectra of different tastes and preferences of the employers; however, in projects where NIAM’s options fails to meet special needs of the projects, our engineers will incorporates the project special needs and conditions into specific design. To elaborate more on standardization, take an example. If we assume the scope of a combined-cycle power plant are concentric circles, the most central circle, where MAPNA is directly involved in design and procurement of equipment and facilities and would pre-plan the so-called power block, is gas and steam turbine and generator. An attempt also has been made to typecast equipment, arrangement, placing, electrical and mechanical connections, and related buildings to avoid unnecessary displacements in every single project. The second concentric circle consists of recycling boiler, transformers, electrical and control facilities of the industrial buildings.
The third concentric circle consists of component systems of the facilities in second circle including major and auxiliary cooling systems, water supply system for firefighters, water purification plant, auxiliary steam, compressed air, firefighting, fuelling, repair centre, and emergency power systems. The last and fourth circle consists of buildings and indoor spaces, and public and non-industrial venues, etc.
Design and manufacturing of the equipment and facilities in the central circles, where there is limited room for later changes and diversity, has been typical and fixed-standard; however, in outer circles, facilities and buildings take into consideration the tastes and preferences of customers and special needs of the project and the regional climatic conditions to provide more diverse options in design through pre-designed structures. This consideration makes structures re-usable many times in later projects. Different voltage and electrical pole arrangements and main cooling system of steam section, which significantly affects the power block design, are designed in a way so as to meet different needs and modules of the project.

MAIN FACILITIES OF NIAM

The following main facilities of the second circle are changeable according to specific requirements of the employers:
• Horizontally-installed double-pass heat recovery steam generator (HRSG) with 285 tone/h steam generation capacity, with or without added burner;
• Major transformer of the unit with minimum of 200MVA capacity, working in three different voltages of 132, 230, and 400kV;
• Quick disconnect switch for Iran-made HEC3 generator (under ABB licence) with a 12,000A capacity;
• 8,600 amp busduct;
• Auxiliary systems of gas and steam turbines and generators

The following main equipment of the power plant is the central parts and would not be changed:
• Edition 5 of V94.2 gas turbine (under Siemens licence) with nominal capacity of 162MW;
• MAP2+ gas turbine made by Tuga (under Siemens licence) with nominal capacity of 166.2MW;
• E-type steam generator (under Siemens licence) with nominal capacity of 160MW;
• TY10546 generator (under Ansaldo licence) with nominal capacity of 202MVA, generally coupled to steam turbine;
• Electricity and control systems of all units (under Siemens and ABB licences)

تجهیزات اصلی در طرح نیام

NIAM; OBJECTIVES AND ACHIEVEMENTS

The initial idea of NIAM was conceived in MAPNA’s engineering section and the primary objective was to guarantee customer and employer satisfaction through accelerated pace of project engineering and minimizing the power plant completion time. However, the advantages of the NIAM have encompassed the following as well:
• Bringing a feeling of self-reliance to Iranian engineers enough for them to involve in power block design and going even deeper in design and engineering layers;
• Reducing time needed to plan and prepare technical proposals (typecasting of proposals);
• Investigating and identifying the possible contradictions in employer tender papers and NIAM, and negotiating with employers;
• Respecting wide spectra of customer tastes along with compliance with value engineering principles;
• Ordering raw mat material and equipment as wholesale;
• Reducing ordering time for equipment and facilities and subsequent reduction in project completion time;
• Reducing preparing and communicating design and engineering data (base and detailed) and improving project engineering process;
• Reusing experiences gained during prior projects thanks to similar design;
• Sharing of technical and expert capabilities of operating and maintenance staff and subsequent improvement of services to operating projects;
• Reducing costs of training operating staff for employers;
• Optimizing using of spare parts of different projects by staff and a proposing a centralized spare parts warehouse;
• Preparing grounds conducive to receiving feedback from projects and establishing a database from lessons learned in prior projects, and providing improved designs in a regular basis;
• Avoiding past mistakes and pitfalls and improved performance in future projects.

The scope of work and technical specifications of a combined-cycle power plant with several options in cooling system typecast for different climatic conditions of the country, along with a number of basic credentials, potentially would be typecast, have been finalized and joined the list of reference credentials through multistep examinations. Electricity and control facilities of gas and combined-cycle pre-planned units according to accredited standards would be transported in few containers, which make installation and pre-operation tests possible to carry out right in the manufacturer’s venue; the process is further shortened, since the only work to carry out is to ensemble the components into a whole and to operate the system.
In localizing NIAM, relevant sizes of the facilities have been identified through an archive of the information from different developers, and accordingly space is allocated to facilities. Through predicting these factors, we typecast also different arrangement of the facilities and their electrical and mechanical connections. Auxiliary equipment inside the turbines hub is possibly installed on the chassis of the turbine, which is fixed on the floor. In placing facilities, enough space has been predicted for operation and maintenance activities and access; a software PDMS (Plant Design Management System) helps in 3D modelling of all space available, and guarantees that no component will interfere with any other components’ activities. In any project, there is a level of coordination among shareholders; diverse plans are worked out into an integrated whole in a joint platform, and possible modifications in NIAM are dealt with. Given MAPNA gas and steam turbine specifications and different specifications also of outflowing exhaust gases from gas turbines in different conditions, heat recovery steam generator is designed in a unique way; this was once a critical step of combined-cycle projects; however, MAPNA engineers standardized the equipment and process to typecast them in 3 types through data available about gas turbines from potential sources of combined-cycle project websites. Raw material, pumps, and other typecast components are purchased wholesale, thus effectively reducing designing time.
Noise pollution from plant main equipment is gauged and modelled through a scientific method, which provides ways to reduce, minimize, and block the noise source according to domestic and international standards, in attempt to comply with occupational health standards along with improving easy access and reduced maintenance and repair time.
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NIAM: PROSPECTS FOR FURTHER DEVELOPMENT

Development Plans

  • Spotting and adding possible options available;
  • Working out of plans and new options such as integrated gas and steam turbine hub plan in combined-cycle projects;
  • Preparing division map for country according to NIAM;
  • Preparing a standard plan for new products now available in the basket of MAPNA Group by NIAM developers; in doing so, preparing an edition of NIAM for small-scale power plants, electricity and water cogeneration plants, and water desalinator facilities have been in the agenda.
  • Identifying and adding all credentials with potentials for typecast into NIAM scope of activities;
  • Compiling and gradually completing design basics, type specifications, and technical support necessary to enrich NIAM.

Improvement Plans
Feedback received from domestic and international shareholders and customers and their consultants on design, procurement, building, and operation is regularly collected by a permanent secretariat for NIAM revision. The secretariat establishes different expert committees which meet regularly to reform the credentials and publish a reviewed version of the credentials. In collaboration with shareholders, the cruxes and deadlocks in the engineering intersections are identified and solutions are devised accordingly.
To accelerate installation and operation, all auxiliary systems outside the power block such as firefighter water reserves and pump systems, water purification plant, and emergency diesel generator are designed as in containers, installed on the place and enter into operation after necessary connections.

 

Attempts have been made to explain different aspects of NIAM in seminars, conferences, exhibitions, and forums, to come to a common culture and language among different classes of shareholders on power plant projects and to prepare grounds to exchange of new ideas and proposals.

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