MAPNA GROUPTUGA. ~ > PRODUCT CATALOGUE .>.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. Alter 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 wellknown intemational partners, os well os 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 milion EOH. In addition fo the power gas and steam turbines, the company is new producing a range of industrial gas turbines and turbo-compressors. | In order to offer more value to customers, MAPNA Turbine is developing its product and service range by taking new strategies. The company is'adding larger turbines with higher output and efficiency to its fleet, and providing increasingly diverse and reliable after-sale services'es well. Trained andthighly qualified professional personnel, state-of the-art manufdicturing, equipment Gnd facilities, modem engineeting/manufacturing methods. and high-quality raw materials sourced from well-known international supplaes ‘alloW/vs to fulfil the customer's needs at the highest of levels!MnPower Steam Turbine if ] MAPNA Steam Turbine Knowing the time, money and effort that must be consumed for maintenance and overhauls, most customers are eager to buy machines that are robust enough to with- stand difficult working conditions and stil be available to keep on making electrical power. The MAPNA steam turbine has been designed to meet the requirements with fewer overhauls and more availability. High performance, cleaner power, reliability and simplicity are among the other characteristics of this product, producing 159 MW and 50 Hz electricity to be used only in combined cycles. Product Specifications | Main team tow ethals 2) Moinsteam presane sobor 3 | Main steam temperate s0°c 4 | Supply tec fow kgs 5_|__ supply sleom presse asbar 6 _Supoly steam temperate 30°C 7 | tack presure o.14bor 8 | Rated ouput power 159 9_|__ Bticieney fat above conaliions) 33.38 “10_| — Freque “SoH 11_| Max. lowedmain team low fong fr) 152hg/ 12_| Men. ouput power het term) 186 mn 13__| Max. glowed back presi tip valve) O5bar 14 Overateimenions em Fm Sem 15_|__ shiopina weight V5 Advantages + One common outer casing for HP and LP sections + Shrouds for all the stages of blading, allowing for increase of mechanical and vibrational strengths + Spting-backed seal segments to withstand potential of rubbing against the rotor + Single outer casing with HP inner casing to minimize heat loss + Integrated stop and control vaives in a single body * Laser-hardening on the last stage blades for minimal erosion + High resistance to increased condenser pressure + Hood spray to decrease windage effects * Electro-hydraulic actuator for main, supply and bypass valves + Fully-automated turbine operation to minimize operator faults + Self-cligned bearing design compatible with any rotor train alignment + Deep part load operationOther Features Highly Resistant to Windage Two stages totaling 9 water spray nozzles are considered to lower the exhaust steam temperature in case of windage, so that the turbine can be operated at small percentages of MCR with no time restrictions. The nozzles come info operation sequentially depending on the exhaust steam temperature. LP Blades Resistant to High Condenser Pressure Thanks to the shrouded last stage blades, the steam turbine is highly resistant to condenser pressure up to 0.5 bara which is a great bonus if the condenser is not able to maintain the required vacuum mainly during startup and/or in undesired ambient circumstances. The shrouds serve the long blades to flutter less due to flow separation. Hardened Last Stage Blades Surface The steam passing through the last stage blades contains a certain amount of water droplets which can cause erosion effects. To minimize this, surface hardening Is performed using laser beams on a specific portion of the rotary blade surface. Bearing Dismantling Without Casing Removal The condenser-side journal bearing can be dismantied via an opening on the exhaust casing without need to remove the casings. This characteristic is mostly valuable during maintenance, since it allows the customer to avoid the extra effort involved in dismounting the casing. ‘Main and Standby Lube and Lifting Oil Pumps ~ More Availabilty ‘Two 100% oll pumps can serve as a safety feature to ensure that the turbine does not run without oil in low and high rotor velocities. The pumps are driven by AC motors. Power Steam Turbine Power Gas Turbine 5 8 5 E 6 0 3 3 2 2 € 5 OoMinimal Steam Admission Losses The integrated design of the stop and control valves in a common body eliminates the entering losses. Moreover, the full arc passage upstream from the blading has a special curve that prevents pressure drop. This arc is formed half in the rotor and half in the inner casing, Shrouds for All the Blades All the turbine blades have shrouds that contribute to increased mechanical and vibrational strengths. The shrouds accommodate seal strips of labyrinth and see-through types depending on the amount of relative thermal expansions of the rotor and casings. The shrouds of the last two stages of rotary blades have a small gap in between in standstill conditions. At full speed, this gap fill in to form ai solid ring that allows for higher blade mechanical strength. This keeps the blades’ natural frequencies safely distant from the working speed. This contributes to a safe change in condenser pressure without causing harm to the blades. Optimum Design of the Last Stage Blades The final stages of the LP turbine section are grouped in standardized stages. The aifference in rotational speed between blade root and tip accounts for the twisted design of the rotary blades. Units in Action The excellent performance of the MAPNA steam turbines has been proven in different power plants. Around 4000 MW have been implemented as of the end of 2011. The Damavand 2800-MW combined cycle power station is the largest plant in the region constructed by MAPNA, which includes 6 steam turbines of this type operating in the same location since 2008. Tishreen and Jandar combined cycle blocks in Syria are among the oversees plant that use MAPNA steam turbines.Services Offered After Sales Compared with other machines operating at the same output level, the simplicity of the MAPNA steam turbine design facilitates the overhaul procedure, allowing for minimum operational delay. The first minor inspection takes place after 25000 EOH of the turbine. The first major inspection or overhaul is recommended after 100,000 EOH. This demonstrates the turbine’s high level of availabilty and reliability. Thanks to the two provided boroscopic holes on the top of the outer casing, the last stage HP blades and first stage of LP ones can be inspected visually while the rotor is rotated by the manual turning gear. In special cases, an inspector can even enter the turbine via the opening on the exhaust casing through which the condenser-side bearing is normally mounted and dismounted. In this case, the inspection can take place without removing the casings. This enables the inspector to check closely for any probable damage to the last stage rotary blades. In addition, MAPNA Turbine Company offers the following services after sales. Provision of spare parts for 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 adaiition, by providing consumable materials and strategic components from cour 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. Power Steam Turbine Power Gas Turbine 5 8 5 E 6 0 3 3 2 2 € 5 OoSupervision with installation and commissioning Installation and commissioning of turbines 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's available for consultation at any time. 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 over- hauls thoroughiy. 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SUIGUN| SOD 18MOd euIqun |OLYSNPU} Jossaid od JOBNyujUeD POWER GAS TURBINE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 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* 1_| Frequency sone 2 | Grosspower output 146.2 aw 2 | Grometciency 35% 4 | Heat ate Tos22ka/keh 5._| Design utine ret temperate ore | East empetture sec 7 | Bthaust mass tow S35kats 2 | Preswerato ne 9_| Numberof compresior stages 16 10_| Nunbertypeotcombustor 2Si0 type 1L1_|_ Noxemislonvith natal gas 25ppm 12_| Noietove! 5b 13. | Over mensions 10243937 14_| skipping weight ve5Ma Advantages * Utized in simple or combined cycle plants * Generator at the cold end * Central tie bolt rotor with intemal air circulation around * No direct flame radiation on the turbine blades * Hybrid bumers and large combustion chambers + Easy inspection of bumers and turbine blades by means of manholes on combustion chambers * Replaceable blades + Ablity to use wide variety of fuel compositions + Fast startup * Low emissions even in part-load condition due to DLN (dry low NOx) technology * High EOH inspection * Low cost maintenance * Grid stabilization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 re- placed 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 bumers per each chamber with dry low NOx technology result in high efficiency with less emission. The hybrid bumers enable the system to operate on premix and diffusion modes with both gas and cil. Manholes allow personnel to directly inspect the hot-gas path components from bumers 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 Abriliant feature of the system Is ts dualuel design (gas and oll) 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 oll system are the injection pump and duplex filters as well as stop and control vaives. A hydraulic oil system provides high-pressure hydraulic oll to operate the control and emergency stop valves of the fuel systems. A purge water system is used to prevent coking of fuel oll in the bumers. Air Intake Air filtration provides a pollutant-free air with a suitable temperature at the engine inlet and basically consists of ant-icing and three stages of filtration, as welllas silencers Power Gas Turbine 5 8 5 E 6 0 3 3 2 2 € 5 OoExhaust The exhaust duct vacates the five 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 Liffing 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 Al-Sadir simple cycle in Iraq are all among the plants abroad that use the MAPNA gos turbine.Services Offered After Sales The hot gas path sections are the most likely to be damaged. However, he 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 64000 EOH. This interval may differ depending on the order. The MAPNA power GT's 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. Power Gas Turbine 5 8 5 E 6 0 3 3 2 2 € 5 Oo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 over- hauls theroughly. Fabrication and repair of turbine special parts Thanks to our state-of-the-art machineries and skiled manufacturing personnel, we con 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Wr, SUIqUN| |OUISNPUL Jossaid od JOBNyujUeD INDUSTRIAL TURBINEIndustrial Turbine MAPNA Industrial Gas Turbine Our industrial gas turbine meets customer requirements for economic installation and operation and provides excellent flexibility for complex industrial processes. There are various types of applications that use industrial gas turbines. However, the most prevalent are found in the oil and gas industry (refineries, petrochemical plants} and the mining and cement industry, as well as those requiring independent and dispersed power generation. Whether you need a generator drive for power generation or a mechanical drive for compressors, blowers or pumps, just talk to us and together we can select the turboset that optimally suits your needs. Product Specifications* 1 ]__ So rated power ze 2_|_Eficleney ory 3 | Heat rate. 110000 ks/kWh 7 | Ltubine ristlenpersiaw raaise 5 | Eshowst gas temperahxe 3c | Exhaust gas mass fow elas 7 | Preeare rao aie 8 | Semberofcomproncr tages aoa __9_|___Combustion chamber 0) Cran 10. | Gar generator tbines Arising stage LT and PT 38005280 pm ese eso " Power turbine speed Ea oar 2 (comptesoropoteatin 12 | Powertubne stages 2 compre cpptcan] “13_|_ Turbine dimensions 64x25 127m, | Shipping weight 1éMa “nO conditions with natural got Advantages + High simple cycle efficiency + Combined cycle and CHP reliability * Mechanical drive reliability specially for centrifugal compressors * Mixed duty applications Other Features The machine consists of two main sections, Gas Generator (GG) and Power Turbine (PT), which are thermodynamically coupled to each other. These special design considerations make our product unique:Anti Stall and Surge Built-ins Twin-shatt configuration in the Gas Generator unit leads to maximum reliability hindering stall and surge phenomena. Additionally, integrated IGV and VGV rings applied in the GG's structure improve the flow inside. Also blow-offs along the flow path inside the GG provides maximum safety. Design Reliabilities Due to using a centrifugal ratchet clutch, start-up as a mechanical interchange between the starting system and the lube oil power pack runs as easily as possible. Nearly maintenance-free roller bearings are used in the whole machine design. Furthermore, fir grooves/trees are applied to the first three stages of the compressor to enhance fatigue strength on both the blades and disks. A by-pass anti-surge chamber in the vicinity of the fist rotary stage contributes to stability and sustainability of transition regimes. ‘Simple Installation and Maintenance The GTis available as a factory-cssembled package. Itis easily transported, installed and maintained on-site. The package includes the gas generator and the power turbine and. ll the wiring and piping mounted on a single base. For maintenance purposes the gas generator part can be slid off completely from the whole package fo make room for any ensuing operation. These characteristics have made the GT stand out from its competitors in terms of safety, long life cycle, maintenance, and reliability. Services Offered After Sales After 25000 EOH, the gas turbine flow path is inspected on site. Depending on the machine condition ond operating parameters, « deckion is made either fo extend further operation or carry out an overhaul. In the aggregate, total recommended service lifetime is 100,000 OH, which is normally reached in approximately 25 years. Based on the machine inspection, the time between overhauls and otal service time may be extended in case of good machine condition. The following services are available to the clients after sales. 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. 5 8 5 E 6 0 3 3 2 2 € 5 Oo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 turbines and auxiliaries are performed by skiled 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 plant. Technical consultation services for end users Our experienced and knowledgeable technical and engineering team is available for consultation at any time. Training of end-user staff We offer several training courses for new staff on site, such as general plant knowledge, operation, maintenance, and some special training, such as firefighting. Performing inspections and overhauls Our experienced maintenance personnel can perform turbine inspections and over- hauls 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.CENTRIFUGAL COMPRESSOR Centrifugal CompressorCentrifugal Compressor nem MAPNA Centrifugal Compressors Together with industrial turbines as mechanical drives, three types of centrifugal compressors for gas pipelines are produced in different ranges of flow and pressure. The two-stage gas compressor provides the client with a wider range of flow rate, while three-stage compressors offer a higher pressure range. The reliable and flexible centrifugal compressors with a life-long service ensure safe and smooth operation of the turbo- compressor system. Product Specifications 2 | Speed (tp) =a | tnpeter arate rm) 4 | Gommecial output MGM) Advantages + Split configuration * Forged steel casing with end cover * Covering maximum changes in operating points * Tiling pad bearings equipped with thermocouples Other Features These special design considerations make our centrifugal gas compressors unique: Oil System The oi system provides lubrication for compressor rotor bearings conforming to the require- ments of API 614, The seal oll provided is filtered, which ensures safe operation of bearings. Gas seal system The gas seal, which is designed for tightening the compressor shaft, plays a significant role in ensuring that the compressor rellably produces an appropriate pressure ratio. Dry Gas Seal {DGS} system includes two sub-systems: butfer gas supply and banter air supply.Control System Protection against the destructive surge phenomena is among the most important points in a control system. Ours is a complete solution that ensures reliable operation. Anti-surge regulator is one of the components used by the multi-processor control system, of the mechanical drive to control the gas compressor unit. The anti-surge regulation Consists of three functional blocks: diagnostic block of pre-surge conditions, block of surge reserve calculation and ASV (antisurge valve) control block. Services Offered After Sales The following services ore available to the clients after sales. Provision of spare parts for the machine (Our reflable network of spare parts suppliers enables us to satisfy individual cient demands, including capital spares, as per order. 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 are performed by skilled personnel under our direct supervi- sion, Personnel can also be made readily available on and off the client site until the end of the guarantee period. Technical consultation services for end users (Our experienced and knowledgeable technical and engineering team is available for consultation at any time, Centrifugal CompressorTraining of end-user staff We offer several training courses for new staff on site, such as general plant knowledge. operation, maintenance, and some special training, such as firefighting. Performing inspections and overhauls Our experienced maintenance personnel can perform inspections and overhauls thoroughly. Fabrication and repair of 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,(Customer needs and new markets are what dive ourinvestment in research and devel- ‘opment. MAPNA Turbine (TUGA) is now heading towards mere diversity in products os well asimproving flexibility of the turbines for different applications and customer requirements. This involves not only improving the power output and efficiency of the machines, but ao 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 valve for our customers,