Iran Entered the World Gas Turbine Manufacturers Club
Offering a National Turbine Against Global Competitors
Few countries in the world have the ability to build gas turbines; this strategic equipment and advanced technology.The technology of turbine manufacturing is mainly in the possession of prominent American, German, Italian, Japanese and Russian companies, and in recent years, Iran has joined the club of technology owners of this equipment thanks to the efforts of Iranian technologists and engineers.
The National Iranian Gas Company, with the full support of domestic turbine manufacturers, has played a key role in this proud process and has completed the plans by designing and implementing precise strategies.
In this interview, Mohsen Mazloum Farsi Baf, Director of Research and Technology of NIGC, while enumerating the localization benefits of this equipment, has described the plans of this group for the continuous improvement of the national turbine.
What activities has the National Gas Company undertaken to localize the national turbine?
A project called National Turbine in Research and Technology Management was defined to localize the equipment based on Germany"s SGT600 Siemens technology.
The design and construction project of the Iranian 25 MW gas turbine entitled IGT25 with the support of the National Gas Company and the effective implementation of the group of oil turbocharger companies was successful and in 1394, the first Iranian device was installed in the Dehagq facility on the fourth national line, which had a very good efficiency.
Have any repair programs been performed on this compressor?
Last year, level 1 repair license for this device was obtained from the gas transmission company. The turbocharger installed with more than 20,000 hours of effective and flawless operation has been successfully repaired and overhauled by the manufacturer under the original contract (OTC) and is now ready for service in winter conditions.
What are your plans for redesigning the national turbine?
Due to the fact that this turbine was built based on the technologies of a few years ago and has been in orbit since 1394, it was necessary to periodically make improvements in order to improve the technology in it.
Otherwise, leading companies will take over the market by offering more efficient products and tight the field for Iranian turbine competition.
This led us to put the national turbine upgrade plan on the agenda with the permission of the board.
The issue of rearrangement began in 1398 and the weaknesses of the existing turbine were identified, including the decline in performance of this equipment in high temperature conditions.
What are the problems for the turbine when working in hot environments and what solution has been offered for it?
As you know, gas flow in Iran is more from south to north and most of the strategic stations are located in tropical or desert areas.Studies have shown that turbines drop in power at high temperatures by between 10-15%, so the national turbine upgrade project named H.A.S(High Ambient Solution)was put on the agenda to increase performance at high temperatures.
In this project, which started last year, the strategies for overcoming hot weather were examined, and in September of this year, after the production of the version was updated and operational tests were performed, this turbine is now ready to be transported to Khormuj station.
From now on, this type of upgraded turbine will be used in new stations in the tropics and their complementary units.
What programs have you implemented in designing the turbine in accordance with the conditions of the cold regions of the country?
In our studies, we found that the national turbine also experiences power outages in very cold areas and in winter conditions.
The reason for this problem is that during extreme cold weather, microscopic particles of frozen air enter the air compressor stream.
While this equipment is primarily designed to compress gas flow, solid flow has many problems such as corrosion and mechanical consequences, and ultimately leads to reduced turbine efficiency.
Therefore, some changes were made to the existing turbine, and the modified turbine (IGT25-Anti Icing) is ready to be sent to the relevant stations in cold winter weather after passing the operational tests.
Therefore, in general, it can be said that so far, two types of turbines have been improved and upgraded in accordance with the cold and hot climates of the country.
What plans do you have in place to upgrade the power of the IGT25 turbine?
The main plan is to upgrade the national turbine from 25 to at least 28.5 MW.The important point is that this upgrade is done without changing the overall size of the turbine so that there is no need to make infrastructure changes in the facilities.
According to the plan, experimental works will be carried out by the end of this year and the upgraded turbine will enter the commercial production circuit next year.
This major upgrade is being carried out in accordance with the latest Siemens technology and will make Iran continue to keep pace with its major competitors in technological competition and will not lag behind the current technology convoy of the world.
What programs are planned to strengthen the main engine (compressor) of the turbine?
Despite several programs to upgrade the turbine, the compressor had not been upgraded so far, so a redesign of the technology was on the agenda to increase the engine efficiency from 82% to 90%.
Achieving 90% efficiency for the compressor is equivalent to the latest global developments in this field.This increase in efficiency causes major changes in pressure boosting facilities.
From now on, with a significant increase in power, we can achieve gas pressure boost by using fewer turbines.
The activity of fewer units in the stations will mean less depreciation, lower operating costs and adverse factors such as electricity, fuel, oil and cabling.
Considering all the successes, can we say that we have all the Iranian technology?
It can be said with confidence that the knowledge of design, redesign, engineering and repairs has been completely internalized and Iran is one of the few developed countries in the world that have the technology to build gas turbines.
But in the field of manufacturing parts of some control systems, alloys and instrumentations, we need foreign goods, which is a natural issue in the market.
As far as I know, some knowledge-based companies have now entered the field of manufacturing these parts, and the process of supplying goods is also evolving and progressing, and in the near future, more than 90% self-sufficiency will be achieved in the supply chain.