Research and Development (R&D) in Monenco Iran aims to apply new idea in power plantengineeringand to increase efficiency and improve quality of products. Improvement of design, manufacturing procedures and engineering methods cause increase of efficiency and reliability and decrease of expenses and wastes and finally cause increase client's satisfaction. Research groups of Monenco work closely with manufacturers, universities and clients to develop the systems and products which are improved and meet future requirement by using new technologies.
R&D of Monenco steps up the challenge of creating the pioneer systems and engineering services that enhance energy efficiency, reliability and productivity.
Monenco meets the present and future demands of industries, while helping clients to make a better use of available resources, preserves the environmental impact and maintenance costs as low as possible.
R&D Office is involved in the Following Projects:
HRSG of 6CC Project
This project is intended to repower the Old CCPP in Iran. In summer time the power output of CCPP decreases due to the reduction in air density. To recover this reduction, additional combustion in HRSG by duct burner is investigated. Result shows an increase in steam turbine power output with duct burner. This increase is limited to the cooling system capacity and HRSG characteristics.
CFD of HRSG in Rajaei CCPP
This project followed Rajaei CCPP Repowering Project. Present project, consiered the influences of heat distribution pattern in HRSG by Fluent code. As the major result gas temperature and velocity distributions on the third super-heater is studied carefully. Finally, based on temperature restriction of heat exchanger materials and uniform heat flux distribution on the third super-heater, duct burners configurations are decided.
TOT of ACC
The project called TOT of ACC deals with Technology Transferring of Air Cooled Condenser's Design, Engineering and Construction Know-How from Swiss company, INNOSPIN, to Monenco Iran. This includes acquisition of design and construction know how of ACC cooling system. This objective is supposed to be completed sequently over four different combined cycle power plant projects namely, Isfahan II, Abadan I & II and Genaveh. By the end of January 2010, the 4 projects statuses are as follows:
Isfahan II:
Approximately all of the documents are in Innospin scope. 96% of documents were issued up to now.
Abadan I:
In this project, 42% of documents are in Innospin scope that have been completely issued, and 58% of documents of documents are in Monenco scope that 18% of it have been issued up to now.
Abadan II:
In this project, 7% of documents are in Innospin scope, and 93% of documents of documents are in Monenco scope that 7% of it have been issued up to now.
Genaveh:
All of the documents are in Monenco scope. 10% of documents were issued up to now.
TUGA Project
This project deals with structural and fluid dynamics analysis of V94.2 gas turbine's air intake and exhaust systems. This includes geometrical modeling, mesh generation and Fluid and structural analysis of both systems. In this work GAMBIT, FLUENT, Solid Works and ANSYS software are used to do geometrical modeling, mesh generation and required analysis. Final reports are submitted to the client at the beginning of February 2010.
Updating of the Thermal Power Plant Technical Specification
The goal of this project is preparing an updated version of the thermal power plant technical specification of the IPDC Tender Documents. The scope of the project is Steam Turbine, Gas Turbine and Combined Cycle Power plant. Currently the documents of Gas, Steam and Combined cycle have been revised. Moreover other consulting engineers companies suggested some comments which are being assessed.
Gas turbine test rig:
The localization of gas turbine manufacturing in Iran for use in oil and gas industries has attracted much attention over the years. Currently TUGA (part of MAPNA Group) is in the process of TOT (Transfer of Technology) for production of a 25 MW industrial gas turbines for use in natural gas pumping stations. The TOT contract is with Zorya-Mashproket (Ukrain). A prerequisite for development of such capability is the ability to conduct performance tests of the finished product in accordance with relevant and acceptable international and manufacturer’s standards. The purpose of the performance test is to assure safe, reliable and efficient operation of the gas turbine before its commissioning. The complete design of the test station together with the necessary test calculations are in the scope of work of the R&D office. The proposed test station will use a variable speed and power dynamometer. Dynamometer is a device for absorbing and measuring the power of rotating machinery such as the gas turbine.
Compressor test rig:
The objective of this project is performance testing of a Sumy (Ukraine) compressor according to the latest international standards which will be manufactured in TUGA (Part of MAPNA Group). The main objective of the test is about obtaining the performance curves of the compressor and comparison with the manufacturer’s data. Also the trend in compressor behavior because of change in the environmental conditions is investigated. The performance testing is possible using two methods of closed loop and open loop. The appropriate testing methodology is selected after a financial, technical and feasibility study. The eventual goal of this project is the complete design of the testing facility.
Environmental study:
In this study, the suitable solutions for multi-pollutant reduction in power plants have been studying in four stages. Stage one devoted to introduce and review the major pertinent committed projects related to existent Thermal power plants, in order to specify the rank of the country in the universal competition of environmental protection. The second stage discussed the various types of the power plant pollutions like emissions to air, waste water, particulate matter, noise etc... . This chapter provides detailed explanation of pollutions to give a good overview of the serious dangers of them for the environment and the human's life. Recognition of the pollutions, their sources in different parts of various power plants, and their production circumstances will help us to find out better solutions of reduction. In chapter three, various types of industrial methods of controlling power plant pollution have been introduced separately regarding to their gaseous, liquid or solid types of pollutants for all fossil-fuel based thermal plants using coal, fuel oil, or natural gas and also steam turbine power plants and combined cycle ones.
The air pollutant emissions control technologies were divided to three aspects of Pre-Combustion, Concurrent-Combustion and Post-Combustion performances. For example, Pre-Combustion performance is mainly related to choosing of the proper fuel, preparation of the fuel. The prominent factor in this stage is site selection of new power plants regarding to the environmental considerations of the chosen local site to reach a minimum environmental effects in the future. Moreover, there are some methods used in refinery section of plants to purify the waste water of them by removing heavy metals like mercury, sludge and lubricants; controlling PH and temperature of the released water to the receptive waters.
Finally at the forth and last step, an economical and technical comparison of widely used retrofitting technologies in the world will be provided for existing power plants of Iran.
R&D duties include:
- Developing technical software’s for study, design, engineering and system rehabilitation of plants.
- Conducting technical and economy studies in order to maximize efficiency of systems and to minimize costs.
- Improvement of plant performances, development of engineering and design of equipment and parts for manufacturers.
- Obtaining technical know how of new design and engineering and solution for optimization of plants.
- Modifying the procedures of operation, maintenance, protection and utilization of plants.
- Helping the clients to apply updated and high technology equipment in plants in order to achieve more reliable out puts and products.
- Design and engineering of renewable and new energies power plants due to their large potential in the country and in the world.
- Creating new methods to control more efficiently the air, water and solid pollutants and to reuse and recycle wastes.
Goals of R&D Department:
- Exploring research capabilities and capacities in different Monenco Disciplines and help them to use the capabilities in their engineering works.
- Coordination between Monenco and MAPNA groups as major manufacturers in order to compile executive approaches in order to choose suitable technology.
- Seeking for improved approaches to attract and naturalize the selected technologies.
- Guiding the planning and design disciplines to identify useful research projects and allocate financial supports for the projects.
- Providing required facilities for especial scientific training of the engineers in order to update their engineering and technical knowledge.
- Communication with academic and research centers inside and outside the country in order to activate necessary research projects