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Possessing unique capabilities in design and engineering, utilizing home-made software besides the most updated, technical software in the world, and employing experienced experts in different sections of design comprising the basic, the process and equipment, the mechanical (pressure part and non-pressure part), the water chemistry, water purification technologies and material, the electrical, the control and instrumentation, and the piping, MBEC as a cohesive coherent and coordinated company designs projects and equipment, sticking to the principle of meeting clients’ technical needs.

Pivotal role of design department and product development in the company to improve the technical specifications, performance, and efficiency of the current products as well as to develop new products using feedback having been received from clients and accomplished projects, and via definition and conduct of R&D projects in parallel with identification and achievement of today’s world knowledge and technology leads to MBEC’s growing trend toward fulfillment of clients’ demands to a large deal of flexibility. The department has been supported in computational power by a strong infiniband cluster blade server of 120 cores together in parallel to do massive numerical simulations for R&D design projects. The presence of high-tech hardware facilities in the fast computational center of MBEC provides a unique capability for conducting complicated simulations in combustion, heat transfer, and stress analysis.

A technology transfer license agreement for design and supply of HRSGs was signed between MBEC and DOOSAN companies in 2003. The experience thereby gained in design and shared execution of a number of CCPP projects with DOOSAN, as per a consortium at the time, has resulted in an invaluable technical, technological, and practical wealth. Relying on that experience and wealth and also strengthening and advancing them in all sections of design department and development of product, this company has until now succeeded to and deliver around 100 HRSG units downstream of GTs in CCPPs, 34 industrial water tube boilers, and 52 deaerators, delivering them as its important key products to market, making a significant contribution thereby to such industries as power, oil, gas, and petrochemical plants, and maintaining and promoting its position as the greatest source of supply for various types of steam generators and boilers inside Iran and in its neighboring region’s markets.

Keeping environmental regulations and human rights standards noticeably receives MBEC’s attention in products design and projects and MBEC assures its customers of its loyalty to the creation of a sustained value thereof.

MAPNA Boiler factory locates in a 10-hectare land with a 40-hectare closed workshop, equipped with new world technologies and production lines for preparation, machining, welding, assembling, and other complementary processes

In order to create infrastructure facilities for conducting development programs the following actions have been taken:

Physical Development: Expansion of Storage Space and Production Halls

  • Allocating an area of 22 hectares for the growth of storage and production capacities
  • Building production halls according to the comprehensive plan for the company development

Technological Development: Purchase of Machineries, Equipment, Tools, and Improvement of Current Machines Capabilities as well

Employing cutting, rolling, forming, finning, head pressing, lathing, grinding, boring, carousel, and welding machines as well as blasting and painting, heat treatment furnace, normalizing, and hydrotest, manufacturing capabilities of a production capacity more than 25 thousand tons, able to increase dependent upon the basket of products, in the factory of MAPNA Boiler and Equipment Manufacturing and Engineering Company are as follows:

 
  •  Heavy duty 4-roller plate rolling of plates up to 300mm and 180mm thick for hot and cold rolling processes respectively, with the most workholding width of 4m.
  •  High-frequency 3-axis induction bending of pipes used in the piping system of power plant and oil and gas equipment in the range of 4in. to 32in.
  •  Production of fin tubes of spiral fin type to construct HRSGs harps in combined cycle power plants and economizers of industrial watertube boilers for tubes up to 4in. in diameter and 25m in length.
  •  Continuous bending of superheaters and economizers loops up to a neutral axis length of 76m and a loop length of 18m, using a continuous tube bending system with the capability of simultaneous X-Ray test.
  • Precise drilling and milling of metal structures using a 7-axis CNC boring machine with a workholding table (12000mm × 4000mm)and having universal and boring heads.
  •  Carousel vertical lathing and seat grinding of rounded surfaces and structures up to 5m in diameter, 2.3m high, and a weight capacity of 60 tons.
  •  Welding of all types of pressure and non-pressure vessels using automatic submerged arc welding (SAW) machines.
  •  Pipe bending of individual pipes in size range of 2in. to 8in. using CNC pipe bending machine.
  •  Bending of boilers membraned waterwall tube panels together using CNC machine and portable equipment.
  •  Post Weld Heat Treatment(PWHT) of metal structures: 17m length × 6m width × 6m height.
  • Automatic submerged arc welding (SAW) of boilers membraned waterwall tube panels.
  • Manufacturing of elliptical and hemispherical heads up to about 6m in diameter made of plates with the maximum thickness of 60mm.
  •  Vertical bending of pipe and profile with the least workholding diameter of 600mm.
  • Automatic flame plasma cutting of carbon steel and alloy steel plates (shape cutting).
  •  Performing of hydrostatic test of vessels, harps, and other high pressure wall components at separate stations observing safety and environmental issues.
  • Shot blasting of materials and metal structures and products in a closed 20m × 6m × 6m space with filtration and waste recycling facilities and environmental considerations.
  •  Manufacturing technology of heavy pressure vessels.
  • Using of welding technologies such as shielded metal arc welding (SMAW), gas metal arc welding (GMAW), gas tungsten arc welding (GMAW), and submerged arc welding(SAW).
  •  Capability of cutting all types of pipes and nozzles with desired shapes up to 6m in length and 500mm in diameter using a 5-axis robotic cutting machine (oxyfuel and plasma cutting).
  •  Capability of saddle beveling with different cutting parameter choices.
  •  Capability of cutting vessels using a portable 3-axis robotic cutting machine with the most cutting diameter of 1m.
  •  CNC machining and beveling with the sizing capacity of up to 7m in length and 2m in diameter using a DP heavy duty cutting machine.
  •  Manufacturing and retubing technology of shell and tube heat exchangers.
  •  Holding the technology transfer license of HRSGs downstream of H-&J-&F-&E-series and larger scale GTs and having required infrastructures.
  •  Manufacturing capability of power plant and refinery equipment skids.
  •  Manufacturing technology of knowledge-based products of duct burner, heat tracing, and stack damper.
  •  Manufacturing technology of Electro De-Ionization (EDI) and Desalination products.

Within MAPNA Boiler and Equipment Manufacturing and Engineering Company, engineering and quality control and assurance of materials, equipment, and manufacturing processes are all managed by a single independent “Product Quality Division”. This department holds the responsibility of products quality gaining modern methods which are based on the latest version of international standards such as ASME, ASTM, AWS, and ISO.

1- QUALITY CONTROL
  • Technical inspection through manufacturing processes in accordance with international standards
  • Technical inspection of purchased raw materials before shipping- including qualitative and quantitative control and supervision
  • Evaluation of vendors and equipment manufacturers
  • Supervision of vendors/manufacturers shop tests intended for quality equipment delivery
  • Inspection of hot and cold insulation materials
  • Inspection of all coating systems checked for the depth of penetration (Holiday Test), thickness, and adhesion (Field Tests)
2- WELDING, MATERIAL, and PAINTING ENGINEERING
  • Providing Inspection & Test Plans (ITPs) and Quality Control Plans (QCPs) (QCP ITP)
  • Providing procedures for welding (WPS, PQR, WPQ), PWHT, hydrotest, NDT map, and painting according to the standards of ASME, AWS, EN, PD, ISO, NACE, SSPC, etc.
  • Failure analysis of components
  • Presenting repair procedures for welding and painting
  • Welding and painting material selection and estimation
  • Reviewing final vendor books of equipment
3- PRODUCT QUALITY ASSURANCE
  • Root Cause Analysis (RCA) for nonconformities
  • Culturalization of quality throughout the organization in order to do works based upon Total Quality Management (TQM)
  • Determining, measuring, and monitoring of product quality indicators
  • Identification of improvement opportunities in association with product quality
4- LABORATORY
Metallurgy Test Laboratory: ) Holding ISO 17025 certification from the National Accreditation Center of Iran )
  • Specimens preparation using different equipment machines for cutting, grinding, polishing, mounting, grooving, etc.
  • Tensile and proof load test of different specimens up to 60 tons (force)
  • Break, Nick Break, and Fracture Tests on weld specimens in accordance with international standards
  • Flattening, Flare, and Flange tests on tube and pipe specimens
  • Bending test
  • Impact test of energy capacity up to 300 J
  • Hardness test: Macro (Rockwell B & C scales, Brinell, Vickers), Superficial, Micro (Vickers and Knoop), and Portable
  • Chemical composition test using Stationary Quantometer and Portable X-Ray Fluorescence (XRF) methods
  • Metallographic and Microscopic examinations
  • Non-Destructive Tests (NDTs):
    • Visual examination
    • Magnetic Particle examination
    • Penetrant examination
    • Radiographic examination
    • Ultrasonic examination
    • Phased Array & TOFD
CALIBRATION LABORATORY

Calibration of Dimensional Quantity

  • Caliper
  • Inside&Outside Micrometer
  • Protractor
  • Feeler Gauge
  • Level
  • Industrial Set Square
  • Ruler and Tape Measure
  • Dial Indicator

Calibration of Pressure Quantity

  • Pressure Gauge (to 700bar)
  • Transmitter (to 700bar)
  • Transducer (to 700bar)
  • Monometers (to 350bar)

Calibration of Temperature Quantity

  • Furnace
  • Oven

Calibration of Electrical Quantity

  • Pressure Recorder
  • Temperature Recorder

MAPNA Boiler and Equipment Engineering and Manufacturing Company, in accordance with the perspective document, and for the purpose of reaching its goals and to improve efficiency, has deemed the use of information and communication technology, as a principal. To this purpose, the company moves towards maximum activity using services based on information and communication technology. implementing ICT services and equipment based on task-oriented strategic goals, ICT management and appropriate to commercial requirements, which are among the company's main goals and their installation is based on principals of management, the art and knowledge of controlling and managing ICT environments and based on proven methods in prestigious companies and organizations, which is done for gaining maximum management and output efficiency

Hardware and Communicational Capabilities

Regarding communications, the company by installing the MAN area-based communication network, has enabled the communication between its internal network LAN, and has achieved its desired goal. Facilities and capabilities of the company include:

  • Two independent Server Farms capable to support each other
  • Data storage & backup systems with redundancy
  • LAN high-speed network in all offices and workshops, using infrastructure fiber optic
  • MAN high-speed fiber optic network and wireless network among offices
  • WLAN high-speed network in all offices
  • IP-PBX Telephony in central offices and phone services to sites
  • Advanced communicational technology e.g. SIP Phone, Soft Phone and Remote Extension
  • Electricity infrastructure based on BISCI Tier3 standard and isolation of all electricity sources of all IT equipment and server room using Dynamic UPS technology and generator support
  • Implementing monitoring systems for online monitoring of events and network services and equipment, and periodical report
  • Advanced calculation and design center using IBM Blade Center technology
  • High security in external communications using Unified Threat Management equipment
  • Implementing of Information Security Management System (ISMS) according to ISO 27001
  • Providing higher than 40 ICT services, internally or long-distance to users, with the goal of 24x7x365 access
  • Video Conference service between offices used for sessions
  • Deployment of an advanced data encoding system to increase privacy and protection the organization’s key information assets
  • Deployment of a comprehensive management and automation system regarding the ICT services process based on the Information Technology Infrastructure Library method
Software and System Capabilities

Since its foundation, this company according to its needs, has produced and or provided required information systems within different fields. For the realization of Mapna Group's policies regarding the implementation of the SAP ERP system in all companies of the Group, and for the purpose of providing an integrated information system for the company, the SAP ERP system version ECC 6.0 has been installed since the beginning of 2015. This system is designed and produced according to world's most successful experiences and is currently tasked with supporting the Product Life cycle processes, Sales, Purchasing, Inventory Management, Quality Management and Finance of the company, as well as management and smoothing out the information process, generated during different transactions within this process. In addition to the SAP integrated system, a system called MPI2 (Manufacturing & Planning Integrated System) has been produced by the capability and expertise of the ICT section's engineers, to support production processes, production planning, design and is being developed according to new necessities, which is being developed and employed.

Information Systems Development Strategies Pyramid

In order to provide a general perspective of developmental strategies regarding information systems in realizing ICT goals, the following pyramid represents the company's path.
The apex represents the strategy to implement internal capacity and capability of the ICT section in developing Decision Support Systems such as SAP BW and Qlikview; and in the second layer called Systems Workflow Management the ICT section’s capacity and capability regarding developmental strategies of Non SAP systems on the Microsoft CRM platform and the execution of SAP Workflow are shown. In the 3rd layer called Systems Transactional Management, the module set of SAP systems in management processes and production planning system MPI2 are executed and are being developed and used.