GEOil & Gas

Heavy-Wall Reactors and Pressure VesselsMeticulous design and manufacturingfor superior performance

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Pressure vessels for every process

Hydroprocessing reactorsThese reactors are installed in hydrocracking, hydrotreating,heavy oil upgrading and desulfurization plants where highpressures and high temperatures are critical to the process.

Tubular reactorsThese units are used in ethylene oxide, methanol andMTBE production plants and, more recently, in GTL plants.GE's exchangers can contain several thousand tubes andare typically used in low and medium pressure processes.

Steam condensersWith a complete range of steam turbines for both generatordrive and mechanical drive applications, GE’s Oil & Gasbusiness has the capability to provide turbines and condensingsystems with logistic and economic advantages only possiblethrough single-source supply responsibility.

Heat recuperatorsGE has over 20 years experience with heat recuperators andhas unparalleled qualifications to offer turbine upgradingfrom simple cycle to regenerative cycle.

Tailor made for oil and gas operations

GE’s Oil & Gas business has been manufacturing reactors,exchangers and related fabricated equipment for morethan 40 years.

With hundreds of our units installed around the world forhydrocracking, desulfurization, hydrotreating and similarprocesses, GE is one of the most referenced companiesin large vessel manufacturing.

Industry-leading facilities Our plant in Massa, Italy, is dedicated to the production ofhigh tech equipment including heavy wall reactors forrefinery applications; tubular reactors and special vesselsfor petrochemical plants. This facility is also used extensivelyfor welding high strength materials and for manufacturingother equipment for the oil and gas industry.

The Massa plant is ideally located near the seaport ofMarina di Carrara, so there are virtually no limits to thesize of equipment we are able to manufacture and ship.GE's lifting devices and rollers are easily capable of handlingreactors as large as 2,000 tons.

Our Quality Assurance system meets all major internationalstandards including ISO 9001, BS 5750, UNI EN 29001, Vision2000, etc. Compliance is also certified by Lloyd's Register.

The Massa facility is also qualified and certified for ASMEStamps S, U, U2, U3 and is staffed with fully qualified andexperienced NDT personnel (Level III).

High pressure,highest performance

Tubular Reactor 1,400 ton reactor ready to be transported

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ExperienceFor more than 30 years, GE’s Oil & Gas business hasmanufactured hydroprocessing reactors for all majorprocess licensors including UOP, Chevron, Lummus, Axens,Shell and ExxonMobil.

Our design and manufacturing teams and facilities offer fullqualification and experience in reactor fabrication – usingadvanced, state-of-the-art high-strength materials suchas 21/4 Cr 1Mo1/4V in which GE is one of the most highlyreferenced manufacturers in the world.

Product portfolio• Hydrocracking reactors

• Hydrotreating reactors

• Heavy oil upgrading reactors

Industry-leading welding technologiesGiven the extremely high pressures and temperatures, andthe sheer scale of the units involved in the various applica-tions, welding integrity is critical to safety and productivity.Therefore, GE has developed the most advanced technologiesfor reactor welding and manufacturing facilities.

Our production capabilities include:

• Wall thicknesses up to 400 mm

• Unit capacities in excess of 2,000 tonnes

• Reactor lengths of 60 m

• No shipping limitations

Advanced processes and continuous improvementThrough continuous technology upgrades and operatortraining initiatives, we have greatly improved reactor qual-ity resulting in increased efficiency and productivity forour customers. Latest enhancements to our approachinclude:

• Direct supervision of welding processes at the shopfloor

• Flux handling with no moisture absorption using theSAW welding technique

• Controlled procedure of pre- and post-heating

• Ultra-narrow gap bevelling

• Ergonomic arrangement of welding station

Heavy wall reactors

Heavy wall reactors are used in high pressure andhigh temperature processes in refineries and petro-chemical plants such as hydrocracking, hydrotreat-ing, desulfurization and ammonia production.

Key factors enabling GE to manufacture this type ofequipment are:

• Full qualification and experience in manufacturingwith advanced high-strength material such as21/4 Cr 1Mo1/4V

• Automatic welding technology with ultra-narrowgap beveling

• Top class facilities

Hydrocracking reactor; 1,485 tons; 267 mm thicknessHydrocracking reactor being loaded by SPMT

Comprehensive capabilitiesContinuous effort is dedicated to product development andplant facilities improvement to maintain our leadershipposition and to guarantee defect free manufacturing. TheMassa plant is equipped with state-of-the-art facilities toensure the highest quality fabrication of hydroprocessingreactors.

Heat treatment furnaceOur large furnace can stress relieve in one piece pressurevessels up to 32 m long, 9 m in diameter and 2,000 tons.Longer reactors can be manufactured in two sections withNDT and stress relief on the last circumferential weldingperformed locally.

RT bunkerThe Radiografic Bunker is equipped with a linear acceleratorsuitable for performing x-ray inspections of welds up to400 mm thick.

NDT techniquesGE Oil & Gas is equipped and experienced with veryadvanced NDT techniques such as TOFD (Time of FlightDiffraction), BC Scan and Phased Array for very high thicknesswelds. These NDT techniques have been used in accor-dance with ASME C.C. 2235 in lieu of RT on several heavywall reactors.

Consumable storageAll consumables are supplied by highly qualified manu-facturers and are stored in a state-of-the-art facilityequipped with ovens to maintain flux and electrodes in a dry environment.

Weld OverlaySingle and double layer weld overlays have been applied formany years using SMAW, FCAW, SAW and ESW techniques.Latest generation technology welding machines are availablefor overlay of the shell ring inner surface.

With these welding techniques GE Oil & Gas is capableof achieving outstanding results, such as the absence ofdisbonding of weld overlays during maximum cooling ratescommonly experienced during shut down transients.

Hydrogen Control During WeldingConservative and experienced procedures and specialdevices are used to control and reduce hydrogen contentduring welding.

Ultra Narrow Gap BevelingUltra-narrow bevel angles are used in circumferentialwelding to reduce shrinkage and residual stresses. This ismade possible by the use of automatic self-adjustmentdevices and the application of industry best practices.

Unique capabilities forrefinery and oil sandsapplications

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Steam condensers

Steam condensers are a type of shell and tube heatexchanger. GE’s improved design features:

• increase condensing efficiency and avoid airblanketing through an innovative new tube layout

• reduce the thickness of tubesheets, flanges andcovers by FEM analysis

• facilitate maintenance and service through abolted channel design.

Surface condensers are fabricated in accordancewith applicable international standards, using thehighest quality materials including tubes in admiralty,cupro-nickel, stainless steel and titanium in additionto common carbon steel.

With a complete range of steam turbines for bothgenerator drive and mechanical drive applications,GE has the ability to provide turbines and condensingsystems with single source responsibility.

ExperienceIn over 25 years, GE's Oil & Gas business has developedextensive experience in designing and manufacturing sophis-ticated equipment such as tubular reactors for ethyleneoxide, MTBE and methanol plants.

Product portfolio• Ethylene oxide reactors

• MTBE reactors

• Gas-to-liquid reactors

Industry-leading welding technologiesGE has developed automatic welding technology for tubeto tube-sheet welding.

Our welding technology has very narrow tolerances in orderto deliver high-quality, precision results.

It is designed for the special application of materials suchas duplex stainless steel, titanium and zirconium whichsignificantly increase the stability of the finished units.

Tubular reactors

Tubular reactors are usually the principal piece ofequipment in petrochemical plants for the productionof ethylene oxide, methanol and MTBE. These unitsconsist of large shell and tube heat exchangerswith very large diameters of up to 26 ft. (8 m) andmore than 10,000 tubes. More recently, tubularreactors have also been employed in Gas-to-Liquidsprocess plants.

How they work

Ethylene, methanol, MTBE etc. are produced withinthe tubes through an exothermic chemical reaction.The heat of reaction is removed by cooling waterflowing within the shell side.

Ethylene Oxide Reactor

ExperienceGE’s Oil & Gas business has a long history of success inthe design and fabrication of surface condensers withintegrated vacuum systems.

Our steam condensers are able to work in extreme condi-tions – including temperatures ranging from –40°C to50°C. As a result, they have been installed from Russia tothe Sahara desert.

Applications• Waste to energy

• Combined cycle power generation

• Mechanical drive applications with steam turbines

Copper alloy steam condenser

Time-tested technology

Double passage steam condenser

Exhaustgases to

stack

Compressed airto regenerator Regenerator

Inlet air

Com

pres

sor

Fuel Combustionchamber

Turbine Load

Regenerative cycle

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Design advantages GE upgrading of gas turbines from simple cycle to regen-erative cycle delivers significant efficiency improvementsand reduced operating costs.

Key features of our comprehensive in-house solutionsinclude:

• High efficiency with drastic heat rate reduction

• Rugged construction with tailored metallurgy for specificplant/process requirements

• Designed for low maintenance operation

• Optimized tube bundle design

• A variety of ducting system options are available(symmetric and asymmetric)

• Risk free retrofit

ExperienceGE’s Oil & Gas business has extensive experience in thedesign and manufacture of heat recuperators.

Heat recuperators

Heat recuperators are used in gas turbine regenerativecycles to recover heat from the exhaust gas and addit to the compressor outlet air before the air entersthe combustion chamber.

This improves fuel efficiency by 5-7% and reducesthe cycle's heat rate by an average of 20%.

Unmatched experiencein applications aroundthe world

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Site activities and technical services

Site activitiesThere can be practical constraints on shipment of fullyassembled reactors to some job sites.

In such cases, GE’s capabilities enable field fabrication andassembly of reactor sections shipped from our Massaplant . With leading edge technology, manufacturingcapabilities and unparalleled field experience, our teams canprovide complete field fabrication of complex hydropro-cessing reactors to the same specifications and standardsas units assembled at our own facilities.

Our teams have accumulated extensive experienceassembling and installing units in many locations worldwide,under diverse weather and environmental conditions.

Technical servicesGE’s Oil & Gas business offers comprehensive technicalservice programs for all types of static equipment, designedto help deliver reduced plant operating costs and increasedplant efficiency.

Extensive technical expertise, advanced diagnostics, NDTsystems and regional service teams combine to guaranteefull coverage of customer needs.

Our services include:

• Installation assistance

• Spare parts supply

• Routine inspections, repairs and maintenance

• Predictive inspections

• Preventive maintenance

• Performance assessment, upgrading & modification

• Diagnostics and NDT inspection

• Residual life assessment and failure analysis

• Plant shutdown planning

• Gas turbine heat recovery

Quality assurance

GE’s reactors and fabricated equipment are manufacturedand tested in our Massa plant.

The entire process is carried out under a system thatintegrates the GE Six Sigma Quality Program with ISO 9001Quality Standards to guarantee total customer satisfaction.This stringent quality program ensures the long term stabilityof our own process improvements as well as the quality ofproducts for our customers.

Our Quality Assurance Manual documents the policiesestablished for all aspects relating to the quality of ourreactors and is the company reference for all departments.The program is certified by Lloyd's Register. The Massa Plantis also qualified and certified for ASME Stamps S, U, U2, U3and is staffed with third level NDT personnel.

Canada: 4 HCU reactors, 212 mm thickness, 2 assembled on-site

“…outstanding service and support provided by GEwith respect to the design, shop fabrication, deliveryand field fabrication…we look forward to having theopportunity to do business again with you in the future.”

Project Procurement ManagerDecember 1, 2003

France: 1 HDT reactor, 920 tons

“…excellent performance of the GE team…This state-of-the art pressure vessel is essential to PJ21 andwas completed on-time and to the Company's qualitystandards. We look forward to future business activitiestogether.”

Project DirectorJune 21, 2003

France: 1 HCU reactor, 1500 tons. One of theworld’s largest and heaviest HCU reactors

“…congratulate all GE team for the good jobperformed during the whole execution of the order,in terms of quality, follow up and respect of schedule.Thank you.”

Project Procurement ManagerFebruary 24, 2005

Kuwait: 1 HDT reactor

“…thank all the team for all the effort made forsuccessful Hydro Test and Dimensional check. Ourteam is happy with the job and effort made.”

Project TeamApril 11, 2005

What our customers say about us

Our customers’ words of praise are our highest source of pride. Here are just a fewexamples of what our customers think of us:

State-of-the-Art manufacturing capabilities, in plant or in the field

imagination at workReactors_A4_110706

Nuovo Pignone S.p.A.Via Felice Matteucci, 250127 Florence, ItalyT +39 055 423 211F +39 055 423 2800

Reactors FacilityVia Dorsale, 354100 Massa, ItalyT +39 0585 7951F +39 0585 791322

www.ge.com/oilandgas

The information contained herein is general in natureand is not intended for specific construction, installationor application purposes. GE reserves the right to makechanges in specifications or add improvements at anytime without notice or obligation.

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