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REACTORS &FABRICATED EQUIPMENT

GE Power SystemsOil & Gas

Introduction 3

Equipment Types 4

Hydroprocessing Reactors 5

Tubular Reactors & Large Heat Exchangers 6

Steam Condensers & Heat Recuperators 7

Site Activities & Technical Services 8

Facilities 9

Welding Technology 10

Quality Program 11

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GE Oil & Gas Nuovo Pignone has been manufacturingreactors, exchangers and fabricated equipment for morethan 40 years.

With a fleet of hundreds of Reactors and Separators, forhydrocracking, desulfurization, hydrotreating, platformingand similar processes, GE Oil & Gas is one of the mostreferenced Companies in large vessel manufacturing.

The GE Oil & Gas Massa plant is dedicated to the produc-tion of high-tech equipment including Heavy WallReactors for refinery applications, Tubular Reactors,Special Vessels for petrochemical plants and Large,High-Pressure Heat Exchangers. Extensive experiencewith numerous references has been developed in weld-ing high strength materials and in manufacturing equip-ment for urea and ammonia production plants.

The Massa plant is located near the seaport of Marinadi Carrara and there is virtually no limitation in manufac-turing and shipping of large size equipment.

Our Company Quality Assurance (Q.A.) system meetsall major international Standards such as ISO 9001, BS5750, UNI EN 29001, etc.Compliance of the Q.A. system with these standards iscertified by LLRR. The Massa plant is also qualified andcertified for ASME Stamps S, U, U2, U3 and is staffedwith qualified NDT personnel.

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Hydroprocessing ReactorsThese reactors are installed in hydrocracking, hydrotreating,heavy oil upgrading, desulfurization, and CCR refinery processes.With the exception of CCR process reactors, this equipmentoperates at very high pressure and temperature conditions.

Tubular Reactors & Large Heat ExchangersThis equipment is used in ethylene oxide, methanol and MTBEproduction plants. They have recently been introduced in Gas-To-Liquids processes. These exchangers containing severalthousand tubes, are typically used in low and medium pressureprocesses.

Steam CondensersWith a complete range of steam turbines for both generatordrive and mechanical drive applications, GE Oil & Gas has thecapability of providing turbines and condensing systems withsingle source responsibility.

Heat RecuperatorsGE Oil & Gas has over 20 years of experience with HeatRecuperators and has unparalleled qualifications to offer tur-bine upgrading from simple cycle to regenerative cycle.Eq

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High Thickness Reactors are used in high pressure and hightemperature processes. Nuovo Pignone developed one of themost advanced technologies for welding and manufacturingreactors up to 400 mm thick. Depending on thickness and diam-eters, reactor belts can be either rolled plates or forgings.Heads are made in one or two sections. Internals are suppliedby the most highly qualified companies.GE Oil & Gas has full qualification and experience with majorprocess licensors such as UOP, Chevron, IFP, HRI, Lummus, Shell,ExxonMobil, in manufacturing reactors up to 2,000 tons and 60 min length with advanced high strength materials (Cr Mo V).Nuovo Pignone is one of the world’s most experienced companyin manufacturing Reactors of 21/4Cr1Mo1/4V.Automatic welding technology with ultra-narrow gap beveling isextensively used in our manufacturing operations.

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Tubular Reactors consist of large shell & tube heat exchangerswith very large diameters (up to 8 m) and over 10,000 tubes.Each tube is welded to the tube sheets with special weldingtechnology for conventional and high alloy materials. Keyfactors for tubular reactor manufacturing are tube sheetdrilling technology with reduced tolerances and tube to tubesheet welding operations.GE Oil & Gas has extensive experience in designing and man-ufacturing shell and tube heat exchangers, including in shoptubesheet drilling operations.

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Steam CondensersGE Oil & Gas has extensive experience in designing and man-ufacturing Air Cooled and Surface Condensers. Our SurfaceCondensers employ a GE Oil & Gas Nuovo Pignone proprietarydesign and are supplied in accordance with applicable inter-national standards and with suitable materials to meetprocess conditions (e.g., tubes in carbon steel, admiralty,cupro-nickel, stainless steel, titanium).

Heat RecuperatorsUp-grading of Simple Cycle Gas Turbines to RegenerativeCycle delivers significant efficiency improvement and reducedoperating cost. GE Oil & Gas is fully experienced to design,manufacture and install heat recuperators.

- High efficiency with drastic heat rate reduction - Rugged construction; tailored metallurgy- Low maintenance- Optimized Tube bundle design- Ducting system options (symmetric and asymmetric)- Risk-free retrofit - Complete in-house supply

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Site ActivitiesIn some cases constraints on shipping to the job site require fieldfabrication of reactors shipped in sections from our Massa plant.With leading edge technology, manufacturing capabilities andfield experience, GE Oil & Gas can provide complete field fabrica-tion of hydroprocessing reactors.Extensive current experience has been accumulated in manylocations worldwide and under diverse weather and environ-mental conditions.

Technical ServicesGE Oil & Gas offers comprehensive technical service programsfor all types of static equipment, focused on reduction of plantoperating costs and increased plant efficiency. Deep technicalknow-how, advanced diagnostics, NDT systems and a regionalpresence guarantee full coverage of customer needs.

We provide:- 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

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Continuous effort is dedicated to product development andplant facilities improvement to maintain our leadership positionin the industry and to guarantee defect free manufacturing. TheMassa plant is equipped with state-of-the-art facilities to ensurethe highest quality fabrication of hydroprocessing reactors. Located near the seaport of Marina di Carrara, the Massa Planthas virtually no dimension or weight restrictions for shipment.Lifting systems and rollers are capable of handling reactors of2,000 tons.

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 with NDTand stress relief on the last circumferential welding performedlocally.

RX BunkerThe Radiografic Bunker is equipped with a linear acceleratorsuitable for performing x-ray inspections of welds up to 400 mmthick.

NDT TechniquesGE Oil & Gas is equipped and experienced with very advancedNDT techniques such as TOFD (Time of Flight Diffraction) forvery high thickness welds. The TOFD technique was used inaccordance with ASME C.C. 2235 in lieu of RX on one of thelargest heavy wall hydrocracking reactors ever built using21/4Cr1Mo1/4V material. This reactor was delivered and installedin the USA in early 2000.

Consumable StorageAll consumables are supplied by highly qualified manufacturersand are stored in a state-of-the-art facility equipped with ovensto maintain flux and electrodes in a dry environment.

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Weld OverlaySingle and double layer weld overlays have been applied formany years using SMAW, FCAW, SAW and ESW techniques.Double head welding machines are available for SAW overlayof the shell ring inner surface.With these welding techniques GE Oil & Gas is capable ofachieving outstanding results such as the absence of dis-bonding of weld overlays during maximum cooling rates com-monly experienced during shut down transients.

Hydrogen Control During WeldingEvery batch of flux is checked for total water content afterbaking to reach very low humidity (0.02%). Transportation ofthe flux between the warehouse and weld stations is alwaysperformed in special containers equipped with electricheaters.The flux is pneumatically supplied to the welding machinehead through a feeder pipe using clean, dry air.

Ultra Narrow Gap BevelingUltra-narrow bevel angles are used in circumferential welding.This technique is allowed by the automatic self-adjustment ofarc stick-out and position and the anti-drift (bevel self-aligning)rollers.

Advanced Materials For Hydroprocessing ReactorsGE Oil & Gas has extensive experience in manufacturingReactors using 3Cr1Mo1/4V - 21/4Cr1Mo1/4V, the mostadvanced material for this application.W

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GE Oil & Gas Reactors and Fabricated Equipment are manu-factured and tested in the Massa Plant. The entire productionprocess is carried out under the GE Oil & Gas Quality Systemthat integrates the GE Six Sigma Quality Program with ISO 9001Quality Standards to guarantee customer satisfaction. TheProgram ensures the long-term stability and sustainability ofprocess improvements guaranteeing the quality of products.

The Quality Assurance Manual documents the policies estab-lished for all aspects of the quality of reactors and is the com-pany reference for all departments. The Quality Program iscertified by LLRR.

The Massa Plant is also qualified and certified for ASMEStamps S, U, U2, U3 and is staffed with third level NDT per-sonnel.

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GE Power SystemsOil & GasHeadquarters:Nuovo Pignone S.p.A.Via Felice Matteucci, 250127 Florence - ItalyTel. +39-055-423 211Fax +39-055-423 2800e-mail: info.geoil&gas@np.ge.com www.gepower.com/geoilandgas

Massa plant:Nuovo Pignone Via Dorsale, 354100 Massa - ItalyTel. +39-0585-7951Fax +39-0585-791322

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