GE

Oil & Gas

Heavy-Wall Reactors
and Pressure Vessels
Meticulous design and manufacturing
for superior performance
Tailor made for oil and gas operations
GE’s Oil & Gas business has been manufacturing reactors,
exchangers and related fabricated equipment for more
than 40 years.
With hundreds of our units installed around the world for
hydrocracking, desulfurization, hydrotreating and similar
processes, GE is one of the most referenced companies
in large vessel manufacturing.
Industry-leading facilities
Our plant in Massa, Italy, is dedicated to the production of
high tech equipment including heavy wall reactors for
refinery applications; tubular reactors and special vessels
for petrochemical plants. This facility is also used extensively
for welding high strength materials and for manufacturing
other equipment for the oil and gas industry.
High pressure,
highest performance
Tubular Reactor
2
The Massa plant is ideally located near the seaport of
Marina di Carrara, so there are virtually no limits to the
size of equipment we are able to manufacture and ship.
GE's lifting devices and rollers are easily capable of handling
reactors as large as 2,000 tons.
Our Quality Assurance system meets all major international
standards including ISO 9001, BS 5750, UNI EN 29001, Vision
2000, etc. Compliance is also certified by Lloyd's Register.
The Massa facility is also qualified and certified for ASME
Stamps S, U, U2, U3 and is staffed with fully qualified and
experienced NDT personnel (Level III).
1,400 ton reactor ready to be transported
Pressure vessels for every process
Hydroprocessing reactors
These reactors are installed in hydrocracking, hydrotreating,
heavy oil upgrading and desulfurization plants where high
pressures and high temperatures are critical to the process.
Tubular reactors
These units are used in ethylene oxide, methanol and
MTBE production plants and, more recently, in GTL plants.
GE's exchangers can contain several thousand tubes and
are typically used in low and medium pressure processes.
Steam condensers
With a complete range of steam turbines for both generator
drive and mechanical drive applications, GE’s Oil & Gas
business has the capability to provide turbines and condensing
systems with logistic and economic advantages only possible
through single-source supply responsibility.
Heat recuperators
GE has over 20 years experience with heat recuperators and
has unparalleled qualifications to offer turbine upgrading
from simple cycle to regenerative cycle.

Heavy wall reactors
Heavy wall reactors are used in high pressure and
high 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 of
equipment are:
• Full qualification and experience in manufacturing
with advanced high-strength material such as
21/4 Cr 1Mo1/4V
• Automatic welding technology with ultra-narrow
gap beveling
• Top class facilities
Experience
For more than 30 years, GE’s Oil & Gas business has
manufactured hydroprocessing reactors for all major
process licensors including UOP, Chevron, Lummus, Axens,
Shell and ExxonMobil.
Our design and manufacturing teams and facilities offer full
qualification and experience in reactor fabrication – using
advanced, state-of-the-art high-strength materials such
as 21/4 Cr 1Mo1/4V in which GE is one of the most highly
referenced manufacturers in the world.
Product portfolio
• Hydrocracking reactors
• Hydrotreating reactors
• Heavy oil upgrading reactors
Industry-leading welding technologies
Given the extremely high pressures and temperatures, and
the 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 technologies
for 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 improvement
Through continuous technology upgrades and operator
training initiatives, we have greatly improved reactor qual-
ity resulting in increased efficiency and productivity for
our customers. Latest enhancements to our approach
include:
• Direct supervision of welding processes at the shop
floor
• Flux handling with no moisture absorption using the
SAW welding technique
• Controlled procedure of pre- and post-heating
• Ultra-narrow gap bevelling
• Ergonomic arrangement of welding station
Comprehensive capabilities
Continuous effort is dedicated to product development and
plant facilities improvement to maintain our leadership
position and to guarantee defect free manufacturing. The
Massa plant is equipped with state-of-the-art facilities to
ensure the highest quality fabrication of hydroprocessing
reactors.
Heat treatment furnace
Our large furnace can stress relieve in one piece pressure
vessels up to 32 m long, 9 m in diameter and 2,000 tons.
Longer reactors can be manufactured in two sections with
NDT and stress relief on the last circumferential welding
performed locally.
RT bunker
The Radiografic Bunker is equipped with a linear accelerator
suitable for performing x-ray inspections of welds up to
400 mm thick.
NDT techniques
GE Oil & Gas is equipped and experienced with very
advanced NDT techniques such as TOFD (Time of Flight
Diffraction), BC Scan and Phased Array for very high thickness
welds. These NDT techniques have been used in accor-
dance with ASME C.C. 2235 in lieu of RT on several heavy
wall reactors.
Unique capabilities for
refinery and oil sands
applications
Hydrocracking reactor being loaded by SPMT
Consumable storage
All consumables are supplied by highly qualified manu-
facturers and are stored in a state-of-the-art facility
equipped with ovens to maintain flux and electrodes in
a dry environment.
Weld Overlay
Single and double layer weld overlays have been applied for
many years using SMAW, FCAW, SAW and ESW techniques.
Latest generation technology welding machines are available
for overlay of the shell ring inner surface.
With these welding techniques GE Oil & Gas is capable
of achieving outstanding results, such as the absence of
disbonding of weld overlays during maximum cooling rates
commonly experienced during shut down transients.
Hydrogen Control During Welding
Conservative and experienced procedures and special
devices are used to control and reduce hydrogen content
during welding.
Ultra Narrow Gap Beveling
Ultra-narrow bevel angles are used in circumferential
welding to reduce shrinkage and residual stresses. This is
made possible by the use of automatic self-adjustment
devices and the application of industry best practices.
Hydrocracking reactor; 1,485 tons; 267 mm thickness
5

Tubular reactors
Tubular reactors are usually the principal piece of
equipment in petrochemical plants for the production
of ethylene oxide, methanol and MTBE. These units
consist of large shell and tube heat exchangers
with very large diameters of up to 26 ft. (8 m) and
more than 10,000 tubes. More recently, tubular
reactors have also been employed in Gas-to-Liquids
process plants.
How they work
Ethylene, methanol, MTBE etc. are produced within
the tubes through an exothermic chemical reaction.
The heat of reaction is removed by cooling water
flowing within the shell side.
Experience
In over 25 years, GE's Oil & Gas business has developed
extensive experience in designing and manufacturing sophis-
ticated equipment such as tubular reactors for ethylene
oxide, MTBE and methanol plants.
Product portfolio
• Ethylene oxide reactors
• MTBE reactors
• Gas-to-liquid reactors
Industry-leading welding technologies
GE has developed automatic welding technology for tube
to tube-sheet welding.
Our welding technology has very narrow tolerances in order
to deliver high-quality, precision results.
It is designed for the special application of materials such
as duplex stainless steel, titanium and zirconium which
significantly increase the stability of the finished units.
Ethylene Oxide Reactor
Experience
GE’s Oil & Gas business has a long history of success in
Steam condensers the design and fabrication of surface condensers with
integrated vacuum systems.
Steam condensers are a type of shell and tube heat
exchanger. GE’s improved design features: Our steam condensers are able to work in extreme condi-
tions – including temperatures ranging from –40°C to
• increase condensing efficiency and avoid air 50°C. As a result, they have been installed from Russia to
blanketing through an innovative new tube layout the Sahara desert.
• reduce the thickness of tubesheets, flanges and
covers by FEM analysis Applications
• facilitate maintenance and service through a • Waste to energy
bolted channel design. • Combined cycle power generation
• Mechanical drive applications with steam turbines
Surface condensers are fabricated in accordance
with applicable international standards, using the
highest quality materials including tubes in admiralty,
cupro-nickel, stainless steel and titanium in addition
to common carbon steel.
With a complete range of steam turbines for both
generator drive and mechanical drive applications,
GE has the ability to provide turbines and condensing
systems with single source responsibility.
Time-tested technology
Copper alloy steam condenser Double passage steam condenser
7
 Design advantages
GE upgrading of gas turbines from simple cycle to regen-
Heat recuperators erative cycle delivers significant efficiency improvements
and reduced operating costs.

Unmatched experience
Heat recuperators are used in gas turbine regenerative
cycles to recover heat from the exhaust gas and add Key features of our comprehensive in-house solutions
it to the compressor outlet air before the air enters include:
the combustion chamber.
• High efficiency with drastic heat rate reduction
This improves fuel efficiency by 5-7% and reduces
the cycle's heat rate by an average of 20%.
• Rugged construction with tailored metallurgy for specific
plant/process requirements
• Designed for low maintenance operation
in applications around
the world
• Optimized tube bundle design
• A variety of ducting system options are available
Experience (symmetric and asymmetric)
GE’s Oil & Gas business has extensive experience in the • Risk free retrofit
design and manufacture of heat recuperators.

Exhaust
gases to
stack
Regenerative cycle

Compressed air
Regenerator
to regenerator

Inlet air

Fuel Combustion
chamber
Compressor

Turbine Load

8
Site activities and technical services
Site activities
There can be practical constraints on shipment of fully
assembled reactors to some job sites.
In such cases, GE’s capabilities enable field fabrication and
assembly of reactor sections shipped from our Massa
plant . With leading edge technology, manufacturing
capabilities and unparalleled field experience, our teams can
provide complete field fabrication of complex hydropro-
cessing reactors to the same specifications and standards
as units assembled at our own facilities.
Our teams have accumulated extensive experience
assembling and installing units in many locations worldwide,
under diverse weather and environmental conditions.
Technical services
GE’s Oil & Gas business offers comprehensive technical
service programs for all types of static equipment, designed
to help deliver reduced plant operating costs and increased
plant efficiency.
Extensive technical expertise, advanced diagnostics, NDT
systems and regional service teams combine to guarantee
full 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 manufactured
and tested in our Massa plant.
The entire process is carried out under a system that
integrates the GE Six Sigma Quality Program with ISO 9001
Quality Standards to guarantee total customer satisfaction.
This stringent quality program ensures the long term stability
of our own process improvements as well as the quality of
products for our customers.
Our Quality Assurance Manual documents the policies
established for all aspects relating to the quality of our
reactors and is the company reference for all departments.
The program is certified by Lloyd's Register. The Massa Plant
is also qualified and certified for ASME Stamps S, U, U2, U3
and is staffed with third level NDT personnel.
What our customers say about us
Our customers’ words of praise are our highest source of pride. Here are just a few
examples of what our customers think of us:
Canada: 4 HCU reactors, 212 mm thickness,
2 assembled on-site
“…outstanding service and support provided by GE
with respect to the design, shop fabrication, delivery
and field fabrication…we look forward to having the
opportunity to do business again with you in the future.”
Project Procurement Manager
December 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 and
was completed on-time and to the Company's quality
standards. We look forward to future business activities
together.”
Project Director
June 21, 2003
France: 1 HCU reactor, 1500 tons. One of the
world’s largest and heaviest HCU reactors
“…congratulate all GE team for the good job
performed during the whole execution of the order,
in terms of quality, follow up and respect of schedule.
Thank you.”
Project Procurement Manager
February 24, 2005
Kuwait: 1 HDT reactor
“…thank all the team for all the effort made for
successful Hydro Test and Dimensional check. Our
team is happy with the job and effort made.”
Project Team
April 11, 2005

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

10 11
Nuovo Pignone S.p.A.
Via Felice Matteucci, 2
50127 Florence, Italy
T +39 055 423 211
F +39 055 423 2800

Reactors Facility
Via Dorsale, 3
54100 Massa, Italy
T +39 0585 7951
F +39 0585 791322

www.ge.com/oilandgas
The information contained herein is general in nature
and is not intended for specific construction, installation
or application purposes. GE reserves the right to make
changes in specifications or add improvements at any
time without notice or obligation.

©2006 General Electric Company

All Rights Reserved

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