GE Power Systems

Oil & Gas

REACTORS &
FABRICATED EQUIPMENT

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 Contents Introduction

Equipment Types
3

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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 Introduction
Reactors and Fabricated Equipment
GE Oil & Gas Nuovo Pignone has been manufacturing
reactors, exchangers and fabricated equipment for more
than 40 years.

With a fleet of hundreds of Reactors and Separators, for

hydrocracking, desulfurization, hydrotreating, platforming
and similar processes, GE Oil & Gas is one of the most
referenced Companies in large vessel manufacturing.

The GE Oil & Gas Massa plant is dedicated to the produc-

tion of high-tech equipment including Heavy Wall
Reactors for refinery applications, Tubular Reactors,
Special Vessels for petrochemical plants and Large,
High-Pressure Heat Exchangers. Extensive experience
with 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 Marina

di Carrara and there is virtually no limitation in manufac-
turing and shipping of large size equipment.

Our Company Quality Assurance (Q.A.) system meets

all major international Standards such as ISO 9001, BS
5750, UNI EN 29001, etc.
Compliance of the Q.A. system with these standards is
certified by LLRR. The Massa plant is also qualified and
certified for ASME Stamps S, U, U2, U3 and is staffed
with qualified NDT personnel.

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Equipment Types Hydroprocessing Reactors
These reactors are installed in hydrocracking, hydrotreating,
heavy oil upgrading, desulfurization, and CCR refinery processes.
With the exception of CCR process reactors, this equipment
operates at very high pressure and temperature conditions.
Tubular Reactors & Large Heat Exchangers
This equipment is used in ethylene oxide, methanol and MTBE
production plants. They have recently been introduced in Gas-
To-Liquids processes. These exchangers containing several
thousand tubes, 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 Oil & Gas has the
capability of providing turbines and condensing systems with
single source responsibility.
Heat Recuperators
GE Oil & Gas has over 20 years of experience with Heat
Recuperators and has unparalleled qualifications to offer tur-
bine upgrading from simple cycle to regenerative cycle.

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 Hydroprocessing Reactors
High Thickness Reactors are used in high pressure and high
temperature processes. Nuovo Pignone developed one of the
most advanced technologies for welding and manufacturing
reactors 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 supplied
by the most highly qualified companies.
GE Oil & Gas has full qualification and experience with major
process licensors such as UOP, Chevron, IFP, HRI, Lummus, Shell,
ExxonMobil, in manufacturing reactors up to 2,000 tons and 60 m
in length with advanced high strength materials (Cr Mo V).
Nuovo Pignone is one of the world’s most experienced company
in manufacturing Reactors of 21/4Cr1Mo1/4V.
Automatic welding technology with ultra-narrow gap beveling is
extensively used in our manufacturing operations.

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

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

Heat Recuperators
Up-grading of Simple Cycle Gas Turbines to Regenerative
Cycle delivers significant efficiency improvement and reduced
operating 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 Exhaust
gases to
- Complete in-house supply stack

Compressed air
to regenerator

Regenerator

Inlet air

Fuel

Combustion
chamber
Compressor

Regenerative cycle
diagram Load
Turbine

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

Technical Services
GE Oil & Gas offers comprehensive technical service programs
for all types of static equipment, focused on reduction of plant
operating costs and increased plant efficiency. Deep technical
know-how, advanced diagnostics, NDT systems and a regional
presence 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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 Facilities
Continuous effort is dedicated to product development and
plant facilities improvement to maintain our leadership position
in the industry 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.
Located near the seaport of Marina di Carrara, the Massa Plant
has virtually no dimension or weight restrictions for shipment.
Lifting systems and rollers are capable of handling reactors of
2,000 tons.
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.
RX 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) for
very high thickness welds. The TOFD technique was used in
accordance with ASME C.C. 2235 in lieu of RX on one of the
largest heavy wall hydrocracking reactors ever built using
21/4Cr1Mo1/4V material. This reactor was delivered and installed
in the USA in early 2000.
Consumable Storage
All consumables are supplied by highly qualified manufacturers
and are stored in a state-of-the-art facility equipped with ovens
to maintain flux and electrodes in a dry environment.

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 Welding Technology Weld Overlay
Single and double layer weld overlays have been applied for
many years using SMAW, FCAW, SAW and ESW techniques.
Double head welding machines are available for SAW 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 dis-
bonding of weld overlays during maximum cooling rates com-
monly experienced during shut down transients.

Hydrogen Control During Welding

Every batch of flux is checked for total water content after
baking to reach very low humidity (0.02%). Transportation of
the flux between the warehouse and weld stations is always
performed in special containers equipped with electric
heaters.
The flux is pneumatically supplied to the welding machine
head through a feeder pipe using clean, dry air.

Ultra Narrow Gap Beveling

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

Advanced Materials For Hydroprocessing Reactors

GE Oil & Gas has extensive experience in manufacturing
Reactors using 3Cr1Mo1/4V - 21/4Cr1Mo1/4V, the most
advanced material for this application.

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GE Oil & Gas Reactors and Fabricated Equipment are manu-

Quality Program
factured and tested in the Massa Plant. The entire production
process is carried out under the GE Oil & Gas Quality System
that integrates the GE Six Sigma Quality Program with ISO 9001
Quality Standards to guarantee customer satisfaction. The
Program ensures the long-term stability and sustainability of
process 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 is
certified by LLRR.

The Massa Plant is also qualified and certified for ASME

Stamps S, U, U2, U3 and is staffed with third level NDT per-
sonnel.

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 COMK/MARK 832/II - Studio Tre Fasi - 10-2002 ©2002 Nuovo Pignone S.p.A. all rights reserved

GE Power Systems
Oil & Gas
Headquarters: Massa plant:
Nuovo Pignone S.p.A. Nuovo Pignone
Via Felice Matteucci, 2 Via Dorsale, 3
50127 Florence - Italy 54100 Massa - Italy
Tel. +39-055-423 211 Tel. +39-0585-7951
Fax +39-055-423 2800 Fax +39-0585-791322
e-mail: info.geoil&gas@np.ge.com
www.gepower.com/geoilandgas