By Joe Mastrangelo
General Manager
Equipment

Three of the most common speed bumps in any large oil and gas project are equipment compatibility issues, large unit manufacturing lead times, and the ability to effectively design and configure a plant to meet increasing environmental regulations.

GE’s Oil & Gas business provides advanced technologies for all critical equipment and oil and gas processes.

We are known for innovation, but also for managing risk and optimizing performance through a continuous evolutionary approach to product development – gradually combining new designs with longstanding, well-proven technologies. We have invested massive resources in our Centers of Excellence and Global Research Centers for all oil and gas technology types. Our efforts in research, development and product improvement are literally never-ending.

Technology flowdown to the installed base

Although our technology focus is usually on developing solutions for new oil and gas industry challenges, many of the innovations are relevant to improving the performance and extending the life of machines in the installed fleet. Technology that first appears in new machinery is frequently transferable to the installed base through upgrades available during scheduled inspections or other planned outages.

Turning designs into reality

Through an extensive manufacturing modernization program, we have created world-class production and test capabilities that have increased our capacity for virtually every type of machinery and equipment, shortened the manufacturing cycle time, and in the process, improved quality. We call this Lean Manufacturing. Launched for our gas turbine and centrifugal compressor products, it now covers all rotating machinery,- reactors and air coolers as well.

When it comes to heavy wall reactors, we have made significant capacity improvements over the past 18 months – with the driving forces being unit size, material strength and delivery time. The advanced welding and material technologies - for which we have certified capabilities - have made GE the most referenced company in the world for Cr-Mo-Vanadium welding. Our massive new pulsing manufacturing and assembly line with twin tandem welding stations and multi-belt overlay stations can produce reactors as large as 1,500 tons. In the past year alone, our production capacity has doubled while maintaining a 100% on-time
delivery record.

Similarly impressive innovations for our air-cooled heat exchangers have resulted in a one-third reduction in unit size and weight – with no loss in performance. We also doubled our production capacity in 2007 to meet customer demand.

This gives us the capacity to meet the expanding demands of the oil and gas market and the ability to help our customers to shorten their project schedules.

Environmental standards

Our machinery designs are focused on performance and quality but our strong commitment to the environment does not come second. This is exemplified by our achievements in reducing emissions from gas turbines, reduced compressor leakage through improved seal technology, and by the recent ecomagination certification of our hot gas expanders. By maximizing energy recovery from waste gas, over the course of a single year, one of our 18-MW systems can avoid 244,000 metric tons of CO2 and save $9 million in electricity costs. We also provide a wide range of proven and practical remote monitoring services that will keep emissions under control long after plant commissioning.

Putting it all together for the Oil & Gas Industry

The refining industry is a great example of how we work with our customers to provide innovative, integrated solutions. In response to the increasing demand of bottom of the barrel refining, GE Oil & Gas provides one of the most comprehensive packages of equipment dedicated to hydrocracking and hydrotreating plants. From heavy-wall reactors to heavy duty feedstock centrifugal pumps; hydrogen compressors; 10-cylinder single-frame reciprocating compressors that deliver a hydrogen flow rate well above 90,000 Nmc per hour; and corrosion resistant alloy air coolers for the main process stream. We also cover all the critical processing requirements of FCC units – the core of every refinery – including axial compressors for air blower service and centrifugal compressors for handling wet gas.
All our products are designed to work together from the start – making installation smooth and straightforward, and optimizing performance for all aspects of the process. It is a far more efficient solution than a multiple supplier approach.

Summary

To date, GE’s Oil & Gas business has invested more than $100 million in technological enhancements in areas that are critical to performance and the ongoing balance of risk and reward for our oil & gas customers. With benefits ranging from faster start-up to more cost-effective long-term operation, our integrated approach is clearly ideal for the extreme demands of this challenging industry.