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Creating Value in Refinery, Petrochemical and Fertilizer Applications
#GEAM17 #FueltheFuture
© 2017 General Electric Company - All rights reserved
Meeting downstream key applications’ challenges
Paolo PecchiEngineering Director Downstream
GE Oil & Gas
© 2017 General Electric Company - All rights reserved
Meeting downstream key applications’ challenges
Fertilizer Petrochemical
RejuvenateInnovate
Modularize
Refining: Complexity + Economy
of scale driving growth...
oversupply adding pressure on
margins
Petrochem: Ethylene shortages,
cost advantage feedstock &
healthy integrated margins drive
growth
Fertilizer: Lower ammonia &
Urea prices + oversupply add
pressure on producer's margins...
demand expected increase as of
2017
Refinery
© 2017 General Electric Company - All rights reserved
Developments by Product
Steam turbines• Train Modularization• Package Redesign• New Scalable Platforms• Power Density
Multistage centrifugals• Power Density HPRC• Durable Coating solutions• High efficiency Impellers
for Integrally gearcompressors
Overhung compressors• High flow/head impellers• Movable IGV• Anti-fouling features
API 618 Reciprocating• Power Density• New cylinder technology
Pumps• High diffuser pumps family
evolution• High efficiency solutions for
fertilizer
Valves• Flow path optimization• Adv diagnostics and
intelligence• Sustainable design
©2016 General Electric
© 2017 General Electric Company - All rights reserved
Steam Turbines
• Train Modularization (Refinery)
• Package Redesign (Electrification)
• New Scalable Platforms (Refinery)
• Power Density (Flow path development)
© 2017 General Electric Company - All rights reserved
Machinery SelectionProject Specs + Modules=
Refinery: Hydrogen Recycle
2 4 6 8 10
MW
Steam Turbine
0
10 000
20 000
30 000
40 000
50 000
60 000
70 000
80 000
BCL300 BCL350 BCL400 BCL450 BCL500 BCL600
m3/h Compressor
SNC1-2/SC1-4
SNC1-3/SC1-6
SNC1-4/SC1-8
© 2017 General Electric Company - All rights reserved
Hydrogen Recycle Modules
Recycle Module + | RMRecycle Module | RM Recycle Module ++ | RM
++Back-Pressure Condensing Condensing CondensingBack-Pressure Back-Pressure
8.0 x 4.0 m
44 to 69 tons
9.0 x 4.5 m
30 to 50 tons
SNC1-2/SC1-4 + BCL300/350/400 SNC1-3/SC1-6 + BCL350/400/450
44 to 78 tons
10.0 x 4.5 m
SNC1-4/SC1-8 + BCL450/500/600
Modular Concept Benefits Quick and cost effective solution
Application oriented design
Pre-engineered design
Plug and play, Fast delivery/erection
© 2017 General Electric Company - All rights reserved
Valves Electrification
max 30 % oil consumption: no control & trip oil flow required
90% equipment for actuation: control & trip oil system eliminated
maintainability: eliminates oil flushing and filters maintenance
reliability: self-contained design eliminates water and air contamination
Trip ValveControl ValveCurrent Design
© 2017 General Electric Company - All rights reserved
Light
• 30% Weight
• 15% Bearing Span
Enable Power Density
• 20% Rotating Speed
Advanced Flow Path
• Simplified steam path
• Best in Class Efficiency
Refinery Steam Turbine Light Platform
© 2017 General Electric Company - All rights reserved
Refinery Light Platform – Technology Overview
Advanced Seals• Abradable seals
• Brush seals
• Back spring laby seals
• Traditional strips seals
Advanced HP/IP Stages• Best in class efficiency
• Higher load stages
• 35% blade count
High Speed LP Stages• 20% speed
• 6 pts efficiency
• Scaled down from existing HS family
© 2017 General Electric Company - All rights reserved
Centrifugal Compressors
• Power density HPRC (H2 Recycle)
• Coating solutions (3 in 1 Fouling, Erosion, Corrosion)
• Overhung compressors (DH, D series)
© 2017 General Electric Company - All rights reserved
BENEFITS:
7 Impellers
7 Diaphragms
1 Size each machine
2% Steam consumption
Baseline
HPRC
BCL1209 BCL1009 BCL1207
BCL1006 BCL807 BCL1005
STEAM TURBINE
STEAM TURBINE
15% smaller footprint and 20% lighter weight
Large multi-phase H2 RecycleHigh Pressure Ratio Compression
© 2017 General Electric Company - All rights reserved
Coating Solution IP9188 Sermalon® ENP
ENP
+
PTFE
ENP
+
SiC
Coating type Organic
Topcoat :
Organic
Bond coat:
Metallic-Organic
Metallic
Metallic
organic
nano
doped
Metallic
nano
doped
Application
methodSpray Spray Bath Immersion
Fouling
resistanceHigh High Medium High Medium
Erosion/abrasion
resistancePoor Poor High Medium High
Corrosion
ProtectionMedium Medium High High High
Baseline solutions Alternative coatings
ENP
ENP +
PTFE
ENP +
SiC
No geometry
coverage
limits!
Sermalon®
Hydrophilic
ENP+nPTFE
Highly Hydrophobic
1. Higher hydrophobicity
2. Improved erosion
Cracks at the interface
PTFE top coatOrganic layer
Al/Mg bond coat
ENP+PTFE: Fouling & Wear resistant
ENP
Base material
ENP + PTFESermalon®
Thight
adhering ENP
3. Improved adhesion & corrosion
3 in 1 Coating Against Fouling – Erosion – Corrosion
© 2017 General Electric Company - All rights reserved
DH Series – Product update
Technical Developments
• High Flow: polytrophic efficiency up to
90%
• Movable IGV: 20 efficiency pts at
closed angles
• Built-in antifouling features
• impellers by single piece technology
Robust & Referenced
• Rugged construction and standard
frames
• Easy maintenance: pull-out design
• Unipol LLDPE qualified
• >200# in petrochemical applications
© 2017 General Electric Company - All rights reserved
D Series – Product Rejuvenation
Reliable
• Superior availability vs fans and integral gear units
• Designs based on API and other industry standards
Proven Technology
• 500+ units in Refinery, Petrochem, Industrial
service
• Structured frames with low cost single stage design
Performance
• 1600 – 600,000 m3/hr flow rate
• Single piece high head impellers, up to 13,700 m
• Product upgrades: Recent case with +6% efficiency
in soda-ash application
© 2017 General Electric Company - All rights reserved
Reciprocating Compressors
• Power density
• New cylinder technology
© 2017 General Electric Company - All rights reserved
Power Density Technology in Reciprocating compressor
Market trends:
flow rates with # of units
Footprint and plant layout with Availability & Reliability
Benefits:
• Scaled up compressor: 25% load
capability
• 2 cylinder on a current configuration
• efficinecy up to 4%
Power density
philosophy
Parametric design
Technology and testing+ lower number of high
efficiency cylinders=
© 2017 General Electric Company - All rights reserved
New Cylinder Technology
Fast & robust development of dedicated cylinders for all application
FEA
model
CFD
model
CFD
optimization
FEA
optimization
Casting
simulation
Machining
simulation
Test validation
Indicated power reduction
up to 4% measured and
validated on Florence test
Rig (Gas: N2)
© 2017 General Electric Company - All rights reserved
Pumps
Carlo Del VescovoProduct Leader Pumps
GE Oil & Gas
• High efficiecy solutions for fertilizer
• High diffuser pumps family evolution
© 2017 General Electric Company - All rights reserved
High efficiency pumps for fertilizers market
Hydro TurbineClutch Pump
Steam
Turbine
Gear
+4 pts+6 pts -1400 kg/hrof Steam
#Rank 1 in Life Cycle Cost
© 2017 General Electric Company - All rights reserved
13.8m
2.5m
High efficiency pumps for fertilizers market
Project Scope:
#12 Semi Lean pumps
• #4 trains HPRT-CL-CP-GB-ST
• #4 trains HPRT-CL-CP-EM
• #4 train CP-EM
#8 Lean pumps
• #2 trains CP-GB-ST ;
• #6 trains CP-EM Main efficiency enablers• Ultra-Optimized Hydraulic design
• Wear Rings in composite materials
Project challenges• 14 string test performed
• 20 skids delivered in short cycle.
Plant expected saving $0.5M/yr(*) (*) Rs/KWH 7
RS/MT 2000
Fx RS/$ 1,15
© 2017 General Electric Company - All rights reserved
High Power Diffuser Pumps
arrangements
BB5 Barrel Diffuser pumps BB4 Ring Section Diffuser pumps
Main Benefits
• Ultra-Reliability driven by oil and gas API 610 compliant design.
• Flexibility aligned with multiple «Start and Stop» per day.
• Design aligned with Max Theoretical efficiency.
• Customized solutions applicable to each item within pump skid edge.
Up to ~6MWUp tp ~10MW
© 2017 General Electric Company - All rights reserved
High Speed BB5 Diffuser pumps for Refinery
Accurate Balancing of entire rotor granted ... API fully compliant
Train configuration EM – GEAR - PUMP
Application Water Washer
Material Class S8
Rotational Speed 5450 rpm
BB5 Diffuser pump
Balancing of entire rotor
Reliability
© 2017 General Electric Company - All rights reserved
Control Valves
Stephen James Sales Director Flow and Process Technologies
GE Oil & Gas
• Innovation for advanced refining processes
© 2017 General Electric Company - All rights reserved
Building on 130+ years of experience and over 1,000,000 operational
valves in refining and petrochemical plants…How can we do it better?
© 2017 General Electric Company - All rights reserved
Desalter
Va
cu
um
Dis
tilla
tio
n
LPGGas Plant
Methane, Propane, Butane
Gasoline
Jet Fuel
Diesel
Hydrotreating
Hydrotreating
Resid-Hydrocracking
Resid-Hydrotreating
Coking
Hydrocracking
Catalytic Dewaxing
Catalytic Cracking
Light Straight Run Gasoline
Naptha
Kerosene
Middle Distillate
Atm. Gas Oil
Atm
osp
heric D
istilla
tio
n
Coke
Lube Oil
Vac. Gas Oil
Gasification
Resid-FCC
© 2017 General Electric Company - All rights reserved
HC
Feed
Feed Surge
Drum
Stripper/Fractionator
Hydrogen Makeup
Compressor
Washwater
Pump
Hot High
Pressure
Separator
Cold High Pressure
Separator
Charge
Pumps
Charge
Feed/Effluent
Exchangers
Main
Reactor
Recycle Gas
Compressor
RGC KO
Drum
HP Amine
Contactor
HHP Separator
Cooler
Recycle Gas
Exchanger
Charge
Heater
Nitrogen
Amine
Booster
Pumps
© 2017 General Electric Company - All rights reserved
Residue Hydrocracking:
74000 series
Application Challenges:
• High Pressure (200+ bar)
• High Particulate Content
• Heavy Erosion
• Flashing
• Outgassing
• Significant Catalyst Carryover
Valve Design Criteria:Single stage trim with streamlined flow
passage to reduce erosion.
Extremely hard trim material.
Traditional Hydrocracking:
77000 series
Application Challenges:
• High Pressure
• Flashing
• Outgassing
• Cavitation
• Particulates
Valve Design Criteria:Multi-Stage trim to minimize cavitation
and contain flashing and off-gassing.
Hydrocracker Hot High Pressure Separator Letdown
© 2017 General Electric Company - All rights reserved
Original Top
Entry Design
77002
2100 kg
Original
Bottom Entry
Design 77001
1700 kg
Hydrocracker Hot High Pressure Separator Letdown
© 2017 General Electric Company - All rights reserved
Original Top
Entry Design
77002
2100 kg
Original
Bottom Entry
Design 77001
1700 kg
Hydrocracker Hot High Pressure Separator Letdown
NEW
DESIGN
77003
1000 kg
40 – 50% Mass Reduction Reduced CAPEX
Reduced piping support expense
Easier removal for maintenance
More sustainable solution
© 2017 General Electric Company - All rights reserved
A) Reduced stage, axial flow, expanding trim
Tailored for Hot High Pressure Separator applications
Decreases valve sub-assembly size and cost
Maintains advantages of existing trim design
B) Reduced plug, seat, and stem diameters
Minimizes actuator thrust requirements
C) Partially balanced trim for 5-stage, high ∆P trim
Further reduces actuator thrust requirements
D) Unbalanced trim for 3-stage, low ∆P trim
Reduces trim cost without increasing required actuator thrust
E) Nested trim assembly
Minimizes clamped height for use at high temperatures
Maintains existing ease of maintenance
F) Inverted actuator linkage
Removes stem side load, improving stem life and LE performance
C
D
F
A
77003 Improved Technical Approach
© 2017 General Electric Company - All rights reserved
Resid-Hydrocracker Hot High Pressure Separator Letdown
Original Design
3300
3-4 Year Trim Life
Seat Ring
with Outlet
Venturi
Bull Nose
Plug
Seat
Protection
with Plug
Overlap
© 2017 General Electric Company - All rights reserved
Multi-Flow
Channel
Fluted Plug
Seat Ring
with Outlet
Venturi
Resid-Hydrocracker Hot High Pressure Separator Letdown
New Design
74000
6-8 Year Trim Life
~100% Trim Service Life Increase Reduced OPEX
Supports longer time between outages
Reduced inventory levels
More sustainable solution
© 2017 General Electric Company - All rights reserved
A) Multi-Path Flow
The 74000 series trim utilizes multiple paths and an expanded area outlet
venture to handle the damaging service conditions
B) Minimize Erosion Damage
Trim avoids direct impingement and smoothly channels the fluid into the
expanded outlet venture to resist erosion caused by solids and heavy flashing
C) Seat Protection
Additional seat protection from the plug design. Seat sits at the tope while the
flute is the throttling surface.
D) Vibration Resistant Design
Upper and lower guiding of the plug improves operational stability and reduces
damage due to severe vibration.
E) Optimized Trim Materials
A wide range of trim materials are selected to provide a balance between
optimal trim life and cost. Advanced materials include tungsten carbide,
ceramic, Inconel, stainless steel and specialty overlays and hard-facing
technologies.
74000 Improved Technical Approach
© 2017 General Electric Company - All rights reserved
GE Store – Learning From Each Other
Differential Velocity Device (DVD™)
Patented design uses Differential Velocity
Concept similar to commercial jet engines
© 2017 General Electric Company - All rights reserved
Digital Transformation in Downstream
Christina WatersSenior Director Customer Solutions
GE Oil & Gas
© 2017 General Electric Company - All rights reserved
Digital essential to unlock productivity
Productivity
• Digital thread
• Brilliant manufacturing
Apps
• Service transformation
• Digital enabled CSAs
Platforms
• Predix Industrial Internet
Operating System
• Digital twin
• Services effectiveness and
efficiencies
• Design and innovation acceleration
• Better outcomes for customers
• Optimize GE/BHI equipment
• Fullstream data analytics
• Leapfrog digital industrial transformation
• Industrial strength, cyber security, scale
• Predix Process and production
optimization
GE for GE GE for customers GE for industry
ProductivityNew offerings/
business models
New revenue
streams/markets
Delivering better customer outcomes and shareholder value
© 2017 General Electric Company - All rights reserved
Digital Refinery Demo
#GEAM17 #FueltheFuture