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GE Oil & Gas
Low Density Polyethylene
(LDPE) Compressors
With over a century of proven experience in compressor design, GE Oil & Gas
is a leading manufacturer of machines for the most extreme LDPE applications
– both booster primary and secondary hypercompressor duty. We also provide
comprehensive lifecycle support through a dedicated Global Services network of
experts, test and repair facilities around the world.
Technologically advanced and work-proven
API 618 machines that reliably enable the
economies of scale needed for commercial
LDPE plant success.
The average size of an LDPE plant has more than doubled in the last
decade, and plant configurations have changed significantly from strictly
processing to fully integrated export-oriented complexes. Modern facilities are
characterized by operating pressures up to 3,500 bar and highly fouling fluids
that put extreme demands on compressor reliability and availability, and in fact
are some of the most exacting challenges in the entire oil and gas industry.
Our design and manufacturing philosophies focus on highest guaranteed reliability, ease of
maintenance and maximum plant availability. This commitment to customers is exemplified by our in-
house manufacturing line exclusively for LDPE hypercompressors, which ensures the highest quality and
consistency of all critical components.
Booster primary
There are more than 100 GE Oil & Gas compressors currently
operating worldwide for this critical application. Our booster
primary compressor designs merge 40 years of experience in both
LDPE and large hydrocrackers – resulting in our state-of-the-art HG
high-power frame with up to 10 cylinders.
We also provide our customers with unmatched in-house
capabilities for the design and supply of all main process
equipment (process gas coolers and separators), interconnecting
piping, process gas control and block valves and associated
instrumentation, as well as layout and pipe-routing studies.
Secondary compressor
There are currently more than 50 GE Oil & Gas ethylene
hypercompressors installed worldwide, with a proven plant
capability of 500 kty and the largest installed power with a 33-MW
electric motor.
Key features include the unique frame design that eliminates the
auxiliary crosshead, fatigue-resistant cylinder bore diameters and
flow distribution on more cylinders. These and others combine to
ensure minimal pulsation, low vibration and smooth operation that
in turn contribute to longer life of the most highly stressed parts
such as packing cups and cylinder valves.
Acoustic plant simulation
When designing compression plants with reciprocating
compressors, special consideration must be given to the effects
of pressure and flow pulsations in order to achieve performance
targets and avoid discontinuous gas flow from the cylinders.
Since 1965, we have conducted comprehensive compressionsystem simulations, including precise analyses of pulsations and
interactions between compressor and piping system. To ensure
optimal reliability and efficiency of the whole LDPE plant, our study
includes primary-booster compressor, hypercompressor, reactor,
vessels and all interconnecting piping.
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Frame Size Throws
HF 2-10 34,600 1,140 360 514
HG 2-10 41,000 1,550 400 450
PK 4-24* 60,000 2,500 400 310
*Number of cylinders. Up to 12 cylinders in a single crankcase.
Max. Power
Booster primary
Single-piece, cast iron crankcase with tight-tolerance
transverse spacers fitted above the bearing housings
between the two sides of the frame. Extremely stiff,
closed body with large openings that cut maintenance
time and cost.
(kW)
Max. Rod Load
(kN)
Max. Stroke
(mm)
Steel crossheads equipped with amply sized
shoes that are completely machine finished and
interchangeable, eliminating the need for any manual
adjustment or shimming.
Max. Speed
(rpm)
Proprietary bi-metallic (aluminum and tin) main and
big-end bearings. Main bearings are vertically split to
eliminate surface discontinuities from the most heavily
loaded area, thereby increasing the load capability and
reliability.
Hypercompressor
Special crossheads design
Sliding surfaces pass through plunger axis for perfect
straight plunger action in both cold and hot conditions.
No on-site realignment required.
Optimized packing design
Second stage cylinders have an average
operating life of 20,000 hours and frequently
achieve well over 32,000 hours without
replacement.
All main threaded connections (piston to piston rod,
piston rod to crosshead, connecting rod to big-end tie
rods, frame crosspieces, anchor bolts, high-pressure
cylinder bolting) are hydraulically tightened.
Easy accessibility & maintenance
Frame and cylinder tie rods tighten with hydraulic
jacks. Preassembled cylinder components enable
simple and quick maintenance and replacement.
High-performance cylinders
Maximum reliability through shrink-fit packing cups,
extensive use of auto frettage, silver plating and shot
peening. Plunger is made of solid tungsten carbide
with a cobalt binder or tungsten carbide-coated steel.
GE imagination at work
ge.com/oilandgas
© 2012 General Electric Company. All rights reserved.
LDPE_FS_012412
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