GE LDPE Hypercompressors Brochure

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.

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

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