Testing CapabilitiesTo guarantee field performance

GE Oil & Gas

GE operates major testing facilities around the world with all the infrastructure, hardware and software tools, andexperienced personnel needed to perform accurate, reliabletesting on our compressors, turbines and related technologies.

These resources are used to evaluate new concepts underdevelopment, to validate evolving computer-aided designtools and to test products before final delivery to customers.

Our broad range of capabilities includes the performance offull-load string tests on large turbocompressor trains andutilization of feed-gas preparation systems for testing bothgas turbines and compressors on virtually any gas mixtureof interest to a customer.

Tried and true methods are combined with emergingtechnologies to enhance testing capabilities, customizationand customer service. For example, our Virtual WitnessSystem, combined with new tools that help automate test dataacquisition and reporting, now allows us to give customers theconvenient option of monitoring some tests remotely via theinternet, eliminating the need for them to travel to the test site.

All our test facilities are completely instrumented andfurnished with real-time data-acquisition systems integratedwith analysis tools to provide a complete picture of equipmentperformance, even while the test is still in progress.

Every product GE designs for the oil and gas industryundergoes stringent testing at every stage of thedesign and manufacturing process. We employ themost advanced techniques and seasoned professionals– not simply to confirm specifications, but to find newopportunities to improve.

Testing performance,discovering opportunities

Pushing boundaries

Contents

Comprehensive testing capabilities 3The drive for quality 4Ensuring compressor performance 5Testing facilities 6Florence capabilities 7Massa capabilities 7Centrifugal and axial compressors 8Reciprocating compressors 9Steam turbines 9Gas turbines 10High speed balancing technology 11String tests 12Streamlined no-load string test 13Virtual Witness System 14Pipeline inspection testing 15

Comprehensive testing capabilities

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4

GE defines quality in customer terms: on-time delivery ofmachinery that performs as promised, reliably, throughoutits life cycle, at an acceptable price.

Our total quality program began in the late 1980s and pavedthe way for Six Sigma which, since the mid-90s, has provideddata-driven tools for analyzing procedures and processesin order to reduce the possibility of defects. The company’ssuccess with Six Sigma exceeded the most optimisticpredictions, and the program continues to be the main driver of the GE quest for leadership in manufacturing quality.

Lean Manufacturing joins Six SigmaOur combination of Lean Manufacturing practices with ourSix Sigma quality assurance program has proved its abilityto raise our level of responsiveness to customer needs. In thepast two years, cycle times have been reduced significantly –often as much as 30 to 50 percent. On-time deliveries haveimproved beyond expectation, and customers tell us thatthey have already begun to feel the improvements.

Right-to-Left planningThe manufacturing industry typically takes an ‘assembly-line’approach to project planning – where timelines start with‘now’ on the left side of a worksheet and end with ‘then’ onthe right. Instead, we begin all our manufacturing projectswith the date that the customer plans to go live. This right-to-left approach puts us in a position to identify and preplancritical stages as early as the bidding and proposal phase so that, by the time an order is confirmed, we have all theprocesses in place to ensure on-spec, on-time installation.

Streamlined operationsApplying ‘Lean Six Sigma’ thinking, we recently completedan integration of our scheduling, information management,design engineering, manufacturing and testing systems, in orderto optimize time, materials and resources within customer-driventime frames.

This enables Lean Manufacturing solutions such as PulsedManufacture whereby downtime intervals are minimizedbetween production tasks – so that, as workflow progresses,everything is in the right place at the right time.Benefits: reduced cycle time, less waste, consistent quality.

It enables the closest possible integration of ComputerAided Design and Computer Aided Manufacturing resources.Computer modeling enables defects to be identified onscreen rather than on machine. Component fit can beverified in advance, avoiding re-machining and bad fits.Custom packaging procedures can be figured out in advance. Benefits: reduced manufacturing and assembly errors,reduced cycle time and fewer delivery delays.

It enables full implementation of advanced manufacturingtechnologies. For example, Electrical Discharge Machiningenables GE to standardize one-piece impellers across thecentrifugal compressor range, for enhanced reliability andreduced maintenance. Additional 5-axis machines enablefast , accurate production of complex components. And aunique facility now under construction, is specially designedfor high speed balancing of large centrifugal compressorsand turbines under full load conditions.Benefits: higher quality geometrics and reliable performance.

GE’s right-to-left planning process ensures production and testing is drivenby client needs.

Centrifugal compressor “pulsed manufacture” assembly, part of our LeanManufacturing process.

The drive for quality

5

GE’s full-capacity test facilities accommodate testing ofvirtually any type of compressor before on-site installation.Using four main test stands and custom designed, automateddata-acquisition equipment, we conduct performance testingand mechanical analyses, applying the industry’s moststringent test standards and methods.

Whatever your testing, data-processing or reportingrequirements, we have the plant capabilities and extensive experience to deliver effective results.

Specific features• Test power up to 9,000 hp

• Steam pressures up to 500 psig

• Condenser pressures from 3 psia to 15 psia

• Train (string) testing of customer steam turbine driversand/or gears

• Contract lube/seal console and related equipment testing

• Contract motor drive testing

• Open-loop air and closed-loop gas options

• Full-load, full-pressure mechanical testing with inlet pressures up to 1,000 psig

• A wide variety of test gases including air, nitrogen, helium, carbon dioxide and Refrigerant 22

• Test gas matching using ASME PTC 10 methods

Test facility capabilities• Detailed mechanical analysis

• Pre-installation performance testing

• Precise, automated data acquisition

• Accurate, versatile, multi-media reporting

• Determination and diagnosis of potential problems

• Development of new compressor designs

Extensive mechanical analyses• Vibration Response Plots (Bode, Polar, Unfiltered,

and Orbit Axis Amplitude/Phase, Orientation)

• Time Traces/Orbit Plot

• Spectrum/Time Trace Plot

• Spectra Waterfall

• Shaft Center Plots

• High Speed Strip Charts

• Vibration signals available for recording and analysis

• VHS 16-channel tape recording facilities

Automated data acquisition and control systemsPerformance and mechanical testing are conducted via a custom configured Hewlett Packard 3852A intelligentacquisition/control unit (DAC) in communication with twoHewlett Packard computers which retrieve, analyze andreport mechanical and performance test data.

System features include:• Local boom with electrical and pneumatic instrumentation

hook-ups

• Up to 600 individual rapid-assembly instrumentationconnections

• Concurrent test monitoring (two at a time)

• Permanent microdisk storage of testing data for future retrieval

Comprehensive performance testingTo ensure reliable results, we create performance test conditions which simulate the actual operating conditions of each compressor. Our rugged, customizable test standsprovide a wide variety of options – creating specifiedconditions and testing a large number of factors.

Ensuring compressor performance

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Natural gas supply (fuel gas)• 38,000 Sm3/h

Heat removal capacity• 100 MW

Electric power supply• National grid: 20 MVA

Steam generator• Capacity: 65 t/h

• Pressure: 50 bar

• Temperature: 450 °C

Natural gas supply (fuel gas)• 50,000 Sm3/h

Heat removal capacity• 130 MW

Electric power supply • 30 MW (summer)

• 60 MW (winter)

Capacity for generator tests• 47.5 MW (on shop load banks)

Florence capabilities Massa capabilities

GE has the largest and most complete testing capability in the industry to perform tests under actual load andpressure conditions – including LNG and re-injection. Ourfacilities in Florence, Massa and Le Creusot have a widerange of indoor and outdoor test beds for a variety ofstandardized tests, as well as the capability to performtests for plant-specific customized configurations.

These facilities are all equiped with sophisticated systemsfor data acquisition and processing of test results. Testscan be performed on centrifugal, axial and reciprocatingcompressors, steam and gas turbines, electric motors, andany combination of modules as required in your train.

Testing facilities

Test

Standard mechanical and/orthermodynamic tests on centrifugalcompressors and steam turbines

Running-in and/or string tests onreciprocating compressors

Standing and full-load tests byhydraulic dynamometer on gasturbines

Special string test

HSPT LM2500 spin test

LM2500 gas generator load test

Load test on combined modules

Florence

13

6indoor test beds

4indoor test beds

6outdoor test beds

1spin test bunker

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–

Massa

1

1outdoor test beds

2outdoor test beds

16outdoor test beds

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1test cell

1dedicated area

Schematic of the Massa testing facility.

Schematic of the Florence testing facility

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MASSA PLANTOutdoor stands for gas turbine testsand turbogroup full load tests

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FLORENCE PLANTOutdoor string and load test stands

Centrifugal/ axial compressor test

Gas turbine test

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Centrifugal compressors are carefully tested throughout themanufacturing process in order to guarantee an optimalmatch to their design criteria and to assure long-lasting,continuous operation.

The following tests are typically carried out on componentsand assembled machines:

• Casing: hydraulic pressure test

• Impellers: ultrasonic and dye-penetrant liquid tests,over-speed testing

• Impellers/rotors: over-speed testing

• Mechanical running test verifying:- Vibrations using non-contact probes- Bearing temperatures using thermocouples/thermore-

sistance- Lube oil parameters

Optional tests may be performed based on specific jobrequirements. For example:

• Performance tests with air or other gases in an open orclosed loop

• Full-load performance tests (including flammable gases)to check rotor

• Stability and the performance of the machine

• Mechanical string test

Centrifugal and axial compressors

Centrifugal compressor testsStandard full-load testing uses one point to verify themechanical behavior of a complete string at the maximumpower and maximum continuous speed, running withoutsimilarity law conditions.

Full-load testing can be enhanced with ASME PTC 10 Type Icriteria – using five points to verify performance andmechanical behavior of a complete string at rated speed,running with Type 1 similarity law conditions.

In accordance with similarity law, the thermodynamic conditions of a Type 1 test include contractual density,speed and conditions. For Type II, density, speed and powerconditions are low.

Le Creusot test capacitiesTesting is available for all centrifugal compressor equipment,including components and assembled machines, as well ashigh-speed rotor balancing. Facilities include:

• Mechanical and ASME PTC 10 type 2 performance tests– 3 test beds with electric motors up to 12 MW

• Full-load or ASME PTC 10 type 1 tests – 2 test beds forpackage with gas turbine up to 30 MW or electric motorsfrom 20 MVA power supply, for discharge pressure up to550 bar

• String tests – 2 test beds for electric motor packagesand 1 test bed for steam turbine driven compressors

Test facilities for steam turbines include:

• Mechanical tests – 5 tests beds for condensing or backpressure steam turbines

• Boilers and condensers with 28 tons per hour capacity

• Two special test beds for steam turbine tests in a semianechoic environment

Time

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TYPE 1 ASME PTC10

Reciprocating compressors

GE’s reciprocating compressors for oil and gas applicationsare subjected to thorough inspection and testing throughoutthe manufacturing process, in order to ensure the highestquality and a long, productive life.

All machines receive a full-speed run-in test with a shopmotor. The STD Quality Control Plan can be integrated withparticular customer requests, from simple additional checkson components to a running test of complete compressionplants, at either no-load or full-load conditions.

Our reciprocating compressors are subjected to the samebattery of standard and optional tests as our centrifugaland axial compressors.

In carrying out these and other tests, our customers benefitfrom some the largest and most complete testing facilities inthe compressor industry.

OshkoshOur North American Oil & Gas operations have one of thelargest and most complete testing capabilities in the industry.Using facilities in Oshkosh and Appleton, Wisconsin, we havethe capability to test both centrifugal and high speed recip-rocating compressors. We are able to provide mechanicaltesting to meet any industry standard, including API.Aerodynamic performance testing meets ASME PowerTest Codes as applicable. Using the most stringent Type IIcalculation methodology accommodates PTC 10 Type Iand II tests.

With test stands in many sizes, we are able to perform full-load string tests using a wide range of horsepower, steampressure, temperature and flow conditions, exhaust pressureand driver speeds to meet customer requirements.

Indoor centrifugal compressor and steam turbine Florence testing facility

Steam turbines

The Florence test facilities are equipped with four test benchesand a complete steam plant, with max 65 t/h live steam at50 bar/450°C.

The Le Creusot test center is equipped with five test benchessupplied by a steam plant capable of generating 28 t/h ofsteam at 45 bar/450°C. Le Creusot also features a largeanechoic chamber with suspended low-frequency foundationblock for vibration and noise measurements.

Mechanical string tests can be conducted on complete trainsboth in Florence and in Le Creusot. Full-load, full-pressure testscan be carried out up to full steam plant capacities.

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High speed balancing technology

We recently constructed a large scale, specialized bunker forhigh speed rotor balancing. It accommodates centrifugalcompressor, steam and gas turbine rotors. High speed balancing ensures optimal rotor weight configurationadjustments for actual operating speed.

This balancing facility is a key asset for enhancing our portfolio of advanced rotor technologies and will help usoffer customers even higher quality equipment and greaterconfidence in their operations.

Some of the main features of the bunker include:

• Low and high speed balancing capability

• Vacuum chamber (0.002 bar)

• AC motor (1 MW)

• Two types of adaptable pedestals available

• Control room, PLC control system, balancing software

Flange-to-flange testing

After the rotor is fully balanced, we test the core turbine orcore compressor unit in isolation, using in-house equipmentand personnel.

GE's PGT5 gas turbine-driven compressor during full load test

Improving rotor dynamics

Gas turbines

GE carries out mechanical tests on all its gas turbines.Complete turbocompressors and turbogenerators, includingall auxiliary equipment, can be full-load tested on outdoor testbeds complying with API, ASME, VDI and ISO internationalstandards at the Florence and Massa plants.

Our no-load tests to verify the mechanical behavior of gasturbines include:

• Vibrations using non-contact probes and casing seismic probes

• Bearing temperatures using thermocouples/thermore-sistance sensors

• Lube oil parameters

On request, we can also conduct complete on-site tests ofcustomer plants.

Gas turbine testsUsing the ASME PTC 22 test philosophy, a full-load test is usedto verify gas turbine performance with the following criteria:

• Tested power ≥ guaranteed power

• Tested Heat Rate ≤ guaranteed heat rate

The tested and guaranteed values must be corrected to correspond to ISO or site conditions with performancecurves considering:

• Inlet temperature

• Inlet pressure

• Inlet and exhaust pressure drop

• Relative humidity

The ASME PTC22 test is performed with gas turbine exhausttemperatures under control.

MassaComplete modules can be tested at the Massa plant and thenshipped without disassembly due to the site’s proximity tothe Massa harbor. Test beds are equipped with DataAcquisition Systems capable of collecting thermodynamicand mechanical data and computing in real time.

Test facilities include a high pressure feed system for gasmixtures (inert and flammable gases), a gas chromatographfor gas analysis, a 60 Hz generator, low and high pressuregas coolers, and steam and lube oil supply. The cooling towersallow closed-loop tests up to 90,000 hp.

Sample display: verification of bearing drain oil temperature

From lube oil tank

To lube oil tank

Other informationTemp to lube oil tankTemp from lube oil tank

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LT-TH53, 1014 C

LT-BT1D53, 6019 C

LT-B1D52,9 C

LT-B2D57,0016 C

LT-B3D55,3964 C

LT-B4D54,4015 C

TNH6,5587 %

TNH5.504 mm/s

BB_MAX0.307 mm/s

TT_XDM219,1974 C

Heat Rate

Airflow Heat Consumption

Power Output

Compressor Inlet Temperature (ºC)

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The main purpose of a full-speed, no-load string test is toverify the mechanical behavior of the complete train afterindividual component testing. Typically, these tests are performed on an outdoor test bed.

For a rotating unit , the purpose of the API functional testis to check the rotating behavior of each component . Inaddition, the string test allows us to verify the rotationalbehavior of the whole train in order to mitigate risks and minimize the possibility of a long and expensive test campaign on site.

Special facilitiesIn order to facilitate string testing and reduce costs, a specialfull-speed, no-load test facility has been created.

It consists of a mobile enclosure containing the completeinlet and exhaust duct, the complete ventilation filter and thecomplete enclosure including fire-fighting system.

All the major components (i.e., gas turbine, coupling,compressor and mobile enclosure) are installed on the baseframe to allow quick and simple setup for the completetesting of the rotating equipment lineup. This capabilityreduces the long cycle time and high cost usually associatedwith the use of all the actual job components during testing.

Streamlined string tests are carried out in our Florence andMassa facilities before unit shipment. Test or inspection resultsare recorded on appropriate log sheets and signed by thewitnessing parties, and an official test report , including alllog sheets, is issued after test completion. A copy of the rawdata, recorded during the witnessed tests, is submitted aftereach test as a part of the customer’s inspection record.

Job itemsThe main job items normally used in the string test are:

• Gas turbine assembled on base plate with piping andelectrical connections (up to junction box) without enclosure

• Inlet and exhaust plenum

• Job gear box

• Job couplings

• Centrifugal compressor assembled on base plate withseal-gas panel, piping and electrical connections (up tothe junction box)

• Unit control panel

• Synthetic lube-oil console assembled on gas turbinebase plate with piping and instruments

Shop itemsThe main shop items normally used in the string test are:

• Lube-oil console (when not included in auxiliaries base plate)

• Vacuum system

• Motor Control Center (MCC)

• Lube-oil cooler

• Synthetic lube-oil cooler

• Inlet duct

• Exhaust duct

• Ventilation system

• Mobile enclosure

• Fire fighting system

• Uninterruptible Power Supply (UPS)

String test configuration: 1. gas turbines 2. compressors 3. helper 4. shop process gas piping (including coolers, valves, etc.)

Streamlined no-load string testString tests

Overview Our 1 million square foot, state-of-the-art facility allows usto perform a complete train validation, precisely replicatingour customers’ unique site conditions. Software inputs andphysical infrastructure modifications simulate your exactoperating parameters. This outdoor facility meets the samerigorous standards found throughout our manufacturingenvironments.

The testing facility can accommodate: • 130 MW gas turbine driver and compressor (up to FR7

and FR9 models under full load testing conditions usingnatural gas supply)

• 60 MW electric motor driver and compressor underfull-load conditions.

This extensive capacity allows us to take testing out ofthe theoretical realm and into the practical world of ourcustomers’ business – offering the utmost confidence insystem performance prior to installation. No other companyin the world can provide this benefit.

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String Test Configurations

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The Virtual Witness System (VWS) is a web applicationthat shows, in real time, the measured parameters and thecollected data during standard factory tests of CentrifugalCompressors and Gas Turbines. Oil & Gas customers canaccess the application via a secure internet connectionand witness Official Tests from their own offices, therebysaving them money and time.

The graphical pages displayed by the Virtual WitnessSystem have the same format as those the test bed technician sees during the test .

All operating parameters such as gas and oil pressuresand temperatures, speed, bearing temperatures, etc., aremonitored and displayed in real time. Test performancecurves can be continuously displayed and compared withthe calculated curves throughout the testing procedure.

Mechanical oil seals 2BCLVWS is available for Centrifugal Compressor mechanical(API 617*) and performance (type II ASME PTC10*) tests.

The compressor types that can be monitored using VWS include:

• BCL, 2BCL, 3BCL

• MCL, DMCL, 2MCL, 3MCL

• PCL

• SRL

The Gas Turbine models available for mechanical test (API 616*) using this tool include:

• MS3002, MS5002

• MS5001, MS6001

• PGT5, PGT10

• GE10-2

This Virtual Witness System is also available for performancetesting (ASME PTC22*) of the following Gas Turbine types:

• GE5-1

• GE10-1

The VWS requires only a PC with a browser and a connectionto the internet. Once the customer has been given access tothe application, it is available from any location. Customersthat request access to VWS will be provided with a User IDand Password that guarantees security. When the customerconnects, the system opens a connection dedicated to thecustomer that will deny access to unauthorized parties.Confidentiality of information is guaranteed.

The data displayed by the system are gathered exclusivelyby the data acquisition systems that collect test information.No input is permitted. The customer has a completely transparent view of what is happening on the test bed.

*with NP Oil & Gas exceptions

Virtual Witness System

Our in-line inspection tools undergo rigorous mechanicalperformance and data accuracy testing at the Stutenseetest loop

Flow loop in Alvin, Texas with innovative new launchchute and special fittings including diameter transitionsand back-to-back bends (painted blue)

GE also operates two of the pipeline industry’s most advancedtest loop facilities for validating the performance of ourindustry-leading in-line inspection tools.

Technology development and product enhancementOver 20 years, we have amassed the largest and most detaileddatabase of pipewall defects in the industry. As it grows, wecontinually feed information back into the research anddevelopment process for our new and proven inspection toolsand software. In addition to advanced computer simulations,every tool we develop undergoes a series of stringent in-linetesting – through a comprehensive range of pipeline operatingconditions, fittings, bend configurations and other variations.

Client-specific inspection modificationsWhen a pipeline system has unusual or troublesome configurations, especially in the case of previouslyuninspected pipelines, we are able to configure our testloops to replicate the segments in question and conduct pre-inspection runs before going in-field. By tailoring toolgeometrics, speed and many other parameters, we are able to optimize in-field procedures – saving time and money for our clients.

CramlingtonThis site has a number of specialized test facilities for isolatedparts modification and in-line performance testing of pipelineinspection tools. A high pressure system provides testing to1475 psi and also drives the 8” blowthrough line. The systemcan be split into various configurations to produce watertesting and higher pressure air tests. A Drop Tower structuresimulates vertical launch and receive facilities, whileautomatic drop and lifting can be fitted and configured tosimulate offshore conditions. Other facilities include a rivercrossing simulation and 8” blowthrough rig, a Mayes tensiletesting machine for ranges of -50 Kn and 0-500 Kn, a Lingvibration machine for component testing in various simulatedvehicle run conditions and an environmental chamber to controltemperature conditions to very close limits from 30-100°C.

StutenseeThe Stutensee test loop consists of 16” and 20” pipes, runningparallel to one another in a continuous 250-meter loop. One of only a handful of its kind in the world, the loop isfully automated and custom built for the testing of in-lineinspection tools, including MFL, ultrasound, caliper andmapping. The loop verifies an in-line tool’s precision inlocating and accurately defining corrosion, cracking,laminations, geometric anomalies, artificial defects, andmore. The test line is fully adaptable – if a customer wantsto have a specific piece of pipe tested, it can be readilyspooled into the loop.

Pipeline inspection testing

Industry-wide solutions

imagination at workTest_NA_011806

Nuovo Pignone S.p.A.Via Felice Matteucci, 250127 Florence, ItalyT +39 055 423 211F +39 055 423 2800

GE Oil & Gas1333 West Loop South, Suite 800Houston, Texas 77027-9116 USAT +1 713 803 0900F +1 713 803 0499

GE Oil & Gas Operations, LLC3300 Medalist DriveOshkosh, Wisconsin 54902 USAT +1 920 237 6000F +1 920 237 6013

GE Oil & GasBP 119 Site industriel71203 Le Creusot T +03 85 80 68 10F +06 19 12 76 02

GE Oil & Gas, PIIAtley Way, CramlingtonNorthumberland NE23 1WWUnited KingdomT +44 191 247 3200F +44 191 247 3101

www.ge.com/oilandgas

The information contained herein is general in nature andis not intended for specific construction, installation orapplication purposes. GE reserves the right to makechanges in specifications or add improvements at anytime without notice or obligation.

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