Ge Appliances Operations And Maintenance Brochure
Ge-Operations-And-Maintenance-Brochure-656414 ge-operations-and-maintenance-brochure-656414
2015-08-07
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Subsea Systems in the UK
Fueling the future with comprehensive technologies and
support services for the most extreme conditions
Technology
GE Oil & Gas is a world leader in advanced technologies and services with 43,000 employees
in more than 100 countries. We work closely with customers across the industry’s entire
value chain – planning and developing solutions that respond to their real operating
needs. In collaboration, we address today’s toughest challenges, push the boundaries of
technology and fuel the future.
We invest significant research and development resources every year and maintain Centers
of Excellence (COE) around the world, each dedicated to delivering the highest quality for its
particular technology area.
These widespread oil and gas specific resources have the unique advantage of drawing
on GE’s strengths in other key transferable-technology areas like aviation, energy and
healthcare. We cast a much wider net than most for identifying and applying solutions to
improve performance in subsea applications.
Talent
We cast a similarly wide net for innovative thinkers. In addition to recruiting top graduates
in every region where we do business, we also have programs focused on closing the
demographic ‘talent gap’ that the oil and gas industry is currently facing. By attracting
trained and experienced engineers and managers from other high-tech industries, and
tailoring training to their already advanced levels, their new perspectives and approaches to
problem-solving bring tremendous value to all aspects of our business.
Because of these unparalleled training and career development programs, as well as the
high integrity through all other aspects of the way we work, GE Oil & Gas is recognized as
an employer of choice around the world and, in particular, in the exciting and challenging
subsea sector.
Fueling the future
with subsea systems
Aberdeen
Bristol
• Nailsea
• Aztec West
Montrose
• Charleton Road
• Brent Avenue
Newcastle
Subsea excellence for the world
Our UK operations play a crucial role in GE’s forward-reaching
strategy for subsea technologies, with four Centers of Excellence
serving the worldwide subsea industry.
The Aberdeen COE is continually pushing depth and distance
boundaries through advanced engineering for all three lines of GE
subsea trees.
Our Bristol COE focuses on subsea control systems, most notably
our SemStar5 subsea electronics module and ModPod designs.
The Montrose COE specializes in master value block (MVB)
components and subsea connector parts.
Finally, our Newcastle COE is the global headquarters for design
and manufacturing of all our Wellstream flexible pipe technologies.
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This state-of-the-art manufacturing facility is our Center of Excellence for Subsea Systems
and the primary location for design, assembly, testing and integration of industry-leading
subsea equipment.
We manufacture, fabricate and test the complete line of VetcoGray equipment.
In-house technical support includes quality assurance, engineering, manufacturing,
planning, procurement and logistics.
Aberdeen is also a key research and development center, focused on helping operators meet
the most complex challenges, today and in the future. Our technical experts are responsible
for many of the incredible advances in subsea applications over the past 20 years.
Footprint
Area m2 (ft2)
Total site 37,310 (401,630)
Covered space 10,390 (111,750)
Office 2,917 (31,400)
Warehouse storage 929 (10,000)
Maintenance shop 153.3 (1,650)
Test & assembly #1 2,044 (22,000)
Test & assembly #2 1,700 (18,300)
General yard area 26,940 (290,000)
Aberdeen
Key technologies
• Subsea trees and production systems
• Subsea chokes and valves
• Rental of subsea systems equipment and
tools
Significant assets
• Welding/cladding equipment
• Heavy lift overhead cranes
Testing
• Advanced test and assembly facility
incorporating test pits and high pressure
test bays
• Fully-equipped laboratory facility
TECHNOLOGY
SPOTLIGHT:
Deepwater tree systems
Since 1961, we have installed 1,400 tree systems
operating in all water depths across every major
production basin in the world. Our field-proven designs
include a standard foundation for each tree series,
to which pre-engineered modular components are
configured to best meet specific project needs.
Our VetcoGray D-Series deepwater tree systems come
in horizontal and vertical orientations, are optimized
for flow assurance and qualified for up to 1,035 bar
(15,000 psi) and 3,000 m (10,000 ft). The highly reliable
DHXT horizontal tree offers lowest installed cost through
minimized rig and ROV operations. It includes the field-
proven, integral VetcoGray ‘ModPod’ control module
powered by the award-winning SemStar5™ subsea
electronics system. Highly flexible and configurable for
water, gas or alternating injection, DHXT systems are
available for standard, enhanced and gas-lift production
with a full-bore drill-through option for each.
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Bristol
Significant assets
• Proof pressure bay for SCMs
• 2 Fixed stands for flushing and 4 for SCM testing
• 5 Environmental stress screening (ESS) chambers
• Hyperbaric chamber (270-bar)
• P-SPICE and Hypac design stations for analysis
• Clean room (Assembly SCMs, DCVs, HPIs)
Aztec West
This recently expanded facility is our Center of Excellence for Engineering, Procurement &
Construction – a major hub for all our subsea installation and intervention activities around the
world. The local team includes some of our most experienced project managers, application
engineers and logistics experts, and is involved at all stages of the subsea field lifecycle – from
FEED studies and system design, to installation, service, expansion and intervention.
Footprint
Area m2 (ft2)
Subsea Systems 2,444 (26,307)
GE Capital 1,846 (19,875)
Nailsea
Established over 35 years ago, our Nailsea facility continues providing leading-edge
design, manufacturing and testing of subsea production control systems – including
concept definition and FEED studies. This is the primary location for project management,
engineering, procurement, and R&D activities for our Subsea Controls projects worldwide.
The team also designs smart applications for remote monitoring, diagnostics and flow
integrity control of subsea facilities.
Footprint
Area m2 (ft2)
Total Site 5 acres
Offices 13,000 (139,900)
Workshops 13,500 (145,300)
Yard 16,398 (176,500)
Assembly & Integration 2,896 (31,170)
& Test (AIT)
SIT Area 2,896 (31,170)
Electrical Assembly 1,646 (17,720)
MCS Assembly 76 (818)
ESS 549 (5,909)
GE © 2014 – All Rights Reserved
Unauthorized Reproduction Prohibited
TECHNOLOGY
SPOTLIGHT:
VetcoGray SemStar5™
Our fifth-generation subsea electronics module draws on
field-proven technologies and over 30 years of subsea
experience. Ruggedized to exceed ISO 13628-6 2006
requirements, the radical new design optimizes flexibility,
durability, reliability and obsolescence mitigation. It’s
been critically acclaimed by industry leaders and media
alike, including receipt of an OTC Spotlight on New
Technology Award.
With ambitious expansion plans for the Tordis and Vigdis
fields in the North Sea, Statoil became the first company
in the world to use SemStar5. Although the fields have
produced over 629 million barrels of oil – roughly 300
million more than expected – this upgrade will enable
nearly 400 million more barrels in the next 15 years.
A total of 27 wells were upgraded including subsea control
module retrofits, installation of a new electrical distribution
system, and replacement of topside control systems.
The field was greatly simplified by eliminating many of
the original multiple-vendor control modules and using
SemStar5 instead. The module enables complete
operation from shore, including real-time monitoring
and diagnostics of all seabed equipment. It also
enhances safety and productivity with advanced
sand-monitoring and leak-detection capabilities,
and has the flexibility to integrate more features
in the future.
Aside from being the first SemStar5 installation,
it was also the first major brownfield subsea
controls upgrade in the world.
Montrose
Charleton Road
This state-of-the-art facility was designed for flexible capacity and high efficiency to
provide enhanced customer support through the entire product lifecycle. We manufacture,
fabricate, repair, maintain and test the complete line of VetcoGray equipment. We also
have extensive warehousing and storage facilities as well as full rental tool service
capabilities. In-house technical support includes quality assurance, engineering,
manufacturing and logistics.
Footprint
Area m2 (ft2)
Total site 51,000 (549,000)
Yard storage 35,571 (382,900)
Manufacturing & maintenance 8,121 (87,410)
Test & assembly 1,830 (19,700)
Test & assembly
• Fully serviced test bays with electronic recording for MWP and function testing
• 75-ton crane with 20-ton auxiliary hook high bay capable of performing
full system stack-up
• Two 10-ton overhead cranes that run the full length of the test and
assembly cell
• 20-ft deep test pit with full flooding capability for gas testing subsea trees
• Pressure testing capabilities to 22,500 psi
Fabrication
• Two 15-ton cranes that run the full length of the fabrication cell and
that can be linked for tandem lifting
• Full roll-though line capability for tubular fabrication
• Manipulator and roller facilities
• Wide range of advanced welding capabilities including MIG, TIG and sub-arc
• Cladding and heat-treatment equipment
Machine shop
• Over 8,000 m2 floor space
• 10-ton overhead crane capacity
• Phosphate cell
• Fronius 9000 cladding rig
• Hancook 9NC lathe
• Hyundai KIA HS630 machining center
• Hartford PBM 115A borer milling center
• Hancook VTC-160E APC lathe
Key technologies
• Subsea wellheads including HP and LP, SG-5 and
MS-700
• Subsea trees, workover systems and running
equipment
• Specialty connectors and pipe (16" to 48")
• Capital drilling equipment
• Marine risers, diverters and H-4 connectors
• Surface equipment
• Subsea production equipment
• Production control choke repair
• Production control systems
Brent Avenue
This modern facility is a GE Oil & Gas Center of Excellence for manufacturing, assembly and
testing of subsea equipment, with a specialization in master valve block (MVB) components
and associated subsea connector parts.
Our manufacturing portfolio spans some of the most impressive subsea developments in
the world, including core technologies for the Kizomba Satellite and Gorgon projects.
The plant was established in 2001 and has been continually updated with the latest
machining tools, cladding rigs and other sophisticated manufacturing technologies. We are
currently increasing our machining and assembly capabilities for the next generation of
MVBs and associated equipment.
Footprint
Area m2 (ft2)
Total site 3,902 (42,000)
Test pit 88 (947)
11 x 8 x 9 m deep
Storage yard 2,508 (27,000)
Significant assets
• 11 x 8 x 9 m deep gas test pit
• 5 state of-the-art test bays;
• HS-2 block cell
• Large and medium envelope cells
• 5-axis MillTurn centers
• Fully automatic Inconel cladding systems
• Coordinate measuring machine
• Tacchi heavy-duty horizontal lathe
• Soraluce horizontal borer
GE © 2014 – All Rights Reserved
Unauthorized Reproduction Prohibited
Newcastle
Newcastle is the global Centre of Excellence for custom engineering design, manufacturing
and testing of all GE’s Wellstream flexible pipe products for subsea oil and gas production.
This state-of-the-art facility is strategically located for its deepwater access and heavy lift
load-out capability to enable global shipping. Wellstream products can be found in every
major offshore production basin worldwide.
Wellstream flexible pipes are exponentially lighter and more adaptable to harsh
sea conditions than rigid steel pipes, often the preferred solution due to the varied
installation offerings available. Our portfolio draws on more than 20 years of research
and development, material science and installation experience in some of the harshest
conditions the industry has to offer – particularly where water depth and seabed conditions
impose unusual restrictions.
Footprint
Area m2 (ft2)
Total site 64,592 (695,200)
Engineering & manufacturing
Our systems are currently operating in depths well beyond 2,000 m and are being qualified
up to 3,000 m, our products offer proven reliability, structural robustness and corrosion
resistance from both the external marine environment and internal pressures. Every
Wellstream product is customized to meet the specific requirements of each project.
Our facility is designed for sequential manufacturing to deliver the most efficient material
usage and workflow. Our annual manufacturing capacity is currently 300 km of 8-inch
normalized pipe, with a product range from 2-inch ID to 24-inch OD.
Testing & lifecycle optimization
Newcastle also has comprehensive testing capabilities including prototype testing,
qualification procedures for new flexible pipe materials and structures, and a full range of
monitoring and inspection services.
Using specialized magnetic technologies, we can deliver a detailed description of the
service history, future performance and remaining service life of flexible pipeline structures.
Key benefits include reduced operational, safety and environmental risk, as well as
extended asset service life and cost optimization.
Key technologies
• Risers – dynamic lines suspended in the water column, connecting production
facilities to subsea infrastructure
• Flowlines – static pipelines that carry fluids along the seabed
• Fluid transfer lines – typically large diameter pipelines connecting two structures
which are often dynamic
• Jumpers – short pipes connecting static structures either above or below water
TECHNOLOGY
SPOTLIGHT:
Wellstream flexible pipes
Wellstream’s unbonded dynamic flexible risers, static
flowlines, fluid transfer lines and jumpers ensure
maximum versatility when connecting subsea structures
and surface production units. Our designs comprise the
helical application of metallic wires and tapes, along with
extruded thermoplastics to form a flexible pipe structure
that can address field-specific pressure, temperature,
water depth and fluid characteristics.
Our products are ideal for new field developments that
are of continually higher complexity as well as mature
fields being upgraded for much-needed increased
recovery rates.
The Troll offshore development is one of the world’s
largest offshore gas discoveries, with an estimated
production life of over 50 years. In 1996, Wellstream
products were incorporated as to help exploit the highly
fragmented reserves via Troll B and C. Over six years, we
supplied large-diameter flowline and riser products to
support the subsea system tying clusters of wells back to
the FPUs via central manifolds.
Our project scope of supply includes:
• 220 km of 8/10-inch production flowlines
• 17 km of 10-inch dynamic production risers
• 2 km of 15-inch dynamic export risers & jumpers
• 10 km of dynamic service umbilicals (hydraulic/
electric/optics/dosing/methanol)
• 3.5 km of 4 & 6 hose gas-lift umbilicals (gas/methanol)
GE © 2014 – All Rights Reserved
Unauthorized Reproduction Prohibited
GE Oil & Gas
Global Headquarters
Via Felice Matteucci, 2
50127 Florence, Italy
T +39 055 423 211
F +39 055 423 2800
customer.service.center@ge.com
Nuovo Pignone S.p.A.
Nuovo Pignone S.r.l.
Aberdeen
Broadfold Road
Bridge of Don Industrial Estate
Aberdeen, Scotland AB23 8EY
T +44 1224 852 000
F +44 1224 852 434
Bristol, Aztec West
2630 The Quadrant
Aztec West
Bristol, England BS32 4GQ
T +44 (0) 870 241 8899
Bristol, Nailsea
2 High Street
Nailsea
Bristol, England BS48 1BS
T +44 1275 810100
F +44 1275 851467
Montrose, Brent Avenue
Forties Industrial Estate, Brent Avenue
Montrose, Scotland DD10 9PB
T +44 1674 643000
F +44 1674 643020
Montrose, Charleton Road
Charleton Road
Montrose, Scotland DD10 9EB
T +44 1674 643111
F +44 1674 643127
Newcastle
Wellstream House, Wincomblee Road
Walker Riverside
Newcastle upon Tyne, England NE6 3PF
T +44 1224 852 000
F +44 1224 852 434
For complete contact information,
please refer to our website.
geoilandgas.com
The information contained herein is general in nature
and is not intended for specific construction, installation
or application purposes. GE reserves the right to make
changes in specifications or add improvements at any
time without notice or obligation.
GE, the GE Monogram, and imagination at work are
registered trademarks of the General Electric Company.
©2014 General Electric Company
All Rights Reserved
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