Powering

Saudi Arabia

GE Manufacturing Technology Center Dammam, Kingdom of Saudi Arabia High Technology Capabilities & Services Supporting the Power Generation, Oil & Gas and Water Needs of the Kingdom

Table of Content

P.O. Box 181 Dammam 31411 2nd Industrial City – KSA Tel: +966 3 8027882 Fax: +966 3 8027883 * Trademark of the General Electric Company; may be registered in one or more countries. This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner. ©2012, General Electric Company. All rights reserved. GEA20068 (09/2012)

A History of Innovation

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Manufacturing, Services, Repair and Much More

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Investing in People and Training

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Customized Technology Solutions

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Expanding the Resource Commitment

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Timeline: GE in Saudi Arabia Provides two Frame 5 turbines to Riyadh’s first power plant, Riyadh PP1, to power the city of Riyadh

• Ships 1,000th F-technology turbine to Saudi Arabia • Establishes the Fuel Research Center in KFUPM to become the sixth research and development facility in Saudi Arabia

• Is the first company to use crude oil as fuel for power generation in the Kingdom Supplies turbomachinery to Saudi Arabia’s first oil refinery

A History of Innovation

• Leads the winning consortium for Marafiq IWPP, the world’s largest integrated water and power plant

• Delivers gas turbines to the Eastern Region (Faras, Othmania, and Nuarryah)

Construction begins on Phase Two of the GE Manufacturing Technology Center

• Graduates the first group of GE-TVTC (Technology Vocational Training Center) students

Technology leadership grows the economy and the workforce At 1700,000 square feet, the GE Manufacturing Technology Center that opened in Dammam in 2011 is one of the largest and most sophisticated of GE’s energy technology centers. Strategically located to better serve our customers in the Kingdom, the Middle East and the world, the center underscores our full support of the Kingdom’s

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Saudization goals and its transition to a knowledge-based economy.

• Supports Dhahran Electric Power Company (DEPCO) with power generation technology to meet power needs in Dhahran and Khobar • Inaugurates Middle East Engineering Ltd, Saudi Arabia (MEELSA) to expand local service capabilities in Saudi Arabia

repair advanced technology gas turbine-related parts locally locally to save time and cost, rather than sending them out of the country. (We can already repair E-class turbine parts locally.) We are also pleased to see the realization of GE’s promise

a technology ally working to build a sustainable future.

to expand the training of young Saudis, giving them

development that will double the size of the current facility with

Introduces Frame 5 turbines to Saudi Arabia

forward to a high quality integrated service facility where GE can

And, this facility further solidifies our commitment to the Kingdom as

Phase two of the center, now under construction, is a grand

• Begins delivering power generation technology to Saudi Electricity Company’s Riyadh PP9 power plant, which, with 60 turbines, is the world’s largest power plant

“As part of GE’s commitment to Saudi Arabia, we are looking

five new buildings, four of which will become operational by 2014. Activities in the massive 219,000-square-foot expansion will include state-of-the-art manufacturing for many unique,

the opportunity to know more about the operation and maintenance of the GE units with the advanced training center. We look forward to the future of more cooperation and partnership with GE.”

— Saudi Electricity Company

sophisticated gas turbine components, plus engineering, assembly and testing for oil flow cells and Bently Nevada control

Officially inaugurates the GE Manufacturing Technology Center in Dammam

• Establishes the Middle East Power Company (MEPCO) to manufacture equipment for the power generation and oil and gas industries

solutions. The Kingdom’s only high-speed balancing facility for generator rotors will be housed here, along with a new GE Repair Development Center—one of only five in the world. The GE Repair

technologists will focus on finding new repairs technology to serve regional customers in the power, water, and oil and gas industries. GE’s longstanding commitment to Saudi Arabia dates back to 1942,

“This GE facility is a game-changer for Saudi Arabia, creating

when we supplied the Kingdom with its first turbine for its very first oil

a manufacturing hub to help make the Kingdom a net

refinery. Today, over 500 GE turbines are generating power in Saudi

exporter of advanced technology equipment, accelerate the

Arabia, supported by more than 800 employees in three local offices

diversification of Saudi Arabia’s economy to support of the

and seven energy facilities—the largest GE presence in the Middle East.

country’s long-range development goals, and enhance the GE’s product-and-service delivery outreach throughout the region. From project conception to commissioning to world class aftermarket services, GE provides unrivaled end-to-end solutions coverage, and the Dammam center is integral to this flawless execution.” Powering Saudi Arabia | A History of Innovation

Development Center is where researchers, engineers and skilled

— Karl Fessenden, president & CEO, Power Generation Services, GE Power & Water

Throughout our 80 years in Saudi Arabia, GE has not only supplied the equipment needed to expand the Kingdom’s energy infrastructure, we have also provided a continuous stream of solutions to help solve our customers’ toughest challenges in the region. In addition, GE has steadily expanded our knowledge-sharing initiatives in the Kingdom to include several successful co-operative programs with such leading Saudi institutions as the King Abdullah University of Science and Technology, and we recently brought our highly successful Graduate Management Program to Saudi Arabia, too.

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Manufacturing, Services, Repair and Much More GE Manufacturing Technology Center in Dammam is our largest turbine service center worldwide, and it also strengthens our local service and repair capabilities for customers in the Kingdom’s power, oil and gas, and water sectors. The center eventually

Our team-based approach provides multiple benefits

A multi-faceted manufacturing facility At 103,000 square feet, the largest of the second-phase buildings

and by 2015, as many as 65 percent

The GE Manufacturing Technology Center gives the region its

will manufacture many types of gas turbine skids – for the 7F

of them will be Saudi nationals.

first F-technology turbine manufacturing, service and repair

turbine accessory base and liquid fuel accessories, and for water

The training facility at the center is

center as well as the first balance of plant (BOP) test and

injection, fuel forwarding and fuel recirculating systems. We will

created to increase local engineering

inspection resources in the region. Using genuine GE-designed

also produce centrifugal compressors and positive displacement

capability, enable talented young

and manufactured parts, backed by GE-trained technologists

blowers. The 43,000-square-foot building that is next in size will

Saudis to take advantage of the latest

and engineers, the center offers a spectrum of service-based

house production for Bently Nevada monitoring and control

technology and managerial courses,

solutions including:

solutions making us the first company to manufacture vibration

so they can grow into the leadership

systems in Saudi Arabia. Technicians at our 10,000-square-foot

roles needed to drive the Kingdom’s

• Advanced technology innovation and upgrades

will employ more than 1,000 people,

High Speed Balance building will provide dynamic balancing for

future energy industry. Here are other

• Dedicated customer service professionals

generator rotors, including thermal run and over-speed testing,

key facts about the center:

• Controls, diagnostic and analytical tools for performance

while the 10,000-square-foot Repair Development Center’s

optimization and smarter grid integration • Training and education • Access to more than 100 years of technical expertise and fleet

core work will focus on optimizing parts, repair and inspection technologies, to improve outages and field repairs. A unique aspect of that facility is its crude oil burner lab, which will test gas turbine combustion parts.

operability knowledge Ultimately, the center gives our customers much more than a

• Advanced technology equipment

new part. They get the benefit of a team that helps improve

• F-technology gas turbine component repair

the plant’s performance, reliability, safety, and emissions. They also get better control of operating and maintenance costs as

• Generator repair/rewind

their assets age. And they preserve the ability to incorporate

• First balance of plant (BOP) test and inspection in Saudi

technology improvements down the road.

• Developed in association with Ali A. Tamimi Company

Powering Saudi Arabia | Manufacturing, Services, Repair and Much More 4

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GE Manufacturing Technology Center, Dammam

Administration Employee Services Expansion

Services and Repair Center (operating since 2011)

Repair Development Center

Blowers & Turbine Accessories

Measurement & Control Solutions 6

Central Warehouse

High Speed Balance Powering Saudi Arabia | Manufacturing, Services, Repair and Much More

Featured Repair Technologies Combustion Combustion system repairs cover transition pieces (TPs), liners, cap plates and seals. Repairs include heat treatment, brazing and welding of worn parts, and thermal barrier stripping and recoating on B-, E-and F-class system components. RenewAlloy* technology braze repairs enable turbine components to approach new part performance levels. The Dry Low NOx (DLN) Extendor System has improved standard

E-class TPs at 12,000 fired hours can be upgraded to 24,000 fired

F-class heavy-duty gas turbines are particularly critical to

Benefits

hours for longer parts life and maintenance intervals.

turbine performance, GE has developed a sophisticated series of

• Enhances performance reliability

Benefits • Provides emission control and reduces nitrogen dioxide (NOx) • Extends life and reduces repair cycle of turbine components

precision repair and inspection technologies especially designed to address known failure modes. A calibrated sonic flow bench, for example, accurately tests liquid and gas flow performance

• Assures correct reassembly and flow, including precision fuel nozzle tuning to fit and match around the entire unit

after each repair, to ensure the part meets our

• Regains OEM specifications for flow and pressure of fuel

exacting standards.

Power Nozzles

• Eliminates heat-affected zone cracking

Components are carefully disassembled, cleaned and inspected

Careful power nozzle repair is critical to turbine performance and

• Removes the need to replace large liner sections or cracked

with precision equipment. Inspections typically occur during

can significantly impact outage intervals. Power nozzle repairs

combustion service intervals, after which special repairs

include these steps:

indicated by the inspection are performed.

• Each nozzle segment is carefully tuned to regain new

(liners and TPs)

combustion cap effusion plates • DLN system available in new and modified upgraded units

E-class Extendor interface connections, making repair upgrades

Fuel Nozzles

easier, boosting performance and lengthening repair cycles.

Because endcover and fuel nozzle assemblies in B-, E- and

Next, the components are reassembled, a flow test is performed,

part tolerances for gas flow area and harmonics using GE

and the fuel nozzle and cover assembly are returned to

proprietary measurement system and balancing methods

the customer.

Powering Saudi Arabia | Manufacturing, Services, Repair and Much More 8

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• Cloth seal breach inspection, seal replacement and upgrading • Radial and horizontal diaphragm seal teeth removed and replaced

Generator rotor repairs include complete rewinding with new or existing copper, and/or basic overhaul cleaning of the generator rotor coils and body. Rewinding involves replacing all old, dated insulation with new, technology-enhanced insulation.

• Cast iron diaphragm welding

Retaining ring replacement with new alloy materials is an

• Advanced coating removal of aged coatings prior to

option, as is high-speed balancing of the generator rotor to

component repair, plus application of new coatings

operating specifications.

to OEM specifications

All generator stator rewinds are done with new copper bars and

Benefits

technology-enhanced insulation.

• Efficiency-boosting upgrades available for E-class non-

Non-destructive inspections of the rotor forging can be

pressurized airboxes to drive performance improvement • Balanced gas flow and harmonics help avoid harmful rotor vibration

performed utilizing magnetic particle testing (MPI), ultrasonic testing (UT) and eddy current testing, where applicable. Benefits

• Trailing edges restored to correct dimensions

• Reduces forced outages

• Advanced heat treatments rejuvenate base material

• Extends life cycle operations

Buckets

• New retaining ring material for less cracking

Stage 1 buckets in E-class turbines can experience typical wear

• Technology-enhanced insulation for improved

and tear. Other potential problems are rupture, creep deflection, corrosion and foreign object damage.

turn–turn protection Rotors

Typical services for these problems include inspection,

Since they operate at high speeds, compressor and turbine

evaluation, weld repairs and re-machining, machining to

rotors require complex inspection work to prevent major faults

incorporate design modifications, re-inspection, strip coatings

that could render the power plant inoperable. Careful inspection

and recoating, heat treatments, and dovetail shot peening.

and evaluation ensures that parts are in good condition and

Tip repairs are made with adaptive laser welding and other

within precise tolerances. This covers visual, airfoil condition and

welding processes designed to improve oxidation resistance. Benefits • Ability to make design modifications and/or upgrades to support performance output • Adaptive laser and other welding process repairs to improve oxidation resistance and bucket performance • Reduced platform creep • Custom-designed bucket coatings • Bucket life extended up to 96,000 hours • Ability to make any design modifications and/or upgrades Generators Generator fields receive partial or full rewinds; TIL modifications;

borescope inspections; critical parts measurement; balance, rotor bow and run out checks; and non-destructive testing (NDT). Repairs can involve un-stacking and re-stacking of the compressor or turbine rotor, blade or buckets installation, NDT, drop and run out checks, machining, tip grinding, modification, burnishing, and balancing. Benefits • Capitalizes on LES (Life Extension Services) to improve reliability • Extends component life • Reduces maintenance cost • Minimizes rotor imbalance • Ability to make design modifications and/or TIL upgrades.

and machining, grinding, and balancing repairs, all here at the Dammam facility.

Powering Saudi Arabia | Manufacturing, Services, Repair and Much More 10

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Investing in People and Training Knowledge advances localization Training GE supports the Kingdom’s expansion of its energy infrastructure

an inaugural graduating class of more than 30 students in

by providing knowledge-sharing and training initiatives to build a

2011. In the program, high-performing graduates from such

skilled Saudi workforce for the energy industry.

distinguished technical colleges as the Dammam, Al Hasa and

More than 30 graduates of our highly successful cooperative program with King Fahd University of Petroleum & Minerals (KFUPM) now work for GE, including eight in the Operations Management Leadership Program. Similar initiatives in the pipeline

Al-Ahsa Colleges of Technology were provided with a targeted curriculum – focused on maintenance and repair of gas turbines, electrical motors and generators – as well as internships and cooperative learning experiences.

GE invests about $1 billion annually in training and leadership development programs worldwide, and GE’s Saudi employees can take advantage of that investment in several ways. For instance, there is supervisor and lead engine training at the Saudi Repair Development

include an internship program with Prince Mohammad Bin Fahd

In addition to our programs with KFUPM and PMBF, we also

Center (SRDP); on-the-job training

University (PMBF).

have a contract with the Human Resources Development Fund

at the engineer and technician

(HRDF) to support new graduates for up to three years.

levels from GE experts on short-

The GE Manufacturing Technology Center is GE’s largest commitment of this kind in the Kingdom. It advances localization

We develop talented Saudi professionals for GE from all walks

efforts with expanded job creation and on-the-job training, and its

of Saudi life, and they master a broad range of technical and

advanced training center will offer the latest energy technology

managerial skills. This includes people like Ahmad Al-Naim,

and managerial training. By 2015, as much as 65 percent of the

a combustion method engineer and mechanical engineering

center’s employees will be Saudis.

graduate of KFUPM, and Saleem Idrees Barnawi, a repair sales manager for the Western and Southern regions, with a similar

Talent Development Alliances and Joint Programs with Technical Colleges and Universities

degree from King Abdulaziz University. Says Ahmad, “GE provides great opportunities for Saudis to prepare themselves for a successful career with the company, right here at home. GE always tries to develop local talent and

Throughout the world and at several leading Saudi academic

help them become leaders for the future. Thus, Saudi Arabia will

institutions, GE forms alliances and joint programs with leading

benefit from local talent leaders to grow and be competitive in the

colleges, universities and institutes to educate and enhance

industry.”

employment prospects for young people in the communities where we operate.

Saleem concurs. “GE gives all the required tools for growth, and keeps focusing on investing in employees. Every day I learn

For instance, we established a training center in cooperation

something new, which is the great indication of continuing

with the Technical and Vocational Training Corporation

development within GE. By having the required skills and

(TVTC), and our first joint technical program with TVTC produced

knowledge, we can implement the most efficient solutions in Saudi.”

term assignments; continuous Lean Six Sigma action workouts for each component repair cell; Quality and Environment, Health and Safety (EHS) training; pre-production qualification of all processes and equipment by GE experts; global skill registration and certification; and ongoing Center of Excellence audit and training courses.

”I know how important this kind of training and education is, because GE has helped me develop my career ever since I joined GE 15 years ago. I know how much GE believes and invests in the Saudi nationals who join the GE family.” — Hisham Bahkali President and CEO, GE Saudi Arabia and Bahrain

Powering Saudi Arabia | Investing in People and Training 12

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Customized Technology Solutions Supportive working relationships meet customer needs

Many of GE’s award-winning solutions are tailored to the needs

Saudi Aramco

of our key customers in Saudi Arabia. Here are a few examples:

GE signed a long-term Corporate Procurement Agreement

Saudi Electricity Company (SEC) With more than 400 turbines installed at nearly 40 sites, GE and SEC have worked together for more than 40 years. Those turbines generate more than 20 GW of power, which is half of SEC’s installed capacity – and half of the Kingdom’s power supply.

(CPA) with Saudi Aramco, the Kingdom’s national oil company, to supply GE turbomachinery equipment and services to efficiently produce oil and gas in the Kingdom. The CPA includes a joint technology development program that is focused on enhancing the performance of Saudi Aramco’s installed fleet and covers more than 60 gas turbines, 90 compressors, and more than 100

There are 60 GE turbines at the Middle East’s largest combined-

pumps. Also, GE’s advanced power generation technology will

cycle power plant, SEC’s 4,000 MW Riyadh PP9, which supplies

expand Saudi Aramco’s Shaybah gas-oil processing facilities

35 percent of SEC’s Central region power generating capacity

in the remote south¬eastern section of the Kingdom and the

and is also the world’s largest power plant. GE will supply power

company’s Southern Area Seawater Capacity Expansion

generation equipment and long-term services to the new Riyadh

Project in Ghawar (the world’s largest oil field) and the Khurais oil

PP11 gas-fired, independent power plant, which will constitute

field. (To generate the additional 729 MW that Shaybah requires

15 percent of the power generation capacity in the Central

to increase its crude oil production to 1 million barrels per day,

region and add nearly 1,730 MW of power to SEC’s grid. GE also

GE is supplying 11 GE gas turbines, 44 compressors, motors

will boost power capacity in the Central region by 20 percent by

and services.) GE has more than 110 gas turbines and almost

supplying more than 30 Frame 7EA gas turbines for SEC’s Riyadh

100 centrifugal compressors in place to support Saudi Aramco

PP10. And, by adding five steam turbines to GE’s 15 F-technology

operations in the Kingdom.

turbines already in place at the Qurayyah Open Cycle Power Plant in Saudi Arabia’s Eastern Province, GE will convert the plant to combined-cycle operation. The conversion will increase the site’s power output from 1,907 to 3,148 MW—a boost that’s equivalent to 10 percent of the SEC’s installed capacity in the Eastern Province.

Saline Water Conversion Company For more than 20 years, GE has furnished our water and processing technologies and services from Shuqaiq to Shuaiba to support SWCC sites that provide freshwater in the Kingdom. The GE portfolio items installed at SWCC projects include world-class filters, membranes and chemicals for seawater and brackish water, electrodialysis reversal (EDR) technology for recovery and

Did you know:

reuse of saline water, reverse osmosis (RO) desalination systems,

The 1,000th F-class turbine built by GE now

and ZeeWeed* ultrafiltration (UF) systems for RO pretreatment.

generates power at Riyadh PP8.

Powering Saudi Arabia | Customized Technology Solutions 14

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Marafiq

Al Tamimi Group

International Medical Center, Jeddah

GE led the winning consortium for Marafiq IWPP, the world’s

Through the “GET WATER” partnership, GE has provided the

GE provided our advanced membrane bioreactor wastewater

largest independent water and power plant, in Jubail Industrial

Al Tamimi Group with more than 60 mobile water treatment

treatment system to treat and recycle 250 cubic meters of

City in Saudi Arabia’s Eastern Province. The project, for which

systems for rapid onsite treatment, reuse and filtration of both

wastewater per day for flush water and landscaping at this 300-

GE won Marafiq’s inaugural Award for Sustainability, will

seawater and brackish water. Each unit can treat up to 1,500

bed facility. The water exceeds cleanliness standards.

provide 2,700 MW of power (10 percent of the Kingdom’s total

cubic meters of water per day and be deployed in as little as 72

grid supply) and 800,000 cubic meters of desalinated water

hours. All told, GE delivers more than 180 million liters of clean

(20 percent of the country’s daily potable water) for industrial

water throughout the Kingdom each day.

and domestic use every day. Our solutions package includes advanced power generation technology and the Mark* Vle

Saudi Chevron Phillips Co. In Al-Jubail, GE supplied three compression trains for a largescale ethylene cracker plant in Al-Jubail that has an annual capacity of nearly 1.17 million tons.

integrated controls system for more flexible management

Saudi Basic Industries Corporation (SABIC)

of the project infrastructure.

GE has delivered advanced power generation equipment and services, as well as water process and treatment technology, to various SABIC sites for more than 30 years. We also recently established a Global Petrochemical Center of Excellence in the region to further support SABIC’s business activities.

Powering Saudi Arabia | Customized Technology Solutions 16

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Expanding the Resource Commitment Key investment initiatives promote innovation

GE Granite

its kind in the world, this center specializes in sensing product

With more than 40 people based in Saudi Arabia, GE Granite,

testing and calibration.

a subsidiary of GE, supports various infrastructure businesses

Abdulla Fouad Application Center, Dammam

with a variety of professionals, from service managers to field engineers and technicians, to provide effective operational execution, especially in Marafiq and at the GE Power & Technology Center. GE Granite also trains local employees to better understand GE technology.

technology to Saudi Arabia. While the GE Manufacturing Technology Center is at the core of that outreach, so are seven additional key initiatives, including five more critical facilities that hire the graduates of our education and training programs in the Kingdom. These multifaceted investments bring GE closer to our customers and make our operations more efficient. GE Saudi Water & Process Technology Center, Dammam GE invested nearly $10 million to establish the 7,500-squaremeter Water & Process Technology Center to provide water treatment solutions for local and regional customers. A joint venture with Al Tamimi Group, the center incorporates a blending plant for water treatment chemicals and offers advanced water, water reuse, wastewater and process solutions. GE Fuel Research Center, King Fahd University of Petroleum & Minerals, Dhahran The GE Fuel Research Center at King Fahd University of Petroleum & Minerals will coordinate several fuel-related research and development programs. These include potentially expanding the use of alternative fuels to address fuel issues, operating efficiency and emissions.

Powering Saudi Arabia | Expanding the Resource Commitment 18

carries a wide portfolio of inspection solutions and provides

GE-Al Tamimi Heat Exchanger Manufacturing Facility, Dammam

a subsidiary of the Arabian Company for Water and Power Development Ltd. (ACWA Holding), to assist the Kingdom in sustaining a reliable water supply and meeting wastewater management requirements. The MOU combines GE’s global water technology experience and expertise with Miahona’s established local presence and knowledge of regional water needs to provide a framework for promoting the use of advanced membrane technology, such as membrane bioreactors, in water reuse, and pursuing wastewater treatment, wastewater reuse, and zero liquid discharge projects in the Saudi Arabia.

companies can sell, service, and train in one place. The third of

is intensifying our commitment to bringing innovation and

oil and gas, aerospace, and power generation sectors. The center

GE has a memorandum of understanding (MOU) with Miahona,

Sensing Solutions Co. (SASSCO) Service Center, where the two

unflagging personnel support, and joint venture projects – GE

testing technology, which is applied throughout the region in the

customers with quick turnaround time for service-related issues.

GE and Ali A. Tamimi Co. have developed the Saudi Arabian

development facilities, institutional expertise, extensive and

only one of its kind in the region—is dedicated to non-destructive

GE-Miahona MOU

SASSCO Service Center, Dammam

Through a combination of resources – research and

The 460-square-meter Abdulla Fouad Application Center—the

GE and Al Tamimi will manufacture and test air-cooled heat exchangers for oil and gas industry applications in the Kingdom where a reliable source of water is unavailable. The joint venture, which combines Al Tamimi’s local engineering strength and GE’s global technology leadership, also serves Saudi customers with rigorous supply chain logistics and transportation and promotes Saudi Arabia’s growth through technology transfer and local workforce skills development.