Commissioning milestone in 2023 for innovative SeaGreen™ shore power system at the busy port of Brest, France.

The Brest ESID (Defence Infrastructure Service Establishment) has a new, unique Shore Power System equipped by GE Vernova’s Power Conversion business.

It is delivering critical electric power to ships in port. The equipment helps to significantly reduce the port’s carbon and noise emissions.

Shore power applications have very specific demands, including the ability to accommodate repeat, frequent cycles of connection and disconnection from shore to ship, so converters especially semiconductors must be robust. The GE Vernova technology is resilient to component failure, making it safe and reliable.

With its dynamic power management capability, Power Conversion’s system is particularly adaptive. The conversion systems can rapidly, automatically reconfigure for different ships berthed in port, without interruption to electrical power supply.

For example, if a dock needs more power than its allocated converter’s capacity, another converter automatically connects to ensure continuity of service. This feature gives extraordinary flexibility, protection and safety.

Providing 50:60Hz frequency conversion between the port main 20kV network and 6.6kV vessel power networks.

Frequency conversion is carried out by static frequency converter sets over two sites:

Site 1: set of four power conversion systems, each 3.55MVA
Site 2: set of two power conversion systems, each 3.55MVA

Each 50/60Hz converter system with capacitors includes:

• Transformer room for 24-pulse 4.4MVA input transformer,
• MV7315 static frequency converter comprising skid-mounted cabinets with:
  • 50/60Hz frequency conversion with integrated system automation
  • Voltage maintenance function via a DC/DC chopper with integrated automation and control
• Capacitive storage system,
• 4.1MVA output transformer installed in the transformer room,
• Effective air-cooling for heat dissipation of static converter losses,
• Control system cubicle alongside the converter PLC cabinet for user HMI functionality.

Safety & availability

• 20 KV protection, grid side of the frequency converter system.
• 6.6 KV protection between frequency converters and vessel.
• Capability to limit overcurrent with safe turn off under all operating and failure conditions.
• Voltage maintenance function with capacitive storage system maintains supply to the 60Hz vessel power network if there is a voltage dip on the 50Hz network.
• Vessel 60Hz power supply is maintained for a maximum power of 3.55MVA for a duration less than or equal to 500ms.
• Automation systems that synchronize, connect or disconnect converters developed, operated and tested successfully with vessels.

Freeport LNG, world largest all-electric liquefaction plant – Quintana Island, Texas, US

Freeport LNG, founded in 2002 and headquartered in Houston, is the world’s seventh largest LNG export company and the second largest in the United States. The company is focused on providing its customers with low carbon intensity LNG. 

In 2014, Freeport LNG received an authorization to construct a world-class natural gas liquefaction and liquefied natural gas export facility, designed to have a capacity to export 15.3 million metric tons per annum (MTPA), equivalent to approximately 2.2 billion standard cubic feet (Bscf) of gas per day.

As part of this project, GE Power Conversion was awarded a contract to provide Freeport LNG with all-electric drivers for the three trains of the liquefaction facility’s (LQF) refrigerant compressors.

With 675 MW total electric power installed, Freeport LNG is the world’s largest all-electric plant built to date.

Challenge

The Freeport LNG development project is bound by strict local environmental rules including emission standards. Electric power is available from the local grid removing the need to generate electricity, this led the company to select a full-electric technology over conventional steam or gas turbines solutions for the main refrigeration process.

Solution

The three liquefaction trains each comprise two entirely electrically driven refrigeration cycles. Three 75 MW complete electrical systems were then needed to drive the low-pressure mixed refrigerant (MR) compressor, the medium pressure and high-pressure MR compressors combined as well as the propane compressor.

Scope of supply

Each of the nine systems provided by GE Power Conversion includes:

• A 2-pole synchronous motor –75 MW – 3,000 rpm. This is the largest electric motor ever supplied for an LNG facility.
• A 96 MVA Step Down transformer consisting of 1 primary and 3 secondary 138 kV
• An e-house with all its utilities (HVAC, lighting, fire detection, etc.) accommodating:
  • 1 Variable Speed Drive (VSD) based on LCI technology
  • 1 low voltage distribution center (MCC) 480 VAC
  • 1 low voltage distribution center (PRC/LVD) 120 VAC, 125 VDC
  • 1 UPS AC and UPS DC power supply system
  • 1 harmonic filter composed of 4 ranks with its associated 13.8 kV switchgear

Extensive effort has been applied to modelling, understanding and analyzing torsional issues. The three compressor strings for Train 1 underwent complete full load and full speed string tests, with all auxiliaries, including string shaft torsional vibrations measurement.

Benefits

GE Power Conversion’s e-LNG drivers contribute to reduced emissions, shorter restarts, increased operating flexibility and improved efficiency and production.

• Reduction of site combustion emissions by 90%* (2), resulting in more savings on carbon taxes.
• Net production increase by over 6.5%* (2) – The use of electric power allows all the natural gas entering the facility to be turned into LNG.
• High flexibility, resulting in production increase – Thanks to a nearly constant amount of power throughout the year and fewer outage days, the eLNG plant can produce the equivalent of 10 to 15 days more of LNG per year (2.7% to 4.1 %)* (2).
  • Help achieve reduced performance loss due to high temperatures – the production loss for a given installed specific power is estimated to be less than 2% of production per 5°C ambient temperature increase* (1).
  • For the Freeport LNG project, GE Power Conversion’s electrical equipment is estimated to run 6 years before minor maintenance and 12 years before major one*.
• Maintenance cost reduction – the maintenance of an electric system is estimated to cost approximately 30% less than for a turbine* (1).
• Operational flexibility – Freeport LNG’s concept of three motors per train also separates control of two refrigeration loop compressors from each other, which simplifies overall liquefaction operation control. The propane refrigeration compressor rotating speed can be adjusted without necessarily affecting the MR compressors, since they are not coupled to the same driver.

* Data may vary depending on manufacturer, site particular conditions, and market conditions.

Looking at the future

The Freeport LNG facility commenced commercial export operations in December 2019 and reached full commercial operation when Train 3 completed startup on 1 May 2020. A fourth liquefaction train has received all regulatory approvals and a final decision should be made in early 2023, with operations expected to start in 2026 or 2027. This additional train is expected to increase the plant’s total liquefaction capacity to approximately 20.4 MTPA. Train 4 will also make use of all-electric drive technology.

Sources

(1) Vara, Roberto Ruiperez, and Mohammad Pouran. “Electric LNG.” (LNG Industry), no. April 2016 (n.d.): 37-40

(2) Roberto Ruiperez Vara – Freeport LNG, Lance Goodwin – Freeport LNG, William P. Schmidt – Air Products and Chemicals Inc., Robert P. Saunderson– Air Products and Chemicals Inc. “Freeport LNG’s Lessons Learned from All-Electric LNG Liquefaction Trains Start Ups” – Gastech Technical Conference | 21-23 September 2021

The Type 45 Destroyer, Daring (or 'D') Class, is the UK Royal Navy's state-of-the-art air defense destroyer. The class not only provides a step change in military capability, but also truly represents a landmark in power and propulsion with GE’s integrated, full electric power and propulsion.

Challenge
 

Enabling the backbone of naval air defense
The Type 45 Anti-Air Warfare Destroyers will provide the back bone of the Royal Navy's air defenses for the first half of the 21st century, replacing the ageing Type 42.

With state-of-the-art radar, weapons and electric propulsion she is billed as 'The world's most advanced warship'. Six of the class are built; the first of class, 'Daring', was launched in 2006 followed by the next five ships: Dauntless, Diamond, Dragon, Defender and Duncan.

With demanding mission scenarios a wide range of speed profiles and deployment of energy-hungry mission and defense systems, the challenge was to bring a novel and integrated approach to provision of power across the ship’s systems.

The Decision-Making Process
A decision conference to review the various propulsion systems proposed for the Type 45 was undertaken by the by the UK MOD with GE's Power Conversion business and other UK industry. The review compared the COGAL (Combined Gas and Electric) system with more classical fits as well as Integrated Full Electric Propulsion (IFEP).

The direct drive IFEP with fixed pitch propellers was selected as the best option in terms of through-life costs, performance and risk, recognizing the fact it would be by far the highest power, most compact, militarized IFEP package to go to sea.

Solution
 

High Power, Integrated Full Electric Power & Propulsion With a 4.16kV system and GE’s full electric propulsion fitted to a front-line combatant, integrated full electric propulsion (IFEP) has truly arrived in the naval arena.

• GE’s IFEP electric propulsion system is connected to four prime movers: two large-advanced cycle gas turbines powering 21MWe alternators and two 2MWe diesel generator sets.
• GE’s complete Ship’s Electric Grid for propulsion and on-board power is provided by Power Conversion's Advanced Induction Motors (AIM) and VDM25000 P\WM Converters providing 40MW of highly compact propulsion power without the use of heavy and bulky transformers or gearboxes.
• The power and propulsion system is operated from the Ship'sPlatform Management System via the Electric Power Management System (EPMS), supplied and fully integrated with the power system by Power Conversion.
• The two main HV switchboards are separated in the vessel and each connects 50% of the generation, propulsion and services in a symmetrical architecture.

A well-coordinated set of de-risking events formed part of Power Conversion's delivery under the Type 45 Contract. This included full power characterization of the propulsion system in a back-to-back test undertaken in 2004 in Power Conversion's factory, and a comprehensive PMS/EPMS combined test.

Integration testing included a complete, full scale and load half ship set of equipment at Power Conversion's land-based Marine Power Test Facility.

HMS Daring undertook her first sea trials in July 2007 and with an initial design target of 28 knots, the ship soon comfortably exceeded 30 knots and was proven to reach top speed in little over two minutes from a standing start, an outstanding performance for a ship of this size.
 

Benefits
 

Enabler of the ship’s mission:

• Although not the highest power IFEP ship at sea, Type 45 is by far the highest power relative to the ship's displacement – 40MW at just 7,500 tonnes. In comparison, a high-power, contemporary cruise liner, such as Queen Mary 2, has a power to weight ratio around 0.5MW/1000 tonnes; Type 45 has a ratio of 5.5MW/1000 tonnes, more than ten times higher, even at full military specification.
• In GE’s Ship’s Electric Grid, all main power is generated and managed at a substantial 4.16kV, which also forms the input voltage to the propulsion converters, removing the need for propulsion transformers.

Increased vessel safety:

• High redundancy a tall levels, quiet and shock-capable electrical drive trains. Physical separation configured to suit layout and survivability, connected only by electrical network.
• Enhanced availability, reliability and maintainability: Inherently robust power and propulsion plants.

Flexible, Frugal and Futureproof:

• 50% larger than the Type 42 Destroyer it replaced, but uses 45% less fuel.
• Through-life cost savings in fuel and maintenance, due to running optimum number of prime movers at optimum loadings to match power demand.
• Lowest number of installed prime movers compared with mechanical or hybrid.
• Easily adaptable to changing mission profiles, and future integration of low/zero emission power sources.
• Large amounts of installed electrical power can accommodate significant future increases in combat system loads such as weapons and radar with minimal impact.