High-tech from Erfurt
makes the world go round
The Erfurt plant – Innovation center for generator technology
www.siemens.com/energy
Answers for energy.
Humming with energy
A tradition of expertise
Ensuring a reliable energy mix
The Erfurt generator plant has evolved remarkably since
it was founded – an evolution in which employees consistently played an important role. Over the past nearly 70
years now, they have been making the plant one of the
world’s top research and development as well as production facilities for air-cooled generators. Erfurt has also
become a competence center for manufacturing the stator
windings that are used in generators cooled with air, water,
and hydrogen and for producing stator core laminations,
brushless exciters, and slip ring shafts. Components and
generators from Erfurt are shipped to power suppliers and
companies all over the world. The Siemens Energy global
production network also relies on high-tech from the German state of Thuringia.
Thanks to their high quality and reliability, generators from
Erfurt are making a significant contribution to ensuring
that the world’s current and future energy needs are met.
Forecasts indicate that about half of the electricity consumed in 2030 will still come from fossil fuels. Only a
balanced mix of renewables – such as wind, solar, and
hydroelectric power – and clean electricity from fossil
sources will keep the supply of electricity secure even
as consumption increases. With its expertise, creativity,
and experience, the team in Erfurt contributes notice­ably to an efficient power supply through advanced
technologies.
Milestones from nearly 70 years of an eventful history
1945:
Production hall
expanded northward
1946: Contract between Thüringen-
Included as a branch of Vereinigte Energiewerke AG (VEAG) Berlin
werk AG and the Erfurt branches of AEG
Berlin and Siemens Schuckert Berlin to
provide support and assistance for the
repair department
1948:
Nationalized as the stateowned enterprise “VEB Elektro-Reparaturwerk Erfurt”
1951:
Name changed to
“VEB Reparaturwerk Clara Zetkin“
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1961:
Founded as the repair department of Thüringenwerk AG on the premises
of the press manufacturer Henry Pels Erfurt
1978:
1984:
Construction start of the first
directly water-cooled stator winding with
an epoxy resin-mica-glass insulation and a
performance of 220 MW
1987:
Delivery of the first newly
­constructed traction current converter
1988:
Delivery of the first modernized 200 MW generator stand
The Erfurt plant –
Facts and figures
Approximately 115,000 square meters in size*
More than 800 employees*
More than 30 trainees in eight training disciplines*
Comprehensive knowledge on-site: purchasing, sales,
research and development, engineering, manufacturing, quality management, quality assurance, and
service
Production of two- and four-pole air-cooled
generators
Production of stator bars and stator core laminations
Production of brushless exciters and slip ring shafts
* As of December 31, 2011
1991:
Plant acquired by Siemens AG;
production of four-pole generators based
on the design of the Berlin dynamo plant
1993:
2004:
Development and
production of a new four-pole
generator in only 12 months;
market launch with 40 orders
Competence center for developing and manufacturing air-cooled generators; component supply to the Siemens
Power Generation global network
Delivery of the
250th generator
1996: First in-house construction of
Delivery of the
500th generator
1998: Profit center with worldwide
20th anniversary
of Siemens in the German state
of Thuringia
two-pole generators
rights of sale
2005:
2008:
2011:
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Generating power
with a generator
A generator is an electric machine that converts mechanical
energy into electric power. It operates on the basis of the
dynamoelectric principle, that Werner von Siemens registered for a patent with the first dynamo generator in 1867.
It states that an electric generator does not need to have
electric current supplied from the outside to start generating electric power. A self-reinforcing electrical induction
can take place due to the iron’s residual magnetism. Today,
the mechanical excitation that a generator needs to generate electricity is often provided by a turbine. It drives a
shaft, which is known as the rotor. It rotates in the stator
core, in other words inside the generator. The rotor is
equipped with an electromagnet, and the moving magnetic field of the rotor causes a charge transfer in the conductor coils of the stator. The charge transfer generates
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electric voltage between the ends of the conductors. This
is how the mechanical energy that acts on the rotor produces electric energy – power – in the stator.
Rotor and stator – a strong team
The torque needed for the generator is transferred from the
turbine to the rotor through the coupling. To reach a frequency of 50 Hz, it must rotate 3,000 times per minute –
50 rotations per second – in the stator core. The centrifugal
forces of a rotor that weighs as much as 65 metric tons and
is up to 16 meters long are enormous. Every single rotor is
tested on a gigantic test stand and adjusted with a clockmaker’s precision. It is mechanically balanced and has to
pass electrical as well as overspeed tests.
Masterpieces made in Erfurt
Siemens is one of the world’s leading generator manufacturers. High-tech production methods and meticulous
detail work adapt every generator to customer requirements.
Air-cooled two- and four-pole generators are built in Erfurt
to state-of-the-art standards. The different number of poles
relates to the characteristics of the rotor and determines
the frequency of the voltage produced by a generator.
A gas or steam turbine drives the rotor. Two-pole and fourpole generators are produced in versions for the 50 Hz and
60 Hz markets. The rotor speed of a two-pole generator
must be twice as high as the rotor speed of a four-pole
generator to reach the same frequency. The four-pole
generators made in Erfurt are very compact and can
achieve ratings of up to 70 MVA. Thanks to their special
design, two-pole generators from Erfurt can achieve peak
ratings of more than 300 MVA. Both generator types have
achieved world-class efficiency of almost 99 percent and
can be used to generate power for all applications – from
power plants to industrial facilities.
More than 750 generators from Erfurt with a total capacity of almost 65,000 MVA are operating all over the world.
Those generators together can supply electricity to almost
65 million people, equivalent to the population of France.
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Cutting-edge generator
components
Step by step to high-tech products
Erfurt is more than just a competence center for manufacturing generators. It also develops and produces the individual components of a generator: stator bars, stator core
laminations, brushless exciters, and slip ring shafts.
A stator winding consists of many stator bars. They are
made of high-quality electro copper. The process of manufacturing the bars requires precise knowledge of materials
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and extensive production experience. Erfurt supplies rods
that are cooled with air, water, and hydrogen. They are installed in the generators that are produced in Erfurt, as well
as generators from other Siemens production sites, depending on the type of cooling. This includes the MICALASTIC®
GVPI (global vacuum pressure impregnation) insulation
system that was developed by Siemens. A solvent-free
epoxy resin is used in this insulation system. It ensures
outstanding electric, mechanical, and thermal properties.
The stator core laminations form the stator core, which
has the stator winding fitted to it in grooves. Each year,
gigantic punching machines and the laser cutting system
produce ten million segment laminations, which are only
0.65 millimeters thick. After the laminations are deburred
and coated, robots stack 60,000 of the laminations into
one stator core, which weighs several tons.
Brushless exciters are also developed and produced in
Erfurt. An exciter is a small auxiliary generator that produces the necessary electric power to supply DC voltage
to the rotors.
Slip ring shafts are used in larger generators – like those
produced at the Siemens Mülheim/Ruhr plant – to supply
externally generated DC to the rotor through brushes and
slip rings.
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Erfurt electrifies the world
Crucial part of the Siemens
global production network
Generator technology from Erfurt makes an important contribution to the success of a wide variety of different projects
around the world. The Erfurt plant and its products also play
an important role in the Siemens Energy global production
network, in which selected partner companies inside and outside of Siemens work together, adhering to strict quality standards and offering maximum cost efficiency. The objective of
the production network is to take advantage of synergies and
to supply innovative, top-quality technology to customers
all over the world at fair market prices. The Erfurt generator
plant supplies components to all Siemens partner plants that
specialize in generator production: Mülheim an der Ruhr in
Germany, as well as Charlotte, North Carolina, and Fort Payne,
Alabama, both in the United States.
Quality counts all over the world
Cutting-edge technology from the Erfurt plant is used to generate
reliable energy supplies all over the world. Applications include
cogeneration plants based on fossil fuels or combined gas and
steam power plants. Siemens generators made in Thuringia are
also in great demand for projects with high sustainability, such
as solar-thermal or biomass power plants, as well as for industrial applications and in the oil and gas industry.
Siemens locations
Joint venture / strategic partner / licensee
Technology from Erfurt –
proven all over the world
Two- and four-pole generators made in Erfurt are in use
on every continent, making a vital contribution to the
efficiency of many different power plants and production facilities. The Prunéřov II steam power plant is the
largest in the Czech Republic, supplying 1,050 MW. It is
now the home of the most powerful two-pole generator
ever made in Erfurt, with a capacity of 294 MVA and
voltage of 15.75 kV. The following sites also rely on technology from Thuringia:
Andasol 2 solar-thermal power plant:
Granada, Spain
Generator type: SGen6-100A-2P
Capacity: 61 MVA
Voltage: 11 kV
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Las Flores gas-fired power plant:
Barranquilla, Columbia
Generator type: SGen6-100A-2P
Capacity: 200 MVA
Voltage: 16.5 kV
BASF combined-cycle power plant:
Ludwigshafen, Germany
Generator type: SGen5-100A-2P
Capacity: 112 MVA
Voltage: 10.5 kV
Stora Enso paper mill:
Eilenburg, Germany
Generator type: SGen5-100A-4P
Capacity: 42 MVA
Voltage: 10.5 kV
Andasol 2 solar-thermal power plant – Granada, Spain
Las Flores gas-fired power plant – Barranquilla, Columbia
BASF combined-cycle power plant – Ludwigshafen, Germany
Stora Enso paper mill – Eilenburg, Germany
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Always one step ahead
thanks to mutual commitment
Employees are the heart and soul
The Erfurt generator plant has had an eventful history
since it was founded in October 1945. The facility is a
technological leader today primarily because of its
employees. Their skills, talents, and dedication, as well
as their flexibility and passion for building, created a very
innovative research and development as well as production site for generators. To keep it that way, great emphasis is placed on the well-being of the employees who work
at the generator plant. Finding the right balance between
work and family plays a decisive role. This is reflected by
the generator plant’s complete “service for families”,
including a preschool and daycare center, childcare allowances, concessionary public transportation passes, and
social services.
Safety first
Occupational health and safety has always been a priority in
Erfurt. The “Sicherheit geht” safety project is setting a new
standard. The causes of accidents are jointly analyzed with
employees in manufacturing and corrected using an eightstep plan. The program includes team competitions, training
sessions, seminars, and other activities. The objective:
to make the Erfurt generator plant accident-free.
The future needs ideas
The 3i program (ideas, impulses, and initiatives) promotes
suggestions for improvement to make processes safer,
simpler, and more efficient throughout the company.
Prizes are awarded for suggestions that are successfully
implemented. The program is very popular at the Erfurt
generator plant. Many employee ideas and suggestions
have already been implemented. Plant management and
the Works Council hold special events like the annual raffle
to encourage employees toward greater achievements
through the 3i program. One example is a project that
makes it much safer and more efficient to transport stator
bars from prefabrication to the fitting of the stator winding. The transport used to be very time-consuming and
the path led through several narrow passages. It would
have been very difficult to apply the brakes to the vehicle
that carries the stator bars in an emergency. The passage
was remodeled and the room where stator bars are produced is now directly connected to the winding room. The
stator bars are now transported simply, quickly, and safely
using a crane. Plus, the remodeling reduced the time
required for the transport by half.
On-the-job fitness
Health management at the location offers employees many
opportunities for active participation in health and wellness.
These include courses on smoking cessation, mobile massages, nutritional advice, back health and relaxation courses,
and many athletic activities. Screenings to prevent cardiovascular disease and strokes are held in conjunction with
the Siemens health insurance program. Medical care provided by an on-site physician, a plant sports club, and discounts at fitness clubs all make important contributions to
employee health. Free flu vaccinations, vision screenings,
and the popular soccer and bowling tournaments round
out health-related activities at the Erfurt generator plant.
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A broad range of training opportunities
Siemens has five locations in the German state of
Thuringia, making it one of the largest industrial
employers there, and also one of the most important
facilities for vocational training in the region. The
Erfurt plant offers many opportunities for professional and vocational training. More than 30 trainees are currently participating in programs at the
plant in the following areas:
Bachelor of engineering in electronics and
information technology
Bachelor of Arts incl. IHK industrial manager
Mechatronics technician
Electronics technician for machine and drive
technology / electronics technician for operating
technology
Cutting-machine operator
“Dual” learning ensures comprehensive
expertise
Dual training teaches theory and practice at the
same time. It is a popular training method that
offers interesting career opportunities. People
who complete a dual course of study receive
either the following degree or certification:
“Bachelor of engineering in electronics and
information technology”
Chamber of Commerce vocational certificate as
mechatronics technician, “Electronics technician
for operating technology”
This course of study was jointly developed by the
Leipzig University of Applied Sciences (HTWK) and
Siemens. Course units are held at the Siemens training
centers parallel to lectures, practical training, and
exercises at the HTWK and are tailored to activities
there.
Materials tester
Toolmaker
Warehouse logistics specialist
Industrial mechanic
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Professionals welcome new perspectives
Sustaining the region
The Erfurt generator plant offers its employees many
opportunities for personal and professional development outside of their daily work. In-house and external education and advanced training confer new qualifications that can give careers a considerable boost.
The wide range of choices includes English courses
that are open to all, training and advanced training
for first responders and fire wardens, various educational opportunities in specific fields, and the possibility of working at another Siemens location for a time.
The Erfurt generator plant is one of the largest employers
in the city, with almost 800 employees – and that number
is rising. To strengthen the region over the long term, the
plant sources many products from the area around Erfurt,
as well as the state of Thuringia. Every generator from
Erfurt carries the Quality from Thuringia label, giving
credit where credit is due to suppliers from the region.
Another positive effect of this sourcing policy: Transport
over shorter distances is better for the environment.
“The generator plant in Erfurt is a very special location for our company.
The generators that are manufactured here are an impressive example of high-tech made in Thuringia.”
Peter Löscher, President and CEO of Siemens
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Published by and copyright © 2012:
Siemens AG
Energy Sector
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