Power from Berlin to the World
The Gas Turbine Plant Berlin – a success story in cutting-edge technology
www.siemens.com/powergeneration
One site,
many
competences
High-tech gas turbines from Berlin Moabit are in
operation in power plants all around the world.
At this traditional location, where turbines have
been manufactured for over 100 years, 3,700
employees work in engineering, on the production line, in test centers, and in service.
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Facts, Figures, Data
A bout 3,700 employees from more
than 45 nations
Over 250 technical and commercial
trainees
Over 100 students in dual study
programs
Around 130,000 m2 of facility space
in the Moabit district of Berlin
Further production, testing, service
and storage facilities in Berlin
Siemensstadt, Berlin Tegel and
Ludwigsfelde (Brandenburg)
Co-location of production competency and service expertise
First gas turbine for power plants
delivered in 1972
More than 950 gas turbines sold
in more than 60 countries
Products for the world’s most efficient power plants
More than
100 years of
experience in
cutting-edge
technology
– the success
story continues
Ultimate heavy duty. For over 40 years,
giant rotating machines have been coming off the production line in Berlin Moabit
for operation in simple and combinedcycle power plants. Gas turbine components must withstand an aggressive
operational environment where they are
exposed to extremely high combustion
temperatures and large centrifugal forces
as well as vibration and transient stress.
Customer-focused quality assurance.
The Gas Turbine Plant Berlin has one of
the most modern and highest-capacity
test beds in the world, which allows test
run loads of up to 330 megawatts (MW).
Not only prototypes of next-generation
gas turbines but also advanced designs
of individual gas turbine components
can be tested under realistic conditions.
By virtue of its independence from the
public power grid, the test bed allows
shorter test phases and accelerates
release of prototypes and advanced gas
turbine components for series production and retrofit installation in units that
are already in service.
Intensive research with real prospects.
One of the outstanding projects of the
engineering organization is the operation of a burner test center at Ludwigsfelde in Brandenburg, where combustion
experiments are conducted using natural gas and oil fuels. Synthetic fuels will
also be tested in the future. Current
burner technologies are continuously
being improved and new burner designs
are being developed, which will lead to
increased efficiency and will further
reduce emissions from gas turbines.
Competency for the future. Before the
test series, the gas turbines are comprehensively instrumented, which allows
greater quantities of data from more
instruments than is necessary for the
power plant during normal operation.
The various research and development
activities overseen by the Gas Turbine
Plant Berlin – in the test bed, in the
burner test center or during testing at
customer’s plant – lay the foundations
for developing the gas turbines of the
future.
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Professional,
global, close to
the customer
The Gas Turbine Plant Berlin serves customers
in more than 60 countries around the world.
Its service experts provide customers with
expert and comprehensive advice throughout
the entire service life of power plants. This
enables more profitable operation of power
plants and, at the same time, prepares customers
to adapt to changing demands in the future.
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A worldwide service network exists to
support power plant owners and operators in the drive to sustain the long-term
reliability and availability of assets. Individually-customized long-term maintenance and servicing concepts also ensure
optimum performance of power plants.
Field Service. Siemens’ Field Service organization manages the on-site installation,
commissioning and maintenance of gas
turbines, as well as steam turbines, generators and ancillary systems. Modernization and upgrade solutions can be
integrated into the Field Service scope
of work to allow older plants to profit
from the latest technology, increasing
their output, efficiency, and responsiveness while also reducing emissions. The
benefit for the customers is immense:
power plants can be upgraded to the
state of the art with comparatively little
effort and expense and can thereby be
better equipped to cope with current
and future market demands.
Field Service Training and Repair Center.
Field Service has its own training center
where experts give customers’ and inhouse Service employees basic and
advanced training in the assembly and
installation of gas turbines under realistic conditions.
Ludwigsfelde Logistics Center. The
Ludwigsfelde Logistics Center stocks
more than 30,000 replacement parts for
gas turbines – on call at any time for the
fastest possible delivery. More than two
million spare and replacement parts are
sent to customers every year: from the
smallest items weighing less than an
ounce up to casing sections that each
weigh as much as several hundred tons.
This service assures customers of maximum reliability and availability.
Power Diagnostics Technology Center.
The Power Diagnostics Technology Center
provides remote monitoring of power
plants for customers with long-term
maintenance agreements. This involves
recording and evaluating the on-line
operating data from the plants around
the clock. The benefit for customers is
that any deviations from normal running behavior can be identified quickly
and any necessary repairs can be scheduled and implemented early. The Power
Diagnostics Technology Centers in Berlin,
Erlangen, Muelheim and Orlando keep
a watchful eye on over 600 power plants
around the world.
Innovative
service for
flexibility and
sustainability
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Award-winning,
world-recordholding
gas turbines
The Gas Turbine Plant Berlin produces gas turbines
with ratings from 114 to 400 MW for the 50- and
60-Hertz markets. Since the first gas turbine was
delivered to a customer plant in 1972, more than
950 units have been delivered. Continuous evolution of production methods and introduction of
innovative materials ensures that the gas turbines
produced in Berlin meet customers’ high expectations in terms of profitability, flexibility and sustainability. Today, the manufacturing plant produces
award-winning gas turbines, among them the most
powerful gas turbine in the world.
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Gas turbines combine traditional
heavy duty mechanical engineering with ultra-modern production
technology in a unique way. They
convert heat from combustion of
liquid or gaseous fuels into rotational kinetic energy. As the core
component of the gas turbine, the
rotor – which turns at 3,000 or 3,600
revolutions per minute depending
on the grid frequency – must transmit this mechanical power to the
generator. Thanks to innovative
designs such as ceramic heat
shields, sophisticated materials
and advanced cooling systems for
turbine blades, temperatures of up
to 1,500 °C can be reached in the
turbine inlet section. Over 60% efficiency can be achieved in combined
cycle operation.
Core competencies and long-term
experiences at a glance
High availability and reliability
High flexibility in operation
Efficient and low emissions
Low lifecycle costs
Easy maintenance
Long inspection intervals
SGT5-2000E
Rated power output: 172 MW / 253 MW*
Efficiency: 35.3% / 52.5%*
Weight: 216 t
Robust design, multi-fuel capability
First commissioned in 1981
> 240
engines sold
> 15,000,000 EOH **
Operating experience
> 260,000 EOH
Fleet leading gas turbine
SGT6-2000E
Rated power output: 114 MW / 171 MW
Efficiency: 34.3% / 51.3%
Weight: 163 t
Robust design, multi-fuel capability
First commissioned in 1989
> 100
engines sold
> 5,900,000 EOH
Operating experience
> 170,000 EOH
Fleet leading gas turbine
SGT5-4000F
Rated power output: 307 MW / 445 MW
Efficiency: 40.0% / 58.7%
Weight: 312 t
F
ast startup and shutdown as well as fast
load changes
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> 300
engines sold
> 10,000,000 EOH
Operating experience
First commissioned in 1996
> 140,000 EOH
* Configuration combined cycle 1x1
** Equivalent operating hours
Fleet leading gas turbine
SGT6-5000F
Rated power output: 232 MW / 345 MW
Efficiency: 38.8% / 57.6%
Weight: 193 t
V
ery low emissions: NOX and CO emissions
in the single-digit range
First commissioned in 1993
> 350
engines sold
> 9,400,000 EOH
Operating experience
> 170,000 EOH
Fleet leading gas turbine
German Business Innovation Award
2011 Winner in the category: Large enterprises
SGT5-8000H
Rated power output: 400 MW / 600 MW
Efficiency: 40% / > 60%
Weight: 390 t
F
ast startup and shutdown and highly
flexible in operation
First commissioned in 2008
Berlin-Brandenburg Innovation Award
> 10
2008Development of materials and production of
ceramic heat shields for gas turbine combustion chambers
engines sold
> 16,000 EOH
Operating experience
> 16,000 EOH
Guinness Book of Records
Fleet leading gas turbine
2007SGT5-8000H – world’s biggest gas turbine
1996SGT6-4000F – for 38% efficiency
SGT6-8000H
Rated power output: 274 MW / 410 MW
Efficiency: 40% / > 60%
Weight: 286 t
F
ast startup and shutdown and highly
flexible in operation
Fast hot start
First commissioned in 2011
Awards won by the SGT5-8000H
> 25
2011German Industry’s Innovation Award;
prize for the world’s most efficient power
plant (Ulrich Hartmann Power Plant)
engines sold
> 65,000 EOH
2010German Innovation Award for Climate and
Environment
Operating experience
> 7,000 EOH
2010Bavarian Energy Award for the Ulrich
Hartmann Power Plant
Fleet leading gas turbine
2009German Steel Innovation Award for “Climate
Protection with Steel” (special award)
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Focus
on
people
Our dedicated and creative employees are
the key to our ongoing success. They drive
quality and innovation at the Gas Turbine
Plant Berlin. Their expertise, experience and
inventiveness push our products forward.
Therefore, recruiting qualified, talented and
motivated employees is crucial for the continuing success of our site.
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Advantage through know-how. Around
3,700 designers, engineers, technicians
and service experts join forces at the Gas
Turbine Plant Berlin. Their skills, their
creativity and their experience drive innovation and are the key factors for continuing success. Each individual shows
outstanding commitment – and each of
them plays an important role in securing
the future of our site.
Theory and practice. There is a long history of training and promoting young
talents at our site. Every year about 150
talented new employees begin apprenticeships and dual study programs at
the Gas Turbine Plant Berlin. In particular, students of engineering disciplines
gain valuable insights into the design,
manufacturing and service of advanced
gas turbines.
Development and research. We know
that complex technologies call for sound
expertise. Siemens continuously invests
in the development of people and relationships to support our aims. Cooperation with universities and research institutes as well as providing numerous
apprenticeships is the foundation upon
which our continuing success is built.
Benefits for life. Siemens has always
assumed responsibility for its employees
and attaches great importance to their
working conditions. In a constantly
changing working environment, maintaining work-life balance takes high
priority. Siemens takes an active interest
in assisting its staff in balancing work
commitments with their personal and
family lives.
Shaping
cutting-edge
technology of
the future
with leading
specialists
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Tradition
and
modernity
Turbines have been built at the Moabit plant since
1904. An era of manufacturing steam turbines for
industrial applications, power plants and for marine
propulsion was followed by a shift to the production of gas turbines for power plants. Then, as now,
these advanced turbines are destined for customers
around the world.
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Milestones in
cutting-edge
technology
– more than
one century
of gas turbine
production
in Berlin
The AEG turbine factory. On February 27,
1904, “Allgemeine Elektricitäts-Gesellschaft” (AEG) founded its turbine factory
on the site that is still in operation today.
The facility mainly produced steam turbines for industrial applications, power
plants and for marine propulsion. At
first, the output of the steam turbines
was less than 1 MW – rising within just
25 years to what was then a record value
of 85 MW. In the 1920s and 30s, the
factory also manufactured marine diesel
engines. After the Second World War, the
workforce almost completely rebuilt the
factory for the repair of public transport
vehicles and bridges, before the production of steam turbines and generators
was resumed on a regular basis in 1948.
A cathedral of labor. The Gas Turbine
Plant Berlin is world-famous among architects for its assembly bay. Designed in
1909 by Peter Behrens (1868–1940) on
the basis of structural calculations prepared by Karl Bernhard (1859–1937),
this revolutionary example of industrial
architecture was celebrated by contemporaries as resembling an “iron church”
or a “cathedral of labor”. Protected as a
historic landmark since 1969, the hangarshaped building still serves its original
purpose: the construction of turbines.
Other buildings where high-tech components are still being produced are as well
under protection as historic landmarks.
The Siemens AG Gas Turbine Plant Berlin.
The manufacture of gas turbines at the
Berlin site began back in 1969, when
AEG and Siemens merged their power
plant activities in the subsidiary Kraftwerk Union (KWU). During this merger,
the steam turbine construction was
relocated to Muelheim / Ruhr. Since 1977,
the Gas Turbine Plant Berlin has exclusively been a Siemens site and delivers
cutting-edge technology to customers
worldwide.
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Published by and copyright © 2014:
Siemens AG
Power and Gas Division
Freyeslebenstrasse 1
91058 Erlangen, Germany
For more information, please contact our
Customer Support Center.
Phone: +49 180 524 70 00
Fax:
+49 180 524 24 71
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