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    www.siemens.com/energy

    High-tech from Erfurtmakes the world go roundThe Erfurt plant – Innovation center for generator technology

    Answers for energy.

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    A tradition of expertiseThe Erfurt generator plant has evolved remarkably sinceit was founded – an evolution in which employees consis-

    tently played an important role. Over the past nearly 70years now, they have been making the plant one of theworld’s top research and development as well as produc-tion facilities for air-cooled generators. Erfurt has alsobecome a competence center for manufacturing the statorwindings that are used in generators cooled with air, water,and hydrogen and for producing stator core laminations,brushless exciters, and slip ring shafts. Components andgenerators from Erfurt are shipped to power suppliers andcompanies all over the world. The Siemens Energy globalproduction network also relies on high-tech from the Ger-man state of Thuringia.

    Ensuring a reliable energy mixThanks to their high quality and reliability, generators fromErfurt 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 con-sumed in 2030 will still come from fossil fuels. Only abalanced mix of renewables – such as wind, solar, andhydroelectric power – and clean electricity from fossilsources will keep the supply of electricity secure evenas consumption increases. With its expertise, creativity,and experience, the team in Erfurt contributes notice-ably to an ef ficient power supply through advancedtechnologies.

    Humming with energy

    1945: Founded as the repair depart-ment of Thüringenwerk AG on the premisesof the press manufacturer Henry Pels Erfurt

    1946: Contract between Thüringen-werk AG and the Erfurt branches of AEGBerlin and Siemens Schuckert Berlin toprovide support and assistance for therepair department

    1948: Nationalized as the state-owned enterprise “VEB Elektro-Reparatur-werk Erfurt”

    1951: Name changed to“VEB Reparaturwerk Clara Zetkin“

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    1961: Production hallexpanded northward

    1978: Included as a branch of Ver-einigte Energiewerke AG (VEAG) Berlin

    1984: Construction start of the firstdirectly water-cooled stator winding withan epoxy resin-mica-glass insulation and aperformance of 220 MW

    1987: Delivery of the first newlyconstructed traction current converter

    1988: Delivery of the first modern-ized 200 MW generator stand

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    1991: Plant acquired by Siemens AG;production of four-pole generators basedon the design of the Berlin dynamo plant

    1993: Competence center for devel-oping and manufacturing air-cooled gener-ators; component supply to the SiemensPower Generation global network

    1996: First in-house construction oftwo-pole generators

    1998: Profit center with worldwiderights of sale

    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, manufactur-ing, quality management, quality assurance, andservice

    Production of two- and four-pole air-cooledgenerators

    Production of stator bars and stator core laminations

    Production of brushless exciters and slip ring shafts

    The Erfurt plant –Facts and figures

    * As of December 31, 2011

    2004: Development andproduction of a new four-polegenerator in only 12 months;market launch with 40 orders

    2005: Delivery of the250th generator

    2008: Delivery of the500th generator

    2011: 20th anniversaryof Siemens in the German stateof Thuringia

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    Generating powerwith a generatorA generator is an electric machine that converts mechanicalenergy into electric power. It operates on the basis of thedynamoelectric principle, that Werner von Siemens regis-tered for a patent with the first dynamo generator in 1867.It states that an electric generator does not need to haveelectric current supplied from the outside to start generat-ing electric power. A self-reinforcing electrical inductioncan take place due to the iron’s residual magnetism. Today,the mechanical excitation that a generator needs to gener-ate electricity is often provided by a turbine. It drives ashaft, which is known as the rotor. It rotates in the statorcore, in other words inside the generator. The rotor isequipped with an electromagnet, and the moving mag-netic field of the rotor causes a charge transfer in the con-ductor coils of the stator. The charge transfer generates

    electric voltage between the ends of the conductors. Thisis how the mechanical energy that acts on the rotor pro-duces electric energy – power – in the stator.

    Rotor and stator – a strong teamThe torque needed for the generator is transferred from theturbine to the rotor through the coupling. To reach a fre-quency of 50 Hz, it must rotate 3,000 times per minute –50 rotations per second – in the stator core. The centrifugalforces of a rotor that weighs as much as 65 metric tons andis up to 16 meters long are enormous. Every single rotor istested on a gigantic test stand and adjusted with a clock-maker’s precision. It is mechanically balanced and has topass electrical as well as overspeed tests.

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    Masterpieces made in ErfurtSiemens is one of the world’s leading generator manufac-turers. High-tech production methods and meticulousdetail work adapt every generator to customer requirements.Air-cooled two- and four-pole generators are built in Erfurtto state-of-the-art standards. The different number of polesrelates to the characteristics of the rotor and determinesthe frequency of the voltage produced by a generator.A gas or steam turbine drives the rotor. Two-pole and four-pole generators are produced in versions for the 50 Hz and60 Hz markets. The rotor speed of a two-pole generatormust be twice as high as the rotor speed of a four-polegenerator to reach the same frequency. The four-polegenerators made in Erfurt are very compact and canachieve ratings of up to 70 MVA. Thanks to their specialdesign, two-pole generators from Erfurt can achieve peak

    ratings of more than 300 MVA. Both generator types haveachieved world-class efficiency of almost 99 percent andcan be used to generate power for all applications – frompower plants to industrial facilities.

    More than 750 generators from Erfurt with a total capac-ity of almost 65,000 MVA are operating all over the world.Those generators together can supply electricity to almost65 million people, equivalent to the population of France.

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    Cutting-edge generatorcomponentsStep by step to high-tech productsErfurt is more than just a competence center for manufac-turing generators. It also develops and produces the indi-

    vidual components of a generator: stator bars, stator corelaminations, brushless exciters, and slip ring shafts.

    A stator winding consists of many stator bars. They aremade of high-quality electro copper. The process of manu-facturing the bars requires precise knowledge of materials

    and extensive production experience. Erfurt supplies rodsthat are cooled with air, water, and hydrogen. They are in-stalled in the generators that are produced in Erfurt, as wellas generators from other Siemens production sites, depend-ing on the type of cooling. This includes the MICALASTIC®GVPI (global vacuum pressure impregnation) insulationsystem that was developed by Siemens. A solvent-freeepoxy resin is used in this insulation system. It ensuresoutstanding electric, mechanical, and thermal properties.

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    The stator core laminations form the stator core, whichhas the stator winding fitted to it in grooves. Each year,gigantic punching machines and the laser cutting systemproduce ten million segment laminations, which are only0.65 millimeters thick. After the laminations are deburredand coated, robots stack 60,000 of the laminations intoone stator core, which weighs several tons.

    Brushless exciters are also developed and produced inErfurt. An exciter is a small auxiliary generator that pro-duces the necessary electric power to supply DC voltageto the rotors.

    Slip ring shafts are used in larger generators – like thoseproduced at the Siemens Mülheim/Ruhr plant – to supplyexternally generated DC to the rotor through brushes andslip rings.

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    Crucial part of the Siemensglobal production networkGenerator technology from Erfurt makes an important contri-bution to the success of a wide variety of different projectsaround the world. The Erfurt plant and its products also playan important role in the Siemens Energy global productionnetwork, in which selected partner companies inside and out-side of Siemens work together, adhering to strict quality stan-dards and offering maximum cost efficiency. The objective ofthe production network is to take advantage of synergies andto supply innovative, top-quality technology to customersall over the world at fair market prices. The Erfurt generator

    plant supplies components to all Siemens partner plants thatspecialize in generator production: Mülheim an der Ruhr inGermany, as well as Charlotte, North Carolina, and Fort Payne,Alabama, both in the United States.

    Quality counts all over the worldCutting-edge technology from the Erfurt plant is used to generatereliable energy supplies all over the world. Applications includecogeneration plants based on fossil fuels or combined gas andsteam power plants. Siemens generators made in Thuringia arealso in great demand for projects with high sustainability, suchas solar-thermal or biomass power plants, as well as for indus-

    trial applications and in the oil and gas industry.

    Erfurt electrifies the world

    Technology from Erfurt –proven all over the worldTwo- and four-pole generators made in Erfurt are in useon every continent, making a vital contribution to the

    efficiency of many different power plants and produc-tion facilities. The Prunéřov II steam power plant is thelargest in the Czech Republic, supplying 1,050 MW. It isnow the home of the most powerful two-pole generatorever made in Erfurt, with a capacity of 294 MVA andvoltage of 15.75 kV. The following sites also rely on tech-nology from Thuringia:

    Andasol 2 solar-thermal power plant:Granada, SpainGenerator type: SGen6-100A-2PCapacity: 61 MVAVoltage: 11 kV

    Siemens locations Joint venture / strategic par tner / licensee

    Las Flores gas-fired power plant:Barranquilla, Columbia

    Generator type: SGen6-100A-2PCapacity: 200 MVAVoltage: 16.5 kV

    BASF combined-cycle power plant:Ludwigshafen, GermanyGenerator type: SGen5-100A-2PCapacity: 112 MVAVoltage: 10.5 kV

    Stora Enso paper mill:Eilenburg, GermanyGenerator type: SGen5-100A-4PCapacity: 42 MVA

    Voltage: 10.5 kV8

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    Andasol 2 solar-thermal power plant – Granada, Spain

    Stora Enso paper mill – Eilenburg, GermanyBASF combined-cycle power plant – Ludwigshafen, Germany

    Las Flores gas-fired power plant – Barranquilla, Columbia

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    Always one step aheadthanks to mutual commitmentEmployees are the heart and soul

    The Erfurt generator plant has had an eventful historysince it was founded in October 1945. The facility is atechnological leader today primarily because of itsemployees. Their skills, talents, and dedication, as wellas their flexibility and passion for building, created a veryinnovative research and development as well as produc-tion site for generators. To keep it that way, great empha-sis is placed on the well-being of the employees who workat the generator plant. Finding the right balance betweenwork and family plays a decisive role. This is reflected bythe generator plant’s complete “service for families”,including a preschool and daycare center, childcare allow-ances, concessionary public transportation passes, andsocial services.

    Safety firstOccupational health and safety has always been a priority inErfurt. The “Sicherheit geht” safety project is setting a newstandard. The causes of accidents are jointly analyzed withemployees in manufacturing and corrected using an eight-step 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 ideasThe 3i program (ideas, impulses, and initiatives) promotessuggestions for improvement to make processes safer,simpler, and more efficient throughout the company.Prizes are awarded for suggestions that are successfullyimplemented. The program is very popular at the Erfurtgenerator plant. Many employee ideas and suggestionshave already been implemented. Plant management andthe Works Council hold special events like the annual raffleto encourage employees toward greater achievementsthrough the 3i program. One example is a project thatmakes it much safer and more efficient to transport statorbars from prefabrication to the fitting of the stator wind-ing. The transport used to be very time-consuming andthe path led through several narrow passages. It wouldhave been very difficult to apply the brakes to the vehiclethat carries the stator bars in an emergency. The passagewas remodeled and the room where stator bars are pro-duced is now directly connected to the winding room. Thestator bars are now transported simply, quickly, and safelyusing a crane. Plus, the remodeling reduced the timerequired for the transport by half.

    On-the-job fitnessHealth management at the location offers employees manyopportunities for active participation in health and wellness.These include courses on smoking cessation, mobile mas-sages, nutritional advice, back health and relaxation courses,and many athletic activities. Screenings to prevent cardio-vascular disease and strokes are held in conjunction withthe Siemens health insurance program. Medical care pro-vided by an on-site physician, a plant sports club, and dis-counts at fitness clubs all make important contributions toemployee health. Free flu vaccinations, vision screenings,and the popular soccer and bowling tournaments roundout health-related activities at the Erfurt generator plant.

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    A broad range of training opportunitiesSiemens has five locations in the German state ofThuringia, making it one of the largest industrialemployers there, and also one of the most important

    facilities for vocational training in the region. TheErfurt plant offers many opportunities for profes-sional and vocational training. More than 30 train-ees are currently participating in programs at theplant in the following areas:

    Bachelor of engineering in electronics andinformation technology

    Bachelor of Arts incl. IHK industrial manager

    Mechatronics technician

    Electronics technician for machine and drivetechnology / electronics technician for operating

    technology Cutting-machine operator

    Materials tester

    Toolmaker

    Warehouse logistics specialist

    Industrial mechanic

    “Dual” learning ensures comprehensiveexpertise

    Dual training teaches theory and practice at thesame time. It is a popular training method thatoffers interesting career opportunities. Peoplewho complete a dual course of study receiveeither the following degree or cer tification:

    “Bachelor of engineering in electronics andinformation technology”

    Chamber of Commerce vocational certificate asmechatronics technician, “Electronics technicianfor operating technology”

    This course of study was jointly developed by theLeipzig University of Applied Sciences (HTWK) andSiemens. Course units are held at the Siemens trainingcenters parallel to lectures, practical training, andexercises at the HTWK and are tailored to activitiesthere.

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    Sustaining the regionThe Erfurt generator plant is one of the largest employersin the city, with almost 800 employees – and that numberis rising. To strengthen the region over the long term, theplant 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, givingcredit where credit is due to suppliers from the region.Another positive effect of this sourcing policy: Transportover shorter distances is better for the environment.

    Professionals welcome new perspectivesThe Erfurt generator plant offers its employees manyopportunities for personal and professional develop-ment outside of their daily work. In-house and exter-nal education and advanced training confer new qual-ifications that can give careers a considerable boost.

    The wide range of choices includes English coursesthat are open to all, training and advanced trainingfor first responders and fire wardens, various educa-tional opportunities in specific fields, and the possibil-ity of working at another Siemens location for a time.

    “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 AGEnergy SectorFreyeslebenstrasse 191058 Erlangen, Germany

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    All rights reserved.Trademarks mentioned in this documentare the property of Siemens AG, its affiliates,or their respective owners.

    Subject to change without prior notice.The information in this document containsgeneral descriptions of the technical optionsavailable, which may not apply in all cases.The required technical options should thereforebe specified in the contract.