Werksschrift Erfurt En

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    www.siemens.com/energy

    High-tech from Erfurt makes the world go round The Erfurt plant – Innovation center for generator technology

    Answers for energy.

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    A tradition of expertise The Erfurt generator plant has evolved remarkably since it 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 the world’s top research and development as well as produc- tion 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 Ger- man state of Thuringia.

    Ensuring a reliable energy mix 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 con- sumed 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 notice- ably to an ef ficient power supply through advanced technologies.

    Humming with energy

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

    1946: Contract between Thüringen- 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 state- owned enterprise “VEB Elektro-Reparatur- werk Erfurt”

    1951: Name changed to “VEB Reparaturwerk Clara Zetkin“

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    1961: Production hall expanded northward

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

    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 modern- ized 200 MW generator stand

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

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

    1996: First in-house construction of two-pole generators

    1998: Profit center with worldwide rights 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, 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

    The Erfurt plant – Facts and figures

    * As of December 31, 2011

    2004: Development and production of a new four-pole generator in only 12 months; market launch with 40 orders

    2005: Delivery of the250th generator

    2008: Delivery of the 500th generator

    2011: 20th anniversary of Siemens in the German state of Thuringia

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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 regis- tered 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 generat- ing 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 gener- ate 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 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. This is how the mechanical energy that acts on the rotor pro- duces 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 fre- quency 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 clock- maker’s precision. It is mechanically balanced and has to pass electrical as well as overspeed tests.

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    Masterpieces made in Erfurt Siemens is one of the world’s leading generator manufac- turers. 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 four- pole 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 capac- ity 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 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 are made of high-quality electro copper. The process of manu- facturing the bars requires precise knowledge of materials

    and extensive production experience. Erfurt supplies rods that are cooled with air, water, and hydrogen. They are in- stalled in the generators that are produced in Erfurt, as well as generators from other Siemens production sites, depend- ing 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.

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    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 pro- duces 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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    Crucial part of the Siemens global production network Generator technology from Erfurt makes an important contri- bution 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 out- side of Siemens work together, adhering to strict quality stan- dards 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