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

Answers for energy.

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 70 years 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 efficient 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“

Milestones from nearly 70 years of an eventful history

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 the 250th generator

2008: Delivery of the 500th generator

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

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Generating powerwith a generatorA 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 componentsStep 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 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 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 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 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 use on 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 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 tech-nology from Thuringia:

Andasol 2 solar-thermal power plant: Granada, Spain Generator type: SGen6-100A-2P Capacity: 61 MVA Voltage: 11 kV

Siemens locations Joint venture / strategic partner / licensee

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

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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 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 produc-tion site for generators. To keep it that way, great empha-sis 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 allow-ances, 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 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 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 wind-ing. 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 pro-duced 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 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 with the 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 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 profes-sional and vocational training. More than 30 train-ees 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

Materials tester

Toolmaker

Warehouse logistics specialist

Industrial mechanic

“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.

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Sustaining the region

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.

Professionals welcome new perspectives

The Erfurt generator plant offers its employees many opportunities 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 courses that are open to all, training and advanced training for 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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