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Power from Berlin to the WorldThe Gas Turbine Plant Berlin – a success story in cutting-edge technology

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One site, many competencesHigh-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 produc-tion line, in test centers, and in service.

Facts, Figures, Data

� About 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 compe-tency 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 effi-cient 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 com-ing off the production line in Berlin Moabit for operation in simple and combined-cycle power plants. Gas turbine compo-nents 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 produc-tion 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 opera-tion of a burner test center at Ludwigs-felde in Brandenburg, where combustion experiments are conducted using natu-ral 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 compre-hensively 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 opera-tors in the drive to sustain the long-term reliability and availability of assets. Indi-vidually-customized long-term mainte-nance and servicing concepts also ensure optimum performance of power plants.

Field Service. Siemens’ Field Service orga-nization manages the on-site installation, commissioning and maintenance of gas turbines, as well as steam turbines, gen-erators and ancillary systems. Modern-ization 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 responsive-ness 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 in-house Service employees basic and advanced training in the assembly and installation of gas turbines under realis-tic 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 maxi-mum 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 run-ning behavior can be identified quickly and any necessary repairs can be sched-uled 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-record-

holding 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 evolu-

tion of production methods and introduction of innovative materials ensures that the gas turbines produced in Berlin meet customers’ high expecta-tions in terms of profitability, flexibility and sus-

tainability. Today, the manufacturing plant produces award-winning gas turbines, among them the most

powerful gas turbine in the world.

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*Configuration combined cycle 1x1 ** Equivalent operating hours

Core competencies and long-term experiences at a glance

Gas turbines combine traditional heavy duty mechanical engineer-ing with ultra-modern production technology in a unique way. They convert heat from combustion of liquid or gaseous fuels into rota-tional 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 trans-mit 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% effi-ciency can be achieved in combined cycle operation.

� Rated power output: 172 MW / 253 MW*

� Efficiency: 35.3 % / 52.5%*

� Weight: 216 t

� Robust design, multi-fuel capability

� First commissioned in 1981

SGT5-2000E

engines sold

> 240

operating experience

> 15,000,000 EOH**

Fleet leading gas turbine

> 260,000 EOH

SGT5-4000F

� Rated power output: 307 MW / 445 MW

� Efficiency: 40.0% / 58.7%

� Weight: 312 t

� Fast startup and shutdown as well as fast load changes


engines sold

> 300


> 10,000,000 EOH


> 140,000 EOH

�High availability and reliability

�High flexibility in operation

�efficient and low emissions

�low lifecycle costs

�easy maintenance

�long inspection intervals

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SGT6-2000E


� Efficiency: 34.3% / 51.3%

� Weight: 163 t

� Robust design, multi-fuel capability


engines sold

> 100


> 5,900,000 EOH


> 170,000 EOH

15

SGT6-5000F


� Efficiency: 38.8% / 57.6%

� Weight: 193 t

� Very low emissions: NOX and CO emissions in the single-digit range


engines sold

> 350


> 9,400,000 EOH


> 170,000 EOH

SGT5-8000H


� Efficiency: 40% / > 60%

� Weight: 390 t

� Fast startup and shutdown and highly flexible in operation


engines sold

> 10


> 16,000 EOH


> 16,000 EOH

SGT6-8000H


� Efficiency: 40% / > 60%

� Weight: 286 t

� Fast startup and shutdown and highly flexible in operation

� Fast hot start


engines sold

> 25


> 65,000 EOH


> 7,000 EOH

German Business Innovation Award

2011 Winner in the category: Large enterprises

Berlin-Brandenburg Innovation Award

2008 Development of materials and production of ceramic heat shields for gas turbine combus-tion chambers

Guinness Book of Records

2007 SGT5-8000H – world’s biggest gas turbine

1996 SGT6-4000F – for 38% efficiency

Awards won by the SGT5-8000H

2011 German Industry’s Innovation Award; prize for the world’s most efficient power plant (Ulrich Hartmann Power Plant)

2010 German Innovation Award for Climate and Environment

2010 Bavarian Energy Award for the Ulrich Hartmann Power Plant

2009 German Steel Innovation Award for “Climate Protection with Steel” (special award)

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Focus on peopleOur 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 con-tinuing 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 inno-vation and are the key factors for con-tinuing success. Each individual shows outstanding commitment – and each of them plays an important role in securing the future of our site.

Development and research. We know that complex technologies call for sound expertise. Siemens continuously invests in the development of people and rela-tionships to support our aims. Coopera-tion with universities and research insti-tutes as well as providing numerous apprenticeships is the foundation upon which our continuing success is built.

Theory and practice. There is a long his-tory of training and promoting young talents at our site. Every year about 150 talented new employees begin appren-ticeships and dual study programs at the Gas Turbine Plant Berlin. In particu-lar, students of engineering disciplines gain valuable insights into the design, manufacturing and service of advanced gas turbines.

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, main-taining 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.

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Shaping cutting-edge

technology of the future

with leading specialists

Tradition and modernityTurbines 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 produc-tion 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-Gesell-schaft” (AEG) founded its turbine factory on the site that is still in operation today. The facility mainly produced steam tur-bines 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 produc-tion 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 archi-tects for its assembly bay. Designed in 1909 by Peter Behrens (1868–1940) on the basis of structural calculations pre-pared by Karl Bernhard (1859–1937),

this revolutionary example of industrial architecture was celebrated by contem-poraries as resembling an “iron church” or a “cathedral of labor”. Protected as a historic landmark since 1969, the hangar-shaped building still serves its original purpose: the construction of turbines. Other buildings where high-tech compo-nents 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 Kraft-werk Union (KWU). During this merger, the steam turbine construction was relocated to Muelheim / Ruhr. Since 1977, the Gas Turbine Plant Berlin has exclu-sively 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

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Subject to change without prior notice. The information in this document contains general descriptions of the technical options available, which may not apply in all cases. The required technical options should therefore be specified in the contract.

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