POWER

in a class of its own

TOPGASHydrogen-cooled turbogenerator

Highly reliable and efficient

Excellent reliability and availabilityFrom 1998 to 2007, the average reliability of the TOPGAS fleet was astaggering 99.9%. This is due to its robust design resulting from an evolutionarydesign approach. Quality is built into the product by rigorous application ofAlstom’s Product Development Quality process.

High efficiencyTOPGAS delivers a market-beating 99% efficiency, thanks, in particularto its optimised winding and hydrogen cooling system.

Easy to maintainDesign features such as wedges of the stator bars and the stator core areself-adjusting. In addition, active parts are easily accessible during regularmaintenance.

Flexible arrangementTOPGAS can be table mounted or floor mounted. It comes with a single ordouble drive application for steam or gas turbines.

02 03

If producing electricity reliably and cost effectively is your top priority, you need to look no further thanthe Alstom TOPGAS hydrogen-cooled turbogenerator. TOPGAS is really in a class of its own.It leads the field in reliability and efficiency, thanks to the proven design elements from the high-endair-cooled turbogenerators and the consistent application of operations experience. The TOPGASdesign is unique. It is at the cutting edge of turbogenerators in its class, yet full of future potential.

TOPGAS covers an output range from 300 to 530 MW in 50Hz and 250 to 450 MW in 60 Hz withoutstanding reliability and efficiency, making it the most cost-effective indirectly hydrogen-cooledturbogenerator solution.

Alstom’s TOPGAS turbogenerator is also extremely versatile, being suitable for large utilities as wellas for the increasing number of Independent Power Producers (IPPs). And with its modular design,it is easy to transport and install on site.

The range of TOPGAS applications includes:T conventional steam power plantsT simple and combined cycle gas turbine power plantsT combined heat and power plants

Whatever your needs, Alstom has the solution.

Right technology, right products

The Alstom Turbomachines group (TMG) designs, manufactures,markets and commissions the key equipment that is at the heart ofpower plants, namely:T Gas turbinesT Steam turbinesT Steam turbines retrofit and integrated retrofit solutionsT Conventional islands for nuclear power plantsT Turbogenerators

Alstom has more than 100 years’ experience in designing and manufacturing turbogenerators.Our pioneering work includes the world’s first turbogenerator in 1898, the first 2-pole turbogeneratorin 1901 and the invention of the Roebel bar in 1912. We have a comprehensive range of productsand retrofit solution, from 40 to 2,000 MW in 50/60 Hz markets, covering all applications for bothAlstom and non-Alstom turbines.

TOPGAS: the benefits

TOPGAS

Highly reliable and efficient

Excellent reliability and availabilityFrom 1998 to 2007, the average reliability of the TOPGAS fleet was astaggering 99.9%. This is due to its robust design resulting from an evolutionarydesign approach. Quality is built into the product by rigorous application ofAlstom’s Product Development Quality process.

High efficiencyTOPGAS delivers a market-beating 99% efficiency, thanks, in particularto its optimised winding and hydrogen cooling system.

Easy to maintainDesign features such as wedges of the stator bars and the stator core areself-adjusting. In addition, active parts are easily accessible during regularmaintenance.

Flexible arrangementTOPGAS can be table mounted or floor mounted. It comes with a single ordouble drive application for steam or gas turbines.

02 03

If producing electricity reliably and cost effectively is your top priority, you need to look no further thanthe Alstom TOPGAS hydrogen-cooled turbogenerator. TOPGAS is really in a class of its own.It leads the field in reliability and efficiency, thanks to the proven design elements from the high-endair-cooled turbogenerators and the consistent application of operations experience. The TOPGASdesign is unique. It is at the cutting edge of turbogenerators in its class, yet full of future potential.

TOPGAS covers an output range from 300 to 530 MW in 50Hz and 250 to 450 MW in 60 Hz withoutstanding reliability and efficiency, making it the most cost-effective indirectly hydrogen-cooledturbogenerator solution.

Alstom’s TOPGAS turbogenerator is also extremely versatile, being suitable for large utilities as wellas for the increasing number of Independent Power Producers (IPPs). And with its modular design,it is easy to transport and install on site.

The range of TOPGAS applications includes:T conventional steam power plantsT simple and combined cycle gas turbine power plantsT combined heat and power plants

Whatever your needs, Alstom has the solution.

Right technology, right products

The Alstom Turbomachines group (TMG) designs, manufactures,markets and commissions the key equipment that is at the heart ofpower plants, namely:T Gas turbinesT Steam turbinesT Steam turbines retrofit and integrated retrofit solutionsT Conventional islands for nuclear power plantsT Turbogenerators

Alstom has more than 100 years’ experience in designing and manufacturing turbogenerators.Our pioneering work includes the world’s first turbogenerator in 1898, the first 2-pole turbogeneratorin 1901 and the invention of the Roebel bar in 1912. We have a comprehensive range of productsand retrofit solution, from 40 to 2,000 MW in 50/60 Hz markets, covering all applications for bothAlstom and non-Alstom turbines.

TOPGAS: the benefits

TOPGAS

04 05

TOPGAS: designed to perform

Hydrogen cooling systemA key means of delivering its outstanding efficiency, TOPGAS is cooled with pressurised hydrogen in a closedcircuit to remove heat from the rotor and stator. The heat is removed via hydrogen/water heat exchangers withinthe casing. The multi-chamber cooling system in the stator enables efficient heat transfer and uniform temperaturedistribution on the stator winding. The stator casing is tightly and safely sealed to prevent hydrogen leakage.Depending on hydrogen pressure, typical hydrogen consumption is less than half of the limit set by the IEC.

Stator coreThe stator core is designed for zero maintenance. It is heldunder constant axial pressure by press fingers, press platesand fully insulated through bolts. As a result, there is noexpected loosening of the laminations for the entire life timeof the machine. The stator core is made of low-lossinsulated steel sheet, while the press plates are made ofcast aluminium, which reduces magnetic losses at thestator ends and thereby helps to raise efficiency.

Stator winding and wedgingThe dual-layer stator windings contribute to the efficiencyof TOPGAS. They use Roebel bars (an Alstom patent datingback to 1912) to minimise eddy-current losses and enhanceefficiency. The windings are held in the stator slotsby double tapered concave-convex wedges. These aredesigned to prevent the slot filling from loosening andcompensate for the initial settling and thermal expansion ofthe bars during operation.

MICADUR® insulation systemOne of the key features to boost the reliability of TOPGAS isAlstom’s MICADUR® insulation system, the result ofcontinuous development that started in the 1950s.The insulation consists of a glass-fibre tape incorporatingmica flakes. The taped bars are vacuum impregnated witha solvent-free epoxy resin and thermally cured. The surface isfinally coated with a corona-protection varnish. MICADUR®meets all the requirements of thermal class F (155ºC), whileTOPGAS operates in thermal class B (130ºC), meaning thatit has an intrinsic safety margin for reliable operation. TheMICADUR® insulation system exhibits outstandingmechanical and electrical properties, resulting in excellentlong-term durability under all operating conditions.

Stator end-winding support structureThis truly unique design feature reduces the maintenance effort and increasesavailability. It is axially flexible to allow thermal expansion, and rigid in the radial andtangential directions to withstand high electromagnetic forces. The end winding can bere-tightened easily during regular maintenance, which accelerates maintenance work.

04 05

TOPGAS: designed to perform

Hydrogen cooling systemA key means of delivering its outstanding efficiency, TOPGAS is cooled with pressurised hydrogen in a closedcircuit to remove heat from the rotor and stator. The heat is removed via hydrogen/water heat exchangers withinthe casing. The multi-chamber cooling system in the stator enables efficient heat transfer and uniform temperaturedistribution on the stator winding. The stator casing is tightly and safely sealed to prevent hydrogen leakage.Depending on hydrogen pressure, typical hydrogen consumption is less than half of the limit set by the IEC.

Stator coreThe stator core is designed for zero maintenance. It is heldunder constant axial pressure by press fingers, press platesand fully insulated through bolts. As a result, there is noexpected loosening of the laminations for the entire life timeof the machine. The stator core is made of low-lossinsulated steel sheet, while the press plates are made ofcast aluminium, which reduces magnetic losses at thestator ends and thereby helps to raise efficiency.

Stator winding and wedgingThe dual-layer stator windings contribute to the efficiencyof TOPGAS. They use Roebel bars (an Alstom patent datingback to 1912) to minimise eddy-current losses and enhanceefficiency. The windings are held in the stator slotsby double tapered concave-convex wedges. These aredesigned to prevent the slot filling from loosening andcompensate for the initial settling and thermal expansion ofthe bars during operation.

MICADUR® insulation systemOne of the key features to boost the reliability of TOPGAS isAlstom’s MICADUR® insulation system, the result ofcontinuous development that started in the 1950s.The insulation consists of a glass-fibre tape incorporatingmica flakes. The taped bars are vacuum impregnated witha solvent-free epoxy resin and thermally cured. The surface isfinally coated with a corona-protection varnish. MICADUR®meets all the requirements of thermal class F (155ºC), whileTOPGAS operates in thermal class B (130ºC), meaning thatit has an intrinsic safety margin for reliable operation. TheMICADUR® insulation system exhibits outstandingmechanical and electrical properties, resulting in excellentlong-term durability under all operating conditions.

Stator end-winding support structureThis truly unique design feature reduces the maintenance effort and increasesavailability. It is axially flexible to allow thermal expansion, and rigid in the radial andtangential directions to withstand high electromagnetic forces. The end winding can bere-tightened easily during regular maintenance, which accelerates maintenance work.

Alstom Power,a world leader in power generationAlstom is a global leader in power generation designed tomeet the needs of customers and end users across the world.For over 100 years, Alstom has been helping to satisfy thegrowing need for electricity.Today, we deliver power generation solutions in over70 countries. Our innovative, environmentally-friendlytechnologies have made Alstom a by-word for efficiency,reliability and performance.

Alstom Power R&DAlstom Power R&D focuses on creating innovativetechnologies to be applied at all stages of a product’s lifecycle. We aim for the best utilisation of the customers’investment, the earth’s materials and the fuel used, throughefficiency, availability and cost reduction.Across over 20 development centres and more than10 laboratories worldwide, Alstom R&D activities focus mainlyon the improvement of plant performance and efficiency andon the reduction of environmental impact.

Quality manufacturingAlstom’s 100-year manufacturing experience gives customersspecial advantages. Our worldwide plant network, all ISO9001/14001 certified, ensures that high quality standards areconsistently met through continuous quality improvementinitiatives. A key focus area of our R&D effort is newmanufacturing technology and processes. Laser cutting ofcore laminations as well as automatic stator bar and rotorcoil manufacturing are some of the innovative methods thatkeep us at the technology forefront.

In accordance with IEC and ANSI/IEEE standards, everyTurbogenerator is subjected to a series of tests over andabove the material and manufacturing checks.

Extensive service experienceThrough our 200 Local Service Centres in 70 countries,you have direct access to Alstom Power Service’s full rangeof maintenance and emergency repair services.Our services include performance improvement, lifetimeextensions and consultancy packages for Alstom and otherOEM Turbogenerators. Alstom can also advise you on theeconomics and risks associated with different maintenance andrepair strategies.Upgrades offer a very economic opportunity to benefit fromAlstom’s latest technology. Various upgrade packages havebeen developed to match your operating strategy. Increasedpower output, improved operational flexibility or reliability arethe major aims of an upgrade.

Alstom service packages to re-wind and repair majorcomponents, coupled with new design techniques and modernmaterials, help improve plant performance.

Alstom’s long-term service contracts will meet your uniquerequirements. You can choose from traditional Purchase OrderContracts, Service Agreements, and Operations andMaintenance Contracts.

06 07

TOPGAS: a success storySince the 1960s, more than 600 TOPGAS Turbogenerators have been installed worldwide,with total capacity in excess of 50,000 MW.

Chiba Mill / JAPANTOPGAS in high cyclic operationChiba Mill is a 400 MW gas firedcombined-cycle power plant owned byJFE for steel production. FromSeptember 2002 till 2007, the plant hasbeen operating reliably in daily start-stopmode, accumulating more than 1300starts and over 18,000 operating hours.

Neyveli CMS1 / INDIATOPGAS for conventional steam powerplantThe Neyveli CMS1 power train ispowered by a 260 MW Alstom STF25steam turbine with a TOPGAS. Thelignite-fired power plant hasaccumulated more than 35,000operating hours and 150 starts sincefirst synchronisation in June 2002.

Severnaya / AZERBAIJANTOPGAS driven by non-Alstom turbineTOPGAS not only fits Alstom turbinesperfectly, but also those of othermanufacturers. This versatility of theTOPGAS is demonstrated at the plant inServernaya, where it is part of a non-Alstom combined-cycle power plant.Over 30,000 operating hours have beenaccumulated since 2002.

Taranaki / NEW ZEALANDTOPGAS demonstrates high reliabilityThe Taranaki combined-cycle powerplant owned by Contact Energy ispowered by Alstom’s KA26-1 single-shaft arrangement. The plant typicallyoperates at base load. In the past tenyears, the TOPGAS Turbogenerator hasbeen in continuous base load operation,accumulating over 70,000 operatinghours and 300 starts.

Taranaki / New Zealand

Alstom Power,a world leader in power generationAlstom is a global leader in power generation designed tomeet the needs of customers and end users across the world.For over 100 years, Alstom has been helping to satisfy thegrowing need for electricity.Today, we deliver power generation solutions in over70 countries. Our innovative, environmentally-friendlytechnologies have made Alstom a by-word for efficiency,reliability and performance.

Alstom Power R&DAlstom Power R&D focuses on creating innovativetechnologies to be applied at all stages of a product’s lifecycle. We aim for the best utilisation of the customers’investment, the earth’s materials and the fuel used, throughefficiency, availability and cost reduction.Across over 20 development centres and more than10 laboratories worldwide, Alstom R&D activities focus mainlyon the improvement of plant performance and efficiency andon the reduction of environmental impact.

Quality manufacturingAlstom’s 100-year manufacturing experience gives customersspecial advantages. Our worldwide plant network, all ISO9001/14001 certified, ensures that high quality standards areconsistently met through continuous quality improvementinitiatives. A key focus area of our R&D effort is newmanufacturing technology and processes. Laser cutting ofcore laminations as well as automatic stator bar and rotorcoil manufacturing are some of the innovative methods thatkeep us at the technology forefront.

In accordance with IEC and ANSI/IEEE standards, everyTurbogenerator is subjected to a series of tests over andabove the material and manufacturing checks.

Extensive service experienceThrough our 200 Local Service Centres in 70 countries,you have direct access to Alstom Power Service’s full rangeof maintenance and emergency repair services.Our services include performance improvement, lifetimeextensions and consultancy packages for Alstom and otherOEM Turbogenerators. Alstom can also advise you on theeconomics and risks associated with different maintenance andrepair strategies.Upgrades offer a very economic opportunity to benefit fromAlstom’s latest technology. Various upgrade packages havebeen developed to match your operating strategy. Increasedpower output, improved operational flexibility or reliability arethe major aims of an upgrade.

Alstom service packages to re-wind and repair majorcomponents, coupled with new design techniques and modernmaterials, help improve plant performance.

Alstom’s long-term service contracts will meet your uniquerequirements. You can choose from traditional Purchase OrderContracts, Service Agreements, and Operations andMaintenance Contracts.

06 07

TOPGAS: a success storySince the 1960s, more than 600 TOPGAS Turbogenerators have been installed worldwide,with total capacity in excess of 50,000 MW.

Chiba Mill / JAPANTOPGAS in high cyclic operationChiba Mill is a 400 MW gas firedcombined-cycle power plant owned byJFE for steel production. FromSeptember 2002 till 2007, the plant hasbeen operating reliably in daily start-stopmode, accumulating more than 1300starts and over 18,000 operating hours.

Neyveli CMS1 / INDIATOPGAS for conventional steam powerplantThe Neyveli CMS1 power train ispowered by a 260 MW Alstom STF25steam turbine with a TOPGAS. Thelignite-fired power plant hasaccumulated more than 35,000operating hours and 150 starts sincefirst synchronisation in June 2002.

Severnaya / AZERBAIJANTOPGAS driven by non-Alstom turbineTOPGAS not only fits Alstom turbinesperfectly, but also those of othermanufacturers. This versatility of theTOPGAS is demonstrated at the plant inServernaya, where it is part of a non-Alstom combined-cycle power plant.Over 30,000 operating hours have beenaccumulated since 2002.

Taranaki / NEW ZEALANDTOPGAS demonstrates high reliabilityThe Taranaki combined-cycle powerplant owned by Contact Energy ispowered by Alstom’s KA26-1 single-shaft arrangement. The plant typicallyoperates at base load. In the past tenyears, the TOPGAS Turbogenerator hasbeen in continuous base load operation,accumulating over 70,000 operatinghours and 300 starts.

Taranaki / New Zealand

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