TOPGAS

Hydrogen-cooled turbogenerator
in a class of its own

POWER
 TOPGAS Highly reliable and efficient

If producing electricity reliably and cost effectively is your top priority, you need to look no further than
the 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-end
TOPGAS: the benefits
air-cooled turbogenerators and the consistent application of operations experience. The TOPGAS
design 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 with
outstanding reliability and efficiency, making it the most cost-effective indirectly hydrogen-cooled
turbogenerator solution. Excellent reliability and availability
Alstom’s TOPGAS turbogenerator is also extremely versatile, being suitable for large utilities as well From 1998 to 2007, the average reliability of the TOPGAS fleet was a
as for the increasing number of Independent Power Producers (IPPs). And with its modular design, staggering 99.9%. This is due to its robust design resulting from an evolutionary
it is easy to transport and install on site. design approach. Quality is built into the product by rigorous application of
Alstom’s Product Development Quality process.
The range of TOPGAS applications includes:
T conventional steam power plants
T simple and combined cycle gas turbine power plants
T combined heat and power plants High efficiency
TOPGAS delivers a market-beating 99% efficiency, thanks, in particular
Whatever your needs, Alstom has the solution. to its optimised winding and hydrogen cooling system.

Right technology, right products Easy to maintain

Design features such as wedges of the stator bars and the stator core are
The Alstom Turbomachines group (TMG) designs, manufactures, self-adjusting. In addition, active parts are easily accessible during regular
markets and commissions the key equipment that is at the heart of maintenance.
power plants, namely:
T Gas turbines
T Steam turbines
T Steam turbines retrofit and integrated retrofit solutions Flexible arrangement
T Conventional islands for nuclear power plants TOPGAS can be table mounted or floor mounted. It comes with a single or
T Turbogenerators double drive application for steam or gas turbines.

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 turbogenerator
in 1901 and the invention of the Roebel bar in 1912. We have a comprehensive range of products
and retrofit solution, from 40 to 2,000 MW in 50/60 Hz markets, covering all applications for both
Alstom and non-Alstom turbines.

02 03
 TOPGAS Highly reliable and efficient

If producing electricity reliably and cost effectively is your top priority, you need to look no further than
the 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-end
TOPGAS: the benefits
air-cooled turbogenerators and the consistent application of operations experience. The TOPGAS
design 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 with
outstanding reliability and efficiency, making it the most cost-effective indirectly hydrogen-cooled
turbogenerator solution. Excellent reliability and availability
Alstom’s TOPGAS turbogenerator is also extremely versatile, being suitable for large utilities as well From 1998 to 2007, the average reliability of the TOPGAS fleet was a
as for the increasing number of Independent Power Producers (IPPs). And with its modular design, staggering 99.9%. This is due to its robust design resulting from an evolutionary
it is easy to transport and install on site. design approach. Quality is built into the product by rigorous application of
Alstom’s Product Development Quality process.
The range of TOPGAS applications includes:
T conventional steam power plants
T simple and combined cycle gas turbine power plants
T combined heat and power plants High efficiency
TOPGAS delivers a market-beating 99% efficiency, thanks, in particular
Whatever your needs, Alstom has the solution. to its optimised winding and hydrogen cooling system.

Right technology, right products Easy to maintain

Design features such as wedges of the stator bars and the stator core are
The Alstom Turbomachines group (TMG) designs, manufactures, self-adjusting. In addition, active parts are easily accessible during regular
markets and commissions the key equipment that is at the heart of maintenance.
power plants, namely:
T Gas turbines
T Steam turbines
T Steam turbines retrofit and integrated retrofit solutions Flexible arrangement
T Conventional islands for nuclear power plants TOPGAS can be table mounted or floor mounted. It comes with a single or
T Turbogenerators double drive application for steam or gas turbines.

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 turbogenerator
in 1901 and the invention of the Roebel bar in 1912. We have a comprehensive range of products
and retrofit solution, from 40 to 2,000 MW in 50/60 Hz markets, covering all applications for both
Alstom and non-Alstom turbines.

02 03
TOPGAS: designed to perform

Stator core
The stator core is designed for zero maintenance. It is held
under constant axial pressure by press fingers, press plates
and fully insulated through bolts. As a result, there is no
expected loosening of the laminations for the entire life time
of the machine. The stator core is made of low-loss
insulated steel sheet, while the press plates are made of
cast aluminium, which reduces magnetic losses at the
stator ends and thereby helps to raise efficiency.

Stator winding and wedging

The dual-layer stator windings contribute to the efficiency
of TOPGAS. They use Roebel bars (an Alstom patent dating
back to 1912) to minimise eddy-current losses and enhance
efficiency. The windings are held in the stator slots
by double tapered concave-convex wedges. These are
designed to prevent the slot filling from loosening and
compensate for the initial settling and thermal expansion of
the bars during operation.

MICADUR® insulation system

One of the key features to boost the reliability of TOPGAS is
Alstom’s MICADUR® insulation system, the result of
continuous development that started in the 1950s.
The insulation consists of a glass-fibre tape incorporating
mica flakes. The taped bars are vacuum impregnated with
a solvent-free epoxy resin and thermally cured. The surface is
finally coated with a corona-protection varnish. MICADUR®
meets all the requirements of thermal class F (155ºC), while
TOPGAS operates in thermal class B (130ºC), meaning that
it has an intrinsic safety margin for reliable operation. The
MICADUR® insulation system exhibits outstanding
mechanical and electrical properties, resulting in excellent
long-term durability under all operating conditions.

Hydrogen cooling system Stator end-winding support structure

A key means of delivering its outstanding efficiency, TOPGAS is cooled with pressurised hydrogen in a closed
circuit to remove heat from the rotor and stator. The heat is removed via hydrogen/water heat exchangers within
the casing. The multi-chamber cooling system in the stator enables efficient heat transfer and uniform temperature
distribution 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.
This truly unique design feature reduces the maintenance effort and increases
availability. It is axially flexible to allow thermal expansion, and rigid in the radial and
tangential directions to withstand high electromagnetic forces. The end winding can be
re-tightened easily during regular maintenance, which accelerates maintenance work.

04 05
TOPGAS: designed to perform

Stator core
The stator core is designed for zero maintenance. It is held
under constant axial pressure by press fingers, press plates
and fully insulated through bolts. As a result, there is no
expected loosening of the laminations for the entire life time
of the machine. The stator core is made of low-loss
insulated steel sheet, while the press plates are made of
cast aluminium, which reduces magnetic losses at the
stator ends and thereby helps to raise efficiency.

Stator winding and wedging

The dual-layer stator windings contribute to the efficiency
of TOPGAS. They use Roebel bars (an Alstom patent dating
back to 1912) to minimise eddy-current losses and enhance
efficiency. The windings are held in the stator slots
by double tapered concave-convex wedges. These are
designed to prevent the slot filling from loosening and
compensate for the initial settling and thermal expansion of
the bars during operation.

MICADUR® insulation system

One of the key features to boost the reliability of TOPGAS is
Alstom’s MICADUR® insulation system, the result of
continuous development that started in the 1950s.
The insulation consists of a glass-fibre tape incorporating
mica flakes. The taped bars are vacuum impregnated with
a solvent-free epoxy resin and thermally cured. The surface is
finally coated with a corona-protection varnish. MICADUR®
meets all the requirements of thermal class F (155ºC), while
TOPGAS operates in thermal class B (130ºC), meaning that
it has an intrinsic safety margin for reliable operation. The
MICADUR® insulation system exhibits outstanding
mechanical and electrical properties, resulting in excellent
long-term durability under all operating conditions.

Hydrogen cooling system Stator end-winding support structure

A key means of delivering its outstanding efficiency, TOPGAS is cooled with pressurised hydrogen in a closed
circuit to remove heat from the rotor and stator. The heat is removed via hydrogen/water heat exchangers within
the casing. The multi-chamber cooling system in the stator enables efficient heat transfer and uniform temperature
distribution 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.
This truly unique design feature reduces the maintenance effort and increases
availability. It is axially flexible to allow thermal expansion, and rigid in the radial and
tangential directions to withstand high electromagnetic forces. The end winding can be
re-tightened easily during regular maintenance, which accelerates maintenance work.

04 05

TOPGAS: a success story
Since the 1960s, more than 600 TOPGAS Turbogenerators have been installed worldwide,
with total capacity in excess of 50,000 MW.
Taranaki / NEW ZEALAND
TOPGAS demonstrates high reliability
The Taranaki combined-cycle power
plant owned by Contact Energy is
powered by Alstom’s KA26-1 single-
shaft arrangement. The plant typically
operates at base load. In the past ten
years, the TOPGAS Turbogenerator has
been in continuous base load operation,
accumulating over 70,000 operating
hours and 300 starts.
Neyveli CMS1 / INDIA
TOPGAS for conventional steam power
plant
The Neyveli CMS1 power train is
powered by a 260 MW Alstom STF25
steam turbine with a TOPGAS. The
lignite-fired power plant has
accumulated more than 35,000
operating hours and 150 starts since
first synchronisation in June 2002.
06
Taranaki / New Zealand
Severnaya / AZERBAIJAN
TOPGAS driven by non-Alstom turbine
TOPGAS not only fits Alstom turbines
perfectly, but also those of other
manufacturers. This versatility of the
TOPGAS is demonstrated at the plant in
Servernaya, where it is part of a non-
Alstom combined-cycle power plant.
Over 30,000 operating hours have been
accumulated since 2002.
Chiba Mill / JAPAN
TOPGAS in high cyclic operation
Chiba Mill is a 400 MW gas fired
combined-cycle power plant owned by
JFE for steel production. From
September 2002 till 2007, the plant has
been operating reliably in daily start-stop
mode, accumulating more than 1300
starts and over 18,000 operating hours.
Alstom Power,
a world leader in power generation
Alstom is a global leader in power generation designed to
meet the needs of customers and end users across the world.
For over 100 years, Alstom has been helping to satisfy the
growing need for electricity.
Today, we deliver power generation solutions in over
70 countries. Our innovative, environmentally-friendly
technologies have made Alstom a by-word for efficiency,
reliability and performance.
Alstom Power R&D
Alstom Power R&D focuses on creating innovative
technologies to be applied at all stages of a product’s life
cycle. We aim for the best utilisation of the customers’
investment, the earth’s materials and the fuel used, through
efficiency, availability and cost reduction.
Across over 20 development centres and more than
10 laboratories worldwide, Alstom R&D activities focus mainly
on the improvement of plant performance and efficiency and
on the reduction of environmental impact.
Quality manufacturing
Alstom’s 100-year manufacturing experience gives customers
special advantages. Our worldwide plant network, all ISO
9001/14001 certified, ensures that high quality standards are
consistently met through continuous quality improvement
initiatives. A key focus area of our R&D effort is new
manufacturing technology and processes. Laser cutting of
core laminations as well as automatic stator bar and rotor
coil manufacturing are some of the innovative methods that
keep us at the technology forefront.
In accordance with IEC and ANSI/IEEE standards, every
Turbogenerator is subjected to a series of tests over and
above the material and manufacturing checks.
Extensive service experience
Through our 200 Local Service Centres in 70 countries,
you have direct access to Alstom Power Service’s full range
of maintenance and emergency repair services.
Our services include performance improvement, lifetime
extensions and consultancy packages for Alstom and other
OEM Turbogenerators. Alstom can also advise you on the
economics and risks associated with different maintenance and
repair strategies.
Upgrades offer a very economic opportunity to benefit from
Alstom’s latest technology. Various upgrade packages have
been developed to match your operating strategy. Increased
power output, improved operational flexibility or reliability are
the major aims of an upgrade.
Alstom service packages to re-wind and repair major
components, coupled with new design techniques and modern
materials, help improve plant performance.
Alstom’s long-term service contracts will meet your unique
requirements. You can choose from traditional Purchase Order
Contracts, Service Agreements, and Operations and
Maintenance Contracts.
07

TOPGAS: a success story
Since the 1960s, more than 600 TOPGAS Turbogenerators have been installed worldwide,
with total capacity in excess of 50,000 MW.
Taranaki / NEW ZEALAND
TOPGAS demonstrates high reliability
The Taranaki combined-cycle power
plant owned by Contact Energy is
powered by Alstom’s KA26-1 single-
shaft arrangement. The plant typically
operates at base load. In the past ten
years, the TOPGAS Turbogenerator has
been in continuous base load operation,
accumulating over 70,000 operating
hours and 300 starts.
Neyveli CMS1 / INDIA
TOPGAS for conventional steam power
plant
The Neyveli CMS1 power train is
powered by a 260 MW Alstom STF25
steam turbine with a TOPGAS. The
lignite-fired power plant has
accumulated more than 35,000
operating hours and 150 starts since
first synchronisation in June 2002.
06
Taranaki / New Zealand
Severnaya / AZERBAIJAN
TOPGAS driven by non-Alstom turbine
TOPGAS not only fits Alstom turbines
perfectly, but also those of other
manufacturers. This versatility of the
TOPGAS is demonstrated at the plant in
Servernaya, where it is part of a non-
Alstom combined-cycle power plant.
Over 30,000 operating hours have been
accumulated since 2002.
Chiba Mill / JAPAN
TOPGAS in high cyclic operation
Chiba Mill is a 400 MW gas fired
combined-cycle power plant owned by
JFE for steel production. From
September 2002 till 2007, the plant has
been operating reliably in daily start-stop
mode, accumulating more than 1300
starts and over 18,000 operating hours.
Alstom Power,
a world leader in power generation
Alstom is a global leader in power generation designed to
meet the needs of customers and end users across the world.
For over 100 years, Alstom has been helping to satisfy the
growing need for electricity.
Today, we deliver power generation solutions in over
70 countries. Our innovative, environmentally-friendly
technologies have made Alstom a by-word for efficiency,
reliability and performance.
Alstom Power R&D
Alstom Power R&D focuses on creating innovative
technologies to be applied at all stages of a product’s life
cycle. We aim for the best utilisation of the customers’
investment, the earth’s materials and the fuel used, through
efficiency, availability and cost reduction.
Across over 20 development centres and more than
10 laboratories worldwide, Alstom R&D activities focus mainly
on the improvement of plant performance and efficiency and
on the reduction of environmental impact.
Quality manufacturing
Alstom’s 100-year manufacturing experience gives customers
special advantages. Our worldwide plant network, all ISO
9001/14001 certified, ensures that high quality standards are
consistently met through continuous quality improvement
initiatives. A key focus area of our R&D effort is new
manufacturing technology and processes. Laser cutting of
core laminations as well as automatic stator bar and rotor
coil manufacturing are some of the innovative methods that
keep us at the technology forefront.
In accordance with IEC and ANSI/IEEE standards, every
Turbogenerator is subjected to a series of tests over and
above the material and manufacturing checks.
Extensive service experience
Through our 200 Local Service Centres in 70 countries,
you have direct access to Alstom Power Service’s full range
of maintenance and emergency repair services.
Our services include performance improvement, lifetime
extensions and consultancy packages for Alstom and other
OEM Turbogenerators. Alstom can also advise you on the
economics and risks associated with different maintenance and
repair strategies.
Upgrades offer a very economic opportunity to benefit from
Alstom’s latest technology. Various upgrade packages have
been developed to match your operating strategy. Increased
power output, improved operational flexibility or reliability are
the major aims of an upgrade.
Alstom service packages to re-wind and repair major
components, coupled with new design techniques and modern
materials, help improve plant performance.
Alstom’s long-term service contracts will meet your unique
requirements. You can choose from traditional Purchase Order
Contracts, Service Agreements, and Operations and
Maintenance Contracts.
07
PT-PE/BPROB/TPGSHT08/eng/TMG/06.08/CH/6558 © - Alstom, the Alstom logo and any alternative version thereof are trademarks and service marks of Alstom. The other names mentioned, registered or not, are the
property of their respective companies. The technical and other data contained in this document are provided for information only. Neither Alstom, its officers nor employees accept responsibility for or should be taken as
making any representation or warranty (whether express or implied) as to the accuracy or completeness of such data or the achievements of any projected performance criteria where these are indicated. No liability is accepted
for any reliance placed upon the information contained in this brochure. Alstom reserves the right to revise or change these data at any time without further notice. Design and production: Les Editions Stratégiques.
Photo credits: © 2007 Bryon Paul McCartney | www.atelier-mccartney.com, Alstom and others. Printed on paper made with pure ECF (Elemental Chlorine Free) ecological cellulose produced from trees grown in production
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