MSD 10MW Tri-Generation Power Plant

PROJECT CONTEXT

Client Profile

MSD (Merck Sharp & Dohme (Singapore) Ltd) is a global research-driven pharmaceutical company that discovers, develops, manufactures and markets a broad range of innovative products to improve human and animal health, directly and through its joint ventures.

It is located at Singapore Tuas Biomedical Park. The manufacturing facilities of MSD Singapore consist of a bulk active pharmaceutical ingredient (API) plant and a pharmaceutical formulation plant.

Project Objectives and Constraints

The main objective of this project for constructing a 10MW Tri-generation power plant was to supply electrical power, saturated process steam and chilled water to the existing plant utilities.

It is costly for the plant to import power electricity from grid for their utilities. Hence it was decided to have a more cost effective and energy saving solution by constructing a Tri-Generation Power Plant for the main plant.

In line with its objective of saving energy, natural gas was fed to fire a gas turbine which generates electrical power. Flue gas (exhaust) generated by the gas turbine was directed to a Heat Recovery Steam Generator (HRSG). At the HRSG, steam was generated, produced and delivered for the plant’s process utilization. Excess steam was directed to an absorption chiller to produce chilled water for cooling requirements.

IMPLEMENTATION OF SOLUTION

Project Phases

This project consists of partial engineering design, equipment supply and all mechanical and electrical Hook-Up work as follows:

  • Supply and Installation of Absorption Chiller
  • EPC of Blowdown System
  • EPC of Air Receiver Tank
  • EPC of Piping Work including Natural Gas Pipe, Steam Pipe, Compressed Air Pipe, Cooling Water Pipe, Boiler Feed Water Pipe, Chemical Dosing Pipe, Blowdown & Drain-off Pipe, Sampling Line, Instrument Air Tubing etc
  • EPC of Pipe Rack
  • Equipment installation and erection including Gas Turbine (Gas Turbine body, filter housing, platform and other accessories), diverter damper, furnace, evaporator, economizer, duct burner, gas train, bypass stack, main stack, transformer, tanks, pump skids, transition and interconnecting ducts etc
  • Electrical and cabling work

Project Duration

This project was started in February 2008 and was completed within 6 months time.

Solution Overview

With only natural gas as a feed, this plant supplies 10MW electricity power, 25 ton/hour process steam and 4000RT cooling capacity to the end user.

The steam fired Absorption Chiller helps end user save a huge operation cost compared to running a conventional chiller.
To complete above project effectively and successfully within a given time frame, the work was planned and executed by the following factors:

  • Management: Good planning, coordination and task execution by an organized and experienced project management team to complete the project on time and safely.
  • Meeting: Regular meetings were held to ensure reviewing of execution methods, schedules, quality issue etc.. Appropriate response and action were carried out for issues discussed. This ensured the project was always on the right track.
  • Methodology: Our team brainstormed all possible methods for approaching the work and the best cost effective solutions were used to ensure work was done effectively. Work sequence was planned according to factors in all site constraints to achieve smooth site operation.
  • Machine: Specialized machinery and equipment were deployed to help increase productivity of site operation.
  • Manpower: Competent, experienced and skillful manpower were engaged for this project. Each job was assigned to an appropriately skilled personnel, which minimized mistakes and ensured workmanship quality. This project was executed with longer working hours including weekends.

OUTCOMES

Client Benefits

The Tri-Generation Power Plant enabled the end user to have massive cost savings by converting waste steam and heat from its Gas Turbine exhaust into energy for chilled water supply.

Testimonials

“Cyclect’s project management team shows good cooperation, communication, technical knowledge and safety control for this project.” – Mr Pornchai, Construction Manager from Solar Turbines International Company

“Cyclect has always taken client’s suggestion and needs into consideration for delivering the projects.” – Mr Jimmy Fu, Engineer, Tuas Power Ltd

Achievements

  • At 10MW, it is the largest Tri-Generation Power Plant in Singapore.
  • This project was completed on time and with zero lost time incident.

 

 

 
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