Pharma site upgrade boosts energy capacity and cuts costs

Reliable utilities are essential to maintaining production at pharmaceutical facilities, where interruptions can affect complex processes and business continuity. To increase energy efficiency and onsite generation, our client engaged Ramboll as design-build contractor for a major upgrade to its central utility plant. The project replaced ageing equipment, expanded cooling capacity, and integrated a new steam turbine generator with the operating facility. The resulting system enables the plant to produce an average of 11 MW of electricity while supporting dependable utility service for ongoing manufacturing.

Delivering a complex upgrade in an operating facility

Ramboll managed the upgrade from design and equipment purchasing through construction, testing, and startup. At the centre of the project was a new steam-powered generator capable of producing 5 MW of electricity – enough to reduce the facility’s reliance on power purchased from the grid. Ramboll also upgraded the electrical equipment and controls needed to connect the generator safely to the plant’s existing utility systems.

The project expanded the plant’s cooling tower system, which allows for the condensing steam turbine to extract the maximum amount of power out of the steam system. The new system has four cooling towers and built-in backup capacity, allowing it to keep operating if one unit is unavailable. Ramboll also improved the process-water network, removed two older cooling systems, and modified the turbine building to accommodate the new equipment. Because the generator had to be installed on the second floor, the team strengthened the structure to control vibration and created a removable section of roof so the large components could be lifted into place.

Creating lasting operational and financial value

Because the facility remained in operation throughout the project, the work had to be carefully planned to protect employees, avoid disruption, and maintain essential utility services. Ramboll removed the old turbine and its supporting equipment, along with two outdated steam boilers that contained asbestos insulation. Pumps and other equipment connected to the retired boilers were also removed. Dedicated safety specialists oversaw the construction and asbestos removal, and each part of the new system was fully tested before the owner began using it.

The new turbine produces 5 MW of electricity and also helps the facility’s existing turbines generate more power from the same steam supply. Together, the systems now produce about 11 MW on average, reducing the amount of electricity the facility needs to buy from the grid. This saves the client approximately $300,000 each month. The upgraded cooling and electrical systems also make the plant better prepared for equipment outages and changing production needs, helping it operate more reliably over the long term.