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Case Study

New steam turbine provides energy savings for global pharmaceutical manufacturer

Every Challenge Has a Backstory

A global pharmaceutical manufacturer has seen a reduction in its operating facilities and a corresponding drop in steam demand over the last few years at a campus located in the New York metropolitan area. Several buildings have undergone decontamination and demolition as the campus transitioned to biological production. The manufacturer looked to OBG to design and construct a new condensing steam turbine that would generate electricity using the underutilized steam infrastructure. The project aimed to have the electrical generation offset the electricity that was previously being purchased and greatly reduce utility costs. 

OBG’s Focus on Solutions

OBG engineered, constructed, installed, and commissioned a 4.5-megawatt condensing steam turbine and ancillary equipment including a generator, condenser, lube oil skid, motor control centers, and a 15,000-gallons-per-minute cooling tower with associated pumping, filtration, and chemical treatment systems. The project also interconnected with the facility’s existing distributed control system. The new turbine works together with two existing back pressure steam turbines in the building to generate additional power for the campus.     

The project used an innovative approach to install the turbine inside the building by creating a removal skylight in the roof. This opening provided safe rigging operations and can be reused if future rigging is needed. 

Results that Matter

The turbine was safely installed ahead of schedule inside an operating power plant, achieving zero safety incidences. This project increased the client’s steam load, enabling the client to run a greater steam flow through its backpressure steam turbine and produce additional electrical generation. The turbine successfully produces 4.5 megawatts of electrical generation, saving $300,000 a month in electrical costs for the client. In addition, the project has passed stringent performance testing from the American Society of Mechanical Engineers (ASME).