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Energy CenterAMD Fab 36 Dresden
Advanced Electrical Power, Hot and Chilled Water Supply System
AMD has established a second production
plant for microprocessor manufacturing in
Dresden. When Fab 30 was erected years
ago, it was decided by AMD management
to get 100% of energy supply by a cogen-
eration plant (EVC). Encouraged by this
favourable experience, AMD Management
decided to duplicate the model and to in-
stall a second independent Energy Center
for supplying 100% of the required energy
to the new facility AMD Fab 36.
A consortium consisting of the companies
Air Liquide GmbH, Düsseldorf and
DREWAG Stadtwerke Dresden GmbH
received the commission to supply electri-
cal power together with hot and chilled
water by the erection and ownership of a
Trigeneration plant on a site provided by
AMD Fab 36.
The consortium commissioned the con-
struction of the plant on the basis of spark
ignition engines.
Natural gas was selected as fuel to
guarantee low environmental impacts.
Best values for electrical and total effi cien-
cy are achieved by selecting highly effi cient
components for power generation, heat
recovery systems and chilled water genera-
tion. System design and module sizing are
targeted on lowest primary energy con-
sumption rates at 100% reliability without
any interruption. The plant is designed to
be operated in parallel to the grid as well
as in island mode in case of grid blackouts.
Economical • Ecological • 100% Reliable
M+W Group were selected to design,
erect and commission the plant to meet
the specifi cations set by AMD Fab 36.
The construction phase lasted 13 months.
The consortium took over the Plant
on April 1st 2005 as planned to deliver
the various energies to AMD Fab 36.
The plant is designed as a high effi cient,
closely controlled unit able to provide all
necessary supplies to operate a semiconduc-
tor manufacturing facility and consists of
• supply systems to the plant for natural
gas, city water and auxiliary services
• gas engine units with associated exhaust
heat recovery boilers, heat exchangers
and engine cooling loops
• direct heated auxiliary boilers
(natural gas) for backup
• absorption and mechanical chillers
with cooling towers
• all necessary auxiliary equipment
to operate the plant at the designed
specifi cation
The design has been developed using the
experiences gained during the commis-
sioning and operation of the already exist-
ing Trigeneration Plant for AMD Fab 30.
AMD Fab 36 will ramp up the production
during a time period of several years.
Therefore the EVC 2 design encompasses
two phases for build out. All equipment
for phase two will be commissioned under
normal operation of the plant without
interruptions or excursions in quality of
the energies supplied to AMD Fab 36.
The systems have been prepared to
establish this build out accordingly.
Time Schedule
According to the requirements of the
semiconductor industry the design and
construction of the energy center has been
accomplished under a fast track approach
with the following major milestones:
• Start conceptual design
November 2003
• Contract award to M+W Group
March 08, 2004
• Start earthwork / groundbreaking
March 12, 2004
• Start building construction
April 19, 2004
• Start MEP installation
June 25, 2004
• Building temporarily watertight
July 27, 2004
• Start Installation fi rst gas engine unit
July 28, 2004
• First fi ring gas engine unit
November 03, 2004
• Mechanical completion
December 15, 2004
• Start up mechanical plant
January 10, 2005
• Start up of gas engine heat recovery unit
February 01, 2005
• Commercial operation of the plant
(Handover) March 30, 2005
Scope of Work
Total design and construction period
17 months until commercial operation.
Fine tuning of the plant under operating
conditions to achieve the optimum perfor-
mance of the plant lasting 3 months after
handover.
Basic assumptions
The quality requirements of AMD Fab 36
for the electric power supply cannot be
guaranteed by the public 110-kV-grid. In
addition, the supply of heat and cold from
the heat recovery of electricity generation
offers a high effi ciency with a minimum of
primary energy input.
Therefore AMD decided again to be sup-
plied with energy and other media by a
dedicated TriGen plant. To ensure the
security of supplies and to enable the
export of any surplus electrical power, a
110/20-kV-transformer substation with
110-kV-grid supply connection was
erected and connected adjacent to the
TriGen plant.
Operating Capacities
Required data of the project
For the semiconductor manufacturing
process AMD requires uninterrupted
stable conditions for the following media:
Electrical power
• voltage 20 kV
• tolerance of voltage +/- 8%
• voltage drops max. 10 ms
• nominal frequency 50 Hz
• tolerance of frequency +/- 1%
• max. power 22 MW
Heat
• hot water
supply temperature 80°C
return temperature 50°C
max. power approx 19 MW
tolerances +3K / -1K
• warm water
supply temperature 32°C
return temperature 22°C
max. power approx 33 MW
tolerances +4K / -2K
Cold
• chilled water
supply temperature 5°C
return temperature 11°C
max. power approx 9 MW
tolerance +0.5K /-0.5K
• chilled water
supply temperature 11°C
return temperature 17°C
max. power approx 34 MW
tolerance +1K / -1K
Location
The plant is located on the west boundary
of the AMD Fab 36 site. It is necessary for
the main user [AMD Fab 36], the TriGen
plant and 110/20-kV-transformer substa-
tion to be in close proximity to each other.
Water supply and drainage
To maintain the levels of process water
due to losses of water in the distribution
networks, condensation in the evaporative
cooling towers and the necessary soften-
ing process, water will be used from the
public potable water system. Re-using
reject water from AMD‘s reverse osmosis
treatment plant, hot water supply system,
steam generating system, and cooling wa-
ter system considerably reduces the waste
water discharge to public drains.
For fi re protection, the Energy Center is
connected to the fi re hydrant main supply
from the AMD Fab 36 site.
Sanitary waste water and rain water are
discharged to public drains. Contaminated
waste water is removed through the AMD
Fab 36 system and processed prior to
disposal into the public system.
Building dimensions
Main building:
• 102 m x 36 m x 14 m
• 20 kV building
60 m x 11 m x 11.3 m
• including the PCD building
17 m x 11 m x 6.5 m
Exhaust stacks with a total height of 48 m
are erected on both sides of the main
building.
To ensure the required atmospheric dilution
of exhausted fl ue gas the total amount of
gas engines is split between in 3 groups
covering 3 engines each.
One of these groups will be erected during
phase 2 when a total of 9 engines will be
required. In addition to the engines 1 stack
is covered by the exhaust of 2 steam back
up boilers.
To enhance the effi ciency of the cooling
system, the wet cooling towers are located
on the roof of the main plant building.
General Information
Fuel supply system
Natural gas is selected as fuel for engines
and auxiliary boilers. In the south east of
the main building the gas is fed in via a
pressure regulator and metering system at
a pressure of 4 bar.
Engine and waste heat boiler
The “hearts” of the Energy Center are
the ‘lean burn’ Gas Engine Units (GEUs).
During normal operation a total of 8 GEUs
operating at approx 85% of the nominal
capacity is suffi cient to supply the energy
needed in maximum by AMD. To guarantee
high quality energy supply at 100% availa-
bility even when one unit is in failure and a
second one is simultaneously in mainte-
nance, the plant is designed for a total of 9
GEUs. In case of a unit failure the remain-
ing GEUs automatically take over the load.
A power conditioning device (PCD) ensures
consistency in voltage and frequencies
spec even during such sensitive take over
processes.
In addition to electricity and hot water,
steam is also supplied by the engines
using the jacket water waste heat and
the exhaust heat recovery boilers.
Warm water is used at 2 temperature levels
directly by AMD. Furthermore the energy
of hot water and steam is transferred to
chilled water at 5°C and 11°C levels by
using single and double effect absorption
chillers.
The total energy effi ciency may be extend-
ed to a maximum by this “Trigeneration”
effect independent of seasonal outside
conditions (summer or winter).
In case of unbalanced heat capacity and
demand a series of back up cooling de-
vices designed as table cooler are located
on the roof of the main building.
The nominal performance data
of each of 9 GEUs are:
• nominal electrical power
3,916 kW
• natural gas consumption
9,336 kW
• heat extraction hot water
95/80°C 2,200 kW
• heat extraction steam
9 bars 2,050 kW
• nominal electrical effi ciency
approx 40%
• total fuel effi ciency
above 85%
According to the load engine conditions
the exhaust temperature may vary from
400°C to 460°C. Before emission to the
environment the exhaust is cooled down
to approx 100°C by heat recovery systems
for steam and hot water generation.
The heat recovery steam generators are
operated at 180°C/9 to 12 bar levels, the
water boilers at 95°C.
The electrical energy generated on a 6.3 kV
level by the gensets is transformed to 20 kV
as requested by AMD. The engines are
started by a dedicated compressed air
system. The compressed air for the gas
engines is maintained by separate com-
pressors and receivers.
Auxiliary boiler system
For redundancy reasons and to balance
between each required media two auxiliary
boilers 11.5 MW capacity each are installed
for producing steam (180°C, 9 bars (abs).
The steam energy may be used either for
operating the double effect absorption
chillers or for producing hot water by
utilising a number of heat exchangers.
Chilled water system
The chilled water system in fi nal build out
consists of
• 3 double effect absorption chillers for
the supply of 5/11°C or 11/17°C
(5.8 MW each)
• 2 single effect absorption chillers for the
supply of 11/17°C (3.2 MW each)
• 6 Turbo chillers for the supply of 5/11°C
or 11/17°C (5.8 MW each)
The steam (180°C, 9 bar) and hot water is
used to run absorption chillers.
Additional turbo chillers are used for cover-
ing summer time peak loads, for redun-
dancy purposes, and for balancing the
different energy supply systems (hot and
chilled water). The chilled water is supplied
by 2 independent systems:
• supply / return temperature 5/11°C
and
• supply / return temperature 11/17°C
The chiller waste heat removed by the
cooling water system may be reused for
supplying heat on a low temperature level
at 32°C for preheating purposes during
winter time. Waste heat which cannot be
used is fi nally removed to the environment
by evaporative cooling towers.
Electrical system
Transformers, switchgears and the feeder
from the external grid are located in a
separate 20 kV building.
A further building contains the power con-
ditioning devices (PCD) based on fl ywheels
which are needed to guarantee the ex-
ceeding requirements for frequency and
voltage control.
Instrumentation and control system
An automatic system is used for the plant
control and monitoring.
The central control room is located in the
main building.
Environmental protection
During operation the environmental
conditions required by the local
authorities have to be guaranteed.
NO2 < 200 ppm
CO < 300 ppm
Dust 5 mg/m³
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M+W Group
Lotterbergstr. 30 70499 Stuttgart, GermanyPhone +49 711 8804-1100Fax +49 711 [email protected]
© M+W Germany GmbHPhotos: Klaus Schuster