Pharmaceutical Facility – Puerto Rico
Overview:
- Two 1,300 kW 56HM LNG CHP units = 2.6 MW
- Two Battery Energy Storage Systems totaling 4.4 MWh
- One custom 1,750 kW diesel backup generator
- Shared Heat Recovery Steam Generator (HRSG)
- 300-ton absorption chiller
- Steam, hot water, and chilled-water recovery systems
- Custom switchgear and power distribution equipment
- Fully engineered E-House
- Site transformer and electrical integration
- Microgrid controls and automation
- Utility synchronization and interconnection
- Grid-connected and islanded operating capability
- System installation and commissioning
- Ongoing system operation by Martin Energy Group
Industry: Pharmaceutical Facility
Location: Cayey, Puerto Rico
Challenge
Reliable, Cost-Effective Power for a Critical Facility
A pharmaceutical manufacturing facility in Puerto Rico needed a more reliable and cost-effective energy solution to protect its critical operations from an unstable electrical grid and hurricane-related outages. With energy resilience a critical priority, the facility sought an onsite energy system that could provide dependable power while reducing energy costs and improving overall energy efficiency.
Martin Energy Group’s Solution
Martin Energy Group developed a fully integrated turnkey microgrid that combines onsite generation, battery energy storage, backup generation, heat recovery, cooling, and advanced controls into one coordinated energy system.
At the heart of the microgrid are two 1,300 kW 56HM LNG-fueled Combined Heat and Power (CHP) units, providing a combined 2.6 MW of primary onsite generation. Rather than allowing the engines’ thermal energy to go unused, the system captures that energy and puts it to work throughout the facility.
Exhaust heat from both CHP units is routed through a shared Heat Recovery Steam Generator (HRSG) to produce steam for facility processes. Additional recovered thermal energy supports a 300-ton absorption chiller, which converts waste heat into chilled water. This allows the system to provide multiple useful forms of energy from the same fuel source while improving overall system efficiency.
Multiple Layers of Energy Resilience
To provide additional flexibility and redundancy, Martin Energy Group integrated two Battery Energy Storage Systems totaling 4.4 MWh. The batteries support microgrid stability, load management, backup power, and the operation of the onsite generation system.
Martin Energy Group also engineered and manufactured a custom 1,750 kW diesel generator to provide another layer of backup generation. This allows the facility to maintain resilient operation during maintenance events, fuel interruptions, utility outages, or other abnormal operating conditions.
Together, the LNG CHP generation, battery energy storage, diesel backup generation, and utility connection give the site multiple resources that can be coordinated according to operating conditions.
One Integrated Control System
Bringing these different energy resources together required an advanced microgrid control strategy.
Martin Energy Group engineered the controls and integration that coordinate the CHP units, BESS, diesel generator, switchgear, breakers, and utility connection. ComAp controllers are used throughout the system for generator control, battery coordination, synchronization, load sharing, utility interconnection, and breaker management.
This control architecture allows the microgrid’s different assets to operate as a single coordinated system, including operation in both grid-connected and islanded modes.
Rather than treating the CHP units, batteries, diesel generator, and utility as separate pieces of equipment, Martin Energy Group integrated them into one energy platform designed around the operating requirements of the facility.
Turnkey Scope of Supply
Martin Energy Group’s involvement extended well beyond supplying generating equipment. The project included the engineering, manufacturing, integration, installation, commissioning, and ongoing operation of the microgrid.
The system generates power at 480V, which is stepped up through the site transformer for distribution throughout the facility.
Results
Reliable Power with 100% Uptime
The completed microgrid provides the facility with a resilient onsite energy solution capable of producing electricity, steam, hot water, and chilled water from one coordinated system.
According to project operating results, the system has achieved 100% uptime over the past 11 months, providing the reliable power the facility needed while reducing its dependence on an unreliable utility grid.
Just as importantly, the project demonstrates the value of approaching energy as a complete system. Generation, storage, backup power, heat recovery, cooling, switchgear, and controls were designed to work together rather than being supplied as independent components.
A Different Approach to Energy
This project is also different than some because Martin Energy Group doesn’t simply supply the equipment.
Martin Energy Group owns and operates the microgrid under a Power Purchase Agreement (PPA). This model allows the customer to benefit from reliable, onsite energy without having to take on the responsibility of owning and operating a highly sophisticated microgrid themselves.
From the CHP equipment and battery storage to the diesel generator, heat recovery system, switchgear, E-House, controls, commissioning, and ongoing operation, Martin Energy Group provided the expertise required to turn numerous technologies into one complete energy solution.
