Genentech, ECP-1, Tuas, Singapore

Genentech’s LUCENTIS® manufacturing facility was erected on a 30-acre green-field site in Tuas Biomedical Park in Singapore. The facility includes three primary areas: a manufacturing building, central utilities plant/warehouse and bulk tank management, and office space.

Jacobs provided a modular execution approach to address the client’s schedule constraints. The decision to modularize the process area (approximately 27,000 square-feet), while using stick construction for the administrative building and warehouse allowed for simultaneous parallel construction efforts – decreasing the overall build time.

By leveraging our innovative use of large bay modules to maximize the amount of work moved off-site to our module shop, we minimized the interconnection work required during erection. Jacobs completely modularized the manufacturing building, including the building structure, enclosure, and ceilings, as well as the process areas. Also, constructing in the large bay allowed us to capitalize on the greater amount of commissioning performed in a shop manufacturing environment.

The project was mechanically complete several days earlier than originally scheduled. The project team answered Genentech’s challenge for achieving project completion in as short a period as possible – 24 months from preliminary design to pre-qualification completion. As a result, the project received the International Society of Pharmaceutical Engineers’ Facility of the Year Award.

  • Number of modules: 24

  • Number of instruments: 1055 (excludes skids & solenoids)

  • Pieces of equipment: 551 (process, mechanical, electrical)

  • Linear feet of pipe: 31,700

  • Tons of steel (Class A): 472

  • Lost time incidents: 0

KPE, Sulfur Recovery Unit, Europoort, Netherlands

To meet a required reduction in SO2 emissions, the 75-year-old KPE refinery near Rotterdam needed upgrading. Several waste sour gas streams burned directly into furnaces which greatly contributed to the refinery’s SO2 emissions.

A stick built construction approach would require the refinery to restrict operations for a period of time, potentially causing the plant to exceed accepted emissions levels. Constructing onsite presented a challenge due to limited lay down area for materials. As a result of these issues and the additional safety advantages associated with modularization, KPE chose to use modular construction services for completion of this project.

Jacobs fabricated nine modules for KPE that directed the waste sour gas streams to the sulfur plant in an effort to reduce the refinery’s overall SO2 emissions. Our modular approach moved 112,291 craft labor hours off-site to a safer shop environment, where qualified and experienced craft labor completed work indoors at grade. The modules were accessible from multiple work fronts during construction, reducing congestion in the work areas and allowing concurrent access by multiple crafts. This helped reduce on-site craft hours by 50%, resulting in a significant cost savings for the client.

Taking advantage of a favorable exchange rate at the time of fabrication, the modular construction option reduced labor costs by 30 to 40 % while also improving productivity, as the work was completed in Jacobs' Charleston, South Carolina, U.S. fabrication facility. Our off-site modular construction provided KPE reduced interruptions to existing plant operations, eliminated the need for extensive lay down areas, and reduced safety concerns.

  • Number of modules: 9

  • Number of instruments: 255

  • Pieces of equipment: 26

  • Linear feet of pipe: 13,250

  • Tons of steel: 225

  • Lost time incidents: 0

PCS Phosphate, Phosphoric Acid Plant, Train #3 & #4, Aurora, North Carolina, U.S.

To accommodate growing demand for purified acid in both North and South America, PCS Phosphate needed to expand its purified phosphoric acid plant in Aurora, North Carolina. The Train #4 project objective was to increase the company’s total annual purified acid capacity.

Building on our recent success of the PCS Train #3 project, Jacobs replicated the same design to help reduce overall cost and schedule in the Train #4 project. Replication also had a positive impact on the quality of modules, which contributed to reduced startup duration at the jobsite. PCS Phosphate was able to operate at full production of on-grade product within 10 days of mechanical acceptance.

Additional benefits of using modular construction included the availability of a skilled work force to supplement Aurora's limited local resource pool; reduced safety concerns as a result of work conducted in a controlled environment at grade; and minimal disruption to ongoing facility operations. A six month schedule savings was also realized with construction continuing off-site, concurrent with permitting and foundation preparation at the jobsite.

The project’s modular scope was completed 8% under budget, saving the client $1.7 million dollars.

  • Number of modules: 58

  • Number of instruments: 409

  • Pieces of equipment: 145

  • Linear feet of pipe: 69,030

  • Lost time incidents: 0

Flint Hills Resources, Low Sulfur Gas Facility, Corpus Christi, Texas, U.S.

To comply with EPA regulations and local Texas market commitments, Flint Hills Resources looked to Jacobs to implement low sulfur gasoline technology at its Corpus Christi refinery. Modular construction was chosen because it addressed labor shortage concerns; allowed much of the critical path to be constructed indoors to mitigate the risk of schedule delays; and improved site safety by moving craft personnel outside of the operating refinery.

Jacobs' modular work included procurement and fabrication of rack pipe and other module assembly bulks, as well as assembly/installation of all structural, mechanical, electrical and instrumentation scope within the module limits.

Constructing modules indoors helped achieve the aggressive schedule. During construction, the Corpus Christi area experienced the most severe weather conditions it had undergone in 30 years; five weeks of rainouts continued onsite during the same six-month period that module construction continued indoors uninterrupted.

In addition to weather delays, the original 20-week manufacturing schedule for the process modules was reduced by four weeks, as a result of late steel deliveries from the fabricator. The modular manufacturing environment allowed us to quickly implement overtime and a night shift to react to this change. This flexibility ensured the modules shipped on time.

Using the Jacobs' EPC and modular approach, the project was completed two months early and delivered 8% under budget. Additionally, reduced field labor demands helped sustain site productivity at 1.04 and moving labor outside the operating refinery allowed the site to achieve OSHA VPP Star Status (0.00 recordable incident rate).

  • Number of modules: 20

  • Number of instruments: 170

  • Pieces of equipment: 32

  • Linear feet of pipe: 17,500

  • Tons of steel: 553

  • Lost time incidents: 0

Pfizer, Rapid Deployment Module, Locations Worldwide

Jacobs collaborated with Pfizer on a modular process system to deliver the next generation of aseptic formulation processing technologies to its plants and to address the rapidly changing requirements of localized pharmaceutical manufacturing in emerging market countries.

The collaboration brought together Pfizer’s aseptic drug product process expertise and Jacobs' capabilities in modular engineering, fabrication, and testing to create a system that integrates modular equipment, fully-automated control systems and single-use technology for bags, mixers, sterile connectors, manifolds, and filters. The portable system is scalable for different batch sizes, adaptable for various products, and can be rapidly deployed, with a significant cost and schedule advantage compared to large manufacturing facilities with fixed equipment and limited flexibility.

The modular process system uses off-the-shelf, single-use technology which requires minimal space requirements and utilities. It can be replicated globally; mainly because the benefits of reduced equipment, validation, and operating costs, compressed production cycles, product tech transfer and training requirements, are so favorable.

The collaboration began with design and construction of a fully functional system to prove the rapid deployment module concept. After successfully completing process characterization, parameter development, media fill, extractable, leachable, and comparability studies, the system was replicated and delivered to targeted markets. The production systems are currently in their final stages of validation at the local pharmaceutical manufacturing sites. Read more about our relationship with Pfizer.

  • Number of modules: 6

  • Number of instruments: 75

  • Pieces of equipment: 24

  • Linear feet of sanitary pipe/tubing: 150

  • Lost time incidents: 0

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