Case Study: Medical Manufacturing

The mission of Thermo Fisher Scientific is to enable its customers to make the world healthier, cleaner, and safer. Accordingly, it is involved in accelerating life sciences research, improving patient diagnostics and therapies, and increasing laboratory productivity. Its lab business is widespread, covering academia, government, and private industry. Thermo Fisher Scientific also serves the biotechnology and pharmaceutical sectors. Most notably, it is one of several large companies at the forefront of the COVID-19 pandemic response. It is involved with testing as well as therapy and vaccine development. The demands of COVID-19 and other customer needs have accelerated its growth to include a product build-out area and remodel in Rockford, Illinois.

Though headquartered in Waltham, Massachusetts, Thermo Fisher Scientific has a long heritage in Rockford where it has built a strong and competitive workforce. It attracts protein research experts from around the globe. This particular facility provides analytical instruments, equipment, reagents, consumables, software, and services for research, analysis, discovery, and diagnostics. When it came time to revamp its Rockford operation, facility supervisor Ken Deill, knew who he could rely on for reliable emergency standby power - Rehlko Power.

The Rockford facility was already using Rehlko emergency standby generators ranging from 100 kW to 1MW. The quality and proven reliability of the solutions made Rehlko an easy choice. The addition of the Rehlko KD800 generator set and related components would represent the fifth Rehlko emergency standby solution.

Similar to other continuous production facilities, an unplanned outage at Thermo Fisher Scientific can be expensive. While it already had four Rehlko generators on-site, the large remodel would require its own emergency standby system. The challenge for Ken was to find a reputable electrical contractor and supplier to analyze the need, propose a reliable solution, and install and commission the system within a tight timetable. Kelso Burnett was chosen as the electrical contractor, and a Rehlko authorized distributor provided the standby power solution.

A complete Rehlko solution was recommended by the sales engineer. It included a model KD800, 277/480 V, 60 Hz diesel generator with an APM802 controller, delivering an 800 kW standby rating. This generator features the Rehlko KD Series engine, specifically engineered for generator applications. The result is higher performance at reduced operating costs. It runs smoothly and quietly, creating very little vibration, even under extreme operating conditions. On-board diagnostics provide operator insight for easier maintenance and long-term performance.

The generator is contained in an aluminum, sound level 1 enclosure to reduce noise and to guard against the elements. An internal critical silencer is included in the package to help reduce noise even further. The enclosure also features easily accessible doors and panels to facilitate service and local operation. Air inlet louvers reduce moisture entry. A 2500 W, 210/240 V, single-phase block heater, an enclosure heater, and a 24 V, 20-amp battery charger were included to ensure reliable operation during the winter months—which is a good idea in the Midwest.

The generator also features a Rehlko 24-hour, UL 142 integral sub-base fuel tank with a 1749-gallon capacity. It offers continuous operation until grid power is restored or refueling is needed. The sub-base tank also features an environmentally friendly secondary containment tank surrounding the primary tank. Both the inner and outer tanks have emergency relief vents.

The solution also includes a service-entrance-rated Rehlko KEP DMTC 1200S TR automatic transfer switch with MPAC 1500 control. The system provides fast, automatic transitions from grid to generator. A NEMA 3R enclosure protects the switch from the elements, ensuring reliable operation.

According to Ken Deill, “The project has been a great success. The emergency standby power solution from Rehlko has been in service for several months … and its presence helps us focus on our COVID-19 and other scientific efforts with confidence. The service team from the Rehlko authorized distributor continues to monitor the system to ensure continued reliability, service life, and overall customer satisfaction.” Deill further noted, “While this seemed like a straightforward job, there are always little ‘bumps’ we don’t anticipate. What we can count on with Kelso Burnett and the Rehlko authorized distributor is on-the-fly expertise, based on experience, which allows continuous progress and seamless project work. What we can count on from Rehlko, also based on experience, is reliability.”