The document summarizes the design and operation of a trigeneration plant built by AMD to provide 100% of the energy needs for its new Fab 36 microprocessor manufacturing facility in Dresden, Germany. A consortium led by Air Liquide and DREWAG was commissioned to build the plant using highly efficient gas engine units to generate electricity, steam, and hot and chilled water. The plant was designed by M+W Group and built from 2004 to 2005 to strict quality, reliability and environmental standards required by the semiconductor industry. It operates 9 gas engine units that can generate up to 22 MW of electricity and 52 MW of thermal energy to meet all of AMD's energy needs for its manufacturing processes.

1. Energy Center
AMD Fab 36 Dresden
Advanced Electrical Power,
Hot and Chilled Water Supply System

2. Economical • Ecological • 100% Reliable
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 cogeneration plant (EVC). Encouraged by this
favourable experience, AMD Management
decided to duplicate the model and to install 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 electrical 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 construction 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 efficiency are achieved by selecting highly efficient
components for power generation, heat
recovery systems and chilled water generation. System design and module sizing are
targeted on lowest primary energy consumption 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.

3. Scope of Work
M+W Group were selected to design,
erect and commission the plant to meet
the specifications 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 efficient,
closely controlled unit able to provide all
necessary supplies to operate a semiconductor 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
specification
The design has been developed using the
experiences gained during the commissioning and operation of the already existing 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 first gas engine unit
July 28, 2004
• First firing 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

4. Operating Capacities
Total design and construction period
17 months until commercial operation.
Fine tuning of the plant under operating
conditions to achieve the optimum performance 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 efficiency with a minimum of
primary energy input.
Therefore AMD decided again to be supplied 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.
Required data of the project
For the semiconductor manufacturing
process AMD requires uninterrupted
stable conditions for the following media:
Electrical power
• voltage
• tolerance of voltage
• voltage drops
• nominal frequency
• tolerance of frequency
• max. power
20 kV
+/- 8%
max. 10 ms
50 Hz
+/- 1%
22 MW
Heat
• hot water
supply temperature
return temperature
max. power approx
tolerances
80°C
50°C
19 MW
+3K / -1K
• warm water
supply temperature
return temperature
max. power approx
tolerances
32°C
22°C
33 MW
+4K / -2K
Cold
• chilled water
supply temperature
return temperature
max. power approx
tolerance
5°C
11°C
9 MW
+0.5K /-0.5K
• chilled water
supply temperature
return temperature
max. power approx
tolerance
11°C
17°C
34 MW
+1K / -1K

5. General Information
Location
Building dimensions
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 substation to be in close proximity to each other.
Main building:
• 102 m x 36 m x 14 m
• 20 kV building
60 m x 11 m x 11.3 m
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 softening 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 water system considerably reduces the waste
water discharge to public drains.
For fire protection, the Energy Center is
connected to the fire 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.
• 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 flue 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 efficiency of the cooling
system, the wet cooling towers are located
on the roof of the main plant building.

6. 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 sufficient to supply the energy
needed in maximum by AMD. To guarantee
high quality energy supply at 100% availability even when one unit is in failure and a
second one is simultaneously in maintenance, the plant is designed for a total of 9
GEUs. In case of a unit failure the remaining 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 efficiency may be extended 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 devices 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 efficiency
approx 40%
• total fuel efficiency
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 compressors 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.

7. Chilled water system
The chilled water system in final 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 covering summer time peak loads, for redundancy 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 finally removed to the environment
by evaporative cooling towers.
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.
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 conditioning devices (PCD) based on flywheels
which are needed to guarantee the exceeding requirements for frequency and
voltage control.
NO2
CO
Dust
< 200 ppm
< 300 ppm
5 mg/m³

8. 02.180.02/05.2011
M+W Group
Lotterbergstr. 30
70499 Stuttgart, Germany
Phone +49 711 8804-1100
Fax
+49 711 8804-1111
energy@mwgroup.net
www.mwgroup.net
© M+W Germany GmbH
Photos: Klaus Schuster