Project Profile:

Project:		Merck Steam System Master Plan Study
Owner:		Merck & Co., Inc.
Project Type:		Master Planning Study
Completion Date:		June 2001

Dome-Tech Energy Engineers conducted a steam system utility study of the Rahway, NJ facility.  The scope of the study encompassed the power plant and steam distribution systems and included the following tasks:

• determination of the existing team production capacity of the power plant
• projection of future steam load growth over the next 5 years
• determination of future power plant capacity requirements
• determination of distribution system capacity for present and future loads
• development of distribution system upgrades required for expansion

This study utilized advanced modeling techniques and concluded that the steam distribution system was undersized for the existing site loads.  This condition caused excessive pressure drops in several areas.  The system required the installation of new primary headers to meet existing and future load requirements. Dome-Tech documented detailed header replacements and upgrades throughout the campus steam network. 

 They study also determined that the power plant did not have the capacity to support projected maximum steam loads.  It was determined that an additional bioler capacity of 625,000 pph (pounds per hour) was required.  To support site steam deamnds in the event of boiler outage/ shutdown, an additional 200,000 pph boiler capacity will be required to achive "firm" capacity.  In addition, the study recommended several measures to increase the current capacity and improve the performance of the power plant and steam distribution system.