Client
Bristol-Myers Squibb
Location
Dublin, Ireland

Bristol-Myers Squibb - Active Pharmaceutical Ingredients Bulk Manufacturing Facility

Bristol-Myers Squibb (BMS) is the Number 1 provider in anticancer therapies and a leader in development of cancer, heart disease, HIV / AIDS and mental illness treatments.

BMS Worldwide Medicines Group needed to expand production to meet the increasing consumer demand for its products. The Cruiserath bulk manufacturing facility was designed to produce Active Pharmaceutical Ingredients (API) for a range of healthcare treatments. This expansive $500-million greenfield project is one of the largest bulk operations in the world.

The Cruiserath site encompasses a 100-acre campus, with about 45 acres designated for the planned manufacturing and support facilities. Facilities included API production building, administration building, laboratory, central utilities building, warehouse, security building, bulk tank and drum storage areas, waste treatment facilities (wastewater treatment and incinerator), solvent recovery / thermal energy recovery, and site support facilities.

In addition to being the construction management lead, BMS also selected Fluor to provide operational qualification, validation, start-up, and commissioning services. A distinct value for BMS was Fluor's ability to deliver certainty to cost and schedule performance.


Pharmaceutical Bulk Manufacturing Facility Program Management
Client's Challenge

The Cruiserath bulk manufacturing facility produces API for a range of healthcare treatments including nefazodone hydrochloride products for the treatment of chronic depression and related mental illness. The Cruiserath site was selected by BMS based on the close proximity to BMS's existing bulk facility in Swords. The Dublin site provided convenient access to the new Blanchardstown Institute of Technology to source local technical resources and professional talent. Ireland also offered attractive economic tax incentives and professional business incentives.

Construction of a 100-acre manufacturing facility in Cruiserath County began in January of 2000. In December 2001, Fluor was asked by BMS to conduct a peer review of its Cruiserath initial project. Upon completion of the assessment in February 2002, BMS contracted Fluor to complete the Cruiserath project, based on a cost and schedule certainty. Cost control was key to Client satisfaction.


API Bulk Manufacturing Facility Construction Management
Fluor's Solution

BMS selected Fluor as the program management lead and also to provide construction management, IQ, pre-OQ, design management, validation, start-up and commissioning services. A distinct value for BMS was Fluor's ability to deliver certainty to cost and schedule performance. Fluor was awarded this important project because of demonstrated dependability in successfully completing twelve (12) BMS projects in the United States and Puerto Rico in the past year. Fluor's proven expertise in pharmaceutical bulk technology, full spectrum of validation and commissioning services, and recognized Irish project delivery excellence were keys to the award of this project. Working in various locations for BMS also demonstrated global execution strength.

The Cruiserath project employed over 1,300 workers at peak. Fluor managed 30 Irish subcontractors that addressed over €200 million procurement spend and supported the local communities.

A total of fourteen (14) buildings were completed including the API production building, administration building, laboratory, central utilities building, warehouse, security building, bulk tank and drum storage areas, waste treatment facilities (waste water treatment and incinerator), solvent recovery / thermal energy recovery, and site support facilities. The combined floor area exceeded 20,000 square meters, 1,500 kilometers of cable and 90 kilometers of pipe.

To address environmental protection concerns, an incineration plant was used to destroy the liquid and gaseous waste streams created during various stages of the project's phase. The unit is specifically designed to conform to European Union and U.S. Environmental Protection Agency standards and provide thermal energy recovery, as generated from the destruction of organic wastes in the form of stream from a waste-heater boiler.

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Facility Project Safety Work Practices
Conclusion

BMS Cruiserath project is one of the largest bulk operations in the world ever constructed. As a leader in healthcare, BMS valued Fluor's demonstrated safety doctrine and work practices in the field. BMS has a declared corporate safety strategy to achieve “zero work related” injuries. With Fluor as the CM, the Cruiserath project safety program noted a tenfold improvement. At the one million safe workhour milestone, the Cruiserath project received nationwide recognition in Ireland.

The Irish Minister for Labor, Tom Kitt, visited the site to honor the safety achievement. He commented, "Workers are to be commended for achieving such an excellent standard of safety in a project of the scale that exists at the BMS facility. Both BMS and Fluor are to be congratulated for their commitment to safety on this project."

By leveraging the compatible corporate culture of BMS and Fluor, the Cruiserath project executed 2.98 million safe workhours without a lost-time incident.

BMS Cruiserath was successfully completed in September 2003.