UK’s Largest Pharmaceutical Cleanroom

The client

A leading global supplier of drug delivery devices for injectable and inhaled products.

The brief

The brief was to design, supply and install bespoke HVAC, mechanical and electrical services to a new purpose-built cleanroom facility with a total volume of 18,000 m³. The room required a minimum of 60 m³/s of air to meet the design specification for validation.

The facility (now the UK’s largest Pharmaceutical Cleanroom) was to meet ISO class 7 operational for 50 weeks of the year maintaining a tight temperature control of 21OC (+/- 3 OC) & humidity of 45% RH (+/- 15%) with a positive pressure of 30 pa cascading through the adjoining lobby areas with a maintained differential of 15 pa.

Part of the design challenge on this project was the uneven heat loads across the facility combined with a vast area that requires a minimum of 12 air changes per hour.

In addition to the facility’s air handling, JD Cooling & JD Power were also employed through the main contractor to supply and install a new process water system and full electrical installation package.

We are delighted to have had the opportunity to work closely with our customer on what is now the ‘largest pharmaceutical cleanroom’ in the UK. This project is an installation that we are extremely proud of and one that the end-user is very happy with.

MIKE GOULD
HVAC Manager, JD Cooling

The solution

Heating, Ventilation and Air Conditioning

  • 900 kW multi-circuit chiller serving the AHUs
  • 650 kW adiabatic dry air cooler serving the process
  • Three multi-function close control AHUs
  • Amenities VRF and heat recovery systems
  • Cleanroom air distribution socks and ductwork
  • Acoustic plant packages
  • Both mechanical and electrical services
  • Information and operation validation

Electrical Installation

As part of the scheme, the client required new LV distribution to their new cleanroom, all electrical services, lighting and fire alarm systems.

The power requirement was very high and needed to be designed to be as efficient and economical as a building requiring potentially 5000 amps of power could be.

The challenge was to supply this amount of power along with the potential to expand the electrical supply in the future possibly quite significantly.

The requirement for this amount of power and the building design/usage dictated the use of two mains transformers provided by a local power distribution company, two low voltage mains panels fitted with power factor correction, and numerous sub-panels, distribution boards, and equipment control panels installed by JD Power Systems.

Technical Specifications

Performance Specification – AHU (3) – Custom Built

Design Ambient

+32°c

Design Room

21 °C / 45% RH

Supply Air Volume

21m³/s per AHU

Cooling

300kW per AHU on chilled water

Heating

Indirect gas fired heating with auxiliary electric heating

Fan

Inverter driven EC plug fan (2 per AHU)

Humidification

Steam electrode supplied with RO water

Filtration

G4, F8 & Terminal H14 (pre, bag & Terminal Hepa)

Performance Specification – Chiller (1) – Special Built

Cooling Capacity

900kW

Design Ambient

+32°c

Chilled Water

Supply: +6°c / Return: +12°c

Capacity Steps

9 stages of capacity cooling

Refrigerant

R410a

EEV

Electronic

Modification

Full Acoustic enclosure fitted

Performance Specification – Process Cooler (1) – Special Built

Cooling Capacity

650kW

Type

Adiabatic dry air cooler

Design Ambient

+32°c

Fans

EC

Refrigerant

None

Modification

Full Acoustic enclosure fitted

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