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Abstract: Today, many manufacturing process requires that spaces to be designed to control particulate and
microbial contamination while maintaining clean room facility with reasonable installation and operating
costs. Clean room facilities are typically used in manufacturing, packaging and research facilities associated
with these industries: Semiconductor, Pharmaceutical, Hospitals, Aerospace and Miscellaneous applications.
This project deals with Design, Installation and Commissioning of Clean room and HVAC facility for Stem
cell technologies and Regenerative Medicine. In this thesis, the system design thermal loads , filtration level
and cleanness, pressures produced in the constructed building by varying normal brick wall ,brick wall with
attached panels are calculated..Clean rooms are designed as per ISO14644-4 guidelines to maintain proper air
flow in order to used proper cleanness. The HVAC facility shall be achieved by using the equipments like Air
cooled condensing unit, Air handling units and etc..As a First step towards the project, the system design load
calculations will be done. Air Quantity calculation, Supply/Return air Diffusers, Return Air Risers and Terminal
filters selection, Temperature, RH, Lighting and Fan requirements are as per attached design data sheets. The
classes of cleanliness, filtration and other requirements are to be as per the room list, layout drawings .The
minimum fresh air quantities shall be as per the basis of design above while the exhaust air quantities shall be
as based on the quantities of the leakages and pressures to be maintained in the rooms and Also the leakage
rates considered through the doors to be through the doors to be through a normal single leaf door or double
leaf door for the suggested pressure differentials to be suitably considered.
Keywords: Clean rooms, HVAC facility, Filters, Pressures , Panels ,Temperature, Air flow rates.
I. Introduction
A Clean Room is a controlled environment where products are manufactured. It is a room in which the
concentration of airborne particles is controlled to specified limits. Eliminating sub-micron airborne
contamination is really a process of control. These contaminants are generated by people, process, facilities and
equipment. They must be continually removed from the air. The level to which these particles need to be
removed depends upon the standards required.
The HVAC facility necessity for atmospheric conditions in India is varying in different places of the
country. In the summer season atmospheric conditions are quite un comfortable in most parts of the country and
winter conditions are uncomfortable in few places of the country .So air conditioning is essential for the comfort
of humans, equipment and facilities are staying in hospital. In this thesis, the system design thermal loads ,
filtration level and cleanness, pressures produced in the constructed building by varying normal brick wall ,brick
wall with attached panels are calculated.
The main purpose of clean room and hvac facilities are to supply sufficient amount of air, which should
maintain correct temperature, humidity, air purity, air movement and noise level. Occupants feels quite comfort
in a selected enclosure by maintaining all the factors correctly. The high capacity requirements suggest the
selection of air handling units and require high efficiency filters.
This project work has been intended to suggest a suitable clean room facility and comfort air
conditioning design for the various public areas and rooms of a proposed Nims hospital at Hyderabad. In this
hospital 6th floor contains 12- Clean rooms which have to be cleaned and conditioned and 7-Air lock rooms, 8-
Nurse observation rooms, 2-Corridors, 14-Other rooms,8- Wash rooms which have to be conditioned.
The centralized air conditioning system is suggested for that hospital considering summer and winter conditions
at Hyderabad.
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
Federal Standard 209E defines a clean room as a room in which the concentration of airborne particles is
controlled to specified limits.
British Standard 5295 defines a clean room as a room with control of particulate contamination,
constructed and used in such a way as to minimize the introduction, generation and retention of particles inside
the room and in which the temperature, humidity, airflow patterns, air motion and pressure are controlled.
CLEAN
ROOM CLASS LIMITS NOT TO EXCEED PARTICLES PER CU FT FOR PARTICALS
CLASS SIZES SHOWN
1 0.1m 0.2m 0.3m 0.5m 5 m
10 35 7.5 3 1 -
100 350 75 30 10 -
1000 - 750 300 100 -
10000 - - - 1000 7
100000 - - - 10000 70
1000000 - - - 100000 700
2.2 Sources Of Contamination: The source of the contamination is categorized as external sources and internal
sources
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
A. External Sources - For any given space, there exists the external influence of gross atmospheric
contamination. External contamination is brought in primarily through the air conditioning system through
makeup air. Also, external contamination can infiltrate through building doors, windows, cracks, and wall
penetrations for pipes, cables and ducts. The external contamination is controlled primarily by
1. High efficiency filtration,
2. Space pressurization and
3. Sealing of space penetrations
B.Internal Sources- The potentially largest source is from people in the clean room, plus shedding of surfaces,
process equipment and the process itself. People in the workspace generate particles in the form of skin flakes,
lint, cosmetics, and respiratory emissions. Industry generates particles from combustion processes, chemical
vapors, soldering fumes, and cleaning agents. Other sources of internal contamination are generatedthrough the
activity in combustion, chemical, and manufacturing processes. The size of these particles ranges from 0.001 to
several hundred microns. Particles larger than 5 microns tend to settle quickly unless air blown. The greatest
concern is that the actual particle deposits on the product. Control is primarily through airflow design. Although
airflow design is critical, it alone does not guarantee that clean room conditions will be met. Construction
finishes; personnel and garments; materials and equipments are sources of particulate contamination that must be
controlled. Important control precautions include:
1. Walls, floors, ceiling tiles, lighting fixtures, doors, and windows construction materials that must
be carefully selected to meet clean room standards.
2. People must wear garments to minimize the release of particles into the space. The type of
garments depends on the level of cleanliness required by a process. Smocks, coveralls, gloves,
and head and shoe covers are clothing accessories commonly used in clean spaces
3. Materials and equipment must be cleaned before entering the clean room.
4. Room entrances such as air locks and pass-through are used to maintain pressure differentials and
reduce contaminants.
5. Air showers are used to remove contaminants from personnel before entering the clean space.
2.4 Panels:
ASTM standards are followed strictly in the making of our pre-painted, galvanized steel panels.
There is special gasket for air tightness between the frame and fixed panels. Hot dip galvanized steel
is used for making inner panel for double skin panels. To achieve uniformity, access doors are made
with similar material.
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
Standard cooling and heating coils are made in galvanized steel frame with seamless copper tubes with
aluminum fins .Ms headers with threaded connection and copper return bends. They are arranged in a staggered
form in the direction of air flow .copper tubes are mechanically expanded into continuous corrugated aluminum
fins. coils are assembled in slide- in guides for easy removal for maintenance or replacement. for water coils
,air vents and drain plugs are the standard ones. Moisture eliminator can also be provided for the coils,
according to air velocities and conditions. Insulated drain pan and drain connections are provided for the cooling
coil section
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
Depending on the degree of cleanliness required, it is common for air systems to deliver considerably more
air than would be needed solely to meet temperature and humidity design. Airborne particles can be organic
or inorganic. Most contamination control problems concern the total contamination within the air.Particles of
different sizes behave differently as air moves through a room. Selection of the airflow patterns is a major
step in clean room design. Because airflow is such an important aspect of particle control, the design of a
clean room requires careful consideration of air motion and airflow patterns. The general air patterns are:
Unidirectional: (sometimes referred as laminar flow) is an airflow pattern in which essentially the entire body
of air within a confined area moves with uniform velocity and in single direction with generally parallel
airstreams. Clean rooms; class 100 and below have unidirectional airflow pattern.
Non-unidirectional airflow is not unidirectional by having a varying velocity, multiple pass circulation or
nonparallel flow direction. Conventional flow clean rooms (class 1000 &10000) have non-unidirectional or
mixed air flow patterns.
Mixed patterns: combine some of each flow type.
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
IV. Equations
Load estimation:
1. Solar transmission through wall:
Q = A*U*EqTD
Where A = area of the wall (ft2) , U = Transmission coefficient (Btu/hr/ft2/ f)
EqTD = corrected equivalent temperature Difference
Bleed off Air Qty = Fresher air qty + return air qty-selected supply air qty
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
Dimens
(meters
Room
DIFFUSERS
ions
Return Air
Fresh air qty.
)
Filters
Risers
Dehumid. Air (OR) Based on Velocity air qty. (CMH)
Hepa
(CMH)
Air qty. based on air changes (CMH)
Class of Cleanliness
No. of personnel
width
E
N N
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N 5 6 1 1 9
1 2 6
C 0
E E
1.1.1 L
A
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
M
M
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
A
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
A 5 1 0 8 8
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O
N
W
A 6 6
2 1 N
1 S 3 2 1 4 3 3 0
1. . 3 6 8 M 2 5 6 2 1 0
5 H . 1 4 3 0. . . 0 0 . 3 3
8 7 . . . C T 2 0 0 4 0 0 0 3 . . .
. A 4 5 0 2 7 2 . . 0 6 6
9 4 5 6 1 6 a 3 1 1 4 7
3 R 9 2 5 3 5 5 0
5 1 0
E 3 3
A
VI. Conclusion
Now a days, many manufacturing process requires that space to be designed to control particulate and
microbial contamination while maintaining clean room facility with installation and operating cost. Present days
we are using filters and panels in addition for constructed building In this thesis, the system design thermal
loads, filtration level and cleanness, pressures produced in the constructing building by vary with the normal
brick wall, brick wall with attached panels are calculated. By observing the design of thermal loads in
normalbrick wall with panels is better than normal wall, because its heat transfer rate of normal wall is more. In
this thesis filtration level is good by using brick wall with panels ,because there is no dust particles form on the
wall with panel. In the design analysis the cooling load tonnage value of brick wall with panel is 97TR and
normal brick wall is 140TR.So that the cooling load and air flow is very good by using brick wall with panel.
Design of this system is used in NIMS hospital in Hyderabad.
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Design, Installation And Commissioning Of Clean Room And Hvac Facility For Stem Cell
References
[1] A. Bhatia," A BASIC DESIGN GUIDE FOR CLEAN ROOM APPLICATIONS".
[2] Roy J.Dossat,"PRINCIPLES OF REFRIGERATION SECOND EDITION".
[3] Shan K.Wang," HAND BOOOK OF AIR CONDITIONING AND REFRIGERATION".
[4] National Experts Organization, "STUDY MATERIAL ON EFFICIENT OPERATION AND MAINTENANCE OF A.C AND
REFRIGERATION EQIPMENT".
[5] Carrier air conditioning, HAND BOOK OF AIR CONDITIONING SYSTEM DESIGN".
[6] OPERATION AND MAINTANENCE MANNUAL OF STAGE-1 A.C AND VENTILATION SYSTEM".
[7] OPERATION AND MAINTANENCE MANNUAL OF STAG-2 A.C AND VENTILATION SYSTEM".
[8] S.C.Arora and S.Domakundwar,"REFRIGERATION AND AIR CONDITIONING".
[9] R.S.Kurmi and J.K.GUPTHA,"REFRIGERATION AND AIR CONDITIONING".
www.iosrjournals.org 12 | Page