Utilities In pharmaceutical industries

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ENGINEERING UTILITIES IN PHARMACUTICAL INDUSTRIES :

ENGINEERING UTILITIES IN PHARMACUTICAL INDUSTRIES Pharmaconex 2018 Ahmed El-sayed Helal

Relations :

Relations In pharmaceutical companies production is a small and important circle but it is part of bigger circles We will speak only in utilities circle.

Importance :

Importance HVAC system ( only ) consume around 60 % or more of electricity load in your factory . Around 60% or more of any project initial cost . So you should know and control it ……

Utilities systems in your factory :

Utilities systems in your factory HVAC system . Compressed Air system. Steam system. Water system .

Utilities systems in your factory :

Utilities systems in your factory HVAC system. Compressed Air system. Steam system. Water system.

1- HVAC system:

1- HVAC system

HVAC system:

HVAC system What is meaning of HV AC system?

HVAC system:

HVAC system What is meaning of HV AC system? 1- Temperature control 2- Humidity control 3- Filtration 4- Distribution & 5- ventilation .

HVAC system Components :

HVAC system Components Chillers . Air Handling units . Dehumidifiers . Boilers . Fans . Pumps . Pips . Duct system .

Chillers:

Chillers What Is Chiller? A chiller is a refrigeration cycle to remove heat from a liquid to deliver it in a demand temperature . Types of chillers . How we chose a correct chiller .

Chillers Types :

Chillers Types 1- Vapor compression cycle. 2- Absorption cycle.

Chillers Types :

Chillers Types Vapor compression cycle.

Chillers Vapor compression cycles :

Chillers Vapor compression cycles

Chillers Vapor compression cycles :

Chillers Vapor compression cycles

Chillers Components :

Chillers Components

Chillers Components :

Chillers Components

Chillers Components :

Chillers Components

Chillers Components :

Chillers Components

Chillers Actual cycle :

Chillers Actual cycle

Chillers Components :

Chillers Components Compressor (#1) Air-Cooled Condenser (#2) High Pressure Limit (#3) High Pressure Gauge (#4) Liquid Receiver (#5) Filter Drier (#6) Liquid Line Solenoid (#7) Refrigerant Sight Glass (#8) Expansion Valve (#9) Hot Gas Bypass Valve (#10) Evaporator (#11) Low Pressure Refrigerant Gauge (#12) Low Refrigerant Pressure Limit (#13) Coolant Pump (#14) Freeze stat Limit (#15) To Process Sensor Probe (#16) Coolant Pressure Gauge (#17) Water Make-Up Solenoid (#18) Reservoir Level Float Switch (#19) From Process Sensor Probe (#20) Evaporator Flow Switch (#21) Reservoir (#22)

Chillers :

Chillers Non vapor compression cycles ,,,, Why ??

Chillers :

Chillers Non vapor compression cycles ,,,, Why ?? 1- High Electricity consumption ( Compressor ) 2- Environmental effect for Freon .

Chillers Absorption cycle :

Chillers Absorption cycle

SIMILARITY BETWEEN TWO CYCLES :

SIMILARITY BETWEEN TWO CYCLES

Chillers Absorption cycle :

Chillers Absorption cycle

Chillers Absorption cycle – Basic components :

Chillers Absorption cycle – Basic components Generator . Condenser . Evaporator . Absorber . 3 pumps ( solution , refrigerant , purge ).

Chillers Absorption cycle:

Chillers Absorption cycle To improve chiller efficiency ( C.O.P ) components will be : High temperature Generator . Low temperature generator. Plate heat exchangers . Condenser . Evaporator . Absorber . 3 pumps ( solution , refrigerant , purge )

Chillers Double effect absorption chiller :

Chillers Double effect absorption chiller

Chillers:

Chillers How you choose a correct chiller ? Load ( people , lighting , machines , ……. ) COP. ( What you gain / what you Pay ) IPLV . ( COP in part load ) . Your machine room dimension and weight loads . Electricity , water , Gas . (Consumptions )

Chillers room :

Chillers room

Air Handling unit:

Air Handling unit

Air Handling units Basic components :

Air Handling units Basic components Mixing box . Pre filtration box . Fan box . Cooling coil box. Humidification box ( option ) Final filtration box . Eliminators .

AHU Filters:

AHU Filters

AHU Filters:

AHU Filters

AHU Filters:

AHU Filters

AHU filters:

AHU filters

Air Handling unit Components :

Air Handling unit Components AHU body should be Hygienic double skin thickness 25 mm at least- self supporting frame .

Air Handling Unit Components :

Air Handling Unit Components Sand Trap louver: It is made of heavy gauge galvanized steel with U-shape plates mounted and encased in a galvanized steel frame. The module should be provided with differential pressure taping and gauge.

Air Handling unit Components :

Air Handling unit Components Chilled Water Cooling Coil: Chilled water coil is used for sensible cooling and cooling and dehumidification for Air Handling unit during summer season. The coil shall` be manufactured from copper tube and aluminum fins and framework from stainless steel. Proportional (PID) Controller is used at part load using three- way valve OR Two way valve . Balancing valve is used to adjust the chilled water amount with the chilled water piping system. Although the coils are sensible behavior but they should be provided with eliminator and condensate drip tray.

Air Handling unit Components :

Air Handling unit Components Supply Fan : Supply fan shall be backward blade centrifugal fan horizontal discharge with belt drive complete with electric motor 380 volt/3 phase/ 50 Hz. The fan shall be double inlet with variable pulley. The fan motor assembly will be mounted on a base mounted on vibration isolators of rubber, with spring type as well as anti-vibration connection between fan and casing. Fan operating point should be performed at maximum efficiency point to satisfy the static and dynamic pressure of the duct system and the installed equipment.

Air Handling unit Components :

Air Handling unit Components Terminal ceiling HEPA Filters : For Class "B" & "C" HEPA filter is used as a terminal compounded with the ceiling diffuser. The filter cell shall be gas-tight with securely sealing compression mounting and filter retaining springs Gaskets are provided between the filter cell and the supporting frame work. The filter should be provided with differential pressure taping and gauge. Code is ANSI/UL 586-1990.

Air Handling units Request sheet :

Air Handling units Request sheet

Air Handling units Piping connections :

Air Handling units Piping connections

Air Handling units Critical points :

Air Handling units Critical points Alignment . Leakage . Belts . Drain installation . Measurements access .

Air Handling Units Monitoring :

Air Handling Units Monitoring Air flow rate sensor . Deferential pressure gauges ( filters ,and fans ). Temperature sensors . Humidity sensors .

Cooling towers :

Cooling towers

Cooling towers ( open cooling towers ) Types :

Cooling towers ( open cooling towers ) Types

Cooling towers ( open cooling towers ) Types :

Cooling towers ( open cooling towers ) Types

Cooling towers ( open cooling towers ) Advantages. :

Cooling towers ( open cooling towers ) Advantages.

Cooling towers ( open cooling towers ) Advantages. :

Cooling towers ( open cooling towers ) Advantages.

Cooling towers ( open cooling towers ) Chemical treatment :

Cooling towers ( open cooling towers ) Chemical treatment alkalinity:  will dictate potential of calcium carbonate scale chlorides:  can be corrosive to metals; different levels will be tolerated based on materials of cooling tower and equipment hardness:  contributes to scale in the cooling tower and on heat exchangers iron:  when combined with phosphate, iron can foul equipment organic matter:  promotes microorganism growth, which can lead to fouling, corrosion, and other system issues silica:  known for causing hard scale deposits sulfates:  like chlorides, can be extremely corrosive to metals total dissolved solids (TDS):  contribute to scaling, foaming, and/or corrosion totals suspended solids (TSS):  undissolved contaminants that can cause scaling, biofilms, and/or corrosion

Cooling towers ( open cooling towers ) Chemical treatment :

Cooling towers ( open cooling towers ) Chemical treatment Chemical addition corrosion inhibitors  (e.g., bicarbonates) to neutralize acidity and protect metal components algaecides and biocide  (e.g., bromine) to reduce the growth of microbes and biofilms scale inhibitors  (e.g., phosphoric acid) to prevent contaminants from forming scale deposits

Duct system :

Duct system Why duct system is important . Duct material ( Galvanized steel , S.S. , Aluminum , Textile and pre-insulated ducts) . Dampers . Air outlets . Return grills . Duct and measurements.

Duct system :

Duct system Maximum side Thickness High pressure Gauge Low pressure Gauge From To - 29 cm .85 mm USSG24 USSG26 30 cm 74 cm 1mm USSG22 USSG24 75 cm 149 cm 1mm USSG20 USSG22 Ducts shall be high pressure according to SMACNA specifications. All of them are made of galvanized steel metal according to ASTMA526-71 standard Quality and zinc coating for both sides 275 gm/m 2 ( or more ) . the rectangular duct minimum gauge should respect the followings:

Duct system :

Duct system LEAKAGE TEST .

Duct system :

Duct system

Duct system :

Duct system

2- Compressors :

2- Compressors

Compressor :

Compressor

Compressor Types :

Compressor Types Air compressor types ( Quality and purity ) . Oil free compressor ( why ? ) . Cooling type . How you chose a correct compressor ?

Compressor Measurements :

Compressor Measurements

Air compressor dryer :

Air compressor dryer Air compressor dryer sizing. Vapor compression type . Descant dryers ( Heat or Heat lease ) . Dew point ( +3 or -40 ) .

Compressor room & network . :

Compressor room & network .

3- Boilers :

3- Boilers

3- Boiler:

3- Boiler

Boiler room :

Boiler room

Boilers :

Boilers Boiler types . Boilers safety . Boilers treatment and measurements .

4- Dehumidifiers :

4- Dehumidifiers

Dehumidifiers :

Dehumidifiers Dehumidifiers types . 1- Chemical liquid spray tower . 2- Solid descant dryer .

Dehumidifiers Chemical liquid spray tower :

Dehumidifiers Chemical liquid spray tower

Dehumidifiers Solid descant dryer :

Dehumidifiers Solid descant dryer

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