Supplementary Training Modules on Good Manufacturing Practice

Heating, Ventilation and AirConditioning (HVAC)

Part 2: HVAC systems and components 7 Section

HVAC | Slide 1 of 29 May 2006

HVAC
Objectives
In the following slides, we will study the components of airhandling systems in order to:
1. 2.

Become familiar with the components Know their functions

3.

Become aware of possible problems

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General
Design of HVAC is dependent on required degree of air cleanliness
Suitable components should be selected including:
fans, driers, filters, ducts, grilles, etc.
7.

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HVAC Main subsystems

Exhaust air treatment

Fresh air treatment (make-up air)

Terminal air treatment at production room level

Production Room Central air handling unit

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Components
Components in HVAC may include, depending on need: Filters Fans
no fan failure; including supply air fans, return air fans, exhaust air fan, dust extract system fans

Driers
Drying of air with chemical driers, e.g. rotating desiccant wheel

Frost coils for preheating air

7.1.1 7.1.7

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Components
Components in HVAC may include, depending on need:
Snow eliminators

Dust eliminators
Moisture eliminators

Precooling coils
Alarm systems, grilles/diffusers, etc.
7.1.1 7.1.7

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Overview components
Exhaust Air Grille

Silencer

Flow rate controller

Fan

Filter

Weather louvre

Control damper

+
Prefilter Humidifier

Heater Terminal filter

Cooling coil with droplet separator

Secondary Filter

Production Room

Heating coil
Recirculated air
HVAC | Slide 7 of 29 May 2006

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Components (1)
Weather louvre Silencer To prevent insects, leaves, dirt and rain from entering To reduce noise caused by air circulation

Flow rate controller Automated adjustment of volume of air (night and day, pressure control) Control damper Fixed adjustment of volume of air

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Components (2)
Heating unit Cooling unit/ dehumidifier Humidifier Filters Ducts To heat the air to the proper temperature To cool the air to the required temperature or to remove moisture from the air To bring the air to the proper humidity, if too low To eliminate particles of predetermined dimensions and/or microorganisms To transport the air

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Air-handling unit

Control damper for airflow

Humid room air Adsorber wheel Dry air
AHU with fan Variable Speed Controller

Regeneration air

Humid room air Air heater

Filter Pressure Gauges

De-humidification
HVAC | Slide 10 of 29 May 2006

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Humidifier Silencer Heating and cooling units

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Filter classes
Standard Dust filters Aerosol

Coarse
Dp > 10 m

Fine
10 m > Dp > 1 m

HEPA
Dp < 1 m

ULPA

G1 - G4
EN 779 Standard

F5 - F9

H 11 - 13
EN 1822 Standard

U 14- 17

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HEPA or tertiary filter

Primary panel filter

Secondary filter

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Classification of filters according to their efficiency

Average Efficiency Integral Value Retention in Penetration % 85 0.15 95 99.5 99.95 99.995 0.05 5x10 5x10 5x10
-3 -4 -5

Peak Arrestance Local Value Efficiency Penetration

F9 H11 H12 H13 U14

97.5 99.75 99.975

25x10 25x10 25x10

-3 -4 -5

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Positioning of filters (1)

AHU mounted final filter

Filter in terminal position

HEPA Filter

Production Room HEPA Filter

Production Room

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Positioning of filters (2)
Prefilter

AHU

Main filter
Ceiling exhausts 1 2 3

Low level exhausts

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Positioning of filters (3)
Final filter

AHU
Prefilter

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1

3 4

1 2 3 4
HVAC |

Filter Tightening frame Register outlet Screw fixation for register

Slide 18 of 29 May 2006

Swirl Type air diffusors with terminal filters

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High induction office type diffusor (avoid)

HVAC | Slide 19 of 29 May 2006

Low induction swirl diffusor (preferred)

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Regulation of room pressure pressure differentials concept

Room pressure gauges Room pressure indication panel

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Problems with components
Flow rate controller Control damper Humidifier Cooling battery Filters Ducts Blocked Poorly adjusted, bad pressure differential system Bad water/steam quality/ poor drainage No elimination of condensed water/ poor drainage Incorrect retention rate/damaged/badly installed Inappropriate material/internal insulator leaking

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HVAC
In the next slides
Consider different air types, e.g.:
Supply air Return air (recirculated air) Fresh air (make-up air) Exhaust air

And: Concepts of air delivery to production areas:

Recirculation systems Full fresh-air systems
HVAC | Slide 22 of 29 May 2006

HVAC
Air types

Fresh air (make-up air)

Supply air

Exhaust air

Production Room

Return air (recirculated)

HVAC | Slide 23 of 29 May 2006

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Recirculation systems
There should be no risk of contamination and crosscontamination when air is recirculated
Normally, HEPA filters (EN1822 H13) needed in supply air stream
Not required in single product facility with no risk of cross-contamination Not required where no dust generation (e.g. secondary packaging)

HEPA filters placed in AHU or terminally

Dust from highly toxic processes should not be recirculated
7.2.1 7.2.6

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Ventilation with recirculated air + make-up air
Exhaust Unit

Central Air-Handling Unit

Return air
HVAC | Slide 25 of 29 May 2006

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Full fresh-air systems
100% fresh air - normally where toxic products are processed, and recirculation not recommended
No contamination from fresh air sufficient filtration needed Degree of filtration on exhaust dependent on exhaust air contaminants and environment regulations

Energy-recovery wheels
Should not be source of contamination Relative pressure between supply and exhaust air
7.3.1 7.3.3

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Ventilation with 100% fresh air (no air recirculation)
Exhaust Unit
W

Washer (optional)

Central Air-Handling Unit Production Rooms

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