DESIGN WORKS

INTRODUCTION

In pharmaceutical manufacturing, how space conditions impact the product being
made is of primary importance. The pharmaceutical facilities are closely supervised by Good
Manufacturing Practices. These regulations, which have the force of law, require that
manufacturers, processors, and packagers of drugs to take proactive steps to ensure that their
products are safe, pure, and effective. GMP regulations require a quality approach to
manufacturing, enabling companies to minimize or eliminate instances of contamination, mix
ups, and errors.
The GMP for HVAC services embraces number of issues starting with the selection
of building materials and finishes, the flow of equipment, personnel and products,
determination of key parameters like temperature, humidity, pressures, filtration, airflow
parameters and classification of cleanrooms. It also governs the level of control of various
parameters for quality assurance, regulating the acceptance criteria, validation of the facility,
and documentation for operation and maintenance.

HVAC system performs four basic functions:
1. Control airborne particles, dust and micro-organisms - Thru air filtration using high
efficiency particulate air (HEPA) filters.
2. Maintain room pressure (delta P) - Areas that must remain “cleaner” than
surrounding areas must be kept under a “positive” pressurization, meaning that air
flow must be from the “cleaner” area towards the adjoining space (through doors or
other openings) to reduce the chance of airborne contamination. This is achieved by

1

the HVAC system providing more air into the “cleaner” space than is mechanically
removed from that same space.
3. Maintain space moisture (Relative Humidity) - Humidity is controlled by cooling air
to dew point temperatures or by using desiccant dehumidifiers. Humidity can affect
the efficacy and stability of drugs and is sometimes important to effectively mould
the tablets.
4. Maintain space temperature - Temperature can affect production directly or
indirectly by fostering the growth of microbial contaminants on workers.
Each of above parameter is controlled and evaluated in light of its potential to impact
product quality.

2

CLEAN ROOM OVERVIEW

A cleanroom is defined as a room in which the concentration of airborne particles is
controlled. The cleanrooms have a defined environmental control of particulate and microbial
contamination and are constructed, maintained, and used in such a way as to minimize the
introduction, generation, and retention of contaminants.
Cleanroom classifications are established by measurement of the number of particles
0.5 micron and larger that are contained in 1 ft3 of sampled air. Generally class 100 to 100,000
rooms are used in the pharmaceutical industry. [Note - rooms may be classified as clean at
class 1 or 10 for other applications, particularly in the microchip /semiconductor industry].

Cleanroom Air Flow Principles
Cleanrooms maintain particulate-free air through the use of either HEPA or ULPA
filters employing laminar or turbulent air flow principles. Laminar, or unidirectional, air
flow systems direct filtered air downward in a constant stream. Laminar air flow systems
are typically employed across 100% of the ceiling to maintain constant, unidirectional
flow. Laminar flow criteria is generally stated in portable work stations (LF hoods), and is
mandated in ISO-1 through ISO-4 classified cleanrooms.

Proper cleanroom design encompasses the entire air distribution system, including
provisions for adequate, downstream air returns. In vertical flow rooms, this means the use
of low wall air returns around the perimeter of the zone. In horizontal flow applications, it
requires the use of air returns at the downstream boundary of the process. The use of
ceiling mounted air returns is contradictory to proper cleanroom system design.
3

Cleanroom Classifications
Cleanrooms are classified by how clean the air is. In Federal Standard 209 (A to D)
of the USA, the number of particles equal to and greater than 0.5mm is measured in one
cubic foot of air, and this count is used to classify the cleanroom. This metric nomenclature
is also accepted in the most recent 209E version of the Standard. Federal Standard 209E is
used domestically. The newer standard is TC 209 from the International Standards
Organization. Both standards classify a cleanroom by the number of particles found in the
laboratory's air. The cleanroom classification standards FS 209E and ISO 14644-1 require
specific particle count measurements and calculations to classify the cleanliness level of a
cleanroom or clean area. In the UK, British Standard 5295 is used to classify cleanrooms.
This standard is about to be superseded by BS EN ISO 14644-1.

Cleanrooms are classified according to the number and size of particles permitted
per volume of air. Large numbers like "class 100" or "class 1000" refer to FED_STD-209E,
and denote the number of particles of size 0.5 mm or larger permitted per cubic foot of air.
The standard also allows interpolation, so it is possible to describe e.g. "class 2000."

Small numbers refer to ISO 14644-1 standards, which specify the decimal
logarithm of the number of particles 0.1 µm or larger permitted per cubic metre of air. So,
for example, an ISO class 5 cleanroom has at most 105 = 100,000 particles per m³.

Both FS 209E and ISO 14644-1 assume log-log relationships between particle size
and particle concentration. For that reason, there is no such thing as zero particle
concentration. Ordinary room air is approximately class 1,000,000 or ISO 9.

4

TYPES OF CLEANROOMS

Cleanrooms are also categorized by the way supply air is distributed. There are generally
two air supply configurations used in cleanroom design:

1) Non-unidirectional
2) Unidirectional.

Non-unidirectional air flow

In this airflow pattern, there will be considerable amount of turbulence and it can be
used in rooms where major contamination is expected from external source i.e. the make up
air. This turbulent flow enhances the mixing of low and high particle concentrations,
producing a homogenous particle concentration acceptable to the process.

Air is typically supplied into the space by one of two methods. The first uses supply
diffusers and HEPA filters. The HEPA filter may be integral to the supply diffuser or it may
be located upstream in the ductwork or air handler. The second method has the supply air
pre-filtered upstream of the cleanroom and introduced into the space through HEPA filtered
work stations. Non-unidirectional airflow may provide satisfactory control for cleanliness
levels of Class 1000 to Class 100,000.

5

Unidirectional air flow

The unidirectional air flow pattern is a single pass, single direction air flow of
parallel streams. It is also called 'laminar' airflow since the parallel streams are maintained
within 18 deg - 20 deg deviation. The velocity of air flow is maintained at 90 feet per minute
±20 as specified in Federal Standard 209 version B although later version E does not specify
any velocity standards.

6

Unidirectional cleanrooms are used where low air borne contaminant levels are
required, and where internal contaminants are the main concern.
They are generally of two types:

1. Vertical down-flow cleanrooms where the air flow is vertical „laminar‟ in direction.

2. Horizontal flow where the air flow is horizontal „laminar‟ in direction.

In vertical down-flow arrangement, clean make-up air is typically introduced at the ceiling
and returned through a raised floor or at the base of the side walls. Horizontal flow
cleanrooms use a similar approach, but with a supply wall on one side and a return wall on
the other.

Typically a down-flow cleanroom consists of HEPA filtered units mounted in the
ceiling. As the class of the cleanroom gets lower, more of the ceiling consists of HEPA
units, until, at Class 100, the entire ceiling will require HEPA filtration. The flow of air in a
down-flow cleanroom bathes the room in a downward flow of clean air. Contamination
generated in the room is generally swept down and out through the return.

The horizontal flow cleanroom uses the same filtration airflow technique as the
down-flow, except the air flows across the room from the supply wall to the return wall.
Between the two, the vertical down-flow pattern yield better results and is more adaptable to
pharmaceutical production.

7

Cleanrooms HVAC different from a normal comfort air conditioned space

A cleanroom requires a very stringent control of temperature, relative humidity,
particle counts in various rooms, air flow pattern and pressure differential between various
rooms of the clean air system. All this requires:

1. Increased Air Supply: Whereas comfort air conditioning would require about 2-10 air
changes/hr, a typical cleanroom, say Class 10,000, would require 50 - 100 air changes. This
additional air supply helps, to dilute the contaminants to an acceptable concentration.

2. High Efficiency Filters: The use of HEPA filters having filtration efficiency of 99.97%
down to 0.3 microns is another distinguishing feature of cleanrooms.

3. Terminal Filtration and Air Flow pattern: Not only are high efficiency filters used,
but a laminar flow is sought.

4. Room Pressurization: With the increased fresh air intake, cleanrooms are pressurized
in gradients. This is important to keep external particulates out of clean spaces.

8

SYSTEM DESIGN

The HVAC design process begins with meetings with process engineers, architects,
and representatives from the owner or facility user. The process and instrument diagrams
(P&IDs) are reviewed, and a general understanding of the process is conveyed to all
interested parties. Operation of the facility is reviewed, and any plans for future additions or
modifications are discussed.
After the initial meeting, a written basis of design is produced that describes the
regulations and codes that will govern the design. Spaces are defined by function, and
temperature and humidity requirements are determined. Room classifications are listed and
adjacency of spaces and pressure relationships are documented. Any unusual or unique
facility requirements must also be designed into the HVAC system at this time, such as
emergency backup or redundancy for HVAC systems. This is also the stage of the design
process during which alternate studies are conducted to compare options for the HVAC
system. The cost of a backup or redundant HVAC supply system may be compared with the
cost of product loss or experiment interruption should temperatures or airflow go out of
control or specification. Heat recovery from exhaust systems and thermal storage are
examples of other potential areas for study. Airflow diagrams are produced that show areas
served by a particular air handling system including supply, return, exhaust, and transfer air
between spaces. The basis of design also describes major equipment to be used and the level
of quality of components and construction material.

9

The efficiency of the system design is based on proper consideration of the following
factors:

1. Building construction and layout design
2. Defining the HVAC requirements system-wise and then room-wise.
– Cleanliness level
– Room temperature, relative humidity
– Room pressure
– Air flow pattern
3. Cooling load and Airflow compilation
4. Selection of air flow pattern
5. Pressurization of rooms
6. Air handling system
7. Duct system design and construction
8. Selection, location and mounting of filtration system
9. Defumigation requirement
10. Commissioning, performance qualification and validation
11. Testing and validation
12. Documentation

10

DESIGN WORKS

Temperature and Humidity
The design for each room are according to the its application. Each application have the
recommended temperature and humidity that suitable for the human activity and appliances
in that room. Required psychometric chart was selected

Table: Design temperature and humidity for normal room at Level 1 (first floor)



Room

Room
Training room
Prefunction
Finance & Administration Dept.
H&R Department
Reception
FABX & Server room
Visitors lounge
Purchasing Department
Q&A Office
Meeting room
Rest room 1
Rest room 2
Corridor 1
Corridor 2
Corridor 3
Engineering workshop
Canteen
Engineering office
Corridor lift
Equipment room
Goods lift

RH (%)
50.0
50.0
50.0
50.0
50.0
45.0
50.0
50.0
50.0
50.0
50.0
50.0
50.0
50.0
50.0
45.0
45.0
50.0
50.0
45.0
50.0

Temp room (°C)
25.0
25.0
25.0
25.0
25.0
23.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
23.0
23.0
25.0
25.0
23.0
25.0

11

Temp room (°F)
77.0
77.0
77.0
77.0
77.0
73.4
77.0
77.0
77.0
77.0
77.0
77.0
77.0
77.0
77.0
73.4
73.4
77.0
77.0
73.4
77.0

Enthalpy, H (btu/lb)
21.70
21.70
21.70
21.70
21.70
19.70
21.70
21.70
21.70
21.70
21.70
21.70
21.70
21.70
21.70
19.70
19.70
21.70
21.70
19.70
21.70

Table: Design temperature and humidity for clean room at Level 1 (first floor)



Cleanroom

cleanroom
Bosch Filling room
Packing room 1
Packing room 2
Packing room 3
Bottle Blower room
Bottle washing room
Filling room
Mixing room
Transfer air lock 1
Air Lock 1
Air Lock 2
Air Lock 3
Clean equipment room
Wash room
Wash booth
WIP Dispeen
Weihing booth
Liquid air lock
Liquid dispensary
Liquid store
Pharmacy store
Blending room
Air Lock 4
Wet Granulation & Drying room
WIP Storage
Encapsulation
Preparation rooom
Coating room
Service area
Tablet coating WIP
Air Lock 5
Transfer air lock 2
Tronic labelling

RH (%)
50
45
45
45
45
45
45
45
40
40
40
40
45
45
45
45
45
40
40
40
50
50
40
50
50
50
50
50
50
45
40
40
45

Temp room (°C)
23
24
24
24
24
24
24
24
23
23
23
23
24
24
24
24
24
23
23
23
25
25
23
25
25
25
25
25
25
24
23
23
24

12

Temp room (°F)
73.4
75.2
75.2
75.2
75.2
75.2
75.2
75.2
73.4
73.4
73.4
73.4
75.2
75.2
75.2
75.2
75.2
73.4
73.4
73.4
77
77
73.4
77
77
77
77
77
77
75.2
73.4
73.4
75.2

Enthalpy, H (btu/lb)
19.8
19.7
19.7
19.7
19.7
19.7
19.7
19.7
17.5
17.5
17.5
17.5
19.7
19.7
19.7
19.7
19.7
17.5
17.5
17.5
22.3
22.3
17.5
22.3
22.3
22.3
22.3
22.3
22.3
19.7
17.5
17.5
19.7

Table: Design temperature and humidity for normal room at Level 2 (second floor)



Room

Room
QC Product Development Dept
Board room
General Manager
Managing Director
Senior Manager
Secretary
Corridor
Write station
Existing Platform
M & E Room

RH (%)
50
50
50
50
50
50
50
50
50
50

Temp room (°C)
24
24
22
22
22
22
25
25
25
25

13

Temp room (°F)
75.2
75.2
71.6
71.6
71.6
71.6
77
77
77
77

Enthalpy, H (btu/lb)
20.2
20.2
19.7
19.7
19.7
19.7
21.2
21.2
21.2
21.2

Table: Design temperature and humidity for clean room at Level 2 (second floor)



Clean room

Clean room
Analytical laboratory
Instrument room
Coating room
Blister pack room
Oven room
Liquid storage
Liquid Mfg 1
Liquid Mfg 2
Corridor
Wash room 1
Wash room 2
Clean hose room
Operation room
Cream packing room
Cream filling room
Wet Granulation
WIP storage
Encapsulation
Air lock 1
Air lock 2
Air lock 3
Filling 1
Filling 2
Tablet press 1
Tablet press 2
Blending room
Technical mezzanine

RH (%)
45
45
45
45
45
40
40
40
40
40
40
40
40
40
40
45
45
45
40
40
40
45
45
50
50
50
50

Temp room (°C)
22
22
22
22
22
21
21
21
21
21
21
21
21
21
21
23
23
23
23
23
23
24
24
24
24
25
25

14

Temp room (°F)
71.6
71.6
71.6
71.6
71.6
69.8
69.8
69.8
69.8
69.8
69.8
69.8
69.8
69.8
69.8
73.4
73.4
73.4
73.4
73.4
73.4
75.2
75.2
75.2
75.2
77
77

Enthalpy, H (btu/lb)
18.9
18.9
18.9
18.9
18.9
17.9
17.9
17.9
17.9
17.9
17.9
17.9
17.9
17.9
17.9
19.3
19.3
19.3
19.5
19.5
19.5
22.1
22.1
23.4
23.4
22.4
22.4

HVAC SYSTEM

Pharmaceutical buildings have many room areas that required the HVAC system
installation which are air conditioning and ventilation. The system selection is plan
according to the application of the room, area, air volume flow rate and capacity required
for each room.
Table: Design HVAC system for each room at Level 1(first floor)

Room
Training room
Prefunction
Finance & Administration Dept.
H&R Department
Reception
FABX & Server room
Visitors lounge
Purchasing Department
Q&A Office
Meeting room
Rest room 1
Rest room 2
Corridor 1
Corridor 2
Corridor 3
Engineering workshop
Canteen
Engineering office
Corridor lift
Equipment room
Goods lift
Female toilet
Male toilet
Female surau
Male surau

HVAC system
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
Ventilation
Ventilation
Ventilation
Ventilation

15

Table: Design HVAC system for clean room at Level 1(first floor)

Clean room
Bosch Filling room
Packing room 1
Packing room 2
Packing room 3
Bottle Blower room
Bottle washing room
Filling room
Mixing room
Transfer air lock 1
Air Lock 1
Air Lock 2
Air Lock 3
Clean equipment room
Wash room
Wash booth
WIP Dispeen
Weihing booth
Liquid air lock
Liquid dispensary
Liquid store
Pharmacy store
Blending room
Air Lock 4
Wet Granulation & Drying room
WIP Storage
Encapsulation
Preparation rooom
Coating room
Service area
Tablet coating WIP
Air Lock 5
Transfer air lock 2
Tronic labelling

HVAC system
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU

16

Table: Design HVAC system for room at Level 2(second floor)

Room
QC Product Development Dept
Board room
General Manager
Managing Director
Senior Manager
Secretary
Corridor
Write station
Existing Platform
M & E Room

HVAC System
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF
VRF

Table: Design HVAC system for clean room at Level 2(second floor)

Clean room
Analytical laboratory
Instrument room
Coating room
Blister pack room
Oven room
Liquid storage
Liquid Mfg 1
Liquid Mfg 2
Corridor
Wash room 1
Wash room 2
Clean hose room
Operation room
Cream packing room
Cream filling room
Wet Granulation
WIP storage
Encapsulation
Air lock 1
Air lock 2
Air lock 3
Filling
Tablet press
Blending room
Technical mezzanine

HVAC system
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
AHU
17

AIR LEAKAGE

The leakage air is driven by air pressure differences that exist between the room and other
room and also between the inside of the building and the outside of the building. The
leakage air has the velocity according the pressure differences. The area of the opening area
will give the volume flow rate of air leakage that flow through the opening area.

Leakage velocity (fpm) = 4005 x (∆P)

1/ 2

in w.g

Leakage rate (cfm) = leakage veloccity x opening area (ft²)
Q (btu/hr) = 4.5 x air flow cfm x ∆h enthalpy difference (btu/lb)

18

Table: Air leakage table and it’s extend continuation below

Room

Bosch Filling room
Packing room 1
Packing room 2
Packing room 3
Bottle Blower room
Bottle washing room
Filling room
Mixing room
Transfer air lock 1
Air Lock 1
Air Lock 2
Air Lock 3
Clean equipment room
Wash room
Equipment room
WIP Dispeen
Weihing booth
Liquid air lock
Liquid dispensary
Liquid store
Pharmacy store
Blending room
Air Lock 4
Wet Granulation &
Drying room
WIP Storage
Encapsulation
Preparation rooom
Coating room
Service area
Tablet coating WIP
Air Lock 5
Transfer air lock 2
Tronic labelling
corridor lift

enthalpy
∆h

Opening type

in (w.g)
0.04
0.048
0.048
0.048
0.04
0.04
0.032
0.032
0.04
0.04
0.04
0.04
0.06
0.06
0.06
0.06
0.052
0.052
0.052
0.052
0.06
0.06
0.04

(btu/lb)
19.8
19.7
19.7
19.7
19.7
19.7
19.7
19.7
17.5
17.5
17.5
17.5
19.7
19.7
19.7
19.7
19.7
17.5
17.5
17.5
22.3
22.3
17.5

or door
two side door
two side door
two side door
two side door
two side door
two side door
two side door
one side door
two side door
one side door
one side door
one side door
two side door
two side door
one side door
two side door
two side door
one side door
one side door
one side door
two side door
two side door
one side door

pressure
in
Pa
(w.g)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
10
0.04
0
0
0
0
0
0
0
0
0
0

0.06
0.04
0.052
0.06
0.048
0.04
0.06
0.04
0.04
0.04
0.032

22.3
22.3
22.3
22.3
22.3
22.3
19.7
17.5
17.5
19.7
19.7

two side door
one side door
two side door
one side door
one side door
one side door
one side door
one side door
two side door
two side door
two side door

0
0
0
0
0
0
0
0
0
0
0

Pressure
Pa
10
12
12
12
10
10
8
8
1
1
1
1
15
15
15
15
13
13
13
13
15
15
1
15
10
13
15
12
10
15
1
1
10
8

19

0
0
0
0
0
0
0
0
0
0
0

enthalpy ∆h
(btu/lb)
20.4
20.2
20.2
20.2
20.2
20.2
20.1
21.2
20.2
21.3
21.3
21.3
20.2
21.2
21.2
21.2
21.2
20.4
20.4
20.4
23.1
23.1
21.3
23.1
22.9
23.1
23.1
23.2
23.2
20.4
21.3
20.2
23.3
22.3

dimension
width height
(m)
(m)
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.2
2
1.7
2
1.2
2
1.2
2
1.2
2
1.7
2
1.7
2
1.2
2
1.7
2
1.7
2
1.2
2
1.2
2
1.2
2
1.7
2
1.7
2
1.2
2
1.7
2
1.2
2
1.7
2
1.2
2
1.2
2
1.2
2
1.2
2
1.2
2
1.7
2
1.7
2
1.7
2

opening area

leakage velocity

(m²)
3.4
3.4
3.4
3.4
3.4
3.4
3.4
2.4
3.4
2.4
2.4
2.4
3.4
3.4
2.4
3.4
3.4
2.4
2.4
2.4
3.4
3.4
2.4
3.4
2.4
3.4
2.4
2.4
2.4
2.4
2.4
3.4
3.4
3.4

FPM
801.00
877.45
877.45
877.45
801.00
801.00
716.44
716.44
801.00
801.00
801.00
801.00
981.02
981.02
981.02
981.02
913.28
438.73
913.28
913.28
981.02
981.02
801.00
981.02
801.00
913.28
981.02
877.45
801.00
981.02
801.00
801.00
801.00
716.44

(ft²)
36.6
36.6
36.6
36.6
36.6
36.6
36.6
25.8
36.6
25.8
25.8
25.8
36.6
36.6
25.8
36.6
36.6
25.8
25.8
25.8
36.6
36.6
25.8
36.6
25.8
36.6
25.8
25.8
25.8
25.8
25.8
36.6
36.6
36.6

(m/s)
4.07
4.46
4.46
4.46
4.07
4.07
3.64
3.64
4.07
4.07
4.07
4.07
4.98
4.98
4.98
4.98
4.64
2.23
4.64
4.64
4.98
4.98
4.07
4.98
4.07
4.64
4.98
4.46
4.07
4.98
4.07
4.07
4.07
3.64

20

leakage rate
CFM
29317.29
32115.49
32115.49
32115.49
29317.29
29317.29
26222.19
18509.78
29317.29
20694.56
20694.56
20694.56
35906.21
35906.21
25345.56
35906.21
33426.86
11334.88
23595.43
23595.43
35906.21
35906.21
20694.56
35906.21
20694.56
33426.86
25345.56
22669.76
20694.56
25345.56
20694.56
29317.29
29317.29
26222.19

CMH
49803.11
54556.57
54556.57
54556.57
49803.11
49803.11
44545.25
31443.71
49803.11
35155.14
35155.14
35155.14
60996.1
60996.1
43056.07
60996.1
56784.28
19255.26
40083.02
40083.02
60996.1
60996.1
35155.14
60996.1
35155.14
56784.28
43056.07
38510.52
35155.14
43056.07
35155.14
49803.11
49803.11
44545.25

enthalpy
∆h
Capacity, Q
(btu/lb)
0.6
0.5
0.5
0.5
0.5
0.5
0.4
1.5
2.7
3.8
3.8
3.8
0.5
1.5
1.5
1.5
1.5
2.9
2.9
2.9
0.8
0.8
3.8
0.8
0.6
0.8
0.8
0.9
0.9
0.7
3.8
2.7
3.6
2.6

(btu/hr)
79156.7
72259.8
72259.8
72259.8
65963.9
65963.9
47199.9
124941.0
356205.1
353877.0
353877.0
353877.0
80789.0
242366.9
171082.5
242366.9
225631.3
147920.2
307920.4
307920.4
129262.3
129262.3
353877.0
129262.3
55875.3
120336.7
91244.0
91812.5
83813.0
79838.5
353877.0
356205.1
474940.2
306799.6

AIR VOLUME FLOWRATE

There are 2floor of pharmaceutical factory and each floor has the different space and
different applications. Different applications of the place have different air change per hour
and different air volume flow rate that required to supplies to the place.

There are the formulas required in order to calculate the volume flow rate:-

Area = length x width
Volume = Area x height
Volume flow rate = ACH x Volume

The Air flow rate calculation is only for the room that using the ductings which are its
using the AHU with centralized chiller or ventilation system with exhaust fan. In order to
design the ductwork, air flow rate of each room is important.

Table 10: The ACH (air change per hour) are selected according the standard.

21

Table: Area, volume and air volume flow rate for each room at 1st floor

No.
1
2
3
4
5
6
7
8
9
10
11
12
13

AHU 1
1st floor
for clean room
Room
Bosch Filling room
Packing room 1
Packing room 2
Packing room 3
Bottle Blower room
Bottle washing room
Filling room
Mixing room
Transfer air lock 1
Air Lock 1
Air Lock 2
Air Lock 3
Corridor lift

Height
m
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5

Area
m²
126.63
40.16
27.30
65.30
65.30
65.30
37.41
14.16
9.92
18.24
5.52
6.70
130.38

Volume
m³
443.2
140.6
95.6
228.6
228.6
228.6
130.9
49.6
34.7
63.8
19.3
23.4
456.3

ACH

Supply Air
Volume flow rate / diffuser
Actual Volume Flow rate
CMH/diffuser
1354.2
1265.1
1074.9
1714.2
1571.3
1571.3
1309.2
1486.8
1215.5
1117.2
1353.0
1640.9
1597.2

CMH
24376.3
6325.6
4299.8
10285.1
12570.6
12570.6
7855.3
2973.6
2431.0
4468.8
1353.0
1640.9
15971.6

L/s
6771.2
1757.1
1194.4
2857.0
3491.8
3491.8
2182.0
826.0
675.3
1241.3
375.8
455.8
4436.5

22

CFM
14349.4
3723.6
2531.1
6054.4
7399.9
7399.9
4624.1
1750.5
1431.0
2630.6
796.5
965.9
9401.9

55
45
45
45
55
55
60
60
70
70
70
70
35

Volume Flow rate
CMH
L/s
CFM
24376.3
6771.1875 14349.43
6325.6
1757.1094
3723.65
4299.8
1194.375
2531.11
10285.1
2856.9625
6054.45
12570.6
3491.8431
7399.88
12570.6
3491.8431
7399.88
7855.3
2182.0167
4624.11
2973.6
826
1750.45
2431.0
675.28125
1431.05
4468.8
1241.3333
2630.62
1353.0
375.83681
796.47
1640.9
455.80208
965.93
15971.6
4436.5417
9401.88

cfm/diffuser
1,794
1,241
1,266
1,211
1,480
1,480
1,156
1,750
1,431
1,315
796
966
1,567

1,800
1,240
1,260
1,200
1,480
1,480
1,200
1,750
1,430
1,300
800
1,000
1,550

Diffuser/supply
8
3
2
5
5
5
4
1
1
2
1
1
6

Return Air
Return air

Volume flow
rate / diffuser

Percentage
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7

CMH/diffuser
1138
1107
1003
1200
1257
1257
1100
1041
851
1043
947
1149
1398

Actual Volume Flow rate
CMH
17063.393
4427.9156
3009.825
7199.5455
8799.4445
8799.4445
5498.682
2081.52
1701.7088
3128.16
947.10875
1148.6213
11180.085

L/s
4739.8
1230.0
836.1
1999.9
2444.3
2444.3
1527.4
578.2
472.7
868.9
263.1
319.1
3105.6

cfm/grille

CFM
10044.6
2606.6
1771.8
4238.1
5179.9
5179.9
3236.9
1225.3
1001.7
1841.4
557.5
676.2
6581.3

1,674
1,303
886
1,413
1,727
1,727
1,618
1,225
1,002
1,841
558
676
1,645

1,680
1,300
880
1,400
1,700
1,700
1,600
1,200
1,000
1,840
560
680
1,650

Grille/return
6
2
2
3
3
3
2
1
1
1
1
1
4

Table: Area, volume and air volume flow rate for each room at 1st floor

AHU 2
No.
1
2
3
4
5
6
7
8
9
10

Room
Equipment room
Weihing booth
Liquid air lock
Liquid dispensary
Liquid store
Pharmacy store
Blending room
Air Lock 4
Transfer air lock 2
Tronic labelling

Height
m
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5

Area
m²
12.3
69.68
7.68
12.8
14.08
145
59.69
25.8
48.45
256.5

23

Volume
m³
43.05
243.88
26.88
44.8
49.28
507.5
208.915
90.3
169.575
897.75

ACH
35
45
50
50
50
35
50
70
70
50

Volume Flow rate
CMH
L/s
CFM
1506.75
418.5
887.0
10974.6
3048.5
6460.4
1344
373.3
791.2
2240
622.2
1318.6
2464
684.4
1450.5
17762.5
4934.0
10456.1
10445.75
2901.6
6149.0
6321
1755.8
3720.9
11870.25
3297.3
6987.6
44887.5
12468.8
26423.7

Supply Air
Volume flow rate / diffuser
Actual Volume Flow rate
CMH/diffuser
1506.75
1371.83
1344.00
1120.00
1232.00
1480.21
1305.72
2107.00
1187.03
1726.44

CMH
1506.75
10974.6
1344
2240
2464
17762.5
10445.75
6321
11870.25
44887.5

L/s
418.5
3048.5
373.3
622.2
684.4
4934.0
2901.6
1755.8
3297.3
12468.8

CFM
887.0
6460.4
791.2
1318.6
1450.5
10456.1
6149.0
3720.9
6987.6
26423.7

cfm/diffuser
887
1,615
791
1,319
1,450
1,307
1,230
1,240
1,747
1,651

Diffuser/supply

890
1,600
800
1,300
1,450
1,300
1,230
1,240
1,750
1,650

1
4
1
1
1
8
5
3
4
16

cfm/grille

Grille/return

Return Air
Return air

Volume flow rate /
diffuser

Percentage
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7

CMH/diffuser
1054.73
1280.37
940.80
1568.00
862.40
1243.38
1218.67
1106.18
1038.65
1745.63

Actual Volume Flow rate
CMH
1054.7
7682.2
940.8
1568.0
1724.8
12433.8
7312.0
4424.7
8309.2
31421.3

24

L/s
293.0
2134.0
261.3
435.6
479.1
3453.8
2031.1
1229.1
2308.1
8728.1

CFM
620.9
4522.2
553.8
923.0
1015.3
7319.3
4304.3
2604.7
4891.3
18496.6

621
1,507
554
923
1,015
1,464
1,435
1,302
1,630
1,541

620
1,500
550
930
1,100
1,470
1,440
1,300
1,630
1,500

1
3
1
1
1
5
3
2
3
12

Table: Area, volume and air volume flow rate for each room at 1st floor

AHU 3
No.
1
2
3
4
5
6
7
8
9
10
11

Room
Clean equipment room
Wash room
WIP Dispeen
Wet Granulation &
Drying room
WIP Storage
Encapsulation
Preparation rooom
Coating room
Service area
Tablet coating WIP
Air Lock 5

Height
m
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5
3.5

Area
m²
71.34
64.8
45.76
66.24
61.44
66.24
43.5
39.55
39.55
29.29
9.3025

Volume
m³
249.69
226.8
160.16

ACH

231.84
215.04
231.84
152.25
138.425
138.425
102.515
32.55875

50
50
45
40
55
40
45
70

50
50
50

Volume Flow rate
CMH
L/s
CFM
12484.5
3467.91 7349.2
11340
3150
6675.4
8008
2224.44 4714.0
11592
10752
10432.8
6090
7613.375
5537
4613.175
2279.1125

3220
2986.66
2898
1691.66
2114.82
1538.05
1281.43
633.086

6823.8
6329.3
6141.4
3585.0
4481.7
3259.4
2715.6
1341.6

Supply Air
Volume flow rate /
diffuser
CMH/diffuser
1248.45
1417.50
1334.67
1449.00
1344.00
1304.10
1522.50
1268.90
1384.25
1153.29
1139.56

Actual Volume Flow rate
CMH
12484.5
11340
8008
11592
10752
10432.8
6090
7613.375
5537
4613.175
2279.1125

L/s
3467.91
3150
2224.44
3220
2986.67
2898
1691.67
2114.89
1538.06
1281.45
633.086

25

cfm/diffuser
CFM
7349.2
6675.4
4714.0
6823.8
6329.3
6141.4
3585.0
4481.7
3259.4
2715.6
1341.6

1,470
1,669
1,571
1,706
1,266
1,228
1,195
1,494
1,086
1,358
1,342

1,470
1,700
1,580
1,700
1,300
1,290
1,200
1,500
1,100
1,400
1,340

Diffuser/supply
5
4
3
4
5
5
3
3
3
2
1

Return air
Percentage
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7

Return Air
Volume flow rate / diffuser
Actual Volume Flow rate
CMH/diffuser
1456.53
1323.00
1401.40
1352.40
1254.40
1217.16
1421.00
1332.34
1291.97
1076.41
1595.38

CMH
8739.2
7938.0
5605.6
8114.4
7526.4
7303.0
4263.0
5329.4
3875.9
3229.2
1595.4

26

L/s
2427.5
2205.0
1557.1
2254.0
2090.7
2028.6
1184.2
1480.4
1076.6
897.0
443.2

CFM
5144.4
4672.8
3299.8
4776.7
4430.5
4299.0
2509.5
3137.2
2281.6
1900.9
939.1

cfm/grille
1286
1558
1650
1592
1108
1075
1255
1569
1141
950
939

1290
1560
1650
1600
1100
1100
1300
1600
1150
950
950

Grille/return
4
3
2
3
4
4
2
2
2
2
1

AHU 1 (2nd floor)
Room

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Analytical laboratory
Instrument room
Coating room
Blister pack room
Oven room
Liquid storage
Liquid Mfg 1
Liquid Mfg 2
Corridor
Wash room 1
Wash room 2
Clean hose room
Operation room
Cream packing room
Cream filling room
RHL Preparation & Cleaning
Air lock 1

Height
m
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3

Area
m²
167.4
57.5
39.0
39.0
39.0
21.8
21.8
21.8
170.5
27.6
27.6
27.6
46.9
46.9
46.9
81.3
21.84

Volume
m³
502.2
172.4
117.0
117.0
117.0
65.5
65.5
65.5
511.4
82.7
82.7
82.7
140.6
140.6
140.6
243.8
65.5

Supply Air
Volume flow rate / diffuser
Actual Volume Flow rate
CMH/diffuser
1597.98
1580.15
1608.75
1608.75
1608.75
1310.40
1310.40
1310.40
1491.57
1136.85
1136.85
1136.85
1546.88
1546.88
1205.36
1219.20
1146.60

CMH
35155.6
9480.9
6435.0
6435.0
6435.0
3931.2
3931.2
3931.2
17898.8
4547.4
4547.4
4547.4
7734.4
7734.4
8437.5
14630.4
4586.4

L/s
9765.4
2633.6
1787.5
1787.5
1787.5
1092.0
1092.0
1092.0
4971.9
1263.2
1263.2
1263.2
2148.4
2148.4
2343.8
4064.0
1274.0
27

CFM
20694.8
5581.1
3788.1
3788.1
3788.1
2314.2
2314.2
2314.2
10536.4
2676.9
2676.9
2676.9
4552.9
4552.9
4966.9
8612.4
2699.8

ACH
70
55
55
55
55
60
60
60
35
55
55
55
55
55
60
60
70

Volume Flow rate
CMH
L/s
CFM
35155.6 9765.4
20694.8
9480.9
2633.6
5581.1
6435.0
1787.5
3788.1
6435.0
1787.5
3788.1
6435.0
1787.5
3788.1
3931.2
1092.0
2314.2
3931.2
1092.0
2314.2
3931.2
1092.0
2314.2
17898.8 4971.9
10536.4
4547.4
1263.2
2676.9
4547.4
1263.2
2676.9
4547.4
1263.2
2676.9
7734.4
2148.4
4552.9
7734.4
2148.4
4552.9
8437.5
2343.8
4966.9
14630.4 4064.0
8612.4
4586.4
1274.0
2699.8

cfm/diffuser
1,478
1,395
1,263
1,263
1,263
1,157
1,157
1,157
1,317
1,338
1,338
1,338
1,518
1,138
1,242
1,435
1,350

1,480
1,400
1270
1270
1270
1200
1200
1200
1320
1340
1340
1340
1500
1140
1250
1440
1350

Diffuser/supply
14
4
3
3
3
2
2
2
8
2
2
2
3
4
4
6
2

Return air
Percentage
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7

Return Air
Volume flow rate / diffuser
Actual Volume Flow rate
CMH/diffuser
1538.1
1659.2
1501.5
1501.5
1501.5
1375.9
1375.9
1375.9
1566.1
1061.1
1061.1
1061.1
1353.5
1353.5
1476.6
1280.2

CMH
24608.9
6636.6
4504.5
4504.5
4504.5
2751.8
2751.8
2751.8
12529.2
3183.2
3183.2
3183.2
5414.1
5414.1
5906.3
10241.3

28

L/s
6835.8
1843.5
1251.3
1251.3
1251.3
764.4
764.4
764.4
3480.3
884.2
884.2
884.2
1503.9
1503.9
1640.6
2844.8

CFM
14486.4
3906.7
2651.6
2651.6
2651.6
1619.9
1619.9
1619.9
7375.5
1873.8
1873.8
1873.8
3187.1
3187.1
3476.8
6028.7

cfm/grille
1449
1302
1326
1326
1326
1620
1620
1620
1229
937
937
937
1594
1062
1159
1507

1450
1300
1330
1330
1330
1620
1620
1620
1230
950
950
950
1590
1100
1200
1500

Grille/return
10
3
2
2
2
1
1
1
6
2
2
2
2
3
3
4

Return Air
No.
1
2
3
5
6
7
8
9
10
11
12
13

AHU 2
Room
Wet Granulation
WIP storage
Encapsulation
Air lock 2
Air lock 3
Air lock 4
Filling 1
Filling 2
Tablet press 1
Tablet press 2
Blending room
Technical mezzanine

Height
m
3
3
3
3
3
3
3
3
3
3
3
3

Area
m²
87.5
45.4
45.4
14.2
18.5
17.3
24.7
24.7
34.0
34.0
89.1
382.1

Volume
m³
262.5
136.2
136.2
42.5
55.4
52.0
74.2
74.2
101.9
101.9
267.3
1146.3

ACH
40
40
40
70
70
70
60
60
55
55
60
50

Supply Air
Volume flow rate / diffuser
Actual Volume Flow rate
CMH/diffuser
1312.50
1362.08
1362.08
1487.06
1291.50
1212.75
1112.74
1112.74
1400.95
1400.95
1336.50
1791.04

CMH
10500.0
5448.3
5448.3
2974.1
3874.5
3638.3
4451.0
4451.0
5603.8
5603.8
16038.0
57313.1

L/s
2916.7
1513.4
1513.4
826.1
1076.3
1010.6
1236.4
1236.4
1556.6
1556.6
4455.0
15920.3

29

CFM
6181.0
3207.2
3207.2
1750.8
2280.8
2141.7
2620.1
2620.1
3298.8
3298.8
9441.0
33738.2

CMH
10500.0
5448.3
5448.3
2974.1
3874.5
3638.3
4451.0
4451.0
5603.8
5603.8
16038.0
57313.1

Volume Flow rate
L/s
CFM
2916.7
6181.0
1513.4
3207.2
1513.4
3207.2
826.1
1750.8
1076.3
2280.8
1010.6
2141.7
1236.4
2620.1
1236.4
2620.1
1556.6
3298.8
1556.6
3298.8
4455.0
9441.0
15920.3
33738.2

cfm/diffuser
1,545
1,069
1,069
1,751
1,140
1,071
1,310
1,310
1,649
1,649
1,573
1,687

1,550
1,100
1,100
1750
1200
1100
1300
1300
1650
1650
1570
1690

Diffuser/supply
4
3
3
1
2
2
2
2
2
2
6
20

Return air

Volume flow rate /
diffuser

Percentage
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7

CMH/diffuser
1225.0
1271.3
1271.3
1040.9
1356.1
1273.4
1038.6
1038.6
1307.6
1307.6
1403.3
1671.6

Actual Volume Flow rate
CMH
7350.0
3813.8
3813.8
2081.9
2712.2
2546.8
3115.7
3115.7
3922.7
3922.7
11226.6
40119.2

30

L/s
2041.7
1059.4
1059.4
578.3
753.4
707.4
865.5
865.5
1089.6
1089.6
3118.5
11144.2

CFM
4326.7
2245.1
2245.1
1225.5
1596.5
1499.2
1834.1
1834.1
2309.1
2309.1
6608.7
23616.7

cfm/grille
1442
1123
1123
1226
1597
1499
917
917
1155
1155
1652
1687

1440
1120
1120
1230
1600
1500
930
930
1200
1200
1660
1690

Grille/return
3
2
2
1
1
1
2
2
2
2
4
14

VRF Consideration Selection

Level 1 : Room criteria for non cleanroom space

Room name
Training room
Prefunction
Finance & Administration
Dept.
H&R Department
Reception
FABX & Server room
Visitors lounge
Purchasing Department
Q&A Office
Meeting room
Female toilet
Male toilet
Janitor
Female surau
Male surau
Rest room 1
Rest room 2
Corridor lift
Equipment room
Corridor 1
Corridor 2
Corridor 3
Engineering workshop
Canteen
Engineering office

TR
4.03
1.96
4.00
3.02
6.19
0.66
0.71
3.44
3.57
10.95
1.27
1.27
0.30
2.38
2.38
1.20
1.20
6.02
0.49
2.07
3.41
3.41
4.66
6.98
2.73

kW

HP
14.17
6.91

19
9

14.06
10.64
21.78
2.32
2.50
12.11
12.55
38.52
4.47
4.47
1.07
8.36
8.36
4.22
4.22
21.17
1.74
7.29
12.01
12.01
16.37
24.55
9.59

19
14
29
3
3
16
17
52
6
6
1
11
11
6
6
28
2
10
16
16
22
33
13

Total HP for this room area is 369 HP

31

Level 2 : Room criteria for non cleanroom space

Room name
QC Product Development
Dept
Board room
General Manager
Managing Director
Senior Manager
Secretary
Corridor
Write station
RHL Preparation & Cleaning
M & E Room

TR
14.36
1.13
0.98
0.98
0.61
0.61
3.90
2.26
3.67
3.21

kW

HP
50.51
3.98
3.46
3.46
2.14
2.14
13.71
7.93
12.89
11.28

Total HP for this room area is 149 HP

32

68
5
5
5
3
3
18
11
17
15

SELECTION DIFFUSER

No.
1
2
3
4
5
6
7
8
9
10
11
12
13

AHU 1
1st floor
for cleanroom
Room

cfm/

Bosch Filling room
Packing room 1
Packing room 2
Packing room 3
Bottle Blower room
Bottle washing room
Filling room
Mixing room
Transfer air lock 1
Air Lock 1
Air Lock 2
Air Lock 3
Corridor lift

grille
1,680
1,300
880
1,400
1,700
1,700
1,600
1,200
1,000
1,840
560
680
1,650

Total cfm for AHU 1 = 17190 cfm

33

grille
6
2
2
3
3
3
2
1
1
1
1
1
4

AHU 2
No.
1
2
3
4
5
6
7
8
9
10

Room

cfm/

Equipment room
Weihing booth
Liquid air lock
Liquid dispensary
Liquid store
Pharmacy store
Blending room
Air Lock 4
Transfer air lock 2
Tronic labelling

grille
620
1,500
550
930
1,100
1,470
1,440
1,300
1,630
1,500

grille
1
3
1
1
1
5
3
2
3
12

Total cfm for AHU 2 = 12 040 cfm

AHU 3
No.
1
2
3
4
5
6
7
8
9
10
11

Room

cfm/

Clean equipment room
Wash room
WIP Dispeen
Wet Granulation & Drying room
WIP Storage
Encapsulation
Preparation rooom
Coating room
Service area
Tablet coating WIP
Air Lock 5

grille
1290
1560
1650
1600
1100
1100
1300
1600
1150
950
950

Total cfm for AHU 3 = 14 250 cfm

34

grille
4
3
2
3
4
4
2
2
2
2
1

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

2nd floor
AHU 1
Room

cfm/

Analytical laboratory
Instrument room
Coating room
Blister pack room
Oven room
Liquid storage
Liquid Mfg 1
Liquid Mfg 2
Corridor
Wash room 1
Wash room 2
Clean hose room
Operation room
Cream packing room
Cream filling room
RHL Preparation & Cleaning
Air lock 1

grille
1450
1300
1330
1330
1330
1620
1620
1620
1230
950
950
950
1590
1100
1200
1500
960

Level 2
Total cfm for AHU 1 = 22 030 cfm

35

grille
10
3
2
2
2
1
1
1
6
2
2
2
2
3
3
4
2

No.
1
2
3
5
6
7
8
9
10
11
12
13

AHU 2
Room

cfm/

Wet Granulation
WIP storage
Encapsulation
Air lock 2
Air lock 3
Air lock 4
Filling 1
Filling 2
Tablet press 1
Tablet press 2
Blending room
Technical mezzanine

grille
1440
1120
1120
1230
1600
1500
930
930
1200
1200
1660
1690

Total cfm for AHU 2 = 15 620 cfm

36

grille
3
2
2
1
1
1
2
2
2
2
4
14

SUGGESTED SPECIFICATIONS

Furnish Aluminum Square Diffusers where shown on the plans. The Square
Diffusers shall have margins to cover the ceiling openings and minimize smudging. The
Diffusers shall be of the flush type as shown on the plans. Corners of the outer core shall be
mechanically fastened to provide precise mitered corners. Diffusers shall be in removable
construction to facilitate access to Damper and also for concealed fixing. Where shown, the
Diffusers shall be provided with Opposed Blade Volume Control Dampers manufactured
out of Aluminum. Diffusers shall be powder coated to the approved shade. Dampers shall
be painted to matt black shade.

Table: Selection of size return for AHU

37

Table: Selection of size supply for AHU

38

CAPACITY
First Floor AHU 1
Room

Pressure
in
(w.g)

Pa
Bosch Filling room
Packing room 1
Packing room 2
Packing room 3
Bottle Blower room
Bottle washing room
Filling room
Mixing room
Transfer air lock 1
Air Lock 1
Air Lock 2
Air Lock 3
Corridor lift

dimension
width height
(m)
(m)
1.7
1.7
1.7
1.7
1.7
1.7
1.7
1.2
1.7
1.2
1.2
1.2
1.7

2
2
2
2
2
2
2
2
2
2
2
2
2

10
12
12
12
10
10
8
8
1
1
1
1
10

opening area

enthalpy ∆h

Opening type

(btu/lb)

or door

19.8
19.7
19.7
19.7
19.7
19.7
19.7
19.7
17.5
17.5
17.5
17.5
19.7

hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium

0.04
0.048
0.048
0.048
0.04
0.04
0.032
0.032
0.004
0.004
0.004
0.004
0.04

leakage velocity

pressure
enthalpy ∆h
in
Pa
(w.g)
(btu/lb)
0
0
0
0
0
0
0
0
0
0
0
0
0

enthalpy
∆h

leakage rate

0
0
0
0
0
0
0
0
0
0
0
0
0

20.4
20.2
20.2
20.2
20.2
20.2
20.1
21.2
20.2
21.3
21.3
21.3
22.8

Capacity, Q

(m²)

(ft²)

FPM

(m/s)

CFM

CMH

(btu/lb)

(btu/hr)

3.4
3.4
3.4
3.4
3.4
3.4
3.4
2.4
3.4
2.4
2.4
2.4
3.4

36.6
36.6
36.6
36.6
36.6
36.6
36.6
25.8
36.6
25.8
25.8
25.8
36.6

801.0
877.5
877.5
877.5
801.0
801.0
716.4
716.4
253.3
253.3
253.3
253.3
801.0

4.1
4.5
4.5
4.5
4.1
4.1
3.6
3.6
1.3
1.3
1.3
1.3
4.1

29317.3
32115.5
32115.5
32115.5
29317.3
29317.3
26222.2
18509.8
9270.9
6544.2
6544.2
6544.2
29317.3

49803.1
54556.6
54556.6
54556.6
49803.1
49803.1
44545.3
31443.7
15749.1
11117.0
11117.0
11117.0
49803.1

0.6
0.5
0.5
0.5
0.5
0.5
0.4
1.5
2.7
3.8
3.8
3.8
3.1

79156.7
72259.8
72259.8
72259.8
65963.9
65963.9
47199.9
124941.0
112642.0
111905.7
111905.7
111905.7
408976.3

Total Btu/hr =
Tonne =

1457340.4
121.4

39

AHU 2
Room

Pressure
Pa

Equipment room
Weihing booth
Liquid air lock
Liquid dispensary
Liquid store
Pharmacy store
Blending room
Air Lock 4
Transfer air lock 2
Tronic labelling

dimension
width
height
(m)
(m)
1.2
2
1.7
2
1.2
2
1.2
2
1.2
2
1.7
2
1.7
2
1.2
2
1.7
2
1.7
2

15
13
13
13
13
15
15
1
1
10

opening area
(m²)
2.4
3.4
2.4
2.4
2.4
3.4
3.4
2.4
3.4
3.4

(ft²)
25.8
36.6
25.8
25.8
25.8
36.6
36.6
25.8
36.6
36.6

in
(w.g)
0.06
0.052
0.052
0.052
0.052
0.06
0.06
0.04
0.04
0.04

enthalpy ∆h

Opening type

(btu/lb)
19.7
19.7
17.5
17.5
17.5
22.3
22.3
17.5
17.5
19.7

or door
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium

leakage velocity
FPM
981.0
913.3
438.7
913.3
913.3
981.0
981.0
801.0
801.0
801.0

(m/s)
5.0
4.6
2.2
4.6
4.6
5.0
5.0
4.1
4.1
4.1

40

leakage rate
CFM
25345.6
33426.9
11334.9
23595.4
23595.4
35906.2
35906.2
20694.6
29317.3
29317.3

enthalpy
∆h

pressure
Pa
0
0
10
0
0
0
0
0
0
0

in
(w.g)
0
0
0.04
0
0
0
0
0
0
0

enthalpy ∆h

CMH
(btu/lb)
43056.1
1.5
56784.3
1.5
19255.3
2.9
40083.0
2.9
40083.0
2.9
60996.1
0.8
60996.1
0.8
35155.1
3.8
49803.1
2.7
49803.1
3.6
Total Btu/hr =
Tonne =

(btu/lb)
21.2
21.2
20.4
20.4
20.4
23.1
23.1
21.3
20.2
23.3

Capacity, Q
(btu/hr)
171082.5
225631.3
147920.2
307920.4
307920.4
129262.3
129262.3
353877.0
356205.1
474940.2
2604021.7
217.0

AHU 3
Room

Pressure

Clean equipment room
Wash room
WIP Dispeen
Wet Granulation & Drying room
WIP Storage
Encapsulation
Preparation rooom
Coating room
Service area
Tablet coating WIP
Air Lock 5

dimension
width
height
(m)
(m)
1.7
2
1.7
2
1.7
2
1.7
2
1.2
2
1.7
2
1.2
2
1.2
2
1.2
2
1.2
2
1.2
2

Pa
15
15
15
15
10
13
15
12
10
15
1

opening area
(m²)
3.4
3.4
3.4
3.4
2.4
3.4
2.4
2.4
2.4
2.4
2.4

(ft²)
36.6
36.6
36.6
36.6
25.8
36.6
25.8
25.8
25.8
25.8
25.8

in (w.g)
0.06
0.06
0.06
0.06
0.04
0.052
0.06
0.048
0.04
0.06
0.04

enthalpy
∆h
(btu/lb)
19.7
19.7
19.7
22.3
22.3
22.3
22.3
22.3
22.3
19.7
17.5

leakage velocity
FPM
981.0
981.0
981.0
981.0
801.0
913.3
981.0
877.5
801.0
981.0
801.0

(m/s)
5.0
5.0
5.0
5.0
4.1
4.6
5.0
4.5
4.1
5.0
4.1

41

Opening type
or door
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium

leakage rate
CFM
35906.2
35906.2
35906.2
35906.2
20694.6
33426.9
25345.6
22669.8
20694.6
25345.6
20694.6

pressure
in
Pa
(w.g)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

enthalpy ∆h

CMH
(btu/lb)
60996.1
0.5
60996.1
1.5
60996.1
1.5
60996.1
0.8
35155.1
0.6
56784.3
0.8
43056.1
0.8
38510.5
0.9
35155.1
0.9
43056.1
0.7
35155.1
3.8
Total Btu/hr =
Tonne =

enthalpy
∆h
(btu/lb)
20.2
21.2
21.2
23.1
22.9
23.1
23.1
23.2
23.2
20.4
21.3

Capacity, Q
(btu/hr)
80789.0
242366.9
242366.9
129262.3
55875.3
120336.7
91244.0
91812.5
83813.0
79838.5
353877.0
1571582.1
131.0

Second Floor AHU 1
Room
Analytical laboratory
Instrument room
Coating room
Blister pack room
Oven room
Liquid storage
Liquid Mfg 1
Liquid Mfg 2
Corridor
Wash room 1
Wash room 2
Clean hose room
Operation room
Cream packing room
Cream filling room
RHL Preparation & Cleaning

dimension
width
height
(m)
(m)
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2

Pressure
Pa
in (w.g)
15
0.06
10
0.04
15
0.06
15
0.06
15
0.06
12
0.048
12
0.048
12
0.048
15
0.06
12
0.048
12
0.048
13
0.052
13
0.052
13
0.052
12
0.048
15
0.06

opening area
(m²)
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4

(ft²)
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087

enthalpy ∆h
(btu/lb)
19.7
22.2
19.7
19.7
19.7
20.3
20.3
20.3
19.7
20.3
20.3
19.9
19.9
19.9
20.3
22

leakage velocity
FPM
981.0206
801
981.0206
981.0206
981.0206
877.4515
877.4515
877.4515
981.0206
877.4515
877.4515
913.2805
913.2805
913.2805
877.4515
981.0206

(m/s)
4.983342
4.068881
4.983342
4.983342
4.983342
4.457236
4.457236
4.457236
4.983342
4.457236
4.457236
4.639239
4.639239
4.639239
4.457236
4.983342

42

Opening type
or door
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium

leakage rate
CFM
35906.21
29317.29
35906.21
35906.21
35906.21
32115.49
32115.49
32115.49
35906.21
32115.49
32115.49
33426.86
33426.86
33426.86
32115.49
35906.21

pressure
Pa
in (w.g)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

enthalpy
∆h

CMH
(btu/lb)
60996.1
0.8
49803.11
0.8
60996.1
1.3
60996.1
1.3
60996.1
1.3
54556.57
1.2
54556.57
1.2
54556.57
1.2
60996.1
1.1
54556.57
1
54556.57
0.7
56784.28
0.9
56784.28
0.9
56784.28
0.9
54556.57
1.6
60996.1
1
Total Btu/hr =

enthalpy ∆h
(btu/lb)
20.5
23
21
21
21
21.5
21.5
21.5
20.8
21.3
21
20.8
20.8
20.8
21.9
23

Capacity, Q
(btu/hr)
129262.3432
105542.2612
210051.3076
210051.3076
210051.3076
173423.6317
173423.6317
173423.6317
177735.7218
144519.6931
101163.7852
135378.7791
135378.7791
135378.7791
231231.509
161577.929
2607594.398

Tonne =

217.2995332

AHU 2
Room

Pressure
Pa

Wet Granulation
WIP storage
Encapsulation
Air lock 1
Air lock 2
Air lock 3
Air lock 4
Filling 1
Filling 2
Tablet press 1
Tablet press 2
Blending room
Technical mezzanine

dimension
width height
(m)
(m)
1.7
2
1.7
2
1.7
2
1.2
2
1.2
2
1.2
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2
1.7
2

15
15
15
1
1
1
1
12
12
13
13
15
10

opening area
(m²)
3.4
3.4
3.4
2.4
2.4
2.4
3.4
3.4
3.4
3.4
3.4
3.4
3.4

(ft²)
36.60087
36.60087
36.60087
25.83591
25.83591
25.83591
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087
36.60087

in (w.g)
0.06
0.06
0.06
0.004
0.004
0.004
0.004
0.048
0.048
0.052
0.052
0.06
0.04

enthalpy ∆h

Opening type

(btu/lb)
19.7
19.7
19.7
23.4
23.4
23.4
23.4
20.3
20.3
19.9
19.9
19.7
22.2

or door
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium
hard aluminium

leakage velocity
FPM
981.0206
981.0206
981.0206
253.2984
253.2984
253.2984
253.2984
877.4515
877.4515
913.2805
913.2805
981.0206
801

43

(m/s)
4.983342
4.983342
4.983342
1.286693
1.286693
1.286693
1.286693
4.457236
4.457236
4.639239
4.639239
4.983342
4.068881

pressure
in
Pa
(w.g)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

leakage rate
CFM
35906.21
35906.21
35906.21
6544.195
6544.195
6544.195
9270.943
32115.49
32115.49
33426.86
33426.86
35906.21
29317.29

enthalpy ∆h
(btu/lb)
20.5
20.2
20.2
24.5
24.5
24.5
24.5
21.5
20.5
20.5
20.5
20.6
23

enthalpy
∆h
Capacity, Q

CMH
(btu/lb)
60996.1
0.8
60996.1
0.5
60996.1
0.5
11117.03
1.1
11117.03
1.1
11117.03
1.1
15749.13
1.1
54556.57
1.2
54556.57
0.2
56784.28
0.6
56784.28
0.6
60996.1
0.9
49803.11
0.8
Total Btu/hr =
Tonne =

(btu/hr)
129262.3432
80788.96448
80788.96448
32393.76427
32393.76427
32393.76427
45891.16605
173423.6317
28903.93862
90252.51943
90252.51943
145420.1361
105542.2612
1067707.737
88.97564479

Total Ton
First floor

AHU

Capacity, Q
(btu/hr)

tonne

AHU 1

1457340.40

121.40

AHU 2

2604021.7

217

AHU 3

1571582.1

131

Second floor

AHU

Capacity, Q
(btu/hr)

tonne

AHU 1

2607594.40

217.30

AHU 2

1067707.7

88

Total tonne

= 774.7 ton

Total capacity required

= 774.7 ton

Chiller required capacity

= 774.7 ton / 2
= 387.3 ton

AUTOCAD DRAWING

-

See Appendix

44

COMPUTATIONAL FLUID DYNAMIC (CFD)

CFD stands for computational fluid dynamics. It is a way of modeling complex
fluid flow by breaking down geometry into cells that comprise a mesh. At each cell an
algorithm is applied to compute the fluid flow for the individual cell. Traditional
restrictions in flow analysis and design limit the accuracy in solving and visualization fluid
flow problems. This applies to both single and multi-phase flows, and is particularly true of
problems that are three dimensional in nature and involve turbulence, chemical reactions,
heat and mass transfer. All these can be considered together in the application of
Computational Fluid Dynamics, a powerful technique that can help to overcome many of
the restrictions influencing traditional analysis.
Computational fluid dynamics (CFD) is prediction fluid flow with the
complications of simultaneous flow of heat, mass transfer, phase change, and chemical
reaction using computers. CFD is a part of fluid mechanics that uses numerical
methods and algorithms to solve and analyze problems that involve fluid flows. Computers
are used to perform the calculations required to simulate the interaction of liquids and gases
with surfaces defined by boundary conditions. With high-speed computers, better solutions
can be achieved. With the appearance of powerful and fast computers, new possibilities for
replacing time-consuming model testing and field-testing have arisen.

45

CFD is used in wide variety of disciplines and industries, including aerospace,
automotive, power generation, chemical manufacturing, polymer processing, petroleum
exploration, pulp and paper operation, medical research, meteorology, and astrophysics.
CFD makes it possible to evaluate velocity, pressure, temperature, and species
concentration of fluid flow throughout a solution domain, allowing the design to be
optimized prior to the prototype phase.
The basic principle of the CFD modeling method is that the simulated flow region
is divided into small cells within each of which the flow either kept under constant
conditions or varies smoothly. Differential equations of momentum, energy, and mass
balance are discretized and represented in terms of the variables at the center of or at any
predetermined position within the cells. These equations are solved iteratively until the
solution reaches the desired accuracy.
CFD modeling provides a good description of flow field variables, velocities,
temperatures, or a mass concentration anywhere in the region with details not usually
available through physical modeling. It is especially useful for determining the parametric
effects of a certain process variable. Once the basic model is established, parametric runs
can usually be accomplished with reduced effort. In addition, CFD can be used to simulate
some of the hard to duplicate experimental conditions or to investigate some of the hard to
measure variables

46

Where Can CFD Utilized?

In validation/optimization of HVAC design parameters:



CFD data can be utilized to validate various design parameters such as the
location and number of diffusers and exhausts, and temperature and flow
rate (CFM) of supplied air to meet design criteria. For example, CFD
simulation helps design verification of the following systems: natural
ventilation systems, displacement ventilation systems, raised floor system,
atrium smoke system, etc.

In modification and improvement of malfunctioning HVAC systems:



The system with suggested modifications can be simulated computationally
without actual physical modifications to the existing systems. The
information from CFD reveals what modification satisfies the design
criteria.

In comparisons between alternative systems:

47



Under some circumstances, there may be several different options for
designing HVAC systems for a space (for example, mixing ventilation or
displacement ventilation). Computer simulation data can provide crucial
information to find the best possible system.

In an engineering investigation:



CFD analysis of temperature, velocity and chemical concentration
distributions can help engineers understand the problem correctly and
provide ideas for the best resolution.



Examples of CFD Applications for HVAC Systems:

-

General office/room simulations

-

Contaminant/species simulations

-

Fume hood design

-

Copy machine rooms (VOC)

-

Contamination control chemical lab design

-

Industrial ventilation design

-

Smoking lounges

-

External building flows

-

Problem solving simulations

-

AHU mixing enhancement investigation

-

Fire and smoke management
48

-

Building atria fire simulations

-

Warehouse fire simulation

-

Educational facilities

-

Libraries

-

Classrooms

-

Swimming pool ventilation

-

Medical facilities (operating rooms)

-

Clean room simulations

-

Animal and plant environments

-

Enclosed vehicular facilities

-

Halls, stadiums, arenas, and places of assembly

-

Computer cluster rooms

Strengths and weakness of CFD
Property

CFD

Full scale

Model scale

Simple method

Continuum

no

Yes

Yes

No

Geometric Similarity

Approx

Yes

Some

No

Size limitation

No

Yes

Some

No

Scale effect

Some

None

Yes

Yes

Instantaneous

Indirectly

Yes

Yes

No

Yes

Limited

Limited

Yes

Modeling of moving event

Limited

Yes

Limited

Limited

Empirical content

Some

None

Little

High

Potential accuracy

High

High

Moderate

Low

Turbulence
Hazardous
Events

49

Tuning required

Yes

No

No

No

Capital cost

Moderate

High

Moderate

low

Running cost

High

High

High

Low

Experienced user desirable

Yes

No

No

yes

Usable at design stage

Yes

No

Yes

Yes

For highest accuracy

CFD Working on Pharmaceutical Choosen Room

The condition space of room in pharmaceutical factory was choosen a packing room. Its
situated at first floor on dimension clean room area. This cleanroom room was choosen by
its function and reliability as a cleanroom space in pharmaceutical factory.

Packing room parameters:

Height

= 3.5 m

CMH

Long

= 5.2 m

= 95.6 m³ x 45

Width

= 5.25 m

= 4299.8

Area

= 5.2 m x 5.25 m

L/s

= 27.3 m²
Volume

= 4299.8 / 1000 x 3600
= 1194.4

= 27.3 m² x 3.5 m

CFM

= 95.6 m³
Air change

= Volume x ACH

= 4299.8 x (3.281^3) / 60
= 2531.1

= 45

Diffuser

= 2531.1 / 2 diffuser
= 1260 cfm / diffuser

50

Fluid Dynamic Simulation View

Figure : 3D view on simulation CFD

Figure : Top view on simulation CFD

51

Figure : Side view on simulation CFD

Figure : Front view on simulation CFD

52

CONCLUSION

The pharmaceutical production must effectively control the contamination from
people, raw materials, finished products as well as accommodating-services, process plant
and equipment. The requirements that are available involved in the overall design and a
complex construction process. During process of studying cleanroom technology I firstly
met different requirements and regulations for certain industry. Each of them has their
definite property and purpose. So every clean room in different industry should be designed
according to their own manufacturing characteristics.
In this thesis was shown detailed rules of designing clean rooms by example of
pharmaceutical productionThe present results provide rough estimates of the probable
revenues resulting from improving the air quality in offices in developed parts of the world,
53

and constitute a powerful argument for providing indoor air of a better quality than the
minimum levels required by present Standards. Indoor air quality are very important
especially for pharmaceutical area. In order to determine the perfect design where no
contaminant can enter a workspace is really a challenge for an engineer. Designing a good
design along with good efficiency of system selection, to take into account about utilization
of electricity, water and many more is a good lesson in our study & perhaps it all will be
applied in working field.

54