Professional Documents
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CPI – NBMC
Centre for Process Innovation (CPI) is setting up the National Biologics Manufacturing Centre
(NBMC) in Darlington. This will undertake process development projects for the UK
biopharmaceutical industry. Although this will not be a licenced GMP Facility, it will use
internationally recognised standards for operation to ensure that the processes and results of
experiments are transferable elsewhere.
DOCUMENT HISTORY
Version Verification Reason for Issue Date
Issue
1.0 n/a For Client Review 12th Dec 2013
2.0 n/a Inc client comments – ready for ITT 20th Dec 2013
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
CONTENTS
1. INTRODUCTION................................................................................................................... 3
1.1 Background ................................................................................................................. 3
1.1 Scope and Purpose of this Document ......................................................................... 3
1.2 Definitions .................................................................................................................... 4
1.3 Purpose of the Isolator and Safety Cabinets ............................................................... 4
2 REGULATORY REQUIREMENTS ......................................................................................... 5
2.1 Design ......................................................................................................................... 5
2.2 Qualification Requirements ......................................................................................... 5
3 DOCUMENTATION REQUIREMENTS .................................................................................. 7
3.1 Documentation General ............................................................................................... 7
3.2 Documentation Pre-Delivery ........................................................................................ 9
3.3 Documentation Post-Delivery ...................................................................................... 9
4 GENERAL REQUIREMENTS ................................................................................................. 9
4.1 Design Codes/Standards ............................................................................................. 9
4.2 Mechanical Design ...................................................................................................... 9
4.3 Electrical Design ........................................................................................................ 10
4.4 Site Safety ................................................................................................................. 10
5 LOCATION, UTILITIES AND CONNECTIONS ..................................................................... 11
6 SCOPE OF SUPPLY ............................................................................................................ 11
7 GLOSSARY AND REGULATORY FOCUS .......................................................................... 12
7.3 Health and Safety ...................................................................................................... 12
7.4 Glossary .................................................................................................................... 12
Appendix 1 –Layout of the Isolators 1st Floor Process CPI-NBMC .............................................. 13
Appendix 2 - SPECIFIC REQUIREMENTS ................................................................................. 14
A2.1 Isolator and Safety Cabinets Operation and Performance ........................................ 14
A2.2 Isolator and Safety Cabinets Controls and Instrumentation ...................................... 17
A2.3 Isolator and Safety Cabinets Ancillaries .................................................................... 19
A2.4 Isolator and Safety Cabinets Construction ................................................................ 19
A2.5 Isolator and Safety Cabinets Air Handling Units ........................................................ 22
A2.6 Isolator and Safety Cabinets Sterilisation .................................................................. 23
A2.7 VHP Generator Operation and Performance ............................................................. 25
A2.8 Cleanroom Sterilisation ............................................................................................. 26
A2.9 VHP Generator Controls ............................................................................................ 27
A2.10 VHP Generator Construction ..................................................................................... 29
APPENDIX 3 –3-WAY VALVE OPERATION ............................................................................... 31
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
1. INTRODUCTION
1.1 Background
The Centre for Process Innovation (CPI) is setting up the National Biologics Manufacturing
Centre (NBMC) in Darlington UK to support, develop and progress the biopharmaceutical
manufacturing industry in the UK. It will be involved in process development, analytical methods,
training, new equipment, new technologies, showcasing equipment and technology, funding,
advisory support and act as a centre of collaboration and cross fertilisation of ideas in the UK.
The NBMC comprises 5,000m² flexible laboratory facility for process, analytical and technology
development, small scale production areas for process demonstration and pre-clinical
requirements, clean rooms for GMP simulation of process and equipment and flexible, open-plan
areas where new facility design concepts can be developed and tested.
In addition to the technical facilities, the Centre will provide training and conferencing facilities
together with office and meeting spaces.
The NBMC will not be a licenced GMP facility, and therefore will not be producing pharmaceutical
material for Clinical Trials nor for sale. Therefore none of the equipment nor processes needs to
be qualified or validated according to standard practice in the pharmaceutical industry.
This will employ the same design, specification, installation and commissioning standards as
that for a licenced GMP facility. However it will not be qualified (IQ/OQ) but instead will undergo a
process of Documented Commissioning (DocCom), and DV, IV, OV and PV (Design, Installation,
Operation and Performance Verification).
This will employ many of the standards and technique as for Installation Verification (IV) and
Operational Verification (OV), but will not be subject to review by regulatory agencies.
The building design, construction and commissioning will be undertaken by others on a separate
contract, and will include the shell, clean room and laboratory fit out, HVAC, mechanical services,
electrical and other services.
The process equipment package (of which the Isolator and Safety Cabinets are part of) will be
specified and purchased separately by CPI.
1 vHP mobile generator to sterilise both Isolators/Safety Cabinets and Clean Room
Both Isolator and Safety Cabinets must be designed for automated VHP Sanitisation.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
Appendix 2 of this User Requirement Specification (URS) contains requirements, which relate to
current Good Manufacturing Practice (GMP) and hence will be qualified according to the
requirements of Section 2. User requirements in other sections and appendices relate to Good
Engineering Practice (GEP) and safety or provide information and so will not be qualified but will
become contractual requirements.
1.3 Definitions
The Supplier of the Isolator and Safety Cabinets is required to adhere to the content of this
document; any deviations proposed must be clearly identified and justified by the Supplier.
Compliance with the agreed contents must be a contractual requirement of the purchase order
and any costs associated with meeting the agreed requirements must be included in the
purchase price.
Not withstanding anything to the contrary in this specification, the Supplier must be responsible
for ensuring that the Isolator and Safety Cabinets are “fit for purpose” and in particular for
achieving the performance set forth in this specification.
The Isolator and Safety Cabinets each comprise an aseptic process chamber, its loading and
unloading devices and any built-in equipment. The Isolator and Safety Cabinets are required to
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
The Isolator and Safety Cabinets are to be used for both aseptic and contained bio processing of
microbial fermentation, mammalian cell cultures, purification and conjugation. These activities
support the development of CPI-NBMC processes and product developmemt for clinical use,
however no clinical material will be generated at the CPI-NBMC Centre and therefore any
products manufactured within the Isolator and Safety Cabinets will not be used for human
application.
The VHP necessary to sterilise the Isolator and Safety Cabinets will be generated by an
individual mobile VHP Generator system.
The processes to be carried out in the Isolator and Safety Cabinets are manual, may be
repetitive and may involve frequent material transfers in and out of the Isolator and Safety
Cabinets, thus ergonomics is a major design factor.
Hydrogen Peroxide Vapour (VHP) is hazardous to health, so the Isolator and Safety Cabinets
must incorporate appropriate safeguards for CPI-NBMC, maintenance and engineering
personnel.
2 REGULATORY REQUIREMENTS
2.1 Design
2.1.1. The Isolator and Safety Cabinets will be used in a GMP-like environment, therefore,
design, construction and installation does not have to comply with current Good
Manufacturing Practice, as referenced in Section 7, but should try to meet requirements
where possible.
2.1.2. The Isolator and Safety Cabinets must be designed, tested, supplied and commissioned
in accordance with a documented quality assurance system implemented by the
Supplier
2.2.1. All qualification activities must conform to the requirements set out in the Facility and
Equipment Verification Plan, ####
2.2.2. The Isolator and Safety Cabinets have been assessed as ‘Direct Impact’ systems
requiring the following qualification stages. This qualification is required even though the
unit does not have to comply with cGMP because the gassing cycle development will not
be able to be completed without the unit being verified.
Functional Design Specification (FDS)
Design Verification (DV) including Verifictaion Traceability Matrix (VTM)
Factory Acceptance Test (FAT)
Commissioning
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
2.2.3. To support qualification the Supplier must provide a cross reference matrix (Verification
Traceability Matrix (VTM)) between this URS document, the Functional Design
Specification and specific tests to be carried out during Installation and Operational
Qualification. Appendix 2 is set out in the format of the VTM.
2.2.4. The qualification process will follow the principles set out in the ISPE Baseline Guide
Vol. 5, Commissioning and Qualification.
2.2.5. All Supplier testing of critical items will be carried out following pre-approved protocols
and test sheets and witnessed by the Purchaser.
2.2.6. The Supplier is responsible for providing all necessary documentation. Where test
sheets need to be completed, the Supplier must follow pre-approved documentation
procedures, according to pharmaceutical industry standards and take responsibility for
the correct completion of the test sheets, follow up actions and close-out of the testing
2.2.7.
The Supplier must, at the DV/VTM stage, complete a copy of the matrix given in
Appendix 2 in the following way.
Where “Required” is entered in the DV row, the Supplier must replace this with a statement
which confirms design compliance or not with the URS and gives a documentary reference
to the Suppliers Functional Design Specification which relates to the subject.
Where “Required” is entered in the IV row, the Supplier must replace this with a test
reference from their IV protocol.
Where “Required” is entered in the OV row, the Supplier must replace this with a test
reference from their OV protocol.
Where N.A. is entered in any row, this may be ignored.
Note: Appendix 2 is set out to be printed and used as A3 landscape.
2.2.8. The following table summarises the responsibilities for Supplier qualification services.
(i) Purchaser to
witness
IV Supplier Purchaser Supplier. Supplier Purchaser
Purchaser to
witness
OV Supplier Purchaser Supplier. Supplier Purchaser
Purchaser to
witness
GCD Supplier Purchaser Supplier. Supplier Purchaser
Purchaser to
witness
PV Purchaser Purchaser Purchaser Purchaser Purchaser
(Supplier to (Supplier to
advise) advise)
(i) Correctly documented FAT and / or Commissioning results may be leveraged into IV and OV
by agreement, if FAT and commissioning is undertaken to pre-approved Procedures and
included in the Supplier’s Quality Assurance System
3 DOCUMENTATION REQUIREMENTS
The supplier must provide one paper copy and one digital copy of all other
documentation relevant to the specific Isolator and Safety Cabinets, as listed below.
Digital copies must be delivered on CDROM, DVD or read-only USB Flash-Drive and
must be recoded in industry standard software packages such as Microsoft Office,
Adobe pdf and AutoCad for drawings.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
3.3.1. Any documentation which was issued as “preliminary”, “draft” or “for construction” or any
other documentation which requires revision as a result of commissioning and
qualification must be certified “As Installed” and re-issued.
3.3.2. Executed Commissioning Procedure approved by the Purchaser with a list of
commissioning spares replaced.
3.3.3. Calibration certificates for all test equipment used at any stage.
3.3.4. Executed qualification protocols and qualification reports for approval, as noted in
Section 2.
4 GENERAL REQUIREMENTS
4.1.1. The Isolator and Safety Cabinets must be permanently CE Marked to confirm
compliance with all relevant EU Directives, and a suitable conformance certificate must
be provided.
4.1.2. The Isolator and Safety Cabinets s must be safe to operate and comply with the
Provision & Use of Work Equipment Regulations, 1998.
4.2.1. The Isolator and Safety Cabinets must be designed as a complete, stand alone, unit
comprising process chamber, transfer hatch, air handling units (complete with fans and
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
HEPA filters), VHP connections, controls (with intuitive HMI), powered height adjustment,
sleeves and gloves.
4.2.2. The Isolator and Safety Cabinets must be ergonomically designed to allow ease of use,
cleaning and maintenance.
4.2.3. Sensing devices must be easily accessible and removable for calibration and
maintenance purposes.
4.2.4. Supplier to confirm automated valves are equipped with open/closed limit switches as
standard.
4.2.5. The Isolator and Safety Cabinets must have adequate temporary protection suitable for
transporting to site and for on site storage and protection once installed up to and
including the commissioning stage.
4.3.1. All electrical equipment, documentation and installation must comply with all local
regulations in the UK (the current edition of BS7671, IEE Wiring Regulations) and
EN60204 Safety of Machinery.
4.3.2. Electrical equipment must only be connected to a single source of supply. The machine
must be equipped with an isolation switch that completely isolates the machine from the
mains electricity supply. Any other voltages and frequencies must be produced from
within the equipment. Power supply for instrumentation and control must be 24V DC.
4.3.3. All electrical components and connectors must be compatible with those used in the UK
4.3.4. All electrical components must be contained in protective enclosures, having Ingress
Protection suitable for cleanroom which are frequently cleaned with lIVuid products and
also sterilised with VHP.
4.3.5. Access to electrical enclosures must only be permitted by use of a key or tools. Panel
doors must be interlocked to disconnect power from exposed equipment when the door
is opened. It is permissible to allow low voltage (24V) circuits to remain powered when
the door is open if mains voltage equipment is strictly segregated and effectively
protected from accidental contact.
4.3.6. All Isolator and Safety Cabinets metalwork must be securely earthed and an earth
continuity test carried out.
4.3.7. Adequate short circuit protection must be installed to guard against failure of individual
electrical circuits.
4.3.8. Clear labelling must be fitted to each fixed component and termination, labelling must
correspond to that used on wiring diagrams and parts lists.
4.3.9. An Electrical Safety Test must be carried out and documented to confirm safe
installation.
4.4.1 Where any site work (offloading, unpacking, moving into position, re-assembly,
installation, connection to services, cleaning, commissioning, testing, calibrating etc.) is
to be carried out by the Supplier, this will be under the direct control of the Main
Contractor, although the Purchaser may inspect or witness the work. The Site Rules of
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
the Main Contractor and GSTT must be followed and Risk Assessments and Method
Statements for the work must be submitted and approved before starting work. All
Supplier’s staff working on site will be required to undergo Site Induction by the Main
Contractor.
6 SCOPE OF SUPPLY
The scope of supply must comprise.
6.1. Detailed design, manufacture, installation, commissioning and qualification of the Isolator
and Safety Cabinets
6.2. Packing and delivery to site, including insurances and customs duties etc.
Offloading, unpacking and moving into position.
6.3. Re-assembly and installation, including connection to services, which will terminate
approximately 2m away from the machines.
6.4. Commissioning including supply of all consumables, spare parts, labour and calibrated
test equipment used in the tests. Note that commissioning and qualification may be
scheduled several weeks after installation.
6.5. Qualification services listed in Section 2
6.6. Comprehensive training in both operation and maintenance, with Training Certificates
issued to Purchaser’s staff who have completed the course.
6.7. Documentation, as listed in Section 3.
6.8. Handover will be achieved when a Handover Certificate (prepared by the Supplier) is
signed by the Purchaser.
The Handover Certificate will confirm the completion of the following:
Equipment is installed, commissioned and operating without snags or faults
O & M Manual has been delivered and its content approved
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
7.4 Glossary
o BMS – Building Management System
o EMS - Environmental Monitoring System
o HMI – Human-Machine Interface
o N.A. – Not applicable
o TBA – To be advised or to be agreed
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.1.1. The Isolator and Safety Cabinets must accommodate the following ‘generic’ process steps (Note that specific DV Required
loads and operations will be defined by individual processes and the two typical loads, identified by the batch
sequence diagrams, will be used to inform VHP gas cycle development): IV To be demonstrated at Mock-up stage
a) Preparation
OV N.A.
Manual cleaning
Glove testing
Assemble racking and fixed equipment parts, as necessary.
b) Loading
Load stock boxes of disposable items
Load initial single-use disposable tubing sets’or well-plates or centrifuge tubes or transfer bags or culture
flasks
Load ‘tools’ and static equipment (eg battery powered balance, tube welder) to be used in the process
c) Pre-Process VHP Cycle
Sterilisation of all internal surfaces and items placed inside the Isolator and Safety Cabinets
d) Transfers
Load extra equipment items via Transfer Hatch
Load extra WFI, media and buffer solutions via Transfer Hatch
Introduce blood-bag, cell culture bag, tube or culture flask containing cells
e) Processing
Carry out process manipulations
Remove disposable tubing sets via Transfer Hatch.
Remove wastes via Transfer Hatch.
Return tubing sets via Transfer Hatch.
Introduce new reagents and disposable equipment via the Transfer Hatch
f) Processing and Transfers
Steps (d) – (e) may be repeated several times, with subtle variations
g) Remove Final ‘Product’
Remove final ‘product’ bag or cryo-vial via Transfer Hatch
h) Open, Clean and Tidy
(Note: If viral vectors have been used, it will be necessary to run a VHP sterilisation cycle before opening)
Remove wastes
Manually clean
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.1.2. The ‘working area’ (that which is accessible to the operator using the glove-ports) must accommodate the DV Required
following removable items, whilst leaving adequate space to work
Blood bags, tubing sets, product and buffer bags IV To be demonstrated at Mock-up stage
Wastes (discard) container (200 mm dia.)
OV N.A.
Bottles or bags of media (1 to 5 L)
1 No. Centrifuge racks for 25 mm tubes (150 mm x 80 mm)
2 L container (130 mm dia.)
2 No. Gilsons-type pipettes in rack (300 mm x 100 mm)
2 No. Pipette tip boxes (80 mm x 80 mm)
Sharps container (100 mm x 100 mm)
Syringe and needles
Sample containers
Packs of dry or wet wipes and other minor consumables
Tube welder
Settle plates
A2.1.3. It must be possible to move in or out all the removable items either via the front opening window (prior to or after a DV Required
process batch) or via the Transfer Hatch (during a process batch).
It must be possible to fully open the Isolator and Safety Cabinets window to the same internal width and height of IV To be demonstrated at Mock-up stage
Isolator and Safety Cabinets chamber to manually clean inside and to clean and maintain any built-in equipment.
OV N.A.
A2.1.4. In order to satisfy A2.1.1 and A2.1.2 it is likely that the ‘working area’ (that which is accessible to the operator DV Required
using the glove-ports) of the Isolator and Safety Cabinets may be approximately 2000 mm x 600 mm. The working
area must be supplemented with a perorated storage shelf, 70 mm wide mounted on the ‘back’ wall of the Isolator IV Required
and Safety Cabinets and a ‘x-y-hanging rail grid with hooks for sterile bags etc.
OV N.A.
A2.1.5. 10” gloveports must be sited to suit the process with optimum ergonomics. DV Required
OV N.A.
A2.1.6. An Isolator and Safety Cabinets must maintain a Grade A environment at all times during a production run, which DV Required
may last several days.
IV N.A.
OV Required
A2.1.7. A downward vertical unidirectional velocity of 0.45 + 20 % m/s must be maintained at the expected level of open DV Required
processing, which is understood to be an area approximately 100 mm off the internal walls and approximately 300
mm off the base (to be qualified with the Isolator and Safety Cabinets empty). IV N.A.
OV Required
A2.1.8. The equivalent air flow rate in the Isolator and Safety Cabinets must be at least 500 air changes per hour. DV Required
IV N.A.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
OV Required
A2.1.9. It must be possible to sterilise, with VHP, the Isolator and Safety Cabinets, its equipment and full load of DV Required
disposable items using a cycle of approximately 90 minutes duration, and ideally as short as possible.
“Sterilisation” is defined in Section A2.6. IV N.A.
For clarification of the time, the 90 mins refers to the time from initiating the VHP cycle on the generator until
aeration is completed i.e. H2O2 is below 1ppm. This 90 mins will include the initial gassing, dew point, dwell time OV Required + Gas Cycle Development
and aeration.
A2.1.10. It must be possible to sterilise items placed in the Transfer Hatch either by a ‘short’ VHP cycle (less than 60 DV Required
minutes in total) or by manual wiping down or by ethanol spraying.
IV N.A.
OV Required
A2.1.11. The lighting level in the Isolator and Safety Cabinets must not be less than 600 lux at the ‘working area’ level. DV Required
IV N.A.
OV Required
A2.1.12. When in ‘production’ mode the Isolator chamber must be maintained at a pressure at least 25 Pa higher than that DV Required
of the Transfer Hatch and the Transfer Hatch must be maintained at a pressure at least 50 Pa higher surrounding
IV N.A.
room. This applies to the Isolators;
GMP Simulation in 1.20 OV Required
A2.1.13. When in ‘production’ mode the Safety Cabinets chamber must be maintained at a pressure at least 200 Pa lower
than that of the Transfer Hatch and the Transfer Hatch must be maintained at a pressure at least 50 Pa higher
surrounding room. This applies to the negative pressure safety cabinets;
Cytoxics in 1.20
A2.1.14. The temperature in the Isolator and Safety Cabinets chamber must not be more than 4 °C above the surrounding DV Required
room temperature when in ‘production’ mode.
IV N.A.
OV Required
A2.1.15. The positive pressure Isolators must pass a leak test. The test criterion is a pressure decay of less than 25 Pa in DV Required
1.5 minutes when the pressure is raised to +250 Pa with the Isolators sealed. {This represents ≤1% volume loss
IV N.A.
per hour as per Isolator Class 3, ISO 10648-2 and ISO 14644-7 draft}.
OV Required
A2.1.16. The negative ressure Safety Cabinet must pass a leak test. The test criterion is a pressure decay of less than 25 DV Required
Pa in 1.5 minutes when the pressure is lowered to -250 Pa with the Isolator and Safety Cabinets sealed. {This
IV N.A.
represents ≤1% volume loss per hour as per Isolator Class 3, ISO 10648-2 and ISO 14644-7 draft}.
OV Required
A2.1.17. The noise from the Isolator and Safety Cabinets in operation must be no more than 65dB at 1m away. DV Required
IV N.A.
OV Required
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
Requirement (applies to all Isolator and Safety Cabinets unless indicated) Fulfilment Sign / Date
A2.2.1. The Isolator and Safety Cabinets control panel (HMI) must indicate: DV Required
Isolator and Safety Cabinets and Hatch Pressures (digital)
Air Flowrate or Velocity in the Isolator and Safety Cabinets, annotated in Air Changes per Hour or m/s. IV Required
Terminal and exhaust HEPA filter pressure-drops (Magnahelic or digital).
OV Required
Gassing cycle status
Hatch door status
Alarms
A2.2.2. The HMI requirements of the built-in equipment have been listed in A2.3. These controls should be incorporated DV Required
in the same panel as the Isolator and Safety Cabinets controls, if this is not possible, they must be mounted close-
by. IV Required
OV N.A.
A2.2.3. Settable high and low alarms must be fitted for DV Required
Pressure (independent chamber and hatch)
Flow/velocity IV Required
Seal failures
OV Required
Alarms must be annunciated by audible and visible means.
Alarms must be latched, ie. alarms can only be cleared by manual intervention once the excursion has been
corrected.
Additionally, the Isolator and Safety Cabinets must receive, display and annunciate a common VHP Generator
alarm and a particle counter.
Alarm noise to be noticeable, but not with a disturbing or distracting intonation or volume.,
A2.2.4. The control system must log all alarms (alarm type, time of alarm, time acknowledged and time cleared) and retain DV Required
these for operator information at the end of a batch. These alarms are independent of any EMS alarms.
IV Required
OV Required
A2.2.5. The required range and accuracy of the instrumentation is given in the table below. DV Required
A2.2.6. The Isolator and Safety Cabinets control system must monitor an ‘extract healthy’ signal either from the BMS or DV Required
directly and display and annunciate it.
Furthermore, the Isolator and Safety Cabinets control system must not allow a VHP cycle to start if this signal is IV Required
not present and it must go into a ‘safe-hold’ state if the signal drops out during the aeration phase of a gassing
cycle. OV Required
A2.2.7. The control system must manage and report automatic leak tests: DV Required
leak test on demand
A pre-gassing leak test as part of the VHP sterilisation cycle IV N.A.
Glove leak test.
OV Required
The Isolator and Safety Cabinets must be supplied with a glove leak-test device for semi-automatic operation.
A2.2.8. Control systems must be protected from power failure by a dedicated UPS with capacity for 30 minutes operation. DV Required
UPS to be alarmed for failure or low battery. The UPS must also include power surge protection.
The Isolator and Safety Cabinets will be connected to a ‘maintained’ supply, therefore power interruptions are IV Required
anticipated to be momentary.
OV Required
In the event of power failure, the Isolator and Safety Cabinets must restart automatically to its previous set point,
with no operator intervention.
A2.2.9. The inner door of the Transfer Hatch must be controlled so that a variable delay is applied after the outer door is DV Required
closed until the inner door may be opened. This is to allow alcohol vapour to be swept away and Grade A
conditions to re-establish. IV N.A.
OV Required
A2.2.10. The control system must be password protected, with at least three levels of entry (Operator, Supervisor and DV Required
Engineer). If the selected control system falls within the guidance of Annex 11 (Computerised Systems) of the EU
GMP regulations, then password protection must comply with sections 8 and 10 of Annex 11 of the EU GMP IV N.A.
regulations. This states that all actions carried out under password control must be logged, with the identity of the
person initiating the actions. OV Required
A2.2.11. All instruments must be clearly labelled in English with their function. DV Required
IV Required
OV N.A.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
Requirement (applies to all Isolator and Safety Cabinets unless specifically noted) Fulfilment Sign / Date
The Isolator and Safety Cabinets must incorporate a built in peltier-type cold/heat block.
The cold block must be sealed into the base plate of the Isolator and Safety Cabinets. The cold block must have a
A2.3.2 cover that is flush with the base of the Isolator and Safety Cabinets, with a removable magnetic handle in order to
maximise the working area in the Isolator and Safety Cabinets when the cold/hot block is not being accessed. The
cold block must be 30cm x 20cm x 20 cm. The cold hot block must be able to maintain temperatures between -20°
C to 37° C. The cold block must be supplied filled with proprietary heat transfer beads.
Requirement (applies to all Isolator and Safety Cabinets unless specifically noted) Fulfilment Sign / Date
A2.4.1. The CPI-NBMCIsolator and Safety Cabinets configuration comprises the Isolator and Safety Cabinets chamber DV Required
and a Transfer Hatch at the right-hand end.
IV Required
OV N.A.
A2.4.2. The overall external dimensions of the Isolator and Safety Cabinets, should not exceed 2400 mm (w) x 1200 mm DV Required
(D)x 2100 mm high.
Note should also be made of the access route limitations shown on the layouts in Appendix 1; IV Required
Equipment lift – 2.4m wide, 3.4 long, 2.5m high (to be confirmed) OV N.A.
Corridors on process floor – 2.5m wide
Doors into process rooms – 1.8m wide
A2.4.3. The internal surfaces of the Isolator and Safety Cabinets must be constructed in 316L stainless steel (minimum DV Required
thickness 3mm).
IV Required
OV N.A.
A2.4.4. All internal surfaces must be finished smooth and crevice free. “Folded” metal construction is not permitted, joints DV Required
must be welded, with the welds ground smooth and polished to match the base metal sheet. Internal corners
must be radiused (at least 20mm recommended). IV Required
Internal finish < 0.8 micron Ra. External finish < 1.8 micron Ra.
OV N.A.
A2.4.5. The internal height of the Isolator and Safety Cabinets must be approximately 800 mm. DV Required
IV Required
OV N.A.
A2.4.6. The Isolator and Safety Cabinets base plate height must be approximately 900 mm above floor level, with ±150 DV Required
mm powered adjustment.
IV Required
OV N.A.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.4.7. The Isolator and Safety Cabinets chamber must be equipped with 2 No. power sockets (5 A rating) for removable DV Required
equipment. These should be covered power sockets that will need to be opened during VHP gassing. The
IV Required
location of the sockets should not interfere with the operation inside the Isolator and Safety Cabinets.
The Isolator and Safety Cabinets chamber must be equipped with 2 No. USB bulkhead sockets. One to be type A OV N.A.
on the inside and type B outside and the other vice versa.
Power and data sockets provided in the Isolator and Safety Cabinets must be sealed, allowing no leakage path for
air into/from the Isolator and Safety Cabinets chamber.
A2.4.8. The Isolator and Safety Cabinets must be equipped with at least one permanently installed particle sampling point DV Required
(isokinetic nozzle) for connection to a particle counter at working height (300mm) in a position that doesn’t
IV Required
interfere with the processing.
The head must be connected with “Bev-a-Line” tubing to the particle counting head which must be mounted on the OV N.A.
Isolator and Safety Cabinets. The particle counter should be positioned inside the Isolator and Safety Cabinets
cladding, and be accessed by a removable panel,
Note: Isokinetic nozzle and Bev-a-Line tubing to be supplied and installed by Isolator and Safety Cabinets
Supplier, particle counting head to be supplied by the EMS Supplier. Bev-a-line must be installed to the
manufacturers recommendations. The tubing must be positioned and maintained without any kinks to ensure
particles cannot get trapped inside.
A2.4.9. The Isolator and Safety Cabinets must be equipped with at least one sealable port for the introduction of a low DV Required
concentration H2O2 sensor. (Sensor will be included in the VHP Generator scope of supply).
IV Required
OV N.A.
A2.4.10. The clear aperture of the door between the Transfer Hatch and the Isolator and Safety Cabinets chamber must DV Required
not be less than 400 mm x 400 mm. Likewise the outer door of the Transfer Hatch should be a matching size.
IV Required
The inner and outer doors of the Transfer Hatch must be interlocked, so that only one door can be open at any
time. This interlock may be inactivated when the Isolator and Safety Cabinets is open for cleaning or OV N.A.
maintenance.
A2.4.11. It is intended that the Isolator and Safety Cabinets be installed against the wall of the cleanroom and therefore DV Required
operational or maintenance access will not be available from the rear of the Isolator and Safety Cabinets.
IV Required
Supplier must confirm that this is acceptable or suggest alternatives. For example the Isolator and Safety Cabinets
may be on rollers to allow for access for cleaning or maintenance. OV N.A.
A2.4.12. The support frame must be rigid, fabricated from stainless steel or white powder-coated steel and mounted on DV Required
height adjustable cleanroom-type feet. The support frame must be within the footprint of the main body of the
IV Required
Isolator and Safety Cabinets and allow for wall to floor coving in the room.
The support frame must be designed so that operators of different statures can work at the gloveports; exact OV N.A.
details and specification of any height adjusting devices necessary to be agreed during ergonomic trials.
A2.4.13. The enclosure for the fan/filter unit and controls must be fabricated from polished stainless steel or white powder DV Required
coated steel.
IV Required
OV N.A.
A2.4.14. Doors and windows must be constructed in laminated safety glass or clear cast acrylic, with 316 L stainless steel DV Required
frames.
IV Required
Doors and windows must be interlocked (Isolator and Safety Cabinets can’t run in “production” or “gassing” mode
if the outer doors or windows are open or not locked). OV N.A.
Windows may slope back for operator comfort
A2.4.15. Windows must be interlocked (Isolator and Safety Cabinets can’t run in “production” or “gassing” mode if the DV Required
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.4.25. The Isolator and Safety Cabinets must be identified with a permanently fixed “tag”, the tag having an engraved DV Required
number corresponding to its identification
IV Required
OV N.A.
A2.4.26. All the documentation listed in Section 3 of this URS must be delivered with the Isolator and Safety Cabinets. DV Required
IV Required
OV N.A.
A2.4.27. There must be a sealable port to allow a peristaltic pump tubing (diameter of tubing to determined) to be inserted DV Required
into the Isolator and Safety Cabinets (before VHP gassing) to allow a peristaltic and/or vacuum pump to be kept
IV Required
outside the Isolator and Safety Cabinets, and pump/remove fluid into/out of the Isolator and Safety Cabinets.
OV Required
A2.4.28. A non-slip bar to act as a foot rest will be fitted to allow the operator to sit down in an ergonomic manner when DV Required
using the Isolator and Safety Cabinets.
IV Required
Foot switches to be provided for:
OV Required
Inner hatch door open/close
Centrifuge stop/start
A2.5.1. The Isolator and Safety Cabinets chamber and Transfer Hatch must re-circulate air internally, but must use DV Required
conditioned air from the room for pressure and temperature control purposes.
IV Required
OV N.A.
A2.5.2. When in operation, it is expected that a constant volume of air, 120 +0/-20 L/s, will be drawn from the room into DV Required
the Isolator and Safety Cabinets and exhausted via a flexible duct (Supplier to install) to a ceiling spigot (105 mm)
and onwards to a building a extract fan. The exhaust pressure at the outlet of the Isolator and Safety Cabinets IV N.A.
must be 0 Pa ± 50 Pa.
When the Isolator and Safety Cabinets is shut down or during the gassing phases of a VHP cycle, the Isolator and OV Required
Safety Cabinets controls must open an automatic damper to divert directly to exhaust the same quantity of room
air as is normally lost via the Isolator and Safety Cabinets.
A2.5.3. All air fed and recirculated to the internal space of the Isolator and Safety Cabinets chamber and Transfer Hatch DV Required
must be terminal HEPA filtered, using H14 grade filters. Inlet and recirculated air must be pre-filtered to prolong
the life of the terminal HEPA filters. IV N.A.
OV Required
A2.5.4. Double exhaust HEPA filters are to be fitted to the Isolator and Safety Cabinets, but safe change of the primary DV Required
exhaust filter is not required.
IV Required
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
OV N.A.
A2.5.5. Test ports must be fitted for independent testing of all HEPA filters and their seals. This means the provision of DV Required
test aerosol inlet points, aerosol challenge sampling points (e.g. in plenum chambers) and downstream sampling
points. IV Required
OV N.A.
A2.5.6. Automatic shut-off valves must be provided to permit leak testing by pressure decay. These valves must be fitted DV Required
ahead of the inlet HEPA filters and after the exhaust HEPA filters.
IV Required
OV N.A.
A2.5.7. The air handling unit must be mounted integrally above, below or behind the Isolator and Safety Cabinets DV Required
chamber, within the room.
IV Required
OV N.A.
A2.5.8. The ventilation system of the Transfer Hatch must be compatible with alcohol spraying of process equipment and DV Required
product containers which are placed in it.
IV Required
OV N.A.
A2.6.1. The Isolator and Safety Cabinets and built-in equipment must be engineered for automatic sterilisation by VHP DV Required
treatment.
IV Required
Rotating or static gas distribution nozzles and stirring fans must be installed in the process chamber and hatch as
required by the VHP System supplier. OV Required
It must be possible to completely seal the Isolator and Safety Cabinets and/or Transfer Hatch from the room
during sterilisation.
A2.6.2. The Isolator and Safety Cabinets must have a VHP inlet and a VHP outlet port. Additionally, signal ports and gas DV Required
sampling ports must be fitted to suit the VHP System.
IV Required
The gas inlet and outlet ports must be configured so that the (heavy) VHP hoses do not impart high bending
moments on the ports. OV N.A.
A2.6.3. The Isolator and Safety Cabinets must control the VHP sterilisation sequence. DV Required
Therefore the Isolator and Safety Cabinets controller must first check that an ‘exhaust fan healthy’ signal is being IV N.A.
received from the BMS. If this is not present, the Isolator and Safety Cabinets controller must stop and alarm.
OV Required
If the exhaust fan is OK, the Isolator and Safety Cabinets controller must send a ‘start’ signal to the VHP
Generator (once a successful leak test has been completed), stop its fans and shut its isolation valves.
The Isolator and Safety Cabinets controller then waits for an ‘aeration’ signal from the VHP Generator, at which
point it must restart its fans and aerate the enclosure to finish the cycle.
Finally, the Isolator and Safety Cabinets controller then waits for a “successful cycle completion” signal from the
VHP Generator and then reverts to “Normal Operation”.
Furthermore, the Isolator and Safety Cabinets must send signals to the EMS to close its particle counter/vacuum
valves during VHP sterilisation and suspend particle counting.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.6.4. All valves which must be operated before, during or after a VHP sterilisation cycle must be automated. DV Required
IV Required
OV Required
A2.6.5. Glove hangers must be supplied to hold up sleeves during VHP sterilisation. DV Required
IV Required
OV N.A.
A2.6.6. Prior to an aseptic process batch it must be possible to place the necessary items, typically listed in A2.1.2, in the DV Required
Isolator and Safety Cabinets and carry out a VHP sterilisation cycle (from start to completion of aeration) in
IV N.A.
approximately 90 minutes. In this context sterilisation is defined as a minimum of a 6-log reduction of spore
forming microorganisms. OV Required (CGD)
A2.6.7. It must be possible to VHP sterilise the Transfer Hatch independently from the process chamber, whist carrying DV Required
out process operations in the chamber (Zero VHP leak in the chamber can be tolerated).
IV N.A
The total VHP sterilisation cycle time must be less than 60 minutes.
OV Required (GCD)
A2.6.8. It is proposed that Geobacillus stearothermophilus (ATCC # 12980) will be used as the test organism, prepared on DV Required
proprietary biological indicator (BI) strips
IV N.A.
The Supplier must demonstrate equivalence of Geobacillus stearothermophilus (ATCC # 12980) to typical viruses
that may be processed in the suite. OV Required (CGD)
A2.6.9. A typical Isolator and Safety Cabinets and/or Hatch sterilisation sequence must be carried out as follows: DV Required
Operator prepares load in Isolator and Safety Cabinets and/or Hatch. IV N.A.
Operator moves VHP Generator to the Isolator and Safety Cabinets and connects gas hoses, sample tube
and communications cables OV Required (CGD)
Operator plugs in VHP Generator to the mains and loads it with H2O2 solution.
Operator places VHP Generator in run mode
Operator selects gassing cycle (if there are different cycles validated for different loads) and initiates the
gassing cycle at the Isolator and Safety Cabinets HMI.
Isolator and Safety Cabinets controller sends signals to the EMS to indicate that it is gassing
Isolator and Safety Cabinets controller controls the gassing cycle and aerates the enclosure at the end of the
sterilisation period
Isolator and Safety Cabinets controller indicates a successful cycle and goes into normal operation mode
(sends signal to EMS to indicate normal operation)
Operator stops the VHP Generator and removes the printout for batch records
Operator disconnects hoses and communication cables and returns VHP Generator to its storage position
Operator may take a manual air sample in the enclosure to confirm < 1ppm H2O2.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.7.1. A minimum total of one mobile VHP Generator must be supplied to produce a stream of Hydrogen Peroxide DV Required
Vapour in conditioned air (“gas”) to match the stated sterilisation requirements of the Isolators.
IV Required
OV N.A.
A2.7.2. Mobile VHP Generators must be used to sterilise both Isolators and Safety Cabinet. DV Required
IV Required
OV N.A.
A2.7.3. Mobile VHP Generators (if chosen) will be used to sterilise the following rooms and suites of rooms; DV Required
1.18 – Viral Vectors 122m³ room volume
IV Required
1.20 – Cytotoxics 97m³ room volume
1.33 – GMP Simulation – Grade D 200m³ room volume OV N.A.
1.34 – GMP Simulation – Grade C 144m³ room volume
A2.7.4. A VHP Generator must draw air from the room in which it is located. DV Required
IV Required
OV Required.
A2.7.5. A VHP Generator must produce concentrations of hydrogen peroxide and vapour temperatures and DV Required
H202humidities within their set-point ranges.
IV N.A
OV Required
A2.7.6. The VHP Generators must produce the required environmental conditions and hydrogen peroxide vapour at a DV Required
sufficient rate so that the total Isolator sterilisation cycle times stated in Section A2.6
If a VHP Generator alone cannot achieve the required cycle time then the following equipment must be included if IV N.A
required
Catalytic H2O2 destruction units. Such units may be included in the VHP Generator cabinet or be separate OV Required
mobile or fixed units incorporating appropriate circulation or exhaust fans.
Separate distribution fans if appropriate.
A2.7.7. The VHP Generators must use 30% H2O2 solution to produce VHP. DV Required
IV Required
OV N.A.
A2.7.8. The VHP Generators must control the cycle so that the cycle completion point is when there is a concentration of DV Required
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
OV Required
A2.8.1. Isolator VHP sterilisation will not take place at the same time as room VHP sterilisation. DV N.A
IV N.A
OV N.A.
A2.8.2. The following rooms may be gassed using the vHP DV Required
• 1.18 – Viral Vectors 122m³ room volume 20 air changes per hour IV N.A
• 1.20 – Cytotoxics 97m³ room volume 20 air changes per hour
OV Required (GCD)
• 1.33 – GMP Simulation – Grade D 200m³ room volume 20 air changes per hour
• 1.34 – GMP Simulation – Grade C 144m³ room volume 30 air changes per hour
The vHP Generator will be placed in room during gassing.
This operation will be carried out on an occasional basis, i.e. once or twice a year, but may have to be done in an
‘emergency’ following a major spill or other incident.
A2.8.3. It must be possible to VHP sterilise any one of the occasionally gassed rooms in a total cycle time of DV Required
approximately 8 hours
IV N.A
OV Required
A2.8.4. A typical cleanroom sterilisation sequence must be carried out as follows: DV Required
Operator places VHP Generator in the room to be gassed, in the validated position (previously determined IV N.A
during room gassing cycle development), loads it with H2O2 solution and plugs it into the mains.
OV Required (GCD)
Operator props open inner doors to any Pass Through Hatches in the room(s) and props open any doors
to adjoining rooms to be gassed.
Operator assembles the room gassing nozzle and connects the gas hose between the VHP Generator and
it
Operator connects the communications cable from the VHP Generator to the gassing socket in the room
wall.
Operator places VHP Generator in run mode.
Operator checks rooms for personnel, leaves the room and tapes up all the outer doors and any other
known air transfer paths such as transfer grilles or spool pieces.
Operator posts warning notices.
Operator connects the remote controller to power and to the gassing wall socket in the safe room outside
the room(s) to be gassed.
Operator selects the validated gassing cycle for the room(s) to sterilised and initiates the gassing cycle.
Remote controller sends a signal to the EMS to indicate that it is gassing the rooms
Remote controller sends a signal to the BMS to request that inlet and exhaust dampers are shut to the
rooms
Remote controller waits for a signal from the BMS to confirm that the requested inlet and exhaust dampers
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
are shut.
Remote controller starts the VHP Generator and monitors the gassing cycle.
At the end of the sterilisation period, the remote controller sends a signal to the BMS to request aeration
(i.e. opening the inlet and exhaust dampers for once through aeration of the room(s).
At the end of aeration, the remote controller indicates a successful cycle and sends a signal to EMS to
indicate normal operation.
Operator takes a manual air sample in the room to confirm < 1ppm H2O2.
If safe, operator removes tape from outer door, enters room, stops the VHP Generator and removes the
printout for batch records and dismantles the gassing equipment and returns it and the VHP Generator to
storage.
A2.8.5. In order to facilitate room VHP sterilisation, the Supplier must provide a communications wiring detailed design to DV Required
the Main Contractor and free issue communications sockets, so that the Main Contractor may install the
IV Required
necessary wiring between the communications sockets in the rooms to be gassed, the communications sockets in
the ‘safe’ rooms and the BMS and EMS OV N.A
The Supplier must label all communications sockets in the walls.
A2.8.6. It is proposed that Geobacillus stearothermophilus (ATCC # 12980) will be used as the test organism, prepared on DV Required
proprietary biological indicator (BI) strips
IV N.A
For rooms S21 to S26 the Supplier must demonstrate equivalence of Geobacillus stearothermophilus
(ATCC # 12980) to typical viruses being processed in the suite. OV Required (GCD)
A2.9.1. The control system of the VHP Generator must consist of a PLC with a fixed and a remote Human-Machine DV Required
Interfaces (HMI).
IV Required
OV N.A.
A2.9.2. The fixed HMI must comprise a membrane keypad or touchscreen, an alphanumeric display and a printer. The DV Required
fixed HMI must be integrated within the VHP Generator cabinet.
IV Required
OV N.A
A2.9.3. The HMI must be used to initiate and monitor fully automated VHP sterilisation cycles in an Isolator DV Required
IV N.A
OV Required
A2.9.4. The remote HMI must be capable of communicating with the BMS and EMS, via a communication cable ‘gassing’ DV Required
sockets located in each ‘safe’ room immediately outside the room or suite of rooms to be gassed.
IV N.A
The remote HMI must be capable of sending a signal to the BMS and EMS which identifies the room(s) being
gassed. OV Required
The remote HMI must be capable of communicating with any VHP generator via communications cables and a
‘bulkhead’ type socket in the wall between the ‘safe’ room and the room being gassed where the VHP Generator
is located.
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.9.5. The VHP Generators must be equipped with the following instruments/sensors DV Required
H2O2 solution weight or volume
IV Required
H2O2 vapour concentration
H2O2 vapour temperature OV N.A
Alarms IV Required
Machine status (ready, in-use, not ready) OV N.A
H2O2 solution weight or volume
H2O2 vapour concentration
H2O2 vapour temperature
A2.9.8. The HMI system must be password protected at least three levels DV Required
Operator,
IV N.A
Supervisor,
OV Required
Administrator/Engineer/Validator
A2.9.9. The controller must provide the following alarm systems. DV Required
A2.9.10. The controller must provide the following interlock systems, which must be both hardware and software DV Required
implemented.
IV Required
VHP generation must not start if Isolator leak test fails
VHP generation must not start if room dampers are not closed OV Required
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
A2.9.11. The required range and accuracy of the instrumentation is given in the table below. DV Required
Instrument Range Accuracy Precision
A2.9.12. Settable high and low alarms must be fitted to all analogue instruments. Alarms must be annunciated by audible DV Required
and visible means.
IV Required
Alarms must be latched, i.e. alarms can only be cleared by manual intervention once the excursion has been
corrected.
OV Required
A2.9.13. Both the fixed and remote HMI’s must have an “Abort” button, which has the function of stopping a gassing DV Required
sequence and driving the Isolator or room HVAC to full aeration.
IV Required
OV Required
A2.9.14. All instruments must be clearly labelled in English with their function DV Required
IV Required
OV N.A
A2.9.15 If the selected control system falls within the guidance of Annex 11 (Computerised Systems) of the EU GMP DV Required
regulations, then password protection must comply with sections 8 and 10 of Annex 11 of the EU GMP
regulations. This states that all actions carried out under password control must be logged, with the identity of the IV Required
person initiating the actions.
OV Required
A2.10.1. The VHP Generator’s (if mobile rather than built in) overall footprint must not exceed 700 mm x 900mm. DV Required
IV Required
OV N.A.
A2.10.2. Materials and design of construction must enable easy and effective cleaning to be performed. All functional parts DV Required
of the VHP Generator must be enclosed in a single cabinet, with secure access doors for maintenance. All items
requiring observation, maintenance or calibration must be located so as to allow easy and safe access. IV Required
The external finish of the machine cabinet must be powder coated steel or equivalent.
The Mobile VHP Generator must be mounted on four cleanroom type castors, at least two of which must be OV N.A.
lockable.
A2.10.3. The HMI for the VHP Generator must be ergonomically sited and must be between 800 mm and 1200 mm above DV Required
floor level.
IV Required
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
OV N.A
A2.10.4. The mobile VHP Generator be supplied with two “gas” hoses; one for supply to the Isolator and the other for return DV Required
from the Isolator.
All “gas” hoses shall be armoured platinum crosslinked silicone tubing with ends to match the nozzles on the IV Required
isolator/ and Room Nozzle
OV N.A
A2.10.5. Each major component or sub-assembly in the system must be identified with a permanently fixed tag, the tag 1 Required
having an engraved or embossed number corresponding to its identification on the P&ID.
IV Required
OV N.A
Client: Centre for Process Innovation (CPI) Validation Doc Number: na
Exhaust
1 –Exhaust Stack – Normal and post vHP stack tp
atmosphere
From
From room
Room
Isolator
vHP
Generator
Exhaust
stack to
2 – Exhaust Stack – During vHP Gassing atmosphere
From
From room
Room
Isolator
vHP
Generator