DG 3007 Vacuum, Laboratory Gases and Compressed Air GMS Design Guides for Secondary Manufacturing and Consumer Healthcare ‘Any queries or comments on this Guide should be forwarded to Duncan Livingstone - ETCM. Reason Version 3 Date April 2003 ‘Appendix 7 replaced Copyright ©2002 GlaxeSmihcline Group of Companies. Al ight reserved Pago tofContents 1. Introduction 2. Design Data 3. General Considerations 4. Laboratory and Similar Gases 5. Vacuum System -General. 6. Compressed Air Systems Appendix 1 - Typical Compressed Air System Schematic Appendix 2 ~ Prevention of Internal Condensation 1. Introduction 1.1, This Design Guide covers the following services: + Compressed Air + Laboratory gases + Gases for manufacturing © Fuel gas 2. Design Data 2.1, ‘The following information should be collated and recorded; User point locations User requirements for each point of us ‘Quantity (Storage & flow rate) Quality (purity, moisture content, calorific value ete.) Pressure ‘Temperature limits, if any. Usage pattern Impact of service failure System design life ‘Supply plant locations Commissioning requirements, Documentation Requirements Extremes of temperature and humidity levels, externally, and in the plant rooms External noise limits Vibration limits Copyright ©2002 Glaxo SmithKine Group of Companies. Allrighsresewed Poge 20173. General Considerations 34. 35. 36. 3. ‘The design should include for the provision of piped gas services from either external bottle stores or the site distribution system to the points as required Where pipework is run in open plant rooms or walkways, it should be protected to a level of 2.2m( Tft) above the reference floor level to obviate mechanical damage. Hydrogen and acetylene pipework must be run external to the building, entering at the nearest possible point to the place of use. Such pipework should only be run in mechanically continuously ventilated spaces within the building, or other suitable system to prevent build up of gas in the building. Fuel gas should also be piped external to the building. All pipes, pipe jointing fittings and sub-assemblies of fittings for connection to pipes should be cleaned and de-greased to the standard required for oxygen service and should be free of particulate matter and harmful/toxic residues. Separate certificates should be supplied by the ‘manufacturer(s) giving all relevant information for each batch, including confirmation that de- greasing and subsequent complete removal of de-greasing agent has been carried out. All installed pipework should be pressure tested. Nitrogen should normally be used, except for hydrogen systems which should be tested using helium AS soon as whole distribution systems have been completed, methodical and carefully supervised Anti-Confusion tests should be carried our to determine and record that all pipes and outlets have been correctly identified and that no cross connections exist. All pipework should be installed using the minimum practicable number of joints, brazed or otherwise Identification colours for laboratory gases, compressed air and vacuum pipelines should be to BS 1710 or to a similar accepted National Standard. All pipework should be identified with colour banding, and labelled with the service and direction of flow. All valves fixed out of sight in ventilated cupboards or similar situations should be identified to jcate their service reference number and function with a permanently secured Traffolyte or equivalent label. Where gas is vented into the conditioned area the oxygen levels in the space should be checked to ensure that they remain over 20%, 4, Laboratory and Similar Gases 43. 44. 45. 46. 47. Unless specified otherwise, all laboratory gas distribution should be at Sbarg (73 psig) pressure. Special considerations apply in the case of acetylene gas, which must be distributed at a pressure not exceeding 1.Sbarg (22 psig). Acetylene gas should not be used at pressures above 0.62bang © psig). Outlet oF laboratory pressure regulators should be provided to allow adjustment for individual use. They should be equipped with filters and pressure gauges. Alll laboratory gases (except nitrogen) should be supplied from an economically justified source. ‘Where bottle banks are used they should be located external to the building and nominally sized to provide one week's usage to the area served. A minimum of two cylinders should be on a ‘common manifold to give duty and stand-by with automatic change over. Indication of low gas pressure/bottle change over should be provided in the area served, Valves for oxygen, nitrous oxide and laboratory gas mixtures should be carefully located and positioned so that no leakage from the valves can result in a build-up of gas in an unventilated space. Distribution valves (except those in zone valve boxes) should be lockable in the open or closed position. Al shaits mast he ventilated top and bottom either by natural draught or mechanical ventilation Copyright ©2002 GlaoSmihkine Group ef Companies. Al rights reserved Page 3075. Vacuum System -General. 3 52. 33. 5A, 55. 56. 31, 39. Laboratory communal rough (or general) vacuum systems should be designed to ensure a service vacuum of better than 150 mbar (absolute) at all points of use when loaded to 130% of specified flow. The system index run should not normally exceed a pressure drop of 40 mbar. Pipelines ‘may be oversized to provide a receiver if there is a considerable variation in the demand. ‘The design should take account of whether the system is once through or re-eirculated. A re- circulated system is preferred, which should be complete with pre-settable bleed, over-ridden by a high temperature limit, Each system should operate with one or more duty plus one standby pump. Duplicate drain traps and bacteriological filter assemblies must be installed upstream of the receiver. Each filter should be sized for 200% of the steady state design flow rate with iso valves to facilitate change over and servicing. The filters must have a penetration not exceeding 0.05% when tested with DOP. ‘The CONTRACTOR should ensure that space is left around equipment, including receivers, to permit easy access for test and examination. A valved by-pass connection should be provided between the inlet and outlet connections to each receiver to enable it to be drained without interrupting the piped vacuum service. A discharge silencer should be provided at the outlet from each vacuum pump, with the separated seal water being collected in a re-cireulation tank. The exhaust gases from the silencers should be discharged above the roof level. When a contaminated exhaust air stack is provided for other purposes then all discharges from the rough vacuum pumps must be run tightly against, and terminated flush, with the top of the nearest contaminated air stack ‘The provision of isolating valves outside the plant room should be given careful thought, because their use frequently leads to blockages. Communal vacuum circuits (except high vacuum) should be considered throughout each building, Liquid ring pumps are preferred for general purpose vacuum service. Multi rotary vane pumps should be considered for higher vacuums. Lf mechanical pumps are used, liquid trapping must be installed prior to the pump. If liquid ring pumps are used, closed circuit water systems should be employed to conserve water and drainage, subject to contamination concentration not becoming excessive. tage liquid ring or 6. Compressed Air Systems 61 62. 63. 64. 65. 66. ‘The use of compressors with variable speed drives and the use of a central control system used for multi-compressor installations should be reviewed for energy efficiency, and selected on the basis of economic justification considering both initial and operating costs. ‘To improve efficiency the intake air should be as cold as possible. This, in practice, requires the air to be drawn in from outside the plantroom, at a location which is not contaminated, i.e. by vehicle fumes ete. Unless stated otherwise, compressed air should be distributed at a high pressure to minimise the size of the primary distribution pipework, typically 7 barg (101.5 psig). Local compressed air requirements should be met from pressure reducing valves feeding individual areas or branch lines. Where independent monitoring of Pressure Dew Point (PDP) is linked to an automatic system shut down or auto changeover of the dryer, pipework should be run to “fall” in the direction of flow with automatic drain off points for condensate. A non-lubricated compressor is preferred. ‘The compressed air distribution within a facility should be via a ring main, Where air is supplied to product contact applications a 0.2 micron membrane type filter should be provided, with stainless steel pipework downstream of the filter. Copyright ©2002 GlaxoSmithKline Group of Companies. Alrights reservedFor compressed air supplied to production areas, in addition to the moisture levels stated in GQP. 4206 and FPG 14C, a PDP for the system must be established to eliminate the possibility of internal condensation. The procedure for calculating this PDP is given in Appendix 2. 68. The receiver should be lined, and equipped with at least the following, as well as any local requirements; ‘A plate with the design maximum working pressure and temperature. ‘A Pressure Safety Valve rated at the maximum inlet rate A pressure gauge A condensate drain © Amanway for inspection and cleaning 6.9. Breathing air hose pressure must be controlled at 2 barg (29 psig) by means of line pressure reducing valves and sized to give a minimum of 41/s to each concurrent user. Breathing air humidification must be separate from the fixed installation, i.e. where required it should be part of the User (portable) suit/hood system. Breathing air applications are specialist, and where they are part of a project specific advice should be sought from GSK. 6.10. Unless there isa justification for a difference, the system should follow the concepts given in the schematic in Appendix 1. 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