AdvanceTEC starts with your process requirements and your business objectives. We then design and construct your cleanroom- based on your budget- from that foundation. Our in-house engineering, design, construction management and project management teams enable us to bring constructability and tool requirements into the cleanroom design flow.
All elements of the cleanroom project typically developed by project designer
Plan should define the design & construction related requirements for products and processes specified by user and facility management
List of staff-building, environmental, safety, code regulations, good manufacturer practice guidelines
Consider cost of impact, schedule of design process, milestones
Risks need to be identified & mitigations planned
Cleanroom Contamination Control Considerations
All equipment & processes used in cleanroom should be in a matrix listing requirement
Additional issues that affect the building design and construct ability
Hierarchy of cleanliness should be specified & contamination control concept should be developed
Contaminant movement & mitigation need to be analyzed
Cleanroom Site Selection & Services Requirement
Ground load-bearing capacity
Ground water and soil toxicity
Ambient air quality & airborne pollutants
Availability of utility and services at site versus the required utility and services to determine if additional services or remote connections from adjacent facilities
Environmental issues
Site ambient vibration & noise levels determination of their acceptability for the process with or without special treatments
Ambient electromagnetic fields
Local zoning ordinances & regulation
Cleanroom Critical Flow Arrangements
Operations, maintenances and quality personnel need to be consulted throughout the design
Efficient operation- a systemic design effort to determine functional interdependences adjacencies & efficient flow to minimize the migration of contaminants and to optimize process flow
Design of personnel flow in and out of cleanroom
Equipment and materials entering cleanroom must be precleaned and moved through either an airlock or a pass through
Exposed room surface finish materials must be compatible with the processes in the cleanroom
Cleanroom Facility Design Considerations
Standard-ISO 14644-1
The class of airborne particle concentration is specified
Levels of other cleanliness attributes
Facility Planning- externally -> environment & community
Climate, geology, topography, building codes, height, color
More monolithic, nonporous, non-shedding, easily clean
Pressurization-door seals->direction of swing
Vibration-internal/external
Constructability
General Indoor Design Conditions & Considerations
Temperature
Personnel considerations
Process-related conditions
Construction materials and temperature specification
Monitor and control
Humidity
Process equipment can add moisture
Exhaust
Replacement air should be conditioned before entering the cleanroom
The greater amount of outdoor air introduced, the higher the cost of conditioning
Airborne Molecular Contamination
Makeup Air
Air handling units (AHU) requires series of filters to remove particles from ambient air
Filters protect the coils & extend life of HEPA/ULPA filters
Process Exhaust
Filtration System-HEPA/ULPA filters typically mounted to ceiling
Indoor Environmental Quality
Air temperatures, humidity, supply air distribution speed
Outdoor Emission Control & Outdoor Air Intake
Release of particles, chemical fumes, or microbes
Design for Safety Concerns
Physical barriers & zone separation to reduce the impact of sudden dispersion
Zone-or room-based air purge system
Storage of toxic/flammable material
Proper egress path design to reduce the exit distance
Isolation of hazardous materials
Code requirements
Security & Access Control- Protect against unauthorized personnel Building Codes & Standards- Authority having jurisdiction, international codes, national local codes/standards, OSHA, ADA, EPA, NEC
Cleanroom Testing Terminology
Airborne Molecular Contamination-AMC
Coincidence-presence of 2 or more particles
Colony-forming unit (CFU)
Condensation nucleus Counter (CNC)
Diluter
Functional requirement specification (FRS)
Macroparticle
Master plan
National Metrology Institute (NMI)
Particle Size Cutoff Device
Polydisperse Aerosol
Ultrafire Particle
Viable Particle
Cleanrooms in Semiconductor & Electronic Facilities
Facilities need to be flexible, environmentally benign, extendable, reliable and cost-effective
Wafer & chip are terms used to describe the base manufacturing units
Wafer-refers to mono-crystalline silicone dishes used to produce integrated circuit devices
Wafers & chips are produced in a fabrication facility or “wafer fab” or “fab”
HVAC Configuration Cleanroom
Meet heating & cooling needs- satisfies space air cleanliness requirements with that same system
Traditionally accomplished air cleanliness- by using high airflow rates
Challenge is to configure system when airflow rate required by dilution is higher than required heating & cooling load
A cleaner class cleanroom requires higher airflow rate
ACH= air changes per hour
Engineers first calculate airflow rate required to meet heating/cooling load
Then calculate airflow rate to achieve air cleanliness
Then use flow ratio to determine best practices
Airflow streams can either be mixed, diverted or both
HVAC Design for Various types of Pharma Facilities
Primary means of protection from cross-contamination
As managing partner, Phelan is responsible for ensuring client satisfaction, shaping the company’s strategic direction, and managing all compliance aspects of the organization.
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