High-containment LaboratoryDesign & Construction

Part 3 - Engineering and Commissioning .Engineering and Commissioning .

Presented by:Babak (Bob) Farahpour, P.E.

Harvard School of Public Health Center for Continuing Professional EducationJuly 14 - 25, 2008 Boston, Massachusetts

Engineering and CommissioningEngineering and Commissioning

• Commissioning• Common Engineering issues during

design, construction and commissioning.

• Certification• Challenges of Commissioning and

maintenance in the developing countries.

Commissioning-1

Definition:

“ Commissioning is a systematic process, through documented verification, that all building

systems perform interactively according to the documented design intent and owner’s

operational needs.”

Commissioning-2

• Identifying and documenting the owner’s needs and the requirements of the facility.

• Ensuring that the designed systems are in accordance with the owner’s needs.

• Ensuring that the systems installed are operable and maintainable.

• Testing of the systems to ensure that they are interacting and performing optimally.

• Ensuring that the design intent, the installations and the O&M requirements are clearly and thoroughly documented

• Training of the operators and the facility staff to ensure they operate and maintain the facility per the design intent .

• The Commissioning Authority oversees and coordinates the Commissioning efforts although all parties play a vital role in Commissioning.

1

1-NIH Website: http://des.od.nih.gov/eWeb/research/farhad2/Commissioning/nih_cx_guide/cxplan/plan/hh_start.htm

Commissioning-3

Building an effective commissioning teamWho should be involved in commissioning:

•Commissioning authority

•Owner project manager

•Users

•Biosafety

•Design team

•Contractor/subcontractor

•Security

Commissioning-4

Our experience for successful commissioning:1. Scope of Work:• Understanding what systems need to be commissioned.• Making sure the owner, user and contractor have the

same expectation from the scope of commissioning.• Independent commissioning agent.• Provide specific requirement:

* Involvement during design.-Peer review* Acceptance criteria.* Field installation verification* Developing Function Performance Tests (FPT)* Developing integrated testing protocols*Training.

Commissioning-5

Our experience for successful commissioning:2. Communication:

– Communication between the users, design team, commissioning agent (Cx) and contractors is essential to ensure successful commissioning.

– Communication between Cx and the rest of the team starts at the design phase-Suggest bringing Cx at 15% design for high containment facilities.

– Commissioning activities should be communicated with the contractor and be integrated into the schedule.

– Lack of communication causes delays translating to higher cost.

Commissioning-6

Notes:

YES NO N/A

YES NO N/A

YES NO N/A1.Verify power panel FIV for AHU-13 is complete and approved.

YES NO N/A1.Verify VFD FIV for AHU-13 is complete and approved.

YES NO N/A1.Verify TAB is completed and approved.

YES NO N/A1.Verify AHU-13 ductwork leak testing FIV is complete and approved.

YES NO N/A1.Verify AHU-13 FIV and AHU-13 ATC FIV are complete and approved.

NoteCACMcCompliancePre-Requisite

TEST PRE-REQUISITE’S2.0

FPT Sample:

Commissioning-7

FPT Sample:

YES NO N/A

Steam control valve actuates to full close position.

Verify if associated preheat coil control valve actuates to full close position when commanded by BAS

3.1.7

YES NO N/A

Steam control valve actuates to full open position.

Verify if associated preheat coil control valve actuates to full open position when commanded by BAS system.

3.1.6

YES NO N/AAHU inlet isolation damper goes to full open position.

Verify AHU inlet isolation damper goes to full open position when commanded by BAS system.

3.1.5

YES NO N/AAHU inlet isolation damper goes to full closed position.

Verify AHU inlet isolation damper goes to full closed position when commanded by BAS system.

3.1.4

YES NO N/AVFD will be able to maintain desired air flow.

Verify AHU supply fan VFD operation from maximum to minimum air flow.

3.1.3

YES NO N/ASupply fan rotates in the right direction.

Verify supply fan correct rotation.3.1.2

YES NO N/AAir handling unit fan starts and stops as commanded by BAS system.

Verify air handling unit fan can be started and stopped by BAS system.

3.1.1

NoteCACMcComplianceExpected ResponseProcedureSeq #

Normal Operating Conditions3.1

TEST PROCEDURES3.0

Commissioning-8

Cost

• It needs to be looked at on a project by project basis.• Average cost: 1% to 2% of the total construction cost.

Commissioning-9

Lessons learned during commissioning:• Hire the Cx early on during design.• Have Cx involved during design reviews.• Review the interlocks-sequence of operation.• Integrated Schedule.• Have Biosafety & security involved during testing

and commissioning. Validated SOPs.• Have the local Fire Marshal involved.

Commissioning-10

Lessons learned during commissioning:

• Have building engineer present during commissioning.

• Have all the Functional Performance Tests (FPTs) and Integrated Systems Test (ISTs) prepared well in advance.

Commissioning-11

Lessons learned during commissioning:

• Field coordination• Each zone(BSL-3, BSL-2,etc.)

to have it’s ownredundant system.Combining the back up system for different zones creates control complications.

Commissioning-12

Issues during review and commissioning: (app. 590 items during review)

Commissioning-13

Problems identified during commissioning:

• Design: incorrect duct and equipment size.• Installation: construction debris blocking pipes

and ventilation pathways.• Component failure: faulty electronics in BAS.• Start-Up: ATS not functioning properly, air in the

water system, etc.

Common Engineering Issues During Design, Construction & Commissioning

• Redundancies.• Room pressurization.• Canopy hood design.• Air device locations.• Decontamination.• Back flow prevention devices.

Redundancy Design-1

• Ideal design: 100% redundant or N+1:– N= number of equipments to have 100% capacity.– 1=one independent backup equipment to ensure

system functionality continues in the event of a system failure

• Keep the laboratory and the vivarium systems separate.

• Exhaust to have min. N+1 for each zone (BSL-3, ABSL-3, BSL-4, ABSL-4)

• A common back up for two different systems.

Redundancy Design-2

BSL-2-EF 1&2

BSL-3-EF 3&4

BSL-2 AHU

Standby AHU

BSL-3 AHU

NC

NC

NORMAL OPERATION:

Redundancy Design-3

BSL-2-EF 1

BSL-3-EF 3

BSL-2 AHU

Standby AHU

BSL-3 AHU

NC

NO

UNIT FAILURE:

Room Pressurization-1

CONTROL OF AIRFLOW OFFSETS FOR HIGH CONTAINMENT FACILITIES:

• Passive method

• Active method

Room Pressurization-2

CONTROL OF AIRFLOW OFFSETS:

Passive method:• Not well defined.• Generally constant volume approach• Lower initial cost.• Simpler controls• No/minimal wiring required.• May need rebalancing.• More difficult to commission• Keeping pressurization.

Room Pressurization-3

CONTROL OF AIRFLOW OFFSETS:Active method:• Variable Air Volume Approach (VAV)• Reactive to pressure loss.• Energy efficient.• Easier to commission.• More controllability.• Complicated controls.• Higher initial cost.

Room Pressurization-4

PRESSURE DECAY TESTING:• Done for BSL-4 or ABSL-4, (BSL-3 AG)• Basic principals:

– Charging the room to test pressure – Allowing the pressure to stabilize – Measuring the drop in pressure during testNIH’s Criteria: 2”/20min/50%

Room Pressurization-5

Issues during testing, balancing and Commissioning:

– Room tightness• Door sweeps• Gasketed doors• Transfer ducts.

– Using Fume hoods as exhaust.– Serving more than one room with a single box.

Canopy Hood Design

• Can have a large impact in small places.• Humidity and temperature issues.• Odor control.• Effect on room finishes.• Design to correct capture velocity: 50FPM.• Drain.• Don’t oversize it.

Air Device Locations

• Location of supply air diffusers.• Location of the Exhaust registers.• Animal holding room:

– Ceiling and high level exhaust causes lower room temperature when compared to low level exhaust.

– Ceiling level exhaust provides a better environment for the Scientists.

– Low-level exhaust provides a better environment for the Cages.

Decontamination-1

WHAT NEEDS TO BE DECONTAMINATED?– The laboratory/vivarium area itself.– Any material leaving the high containment

laboratory:• Exhaust Air• Liquid waste• Solid waste• Lab material

Decontamination-2

Laboratory/Vivarium area decontamination:

Most commonly used for Gaseous decontamination:– Formaldehyde (HCHO)– Hydrogen peroxide (H2O2), VHP (Vaporized Hydrogen Peroxide)– Chlorine dioxide (ClO2)

Decontamination-3

Laboratory/Vivarium decontamination:HVAC issues related to decontamination:– There are no standards.– Leaks could create problems:

• Gas dilution• Over pressurizing

– Room preparation issues• Bioseal/Bubble tight dampers:

– Very effective– costly

Decontamination-4

Exhaust Air

• HEPA filter.Decontaminated before removal.

Decontamination-5

LIQUID DECONTAMINATION SYSTEMS:(Effluent Decontamination System-EDS)

• Batch-type Heat treatment. (Cook Tanks)• Chemical Treatment.• Microwave

Decontamination-6LIQUID DECONTAMINATION SYSTEM:

Batch-type Heat treatment.(Cook Tanks)– Steam injected:

» Quicker kill time» Uniform temperature» More waste» Less commonly used

– Steam Jacketed:» More commonly used

now» Longer kill time.» Cleaner heat transfer

– Steam Coils:» Not allowed.

Decontamination-7

LIQUID DECONTAMINATION SYSTEM:

Decontamination-8

LIQUID DECONTAMINATION SYSTEM:Issues During Commissioning:

• Piping to Cook tanks.• Uniform temperature in tank.• Discharge temperature too high.• No sampling ports.• Sizing.

Decontamination-9

SOLID WASTE:

• Lab Material

• Biological, Animal Carcasses

Decontamination-10

SOLID WASTELab Material

• Autoclave:» Most Commonly used.

• Irradiation:» Gamma irradiation.» Microwave irradiation» Ultraviolet irradiation.

Decontamination-11

SOLID WASTEAnimal Carcasses:– Autoclave

• Protocol driven• Timing is very critical

– Tissue Digesters:• Either for decon or disposal• Manufacturers• Sizing• Cycles• Installation• Commissioning issues

– Incineration:• Availability

Back Flow Prevention Devices-1

Issues with BFP Devices:• Lack of understanding

of the containment barrier.

• Improper use of the BFP devices.

Back Flow Prevention Devices-2

Issues with BFP Devices:

• Incorrect installation of BFP devices.

• Required testing criteria.

Back Flow Prevention Devices-3

Lab Certification

– What is Lab Certification?• Differentiate between Lab and equipment.

– Certification Vs. Commissioning– Is it required?– Having a successful certification

process.

Challenges and Limitation of Commissioning & Maintenance in the

Developing Countries

• Finding the right equipment.• Finding the right contractor.• Understanding of high containment facilities.• Finding the right maintenance staff. • Training facility staff.• Availability of equipment and parts.

farahpob@niaid.nih.govfarahpob@niaid.nih.gov

Part 3 - Engineering and Commissioning Engineering and Commissioning issuesissues