The Background

An internationally known UK manufacturer of military helicopters had a requirement to refurbish a 3000m² cleanroom, whilst simultaneously maintaining full production capabilities. The client, committed to sustainable solutions, also wanted to reduce energy consumption, wherever possible.

An investment of GBP 2 million was made to replace and upgrade the existing facilities, and to ensure they would be capable of meeting future manufacturing needs.

Case study

The challenge

The existing cleanroom had an ageing heating and cooling infrastructure, which was no longer 100% reliable. When occasional heating and cooling faults resulted in the stringent temperature and humidity tolerances for the cleanroom production environment being exceeded, production could potentially be stopped. This was at great cost and inconvenience to the client.

Solutions

DencoHappel engineering and technical teams worked with the client throughout the design, planning, and on-site project management phases.

Design

The engineering team designed heating and cooling requirements for the refurbished cleanroom, with the capability to maintain temperature tolerances of 21 degrees C +/− 3 degrees C and 45% +/− 15% humidity, and provide cooling capacity to the blade presses to allow heat rejection to the atmosphere of 800 kW.

Planning

The existing cleanroom had an ageing heating and cooling infrastructure, which was no longer 100% reliable

The client’s requirements for heating and cooling were met by converting the existing air supply to low-level displacement diffusers and integrating pressure independent control valves with the existing pipework system (with inverter pump systems installed accordingly). It also involved replacing the old cooling tower; cooling water, chilled water and low-pressure hot water pump sets and pipework; water-cooled chillers; and two air-handling units, as well as delivering environmental building control capabilities for the client.

Project management

DencoHappel worked with the client and other entities, for example, those replacing the suspended ceiling and installing LED lighting, to produce an installation plan that would ensure continuous production facilities throughout the project. On site, a DencoHappel project manager worked alongside the client’s project manager and installation teams to ensure the seamless execution of the plan.

Products used

DencoHappel Polacel Towers were used to replace the old cooling tower. These modular towers were made to the client’s bespoke needs and custom-installed on-site.

Since the cooling towers deliver water savings and lower climate cooling costs, the client was able to save energy.

The company’s Cair+ air-handling units replaced the old units, delivering specified and controlled air temperature and air quality to meet the needs of the cleanroom environment.

The company’s water-cooled chillers were deployed, in which heat exchangers were used as condensers and evaporators.

Conclusion

The cleanroom replacement and upgrade was delivered on time, in accordance with the 12-month project plan schedule. Full production was maintained throughout.

Other positive outcomes

The cleanroom continued to meet ISO 8 cleanroom standards and tolerances for temperature, humidity and particle counts throughout the refurbishment period.

The systems and new infrastructure enabled the client to have greater environmental climate control for the cleanroom. In the unlikely case of a failure in any part of the system, the client now has a more diverse range of control options, to be able to resolve any issues without the need to shut down production.

The use of the company’s products continues to deliver the client an estimated annual reduction in energy costs of GBP 64,000.