What should be paid attention to in the installation of purification equipment in the factory?

The installation of purification equipment in the factory is a key link to ensure the stable operation of the purification system and meet the cleanliness requirements of the production environment. The key points for attention should be controlled from three stages: pre-planning, installation and construction, commissioning and acceptance, as follows:

First, the pre-planning stage: make pre-preparation to avoid post-rework.

Field survey and scheme matching

It is necessary to confirm the model, air volume and installation location of the purification equipment according to the production type of the factory (such as electronic manufacturing, food processing and pharmaceutical production), cleanliness grade requirements (such as 100-level, 1000-level and 10,000-level), workshop layout and process flow. For example, the medical workshop should focus on the equipment layout in the sterile area to avoid the conflict between the purified air flow and the production line.

At the same time, survey the site space size, ground bearing capacity, power supply interface and ventilation pipeline direction to ensure that the equipment installation space is sufficient and the bearing capacity meets the equipment requirements, so as to avoid installation difficulties caused by insufficient space or bearing capacity.

Compliance check

Check whether the purification equipment and installation scheme conform to the industry norms, such as good manufacturing practice (GMP) for the pharmaceutical industry and Code for Design of Clean Workshop for Electronic Industry, so as to ensure that the project can pass the relevant audit smoothly when it is accepted.

Second, the installation and construction stage: control the details to ensure the installation quality.

Foundation construction and equipment fixing

Purification equipment (such as clean workbench, air shower room, high-efficiency filter and central air-conditioning purification unit) should be installed on a flat and solid foundation. If necessary, concrete foundation should be poured or shock-absorbing pads should be installed to reduce the vibration and noise of the equipment during operation and avoid affecting the purification effect and surrounding equipment.

Large-scale equipment (such as purification unit) should use special lifting tools, and the installation position and levelness should be determined strictly according to the equipment installation drawings, so as to prevent internal parts from being worn or uneven air distribution caused by inclination.

Installation of pipes and interfaces

Ventilation pipes shall be made of materials with good anticorrosion and sealing performance (such as galvanized steel plate and stainless steel plate), and the pipes shall be tightly sealed to avoid air leakage. At the same time, the pipeline should be short and straight to reduce the number of elbows and wind resistance.

The installation of HEPA/ULPA is the core link. It is necessary to ensure the tight seal between the filter and the frame. Sealing strips and sealants can be used to prevent unfiltered air from infiltrating into clean areas and affecting cleanliness. Before installation, check whether the filter is damaged, and it is forbidden to touch the surface of the filter material with bare hands.

Electrical and control system installation

Electrical wiring should meet the power requirements of equipment, and grounding protection should be done to prevent leakage. The control cabinet should be installed in a dry and ventilated area, away from damp and corrosive gases.

Automatic control devices (such as pressure difference sensor, temperature and humidity controller and air volume control valve) of the purification system need to be installed accurately to ensure that the parameters such as pressure difference, temperature and humidity in the workshop can be monitored and adjusted in real time, so as to maintain a clean environment and stability. For example, the pressure difference between clean area and non-clean area needs to be kept at 10-20Pa, which needs to be accurately controlled by sensors.

Clean area protection

During the installation process, it is necessary to protect the clean area from dust and moisture, so as to avoid the construction dust from polluting the clean workshop. Construction personnel should wear clean clothes and use dust-free tools, and clean up the site in time after construction.

3. Commissioning and acceptance stage: comprehensive inspection to ensure the standard operation.

Single machine debugging

Start the purification equipment one by one, and check the running status of the equipment: whether the fan speed is normal, whether there is abnormal noise, and whether the filter is normal. At the same time, the sensitivity of the automatic control system is tested, such as whether the pressure difference can be stabilized in the set range when adjusting the air volume.

System linkage debugging

Start the whole purification system and test the cooperative operation effect of all equipment:

Detection of cleanliness: use particle counter to detect the number of dust particles in different areas of the workshop to confirm whether it reaches the design level.

Detection of pressure difference and air exchange times: ensure that the pressure difference between clean areas and unclean areas and clean areas of different levels meets the requirements, and the air exchange times meet the specifications (for example, the air exchange times in a 10,000-class clean workshop are ≥20 times/hour).

Detection of temperature and humidity and fresh air volume: according to production requirements, adjust the temperature and humidity (generally 20-26℃ and humidity 45%-65%) to ensure sufficient fresh air volume and avoid excessive CO concentration in the workshop.

Acceptance and data archiving

Invite professional testing institutions to conduct third-party testing and issue testing reports. At the same time, the installation drawings, equipment specifications, inspection records, acceptance reports and other data are filed to provide a basis for subsequent equipment maintenance and annual inspection.

Fourth, other matters needing attention

Personnel qualification: Installers should have professional qualifications and be familiar with the installation specifications and operation procedures of purification equipment to avoid affecting equipment performance due to improper operation.

Safety protection: Wear safety belt when working at height, cut off power and hang warning signs during electrical operation to ensure construction safety.

Post-maintenance planning: equipment maintenance space is reserved during installation, which is convenient for later maintenance operations such as filter replacement and pipeline cleaning.