PROJECT DESCRIPTION

This AbbVie project was a secondary pharmaceutical production expansion, which was completed over two phases. Phase 1 involved the MEP fit-out of the existing fallow production space and Phase 2 involved the MEP fit-out of the new extension, both of which were converted to ISO 7 and 8 cleanrooms. The existing office and laboratory building was also expanded to provide additional capacity.

Due to a compressed project schedule, congested working environment and proximity to adjacent pharmaceutical operations, Kirby implemented an off-site fabrication approach with JIT-based deliveries to minimise storage requirements and manpower on site.

The project involved the installation and alignment of all utility and process equipment including drug isolators, centrefuges, blenders, down flow booths, IBC wash stations, API dry/wet milling machines, fluid bed dryers, coaters, hoists and tablet press.

SCOPE OF WORK

Kirby scope of works included the installation of full MEP services: mechanical, electrical/instrumentation and process pipework services.

The electrical and instrumentation systems installed by Kirby included:

• LV Distribution
• UPS
• General and Emergency Lighting
• General Service Power
• Mechanical Plant Service Power
• Fire Detection and Alarm
• Access Control, Intruder and CCTV
• Earthing and Bonding
• Voice and Data Distribution
• Lightning Protection
• EMS
• Impulse Tubing
• DCS
• Profibus
• Scada

The mechanical systems installed by Kirby included:

• Chilled Water
• Low Temperature Hot Water
• Laboratory Gases
• Smoke and Heat Exhaust Ventilation
• Supply and Extract Ventilation Distribution
• DWS
• VRF Air Conditioning
• BMS
• Server Room Air Conditioning
• Argon
• Bioprocess Waste
• Clean In Place (CIP)
• CO2
• Deionized Water
• Humidification Water
• LAB Purified Water
• Nitrogen
• Process Air
• Process Chilled Water
• Process Waste
• Process Water
• RO Water
• Solvent/Solvent Waste
• Vacuum
• Purified Water
• Hot Process Water
• Compressed Air
• Instrument Air
• Steam
• Glycol
• Soils and Wastes
• Domestic Water Services
• Plastic Exhaust
• Stainless Exhaust
• PTFE Lined Stainless Exhaust
• Product Lines

Installed plant items included 8 number AHUs, 16 number utility panels, 10 number extract fans and 14 number sub-boards.

The total project meterage consisted of 243,000m of cable, 7,700m of containment, 620 number of instruments, 465 number of loops, 394 number of calibrations, 104m of impulse piping, 1490 number of I/O points; 3,200m of black utilities pipework, 300m of plastic piping, 900m of copper piping, 2,300m of clean utilities pipework, 800m of product pipework and 5,500m² of ductwork.