Alexion Pharmaceuticals BDS, CUB and Warehouse, Ireland

MAIN CONTRACTOR: PM Group
CONSULTANT: PM Group
PROJECT: Alexion BDS, CUB and Warehouse
VALUE: €16.5m
LOCATION: Dublin, Ireland
SERVICES: Electrical Services and Instrumentation

PROJECT DESCRIPTION

Alexion, a global biopharmaceuticals company, has made a significant investment to build a bulk biological manufacturing facility in Dublin, which was its first biologics manufacturing facility outside the United States.

Kirby was responsible for the installation of HVAC services in the bulk drug substance building (BDS) and central utilities building (CUB), mechanical and HVAC installation in warehouse buildings and installation of BMS instruments; as well as complete installation and commissioning of electrical and instrumentation works at the CUB, warehouse buildings and all the external systems.

SCOPE OF WORKS

The electrical and instrumentation services installed by Kirby included:

• MV Distribution
• LV Distribution
• Generator
• 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
• Profibus

The mechanical systems installed by Kirby included:

• Chilled Water
• Low Temperature Hot Water
• Smoke and Heat Exhaust Ventilation
• Supply &and Extract Ventilation Distribution
• DWS
• VRF Air Conditioning
• BMS
• Water for Injection (WFI)
• Instrument Air
• Stainless Exhaust
• Phenolic Duct

Installed plant items included MV Switchgear and cable, LV Switchgear, UPS Systems, Instrumentation, 5 no. LAF booths, 41 no. AHU’s, CRAC units and extract fans.

The total project meterage consisted of 241,000m of cable, 6,000m of containment, 1,600 no. instruments, 1,000 no. loops,300 no. calibrations, 5,000m of impulse piping, 1,000 no. I/O points, 1,100m of black utilities pipework, 300m of plastic piping, 400m of clean utilities pipework and 36,200m² of ductwork.

Alexion AAMF Biologics Manufacturing Facility

MAIN CONTRACTOR: PM Group
CONSULTANT: DPS
PROJECT: Alexion AAMF Biologics Manufacturing Facility
VALUE: €14.5m
LOCATION: Westmeath, Ireland
SERVICES: Electrical Services and Instrumentation. Mechanical Piping & HVAC Services, Off-Site Manufacturing

PROJECT DESCRIPTION

Kirby was appointed to complete full installation of mechanical, process pipework and electrical/instrumentation services on a new biological purification suite for Alexion Pharmaceuticals. The works were completed on a three storey development, as well as warehouse expansion to provide additional capacity at an existing fill-finish facility. A piperack was also installed from the existing CUB building to the new purification suite.

Kirby utilised Building Information Modelling (BIM) to successfully integrate all elements of design across services and ensure high quality installation. Kirby implemented LEAN construction techniques throughout the project. All pipework was prefabricated off-site, which optimised project efficiency. Labour on site peaked at 89.

SCOPE OF WORK

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

The electrical and instrumentation systems installed by Kirby included:

• MV Distribution
• LV Distribution
• Generator
• 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
• Profibus

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
• Leak Detection
• BMS
• Server Room Air Conditioning
• Bioprocess Waste
• Clean In Place (CIP)
• Clean Steam
• Humidification Water
• Nitrogen
• Process Air
• Process Chilled Water
• RO Water
• Solvent / Solvent Waste
• Vacuum
• Water for Injection (WFI)
• Purified Water
• Hot Process Water
• Compressed Air
• Instrument Air
• Product Lines
• Steam
• Process Waste
• Soils and Wastes
• Domestic Water Services
• Stainless Exhaust

Installed plant items included MV switchgear and cable, LV switchgear, UPS systems and instrumentation.

The total project meterage consisted of 300,000m of cable, 8,500m of containment, 500 number of instruments, 1,000 number of loops, 300 number of calibrations, 10,000m of impulse piping, 1,000 number of I/O points, 5,000m of black utilities pipework, 155m of plastic pipework, 1,500m of copper pipework, 3,300m of clean utilities pipework and 5,580m² ductwork.