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Asahi-America Validation Guide PDF
Asahi-America Validation Guide PDF
Life Science
Application
and Validation
Guide
Section One
Section 1
Introduction
pg. 1
Section Two
Section 2
Section Three
Section 3
Alternative Applications
for Thermoplastics pg. 13
Section Four
Section 4
Section Five
Section 5
Section Seven
Section 7
Section 1
Introduction Hot WFI requires expensive utilities support and
poses safety risks due to its high temperature.
This guide contains many possible applications but its
main focus is on High Purity Water. High Purity Water
Production is perhaps the most visible and important High purity DI water should replace low purity WFI
system in a Biopharmaceutical manufacturing facility. water in all applications except the final purification of
As a critical system evaluated for facility licensing, the parenterals.
water systems importance cannot be overstated. The
FDA utilizes the water system as a benchmark indicator A high purity or DI water system should meet the
of a facilitys current Good Manufacturing Practice following objectives:
(cGMP) suitability because it is an universal compo-
nent, regardless of the intended application. 1) Economically provide high purity water of
exceedingly high quality, suitable for all applica-
The major goal of this application guide is to provide a tions.
high purity water design philosophy to economically 2) Provide water without disruption 24/7/365
improve the quality, reliability, and broaden the utiliza-
tion of Purified Water (PW) systems in pharmaceutical 3) Provide water of suitable quality and consis-
manufacturing. Too much emphasis has been placed tency so as to eliminated water as a variable in
upon the regulatory perceptions of pharmaceutical research and manufacturing.
water systems at the expense of the water quality. PW
systems must fulfill their role as the primary water High quality Purified Water will fulfill virtually all of the
source for most pharmaceutical applications, and technical water requirements of the BioPharm industry.
expensive Water For Injection (WFI) should be rel- PW quality should not be measured by the minimal
egated only to applications as defined by the name; regulatory definition of PW, but be defined as the
water for injection. standard of quality routinely delivered by a DI water
system.
The conceded microbiological integrity of WFI comes
at a price; high cost, low purity and high metals The water should have a TOC less than 50 ppb,
content. Too often, WFI grade water is chosen to meet preferably less than 10 ppb.
all facility applications, without regard to quality, to
The microbial activity should be less than one
avoid regulatory scrutiny. This is costly both technically
colony forming unit (cfu/ml), and typically much
and economically. WFI water is not a high grade of
less.
water. WFI grade water is in contact with the atmo-
sphere and, when piped in stainless steel, has an The water should have no detectable endotoxin.
alarming metals content (see graph on page 2).
Rouging has been treated as an unfortunate byproduct The water should exceed 17.5 MegOhm resistiv-
of pharmaceutical water quality and not recognized as ity and there should be no detectable fluctuations
the gross contaminant that it is. Hot WFI water, in quality, day to day, year to year.
recirculating in 316 L Stainless Steel pipe, will consis- The DI water contains no detectable ions to one
tently contain Iron, Molybdenum, Tungsten, Chrome, part per billion.
Nickel and Cobalt, as well as Copper, Zinc and traces
of other heavy metals. The water should require no heating or cooling to
maintain quality.
Metal laden WFI water, which has a significant
The water quality is reproducible from facility to
carbon dioxide content, is not suitable for most
facility and is easily scaled up.
laboratory, research or chromatographic applica-
tions. The water quality varies and is difficult to The DI water must be piped in thermoplastic
reproduce from facility to facility. There is a con- materials and be provided on an instantaneous
cern that this water impairs some cell culture basis, suitable for all applications, including the
processes as well. feed source of the WFI make up.
PW should comprise the bulk of a facilitys water use challenges of the industry. An Asahi/America system is
with WFI utilized on an as directed basis. This specified with confidence.
Section 1
10
1
316L Stainless Steel
Biotech Systems
ppb 0.1
0.01
0.001
FIGURE 1.A: ION CONTAMINATION COMPARISON BETWEEN FOUR ACTUAL HP INSTALLATIONS. ION CHROMOTOGRAPHY MEASURE-
MENTS TAKEN ON DYNAMIC WATER SAMPLES DEPICT EXPECTED PURITY LEVELS BETWEEN POLYMER AND STAINLESS SYSTEMS.
1.1 PURPOSE OF THIS GUIDE 5. Create Specifications (Refer to the Section 8 for
the specifications of our products).
Section 1
This guide is presented in a unique format, a total stand 6. Prepare a Process and Instrumentation Drawing
alone document which answers questions for the design, (P&ID).
construction, commissioning and validation of a pharma-
ceutical PW system or process application. It is a 7. Prepare Equipment and Materials List.
combination handbook and textbook to guide you
through the entire process from conception to successful 8. Prepare a validation plan.
operation. 9. Order the equipment and materials.
This guide is a source of information for pharmaceuti- 10. Prepare construction and piping drawings
cal and biopharmaceutical managers who need to including isometrics.
make critical decisions in regard to process systems. It 11. Prepare construction schedule.
is directed to high purity applications and takes you
through conception, validation and successful opera- 12. Startup and commissioning
tion.
13. Validation
It is organized in such a way to lead the user through 14. Operation
the steps in the design and construction of an engi-
neering project.
Conductivity
<1 <1 0.057 0.056
As stated in the introduction the major goal of this (S)
application guide is to provide a high purity water design TOC
< 500 < 500 < 50 <5
(ppb)
Section 2
philosophy to economically improve the quality, reliability
and broaden the utilization of Purified Water systems in Bacteria*
< 10,000 10 < 100 < 10
pharmaceutical manufacturing. Purified Water systems (cfu/100ml)
must fulfill their role as the primary water source for most Endotoxin
NA < 0.25 < 0.25 < 0.03
pharmaceutical applications. Expensive WFI water (EU)
should be relegated only to applications as defined by TABLE 2.1 WATER QUALITY COMPARISON
the name, Water for Injection.
Based on the premise that Purified Water (PW) systems higher water quality is actually required to maintain
should be the major water source in a manufacturing and microbial control. Any credible thermoplastic
lab facility, it then needs to be economical and reliable. (RO/DI) water system design should make water that is
Proper utilization of thermoplastic piping systems from 17.5 (0.055 uS), TOC < 50 ppb and bacteria at about
Asahi/America is part of the equation. The design options 1 cfu/ml. By properly utilizing TOC UV lamps in the
provided in section 4.1 are provided to better understand design, the water should be less than 10 ppb TOC, and
PW systems and the use of thermoplastics within these bacteria at considerably less than one cfu/ml.
systems.
2.2 System Design
Purified Water is frequently misunderstood. It is techni- 1. Exceedingly high quality Ultra Pure Water (see
cally a relatively low grade of high purity water at one , Suggested Levels for Table 2.1)
500 ppb TOC (Total Organic Carbon) and a liberal bacteria 2. No detectable product water quality fluctuations.
count of 100 cfu/ml.* The designation PW quality, is a 3. Reduced capital investment
regulatory designation, and often higher product water 4. Minimal operating costs
quality is actually desired. It is important not to confuse 5. Virtually no maintenance except for one scheduled
or combine regulatory specifications with product water maintenance day per year.
quality requirements. From a design viewpoint,
These goals are routinely achieved in the semiconduc-
tor industry and have become more common in the
*The Pharmaceutical Industry usually utilizes a WFI product water
specification of 10 cfus/ ml by convention. Actually there is no biopharmaceutical water systems. With the use of
bacteria specification in the Pharmacopoeia for either Purified or WFI proper design and thermoplastic materials truly re-
water, but the FDA still enforces USP 22 microbiological require- markable water quality is becoming routine.
ments.
It is exceedingly difficult, if at all possible, to constrain In addition to the Table 2.2, please refer Asahi/Americas
microbiology in the pretreatment vessels and in storage Engineering Design guide for complete listings of
tanks. A microbiological control strategy is to allow pressure drops and fluid velocities based on total flow
normal levels of microbiological activity in the pretreat- through a pipe diameter.
ment and storage tanks, but to prevent inoculation of the
distribution loop, and retard growth of organisms in the The storage tank should be sized proportionally with the
product water. RO unit to provide design balance. A rule of thumb is the
RO unit should be capable of filling the tank in no less
Section 2
Pretreatment of bacteria prior to the RO have virtually no than an hour and no more than 3 hours. The RO sizes
relation or effect upon bacteria levels after the RO unit the required pretreatment and feedwater piping and
due to the almost impenetrable RO membrane. Microbi- heating (if used) requirements. You can then figure out
ology in plastic storage tanks should stabilize at no more utilities, electrical, floor drains and room sizing.
than 20 cfu/ml, and are typically in the 1 cfu/ml range.
There should be no or just barely detectable slime layer
under the water line of a DI storage tank. One should be 2.3 Process Design
very concerned with effective microbial control after the
storage tank. Control microbiology in the distribution loop The design of a Purified Water system can be broken
by preventing the inoculation of the distribution loop with down into four sections of design consideration:
a 3 stage barrier to microbes (post treatment) and by
making the product water inhospitable to by operating at 1. Feed Water
less than 10 ppb TOC in the distribution loop. Bacteria 2. Pretreatment
will always be present in a distribution loop, but if there is 3. Purification
no food (i.e.; TOC) in the distribution loop, bacteria may 4. Post Treatment
survive, but they cannot thrive. Microorganisms should
stay almost irreversibly attached to the hydrophobic Each of these categories can be further broken down
surfaces of plastic pipe, resulting in virtually no detect- into the details of the equipment utilized and specific
able bugs in the bulk phase product water. piping layout.
PURIFICATION
PRETREATMENT Material:
REVERSE OSMOSIS SKID
WATER
SOFTENING PolyPure/Proline PP
SF-1
5 MICRON
PI P2 PREFILTERS
CITY FEED
WATER
Section 2
MULTIMEDIA MM-1 CF-1
FILTRATION CARBON pH
SF-2
FILTRATION
Material:
PolyPure/Proline PP Material:
Purad PVDF
STORAGE
TANK Material: RESITIVITY MONITOR
FINAL AND ALARM
Purad PVDF FILTRATION
QUALITY INDICATOR
LIGHT POINTS OF USE
TOC REDUCING
ULTRAVIOLET
STERILIZER Material:
Purad PVDF
POST TREATMENT
RESITIVITY MONITOR
ION EXCHANGE AND ALARM
(electronic deionization may replace mix bed ion exchange)
Biofouled TFC RO membranes are a symptom of poor RO molecular weight Organics due to smaller interstitial
design or insufficient pretreatment filtration resulting in pore spaces. High Micropore density, low Macropore
fouling of the RO membranes. The fouled RO membranes density.
provide a food source that quickly slimes over (instant
biofilm). The RO often fouls on surface feedwater due to Coal based - Bituminous (Steam) Activated Carbon -
excessively high conversions (RO product vs reject ratio) cheaper, may be dirtier, higher ash (10%) content,
or reject water recirculation to conserve water, both of medium dust content. Good physical stability (Abrasion
which are a function of proper RO design per application. #). High micropore & medium macropore density to
Section 2
In lieu of carbon pretreatment, a bisulfite addition is remove wider molecular range of organics.
sometimes utilized to neutralize chlorine. Bacteria can
metabolize the bisulfite itself, that plus the lack of an Lignite Based - a low ranked coal. GAC made from
additional filtration step, can also result in biofouling. lignite has a large pore size. This may result in higher
Bisulfite additions in place of carbon filtration may also TOC removal capacity, perhaps for large fulvic and
results in excess TOC in the product water. High TOC humic acids (organics). This higher capacity may be
levels can result in product water bacteria. offset by reduced physical integrity and high fines
content.
Therefore, the use of carbon in pretreatment is preferred.
Carbon pretreatment effectively removes chlorine mol- Wood based Carbon Low Micropore & High
ecules and does not contribute to TOC build up. Carbon Macropore density. Ash content (5%), dust level High.
beds do not require steam or hot water sanitization, as it
does not enhance performance. Acid washed Carbon (low to no ash due to acid
washing) Low pH > 2, phosphoric acid washed, may
Carbon in pretreatment is found as Granular Activated damage older RO membranes if not rinsed properly.
Carbon (GAC). GAC uses surface area to absorb (trap)
impurities. GAC is an effective filtration method and can NOTE: Check pH of feedwater and new carbon
have a surface area of 1000 1200 square meters per effluent. High pH (approximate 10) due to ash throw
gram. This is equal to 100 football fields laid out side by may cause a significant loss of RO membrane ion
side per pound of GAC rejection. This may occur in non-acid washed (high
ash) carbon.
GAC types are distinguished by raw materials and pore
size distribution. Other properties include Iodine, carbon Coconut shell carbon is recommended for chloramine
tetrachloride activity, surface area, pore volume, moisture removal due to the propensity of micropores present
content, particle size distribution, mean particle size, and when compared to coal based carbon. Beware though,
soluble ash content. The Table 2.3 lists the most common Coconut shell carbon may foul more quickly on the
GAC Types and their properties. macromolecular TOC found in surface water sources.
Coconut Shell - Low ash (5%), low dust, better on low Further, a long path (high column or dual beds in series)
is recommended for chloramine removal, due to the
Property Coconut Coal Lignite Wood slow reaction rate and the formation of carbon oxides
from chloramine removal.
Micropore High High Medium Low
Macropore Low Medium High High In surface waters with chloramines, a safe path may be to
Hardness High High Low Medium use a tall (72 inch straight shell) vessel with coal based
GAC. In severe cases, coal based GAC may be used in
Ash (percent) 5 10 20 5 the primary bed, followed by a coconut shell carbon for
Water Soluble Ash High Low High Medium chloramines in a second carbon bed, operated in series.
Dust Low Medium High Medium
Other chloramine removal techniques involve chloramine
Regeneration Good Good Poor Fair destruction via the addition of sodium hypochlorite and UV
Density (g/cm3) 0.42 0.48 0.3 0.35 dissociation of chloramines utilizing intense levels of high-
pressure UV lamp irradiation.
Iodine # (mg/gm) 1100 1000 600 1000
Section 2
because the RO membrane provides an impenetrable
SECOND PASS PASS RO UNIT
barrier to all solids, including colloids and microbes
found in the city feed. Without this barrier, problems
downstream will eventually become overwhelming. This
is especially true for microbial related issues.
SECOND STAGE
Reverse Osmosis REJECT
A single pass RO unit is typically all that is required in FIRST STAGE
Section 2
favor of Polypropylene. Polypropylene offers thermal systems are the same. Many production techniques are
welding techniques similar to the purification and post suited for industrial applications but are detrimental to
treatment sections and offers enhanced purity properties. system purity. At a minimum, all valves, fittings and
Thermal welding eliminates solvent cement in the piping should be produced in a clean environment and
system, which is a major contributor to TOC. Many PW packaged to protect product cleanliness. Pipe should
systems are exceptionally served by the use of PP be capped and bagged immediately after production.
throughout the entire system. Furthermore, all fittings and valves should be rinsed with
DI water before individual packaging.
System Recommended Product Maximum The evaluation and selection of materials will have a
Description Material Name Temperature direct impact on system quality. A complete review of
Pigmented PP Proline available materials and joining methods is recom-
Pretreatment 195F
Natural PP PolyPure mended. Section Eight contains detailed product
Natural PP PolyPure specifications and Asahi/Americas Engineering Design
Post Treatment 195F
HP PVDF Purad Guide is and excellent source of information for design
Natural PP PolyPure and installation requirements.
Distribution Loop 250F
HP PVDF Purad
Finally, a comparison between thermoplastic and
TABLE 2.4 MATERIALS OF CONTRUSTION BY APPLICATION stainless systems is found in Section Four and more
*See Section 7 for discussion on SIP parameters
detailed information on thermoplastic system properties
is contained in Section Six of this guide.
In post treatment (which is the material immediately after
the reverse osmosis unit) PP or PVDF should be utilized
due to its superior purity compared to other materials.
The requirements for water quality and system cleaning
techniques are the determining factor for which material
should be utilized. Polypropylene is a clean and smooth
material that can operate up to 195F. PVDF offers
superior purity and surface finish over polypropylene and
can withstand most chemicals used in cleaning as well
as ozone sanitization. For exact recommendations on
operating conditions, contact Asahi/Americas Engineer-
ing Department for assistance.
The applications in this section are those which are 3.1.1 Overview
normally constructed with stainless steel but the use of WFI is also commonly used in pharmaceutical and
thermoplastics should be considered as a cost effective biopharmaceutical applications similar to the ones listed
substitute. Table 3.1 provides a quick reference of for Purified Water. WFI systems are considered the most
various pharmaceutical and biotech processes in which critical water system and generally receive the highest
thermoplastics may be considered. A brief description of degree of regulatory scrutiny. High quality WFI systems
these applications (with the exception of Purified Water are often considered an excellent indication of a total
Section 3
which is dealt with in Section Two) can be found in the quality facility.
balance of Section Three.
WFI is most commonly prepared by distillation. The stills
The intent of the process diagrams and corresponding are either multi-effect or vapor compression. Materials of
discussions is to highlight areas in which thermoplastics construction for the stills are generally 316L stainless
should be considered. Many process related issues steel. USP-25 now recognizes WFI can be produced
such as corrosion, pitting and metal ion contamination without distillation by means of Reverse Osmosis and
are effectively resolved with thermoplastics systems. Deionization. However, Japan and Europe still require
The application discussion provides a specific summary distallation for WFI systems.
of features and benefits of thermoplastic utilization.
Although the discussion is by no mean all-inclusive, it 3.1.2 Design
should serve as a guide for initial consultation. Asahi/ The most common WFI system design is a single
Americas experienced staff is available for further storage tank with a continuous recirculating hot loop (65-
clarification or discussion pertinent to your application. 80oC.) loop (see Figure 3.A). A specially designed
Natural PP PolyPure
Purified Water 20 to 80C 150 psi Ambient DI Water
PVDF Purad
316/316L SS N.A. - -
WFI* Hot Water
PVDF-230 Purad 121-130C* 150/230 psi
316/316L SS N.A. - -
Solution Prep Varies
PVDF-230 Purad 121-130C* 150/230 psi
cooled point of use or a separate ambient loop are Purified Water is fed to the still and by the process of
sometimes employed. The other type is the batched tank evaporation, impurities are removed. The vapors are
with a recirculating hot loop. This is almost exclusively condensed by a heat exchanger and the water flows by
used when QA release is required for actual preparation gravity to the storage tank. The water is maintained at
of injectable compounds. approximately 65o to 80o C. and is pumped through the
distribution loop and back to the tank. There are hot and
3.1.3 Materials of Construction cooled Points of Use. Materials of construction histori-
Traditionally WFI systems have been constructed using cally have been 316L stainless steel but Purad PVDF
316L stainless steel. The semiconductor industry has can be substituted in many areas of the system, provid-
demonstrated that PVDF is actually a better material of ing improved purity.
construction in terms of both cost and vulnerability to
contamination. Please refer to Section Seven and
consult Asahi/America for exact conditions under which Utilities
Purad PVDF systems may be steam sterilized for WFI Feed Water Purified Water
applications. Plant Steam 70 to 110 psig.
Section 3
Instrumentation Air
AirPro HDPE
20 to 60C up to 230 psi
Proline PP/PE
Still To Heated Vent Filter
20 to 40C up to 150 psi Condensate
Header
Heat Exchanger
Cooling Water Return (as needed)
Proline PP/PE
20 to 40C up to 150 psi
Purad PVDF
Purad PVDF 20 to 130C* up to 230 psi
Condensate
WFI
Storage Tank
POINTS OF USE
316 SS
Purad PVDF
Purad PVDF 20 to 130C* up to 230 psi
Still Description the loop. It measures both conductivity and Total Organic
For a typical 4 effect unit, the first effect is heated by plant Carbon.
steam and subsequent effects are heated by the product
steam from the previous shell and tube heat exchangers It is important to mention at this point that when utilizing a
(effects). Only the first effect utilizes a double tube sheet PVDF piping system for WFI, certain design requirements,
design. The material of construction is 316L stainless steel. such as thermal stress calculations and related expansion
of the piping must be taken into consideration during the
Condenser design process. For more information on thermoplastic
The condenser is a shell and tube heat exchanger pipe system design, please refer to Asahi/Americas
located on the top of the still. Cold feed water and Engineering Design Guide.
additional cooling water is used for condensation. Pure
steam enters from the evaporator heat exchangers
(except the first effect). The top of the condenser is
vented with a sterile cartridge filter. The pure distillate
drains out of the bottom through temperature and
Section 3
resistivity sensors, a diverter valve and finally to the
storage tank.
Preheaters
Warm feedwater from the condenser enters the heater
on the last effect. This helps to cool the hot overflow from
the last column. The water then goes to the previous
effect and the process is repeated until it reaches the first
effect where it is fed into the column as hot feed water.
Controls
The still system is controlled by a PLC. The panel board
contains the various alarm functions. A chart recorder
provides the temperature and quality information for the
distillate. If the distillate is out of specification, it will be
diverted to drain. A clock recorder indicates the duration
of the still operation.
Storage Tank
This is a 316L stainless steel insulated vessel. It is fitted
with level control, temperature element, rupture disc,
spray ball, jacketed 0.2 micron vent filter and SIP con-
nections.
Distribution Loop
The WFI is distributed by single or dual sanitary pumps.
Points of use are cooled by heat exchangers or may be
used hot. All points of use are fitted with sanitary
diaphragm valves. A back pressure regulating valve
maintains loop pressure. A heat exchanger downstream
of the pump is used to maintain the temperature of the
water in the loop return by means of a temperature
controller. A TOC meter is installed at the beginning of
3.2 Solution and Buffer Preparation reason the use of Purad PVDF provides an excellent
substitute. Its high temperature capabilities allow for both
This section describes a design for preparing various sanitization and sterilization if required.
solutions in a fermentation or cell culture facility.
3.2.3 System Description
3.2.1 Overview Figure 3.B shows a typical solution preparation system. It
There are many requirements for preparing various consists of a batching tank followed by a sterile product filter.
solutions in both pharmaceutical and biopharmaceutical The tank has provisions for adding high purity water and
operations. Solutions are typically used in such opera- solids. It is fitted with a sterile vent filter, agitator, sample port,
tions as chromatography, filtration or other purification pH and conductivity probes, jacket cooling water or glycol.
steps. If sterilization is required, Purad PVDF may be Transfer of final buffer is most often accomplished by
utilized. Many solutions are prepared with salts or pressurizing the tank with sterile air.
corrosive chemicals, therefore a thermoplastic material is
superior to stainless steel. A typical solution preparation After the batching tank has been cleaned, sanitized and
design is shown in Figure 3.B but it should be noted that inspected, the required amount of high purity water is
Section 3
these designs may vary considerably since every added. With agitation, the chemicals are charged in
application is different. either solid or liquid form through the additional port on
the top of the tank. pH is adjusted as necessary. The
3.2.2 Materials of Construction solution is agitated for one hour and cooled to 5o C. After
Many solutions and buffers are required in a typical cell integrity testing the sterilizing filter, the batch is filtered
culture or fermentation operation. They are used in into another tank by pressurizing the tank with com-
purification steps particularly in column chromatography. pressed air. Equipment is rinsed with a predetermined
The use of stainless steel frequently causes problems amount of high purity water and added to the batch. The
when salts or acids are used in the formulation. For this buffer process is now complete.
CLEAN 316L SS
T COLD WFI
F-2
HS
PY
HV
PROCESS
AirPro HDPE PV AirPro HDPE AIR
TRANSFER
PVDF
PVDF
AirPro HDPE
PUMP
PVDF
PT PIC
PSE
PVC
PI
SGL ZS XY ZAL
FLOOR
SGL
PVDF
MANWAY LT LI
AE AT AI
316L SS
Carbon Steel
PH
SOLUTION AE AT AI
Chilled
TANK SPARE
SUPPLY Water
PVDF
SAMPLE VALVE
F-1
PVDF
TE TI
CIP
Return
PVDF
PVDF
T
CHEM WASTE
COLLECTION
Section 3
excellent substitute. The high temperature properties of
Purad PVDF allow for steam sterilization in the same fashion
as 316L stainless steel. Considerations to thermal expan-
sion of PVDF must be accounted for in the design.
3.3.2 Equipment
Figure 3.C shows a typical design for media preparation.
The equipment is similar to that used by buffer prepara-
tion. The tank is outfitted the same way and is supplied with
the same utilities. The only major difference in the setup is
that either 2 or 3 final filters are used to ensure sterility.
WFI
F-4
PROCESS
AIR
AirPro HDPE
CIP PVDF
SUPPLY
316L Stainless Steel
PVDF
PVDF
PT PIC
PVDF PVC
MEDIA
MEDIA PREMIX FLOOR
MANWAY
PI PI
TK-1
316L Stainless Steel
PVDF
SAMPLE VALVE F-1 F-2 F-3
M
PVDF
PVDF
PVDF
CIP
PVDF
RETURN PVDF
T PVDF
TE
TI
FIGURE 3.C MEDIA PREP DESIGN
3.4 Clean-in-Place Systems Polypropylene is ideal for high pH medias and in some
cases strong acids. Polypropylene is not recommended
3.4.1 Overview for chlorinated service or extremely high acid concentra-
Clean-in-Place (CIP) Systems are commonly used in tions.
pharmaceutical and biopharmaceutical facilities. Figure
3.D shows a typical two tank CIP system. Similar designs PVDF is ideal for aggressive acids and many chlorinated
are found with single and three tank variations. services. However, it is not recommended for high pH
levels.
3.4.2 Materials
E-CTFE, known as Halar, is an excellent plastic for a
Although CIP systems are frequently constructed with
broad range of aggressive chemicals. In particular,
either 304 or 316 stainless steel, the use of PVDF or
E-CTFE is excellent in Sodium Hypochlorite applications.
polypropylene (pigmented or unpigmented) can be a
viable alternate. Advantages include: reduced installation
For all systems, factors such as thermal expansion and
costs, corrosion resistance, less insulation needs (for hot
UV exposure must be considered.
Section 3
Vortex Purified
Flow Meter Water
Water Purified
Supply Water
Temperature Water
Supply
Steam Pressure
Supply Level Level
Steam
Water
Water Recirc Conductivity
or or
Recirc Solution
Heat Exchanger Tank Recovery Temperature CIP
(as needed) Tank Return Process Vessel
Return Piping
T
Flow Probe
(to be cleaned)
Drain
Valve
Air Relief
CIP Supply Valve
Pump
Chemical PumpCase Tank Tank To Further
DrainValve Outlet Inlet Processing
Cleaning
Chemical
Feed Loop
Alkaline Acidic
FIGURE 3.D TWO TANK CIP SYSTEM (Note: Either Proline PP or Purad PVDF can be used as piping material depending upon cleaning
agent used. Proline PP is excellent for most caustic agents)
Section 3
become a standard for pharmaceutical and
biopharmaceutical applications. The material is a special grade of high density polyethyl-
ene (HDPE) resin specifically approved for compressed
air systems. HDPE may also be used for special gasses
3.5 Pure Air and Gases such as nitrogen, oxygen, carbon dioxide and others that
are used in both chemical and biopharmaceutical
This section describes a design for the generation and processes. The gas is usually supplied in cylinders or
distribution of compressed air and gasses in a fermenta-
COOLING COOLING
WATER WATER
PSV
ROOM AIR
TI
KO
Oil Free AFTER COOLER POT
F-1
COMPRESSOR Storage
INLET
FILTER Vessel
PSV
C-1
P P
Dryer
P
PL
TK-2
F-2 PI PAL
D-1
PT PI
3.5.3 Gasses
Bulk storage of gasses using multiple cylinders or a
single large storage tank is the preferred method. A
segregated access controlled area should be located
outdoors adjacent to the building. A contract with a local
provider assures that there is always an adequate
supply.
Section 4
0.80
size is equal to one tube dimension size larger. Table 4.1
0.60
compares the dimensions of stainless steel tube to
thermoplastic piping.
0.40
Stainless Tube Purad PVDF, SDR21 PolyPure and Proline PP, SDR11
OD ID OD ID OD ID
Nominal Actual Actual Nominal Actual Actual Nominal Actual Actual
inch inch inch inch inch inch inch inch inch
0.5 0.37
0.75 0.62 20 0.79 0.64 20 0.79 0.59
1 1 0.87 25 0.98 0.83 25 0.98 0.77
1 1 32 1.26 1.07 1 32 1.26 1.02
1 1.5 1.37 1 40 1.57 1.39 1 40 1.57 1.3
2 2 1.87 1 50 1.97 1.74 1 50 1.97 1.61
2 2.5 2.37 2 63 2.48 2.24 2 63 2.48 2.02
3 3 2.87 2 75 2.95 2.66 2 75 2.95 2.41
TABLE 4.1 Tube vs Pipe Dimensional Comparison
MP 316L Stainless Steel 20-30 average In addition Purad PVDF, Proline PP and PolyPure
surface finishes are continuously monitored during
Table 4.3 Surface Finish Comparison PVDF and 316L Stainless production. The roughness data is kept on record by
production lot number. The data from this testing showing
Purad PVDF surfaces are continuously monitored during the Ra values for each production lot can be made
production. In addition to production control, the Quality available upon request.
Control department conducts separate inspections of
surface finish and other quality measures of each lot of
production. 4.3 Leachout Performance
Studies conducted by G. Husted of MicroTechno While the surface profile is an important factor in terms of
Research, Inc have compared the bioadhesion proper- reducing bioadhesion, the leachout from a pipe system is
ties of high performance thermoplastics (PVDF and E- more important to a systems overall purity level. A piping
CTFE) with that of high grades of EP and MP 316L system is the transporter of water to the point of use. Its
stainless steel. Test samples were continuously rinsed at material of construction and joining method directly
a velocity of 3 feet per second with E-1 quality UPW impacts the ability to maintain strict levels of purity. While
stream. the piping cannot positively influence water quality it can
have a dramatic negative effect on water quality.
It is well known; stainless steel piping systems leach ment, it is likely to incorporate contaminates from the
higher rates of metal ions than thermoplastic systems. surrounding production environment. These contami-
Table 4.5 provides a comparison of detectable ions and nants may later leach into the water system.
trace metals in high purity water systems with materials
of construction of PVDF and 316L SS. Water samples When evaluating the merits of a particular material,
were drawn from similar points and analyzed for con- review the production and packaging specification of
tamination levels. As should be expected, metal ion various manufacturers. Systems well suited for PW
contamination levels in the PVDF systems are dramati- applications are easily identified by dedicated cleanroom
cally lower than those of the stainless steel systems. production and protective packaging. Systems such as
(Also refer to Chart Figure 1.1 in Section One). The these will best prevent introduction of contaminates alien
higher rates of contamination of stainless steel systems to material composition.
contribute to elevated conductivity levels, high TOC
levels and increased rates of microbial activity by
providing bacteria a nutrition rich environment.
4.4 System Assembly
As with stainless steel, thermoplastics are not all the
same. Differences exist within each material type as well Orbital welding is the most common method of joining
as between material type. A PVC system, even if made high grades of stainless steel in pharmaceutical and
clean, leaches high amounts of TOC into a system due biotech water systems. Used primarily for 300-series
to the organic matter found in all solvent cements. Other stainless steel, properly conducted orbital welding
sources of contamination can be introduced from the provides reliable, beadless welds. Standard procedures
for orbital welding requires weld inspection coupons at
Section 4
manufacturing method. This is true for all thermoplastic
materials including high performance types such as PP the beginning of every shift and change of material lot or
and PVDF. Unless pipe is made in a cleanroom environ- operator. This requirement is necessary due to the
intrinsic variances in material composition of stainless
Dynamic Leachout Comaprison of HP PVDF vs 316L SS steel. ASTM A270 specifies the allowed variances of
Element PVDF-1 PVDF-2 316L-1 316L-2 composition including iron, carbon, chromium, nickel and
Al < DL 0.006 < DL 0.007 molybdenum. This normally occurring variance trans-
Ba < DL < DL < DL 0.14
lates into slightly different welding characteristics. Which
in turn, explains why welding inspection coupons are
B < DL < DL 5.6 1.7
continuously justified.
Ca < DL < DL < DL 1.1
Cr < DL 0.004 0.03 0.023 The iron content of austenitic stainless steels increases
Co < DL < DL 0.03 0.033 during the orbital welding process. This in turn disturbs
Cu < DL < DL 0.007 0.011
the chromium/iron balance at the product surface.
Systems become more susceptible to corrosion when
Fe < DL < DL < DL 0.02
this balance is disturbed. Passivation is required to
Mg < DL < DL 0.002 0.36 restore the corrosion resistance properties of austenitic
Mn < DL < DL 0.019 0.041 stainless steels.
Mo < DL < DL < DL 0.022
Ni < DL < DL 0.44 0.24 ASTM A380-99 Standard Practice for Cleaning,
Descaling, and Passivation of Stainless Steel Parts,
K < DL < DL < DL 0.5
Equipment, and Systems specifies how nitric acid, or
Si < DL < DL 22 < DL other similar agents, is used to restore the desired
Na 0.015 0.04 0.16 5.4 equilibrium between chromium and iron. By requiring
Sr < DL < DL < DL 0.038 passivation, stainless steel systems must be pitched and
W < DL < DL 0.24 0.15 installed to allow complete drainage. This is the main
reason, as well as those systems requiring Clean In
Zn < DL < DL 0.023 < DL
Place (CIP) or Steam In Place (SIP), beadless and
DL = Detection Limit pitched systems are required. Systems not requiring
Table 4.5 Actual purity comparison of four sample points in systems passivation or CIP (i.e. high performance thermoplastics)
with piping materials in HP PVDF and 316L SS. Measurement type do not require beadless welding and pitched installation.
is Ion Chromotography.
Thermoplastics offer simplified welding techniques and water treatment operations, many of which do not have
installation. Both PVDF and PP are melt-processable the ability to be steamed, to be required to be drained
polymers. Systems are joined by a variety of thermal- completely free of water (2).
fusion welding techniques. As mentioned, PVDF and PP
1. Lee, Ron; Patterson, Michael, Ph.D.; and Painter, John;
resins are extremely pure and immensely consistent
Semicondutors: The Efffect of Velocity on High-Purity Systems Rinse Up
from lot to lot. This purity and consistency allows for and Requalification; Ultrapure Water Journal; March 2002; pg 41.
dependable welding parameters, which translate into 2. Collentro, Andrew; Pharmaceuticals: Practical Microbial Control
repeatable and reliable welding techniques. Stainless Techniques for Pharmaceutical Water Purification Systems;
steel welding concerns such as sulfur concentration, Ultrapure Water Journel; March 2002; pg 56.
chromium depletion, condition of tungsten electrodes are
not issues for thermoplastics. The result is simplified
welding and installation practices with thermoplastic 4.5 Rouging
systems.
Rouging is a ubiquitous and perhaps a misunderstood
One of the most common high-purity welding methods phenomenon that unfortunately is associated with the
for high performance thermoplastics such as PVDF and pharmaceutical industry. Rouge is an unacceptable
PP is a non-contact method known as Infrared (IR) visible evidence of water contamination by 316L stainless
Fusion. IR Fusion is accomplished by bringing the pipe steel with corrosion by-products, primarily heavy metals.
components into close proximity with a heating element. Regardless of cause, rouging is a serious issue, which
Direct contact with the heater is avoided in order to must be dealt with in every stainless sanitary system.
minimize the risk of material contamination. IR Fusion
Section 4
provides superior weld results in terms of purity, reliability The reason rouge is not well explained lies in part with
and speed of installation. This is evident by the semicon- the ephemeral nature of the effect and its unusual
ductor industries overwhelming preference for this association primarily with the pharmaceutical and dairy
method of joining, even when compared to various industries. A review of the literature also reveals little
beadless systems. study of the matter. There is a lot of contradiction on the
(Please refer to Section Seven for greater details on IR Fusion and causes and treatment. Metallurgists hold a part of the
other available joining techniques.) puzzle, but they do not have experience with hot WFI
systems. Pharmaceutical engineers hold another key,
Many pharmaceutical engineers shy away form IR but they may not have corrosion expertise. Passivation
Fusion because of the presence of an internal bead. It is engineers have their take on the rouging problem, but are
incorrectly assumed the bead presents an area for not very helpful in preventing rouge, only treating it.
microbial proliferation. If this were the case, semiconduc-
tor water systems would have continuous problems with It is interesting to note the following two facts:
microbial levels. This is simply untrue as evident by
actual installations. For example, one leading semicon- Nitric acid passivates stainless steel, but does not
ductor manufacturer has warning levels of 2.5cfu/100ml dissolve ferrous or ferric oxides; therefore it does not
and action limits of 5cfu/100ml for their UPW distributed remove rouge.
in IR fused PVDF piping (1). These levels are well below Acid cleaning removes rouge but does not passi-
the cGMP action levels of 10cfu/100ml for WFI and vate 316L stainless steel.
10,000cfu/ml for PW!
Stainless systems inherently require two timely and
Furthermore, leading process engineers have acknowl- costly operations not required in thermoplastic systems.
edged the fact not all PW systems require pitched
installations with drainage capabilities. [T]he intent of a Nobody can convincingly explain the causes or methods
fully drainable system [in the context current Good to prevent rouge in a stainless system. Having been
Manufacturing Processes for Large Volume Parenterals said, water is truly the universal solvent. Therefore,
(21CFR Part 212)] was to facilitate the draining of stainless steel corrodes in high purity water. The metals
condensate after a system had been steam sterilized. content or rate of stainless steel corrosion can be
The complete drain ability of ambient or chemically determined by direct ICP/MS analysis of high purity
sanitized piping systems that do not have the ability to be water for metals. Experience has documented lower
steamed is not required. Nor is it reasonable for many levels of metal ionic contamination is found in ambient
temperature systems than comparable high temperature Storage tanks- Use lined storage tanks for ambient
systems. In other words, stainless systems corrode and temperature storage. Some stainless steel can be
rouge quicker in high temperature operation. High accommodated, and a stainless storage tank alone
temperature systems may be effective in controlling may be acceptable.
microbial activity but contribute to the overall degradation
of water quality. Piping Ideally, piping material should be thermoplas-
tic. Thermoplastic pipe, valves, fittings and measure-
The metal content in these water systems is evidence of ment device will not rouge or corrode. In applications
rouge and its contamination of the water. The heavy absolutely requiring stainless steel, 316L should be
metal contamination by-product of rouge includes: Fe, Al, specified.
Ba, Cr, Cu, Co, Mn, Ni, Mo, W, Zn. For every corrosion
source point, often exhibited by a hard discoloration of
the pipe surface, there can be a deposition including in
extreme cases, visible particles carried in the water.
Rouge may be a self-catalyzing reaction that will reoccur 4.6 Bioadhesion Comparison & Control
some time after treatment.
The control of bacteria as a contaminant in product
The surface area of 316L stainless steel in contact with water should be the primary concern in the design and
UPW should be minimized to avoid rouge and its con- utilization of high purity water systems for Life Sci-
ences applications. It is only recently that scientists
tamination affects. When compared to hot or steam
have begun conceptualizing and treating bacteria not
cleaned systems, ambient systems reduce the speed in as discreet units, but as highly diverse, protected,
Section 4
which rouging spreads its harmful effects. USP25 complex communities, known as biofilm.
guidelines now allow WFI quality water to be achieved
through RO operation instead of traditional distillation. Understanding the formation, properties and behavior
cGMPs also suggest 65C is just as effective as 80C in of the biofilm is required to effectively deal with
controlling microbial activity. Under these guidelines, why bacteria in Life Sciences water systems. This under-
consider water distribution through expensive and standing assists designers and operators in attacking
corrosion susceptible stainless steel? High performance the core issues rather than the symptoms of bacteria
thermoplastics such as PP and PVDF can quickly laden water systems.
become the obvious answer to rouge and its ubiquitous
Biofilm Definitions
and unacceptable industry wide contamination issue.
- A thin layer of bacteria and organic matter that
occurs under the viscous boundary layer, at the
4.4.1 Avoiding Rouge interface between the bulk water phase and solid
Stainless steel can not be completely avoided in high system components such as piping, filters and
purity water systems. In fact, stainless steel may be resins. An immobilized cell thin-film bioreactor.1
the preferred material for certain applications. How-
ever, the best method to avoid rouging is to limit the - A complex and highly diversified community of
usage of stainless steel. viable and nonviable microorganisms, their associ-
ated glycocalyx, adsorbable organics, and en-
Stills- Stills can be a source of rouge and are often trained particles.2
badly corroded when examined. Do not worry about
rouge from main boilers; it will not carry over in the Bacteria cells are present, to some degree, in all
steam. The condenser and all wetted surfaces thereaf- distribution piping systems and adhere to essentially
ter should be 316L stainless steel or Thermoplastic all wetted surfaces. Furthermore, (b)iofilms form
where applicable. expected densities after 2 weeks on all wetted sur-
faces, regardless of flow velocity.3 The presence of
Pumps All pump impellers and wetted surfaces should biofilms in high purity water piping, to some degree, is
be 316L stainless steel, if not coated with high perfor- unavoidable. Once understood, the issue then be-
mance thermoplastic. Erosion due to pump cavitation comes how to best minimize and limit biofilm and it
adverse effects.
will exacerbate rouging episodes.
Recently, ISPEs Baseline Guide, Volume IV, Water and Limiting their growth in the high purity environment may
Stream Systems, Jan 02, has recognized 65C as an best control biofilms and system bacteria levels. In
equally effective temperature as 80C. PolyPure and high purity environments, cell proliferation in the biofilm
Proline PP Systems can and should be considered
is severely inhibited by a combination of colonization or
under these circumstances.
inoculation prevention and nutrient deprivation.
In either case, PVDF and PP are excellent thermal
insulators. Hot piping systems (up to 80C+) con- Inoculation Prevention
structed of PVDF and PP do not require external Preventing inoculation of a piping system is a function
insulation for maintaining critical, hot temperatures or of the water system design, not the distribution piping
for protection from injury resulting from burns. design. The water system design must limit and
prevent both viable and nonviable organisms from
However, those who use heat sanitization for ambient proceeding downstream. It is a function of filtration with
temperature systems such as carbon beds, RO mem- RO being one of the more effective means. This
Section 4
branes, distribution loops, etc. should be aware that prevents seeding of a potential biofilm by colonizing
heat sanitization does not remove biofilm, regardless of bacteria and perhaps more importantly prevents live
material of construction. In such systems, failure to and dead organisms from providing a nutrient source to
remove a biofilm may lead to its re-colonization and downstream biofilms.
growth even faster than with bare pipe. The old biofilm
serves as an excellent capture and attachment site with Nutrient Deprivation
nutrients at hand. In extreme nutrient deficient environments, bacteria will
not attach to surfaces. If they do not attach, they
In addition, hot stainless steel water Life Sciences cannot form biofilm. Costerton7
applications have become less attractive due to safety,
cost and quality considerations (i.e. rouging Please TOC control is essential to preventing biofilm prolifera-
refer to Section 4.5 for discussion on rouging) and the tion. Water systems should not operate with TOC over
move towards in-line mixing and the preponderance of 5ppb. Ideally the systems should run at < 0.5 ppb or
ambient temperature applications. In addition, most 500 ppt TOC. This is a far tighter control of TOC than
points of use must be cooled prior to supply. This can the 500 ppb allowed by regulation in Life Sciences
add to sanitation concerns for improperly operated water systems. Water systems with more than 50 ppb
systems. TOC are decidedly nutrient rich, and bacteria problems
can be expected.
Velocity
Powells work showed the average velocity to remove Multiple nutrient restrictions (phosphorous, nitrogen,
biofilm from electropolished pipe is 12 ft/sec. This is potassium) appear to limit growth.4 Water systems
two times (2X) the average maximum velocity of water should target detectable elements at no more than 10
in distribution piping which results in an unacceptable ppt. Borone should be the exception, which, if required,
pressure drop. The minimum thickness of the laminar must be dealt with separately.8 Standard designed RO/
sub layer for cold water is about 0.1 0.2 mm.8 Even DI water systems are capable of routinely and continu-
mature biofilm with films 5 m thick would require 5 ously providing water of this quality. As shown on chart
layers to begin to protrude into the turbulent flow at 8.6 1.A on page two of this guide, thermoplastic piping
ft/sec. As such, high velocity of water in distribution has systems typically operate at extremely lower rates of
been shown to have little or no effect in the control of ion contamination than 316L systems, thus, avoiding
microbiology and biofilm formation.3, 6 In fact, exces- contribution to nutrition level required for the prolifera-
sive flow velocities may actually accelerate biofilm tion of biofilm and bacteria laden systems. This is the
growth.3 basis of biofilm control in the semiconductor industry
where routine decontaminations and sanitation cycles
are avoided, as the procedures themselves are consid- There is no correlation between the presence of biofilm
ered a source of contamination. Additionally, it requires and the water quality delivered to Points of Use.7 By
downtime that is neither available nor appreciated. inhibiting biofilm growth, the scant biofilm that may be
Although semiconductor water requirements are differ- present is left virtually irreversibly attached to the
ent than those required for Life Sciences, high quality
substrate (pipe surface) in the laminar sub layer where it
water with controlled biocolonization and endotoxin
levels are issues for both industries. is unable to be sloughed into the bulk flow. This allows
the Semiconductor Industry to achieve total bacteria
Materials of Construction counts (dead and alive) of less than 10 cells/liter.
Thermoplastics are the preferred choice for the materi-
als utilized in UPW systems and distribution piping 4.6.2 Conclusion
where water quality is the primary concern. In conclusion, thermoplastic piping systems should be
specified for exceptionally high quality water systems
The product water from Life Science water systems for the following reasons:
utilizing 316L piping, always demonstrate a distinct
metal ion signature, mirroring the composition of the - 316L systems have been shown to be more
316L distribution piping. Trace metals for 64 elements susceptible than PVDF to excessive biofilm
as measured by ICP/MS are typically negative for high formation.
purity thermoplastic water systems to parts per trillion - Hot water systems, if desired, are compatible
(ppt) levels.8 with thermoplastic systems and do not experi-
ence accelerated corrosion as with stainless
It is clear that 316L stainless steel supports the attach- systems.
ment and apparently promotes the growth of biofilm - High performance thermoplastics do not
when compared side by side with thermoplastics in a contribute to the nutrition (ion contamination)
Section 4
series of tests. Gray states that stainless steel was levels of water systems.
generally concluded to allow more extensive biofilm
growth than plastics.9, 6 Husted found consistently lower The key to controlling microbiology in high purity water
microbial cell densities and biofouling, per unit area, are systems is maintaining exceptionally high water quality.
noted for thermoplastics when compared to stainless Operating higher quality systems than mandated by
steel.9 (See Section 4.2 for more details). USP specifications should not be expensive. The use
of very low TOC water (< 10 ppb TOC recommended)
Surface finish alone does not appear to explain the and thermoplastic distribution piping is conducive to
control microbiology via nutrient deprivation.
disparity between 316L stainless steel and Thermoplas-
tic piping systems. The average wall smoothness for The Semiconductor/Thermoplastic approach to higher
Polypropylene is not as good as mechanical finished water quality is proven effective and reliable and results
316L stainless steel, yet experience indicates bacteria in considerable cost savings in:
counts in the bulk water phase for Polypropylene is very
similar to other thermoplastics reported in the data. - Cost of Installation and Maintenance
This may indicate the biofouling is reduced for Polypro- - No boriscoping, passivation or de-rouging
pylene despite a rougher average pipe wall finish. requirements
Further investigation is ongoing. - No hot water utilities infrastructure and opera-
tional costs
As mentioned above, one possible explanation may be
The Semiconductor Industry routinely operates ambient
the metals in 316L provide a source of scarce limiting
DI water systems with less than one cfu/ liter microbiol-
nutrients that are definitely not present in either PVDF
ogy levels without routine sanitizations being required.
or PP thermoplastic piping systems. However, thermo-
The effective and proven practices of biofilm control in
plastics such as PVC should be avoided for the sol-
this industry, of which thermoplastic piping systems is a
vents required for system joining contribute to contami-
major factor, should be considered as applicable and a
nation concerns and system TOC levels. The fact that
cGMP for Life Sciences. Regardless of industry, low
PVDF may be employed at 65C to 80C and can be
bacteria counts and high quality water systems are
steam sanitized could make it an attractive option to
absolutely required.
replace stainless steel in hot WFI applications and is
being utilized more frequently.
Section Five
Validation Plan and It is extremely important to properly plan the validation of
Sample Validation Protocals the system that is being installed. The plan becomes the
basis of the entire activity and establishes the following
components:
Section 5
The IQ should be written at the conception of a project 10. Change Control Procedures
and followed throughout the installation. In many cases it
11. Re-Validation Requirements
is written as an after thought to comply with regulations.
Asahi/America provides the guideline for the IQ to make 12. Appendices
the document useful to a project. Room Classification and Pressurization
Drawings
Operational Qualification (OQ) Personnel and Material Flow Diagram
Verification that the system operates according to the Process Flow Charts
design drawings and specifications. Failure modes and Discussion
alarms are confirmed.
Process Qualification (PQ) Not all of the above items may be needed for a system
Confirmation that the system will produce the product or which is part of an overall facility project. The two most
material as intended. Various operating configurations important documents in the plan and the subsequent
may require simulation. Analytical procedures must also protocols are a system description and a detailed
be validated and the final test results complete the process and instrumentation drawing. These should be
validation report. prepared as soon as the design has been established.
5.1 Schedule
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Design
Engineering
Procurement
& Delivery
Construction
StartUp &
Commissioning
Validation Plan
Protocol Preparation
Initial SOP Prep
IQ Execution
OQ Execution
ValidationGuide@asahi-america.com
Sample Protocols:
TAL INDEX
MANUAL AND SUBMIT
6. EQUIPMENT
Piping System
ral Polypropylene
PolyPure Natu
1. Title: Rev. PP-99A
Number: 1999
Installation Qua :
Revision Date lastic Val
lification: INTR istant Thermop
ODUCTIO Corrosion-Res
N Asahi/America
1.1 PURPOSE 2. Title: Rev. V-00/A
Number: 2000
:
To provide a
protocol for the Revision Date Meters
x Flow
System. This Installation Qua Universal Vorte
Insta lifica
system including llation Qualification will defin tion (IQ) of the new High Asahi/America
modifications/ e Purity W 3. Title:
United States upgrades to prod the established high purity
Phar
executed to asse macopoeia (USP) Purified uce the water wate
quality attributes r Rev. FM-98/B
Water. The Insta Number:
verification that mble all the documents and me : 1998
the equipmen background infor llation Qualification Revision Date Cont rols
specifications. t was
Further, this Insta installed in conformance mation pertaining to Actuation and
attributes and llation Qualificat with the draw Asahi/America
operating para ion will estab ings and 4. Title: Re. AC-99/A
meters. lish standards
for qu Number: 1999
1.2 BACKGROUN :
D/SUMMARY Revision Date PVDF
Valve made of
This new High Agru Sampling
Purity Water Title: 6/F
current Good
Man
System is desig
ned to meet the
5. L-MM/TI-Rm2.9
system will mee ufacturing Practice (cGM standards of Number:
:
t the requirem P). The water the FDA
ents of the curre quality Revision Date iaphragm Valv
es
nt USP for Purif produced by this leg (T) Valves/D
The system was ied Water. Agru Zero Dead
designed by:
____________ 6. Title:
____________
The system was ____Date: ____
____ Number:
installed by: ____ :
____________
____________ Revision Date
_Date: ________ s:
/Discrepancie
Observations
Date:
Submitted By:
mentation is
Above Docu
Y/N
Complete:
Section 5
7.2.3Perform
ance Qualific
atio n
Equipment Des
cription:
Protocol Prep
High Purity Wat
ared By er System
ODUCTION:
lification: INTR
Operational Qua
Approved for Date
Execution
____________ By ____________
____________
_______
1.1 PURPOSE
of the new High Approved for Date
ification (OQ) r Execution
Operational Qual enge this wate ____________ By ____________________
protocol for the rational Qualification will chall ates as specified by ________
To provide a Ope m oper ___
System. This lled sub-syste will result in
Purity Water each correctly insta this valid ation protocol
that of to
system to verify In addition, the execution information pertaining
Approved for
Execution Date
urer. nd
the manufact ts and back grou ition. ____________ By ____________________
of all documen its installed cond ___________
the assembly t operates in
the equipmen
verification that ess of the
ate the effectiven to
ence to demonstr ents for maintenance, and Date
e 1 will comm the requirem d with the high
Further, Phas to esta blish asso ciate
monitoring sche
me, es (SOPs)
dard oper ating procedur Equipment Des
support the stan m. cription:
purity wate r syste Practice High Purity Wat
Manufacturing 1.1 PURPOSE er System
for current Good will meet the
ards of the FDA water system will be tested
To meet the stand r quality produced by this points-of-use To provide a
(cGMP). The
wate
s Phar maco epeia 25. All protocol for the
of United State oved procedure. water system. Performance
requirements This Performan Qualification
appr of the new high
ied Water per document and ce
confirm the appr Qualification will be executed purity
for USP Purif operating rang opriateness of to evaluate,
es. In addition, the critical proc
water system this performan ess paramete
and ce r
D/SU MMARY operated in acco water quality reproducibility qualification will demonst
1.2 BACKGROUN standards of
the rdance with appr over a duration rate both
ned to meet the oved standard of one year when
System is desig (cGMP). The water quality operating proc
Purity Water tice USP for 1.2 BACKGR edures.
This new High ufacturing Prac requirements of the current OUND/SUMMA
nt Good Man t the RY
FDA for curre m will mee
this water syste This new High
produced by FDA for curre
Purity Water
System is desig
r. ___
Purified Wate Date: ________ nt Good Man
ufact ned to meet the
____________ produced by
this water syste uring Practice (cGMP). The standards of the
____________
designed by: _______ Purified Wate m will meet the water quality
The system was _____Date: ____
r. requirements
of the current
____________ USP for
m was insta lled by: ________ The system was
The syste designed by:
___________ ____________
____________
_________Dat
e:
The system was
installed by: ____
___________ ____________
____________
______Date:
Asahi/America offers the Purad PVDF System for high E-CTFE 300 F / 150 C semifinished products:
- Lining of UPW storage tanks
purity applications. Purad is ideal for Pure Water and - Lining of chemical storage tanks
Water for Injection service. It is available in sizes 20mm - Tank construction
to 315mm (1/2 to 12) with a wide assortment of fittings, - Apparatus
Section 6
valves and flowmeters. - Machined components
Section 6
Volume resistivity VDE 0303 OHM cm > 1013
Due to its material properties, surface finish, purity,
mechanical strength and ease of installation, PVDF Surface resistivity VDE 0303 OHM > 1012
has become the flagship piping product of Asahi/
America and high purity water and chemical applica- Dielectric constant at 1MHz DIN 53483 - 7.25
tions.
Dielectric strength VDE 0303 kV/mm 22
The surface of PVDF components prevents the prolifera- Physiological non-toxic EEC 90/128 - Yes
tion of microorganisms, similar to the surface of glass.
This conclusion is the result of a study carried out be CFR 21.1177-
FDA - Yes
Solvay at the Centre dEnseignement et de Recherches 2510
des Industries Alimentaires et Chimigues, CERIA in Friction coefficient DIN 53375 - 0.34
Brussels, analysis no. 284.321 dated the 14th of May
Flammability UL94 - V-0
1974.
UV stabilization - - Yes*
*PVDF is not suitable for direct connection to UV-Sterilizers. UV light traps can be installed
to eliminate the problem.
Section 6
The surface quality is constantly monitored during
production of all high purity components. The surface
roughness (Ra-values) and micropores are measured to
ensure system compliance. These tests are performed
on a statistical basis and provide an excellent indication
of the quality of the manufacturing process. Additionally,
independent labs and interferential microscopy are used
to measure quality in accordance with SEMATECH
9201055 B (SEM).
Permissible service
Severe stress tests have proven that it is not subject to - C -76 to +150
temperature
chemically induced stress cracking from strong acids
and bases, solvents and chlorine. In particular E-CTFE Tensile strength at yield ISO 527 MPa 30
can with stand high concentrations of Sodium Hypochlo-
Elongation at yield ISO 527 % 5
rite and Hydrogen Peroxide, out performing most
available plastic and alloy materials. It is only affected by Tensile strength at break ISO 527 MPa 54
hot amines and molten alkali metals. Elongation at break ISO 527 % 250
Section 6
requirement.
Thermal conductivity at
DIN 52612 W/(mxK) 0.15
High purity Ultra Proline Pipe, as with Purad PVDF, is 20 C
immediately packaged after production in a class 100 Volume resistivity VDE 0303 OHM cm > 1016
cleanroom. Pipe ends are sealed with PE film and PE
cap. The pipe is then sleeved in the PE and heat sealed Surface resistivity VDE 0303 OHM > 1014
on each end. Pipes are shipped in rigid PE tubes which
are non-particle generating and resistant to moisture and Dielectric constant at 1MHz DIN 53483 - 2.6
impacts.
Dielectric strength VDE 0303 kV/mm 30-35
Valves and fittings are cleaned after secondary machin- Physiological non-toxic EEC 90/128 - Yes
ing in a 6 basin automated hot UPW bath system (UPW
quality: TOC <10 ppb, conductivity >18 , FDA
CFR 21.1177-
- in prep.
2510
Temperature >70C). After drying with hot clean-air
(class 100) and 100% inspection, the valves are Friction coefficient DIN 53375 - 0.19
assembled and all fittings and valves are double Flammability UL94 - V-0
packaged under a class 100 cleanroom environment.
UV stabilization - - Yes
Components are produced by application of special maintaining the same SDR. Care should be taken when
design and designated manufacturing equipment and specifying Halar systems to ensure all system compo-
tooling. Special material and finish of tools used for nents are suitable for the application pressure require-
injection molding and extrusion have a significant ments.
influence upon the surface quality of the finished product.
6.2.4 Ultra Proline Advantages
The surface quality is constantly monitored during Asahi/America and Agru are uniquely able to provide
production of all high purity components. The surface Halar piping systems offering the following advantages:
roughness (Ra-values) and micropores are measured to
ensure system compliance. These tests are performed One of the smoothest Surface Finish of any thermo-
on a statistical basis and provide an excellent indication plastic material
of the quality of the manufacturing process. Additionally, Extremely low levels of leachables
independent labs and interferential microscopy are used More cost effective than PFA Pipe
to measure quality in accordance with SEMATECH Superior Chemical Resistance
9201055 B (SEM). Reliable Joining Techniques
6.3 PolyPure Natural Polypropylene additional purity benefit of reduced risk of heater element
cross-contamination. If desired, socket fusion is available
6.3.1 Materials for sizes 20mm - 63mm ( - 2).
PolyPure is a natural, random copolymer polypropylene
offering superior mechanical proper-
ties over homopolymer materials. H H
PolyPures flexural modulus is more - C - C- POLYPURE PHYSICAL CHARACTERISTICS
than 30% lower than homopolymer H H- C -H Property Test Standard Unit PP-R
pipe, making it more flexible in H 3
bending applications. Lower crystallin- Specific gravity ISO 1183 g/cm 0.9
ity in the joints also makes PolyPure more reliable. Water absorption DIN 53495 % (-) < 0.01
Section 6
Produced on dedicated equipment, PolyPure compo-
nents are packaged to protect its purity and quality. Pipe Thermal conductivity at
DIN 52612 W/(mxK) 0.24
ends are immediately sealed with PE film and PE Caps. 20 C
Pipe are then packaged in full length PE bags (quantity Volume resistivity VDE 0303 OHM cm > 1016
dependent) for further protection.
Surface resistivity VDE 0303 OHM > 1013
Valves and fittings are cleaned after secondary machin-
ing in an automated hot UPW bath system (UPW Dielectric constant at 1MHz DIN 53483 - 2.33
quality: TOC <10 ppb, conductivity >18 ,
Temperature >70C). After drying with hot clean-air Dielectric strength VDE 0303 kV/mm (75) 70
(class 100) and 100% inspection, the valves are Physiological non-toxic EEC 90/128 - Yes
assembled and all fittings and valves are double
packaged under a cleanroom class 100 environment. CFR 21.1177-
FDA - Yes
2510
The prefrered methods of system joining are butt or IR Friction coefficient DIN 53375 - 0.3
fusion. Butt and IR fusion methods provides superior Flammability UL94 - HB
weld mechanical properties exceeding the mechanical
properties of socket fusion. IR Fusion provides the UV stabilization - - No
system available
Available in multiple joining techniques, Butt fusion,
Socket Fusion and IR Fusion.
All joints are made using heat fusion, providing
reliability and maintaining purity. No messy cements
which increase TOC levels.
6.4.1 Materials
Proline systems are pigmented PROLINE PHYSICAL CHARACTERISTICS
polypropylene and are manufactured H H
from random copolymer resin. - C - C-
Copolymer materials offer superior Property Test Standard Unit PP-R
H H- C -H
mechanical properties over ho- H Specific gravity ISO 1183 g/cm 3
0.9
mopolymer materials. Prolines Water absorption DIN 53495 % (-) < 0.01
flexural modulus is more than 30% lower than homopoly-
mer pipe, making it more flexible in bending applications. Permissible service
- C -5 to +95
Lower crystallinity in the joints also makes Proline temperature
systems more reliable.
Tensile strength at yield ISO 527 MPa 25
Proline systems have an extremely large application Elongation at yield ISO 527 % (-) 12
range. Equally suited for UPW transport, caustic CIP Tensile strength at break ISO 527 MPa 40
distribution or aggressive vent systems, Proline provides
Elongation at break ISO 527 % 800
maximum system flexibility.
Impact strength ISO 179 kJ/m2 no break
Section 6
sealed on each end. Pipes are shipped in rigid PE tubes Thermal conductivity at
DIN 52612 W/(mxK) 0.24
which are non-particle generating and resistant to 20 C
moisture and impacts.
Volume resistivity VDE 0303 OHM cm > 1016
High purity grades of Proline valves and fittings are Surface resistivity VDE 0303 OHM > 1013
cleaned after secondary machining in an automated hot
UPW bath system (UPW quality: TOC <10 ppb, Dielectric constant at 1MHz DIN 53483 - 2.33
conductivity >18 , Temperature >70C). After
drying with hot clean-air (class 100) and 100% Dielectric strength VDE 0303 kV/mm (75) 70
inspection, the valves are assembled and all fittings and
Physiological non-toxic EEC 90/128 - Yes
valves are double packaged under a cleanroom class
100 environment. CFR 21.1177-
FDA - Yes
2510
Proline systems are joined by a variety if methods. For Friction coefficient DIN 53375 - 0.3
PW, IR is commonly specified. Butt and socket fusion
are available options. For vent systems, butt fusion or Flammability UL94 - HB
slip coupling welding can be utilized depending upon UV stabilization - - Limited
system size.
Mesurement Types:
Ion chromatography (IC) According to SEMI draft doc.
2840 (rev 05/14/98)
Total organic carbon Analyses (TOC) According to
SEMI2840B STD (7d;850C)
Sample setup for static leach out test
Test Procedure:
Sample
Sample preparation in class 10,000 Preparation: PVDF-cap
environment
UPW
Test was performed in class 1 (18.1 MWcm)
according to SEMASPEC.
Section 6
PVDF
Pipe sample
Soak time 7 days
(to be tested)
Anion analyses by IC with suppressed
conductivity and preconcentration unit PVDF-cap
(Release values are notified)
class 1
Anions Sulphate 7 < 1.48 < 0.1 10.6 1.28 0.7 0.14
Chloride 7 4.3 0.29 13.17 1.06 11.7 1.9
Nitrite 7 < 1.48 < 0.1 4.43 0.35 < 1.9 < 0.3
Bromide 7 < 1.48 < 0.1 - - < 0.2 < 0.03
Nitrate 7 < 1.48 < 0.1 0.73 0.03 0.51 0.09
Phosphate 7 < 2.96 < 0.2 0.23 0.02 0.51 0.09
Fluoride 7 12.74 0.86 0.49 0.04 1097 174
Cations Lithium 7 < 1.48 < 0.1 - - < 0.19 < 0.04
Sodium 7 29.18 1.97 2.05 0.34 0.68 0.15
Potassium 7 < 2.96 1.48 0.25 0.02 0.62 0.11
Magnesium 7 38.22 2.58 11.96 1.46 0.38 0.07
TOC Analysis
Results:
100000
90000
80000
Concentration [g/m2]
70000
60000
50000
40000
30000
20000
10000
0
Proline HP PP PolyPure PP Purad PVDF SEMI Spec. E49.new
Polymer Material OD 50 - 63
In designing a thermoplastic water system, the following Knowledge of the above parameters is required in order
items need to be considered: to determine the suitability of thermoplastics for your
Material of Construction application. Compare the actual conditions to the
Operating Parameters allowable ratings of the material being selected for the
System Sizing job. It is important to predict elevated temperatures, as
Thermal Expansion/Hanging Methods thermoplastics have reduced pressure ratings at higher
Instrumentation and Controls temperature. Valves should be verified in terms of
Sanitization Methods temperature and pressure separately from a piping
Welding Method system, as certain styles and brands of valves have
Dead Leg Reduction and End-Point Configuration lower ratings than that of the pipe system.
7.2 System Sizing In addition to this approach recent tests results com-
pared the effectiveness of 0.5 and 1.0ft/sec velocities
It is well known that high purity water systems are in rinsing contaminated UPW into specification1. UPW
designed to operate in a continuously flowing loop to samples were exposed to prolonged stagnation (over 8
prevent stagnant water in the system. Stagnant water hours) allowing prolific microbial growth. High-purity, IR
propagates the growth of bacteria and biofilm. The rate Fused, PVDF systems rinsed into specification from
of microbial growth is dependent on numerous factors greater than 90 cfu/100ml to under 2.5 cfu/100ml in 30
including the initial quality of the water. However, after an minutes with 1.0 ft/sec. This clearly suggests maintain-
initial lag phase, exponential growth is likely to begin ing system velocities at 1.0 ft/sec may be sufficient and
within 12 to 24 hours. can effectively limit microbial activity associated with
stagnant water.
Continuous flow is therefore recommended for all areas
of PW and WFI distribution. General guidelines have Sizing Laterals
traditionally suggested flow velocities between 3 to 5 ft/ A Purified Water system may be made of a main loop
second. and branches known as Laterals. It is important in design
to not dead end laterals and ensure that there is always
However, a more sensible approach with high perfor- flow movement in the main and the lateral. Systems are
mance thermoplastics may be to review the Reynolds designed with different loop configurations to accommo-
Number of the system to insure the flow is turbulent. Use date the needs of production. However, all laterals must
of the Reynolds Number may reduce wasteful over sizing be designed for continuous flow and should feed back
of pumps, excessive pressure drops, and unnecessarily unused water into a return line.
high velocities.
1. Lee, Ron; Patterson, Michael, Ph.D.; and Painter, John;
Determination of Reynolds Number
Semicondutors: The Effect of Velocity on High-Purity Systems Rinse
Once the diameter sizes have been selected for a Up and Requalification; Ultrapure Water Journal; March 2002; pg 41.
given piping system, the next step is to determine
whether the flow through the pipes is laminar or
turbulent. The only accepted way of determining this
characteristic through analytic means is by calculating
7.3 Thermal Expansion
the Reynolds Number. The Reynolds Number is a
dimensionless ratio developed by Osborn Reynolds, Purad and PolyPure systems designed for ambient or
which relates inertial forces to viscous forces. Cold DI water that are inside at a constant temperature
building generally do not need to compensate for thermal
To determine type of flow from Reynolds Number expansion. However, thermal expansion is an important
value, use: factor that should be at least reviewed on each and every
installation design.
Nre = (De v) / ( g)
Hot systems, normally operating at temperatures of 65
C to 120 C, require a more complex design. Purad
Where:
PVDF systems can be used in many hot water applica-
Nre = Reynolds Number (dimensionless)
tions and applications where the temperature is cyclical,
De = equivalent diameter (ft = inside diameter
Section 7
are homogenous with the pipe system. Other devices Thermal Expansion. Figure 7.B an example of an anchor
such as pistons or bellows can also be used, but are not type fitting with a fixing pipe clamp available from Asahi/
recommended for PW or WFI applications as they rely on America, Inc.
mechanical features and connections that could leak over
time and are not compatible with sanitary design.
7.4 Instrumentation and Controls
Offset
In the proper design of an Ultra Pure Water system it is
important to monitor the quality of the water, tempera-
Ls
ture, pressure and the flow rate.
For a thorough review of thermal expansion and proper Feed Water PVC Vortex Flow Meter Line Mount
design, consult Section C of the Asahi/America Engineer- Totalizer Wall Mount
ing Design Guide.
Pretreatment PVC/PP Vortex Flow Meter Line Mount
Hot DI systems also reduce the rigidity of thermoplastic Supply Water Temperature Line Mount
piping systems, which in turn decreases the support
spacing between pipe hangers. In smaller dimensions it Media Filter Pressure Gauges Line Mount
is recommended to use continuous support made of Purification RO Low Feed Pressure Alarm at RO Panel
some type channel or split plastic pipe.
RO Product Totalizer RO Panel
The use of hangers as guides and anchors becomes
PP/PVDF Product Vortex Flow RO Panel
important. As the design procedures in Section C of the Meter
Engineering Design Guide indicate, certain hangers
should be used as guides to allow the pipe to move back RO Reject Flow Meter/Total RO Panel
and forth in-line, while other hangers shall be anchoring
locations used to direct the expansion into the compen- RO Reject Recirculation RO Panel
sating device. The anchors and hangers should be RO Percent Ion Rejection RO Panel
designed to withstand the end load generated by the
Post Treatment Mix Bed Polish Resitivity Polisher Panel
Figure 7.E Steps of Socket Fusion Figure 7.F Steps of IR Non-Contact Fusion
both cases the pipe is completely bead free on the inside, 7.6 Sanitization Methods
but when welded without the balloon a small seam is
present. This seam however is smaller than a gap that Many different methods for the sanitizing of a distribution
would be present between any joint containing a gasket pipe system can be incorporated. If heat or hot water are
such as union or sanitary clamp connection. to be used, the main area of concern is thermal expan-
sion and the temperature/pressure ratings. If a chemical
sanitization method is to be used, the chemical compat-
ibility of the piping material needs to be verified with the
pipe manufacturer.
7.6.1 UV Exposure
All plastics react differently to UV exposure. In addition to
the external exposure of UV lights, it also common for UV
sterilizing lamps to be used to control bacteria levels in a
water system. These lamps, give off high intensity light
to breakup living bacteria in a water. Depending on the
wave length of the lamp, trace amounts of Ozone can be
generated from these lamps. The combination of the
intense UV and Ozone can create stress cracking in
piping components directly in contact with the light
source. To avoid a possible problem it is recommended to
build a light trap from SS components. The use of SS
diaphragm valves or a couple changes in direction will
eliminate the concern altogether. Below is a graphic
Figure 7.G HPF Fusion without and with internal support balloon representation of an efficient light trap.
systems. A heat penetration study documenting suffi- lines at periods 30 minutes or shorter is perfectly accept-
cient temperature is maintained throughout the piping able. However, care should be taken with use of Ozone
system is critical to validation. in PP systems. Please consult our Engineering Depart-
ment for exact application guidelines concerning the use
Steam sterilized Purad PVDF systems offer several of Ozone.
advantages over those constructed of stainless steel.
Purad PVDFs extremely low thermal conductance factor
of 1.32 Btu-in/hr ft2 minimizes heat loss. Heat penetra-
tion throughout a system is more easily ensured without
7.7 Hanging
the need for pipe insulation. Purad PVDF can safely
transport hot media without risk of serious injury to those Polymer piping systems act differently than metal piping
who may come in contact with it. Additionally, the hot systems and varying hanger styles are required. The
temperatures do not contribute to accelerated corrosion three uses of hangers are as a support, a guide and/or
as is the case in with stainless steels. Clean steam is an anchor. The hanger itself may be used to accomplish
highly corrosive to stainless steels. High grades, such as two of these goals, but all three uses need to be consid-
316L, are not immune to its corrosive effects. The ered when laying out the hanger configuration. The
corrosion can contribute to degradation of the systems designer of a system should specify the exact hanger
overall water quality. Purad PVDF, on the other hand, and location and not leave this up to the installer.
can handle SIP without corrosion and without restorative
passivation requirements. This is an important factor to Support spacing for thermoplastic piping systems differs
consider when selecting system material of construction greatly as compared to metallic piping. It generally
and determining operating and maintenance costs. requires more supports, and the introduction of higher
temps will further increase that support spacing require-
Recommended SIP Parameters for Purad PVDF* ment. For support space requirements by
Temperature 121-130 C
Gauge Pressure 15-25 psig
Duration 15-20 minutes
Frequency As Needed
Figure 7.J Improper Dead Leg Design Figure 7. L Dead leg to improper instrument installation
Accepted cGMP design is to keep all dead legs to a Since these tee configurations are narrow in diameter
maximum of 6 internal pipe diameters in length. The they create a dead leg in the branch where microorgan-
turbulent flow in the main trunk line will create significant ism growth can be initiated. The use of instrumentation
amount of movement to keep the leg moving and prevent fittings eliminate dead legs while being a safe adapter for
bacteria from proliferating. However, the Purad system gauges or sample valves. Instrumentation fittings are
allows designers to avoid dead legs altogether with the available in multiple configurations and can accommo-
advent of T-Diaphragm valves and Zero dead leg fittings. date more than one instrument per fitting.
T-valves take the place of a tee, reducer and diaphragm
Figure 7.K Molded T-Valve with significantly reduced dead-leg Figure 7.M Proper instrument installation
Section 7
valve, by combining all three into one component. T- The insert of a resistivity probe can also be a possible
Valves reduce the quantity of welds in a system as well. source for dead legs. Since most probe manufacturers
By using a T-Valve, branch lines can be shut off at any recommend that fluid flows directly at the probe, they are
time without creating a dead leg and turned back on often situated in the leg of a tee and the tee acts as a 90
without an extensive flush procedure. elbow. Since almost all probes are supplied as a or 1
sanitary adapter, there is the necessity to weld
Dead legs in a system can be found in more than just reducers onto the tee leg to accommodate the sensor. A
branch lines. Often times the introduction of a gauge, simple fitting, the probe adapter, conveniently eliminates
measurement device, and/or sampling valve can create a the needs for reducers and shortens the leg of the tee,
dead leg. Standard plastic fittings require the use of Tees see figure 7N. Probe adapters are available in all sizes
and pressure ratings. Pressure gauges can also be End Point Configurations
installed utilizing sanitary adapters. Sample valves can Very often, the quality of product water is maintained
also be built into the same fitting to reduce space and the throughout the distribution system, but cannot be utilized
amount of fittings used. Multiple configurations are without contamination. Gooseneck faucets, dead ended
available. drops, needle valves and ball valves are often improperly
utilized as Point of Use fittings. The microbiological
integrity of a Water System should be measured at a
minimum of at least three places:
All three points are rarely identical with the most impor-
Figure 7.N Instrument probe installation tant, Point of Use, typically the lowest quality of the three.
Section 7
1.6 Submittals
Section Eight Submit the Following:
Product Specifications
A. Product data for the system specified; relative to
Purad High Purity PVDF Piping materials, dimensions of individual components,
profiles and finishes.
Operating Temp: (TBD by Engineer/Project Owner) Turn over to owner at end of construction necessary
Test Pressure: (TBD by Engineer/Project Owner)
welding equipment as suggested by manufacturer for
Media: Deionized Water
repair, additions and maintenance of Purad PVDF
piping system.
PART 2 PRODUCTS
In addition, manufacturer shall test all lots to ensure 9" 225 One
the melt flow index is within allowable range. 10" 250 One
12" 315 One
2.3 Pipe
A. Production
All pipe shall be produced on a dedicated extruder
completely within a class 100 cleanroom and shall be C. Pressure Rating
packaged within a class 100 section of the All pipe shall meet the requirements of Section 1.4.
cleanroom. Pipe shall be stress relieved on line as it
Section 8
1.6 Submittals
Section Eight Submit the Following:
Product Specifications
A. Product data for the system specified; relative to
PolyPure, Natural Polypropylene materials, dimensions of individual components,
profiles and finishes.
C. Pressure Rating
PART 2 PRODUCTS All pipes shall meet the requirements of Section 1.4.
2.2 Material
Criteria Test standard Test interval
Pipe, valves and fittings shall be made from resin
produced by one supplier. The resin shall meet or Measurement ISO/DIS 10931-2 every hour
exceed the requirements outlined for a random Surface visual each pipe
copolymer resin according to ASTM D 4101-96a and Color visual each pipe
Marking visual each pipe
DIN 16774. MFI shall be 0.30 g/10min per 230/2.16 Micropores microscope 1x/shift
according to ASTM D 792. Resin is approved for Inner surface DIN 4768 1x/shift
contact with foodstuff as per the FDA CFR, Title 21 Packaging visual each pipe
(2001) 177.1520. Labels visual each pipe
Pressure RatingValves
Criteria Test standard Test interval Pressure rating of valves shall be per manufacturers
recommendations based on materials, valve type and
Measurement ISO/DIS 10931-3 every 2 hours size.
Condition visual each fitting
Color visual each fitting
Markings visual each fitting Flow Meters:
Inner surface DIN4768 1x/shift All Vortex Meters shall be made of PolyPure and free
Packaging visual each fitting of all seal materials. Supplier shall be capable of
X-ray test visual every 2 hours supplying all sizes - 3 (20mm 90mm) and have
a replace electronics module.
2.5 Valves All Vortex Meters shall be wet bench calibrated and
All valves shall be produced in the same manner as supplied with Calibration Records from the manufac-
High Purity Fittings turer.
All sizes class 150, ball type Proline PP with FPM or either semi automatic (UF2000 style) or fully auto-
EPDM seat and seals. 150 PSI at 73.4F for sizes matic (SP series).
through 4.
B. Pressure Test
1. Test fluid should be deionized water, with quality
level set by Quality Control Engineer. In all cases test
must be done hydrostatically. Air test is not allowed
1.6 Submittals
Section Eight Submit the Following:
Product Specifications
A. Product data for the system specified; relative to
Proline, High Purity PP materials, dimensions of individual components,
profiles and finishes.
PART 2 PRODUCTS
C. Pressure Rating
2.1 Manufacturers All pipe shall meet the requirements of Section 1.4.
Subject to compliance with requirements products
which may be incorporated in the work include: The
Proline System as supplied by Asahi/America, Inc. of D. Production Control
Malden, Massachusetts, (781) 321-5409. Produced During pipe production continuous quality controls are
by Alois Gruber GmbH AGRU of Bad Hall, Austria. performed and monitored. Minimum required production
control:
2.2 Material
Pipe, valves and fittings shall be made from resin Criteria Test standard Test interval
produced by one supplier. The resin shall meet or
exceed the requirements outlined for a random Measurement ISO/DIS 10931-2 every hour
copolymer resin according to ASTM D 4101-96a and Surface visual each pipe
Color visual each pipe
DIN 16774. MFI shall be 0.30 g/10min per 230/2.16 Marking visual each pipe
according to ASTM D 792. Micropores microscope 1x/shift
Inner surface DIN 4768 1x/shift
In addition, manufacturer shall test all lots to ensure Packaging visual each pipe
Labels visual each pipe
the melt flow index is within allowable range.
D. Pressure Rating
Size - Inch Size - mm Qty All fittings, unless otherwise noted, shall meet the
" 20 Five requirements of Section 1.4.
" 25 Four
E. Production Control
Section 8
Pressure RatingValves
Criteria Test standard Test interval Pressure rating of valves shall be per manufacturers
recommendations based on materials, valve type
Measurement ISO/DIS 10931-3 every 2 hours
Condition visual each fitting and size.
Color visual each fitting
Markings visual each fitting Flow Meters:
Inner surface DIN4768 1x/shift All Vortex Meters shall be made of PolyPure and free
Packaging visual each fitting
X-ray test visual every 2 hours of all seal materials. Supplier shall be capable of
supplying all sizes - 3 (20mm 90mm) and have
a replace electronics module.
2.5 Valves
All valves shall be produced in the same manner as All Vortex Meters shall be wet bench calibrated and
High Purity Fittings supplied with Calibration Records from the manufac-
turer.
Type 342 Spigot Diaphragm Valves:
- 2 (20mm 63mm) shall be the type 342 of the 2.6 Joining Equipment
PURAD system. The Valves shall have a PolyPure Proline installation shall be performed by factory
body and a diaphragm of PTFE with EPDM backing certified and trained installers in accordance with
or EPDM. Valves will be spigot single body design. manufacturers ISO procedures, ASTM D 2657 and
Top Works must include integral lockout device on DVS 2207-15. Date of certification or recertifications
the handle and position indicator. shall not exceed two years from the beginning of
project. Available joining techniques are as follows:
Type 342 Flanged Diaphragm Valves:
2 shall be type 342 with stub end and backing A. Butt Fusion
ring IR welded onto both sides. Top Works must Proper equipment selection should be based on pipe
include locking device on the handle and position size and site conditions. Butt fusion equipment
indicator. should be designed and tested to provide reliable
welds. All equipment should utilize electronically
Flanged Diaphragm Valves: controlled heating elements for accurate welding
3 - 4 shall be type 14 single Proline PP body design temperatures. Tools should also incorporate planing
with flanges molded as part of the body. Diaphragm units to face ends prior to heating. Butt fusion
shall be PTFE with EPDM backing or EPDM. Top equipment supplied shall weld joints based on force
Works must include locking position indicator. or pressure and not mechanical stops.
All sizes class 150, ball type Proline PP with FPM or installation requirements and line sizes. Tool shall be
EPDM seat and seals. 150PSI at 73.4F for sizes either semi automatic (UF2000 style) or fully auto-
through 2 nominal 100 PSI at 73.4F for sizes 3 matic (SP series).
and 4.
bolts should be checked for correct torques. 3.3 Cleaning of Proline Piping System
5. All diaphragm valve bonnet bolts shall be checked System shall be cleaned at completion of project
for correct torques. according to requirements set by owner
6. All joints should be reviewed for appropriate
welding technique:
B. Pressure Test
1. Test fluid should be deionized water, with quality
level set by Quality Control Engineer. In all cases
test must be done hydrostatically. Air test is not
allowed
1.6 Submittals
Section Eight Submit the Following:
Product Specifications
A. Product data for the system specified; relative to
Ultra Proline, High Purity E-CTFE materials, dimensions of individual components,
profiles and finishes.
PART 2 PRODUCTS
B. Packaging
2.1 Manufacturers All pipes shall have ends sealed with PE bags and
Subject to compliance with requirements products then capped. Pipe shall be sleeved in a PE encase-
which may be incorporated in the work include: The ment and heat-sealed. Pipe is then packed into a
Ultra Proline System as supplied by Asahi/America, hard PE tube for shipping protection. Cardboard
Inc. of Malden, Massachusetts, (781) 321-5409. tubes are not acceptable. The following chart desig-
Produced by Alois Gruber GmbH AGRU of Bad Hall, nates quantities of pipe per PE shipping tube:
Austria.
All resins shall not introduce contaminations into the C. Pressure Rating
ultra high purity water. Specifically, all raw materials All pipe shall meet the requirements of Section 1.4.
in product manufacturing shall be free of chemical
additives, fillers, property enhancers and reinforce- D. Production Control
ments, such as antioxidants, anti static agents, During pipe production continuous quality controls are
colorants, flame retardants, heat stabilizers lubricants, performed and monitored. Minimum required produc-
mold release agents, pigments, plasticizers, process- tion control:
ing aids, ultraviolet stabilizers and viscosity depres-
sants.
Criteria Test standard Test interval
In addition, manufacturer shall test all lots to ensure Measurement ISO/DIS 10931-2 every hour
the melt flow index is within allowable range. Surface visual each pipe
Color visual each pipe
Marking visual each pipe
2.3 Pipe Micropores microscope 1x/shift
A. Production Inner surface DIN 4768 1x/shift
All pipe shall be produced on a dedicated extruder Packaging visual each pipe
Labels visual each pipe
completely within a class 100 cleanroom and shall be
packaged within a class 100 section of the
cleanroom. Pipe shall be stress relieved on line as it
2.4 Fittings
A. Production
Size Surface Finish All standard fittings through 4 (110mm) shall be injection
mm (inch) m ( inch) molded. All fittings are to be molded with equipment in a
32 - 90 (1 - 3) 0.2 (7.8) class 100 cleanroom environment. After secondary
machining, all molded fittings shall be cleaned for a
110 (4) 0.35 (13.8) minimum of 1 hour in an automated 6-basin Hot DI
rinse stations. The DI Rinse water specification shall
is extruded. Post extrusion annealing is not allowed. be 70 C with resistivity above 18M and TOC less
Surface finish smoothness is as follows: than 10PPB.
In addition manufacturer shall conduct continuous
checking for micropores. The micropores shall not B. Packaging
exceed a size of 1 micron. All fittings are to be packaged in a class 100
Section 8
5. Printer Labels for each weld automatically. installation, any necessary equipment needed on-site
SP Series: should be sold to the owner. Contractor is responsible
Tool shall be made available in 4 (20mm for proper maintenance and care of the fusion tools
110mm) and 2 10 (75mm 250mm) size during construction.
ranges. Tools shall possess electronic planar and
infra heating element. Tools will utilize and measure C. Certification
the welding pressures to join material and not Installers shall be pre-qualified as per section 2.6.
mechanical stops. To avoid improper welded joints, Manufacturer shall provide on-site training in the
tool shall automatically operate clamps and control assembly and installation of the Ultra Proline piping
joining force. Tools shall possess the following system as needed.
features:
Section 8