08/05/2025
Cleanroom AHU Replacement – Executed Within 48 Hours
In environments such as pharmaceutical cleanrooms, precision-engineered HVAC systems are mission-critical to ensure environmental control, regulatory compliance, and product integrity. A recent project entrusted to ProEnergy Solutions Ltd involved the full decommissioning and replacement of an aging Air Handling Unit (AHU) serving a cleanroom at a leading pharmaceutical facility operating continuously, 24/7.
The operation required detailed planning, GMP-compliant work protocols, and multidisciplinary coordination to execute within a strict 48-hour shutdown window. Below is a summary of the technical scope:
🔧 Decommissioning Phase:
• Safe dismantling of the legacy AHU, including removal of double-wall galvanized ductwork, stainless steel chilled water lines, and HVAC electrical panel connections.
• Controlled lowering and crane-assisted removal of all rooftop equipment, adhering to site safety protocols and segregation procedures.
🧱 Structural Modifications:
• Extension and reinforcement of existing I-beam supports using bolted and welded steel sections.
• Realignment of beams and vibration-isolated mounting pads to ensure correct positioning and operational stability.
🌬️ Installation and Commissioning:
• Installation of a modular, double-skin AHU with integrated EC plug fans (supply and return), multi-stage filtration (G4, F9, H14 HEPA), UV disinfection, airflow modulation, and an energy recovery system.
• Reconfiguration of ductwork using pre-insulated rectangular galvanized duct sections, clad in steel sheet for thermal efficiency and surface hygiene.
• Installation of a new chilled water distribution loop, including 2-way modulating control valves, pressure-independent control valves (PICVs), and differential pressure sensors, fully integrated with the site’s ductwork.
• Full Functional Performance Testing (FPT), airflow balancing, and validation of environmental parameters—temperature, and pressure differentials—against ISO 14644 and GMP Annex 1 standards.
What made this project distinctive wasn’t just the engineering complexity or time constraints—it was the need to deliver a turnkey HVAC solution in a highly regulated environment, with zero margin for error.
This operation demonstrates the depth of technical capability and operational discipline that ProEnergy Solutions Ltd brings to HVAC design–build–commissioning in critical environments.
We invite pharmaceutical, biotech, and advanced manufacturing companies planning AHU or HVAC upgrades to get in touch for engineered, compliant, and performance-driven solutions.