Air Distribution

for Laboratories, Hospitals and

Clean Rooms
Dan Int-Hout
Chief Engineer / Krueger
Richardson Texas

3/22/2011

Todays Standard Lab?

Purpose
Recognize the importance
of proper air distribution selection
in laboratory designs

Agenda
Defining the Problem
Lab Types
Design Parameters

Possible Solutions
Types of Air Outlets

Proving the Case

Case Studies

Defining the Problem

Common Laboratory Types

Biological contain biologically active
materials or involve chemical manipulation
Chemical organic and inorganic analysis
and synthesis
Animal manipulation, surgical modification
and pharmacological observation
Physical incorporate lasers, optics, nuclear
material, high and low temp materials
Isolation can be infectious or protective in
nature

HVAC Design Parameters

Define Air Change Rate requirements

Suppress & Remove Airborne Contaminants
Optimize Air Change Effectiveness
Control and Direct Room Air Motion
Provide Occupant Comfort
Room Controls
Aid in Fume Hood Containment

Air Change Rates

Air Change Rates per Hour-ACH
frequently established by exhaust hood
make up air requirement
Typical Labs requires 6 -10 ACH
Animal Housing requires 15 ACH

Example
Room Dims 10Wx20Lx10H = 2000 ft3
@ 10ACH = 333 CFM or 1.6 CFM/ft2
ACH = CFM * 60 / Room Volume

Suppress & Remove

Airborne Contaminants
Factors to Consider:
System Effectiveness
Particulate Concentration &
Dilution Rate
Measurements:
Particulate Dispersion
Particle Count
Gas Concentration
Contaminant Migration

High Count

Low Count

Optimize Air
Change Effectiveness
Efficiency of
Dilution
Speed of
Extraction
Decrease
Age of Air
Improve
Operational
Efficiency

Environmental
Dust
Pollen
Mold

Copiers
Ammonia
Benzaldehyde
Benzene
Isopropanol
Combustion Products

Paints
Acetates
Alcohol
Alkanes
Benzenes

Computer
Butanol
Butanole
Butoxyethanol
Ozone
Phosphoric Acid
Tolune

Occupants
CO2

Floor Coverings
Formaldehyde
Acetates
Styrenes
Xylenes

Room air motion is primarily determined by supply

air delivery and heat load, not exhaust flows

Control and Direct Room Air Motion

Controlled Flow to avoid:
Excessive Drafts
Recirculation
Hot and Cold Spots
Interference with Experiments
Compromise Fume Hood Safety
Temperature Swings
Supply air outlets direct air into the space in different ways.
Supply outlet type and location must be evaluated to assure
satisfactory room air motion.

Laboratory Pressure Controls

Energy
Efficiency

First Cost

Future
Flexibility

Constant Volume

Low

Low

2 Position

Med

$$

Low

Direct Pressure

High

$$$

High

Flow Tracking

High

$$

High

Flow Tracking with

Pressure Feedback

High

$$$

High

Safety

VAV Systems

Provide Occupant Comfort

Noise
Operating Fume Hoods generate NC levels
between an NC 40 to 45
Temperature
Uniform Temperature
No Stratification
Eliminate Drafts
Ventilation
Humidity

Fume Hood Containment

ASHRAE Standard 110: 4.11.2 Supply Air Distribution Supply air distribution shall be provided to create air jet
velocities {distributed towards the hoods}less than half
(preferably less than one-third) of the capture or face
velocity of the exhaust hoods.
Fume Hood Face Velocity = 100 fpm

Fume Hood Containment

Fume Hood Locations
Avoid walkways
Prevent spillage due to walking wake

Avoid fume hoods near exits

Spills or accidents
may increase the
danger

Possible Solutions

3 Most Common Types of Air

Outlets
High-Induction/Entrainment Outlets
Laminar Flow Outlets
Radial/Forced Displacement

High Induction/Entrainment Diffusers

RM

Commercial Office Spaces

High Velocity Jets
Long Throw
Designed to Mix in Zone

PLQ-R

1400

Prism

Prism

Animation of High Induction/Entrainment

Diffusers

Why Not a High Induction Diffuser in

the Laboratory?
High velocity ceiling pattern and colliding jets may enter
occupied zone
Results in mixing & re-circulation of air
particles and gases drawn into supply air stream
air ages before it is exhausted

Operational Efficiency is Sacrificed

Requires higher ACR to reduce particle counts

Interference w/ Fume Hood

Occupant comfort
Uniform Temperatures Only

Laminar Flow Outlets

Hospital Operating Suites when used in

conjunction with air curtain
Hi-Tech Electronics - Bench Top Applications

Why not a Laminar Flow Device in the

Laboratory?
Vertical Column of Air
Velocity 30-100 fpm depending on T

Turbulence in space
Fume Hood Face Velocity Disturbance
No Occupant comfort
Operational Efficiency is Sacrificed
Results in higher ACR to reduce particle counts
Non Uniform SpaceTemperature

Animation of High Laminar Flow Diffuser

Radial Forced Displacement Outlets

Pharmaceutical & Chemistry Labs

University Labs
Isolation Wards
Animal Holding Rooms

Why a Radial Displacement Diffuser

in a Laboratory?
Creates a low velocity radial air flow pattern
Suppresses mixing & re-circulation of air
particles and gases pushed down and away from work area
toward exhausts
minimal age of air (one-pass-then-out)

Operational Efficiency
ACE vs. ACR improved

Occupant comfort
Uniform Temperatures
Improved Acoustics

Minimal Fume Hood

interference

Animation of Radial Flow Diffuser

Proving the Case

Case Study: Integrated-circuit

crystal growth chamber

Test problem: Determine the efficiency in which
particles could be removed from a space based on the
type of air distribution device employed.

Displacement
Parameters:
41x41x9 Room
32 ACH
20F T

vs. Laminar (Qty=10)

- Qty = 10

Case Study: Integrated-circuit

crystal growth chamber

Results:
After 4 min.
207% ACE
difference

Laminar, 800CFM/Diffuser
low efficiency

Displacement TAD, 600

CFM/Diffuser High
efficiency

TAD-800CFM/diffuser

Case Study: Animal Holding Room

Mock-Up
Test Problem: Determine the rate of decay in an animal
holding room

High Induction vs.

Parameters:
20x14x9 Room
15 ACH
10F T

Forced Radial Displacement

- (Qty=2)

Case Study: Animal Holding Room

Mock-Up-High Induction Diffusers

17:40 min to
reach Class
100,000

Case Study: Animal Holding Room MockUp-Forced Displacement Diffusers

13:45 min to
reach Class
100,000
29%, ACE
improvement

Case Study: Animal Holding Room

Mock-Up
Test Problem: Determine the most efficient room layout
and exhaust location in a animal holding room mock up

High Exhaust vs. Low Exhaust

Parameters:

Forced Radial Displacement (Qty=2)

20x14x9 Room
15 ACH
10F T

Case Study: Animal Holding Room

Mock-Up with Ceiling Located Exhaust

Case Study: Animal Holding Room

Mock-Up with Low Sidewall Exhaust

Class 20,000
17%, ACE
improvement
over ceiling
located exhaust

Effective Solutions

Effective Solutions
Intrusive Radial flow

Flush Face Radial flow

Performance Matters
Notice Jets
Competition photo
published in ASHRAE
magazine

Perforated Metal Physics

Air wants to travel Horizontal or Vertical to the face of
the perforated metal
The larger the T the more difficult it is to throw at a
45 angle

Parallel SCC Unit in a Lab Application

Parallel SCC Unit

Lab Pressure Control Valve

Critical Environment Outlets

Hospital Air Curtain Systems

Down the road to bad

assumptions
Total particle counts reductions leads to reductions in
infection rates

+ micro-filtered vertical laminar airflow of a specific velocity

leads to total particle reductions

= micro-filtered vertical laminar airflow of a specific velocity

is the only acceptable air distribution solution

what we observe is not nature in itself, but nature exposed to our

method of questioning Werner Heisenberg, physicist

Where Clean Counts

Other than the surgeons hands,
nothing is more important than sterile in
the hospital OR
Through bad choices, we can dirty an
otherwise clean environment
Assumptions that hold true in the clean
room may not apply in the OR

Fallacy: all vertical

laminar is good laminar

Laminar diffusers do not behave predictably outside a

system that does not include these features:
1. Isothermal entry
2. Unbroken arrays
3. Controlled static (HEPA filter?)
4. Proper exhaust location
5. Precise balancing
6. Distributed heat load

ORs are not clean rooms!

Fact: Vertical laminar

can behave badly

May induce more than expected

Broken arrays may cause chaotic flow

Large arrays produce mass effect

Low velocity may not overpower mass heat

source
No proof that it works!

A Change of Heart
What is needed is a one pass then out system that was sensible,
safe, efficient and economical

Enter the air curtain

Air distribution manufacturers realized
several things:
Howorth systems did not play well
with others
Laminar flow was unpredictable
outside of the clean room
Designers needed a scalar design
proven to reduce viable particle
counts

Enter the air curtain

What an air curtain looks like:

Enter the air curtain

What an air curtain does:

Why air curtains work

better

It doesnt replace laminar; it helps laminar

behave predictably
Mechanically friendly

Catching and counting

microbes

Classifications based on viable microbiologic particle

counts
Counts taken during periods of normal work activity
(during surgery)
Counts taken a locations where air approaches the
site of actual work (incision, instrument tables, etc.)

Reliability to be achieved through repetitive sampling

Minimum sampling 30 cubic feet of air

Record temperature, humidity, ACH, delta P

Class 1 Microbiologic Cleanliness: 1 particle per cubic

foot

Catching and counting

microbes

Real time tests

13 tests

2 hospitals

8 surgeries

5 surgeries were total knee replacements

Meets all requirements of definition

Class 1 Microbiologic Cleanliness inside the curtain, Class 5

outside

There is only one air curtain systems on the market based

on designs tested during actual surgery

What should you do?

Ask facility what level of microbiologic clean air they

want
Use laminar arrays when they count

Dont apply blindly without recognizing the limitations

Keep the big picture in mind

Use air curtain systems when they count

Large ORs or high ACH

Invasive or critical surgery
Other mechanical equipment placement important
Dont apply blindly without recognizing limitations

sensible, safe, efficient and economical design Harold Laufman

CORE Chairman 1972-1979

Summary
The path to clean OR air has not always been clear
Early pioneering efforts did not provide complete
solutions
Assumptions not based on microbe counts have
proven wrong
There is such a thing as a harmful approach
There are solutions based on counting microbes
Air distribution must be part of a complete approach
As surgery advances, we must advance with it
Not all manufacturers may be qualified

Cleanroom Product Overview

Cleanroom Overview
Market Characteristics
- Size: $200M Worldwide NA $50M
- A few companies competing for the larger jobs
- Focus on traditional HEPA/ULPA products

Trends
- Regulations: ISO, SEMI, IEST, UL, CE, FM
- NanoTechnology will be the next driver in the US
market.
- New greenfield projects are down in US. Retrofit
projects are more common.

North America Cleanroom Market

Fan Filter Unit = $20 M

Other = $5 M

10%
40%

MiniEnv. = $5 M

10%

40%

Terminal Filter = $20 M

Technology Overview

HEPA Filters: How They Work

Dirty Air

Pre-Filter

Straining

HEPA Filter

Clean Air

Impingement

Interception

Diffusion

Brownian Effect

Laminar Flow in Cleanrooms

What is Laminar Flow?
Laminar Flow is usually HEPA
filtered. Laminar flow removes
particles and creates a clean zone. It
does this by maintaining a minimum
velocity.

Central Air System

SUPPLY AIR
AIR DUCTS TO EACH FILTER

RETURN AIR
AHU
TERMINAL FILTER
RETURN AIR

CEILING GRID
HEPA/ULPA
FILTER
CLEANROOM CLASSIFICATIONS
ENGLISH
SI
1
M1.5
10
M2.5
100
M3.5
1000
M4.5
M5.5
10,000

LAMINAR AIR FLOW

HOLLOW
RETURN
WALL
PERFORATED
RAISED
FLOOR

Pressurized Plenum
AHU

SUPPLY AIR

POSITIVE PRESSURE PLENUM

(RELATIVE TO ROOM)

HEPA/ULPA
PANEL FILTER
RETURN AIR

CEILING GRID
WALL
CLEANROOM CLASSIFICATIONS
ENGLISH
SI
1
M1.5
10
M2.5
100
M3.5
1000
M4.5
10,000
M5.5

LAMINAR AIR FLOW

PERFORATED
RAISED
FLOOR

Fan Filter Unit System

SUPPLY AIR

NEGATIVE PRESSURE PLENUM

(RELATIVE TO ROOM)

AHU

FAN FILTER UNIT

(MAC 10)
RETURN AIR

HEPA/ULPA
FILTER
CLEANROOM CLASSIFICATIONS
ENGLISH
SI
1
M1.5
10
M2.5
100
M3.5
1000
M4.5
10,000
M5.5

LAMINAR AIR FLOW

HOLLOW
RETURN
WALL
PERFORATED
RAISED
FLOOR

Fan Filter Units

Standard Features
Low sound, low watts, low
profile
Solid State or Digital Speed
Control
Snap-in prefilter; no tools
required
Walkable plenum
UL Listed and CE marked
Various sizes and voltages
available
Exceeds latest ISO 14644

Options
Room-Side Replaceable
(ARS)
ULPA Filter
Airflow Indicator Light
A/C Collar (10 & 12 in dia.)
Painted or Stainless Steel
Exterior
Power Cord
Challenge and Test Port
Knife Edge
Custom-Sizes Available

Data Comparison

PSC
motor
ECM
motor

Unit Motor Average Watts @ DBA

Size
HP
Airflow 90 FPM Sound
24x24 1/5
325
150
48
24x48
24x24

1/5
1/3

650
325

190
80

50
46

24x48

1/3

650

105

48

FFU System Summary

Fan Filter units offer the most cost effective method
of supplying Clean Room Air quantities, with the
lowest maintenance and energy costs.
These include moth PSC and ECM constant flow rate
motor driven units.
Available Smart Control Systems provide both setpoint control and monitoring of system performance
Cost savings from optimized performance and
reduced down-time offset the investment in upgraded
control systems.

Specialty Air System Summary

Hospitals can provide a safer Operating Room
environment with air curtain air delivery systems than
with laminar systems.
Laboratories with Fume Hoods require special air
delivery systems to ensure that supply air doesnt
cause outflow from the hood opening.
Fan Filter units offer the most cost effective method
of supplying Clean Room Air quantities, with the
lowest maintenance and energy costs.