Jubiliant Organosys Limited is an integrated pharmaceutical industry player with a wide range of products and services for global life sciences companies. The company is one of the largest custom research and manufacturing services (CRAMS) and drug discovery services companies in India. The company strives to accelerate the process of pharmaceutical drug discovery by partnering with innovative pharmaceutical companies offering them products and services across the drug discovery process. Jubilant has a presence in generic pharmaceuticals business in the US and supply dosage forms along with regulatory services to European generic companies. The Company is a collaborator who lets innovation work to the advantage of its customers and accelerate global drug development efforts.
When people move in and out of the control room, or power failure occurs there is a fluctuation in temperature and humidity. Small portions of the circuits, then fall below the dewpoint temperature.
Gaseous contaminants like Hydrogen Sulfide, elemental Sulfur , organic sulfur compounds like mercaptans, oxidised forms of sulfur like SO2 (sulfur dioxide), SO3 (sulfur trioxide), Nitrogen oxides No, Cl2, Ammonia and derivatives, photochemical species etc., which present are present in the Control rooms in low concentrations of ppb condense with the metal on ICs, and other electronic and electrical parts and form a non conducting layer which resists current flow leading to thermal failures or short circuits.
Corrosion of metals is caused primarily by the attack of gaseous contaminants and is accelerated by heat and moisture. The severity of damage depends on the kind of contaminant. Chlorine for example is over 200 times more damaging than ammonia. Only 10 ppb of Chlorine causes similar amount of damage as 2500 ppb of ammonia.
The entire plant runs with the help of steam turbine. During manufacture of the pharmaceutical chemicals and steam generated by the coal fire boiler, high concentrations of sulphur dioxide, hydrogen sulphide, nitrogen oxides and ammonia gas are emitted. These gases are not only odorous, but also highly corrosive and damages electronic components of the process control. Power generation and production down time due to corroded circuit was a risk, which Jubiliant Organosys was not willing to take.
Bry-Air, a leading manufacturer of gas phase air filtration systems did an environment assessment at Jubiliant Organosys.Bry-Air installed Environment Condition Monitors at many locations, TG Control room, Boiler Control room and Pyridine Control room and other areas where corrosion was a concern. ECM Monitor is a device used to determine the overall corrosive environment before control measures are implemented and which shows results instantly as per the ISA standard S71.04-1985, which defines environment as G1, G2, G3, and GX based on corrosion severity level.
With the help of ECM Monitors, Bry-Air identified the areas which had greatest need for air filtration and installed Bry-Air deep bed EcoScrub Gas Phase Filtration outside the control room for pressurization purpose and vertical stand along EcoScrub Gas Phase Filtration System inside the control room for recirculating the air.
The deep bed EcoScrub Gas Phase Filtration System are self-contained units incorporating all particulate filters, chemical filters and supply fan.
Bry-Air installed total number of 10 EcoScrub units in various control rooms. These not only maintains the environment as per ISA 71.04 but also removes odour from the control room which affects the human health. The monitoring programme assured G1 level all the time as per Instrument Society of American standard 71.04.
Electronic cities, IT hubs, Television studios, Software parks are now a landmark of almost all major cities. These super modern buildings with state-of-the-art infrastructures houses BPOs, KPOs, television studios, financial and telecom services and many similar centers which run 24 x 7.
The life line of these facilities is their servers which powers all their work. Downtime means loss of business. Owners, developers, facility managers all strive to build and maintain a fail safe IT infrastructure. Yet many of these top of the line facilities incorporating cutting edge technology housed inconditioned power backed server rooms break down all too often. Facility managers and IT heads are often at a loss to pinpoint the cause of frequent breakdowns of their servers !
Gases Pollutants outside air is the single major cause !
These multi-storied buildings are centrally conditioned typically with AHUs on every floor. Most of these systems are designed to take in fresh air and suck in the contaminated outside air.
Contaminants like Hydrogen Sulphide, Sulphur Dioxide, Oxides of Nitrogen Chlorine, etc present in the atmosphere thus gets “sucked” in the conditioned space.
The source of contaminant gases can be a sewerage drain (eg in Noida), or the fact that the building was built on landfill (in Malad), or the building being located in high traffic zone. The contaminant gases reacts with the copper and silver metals in server cards, EVA, computer cards, etc resulting in electronic corrosion which causes the servers to malfunction and breakdown.
PBC, Paharpur Business Centre is a ultra modern business center housing many Fortune 500 companies. PBC is located in one of theoldest modern commercial hub, Nehru place, in Delhi. The high traffic density makes it polluted.
To ensure that the occupants of its fancy offices were breathing in quality air as well to save energy, PBC has installed DRI’s Treated Fresh Air Unit customized with a Bry-Air EcoScrub module. While the TFA ensure energy recovery from exhaust of conditioned air the Ecoscrub module chemically filters out contaminant gases like SO2, NO2 etc emitted by the vehicles from the fresh air stream.
Paharpur Business Centre now breathes easy !
Computers no longer break down due to corrosion. People are breathing pure and clean air. No odour. No corrosion. The air quality is of G1 class (least corrosion rate) inside the facility.
They are breathing easy . . .
ABC Paper, a division of Amrit Banaspati Co. Ltd. Sailakhurd, Punjab, (108 km from Chandigarh) is one of the largest wood-free paper plant. They use only agro-wastes like wheat, rice-straw, kana grass etc. to manufacture fine quality printing & writing paper. ABC Paper is the leader in the cream-wove paper in agro-based segment.
The server in the administrative block was regularly breaking down causing productive losses.
Cocktail of corrosive gases in the Environment !
The open Tank: where the waste liquids from process was being mixed with urea to neutralize the toxic waste. This, however, resulted in Ammonia formation harmful to electronic equipment like servers.
The process itself: The process of pulping, pressing, bleaching uses a variety of corrosive chemicals like chlorine, etc.
Corrosive by products (gases) like H2S, SO2, etc. are generated by the various processes.
As a result the server failed every 20-27 days !!
The Airgineers from Bry-Air did a thorough environment check at ABC Paper with asophisticated ECM (Environment Control Monitor) in the server room.
(ECM is a device used to determine the overallcorrosive environment before control measures are implemented and which show results instantly as per the ISA standard S71.04-1985, which defines an environment as G1,G2, G3, & Gx based on corrosion severity level).
Once the corrosion levelwas determined, the Airgineers suggested installation of a Bry-Air EcoScrub Gas Phase Filtration System (dry scrubber deep bed) BPU-Dmodel outside the server room for pressurization.
The server room is now pressurized with dust and corrosive gas free air. Thus, infiltration of corrosive gases like H2S, CL2, NH3, SO2, NOX, etc. and dust is contained.
This ensures that the environment is maintained as per ISA71.04 but also removes odour from the server room.
The monitoring program ensures G1 level all the times as per Instrument Society of America standard 71.04.
The deep bed BPU-D model units areself-contained units incorporating all particulate filters, chemical filters and supply fan. The unitsucks the outside air where dust isremoved with the help of particulate filters and variousother gases areremoved with the help of dry BrySorb special chemical filters.
HCL Technologies is a leading global IT services company. Although HCL is just a three-decade old enterprise, HCL Technologies was formed 12 years ago, in 1998. Its range of services include IT R&D and Engineering, Custom Applications, Enterprise Applications, IT Infrastructure Management, and BPO Services.<
Computer / Electronic Failure due to the presence of Hydrogen Sulphide Gas in the surrounding environment due to nearby large drain.
The source of the problem was an open drain containing untreated waste/sewerage water which blanketed the whole area with an obnoxious, foul odour. The odours were caused by the presence of hydrogen sulphide gas in methane, which is continuously generated due to the gradual degradation of organic material in the sewerage and the land fill. (Methane, on its own has no odour and thus, is not considered as a contaminant).This was causing break down of computer systems and servers, disrupting work and resulting in loss of business. To add to the woes, people working in the plush air conditioned HCL office were feeling extremely uncomfortable leading to loss in productivity.
Furthering the problem was the wind direction. If the wind direction is towards the building from the contaminant generation zone, then the after effects is quite contrary to the one when it’s been the other way round. Fluctuation in concentrations in gaseous contaminants : Hydrogen Sulphide emission from the landfill peaks when the temperature and humidity is high and carries on till the land mass is relatively warm. Hence, the ‘rotten egg’ smell starts off by mid afternoon and continues till late evenings. During the summer months, the emissions are significantly higher.
Bry-Air Airgineers helped HCL Technologies solve the problem of frequent server/ computer failures and created comfortable working environment for staff by installing EcoScrub. A BPU 1000-T-V-3 model was installed inside the server room which suck 300 CFM from the nearby facility area and 700 CFM from the room. Fresh air pressurize the room and recirculation air clean the room air.
Computers no longer break down due to corrosion. Staff breathes fresh air .The air quality is of G1 class (least corrosion rate) inside the facility.
That is exactly what the super modern IT/ITes service offices of 3G Global services, Mind space located in the premium Malad area of Mumbai, were facing. The buildings, in this area are primarily occupied by call centers of financial services, telecom services, etc. i.e. the service industry, operates 24 x 7. Computer systems and servers were breaking down disrupting work and resulting in loss of business. To add to the woes, people working in the offices were extremely uncomfortable leading to loss in productivity.
The Culprit: Built on landfill site, the building had a large open drain carrying untreated waste/sewage water to the back-waters of Arabian Sea running right next to it.
Thus, the whole area was blanketed with an obnoxious, foul odour. The odours were primarily due to the presence of hydrogen sulphide gas in methane, which is continuously generated due to the gradual degradation of organic material in the sewerage and the land fill. (Methane, on its own has no odour and thus, is not considered as a contaminant).
Plagued with this odorous and corrosive problem, many offices in the building had the air analyzed by an independent testing service. The “Corrosion Classification Coupon“ test, conducted showed a corrosion potential @20,000 angstroms on a 30 day schedule, equivalent to 500 ppb clearly indicating GX Air Quality (severe category).
Extracts from the report showing approximate contamination levels of only the corrosive elements:
|Pollutant||Maximum Concentration (in PPB)|
|Oxides of Nitrogen||125|
The above figures, though very authentic, did not indicate the actual levels of the problems as nature plays a big role in adding to the woes.
Wind directions: If the wind direction is towards the building from the contaminant generation zone, then the after effects are quite contrary to the one when it’s been the other way round.
Fluctuation in concentrations in gaseous contaminants: Hydrogen Sulphide emission from the landfill peaks when the temperature and humidity is high and carries on till the land mass is relatively warm. Hence, the ‘rotten egg’ smell starts off by mid afternoon and continues till late evenings. During the summer months, the emissions are significantly higher.
Having identified the culprit, the building management contacted the Airgineers at Bry-Air.
After studying the problem and space constraints, Bry-Air customized its EcoScrub Gas Phase Filtration System to purify the fresh air coming into the building through the AHUs. 19 EcoScrub units have been installed on the terrace. These units treat 54000 CFM of fresh air. All gaseous contaminants are removed before it enters the AHUs.
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