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Allergan Biologics, Ireland

Allergan Biologics, Ireland

    • Client:
    • Allergan Pharmaceutical, Co. Mayo, Ireland
    • Consultant:
    • RPS Engineering, Dublin, Ireland
    • Project Description:
    • Biologics 2 Facility – Botox Production
    • Work-Scope:
    • Mechanical piping and HVAC services
    • Value:
    • €15.0M

Project Description

Brief Description

Kirby was appointed as lead mechanical services contractor on the construction of a new 100,000 sq.ft. aseptic processing vial fill/finish facility for Allergan Pharmaceutical. The project included for the fabrication and installation of 17,000m2 of Grade C ductwork and 20,000m of piping systems, the latter to cater for low pressure hot water, chilled water, compressed air, process drainage, BMS, purified water, CIP, WFI, clean steam, nitrogen, process water and sterile air systems.

Our responsibility also extended to the installation of client and self-procured utility and process equipment including sixteen AHUs to feed ISO 5 and 7 production areas, steam and LPHW boilers, chillers and compressors. This was a key element of our work-scope with the client entrusting Kirby with responsibility for correctly positioning over $36M of free issue client equipment.

The project duration was 12 months, with peak craft labour on-site reaching 120 persons.

Commissioning Capabilities

Given the validated nature of the process, Kirby was heavily involved in the installation qualification process with overall responsibility for chemical flushing of systems, passivation and balancing, leading to overall commissioning of services for subsequent OQ and PQ by Allergan.

Overcoming Challenges

The key challenge on the project from a mechanical services perspective was the congested nature of services in the void space above the classified cleanrooms. As lead services coordinator on the project, it was our responsibility to successfully deliver a fully coordinated build to our client. To achieve this objective, we engaged our in-house BIM department to completely 3D model this utility space. Clash points were detected early and work-around solutions put in place with close cooperation from the project team and building/cleanroom contractor.