1. Water System Design (PW & WFI)

Water systems in pharmaceutical facilities typically include Purified Water (PW) and Water for Injection (WFI) in accordance with pharmaceutical standards.

Planning & Analysis Stage

• Water demand analysis based on production processes, laboratories, and supporting areas

• Determination of water quality standards (e.g., USP, EP, BP, or WHO)

• Selection of water treatment technologies:

  • Pre-filtration: sand filter, carbon filter

  • Softener: to remove hardness (calcium and magnesium)

  • Reverse Osmosis (RO): for fine particle and ion removal

  • Electrodeionization (EDI): to produce Purified Water (PW)

  • Distillation or membrane systems: to produce WFI

Distribution System Design

• Looping system to maintain continuous water circulation and prevent stagnation

• Piping material: SS316L stainless steel or high-grade food-grade PPR

• Sanitary design using orbital welding to prevent microbial contamination

• Monitoring systems including temperature, pressure, and water quality sensors (TOC, conductivity)

Design Documentation

• P&ID (Piping & Instrumentation Diagram) for the entire water system

• 2D/3D layout of the water system installation

• Equipment specifications: tanks, pumps, RO units, EDI units, WFI generator

2. Water System Installation

• Pretreatment installation: filters, softeners, and RO units in the utility area

• Storage & distribution tanks: PW/WFI tanks with sanitary design and HEPA ventilation

• Piping loop installation: stainless steel/WFI piping with orbital welding

• Control panel & instrumentation installation: pressure, temperature, and flow sensors

• SCADA/BMS integration for automatic monitoring of water quality

3. Wastewater Treatment (WWTP) Design

WWTP is designed to treat wastewater from production, laboratory, and cleaning processes to meet regulatory discharge standards before being released into the environment.

Analysis & Planning Stage

• Wastewater characterization: pH, COD, BOD, TSS, microbiological content, and hazardous chemicals

• Selection of WWTP technologies :

  • Equalization Tank: to balance wastewater load

  • Chemical Treatment: coagulation, flocculation, and pH neutralization

  • Biological Treatment: aerobic/anaerobic processes using bacteria

  • Filtrasi & Disinfeksi: sand filter, activated carbon, chlorine/UV

Wastewater Piping Design

• Separate piping for hazardous and non-hazardous waste streams

• Gravity or pump-based transfer systems for low-level areas

• Emergency storage tanks for critical conditions

4. WWTP Installation

• Installation of tanks, pumps, blowers, and treatment units according to design

• Integration of inlet and outlet piping systems to discharge points

• Installation of monitoring sensors for pH, COD, and flow rate

• Automation system setup to control treatment processes

5. Qualification & Validation

• Installation Qualification (IQ): verifying equipment installation according to design

• Operational Qualification (OQ): ensuring all treatment processes operate within defined parameters

• Performance Qualification (PQ): verifying treated water and effluent meet pharmaceutical and environmental standards