How to Conduct Air Quality Monitoring Well in Dust-free Purification Projects
2024.12.02
In the era of rapid technological development nowadays, the importance of dust-free purification projects has become increasingly prominent in many fields with stringent environmental requirements, such as electronic chip manufacturing, biomedical research and development, and high-end food processing. And air quality monitoring is just like the "eyes" of such projects, accurately observing every slight change in the air and safeguarding the purity and stability of the dust-free space. Today, Guangzhou Kunling Purification Equipment Co., Ltd. will have an in-depth discussion with you on how to conduct air quality monitoring well in dust-free purification projects.
Interpretation of the Core Indicators for Air Quality Monitoring
1. Number of Dust Particles: This is the most intuitive yardstick for measuring the cleanliness of the air. In dust-free workshops, different classification standards (such as the various levels stipulated in ISO 14644) have strict limitations on the particle size and quantity of dust particles. For different particle size ranges, such as those with a diameter greater than or equal to 0.5 microns, greater than or equal to 1 micron, and greater than or equal to 5 microns, the allowable number of particles per cubic meter decreases step by step from the thousand level to the hundred thousand level and even higher purification requirements. In the lithography process of chip manufacturing, once tiny dust particles adhere to the silicon wafer, it may cause short circuits or open circuits in the circuit, resulting in the scrapping of the chip, which fully demonstrates the significance of strictly controlling the number of dust particles.
2. Microbial Content: Microorganisms such as bacteria, fungal spores, and viruses are the "invisible threats" in the purified space. With the help of air samplers for airborne microorganisms, settling plates for microorganisms, and other equipment, samples are taken according to the specified time and flow rate to analyze the number of colony-forming units (CFU) of microorganisms per unit volume of air. In the aseptic preparation workshops for pharmaceuticals, if the number of microorganisms exceeds the standard, the quality and safety of the drugs will be greatly reduced, endangering the lives and health of users.
3. Temperature and Humidity Levels: Although they seem conventional, they are actually of great significance. Appropriate temperature and humidity can not only ensure the comfort and work efficiency of personnel but also meet the operation requirements of precision equipment and the needs of product processes. In the soldering of electronic components, if the humidity is too high, it is easy to cause oxidation and poor soldering of solder joints; in the purified workshop for paper printing, improper temperature will cause paper deformation and abnormal drying of ink. The ideal temperature is usually controlled within the range of 20 - 26 °C, and the humidity is within the range of 40% - 60%.
4. Concentration of Harmful Gases: Even a trace amount of harmful gases such as formaldehyde, benzene series compounds, and TVOC (Total Volatile Organic Compounds) that escape and accumulate over a long period will corrode equipment, pollute products, and damage the health of personnel. In the purified area of chemical laboratories, where reagents volatilize to produce harmful gases, it is necessary to continuously monitor them with the help of professional gas chromatographs and other equipment to strictly adhere to the safety thresholds.
Scientific Planning of the Layout of Monitoring Points
1. Weave a "Monitoring Network" in Key Production Areas: In places like beside the lithography machines in chip production and above the fermentation tanks in biopharmaceutical production, which are the cores of the production process, where products are exposed and extremely sensitive to air quality, multiple sampling points should be set up to accurately capture slight fluctuations in air quality and ensure that any signs of pollution can be detected at the first time, thus building the first line of defense for production safety.
2. Control the Key Nodes of Airflow Organization: Air supply outlets, return air inlets, and fresh air inlets are related to the overall efficiency of air circulation and replacement. The quality of fresh air and the effectiveness of temperature and humidity adjustment should be measured at the air supply outlets; the situation of indoor pollution accumulation should be observed at the return air inlets. Based on this, the direction of air flow and the ratio of air volume can be optimized to ensure the orderly circulation and purification of air.
3. Cover Areas with Frequent Personnel Activities: In dressing rooms, corridor passages, and around workstations, the movement of personnel and the handling of materials are likely to stir up dust and carry microorganisms. Reasonable layout of monitoring points can not only control the impact of personnel activities on the environment but also help standardize operation procedures and strengthen daily cleaning and disinfection management.
Key Points for the Selection and Maintenance of Monitoring Equipment
1. High Precision and Compatibility First: Select equipment according to the monitoring indicators and purification levels. Laser particle counters, based on the principle of high-precision laser scattering, can detect tiny particles with great accuracy and are suitable for monitoring dust in high-grade dust-free rooms. Intelligent temperature and humidity transmitters have sensitive sensors and stable data transmission and are suitable for continuous monitoring in complex environments.
2. Consideration of Stability and Durability: Purification projects run for a long time, so the equipment should be able to withstand changes in temperature and humidity and resist electromagnetic interference. Industrial-grade protective casings and high-quality sensors should be selected, and regular calibration and cleaning and maintenance should be carried out. For example, the optical components of laser particle counters should be regularly cleaned, and the zero drift of temperature and humidity transmitters should be calibrated regularly to ensure the reliability of the data.
3. Integration and Intelligent Trend: Nowadays, monitoring equipment is moving towards integration, integrating multiple indicator monitoring, data storage and analysis, and remote transmission and early warning into one. With the help of the Internet of Things, data can be transmitted to the central control room and mobile terminals in real time, enabling managers to have a comprehensive understanding of the situation and respond and handle abnormalities immediately.
Data Management and Analysis and Application
1. Real-time Presentation and Historical Traceability: Build a visual monitoring platform to display the dynamics of air quality at each monitoring point intuitively in the form of charts, with data updated in seconds. Store historical data to trace back the air quality trends under pollution incidents in the workshop and seasonal environmental changes, so as to find a basis for optimizing purification schemes and troubleshooting hidden dangers.
2. Trend Judgment and Early Warning Triggering: Set indicator thresholds and early warning rules, and predict the trend of air quality with the help of big data analysis. When the number of dust particles is close to exceeding the standard or the temperature and humidity are out of balance, the system will automatically issue early warnings and send messages to the mobile phones of the responsible persons, so that preventive measures can be taken in advance to nip problems in the bud.
3. Find "Pain Points" by Correlating with Processes: Compare the production process with air quality data. When the defective product rate increases during a certain period and is related to a specific pollution peak, dig deep into the root causes to accurately optimize the purification process and upgrade the filtering equipment, so as to improve the product yield and production efficiency.
Doing a good job in air quality monitoring for dust-free purification projects is a meticulous and systematic project. Relying on its profound technological accumulation and rich project experience, Guangzhou Kunling Purification Equipment Co., Ltd. can customize a comprehensive monitoring scheme for you from the precise analysis of indicators, the ingenious layout of monitoring points, the optimal selection of equipment to the in-depth analysis of data, safeguarding the long-term and stable operation of the dust-free space and helping the high-quality development of the industry. If you have any questions or needs in the monitoring of purification projects, please feel free to contact us and let's build a "protective wall" for pure air together!
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