Parnell Laboratories WFI and Pure Steam Systems Replacement

WFI & Clean Steam System Upgrade | Pharmaceutical Water Treatment Project – Parnell

Project Overview – Pharmaceutical Water Treatment & WFI System Upgrade

Triplenine Group delivered a complete WFI (Water for Injection) and Clean Steam system upgrade for Parnell, providing a fully integrated, pharmaceutical-grade water treatment solution.

This project required the system to double production capacity within the existing plant footprint, while also being installed through standard pedestrian access—a highly constrained brownfield environment.

Working in close collaboration with Elettracqua engineers, Triplenine designed and delivered a customised system that integrates seamlessly with existing services, process pipework, and distribution infrastructure.

System Capacity – High Purity Water Production

The installed system delivers:

• Purified Water (PW): 1,500 L/hr

• Water for Injection (WFI): 750 L/hr

• Clean / Pure Steam: 500 kg/hr

All outputs comply with USP and European Pharmacopoeia standards, ensuring suitability for pharmaceutical and biotech manufacturing environments.

Key Challenges – Brownfield Pharmaceutical Plant Upgrade

This project demonstrates Triplenine’s capability in delivering complex brownfield upgrades in regulated environments:

1. Capacity Increase Within Existing Footprint

• Required to double system output without expanding plant room size

• Optimised layout and equipment selection to maximise available space

2. Restricted Access Installation

• All equipment designed for modular installation through standard door access

• On-site reassembly within a confined plant room

3. Integration with Existing Systems

• Connection to existing:

o Process pipework

o Utilities (steam, cooling water, purified water)

o WFI distribution loop

4. Control System Upgrade & Integration

• New PLC-based control panel integrated with existing WFI distribution system

• Legacy wiring carefully removed, identified, and re-terminated into new control system

Engineering & Design – Pharmaceutical Process Systems

Triplenine provided full mechanical, electrical, and automation design, focusing on:

• Modular plant design for restricted access environments

• Brownfield integration with existing infrastructure

• Hygienic system design in accordance with cGMP and GEP

• Optimised plant layout using practical, constructible solutions

This ensured the system could be installed efficiently without compromising performance or compliance.

Water Treatment Process – RO, EDI & WFI Distillation

The system incorporates a complete pharmaceutical water treatment process, including:

Pre-Treatment & Purified Water (PW) Generation

• Multi-stage filtration and duplex softening

• Chemical dosing systems (dechlorination and pH correction)

• Reverse Osmosis (RO) system

• Electro Deionisation (EDI) with >98% salt rejection

WFI & Clean Steam Generation

• Multi-effect distillation system (4-effect)

• Integrated pure steam generator

• High-efficiency heat recovery design

• Pharmaceutical-grade hygienic construction (AISI 316L)

Control System & Automation

A key upgrade included a modern PLC-based automation system, delivering:

• Full system control and monitoring

• Integration with existing WFI distribution loop

• CFR 21 Part 11 compliant data recording

• Improved process visibility and operational reliability

The transition was carefully managed by:

• Identifying and removing existing control wiring

• Re-terminating into the new control panel

• Ensuring seamless commissioning and system continuity

Installation – Modular & Brownfield Execution

Triplenine executed the installation using a modular construction approach, enabling:

• Transport and installation through restricted access points

• Efficient on-site assembly within tight plant room constraints

• Minimal disruption to ongoing operations

This approach is critical for pharmaceutical facility upgrades and retrofits.

Validation & Compliance – Pharmaceutical Standards

The system was delivered in full compliance with:

• cGMP (Current Good Manufacturing Practice)

• GEP (Good Engineering Practice)

• USP & European Pharmacopoeia

• CFR 21 Part 11 (data integrity and control systems)

Validation support included:

• Factory Acceptance Testing (FAT)

• Site Acceptance Testing (SAT)

• Installation Qualification (IQ)

• Operational Qualification (OQ)

Project Outcomes – High Performance & Compliance

The project successfully delivered:

• 2x capacity increase within the same footprint

• Seamless integration with existing plant systems

• Upgraded control and automation platform

• Reliable production of pharmaceutical-grade water and steam

• Future-ready infrastructure for ongoing operations

Triplenine Capability – Turnkey Pharmaceutical Projects

This project highlights Triplenine Group’s expertise in:

• Pharmaceutical water treatment systems (PW, WFI, Clean Steam)

• Turnkey project delivery

• Brownfield plant upgrades and retrofits

• Modular process plant design and installation

• Mechanical, electrical, and automation integration

Conclusion

Triplenine Group delivered a complex WFI system upgrade within a highly constrained pharmaceutical facility, combining innovative engineering with practical execution to maximise performance without increasing footprint.