In biopharmaceutical workshops, the refrigeration station group system is as crucial as the human body's thermoregulatory system is to maintaining life. The production process of biopharmaceuticals has extremely stringent requirements for environmental conditions such as temperature and humidity. The refrigeration station group system shoulders the important task of ensuring a stable production environment and guaranteeing the quality and safety of drugs. If the temperature control is improper, the active ingredients of drugs may become inactive, and the cultivation environment for microorganisms may be damaged, thereby affecting the efficacy of drugs. In severe cases, it may even lead to the scrapping of an entire batch of drugs, causing huge losses.

I. Composition of the Refrigeration Station Group System

(I) Chiller Units: The Core of Refrigeration

Chiller units can be regarded as the "heart" of the refrigeration station group system. Through a series of refrigeration cycles including compression, condensation, throttling, and evaporation, they compress low-temperature and low-pressure refrigerant gas into high-temperature and high-pressure gas. After heat dissipation in the condenser, it becomes high-pressure liquid, and then the pressure is reduced through the throttling device. In the evaporator, it absorbs the heat of the chilled water, reducing the temperature of the chilled water and bringing "coolness" to the workshop. In biopharmaceutical workshops, centrifugal chiller units are commonly used because of their large cooling capacity and high efficiency, which meet the high demand for cooling capacity in large-scale production.

(II) Pumps: The Drivers of Circulation

Pumps are like the "blood vessels" of the refrigeration station group system, responsible for pushing the chilled water and cooling water to circulate within the system. The chilled water pumps transport the low-temperature chilled water to various areas in the workshop that require refrigeration. After absorbing heat and increasing in temperature, it is sent back to the evaporator of the chiller unit for recooling. The cooling water pumps transport the cooling water that has absorbed heat from the condenser to the cooling tower for heat dissipation and temperature reduction, and then it returns to the condenser for recycling. Nowadays, variable-frequency pumps are widely used in biopharmaceutical workshops. They can automatically adjust the rotation speed according to the system load, achieving significant energy-saving effects. They can also precisely control the water flow, ensuring the stable operation of the system.

(III) Cooling Towers: Key Heat Dissipation Equipment

Cooling towers can be called the "heat dissipation masters" of the refrigeration station group system. Their main function is to dissipate the heat carried by the cooling water into the atmosphere, reducing the temperature of the cooling water. In biopharmaceutical workshops, counterflow cooling towers are often used. They utilize the counterflow of air and water to increase the contact area and time, achieving efficient heat dissipation. At the same time, the cooling towers are equipped with intelligent control systems, which can automatically adjust the rotation speed of the fans according to the ambient temperature and the temperature of the cooling water, ensuring the heat dissipation effect while saving electricity.

II. Operation Mechanism of the Refrigeration Station Group System

(I) Intelligent Group Control Technology: The "Smart Brain" of the System

Intelligent group control technology endows the refrigeration station group system with "intelligence" and serves as the "brain" of the entire system. It collects data such as the temperature, humidity, and cooling load of the workshop in real-time through sensors, as well as the operation parameters of equipment such as chiller units, pumps, and cooling towers. Using advanced algorithms for analysis and processing, it precisely controls the operation status of each device. For example, when the cooling load of the workshop decreases, the intelligent group control system will automatically reduce the number of operating chiller units and lower the rotation speeds of the pumps and cooling tower fans, minimizing energy consumption while meeting the refrigeration demand.

(II) Load Regulation Strategy: Precise Adaptation to Requirements

In biopharmaceutical workshops, the cooling load requirements of different production processes fluctuate greatly. The refrigeration station group system adopts flexible load regulation strategies to precisely adapt to these changes. Chiller units have multi-stage energy regulation functions and can automatically adjust the cooling capacity output according to the size of the cooling load. Pumps and cooling tower fans can also change the flow rate and air volume through variable-frequency speed regulation to achieve dynamic matching with the cooling load. For instance, during the drug fermentation stage, which has high requirements for temperature control and a large cooling load demand, the system will operate at full capacity. In the drug packaging stage, when the cooling load demand is small, the system will automatically operate with reduced energy consumption.

III. Innovative Technological Applications of the Refrigeration Station Group System

(I) Internet of Things (IoT) Technology: Achieving Remote Monitoring and Management

IoT technology has brought the refrigeration station group system into a new era of remote monitoring and management. By installing intelligent sensors and communication modules on the equipment, the operation data of the equipment is uploaded to the cloud platform in real-time. Managers can view the operation status of the system anytime and anywhere through terminals such as mobile phones and computers, operate the equipment remotely, and handle fault alarms in a timely manner. This not only improves management efficiency but also enables the prediction of potential equipment failures in advance, facilitating preventive maintenance and reducing downtime.

(II) Big Data Analysis and Predictive Maintenance: Ensuring Stable Equipment Operation

The application of big data analysis technology in the refrigeration station group system provides a safeguard for the stable operation of the equipment. The system collects a large amount of historical operation data of the equipment and uses big data analysis algorithms to uncover the patterns behind the data and establish equipment performance models. By comparing the real-time data with the predicted values of the models, potential fault hazards of the equipment can be detected in advance, and preventive maintenance can be arranged. For example, if it is predicted that the bearing of a certain pump may fail in a week, maintenance and replacement can be arranged in advance to avoid production interruptions caused by sudden failures.

IV. Advantages of the Refrigeration Station Group System

(I) High Efficiency and Energy Saving: Reducing Operating Costs

The refrigeration station group system achieves high efficiency and energy saving through the application of intelligent group control technology, load regulation strategies, and energy-saving equipment, significantly reducing the operating costs of biopharmaceutical workshops. Compared with traditional refrigeration systems, it can save 30% - 50% of energy consumption. Taking a large biopharmaceutical workshop as an example, it can save several million yuan in electricity bills every year. In the long run, the economic benefits are remarkable.

(II) Precise Temperature Control: Guaranteeing Drug Quality

Precise temperature control is the lifeline of biopharmaceutical workshops, and the refrigeration station group system performs excellently in this regard. It can control the temperature of the workshop within ±0.5°C and the humidity within ±5%, providing a stable environment for drug production. During the vaccine production process, precise control of temperature and humidity can ensure the activity and stability of the vaccine, improving the quality and safety of drugs.

V. Key Points of Maintenance and Management of the Refrigeration Station Group System

(I) Regular Inspections and Maintenance: Extending Equipment Lifespan

Regular inspections and maintenance are the keys to ensuring the long-term stable operation of the refrigeration station group system and extending the lifespan of the equipment. Maintenance personnel need to conduct comprehensive inspections of equipment such as chiller units, pumps, and cooling towers according to the specified inspection cycles, including equipment appearance, operation parameters, and connecting components. Regularly add lubricating oil to the equipment, replace vulnerable parts, and clean the condensers and evaporators. Generally, chiller units are comprehensively maintained once a quarter, and pumps and cooling towers are inspected and maintained once a month.

(II) Fault Diagnosis and Troubleshooting: Quickly Restoring Production

When a fault occurs in the refrigeration station group system, quick and accurate fault diagnosis and troubleshooting are of great importance. Maintenance personnel should rely on the built-in fault diagnosis system of the equipment, data from intelligent sensors, and their own experience to quickly determine the cause and location of the fault. For common faults such as pump motor overload and cooling tower fan failure, spare parts should be prepared for timely replacement and repair. For complex faults, technical support from the manufacturer should be contacted in a timely manner to restore the normal operation of the system as soon as possible and minimize the impact on production.