Sharing Best Practice Workshop
最佳实践的分享和研讨
Design and Operation of cGMP Utilities Facility
cGMP公用工程设施的设计和运作
David James
Process Engineering Manager 工艺工程经理
S2F Consulting (Shanghai) 诚赋开朋商务咨询(上海)有限公司
Presentation Agenda 演讲议题
Facility Life Cycle 设施的生命周期
Turning Business Needs into a Design
将业务需求融入设计
Good Design for Commissioning and Qualification
充分考虑调试和验证的良好设计
Good Commissioning and Qualification
良好的调试和验证
What Matters in Operations & Maintenance Phase
运行和维护阶段的主要问题
Design Decisions that Last a Life Cycle
设计中的决策贯穿整个生命周期
Design Impacts on Commissioning & Qualification
设计对调试和确认的影响
Design Impacts on Operations & Maintenance
设计对运行和维护的影响
Critical Design Considerations for cGMP Utilities
cGMP公用设施的设计要点
Questions & Discussion 问题和讨论
S2F Consulting (Shanghai) S2F咨询(上海)
S2F is an established multi-disciplinary
Architectural and Engineering
consulting firm focused on the delivery
of complex buildings where the
integration of science & technology,
building services and architecture
requires a considered response.
S2F是一家多专业的建筑和工程咨询公
司,专注于提供科技、设施和建筑的综合
性解决
方案
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。
S2F Consulting – Our Services and Experience
S2F咨询 –我们的设施和经验
Architecture 建筑
Mechanical Engineering 机械工程
Electrical Engineering 电气工程
Process Engineering 工艺工程
Validation 验证
Project Management 项目管理
Master Planning / Front End Studies
总体规划/前端研究
Procurement 采购
Value engineering reviews工程经济评估
Hazard analysis灾害危险性
分析
定性数据统计分析pdf销售业绩分析模板建筑结构震害分析销售进度分析表京东商城竞争战略分析
Life cycle costing 生命周期成本估算
Energy recovery and sustainability
能量回收和可持续性
Cost engineering and scheduling
造价管理和工期计划
Production capacity modeling生产能力模型
cGMP engineering cGMP工程
Commissioning & Qualification 调试和验证
Sterile Parenterals无菌静脉注射剂
Oral solid dose口服固体制剂
Liquids, Creams and ointments
液体、乳霜和软膏
Potent and toxic compounds
强效及含有毒成分药
Antibiotics抗生素
Biologicals生物制剂
Aerosols气雾剂
Radiopharmaceuticals放射性药物
Complimentary medicines替代性药品
Medical devices医疗设施
Dispensing and compounding配料
Filling & compression充装和压片
Packaging and warehousing包装和仓储
R&D and QA laboratories研发和质检实验室
Containment systems密闭系统
Pilot plants中试装置
Waste treatment facilities废水处理设施
Utilities infrastructure公用工程设施
Facility Life Cycle 设施生命周期
Business Need
业务需求
Design
设计
Construction
施工
Commissioning
& Qualification
调试和确认
Validation 验证
Operation &
Maintenance
运行和维护
Demolition 拆除
Major
Refurbishment
主要的更新
Changes 变更
$
$$
$
$
$$
The V – Model V模型
The V – Model V模型
V – Model Approach – Relies on getting the first stage right
V模型方法 取决于能否使第一阶段正确
– Tends to minimise what is captured in URS
倾向于将URS中捕捉到的特性数最小化
User Req Specs (URS)
用户需求说明
Functional Specs (FS)
功能说明
Performance Qualification
性能验证
Operational Qualification
运行验证
Tendency: Only put in here….….……….………..…..What is tested here
趋向:仅在这里列出 这里需要测试什么
The V – Model V模型
V – Model Approach V模型的方法
Can miss important aspects of the business need and return on investment
可能会忽略业务需求和投资回报的重要方面
Focuses on – Quality Aspects
专注于: 质量方面
– Performance / Capacity – Quality at specified rate
性能/能力 –质量达到指定的级别
Ignores – Unit Costs / Operating Costs
忽略: 装置成本 / 运行费用
– Reliability and long term performance
可靠性和长期性能
– Corporate policies – safety, sustainability, etc
公司策略 –安全性,可持续性等
Solution - Project Brief 解决方案 -项目概要
BUSINESS CASE 业务案例
$$ IN $$ OUT
DESIGN / SPECIFICATION – PROJECT BRIEF 设计/说明书 –项目概要
> Registered Process 合格的工艺
> Product Quality Attributes 产品质量特性
> Performance / Capacity / Output 性能/生产能力/产量
> Reliability / Maintainability / Availability / Efficiency – OOE or OEE
可靠性/可维护性/可用性/生产效率 –总体运行效率/总体设备效率
> Business Case Assumptions – Unit Costs, Capital Budget
业务案例假设-单位造价,基本预算
> Intended Life / Duration of the Facility 预期寿命/设施的延续时间
> Corporate Policies and Standards – Quality, Safety, Sustainability
公司政策和
标准
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–质量、安全、可持续性
> Future flexibility / changes 未来的灵活性/变更
Project Brief in the V-Model
V模型中的项目概要
Project
Brief
项目概要
DQ
The New Lean Approach – e.g. ASTM E2500
新的精益方法 –例如:ASTM E2500
Project
Brief
项目概要
URS FS/TS C&Q PVDQ
Business
Case
Good Design Practice for 充分考虑调试和验证
Commissioning & Qualification 的良好设计实践
To assist with Commissioning and Qualification, the Design must :
为了给调试和验证阶段提供充分的支持,设计应确保以下方面:
> Define a documentation structure – e.g. V–Model, Lean approach
定义文档体系结构 –例如,V模型,精益方法等
> Establish process systems structure and define system boundaries
建立工艺系统结构并定义系统边界
> Assess each system and define Critical Quality Attributes (CQAs)
评估每个系统,并定义关键质量指标(CQA)
> Focus on what defines the product quality and how these attributes
are measured and controlled
关注于用什么来定义产品质量,以及这些指标如何被测量和被控制
> Assessment tools – e.g. FMEA, HACCP, HAZOP, etc
评估工具 –例如潜在失效模式及后果分析FMEA,危害分析和灾害控制点
HACCP,危险和可操作性分析HAZOP
Good Design Practice for 充分考虑调试和验证
Commissioning & Qualification 的良好设计实践
> Assess each system and define Critical Quality Attributes (CQAs)
评估每个系统并定义关键质量指标CQA
> GMP Impact Assessment – e.g. SIA & CIA (ISPE), FLIA (Lean)
GMP影响性评估 –例如:SIA和CIA (ISPE),以及FLIA (精益方法)
> Document the results
将结果文档化
> This is the basis for focused commissioning and qualification
这是我们所关注的调试和确认过程的基础
> Establish operating and acceptance ranges for each CQA
为每个CQA建立运行和验收范围
> These are Acceptance Criteria for Commissioning and Qualification
作为调试和确认过程的验收标准
> Determine what is Good Engineering Practice (GEP) and what is GMP
确定哪些是良好工程实践GEP,哪些是药品质量管理规范GMP
Impact (Risk) Assessment Results 影响性评估结果
Good Engineering Practice (GEP) & Good Manufacturing Practice (GMP)
良好工程实践GEP和药品质量管理规范GMP
From the Critical Quality Attribute Assessments:
来自关键质量指标评估:
GEP – Contractual, Business Impact & Plant Performance Risks
GEP –受制于
合同
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约束,对业主的业务产生影响,存在设备运行风险
> Results go into Functional & Technical Specifications
结果进入功能说明和技术说明
> Test / Prove during FAT, Commissioning & SAT
FAT、调试和SAT过程中的测试和证明
GMP – Product Quality & End User Risks
GMP –产品质量和最终用户风险
> Results go into Qualification and Validation Plans & Protocols
结果进入到确认和验证计划和
协议
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> Test / Prove during Qualification / Validation
确认和验证期间的测试和证明
Efficient Commissioning & Qualification
有效的调试和确认
Good Engineering Practice Good Manufacturing Practice
良好工程实践 药品质量管理规范
Installation Checks Installation Qualification
安装检查 安装确认
Operational Checks Operation Qualification
运行检查 运行确认
Site Acceptance Tests 现场验收测试 Performance Qualification 性能确认
> Reliability 可靠性 > Product Quality 产品质量
> Business Case 业务案例 > Consistency 一致性
Well planned and documented Commissioning means Qualification can focus
on confirming the Commissioning documentation and close-out of defects
经过良好计划和文档化的调试意味着确认过程能专注于调试文档的确认以及缺陷的关
闭。
Qualification documentation is carried through to Operations and Maintenance
phase to support on-going re-validation and periodic performance reviews.
确认文档用于运行和维护阶段,以支持进行中的再验证和阶段性的性能评估。
Examples of Design Impacts on 设计对确认和验证
Commissioning & Qualification 阶段的影响 –举例
Definition of Critical Quality Attributes – Measurable and Responsive
关键质量指标的定义 –可测试并且可响应
> Conductivity of water – cheap and easy to do in-line, rapid response
水的电导率 可廉价并且简单地在线测得,反馈非常快
> TOC in Water – expensive, slow response if not on-line
水的总有机碳含量 如果不是在线测得,较昂贵,反馈较慢
> Hydrocarbons in air – expensive to measure, slow turn-around
空气中的碳氢化合物 测试代价较昂贵,周期缓慢
– eliminate by using oil-free compressors
通过选用无油空压机来消除
> Contaminants in N2 – expensive to measure, slow turn-around
氮气中含杂质量 测试较昂贵,周期缓慢
– eliminate by using bulk liquid Nitrogen system
通过选用散装液氮系统来消除
Examples of Design Impacts on 设计对确认和确认
Commissioning & Qualification 阶段的影响
Specify Contractor to provide construction records for direct impact systems
明确要求承包商为GMP直接影响系统提供施工安装记录。
> Materials of construction
施工材料
> Fabrication / welding records
制作/焊接记录
Specification of instrument ranges – Operating range vs Instrument range
仪器量程说明 –运行范围和仪器范围的比较
Provision of sample points in GMP utilities – at each point of use, to suit all tests
为GMP相关设施提供取样点 –位于每个用户点附近,以适应所有的测试
Access to components for inspection / calibration / adjustment
使用检测/校验/调节的组件
Consideration of local conditions in specification of equipment
考虑设备规格的本地条件
> Impact of quality fluctuations in Town Water on Pre-Treatment
在前处理考虑城市生活水的水质波动。
Operation & Maintenance Phase 运行和维护阶段
What does an Operations Manager care about? 生产经理最关心什么?
Product Out the Door 把产品送出门去
> Throughput 产能 – Manufacture to “the plan”生产满足原计划
> Unit Cost 单位成本 – Use only the materials and labour in the
manufacturing resource plan,
minimum waste, rejects and re-work
仅使用生产资源规划中需要的原料和人工,将废
物、尾料和返工最小化
> Quality 质量 – Follow the validated process, pass the quality
control tests, complete the batch records,
keep the equipment and facility validated
按验证过的过程生产,通过质检测试,完善批次
记录,确保设备和设施已做过验证
> Safety 安全
Operation & Maintenance Phase 运行和维护阶段
Enhancing Manufacturing Output 提高产量 :
Machine Reliability – select equipment that does not need to run at
maximum speed
设备可靠性 –选择设备时考虑一定的裕量,使其不必在最大能力下运行
Documented machine set up procedures and training programs based on C&Q
基于调试确认阶段的机器启动程序和培训程序
Periodic Re-Validation & Validation of Changes
定期的重验证及变更后的验证
– Takes time away from manufacturing 削减了用于生产的时间
– Focused, well organised qualification documents
reduce the burden and time required for re-validation
目标专注且组织良好的验证文件可减少重验证带来的负担和时间
On-going Testing – Focus on CQAs专注于各项CQA
测试过程中 – Use qualification results to justify testing regimes
使用验证结果来调整测试方法
Examples of Design Impacts on 设计对运行和维护
Operations and Maintenance 阶段的影响举例
Capacity of Water Production and Storage 水制备和储存能力
– Manufacturing time lost ‘waiting for water’
生产时间上忘记加上“等待用水”的时间
– Production make-up rate versus Tank capacity versus Holding time
水制备流量,水罐容量和维持时间的对应
Temperature of WFI – Cold WFI is convenient but requires sanitisation
WFI温度 冷WFI更方便,但需要灭菌处理
– Sanitisation takes up to 24 hours of production time
灭菌处理占用生产时间最多达24小时
Sampling of WFI for TOC – Off Line – Convenient, but slow, high operating cost
WFI取样作TOC分析 离线方式 –方便但缓慢,操作成本较高
– On Line – High capital cost, fast response, automated
在线方式 –高成本,快速取得结果,自动操作
Redundancy – Adds to capital cost but eliminates unplanned down-time
冗余备份 增加了费用支出,但消除了未预测的停产时间
Examples of Design Impacts on 设计对运行和维护
Operations and Maintenance 阶段的影响举例
Quality of Equipment – Adds to capital cost but reduces unplanned down-time
设备质量 –增加了总成本支出但减少了未预测的停产时间
Space allowed to remove RO membranes or distillation columns
留出足够空间以便移动RO膜或蒸馏柱
Energy & Water Efficiency – reduces operating costs, increases capital cost
提供能量和水的利用率 –降低操作成本,增加总成本
Level of Automation – Reduces labour cost, improves consistency, reduces
自控的级别 errors but increases training effort, maintenance
costs, capital cost, down time
降低人力成本,增加一致性,减少错误率,增加培训和维
护成本,总体成本和停产时间
– cGMP Critical control systems - Part 11 compliance
cGMP关键控制系统 –第11部分符合性条款
cGMP UTILITIES cGMP公用工程
What defines a utility as cGMP? DIRECT IMPACT on Product Quality
是什么将某种公用工程定义为cGMP? 对产品质量的直接影响性
System Impact Assessment (ISPE) 系统影响性评估(ISPE)
> Does the system have direct product contact?
该系统是否直接接触产品?
> Does the system provide an ingredient, excipient or solvent used in the
product?
该系统是否被用作为产品的某种成分,辅料或溶剂?
> Is the system used in cleaning or sterilizing?
该系统是否被用于清洗和灭菌?
> Does the system produce data used to accept or reject product?
该系统是否形成决定产品是否可被接受的数据?
> Is the system a control system that may affect product quality but has no
independent verification?
该系统是否被作为一种控制系统,从而影响到生产质量,但未被单独鉴定?
cGMP UTILITIES cGMP公用工程
Direct Impact cGMP Utilities cGMP公用工程的直接影响性 –
Water – used in product or cleaning – Water for Injection or Purified Water
水 用于产品或清洗 注射用水或纯化水
Steam – used in product contact – Clean or Pure Steam
蒸汽 用于直接产品接触 洁净蒸汽或纯蒸汽
Air – used in product contact – Process or Sterile Air
空气 用于直接产品接触 工艺或无菌压缩空气
Gases – used in product contact – Nitrogen, Oxygen – Sterile filtered
气体 用于直接产品接触 氮气和氧气 –经无菌过滤
Process Water – Critical Design Considerations
工艺用水 –设计要点
Production Rate - versus - Storage Volume - versus - Holding (turnover) Time
生产率 –存储容量 –事故停顿时间
Balance of factors - Cost of production capacity
各因素的综合平衡 生产能力的成本
- Convenience of holding large volume of water
维持大容量的水是否方便
- Potential Contamination from “old “ water
“老”水中潜在的污染
WFI Cons (L)
4460
Prep Phosphate Buffer WFI flush of Solution Prep tan 100 Sunday 24.00
CIP/SIP 2 x Phosphate Buffer 700 Monday 1.00
WFI to Solution Prep vessel 1000 Monday 2.00
CIP Solution Prep vessel 850 Monday 3.00
Wash sundry items 100 Monday 4.00
Monday 5.00
Conc test Wash sundry items 100 Monday 6.00
Monday 7.00
Mix Phosphate buffer WFI flush SATA Reaction Ves 100 Monday 8.00
Monday 9.00
Mix DMSO & SATA Prepare 30% W/V NaOH 50 Monday 10.00
Wash sundry items 100 Monday 11.00
Monday 12.00
UF SATA Wash UF skid and pump 200 Monday 13.00
Wash sundry items 100 Monday 14.00
Monday 16.00
Filtration of SATA CIP/SIP Conjugation Reaction 350 Monday 17.00
CIP SATA Reaction Vessel ve 350 Monday 18.00
Wash sundry items 100 Monday 19.00
Monday 20.00
Preparation of Hydroxylamine /Wash sundry items 100 Monday 21.00
Add WFI to mix 40 Monday 22.00
Monday 23.00
Preparation of Thiomersal Wash sundry items 100 Monday 24.00
WFI CONSUMPTION ESTIMATES DOW TIME WFI Tank Level
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Process Water – Critical Design Considerations
工艺用水 –设计要点
Model the water consumption – when used, how much
水消耗的模型 –何时使用,多少量
Plan manufacturing to smooth consumption
适当的生产计划使水消耗的变化比较平滑
Accepted Practice - Use water within 24 hours of production?
可接受的实践 采用满足24小时生产的水量
- Validate actual operation
查验实际的操作
WFI Cons (L)
4460
Prep Phosphate Buffer WFI flush of Solution Prep tan 100 Sunday 24.00
CIP/SIP 2 x Phosphate Buffer 700 Monday 1.00
WFI to Solution Prep vessel 1000 Monday 2.00
CIP Solution Prep vessel 850 Monday 3.00
Wash sundry items 100 Monday 4.00
Monday 5.00
Conc test Wash sundry items 100 Monday 6.00
Monday 7.00
Mix Phosphate buffer WFI flush SATA Reaction Ves 100 Monday 8.00
Monday 9.00
Mix DMSO & SATA Prepare 30% W/V NaOH 50 Monday 10.00
Wash sundry items 100 Monday 11.00
Monday 12.00
UF SATA Wash UF skid and pump 200 Monday 13.00
Wash sundry items 100 Monday 14.00
Monday 16.00
Filtration of SATA CIP/SIP Conjugation Reaction 350 Monday 17.00
CIP SATA Reaction Vessel ve 350 Monday 18.00
Wash sundry items 100 Monday 19.00
Monday 20.00
Preparation of Hydroxylamine /Wash sundry items 100 Monday 21.00
Add WFI to mix 40 Monday 22.00
Monday 23.00
Preparation of Thiomersal Wash sundry items 100 Monday 24.00
WFI CONSUMPTION ESTIMATES DOW TIME WFI Tank Level
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
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Process Water – Critical Design Considerations
工艺用水 –设计要点
WFI System Temperature – WFI is used hot (cleaning) and cold (formulation)
WFI系统温度 WFI使用高温(清洗用)和低温(制剂)
– Industry practice is <15°C or >75°C
工业实践中为<15°C 或 >75°C
– Chinese GMP requires <4°C or >80°C
中国GMP要求<4°C 或 >80°C
– All WFI systems require sanitization
所有WFI系统都要求灭菌
– Sanitization takes time – usually up to 24 hrs
灭菌时间 –通常达到24小时
– Heating & Cooling takes time and energy
加热和冷却消耗时间和能量
Sanitization Options – High temperature or Ozone?
灭菌选项 高温法还是臭氧法?
– High temperature is industry norm
高温法是行业标准
– High temp is easy, no extra parts, but takes time
高温法简单易行,没有增加物质,但费时
– Ozone sanitization is usually faster
臭氧法通常更快速
– Ozone is not considered an ‘added substance’
臭氧法并未被认为是“增加物质”
– Many design considerations for ozone
臭氧法有许多设计要点
> Materials, maintenance costs, safety, etc
材料,维护成本,安全性等
– Calibration of ozone sensors
臭氧传感器的校准
Process Water – Critical Design Considerations
工艺用水 –设计要点
Clean Steam – Critical Design Considerations
洁净蒸汽 –设计要点
GMP Requirements – No US FDA or USP requirements
GMP要求 没有美国FDA或USP要求
– No mention in ChP or SFDA cGMP
在ChP或中国SFDA cGMP中提及
– EU - EN285 or HTM 2031 欧盟EN285或HTM 2031
> Dryness 干燥度大于 ≥ 0.9 or ≥ 0.95
> Non Condensable Gas (NCG) 不凝性气体含量≤ 3.5%
> Superheat 强热 ≤ 25°C
Industry Practice – Condensate meets WFI specifications
来自行业实践 冷凝水符合WFI规范
– Limits on additives, pH, superheat, Dryness, NCG
增加物、pH值、过热、干燥度、不凝性气体的限度
– Endotoxins and pyrogens to WFI standard
WFI标准中的内毒素和热原
Clean Steam – Critical Design Considerations
洁净蒸汽 –设计要点
Capacity Testing – Facility to run CS Generator at full capacity
生产能力测试 满负荷运行洁净空气发生装置的设施
Steam Sampling – At CS Generator and Points of Use
蒸汽取样 在洁净蒸汽发生装置及用户点处
– Condenser for conductivity, TOC and micro sampling
用于电导率、TOC和微生物测试取样的冷凝器
– End of distribution line condenser - Conductivity
分布管线末端冷凝器 –电导率
– EN285 test points – next slide
EN285测试点见下页
“Point of Use” – Supply to machine or “product contact”?
用户点 仅提供给机器,或者直接接触产品?
Clean Steam Sampling – EN285:2006
洁净蒸汽取样– EN285:2006
Refer to EN285:2006 for details and procedures
细节及程序请参EN285:2006
Dryness 干燥性
Non
Condensable
Gases (NCG)
不凝性气体
Superheat 强热
Clean Steam Quality Sampling 洁净蒸汽质检取样
EN285 Sample Point
EN285中的取样点
Micro & Chemical Sample Point
微生物和化学取样点
Steam
Condenser
蒸汽冷凝器
Conductivity
Sensor
电导率探头
Temp
Sensor
温度传感器
Sample
Storage
样品存放
Sample
Valve
取样阀
Drain Valve
排放阀
Orifice
孔板
Compressed Air – Critical Design Considerations
压缩空气 –设计要点
GMP Requirements – “dry” and “cleaned to meet requirements” (SFDA)
GMP要求 – “干燥”及“洁净程度符合要求” (中国FDA)
– “free from oil and water vapor” (US FDA)
–无油,无水汽 (美国FDA)
– Micro and particulate levels to match environment
–微生物和粉尘含量应符合所处环境的要求
“Dry” 干燥的 – Measure Dewpoint – In-line sensor at source
–露点测试 –在源头使用在线传感器
– Dryness to suit application – Hydrophobic filters
–干燥度符合应用需要 –带疏水的过滤器
– Refrigerated Dryers to 0°C, Desiccant Dryers -70°C
–冷冻干燥机至0°C,吸附式干燥机至-70°C
“Cleaned” 已清洗 – Particulate filtering – to suit application
–粉尘过滤 –满足应用的需要
– 0.45 micron for product contact, 0.2 micron for sterile
– 0.45μ用于产品接触, 0.2μ用于无菌生产
Compressed Air – Critical Design Considerations
压缩空气 –设计要点
“Oil free” 无油 – No clear, agreed definition of “oil free”
–没有非常清楚的公认的“无油”定义
– Industry norm is <0.1 to <1.0 mg/m3
–工业标准是<0.1 到 <1.0 mg/m3
– Hydrocarbon levels measured by sampling
–通过取样测量碳氢化合物等级
– New on-line meters available down to 0.001 mg/m3
–新的在线测量仪可测得低至0.001 mg/m3
– Desiccant dryers will trap oil but at what cost?
–吸附式干燥器可以捕集油,但其代价如何考虑?
– Oil in the piping? How to clean it?
–管道中含油吗?如何清洗?
– Oil-free compressors strongly recommended
–强烈推荐无油空压机
Refer to ISO 8573 for specific contaminant levels and tests
(杂质等级和测试规定参考ISO8573)Basil V R Greatex oil sensor
Nitrogen – Critical Design Considerations
氮气 –设计要点
Bulk Liquid Storage or Nitrogen Generator
散装液氮储存或者氮气发生器
General Design Considerations 一般设计要点 :-
> Rate of Consumption
消耗程度
> Cost per kilogram
每公斤损耗
> Quality – What purity is required? Are you sure?
质量 –究竟需要多少纯度?是否确信?
> Quality Testing – Who will do this?
品质测试 –谁能做这些?
Nitrogen – Critical Design Considerations
氮气 –设计要点
Considerations for Bulk Liquid N2 :-
散装液氮的考虑:
> Availability of bulk liquid
桶装液体的可获得性
> Security of Supply
供应可靠性
> Size of storage tank – Frequency
of refill
储罐的大小 -重新充满的频率
> Ability to change Suppliers
更换供应商的能力
> Ownership of Storage tank
储罐的拥有权
Considerations for N2 Generator :-
氮气发生器的考虑:
> Ownership of equipment
设备的拥有权
> Who wi