New-energy manufacturing
Li-ion cells, modules and packs; PV polysilicon and wafers, cells and modules; energy-storage integration and optional electrolytic hydrogen: dry rooms, solvent recovery, formation, process gases and thermal-runaway protection.
How FacilityOS helps
- Dry-room dew point and NMP recovery for lithium-ion cell plants.
- Formation and grading, desiccant wheels and battery energy storage monitored alongside the site's power and cooling.
- Energy by workshop and system for cost per unit of production.
Platform modules used
FMCS
Facility management and control
The whole cooling and power chain at a glance, with redundancy, shift handover, utility efficiency and first-out alarm analysis.
Learn more →EPMSElectrical power monitoring system
IEC 61850 read-only, sequence of events to the microsecond, COMTRADE waveforms, power quality, breaker wear, relay settings, arc-flash labels and transformer life.
Learn more →EMSEnergy management system
Electricity, gas, water and steam metering by workshop and system, time-of-use cost, demand, carbon, PUE and tamper-evident report archives.
Learn more →PLC / DCSProcess control
PID loop faceplates, ISA-88 batch records, controller redundancy, EtherNet/IP and Siemens S7, and a soft-PLC IDE with simulation.
Learn more →CMMSMaintenance management
Asset register linked to live data, preventive maintenance by calendar, run hours or starts, signed work orders, QR/NFC inspection rounds, spares and MTBF/MTTR.
Learn more →Segments
Li-ion battery cell
Coating, calendering, assembly, filling, formation and aging; dry rooms at ≤ −40°F dew point.
Learn more →Battery module / pack
Cell sorting, laser welding and end-of-line testing.
Learn more →PV polysilicon / wafer
Polysilicon reduction, crystal pulling and wire sawing: hydrogen, chlorosilanes and very high power.
Learn more →PV cell
Texturing, diffusion, PECVD, screen printing, firing and sorting: silane, ammonia, acids and caustics.
Learn more →PV module
Stringing, lamination, framing, EL and IV testing.
Learn more →Energy-storage system integration
ESS container assembly, testing and on-site storage.
Learn more →Hydrogen / electrolyzer (optional)
Electrolyzer manufacture or on-site hydrogen production.
Learn more →Systems and equipment
Core: every site of this kind has it. Common: most sites have it. Optional: depends on the site.
Chiller plant & process cooling
Dry-room pre-cooling and formation heat are the largest cooling loads.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Large centrifugal chiller | Core | CHW supply temp · CHW return temp · Load · Power draw · Efficiency (kW/ton) · Fault | Thousand-ton centrifugals (Trane, York, Carrier, Daikin) on BACnet/IP, typically N+1. |
| Cooling tower cell | Core | Tower leaving water · Tower entering water · Fan speed · Basin level · Water conductivity · Fan vibration | |
| Pump | Core | Running · Speed · Differential pressure | Chilled and condenser water pumps; drives usually on Modbus TCP. |
| Process cooling water loop | Core | Supply temp · Return temp · Supply pressure · Supply-return differential · Loop flow · Loop conductivity · Leak detected | |
| Heat-recovery chiller / heat pump | Optional | Hot water supply temp · Chilled water supply temp (recovery side) · Power draw · Combined COP | Heat recovery displacing boiler gas — one of the main decarbonization levers. |
| Process chillerBattery module / pack · PV cell · PV polysilicon / wafer · PV module · Energy-storage system integration | Common | Process water supply temp · Process water return temp · Load | |
| Dry cooler / adiabatic cooler | Common | Leaving fluid temp |
Dry rooms & clean areas
Moisture reacts with electrolyte to make HF; dry-room dew point is the lifeline of cell quality.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Dry roomLi-ion battery cell | Core | Dew point · Room temp · Pressure vs corridor · People inside · Airlock door held open | Assembly and filling typically ≤ −40°F (−40°C) dew point, some down to −60°F. |
| Desiccant dehumidifierLi-ion battery cell | Core | Supply air dew point · Regeneration temp · Process airflow · Desiccant wheel turning · Power (incl. regen heat) | Desiccant wheels from Munters, Bry-Air, Seibu Giken and others. |
| Make-up air unitLi-ion battery cell · PV cell · PV polysilicon / wafer | Core | Supply air temp · Supply dew point · Outdoor airflow · Final filter pressure drop | |
| Cleanroom zoneLi-ion battery cell · PV cell · PV polysilicon / wafer | Common | Pressure vs adjacent · Room temp · Relative humidity · Target class (ISO 14644-1) | ISO 7–8 areas. |
| Particle counterLi-ion battery cell · PV cell | Optional | Particles ≥ 0.5 µm · Measured class (ISO equivalent) | |
| Air handlerBattery module / pack · Energy-storage system integration · Hydrogen / electrolyzer (optional) · PV module | Common | Supply air temp · Duct static pressure |
Process: coating, formation, lamination, test
Monitor process equipment's utility and safety status.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Electrode coating ovenLi-ion battery cell | Core | Oven zone temp · Coating speed · Oven exhaust airflow · Exhaust solvent (% LEL) · LEL interlock | NFPA 86 solvent ovens commonly interlock at 25 % LEL. |
| Formation & grading racksLi-ion battery cell | Core | Channels in use · Charging power · Discharge energy recovered · Energy today · Hottest cell temp | Regenerative formation recovers most of the discharge energy. |
| Cell plant energy KPIsLi-ion battery cell | Common | Good cells today · Energy per cell · Formation first-pass yield · Worst dry-room dew point · NMP recovery (average) | |
| End-of-line testerBattery module / pack · Energy-storage system integration | Core | Tested today · First-pass yield · Test cycle time | |
| Robotic weld cellBattery module / pack | Common | Weld current · Parts today · Safety guard tripped | Laser or ultrasonic weld cells. |
| Polysilicon reactorPV polysilicon / wafer | Core | Rod surface temp · Power supply · Hydrogen feed · Trichlorosilane feed · Chlorosilane leak | Reactors are the largest electrical load of a polysilicon plant. |
| CZ crystal pullerPV polysilicon / wafer | Core | Melt temp · Heater power · Pull speed (in/h) · Argon flow · Cooling water temp | Losing cooling water or power scraps the run: back them with UPS and standby cooling water. |
| Diamond wire sawPV polysilicon / wafer | Core | Wire speed · Wire tension · Coolant temp · Wire break | |
| Texturing / cleaning benchPV cell | Core | Texturing bath temp · KOH concentration · DI water flow · Wafers today | |
| Diffusion furnacePV cell | Core | Tube temp · POCl3 carrier flow · Exhaust suction · Boats today | |
| PECVD coaterPV cell | Core | Chamber pressure · RF power · Silane flow · Ammonia flow · Process gas alarm | Silane is interlocked by the gas cabinets and GMS; the platform only monitors. |
| Screen printerPV cell | Core | Print rate (wafers/h) · Breakage · Paste remaining | |
| Firing furnacePV cell | Core | Peak temp · Belt speed · Zone temperature deviation | |
| Cell tester / sorterPV cell | Core | Average efficiency · A-grade share · Cells tested today | |
| StringerPV module | Core | Soldering temp · Breakage · Strings today | |
| PV module laminatorPV cell · PV module | Core | Heating plate temp · Vacuum · Cycle time · Modules today | |
| Framing machinePV module | Common | Modules framed today · Air pressure | |
| EL inspectionPV module | Core | EL defect rate · Modules tested today | |
| IV tester (sun simulator)PV module | Core | Average Pmax · Irradiance (W/m²) · Lamp hours | Calibrate regularly per IEC 60904. |
| Battery energy storage containerEnergy-storage system integration | Core | State of charge · Power (+ discharge) · Hottest cell temp · Lowest cell voltage · Highest cell voltage · Container HVAC running | Factory test and on-site storage. |
| ElectrolyzerHydrogen / electrolyzer (optional) | Core | Hydrogen output · Stack power · Stack temp · Hydrogen purity · H2-in-O2 high | |
| Line controller (OEE)Battery module / pack · PV cell · PV module · Energy-storage system integration | Common | OEE · Output (parts/h) · Energy per part | |
| Thermal oil heater | Common | Outlet oil temp · Low-flow trip |
Solvent recovery & abatement
NMP recovery saves cost and keeps the air permit.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| NMP solvent recoveryLi-ion battery cell | Core | Inlet NMP · Stack NMP · Solvent recovery · Condenser coil temp · Recovered NMP tank | Recovery is usually expected above 95 %. |
| Process exhaust system | Core | Exhaust main static · Exhaust airflow · Fans running · Low exhaust static | Watch general, heat, solvent and acid exhaust separately; N+1 fans. |
| Acid exhaust scrubberLi-ion battery cell · PV cell · PV polysilicon / wafer | Common | Recirculation pH · Recirculation flow | HF from filling; acid mist from PV diffusion and etch; HCl at polysilicon plants. |
| VOC concentratorPV cell | Optional | Outlet VOC · Removal efficiency | |
| Dust collectorLi-ion battery cell · Battery module / pack | Common | Filter pressure drop · Spark detected | Electrode powder and laser-weld fume; mind combustible dust. |
CDA, nitrogen & hydrogen
Dry rooms need very dry CDA; nitrogen inerts and shields welds.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Clean dry air compressorLi-ion battery cell | Core | Discharge pressure · Output · Load · Power draw · Surge detected · Fault | |
| Air compressorBattery module / pack · PV cell · PV polysilicon / wafer · PV module · Energy-storage system integration · Hydrogen / electrolyzer (optional) | Core | Discharge pressure · Load · Power draw · Fault | |
| Desiccant air dryer | Core | Pressure dew point · Pressure drop · Regeneration temp · Fault | Typical pressure dew point −94°F (−70°C). |
| CDA header | Core | Header pressure · Header dew point · Demand | |
| Bulk gas supply | Core | Tank level · Supply pressure · Vaporizer outlet temp · Flow · Impurity · Reserve supply in use | N2, O2, Ar, H2, CO2; tank telemetry is usually the gas supplier's. |
| On-site nitrogen generator | Optional | Product O2 content · Output · Outlet pressure · Off-purity (on LIN backup) | |
| House vacuum systemLi-ion battery cell · PV cell | Common | Vacuum · Pumps running | |
| Cryogenic vaporizer | Common | Outlet gas temp · Low outlet temp |
Water & wastewater
PV and hydrogen need pure water; coating and cleaning make wastewater.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Reverse osmosis unitPV cell · PV polysilicon / wafer · Hydrogen / electrolyzer (optional) | Common | Permeate conductivity · Permeate flow | |
| Electrodeionization unitPV cell · PV polysilicon / wafer · Hydrogen / electrolyzer (optional) | Common | Product resistivity | |
| pH neutralization systemLi-ion battery cell · PV cell · PV polysilicon / wafer | Core | Effluent pH · Flow | |
| Final effluent monitor | Common | Discharge flow · Discharge pH · COD | |
| Domestic water booster | Common | Discharge pressure · Flow |
Power, storage & sub-metering
Formation is the largest electrical load; on-site storage and PV shave peaks.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Medium-voltage switchgear | Core | Bus voltage · Incoming current · Real power · Breaker closed · Protective trip · Relay trouble | Monitor only — never operate breakers. |
| Low-voltage switchgear | Core | Bus voltage · Load current · Real power · Power factor · Current THD · Breaker trip | |
| Power transformer | Core | Top-oil temp · Winding temp · Load · Gas / sudden-pressure alarm · Over-temperature alarm | |
| UPS | Core | Load · Battery runtime · On bypass | SNMP v3 (UPS-MIB). |
| UPS battery string monitor | Core | String voltage · Lowest jar voltage · Highest jar voltage · Highest jar internal resistance · Highest jar temp · State of charge | Per-jar resistance trending (one of the maintenance practices in IEEE 1188). |
| Generator | Common | Running · Output power · Fuel tank level · Starting battery voltage · Not in AUTO | |
| Power quality meter | Common | Voltage THD · Current THD · Voltage sags today · Sag / interruption event | Voltage sags are a common hidden cause of trips. |
| Site utility meter | Core | Site power · Site power (MW) · Energy today · Power factor | |
| Area energy meter | Core | Area power · Energy today · 15-min demand · Power factor | Sub-metering by workshop or system for energy analysis and cost allocation. |
| Natural gas meter | Common | Natural gas flow · Heat input (1,037 BTU/scf) · Gas today (scf) | Natural gas in scfh, converted to BTU/h by heating value. |
| Rooftop solar inverter | Optional | Solar output · Energy today | |
| Motor control centerBattery module / pack · PV cell · PV polysilicon / wafer · PV module | Common | MCC load · Current · Power factor · Current THD | |
| Ring main unit | Common | SF6 low · Fault passage indicator | |
| Insulation monitoring device (IT system) | Common | Insulation resistance · Insulation alarm | |
| Microgrid controller | Optional | Grid exchange · Islanded | |
| Wind turbine | Optional | Output · Fault | |
| Static var generator (SVG / STATCOM) | Common | PF after · Unit load · Modules in fault | |
| Dynamic voltage restorer (DVR) | Optional | Sags corrected today · On bypass | |
| Step voltage regulator | Optional | Tap position · At tap limit | |
| Transformer DGA monitor | Common | Hydrogen · Acetylene | |
| On-load tap changer control (OLTC) | Optional | Tap position · Tap fault · Operations today | |
| Surge arrester monitor | Optional | Total leakage · Resistive current | |
| Surge protective device (SPD) status | Common | SPD failed · Backup breaker open | |
| Weather station | Common | Outdoor temp · Wind speed |
Thermal runaway, gas & fire Monitor only
Cell venting is the earliest warning of runaway, leaving only minutes to react.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Thermal runaway detectorLi-ion battery cell · Battery module / pack · Energy-storage system integration | Core | Electrolyte off-gas · Hydrogen · Hottest spot (IR) · Stage 1: off-gas detected · Stage 2: thermal runaway | Required in formation, aging stores and ESS areas. |
| HF detectorLi-ion battery cell | Core | Hydrogen fluoride (HF) · Alarm 1 (low) · Alarm 2 (high) | Electrolyte filling area. |
| Hydrogen detectorHydrogen / electrolyzer (optional) · Energy-storage system integration · PV polysilicon / wafer | Core | Hydrogen (% LEL) · Alarm 1 (low) · Alarm 2 (high) | |
| Silane detectorPV cell | Core | Silane (SiH4) · Alarm 1 (low) · Alarm 2 (high) | PECVD and gas cabinet rooms. |
| Ammonia detectorPV cell | Common | Ammonia level · Ammonia alarm | |
| Specialty gas cabinetPV cell | Common | Cylinder pressure · Cabinet exhaust · Excess-flow trip · Low cabinet exhaust | |
| Combustible gas detectorLi-ion battery cell · PV cell | Common | Combustible gas (LEL) · Gas alarm | Solvent areas. |
| Oxygen deficiency monitor | Core | Oxygen · Alarm 1 (O2 below 19.5 %) · Alarm 2 (O2 below 18 %) | Nitrogen and inert-gas areas: 19.5 % and 18 % stages. |
| Fire alarm zone & linkage | Core | Fire alarm · Supervisory · Trouble · Linkage: air handlers stopped · Linkage: fire/smoke dampers closed · Linkage: smoke exhaust running · Linkage: elevators recalled | Linkage proofs verify the fire system did what it should. |
| Fire alarm panel | Core | Fire alarm · Supervisory signal · Trouble signal | Monitor only (NFPA 72). |
| Aspirating smoke detector | Common | Smoke obscuration (%/ft) · Alert · Action · Fire 1 · Airflow fault | |
| Fire pump | Common | Running · System pressure · Power phase failure | |
| Sprinkler riser | Common | Riser pressure · Waterflow alarm · Valve tamper | |
| Leak detection cable | Core | Leak detected · Distance to leak · Leak zone · Cable break or contamination | |
| Smoke exhaust fan | Common | Running · Damper not proven | Smoke exhaust or stair pressurization fans; monitor only. |
| Water mist system | Optional | Pump unit not ready · Released |
Security & video Monitor only
Camera and door status, and video linkage: cameras are linked to areas, devices and alarm rules; on an alarm the gateway takes an ONVIF snapshot and attaches it to the alarm, with a live-view link to the NVR/VMS. Core never contacts a camera.
| Equipment | Level | Points worth watching | Notes |
|---|---|---|---|
| Video camera | Common | Online · Recording · Motion detected · Video analytics alarm · Tamper (blocked or moved) | Status via the VMS (Milestone, Genetec…); on an alarm the gateway takes an ONVIF snapshot and attaches it to the alarm — Core never contacts a camera. |
| Access-controlled door | Common | Door open · Door held open · Door forced | Door events can drive camera linkage. |
| Perimeter intrusion detection | Common | Perimeter alarm |
Life-safety equipment (fire alarm, gas detection, emergency power transfer) and protection devices are monitored only. FacilityOS never sends them commands.
Standards and compliance
| Standards and compliance | Notes |
|---|---|
| NFPA 855 | Installation of stationary energy storage systems, including spacing, detection and ventilation for Li-ion. |
| UL 9540 | Safety of energy storage systems and equipment. |
| UL 9540A | Test method for evaluating thermal-runaway fire propagation in battery energy storage systems. |
| UL 1973 | Batteries for stationary and motive auxiliary power applications. |
| NFPA 86 | Standard for ovens and furnaces (flammable-vapor control in solvent ovens). |
| UN 38.3 | Transport testing for lithium batteries. |
| IEC 61215 / IEC 61730 | PV module design qualification and safety qualification. |
| NFPA 2 | Hydrogen Technologies Code. |
| EPA TSCA (NMP) | US EPA risk evaluation and risk management of NMP under TSCA. |
| NFPA 72 | National Fire Alarm and Signaling Code. |
| IEC 62443 | Industrial automation and control system security. |
Standards are listed with what they cover; numeric values are typical figures, not requirements for every site. FacilityOS supports your compliance work; it does not certify a site.
KPIs the platform tracks
| KPIs the platform tracks | Notes |
|---|---|
| Worst dry-room dew point | Maximum dew point across dry rooms (°F). |
| NMP recovery | Recovered ÷ inlet, or the average across units. |
| Energy per cell | Plant kWh ÷ good cells (or kWh per kWh of capacity). |
| Formation energy recovery | Energy returned ÷ energy discharged. |
| Off-gas events | Monthly stage-1 / stage-2 events. |
Reports
| Reports | Notes |
|---|---|
| Daily dry-room dew point report | Dew point, occupancy, door openings and excursion time per room. |
| NMP recovery & emissions report | Recovery, stack concentration and exceedance time. |
| Formation energy report | Energy, recovery and kWh per cell per rack group. |
| Thermal-runaway event report | Detection timeline, isolation actions and affected lots. |
How we deliver
We can take a New-energy manufacturing project from survey and design through procurement, installation, commissioning and training — all of it, or only the stages you need.
- Site survey & needs assessment
- Solution design
- Procurement
- Installation
- Commissioning & acceptance
- Training
- Go-live & support
Demo site
Sparks Battery Cell Plant
A 24/7 lithium-ion cell plant: NMP solvent recovery, −40°F dew-point dry rooms, regenerative formation with thermal-runaway detection, large chillers and CDA.
Open the Sparks Battery Cell Plant demo site to see this industry with simulated live data: process graphics, video wall, alarm drills and remote adjustment.
Try the live demo