Battery module / pack — New-energy manufacturing
Cell sorting, laser welding and end-of-line testing.
Battery module / pack is a segment of New-energy manufacturing. Below are the systems and equipment FacilityOS covers for it, filtered from the New-energy manufacturing solution.
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.
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 chiller | 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 |
|---|---|---|---|
| Air handler | 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 |
|---|---|---|---|
| End-of-line tester | Core | Tested today · First-pass yield · Test cycle time | |
| Robotic weld cell | Common | Weld current · Parts today · Safety guard tripped | Laser or ultrasonic weld cells. |
| Line controller (OEE) | 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 |
|---|---|---|---|
| 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. |
| Dust collector | 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 |
|---|---|---|---|
| Air compressor | 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) | |
| 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 |
|---|---|---|---|
| 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 center | 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 detector | 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. |
| 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.
Segments of New-energy manufacturing
- Li-ion battery cell
- PV polysilicon / wafer
- PV cell
- PV module
- Energy-storage system integration
- Hydrogen / electrolyzer (optional)
Full New-energy manufacturing solution →
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.