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User (October 2026): we only build tools and interfaces that interact with ERPNext; invoices, stock and the rest are kept there, except telemetry and other machine data. digital-factory.md: standing decision, decisions 2, 3, 6, 7 and 10 rewritten (ERPNext holds every record of the business and of production, including artist gates, metal-part genealogy as serial numbers with parents, and quality inspections; the machine-data store keeps only cycle and record rows, the hash chain and time series, keyed to ERPNext names; ERPNext first, then custom fields or document types in cnx_erp, then a tool, never a second business database). Systems table, architecture labels, factory application section (modules as a table: records in ERPNext, what we build, machine data outside; our only tables are the machine-data ones), ownership table, integration rules 4 and 8, phasing and estimates (cnx_erp app 2 to 3 person-months; total 3.5 to 6). artist-platform.md: campaigns are an ERPNext document from launch, pledges post as advance payment entries; traceability, README, facility security (archive location on the serial number), production timeline (sets per mother on the mother's serial number), crane-workshop spares store, total-investment. Factory console: KPI row no longer touches the postings card (user screenshot); ERPNext page, order card, sidenote and ledger say every record lives in ERPNext and only machine data stays outside; new postings for artist gates, stamper metrology inspections, stamper set serial numbers (grown, retired with play count). Checked headless: Edge dark and light, 1440/1024/390, no overflow or page errors, rows aligned, pw_fc, pw_wo, pw_feed and pw_erp pass.
252 lines
14 KiB
Markdown
252 lines
14 KiB
Markdown
# Facility: Security and Site Systems
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What the plant needs beyond the production machinery. Access control, CCTV,
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and whole-factory HVAC control are set requirements; the rest of this list
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is what a plant of this profile definitely needs, to be refined during site
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design.
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## Climate control: whole-factory HVAC
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The entire factory runs under continuous HVAC control, covering temperature,
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humidity, and particulate matter (PM). This is a set requirement, not an
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option per room.
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- **Temperature and humidity**: the process spec already demands 20-26 °C at
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35-60% relative humidity for pressing; the same conditioning extends to
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the whole building so materials, masters, packaging stock, and electronics
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never sit outside controlled conditions. PVC compound and paper packaging
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are both humidity-sensitive.
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- **Particulate matter**: filtration for the whole plant, with stricter
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tiers by zone. Dust in a groove is an audible defect, so the cutting room
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and galvanics clean room run at the tightest spec with positive pressure;
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pressing and packaging run cleaner than ambient; offices and logistics at
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a baseline tier. Northern Thailand's burning season (roughly February to
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April) brings some of the world's worst PM2.5 episodes, so intake
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filtration and building tightness must be designed for those peaks, not
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for average days.
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- **Continuous monitoring and alarms**: temperature, humidity, and PM
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sensors logging in every zone, with alarms on excursions, tied into the
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plant monitoring below.
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- **Energy design**: conditioning a whole factory in a tropical climate is
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a major electrical load on top of the process cooling (up to ~650 kW for
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the five presses), and it must
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be included in the solar PV and battery sizing from the start. Heat
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recovery from the press hall (steam, hydraulics, and hot PVC all reject
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heat) and from compressors should feed the design rather than fight it.
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## Physical security
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- **Access control**: zoned, not just at the gate. Minimum zones: general
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production, galvanics clean room (controlled access is already a safety
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requirement), chemical storage, master/stamper archive, server/IT room,
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finished goods and shipping, and the visitor corridor. Badge or
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biometric, with logs.
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- **CCTV**: entrances, perimeter, loading dock, production floor, chemical
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storage, archive. Retention policy to be defined; Thai PDPA (personal data
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protection) applies to camera footage of staff and visitors.
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- **Intrusion alarm** with monitoring, covering off-hours.
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- **Perimeter and lighting**: fencing appropriate to the site, lit
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approaches and parking.
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- **Visitor management**: sign-in, escort rules, no unaccompanied access to
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production or galvanics. Tours run through the glazed visitor corridor
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([crane, workshop and tours](crane-workshop-tours.md)), which keeps
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visitors out of noise, dust and plating air and so needs no PPE; anyone
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who goes onto the floor itself is escorted and issued PPE at entry as
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before.
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## Protecting the irreplaceable
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- **Master and stamper archive**: fathers and mothers are unique metal
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parts; a destroyed father can mean re-cutting and re-plating a release.
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The archive room needs fire-rated construction or safes, climate control,
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access logging, and an off-site strategy for the most critical masters.
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- **Client audio**: pre-release music is a high-value leak target, and
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labels ask about it before they send masters. Isolated storage for client
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files, encrypted transfer and at-rest storage, strict need-to-know access,
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and a written policy the sales team can show clients.
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- **Chemical inventory**: silver nitrate is valuable and regulated; nickel
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salts are hazardous. Locked storage, inventory tracking, and controlled
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issue to the galvanics team.
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### Archive room: mobile shelving
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Planned (October 2026): the archive in the office is fitted with **mobile
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archive shelving**, carriages on floor rails that close up into one block
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and open a single aisle where it is needed. The reference is A-Z
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Solutions' archive shelving (Vienna; fahrbare Archivregale,
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https://www.a-z-solutions.eu/buero-archiv/archivregale, checked October
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2026): hand wheel or electric push-button drive, optional front panels,
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lockable, and the vendor asks to be involved early because the rails set
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requirements on the floor and the room layout. Prices are not published.
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**What it holds.** The father and the mother of every side (decided
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October 2026, [galvanics](equipment/galvanics.md)): 4 parts per title,
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about 1,200 to 2,400 a year at full capacity, in protective sleeves,
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standing in labelled boxes. Also paper records that have to be kept as
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originals. A reference pressing of every title could go here too; that is
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a proposal, not decided.
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**Size, estimates.** A 12" father or mother grows on a 14" lacquer: about
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35 cm across, 0.25 mm thick, ~9.6 dm² ([plant
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operation](plant-operation.html) and galvanics figures), so about 0.2 kg of
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nickel. In a sleeve with a separator, assume ~3 mm of shelf per part:
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~330 parts and ~75 kg per shelf metre, on 400 mm deep shelves with ~400 mm
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clear height, five levels to ~2.2 m. In the Payap scenario's office the
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archive is a ground-floor room of about 4 × 5.75 m
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([site candidates](site-candidates.md)). With the rails along the long
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side it takes two fixed single-sided runs, four double-sided carriages
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about 3 m long and one ~0.9 m working aisle: ~150 shelf metres, roughly
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50,000 parts, which is 20 years or more of fathers and mothers at full
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capacity. Static shelving with an aisle between every pair of runs
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would hold about 60 % of that.
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**What it asks of the building.**
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- **Floor load.** Fully loaded, a double carriage carries about a tonne
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per metre of length: ~11 kN/m² under the shelving block and ~6 kN/m²
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averaged over the room (estimates), above an office floor. The archive stays on the ground slab, and
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that slab keeps the full rating if the slab is zoned lighter under
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offices ([phase 1 RFQ](finance/phase1-construction-rfq.md)).
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- **Rails.** Set into the floor screed during fit-out, or on a raised
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floor ramped at the door, so the shelving layout and the rail positions
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are fixed before the floor finish. Rail type, depth and floor flatness
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tolerance come from the shelving supplier.
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- **Drive.** A geared hand wheel with an aisle lock is enough for a room
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one or two people use and has nothing to fail; electric drive is an
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option, not a need.
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- **The room around it** stays as above: clean-agent gas suppression
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(the suppression designer confirms the agent reaches into the closed
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carriage block), climate control with the archive in the tightest
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monitoring tier ([digital factory](digital-factory.md)), a water-leak
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sensor along the rails, lockable carriages behind the room's access
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control.
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- **Locations.** Every box carries a barcode and every position an
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address (carriage, face, level, slot); each part's serial number in
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ERPNext carries its archive location, so a repress order says which box
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to pull.
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**Open points.**
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- **Quotes:** A-Z Solutions and LPI Rack Range (Thailand), a Bangkok
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manufacturer of office mobile shelving and industrial racking
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([supplier map](suppliers/equipment-suppliers.md)), against the same spec (carriages ~3 m, five levels, 400 mm
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shelves, at least ~100 kg per shelf level per metre, geared hand wheel
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with aisle lock, central lock, rail embedding detail, delivery and
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installation in Chiang Mai). Steel shelving shipped from Austria is
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heavy, so the A-Z system is the reference spec rather than the default
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buy.
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- **Storage format:** sleeves, boxes, passivation and humidity for
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archived nickel parts, from the galvanics vendors
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([open questions](equipment/galvanics.md#open-questions-for-the-quotes)).
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- **Two compartments:** with fathers and mothers in one room, one event
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can take both. Keeping the fathers (rarely pulled) in a second fire
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compartment or off site, and the mothers (pulled for every repress) in
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this room, would meet the off-site point above.
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## Fire and life safety
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- **Fire detection and alarm** throughout; suppression matched to each zone
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(hot PVC and hydraulic oil in pressing, chemistry in galvanics, paper and
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cartons in packaging/finished goods, and the boiler room).
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- **Boiler room safety**: the steam generator (10 bar, 180 °C) needs its own
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room, safety valves, fuel shutoff interlocks, and inspection per Thai
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boiler regulations (Department of Industrial Works requirements, licensed
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boiler operator).
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- **Emergency equipment in galvanics**: eyewash stations and emergency
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shower at the plating line, spill kits, and neutralizing agents.
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- **Emergency lighting, marked exits, assembly point**, and first-aid
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coverage on every shift.
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### Suppression design position: zoned, not full-building gas
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A full-building gas suppression system is ruled out: gas agents only work in
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sealed volumes that can hold concentration, which a ventilated production
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hall with people and loading doors cannot, and CO2 flooding is lethal in
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occupied spaces. The design position is zoned suppression:
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- **Clean agent gas** (FK-5-1-12, sold as Novec 1230, or inert gas such as
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IG-541) only in small, sealed, high-value rooms: the server/IT room,
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electrical switchrooms, PLC/control cabinets (in-cabinet micro systems),
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and above all the master/stamper archive, where sprinkler water would
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destroy lacquers and paper records and corrode the metal parts even in a
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minor event.
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- **Water** (sprinklers, or water mist where equipment matters) for the
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large spaces: production, warehouse, and packaging/finished goods, where
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paper cartons are the largest fire load in the building. The press hall's
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specific risk is a hydraulic oil spray fire (200 L at 180 bar); water
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mist handles oil fires well and is gentler on machines than deluge.
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- **Battery stack (BESS)**: gas does not stop lithium thermal runaway. Per
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NFPA 855 practice the stack needs off-gas and early-smoke detection,
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electrical isolation on alarm, physical separation from production
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(ideally its own enclosure), and deflagration venting. Detection and
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containment over suppression.
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- **Galvanics**: low fire load (aqueous baths); local clean-agent
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protection for rectifier cabinets is sufficient.
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### Fire water supply
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Sprinklers, water mist, and hose reels are only as good as the water behind
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them. Mains pressure and flow in Mueang Chi cannot be assumed adequate for a
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sprinkler demand, so the site carries its own reserve and pumps.
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- **Stored reserve: ~200 m³**, in a dedicated fire water tank (planning
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figure: 9 m diameter × 4 m, roughly 204 m³ usable above the pump suction).
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Basis is an Ordinary Hazard Group 2 sprinkler demand of about 1,100 L/min
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over the design area, plus a 950 L/min hose-stream allowance, held for 90
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minutes. **This is a planning estimate, not a fire-engineering
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calculation** — the real number comes out of the hydraulic design.
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- **Dedicated, not shared**: the reserve is not drawn on by process or
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sanitary water, and the tank refills automatically.
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- **Fire pump set**: duty pump, standby pump, and a jockey pump holding
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ring-main pressure, in a pump house beside the tank. The duty pump needs a
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power path that survives a plant trip (diesel drive, or a supply ahead of
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the main breaker) — the BESS is not a substitute.
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- **Ring main and hydrants** around the building, laid out so an appliance
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can reach any elevation, with the yard kept clear for access.
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- **Siting**: the tank stands in the front yard between the road and the
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building, reachable directly from the frontage without entering the
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production yard. At 4 m tall it sits well below the building's 7 m low
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eave, so it never shades the roof PV.
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**Warehouse racking height drives the real number.** If finished-goods
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storage goes above roughly 3.7 m, the commodity classification and sprinkler
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design change, and the stored volume grows with them. Fix the racking height
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before the fire design is frozen, not after. The
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[Payap scenario model](site-candidates.md#payap-scenario-model-october-2026)
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draws the 9 m × 4 m tank with its pump house at the front. It also draws
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6 m warehouse racking and about twice the floor area this figure was
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based on, a paper store among it, so treat ~200 m³ as a floor there,
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not as the answer.
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The property insurer will drive much of the final specification, so involve
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them before the design is fixed. The archive gas system and the BESS
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detection affect room layout and belong in the site design brief early.
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## Plant systems and monitoring
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- **Utility monitoring and interlocks**: fume-extraction interlocks on the
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galvanics line (no extraction, no plating), steam and compressed-air
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pressure monitoring, leak detection, and safe-shutdown sequences.
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- **UPS and controlled shutdown** for the IT room, access control, alarms,
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and the press PLCs (a power cut mid-cycle should never leave a press in an
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unsafe state; the battery stack can carry critical loads).
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- **Lightning protection and grounding**: northern Thailand has intense
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storm seasons; the PV array, steel structures, and electronics all need a
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proper LPS and earthing design.
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- **Environmental monitoring**: the whole-factory HVAC monitoring above
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(temperature, humidity, PM in every zone), with the archive and clean room
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as the most tightly alarmed spaces.
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## Compliance anchors (Thailand)
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- Factory license (Ror.Ngor. 4) and Department of Industrial Works
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requirements for the machinery classes and chemical quantities involved
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- Boiler registration and licensed operator requirements
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- Hazardous substance registration for the plating chemistry
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- PDPA compliance for CCTV and personnel data
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- Local fire codes and building permits during construction
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All of this belongs in the site design brief, so contractors quote it from
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day one rather than retrofitting it.
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