cnx_vinyl/docs/facility-security.md

# Facility: Security and Site Systems

What the plant needs beyond the production machinery. Access control, CCTV,
and whole-factory HVAC control are set requirements; the rest of this list
is what a plant of this profile definitely needs, to be refined during site
design.

## Climate control: whole-factory HVAC

The entire factory runs under continuous HVAC control, covering temperature,
humidity, and particulate matter (PM). This is a set requirement, not an
option per room.

- **Temperature and humidity**: the process spec already demands 20-26 °C at
  35-60% relative humidity for pressing; the same conditioning extends to
  the whole building so materials, masters, packaging stock, and electronics
  never sit outside controlled conditions. PVC compound and paper packaging
  are both humidity-sensitive.
- **Particulate matter**: filtration for the whole plant, with stricter
  tiers by zone. Dust in a groove is an audible defect, so the cutting room
  and galvanics clean room run at the tightest spec with positive pressure;
  pressing and packaging run cleaner than ambient; offices and logistics at
  a baseline tier. Northern Thailand's burning season (roughly February to
  April) brings some of the world's worst PM2.5 episodes, so intake
  filtration and building tightness must be designed for those peaks, not
  for average days.
- **Continuous monitoring and alarms**: temperature, humidity, and PM
  sensors logging in every zone, with alarms on excursions, tied into the
  plant monitoring below.
- **Energy design**: conditioning a whole factory in a tropical climate is
  a major electrical load on top of the process cooling (up to ~650 kW for
  the five presses), and it must
  be included in the solar PV and battery sizing from the start. Heat
  recovery from the press hall (steam, hydraulics, and hot PVC all reject
  heat) and from compressors should feed the design rather than fight it.

## Physical security

- **Access control**: zoned, not just at the gate. Minimum zones: general
  production, galvanics clean room (controlled access is already a safety
  requirement), chemical storage, master/stamper archive, server/IT room,
  finished goods and shipping, and the visitor corridor. Badge or
  biometric, with logs.
- **CCTV**: entrances, perimeter, loading dock, production floor, chemical
  storage, archive. Retention policy to be defined; Thai PDPA (personal data
  protection) applies to camera footage of staff and visitors.
- **Intrusion alarm** with monitoring, covering off-hours.
- **Perimeter and lighting**: fencing appropriate to the site, lit
  approaches and parking.
- **Visitor management**: sign-in, escort rules, no unaccompanied access to
  production or galvanics. Tours run through the glazed visitor corridor
  ([crane, workshop and tours](crane-workshop-tours.md)), which keeps
  visitors out of noise, dust and plating air and so needs no PPE; anyone
  who goes onto the floor itself is escorted and issued PPE at entry as
  before.

## Protecting the irreplaceable

- **Master and stamper archive**: fathers and mothers are unique metal
  parts; a destroyed father can mean re-cutting and re-plating a release.
  The archive room needs fire-rated construction or safes, climate control,
  access logging, and an off-site strategy for the most critical masters.
- **Client audio**: pre-release music is a high-value leak target, and
  labels ask about it before they send masters. Isolated storage for client
  files, encrypted transfer and at-rest storage, strict need-to-know access,
  and a written policy the sales team can show clients.
- **Chemical inventory**: silver nitrate is valuable and regulated; nickel
  salts are hazardous. Locked storage, inventory tracking, and controlled
  issue to the galvanics team.

### Archive room: mobile shelving

Planned (October 2026): the archive in the office is fitted with **mobile
archive shelving**, carriages on floor rails that close up into one block
and open a single aisle where it is needed. The reference is A-Z
Solutions' archive shelving (Vienna; fahrbare Archivregale,
https://www.a-z-solutions.eu/buero-archiv/archivregale, checked October
2026): hand wheel or electric push-button drive, optional front panels,
lockable, and the vendor asks to be involved early because the rails set
requirements on the floor and the room layout. Prices are not published.

**What it holds.** The father and the mother of every side (decided
October 2026, [galvanics](equipment/galvanics.md)): 4 parts per title,
about 1,200 to 2,400 a year at full capacity, in protective sleeves,
standing in labelled boxes. Also paper records that have to be kept as
originals. A reference pressing of every title could go here too; that is
a proposal, not decided.

**Size, estimates.** A 12" father or mother grows on a 14" lacquer: about
35 cm across, 0.25 mm thick, ~9.6 dm² ([plant
operation](plant-operation.html) and galvanics figures), so about 0.2 kg of
nickel. In a sleeve with a separator, assume ~3 mm of shelf per part:
~330 parts and ~75 kg per shelf metre, on 400 mm deep shelves with ~400 mm
clear height, five levels to ~2.2 m. In the Payap scenario's office the
archive is a ground-floor room of about 4 × 5.75 m
([site candidates](site-candidates.md)). With the rails along the long
side it takes two fixed single-sided runs, four double-sided carriages
about 3 m long and one ~0.9 m working aisle: ~150 shelf metres, roughly
50,000 parts, which is 20 years or more of fathers and mothers at full
capacity. Static shelving with an aisle between every pair of runs
would hold about 60 % of that.

**What it asks of the building.**

- **Floor load.** Fully loaded, a double carriage carries about a tonne
  per metre of length: ~11 kN/m² under the shelving block and ~6 kN/m²
  averaged over the room (estimates), above an office floor. The archive stays on the ground slab, and
  that slab keeps the full rating if the slab is zoned lighter under
  offices ([phase 1 RFQ](finance/phase1-construction-rfq.md)).
- **Rails.** Set into the floor screed during fit-out, or on a raised
  floor ramped at the door, so the shelving layout and the rail positions
  are fixed before the floor finish. Rail type, depth and floor flatness
  tolerance come from the shelving supplier.
- **Drive.** A geared hand wheel with an aisle lock is enough for a room
  one or two people use and has nothing to fail; electric drive is an
  option, not a need.
- **The room around it** stays as above: clean-agent gas suppression
  (the suppression designer confirms the agent reaches into the closed
  carriage block), climate control with the archive in the tightest
  monitoring tier ([digital factory](digital-factory.md)), a water-leak
  sensor along the rails, lockable carriages behind the room's access
  control.
- **Locations.** Every box carries a barcode and every position an
  address (carriage, face, level, slot); the factory application records
  each part's archive location there, so a repress order says which box
  to pull.

**Open points.**

- **Quotes:** A-Z Solutions and LPI Rack Range (Thailand), a Bangkok
  manufacturer of office mobile shelving and industrial racking
  ([supplier map](suppliers/equipment-suppliers.md)), against the same spec (carriages ~3 m, five levels, 400 mm
  shelves, at least ~100 kg per shelf level per metre, geared hand wheel
  with aisle lock, central lock, rail embedding detail, delivery and
  installation in Chiang Mai). Steel shelving shipped from Austria is
  heavy, so the A-Z system is the reference spec rather than the default
  buy.
- **Storage format:** sleeves, boxes, passivation and humidity for
  archived nickel parts, from the galvanics vendors
  ([open questions](equipment/galvanics.md#open-questions-for-the-quotes)).
- **Two compartments:** with fathers and mothers in one room, one event
  can take both. Keeping the fathers (rarely pulled) in a second fire
  compartment or off site, and the mothers (pulled for every repress) in
  this room, would meet the off-site point above.

## Fire and life safety

- **Fire detection and alarm** throughout; suppression matched to each zone
  (hot PVC and hydraulic oil in pressing, chemistry in galvanics, paper and
  cartons in packaging/finished goods, and the boiler room).

- **Boiler room safety**: the steam generator (10 bar, 180 °C) needs its own
  room, safety valves, fuel shutoff interlocks, and inspection per Thai
  boiler regulations (Department of Industrial Works requirements, licensed
  boiler operator).
- **Emergency equipment in galvanics**: eyewash stations and emergency
  shower at the plating line, spill kits, and neutralizing agents.
- **Emergency lighting, marked exits, assembly point**, and first-aid
  coverage on every shift.

### Suppression design position: zoned, not full-building gas

A full-building gas suppression system is ruled out: gas agents only work in
sealed volumes that can hold concentration, which a ventilated production
hall with people and loading doors cannot, and CO2 flooding is lethal in
occupied spaces. The design position is zoned suppression:

- **Clean agent gas** (FK-5-1-12, sold as Novec 1230, or inert gas such as
  IG-541) only in small, sealed, high-value rooms: the server/IT room,
  electrical switchrooms, PLC/control cabinets (in-cabinet micro systems),
  and above all the master/stamper archive, where sprinkler water would
  destroy lacquers and paper records and corrode the metal parts even in a
  minor event.
- **Water** (sprinklers, or water mist where equipment matters) for the
  large spaces: production, warehouse, and packaging/finished goods, where
  paper cartons are the largest fire load in the building. The press hall's
  specific risk is a hydraulic oil spray fire (200 L at 180 bar); water
  mist handles oil fires well and is gentler on machines than deluge.
- **Battery stack (BESS)**: gas does not stop lithium thermal runaway. Per
  NFPA 855 practice the stack needs off-gas and early-smoke detection,
  electrical isolation on alarm, physical separation from production
  (ideally its own enclosure), and deflagration venting. Detection and
  containment over suppression.
- **Galvanics**: low fire load (aqueous baths); local clean-agent
  protection for rectifier cabinets is sufficient.

### Fire water supply

Sprinklers, water mist, and hose reels are only as good as the water behind
them. Mains pressure and flow in Mueang Chi cannot be assumed adequate for a
sprinkler demand, so the site carries its own reserve and pumps.

- **Stored reserve: ~200 m³**, in a dedicated fire water tank (planning
  figure: 9 m diameter × 4 m, roughly 204 m³ usable above the pump suction).
  Basis is an Ordinary Hazard Group 2 sprinkler demand of about 1,100 L/min
  over the design area, plus a 950 L/min hose-stream allowance, held for 90
  minutes. **This is a planning estimate, not a fire-engineering
  calculation** — the real number comes out of the hydraulic design.
- **Dedicated, not shared**: the reserve is not drawn on by process or
  sanitary water, and the tank refills automatically.
- **Fire pump set**: duty pump, standby pump, and a jockey pump holding
  ring-main pressure, in a pump house beside the tank. The duty pump needs a
  power path that survives a plant trip (diesel drive, or a supply ahead of
  the main breaker) — the BESS is not a substitute.
- **Ring main and hydrants** around the building, laid out so an appliance
  can reach any elevation, with the yard kept clear for access.
- **Siting**: the tank stands in the front yard between the road and the
  building, reachable directly from the frontage without entering the
  production yard. At 4 m tall it sits well below the building's 7 m low
  eave, so it never shades the roof PV.

**Warehouse racking height drives the real number.** If finished-goods
storage goes above roughly 3.7 m, the commodity classification and sprinkler
design change, and the stored volume grows with them. Fix the racking height
before the fire design is frozen, not after. The
[Payap scenario model](site-candidates.md#payap-scenario-model-october-2026)
draws the 9 m × 4 m tank with its pump house at the front. It also draws
6 m warehouse racking and about twice the floor area this figure was
based on, a paper store among it, so treat ~200 m³ as a floor there,
not as the answer.

The property insurer will drive much of the final specification, so involve
them before the design is fixed. The archive gas system and the BESS
detection affect room layout and belong in the site design brief early.

## Plant systems and monitoring

- **Utility monitoring and interlocks**: fume-extraction interlocks on the
  galvanics line (no extraction, no plating), steam and compressed-air
  pressure monitoring, leak detection, and safe-shutdown sequences.
- **UPS and controlled shutdown** for the IT room, access control, alarms,
  and the press PLCs (a power cut mid-cycle should never leave a press in an
  unsafe state; the battery stack can carry critical loads).
- **Lightning protection and grounding**: northern Thailand has intense
  storm seasons; the PV array, steel structures, and electronics all need a
  proper LPS and earthing design.
- **Environmental monitoring**: the whole-factory HVAC monitoring above
  (temperature, humidity, PM in every zone), with the archive and clean room
  as the most tightly alarmed spaces.

## Compliance anchors (Thailand)

- Factory license (Ror.Ngor. 4) and Department of Industrial Works
  requirements for the machinery classes and chemical quantities involved
- Boiler registration and licensed operator requirements
- Hazardous substance registration for the plating chemistry
- PDPA compliance for CCTV and personnel data
- Local fire codes and building permits during construction

All of this belongs in the site design brief, so contractors quote it from
day one rather than retrofitting it.