In our first Facility Monitoring and Control System (FMCS) blog, we examined the differences between an FMCS system and a BAS system and where each fit. In this blog we’ll dive deeper into how FMCS systems are deployed in semiconductor, data center and life science industries. In these mission critical environments maintaining tight control over facilities is about more than comfort or efficiency. It is essential for ensuring product quality, data integrity, and uptime reliability.
What is a Facility Monitoring and Control System (FMCS)?
An FMCS is a comprehensive facility management platform that combines control and monitoring across a facility’s critical systems. In essence, an FMCS extends the capabilities of a BMS/BAS (which typically handles HVAC, lighting, etc.) by adding real-time monitoring, data logging, analytics, and integration of additional subsystems. For example, an FMCS may manage climate control like a BAS, but simultaneously monitor a wide range of environmental parameters (temperature, humidity, pressure, air quality, etc.) in real time. It’s often deployed in environments where even minor deviations can have serious consequences such as semiconductor cleanrooms or data centers and is built with reliability and regulatory compliance in mind.
FMCS platforms can also integrate with specialized monitoring systems, pulling in data from systems such as an Electrical Power Monitoring System (EPMS) or an Environmental Monitoring System (EMS). By tying together BAS functions with EPMS and EMS data, an FMCS acts as a central nervous system for the facility, controlling equipment setpoints and collecting continuous data from power infrastructure and environmental sensors in one place. This integration means facility engineers and operators have a complete view of both the utilities (power, HVAC, etc.) and the environment, which enables quick responses and decisions.
Semiconductor manufacturing facilities (fabs) contain some of the most stringently controlled environments in any industry. Silicon wafers are processed in cleanrooms where even microscopic contaminants or slight environmental fluctuations can ruin production. An FMCS in a semiconductor fab integrates cleanroom environmental controls with continuous monitoring to ensure conditions remain within the tight specifications defined by industry standards like ISO 14644 for cleanroom air cleanliness. For example, ISO 14644-1 Class 5 allows only a very small number of particles ≥0.5 µm per cubic meter; far cleaner than normal room air which would be ISO Class 9. To maintain this, an FMCS monitors airflow rates, filter pressures, and particle counters, adjusting fan speeds and air change rates automatically to keep particulate counts within limits. It also logs these readings to prove compliance with the required cleanroom classification.
Beyond particle control, semiconductor processes require tight temperature and humidity control for equipment calibration and process yields. Typical setpoints might be, say, 21.0 °C ±0.1 °C and 45% ±5% RH in a photolithography area. The FMCS continuously tracks these values across the fab and within equipment enclosures, not only controlling the HVAC but also issuing alarms the instant any sensor drifts out of range. If a wafer fabrication area begins warming beyond the setpoint, the FMCS might automatically increase chiller output or alert technicians before wafers are exposed to out-of-spec conditions. This real-time responsiveness can save an entire batch of semiconductor product by preventing an environmental excursion at the earliest moment.
FMCS in fabs also extends to monitoring critical utilities and systems that support manufacturing. This includes systems like ultra-pure water, process gases, vacuum pumps, chemical delivery and exhaust scrubbers, all of which have parameters that must be within spec to avoid process contamination or safety hazards. The FMCS often interfaces with PLCs or SCADA systems controlling these utilities, centralizing their status and alarms. For instance, the Electrical Power Monitoring System (EPMS) integration means power quality feeding the fab tools is tracked; voltage sags or frequency deviations can be detected and mitigated (e.g., by switching to backup power) in milliseconds. Semiconductor tools are highly sensitive to power disturbances, so the FMCS helps maintain uninterrupted, clean power and coordinates backup generators or UPS systems if needed.
Finally, regulatory and quality compliance in semicon manufacturing benefit from FMCS data. While semiconductor fabs are not regulated by the FDA like pharma, they have ISO-certified quality management systems and often customer audits. FMCS provides the electronic records showing temperature/humidity trends, differential pressures between cleanroom zones, particle counts over time, equipment alarm histories, and more. This documentation proves that the facility environment remained in control throughout each production run – a key part of ensuring product yield and reliability.
In essence, an FMCS is indispensable in a semiconductor facility to maintain the ultra-clean, stable environment that microelectronics production demands. It minimizes costly downtime or product loss by catching problems early (a HEPA filter nearing saturation, a faulty fan, a drifting sensor) and by providing robust redundancy. Fabs that run 24/7 rely on FMCS features like redundant networking and automated failovers so that even if a control module goes down, the climate and monitoring stay uninterrupted. Given that a single hour of downtime in a fab can cost millions, this level of reliability and insight is not just ideal but required.
Data centers are another prime example of mission-critical facilities that greatly benefit from FMCS implementation. FMCS systems in data centers are commonly called DCIM (Data center infrastructure management) systems. In a data center, the primary goals are to maximize uptime of IT equipment (servers, storage, network) and to optimize energy usage of power and cooling infrastructure. DCIM ties together the monitoring of electrical supply (via EPMS) and cooling/HVAC (often via BAS or dedicated controls) to ensure a stable environment for the servers.
One of the core functions in a DCIM is maintaining proper thermal conditions for IT hardware. Servers generate a lot of heat, and if not cooled effectively, they can overheat leading to failures. The American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) publishes environmental guidelines for data centers recommends that server inlet air temperatures be kept roughly between 18 °C and 27 °C for safe operation. Relative humidity and dew point are also constrained to prevent electrostatic discharge or condensation. A DCIM continuously monitors temperature at multiple points (often top, middle, bottom of racks across the room) and controls CRAC/CRAH units and chillers to maintain conditions within these recommended ranges. If a hotspot arises in one aisle, the DCIM can trigger the BAS to increase air flow or cooling to that zone, and it will alarm if any rack inlet exceeds the allowable threshold. This fine-grained monitoring is far beyond what a simple thermostat-based AC control would do, and it often involves hundreds of temperature sensors networked into the DCIM. By keeping temperatures within ASHRAE’s envelope, the DCIM helps protect equipment reliability and longevity, while also identifying opportunities to raise setpoints slightly for energy savings without crossing risk boundaries.
On the power side, data centers have elaborate electrical distribution with redundancy. A DCIM typically integrates the EPMS to monitor utility feeds, switchgear, UPS systems, PDU outputs, and generator status in real time. Power use effectiveness (PUE) calculations, load balancing, and power quality monitoring (voltage, frequency, harmonic distortion) are done to ensure the facility’s power remains clean and sufficient. For example, if a UPS battery string shows a weakness or a breaker trips, the DCIM will immediately alert operators to transfer loads or initiate maintenance. In large data centers pursuing Uptime Institute Tier III or IV reliability, continuous monitoring and fast response are crucial. Tier standards require redundant capacity and fault tolerance – e.g., Tier III mandates multiple power and cooling paths (N+1 redundancy) with 99.982% availability, and Tier IV requires 2N redundancy (fully fault-tolerant) with 99.995% availability. DCIM assists in meeting these standards by ensuring backup systems (like standby generators or cooling towers) kick in seamlessly when needed, and by verifying that at no point is a single failure allowed to bring down operations. The system will alarm on any component failure and often can automate switchover to secondary systems. For instance, if a chiller fails in a Tier IV data center, the DCIM would detect loss of cooling capacity, send alarms, and automatically ramp up spare chillers – all while logging the event for later analysis.
Another important aspect in modern data centers is energy efficiency and capacity planning. DCIM data helps operators identify where they have cooling over-provisioned (cold spots) or under-provisioned (hot spots), enabling intelligent adjustments to airflow management (like installing blanking panels or tuning fan speeds). The integrated view provided by DCIM can correlate power usage and cooling performance with IT load in real time. By analyzing trends, the DCIM might highlight that a particular server row consistently runs cooler than others, suggesting cooling resources could be reallocated, or that certain times of day have power load spikes, prompting preemptive cooling adjustments. All of this contributes to efficiency and avoiding wasted capacity.
From a security and redundancy standpoint, DCIM often has features like automated failover and remote monitoring. Many data centers are lights-out facilities; if something goes wrong at 3 AM, the DCIM’s alarm management will ensure on-call engineers are notified via multiple channels (text, email, etc.). The system’s redundancy means that even if a monitoring server were to crash, a secondary server would immediately take over monitoring so that no alerts are missed. For example, the DCIM might run on a failover server cluster, or have a local HMI panel that continues to function if the central server is offline. This kind of design aligns with the expectation of near-zero downtime.
In summary, a DCIM or FMCS in a data center environment serves as the nerve center for all facilities operations, integrating cooling and power system management under one umbrella. It ensures compliance with industry guidelines like ASHRAE’s environmental recommendations and helps achieve reliability targets such as those defined by Uptime Institute Tier standards. With real-time visibility and control, operators can trust that their data center’s critical infrastructure is being vigilantly managed around the clock – which in turn protects the uptime of the digital services that depend on that infrastructure.
Pharmaceutical manufacturing plants and biotech laboratories operate under stringent regulations that demand tightly controlled environments. Applicable Good Manufacturing Practices (GMP) outline strict requirements for monitoring critical parameters in these facilities. To meet these demands, it seems like an integrated FMCS would be a natural choice, however FMCS platforms in regulated industries are usually not implemented in the same integrated fashion due to validation requirements. FMCS in GMP environments is often divided into two distinct systems (EMS and FMCS) that operate side by side for regulatory purposes. EMS platforms are validated systems designed to securely log and protect GMP-critical data, while FMCS platforms are primarily focused on facility control and energy optimization. Keeping them separate reduces risk. If the FMCS fails or is modified, the EMS can continue uninterrupted monitoring. This separation also simplifies validation and change control, ensuring that updates to non-GMP systems don’t impact regulated monitoring.
EMS systems are designed in accordance with regulations like FDA 21 CFR Part 11 and EU GMP Annex 11, which govern electronic records and require comprehensive validation and audit trails for any computerized system handling GxP data. In practice, this means an EMS must securely record all relevant data and user interactions in a tamper-evident manner. Part 11, for example, mandates that electronic systems maintain secure, computer-generated, time-stamped audit trails capturing all modifications, along with the user identity and timestamp for each change. To fulfill these data integrity requirements, EMS platforms log events such as system start-ups, user logins/logouts, changes to critical setpoints or alarm limits, and other GxP-critical actions. This level of traceability ensures every adjustment or excursion is documented and can be reviewed during internal or regulatory audits, supporting compliance and accountability.
In life science cleanrooms and controlled areas, the EMS continuously tracks a range of environmental parameters to maintain product quality and regulatory compliance. GMP guidelines (e.g. EU GMP Annex 1) emphasize monitoring of particulate and microbiological contamination along with physical conditions like temperature and humidity, and they prescribe defined alert and action limits for deviations. An EMS in a pharmaceutical facility typically monitors all key cleanroom conditions in real time, including:
These environmental parameters are recorded in a centralized database, where the EMS software can trend the data, generate reports, and compare against specifications. Cleanroom standards like ISO 14644-2 explicitly encourage continuous particle monitoring with defined alert/action thresholds, and the EMS supports this by providing real-time feedback. Whenever any environmental condition drifts out of the acceptable range, the system will issue immediate audible/visual alarms and send electronic notifications to responsible personnel. Alarms in GMP settings are typically classified by severity, and critical excursions may require formal acknowledgment by an authorized user. Modern EMS implementations include robust alarm management tools, for example, requiring users to log in and acknowledge or sign off on critical alarms, with those actions and timestamps recorded as part of the compliance audit trail. This ensures that out-of-spec conditions are not only detected promptly but also properly documented and addressed per procedural requirements.
The FMCS system works in concert with the EMS to control and monitor all facility systems. While the EMS system is a validated GMP system, the FMCS handles non-validated functionality. This includes traditional BAS functions such as HVAC and lighting, but can also extend to things like monitoring process utilities. Life sciences facilities rely on a range of critical utility systems (sometimes called clean utilities). A FMCS integrates these supporting systems so that their status and key parameters are continuously monitored from a centralized command center. For instance, the FMCS can interface with Water for Injection (WFI) generation and distribution loops, tracking storage tank levels, loop circulation temperature, and water quality metrics. Clean steam systems used for sterilization can be monitored for steam pressure and temperature. Compressed gas supplies can be tied in as well and the BAS will log line pressures, flow rates, and dew point, issuing alarms if, say, compressed air pressure falls out of range. Additionally, the FMCS works in concert with the facility’s HVAC systems: it monitors the performance of air handling units, fan filters, and exhaust systems that maintain the cleanroom environment. By bringing these subsystems under one umbrella, the FMCS provides unified oversight of all the critical infrastructure that could impact product quality or regulatory compliance. In practice, such a system might pull data from dozens of distributed sensors on equipment and utility lines (temperature, pressure, flow, etc.) and consolidate it in real time. If any utility parameter deviates beyond preset limits for more than an allowed delay, the FMCS will generate alarm notifications just as the EMS does for environmental excursions. This holistic monitoring approach helps ensure that issues are caught immediately, preventing minor problems from escalating.
An effective FMCS brings a suite of advanced capabilities that address the needs of critical facilities. Some of the key features include:
All these capabilities work in concert to reduce risk and improve operational insight. By deploying a system with these features, facility operators gain a powerful tool to maintain optimal conditions, ensure compliance, and optimize performance continuously rather than reactively.
In high-stakes operations where even a moment of out-of-control conditions can lead to product loss or service downtime, a FMCS/DCIM/EMS is not just a convenience but a necessity. It complements the building’s basic automation by adding a higher level of intelligence and vigilance. As a result, organizations that deploy these systems in their critical facilities gain peace of mind and operational excellence knowing that the environment is being actively guarded and optimized around the clock.
About the Author
Ian Mogab is the Regional Manager and Senior Project Manager leading Hallam-ICS’s Texas expansion. With over 10 years of experience managing large automation and controls projects, he enjoys helping clients improve their processes and manufacturing systems through automation.
Read My Hallam Story
About Hallam-ICS
Hallam-ICS is an engineering and automation company that designs MEP systems for facilities and plants, engineers control and automation solutions, and ensures safety and regulatory compliance through arc flash studies, commissioning, and validation. Our offices are located in Massachusetts, Connecticut, New York, Vermont and North Carolina, Texas and Florida and our projects take us world-wide.