Reopening a Factory - post-COVID 19 lockdown
A serious gas leak happened at the LG Polymer factory in Vizag on 7th May 2020, when the plant was trying to reopen the plant after a prolonged shut owing to the COVID 19 lockdown. (https://www.livemint.com/news/india/andhra-pradesh-chemical-plant-gas-leak-live-updates-6-died-200-reportedly-in-hospital-11588826050031.html).
The consequence of such a failure was disastrous. Eight people, including a child, died and at least 800 were rushed to the hospitals.
To avoid such consequences my suggestions for opening a closed factory after the prolonged lockdown, which was necessitated to contain COVID 19 infection in India are the following:
1. Rank the machines as per their failure rate (refer equipment history for the past year).
2. Only concentrate on the top 10 critical machines (ranked in order of failure rate)
3. List their 'failure modes'
4. Discover other potential 'failure modes' based on the previous condition assessment (e.g. vibration signatures, trends, etc).
5. Segregate the failure modes as -- a) probabilistic and b) deterministic
Deterministic -- where the condition can be determined through tests (fan or pump impellers): Probabilistic -- where condition can't be determined by test (e.g. couplings, electronic cards)
6. Plan replacement of 'probabilistic' elements, if warranted, (based on life assessment and history).
7. Determine the condition of 'deterministic' components through inspections or instrumentation (CBM). Replace if warranted.
8. Change the oil lubricants or test and replace them, if possible.
9. Regrease, (after attempting to take out old grease).
10. Keep instruments in 'warm standby' mode and then check their functioning (Detective Maintenance).
11. Also, apply Detective Maintenance to all pipe joints and flanges and interfaces for possibility of gradual or sudden leakage. Replace as necessary.
12. Take a trial run and check the condition of the machines and instrumentation. Correct abnormalities, if found.
13. Then go for the full run as desired.
CKO and Director, Center for Reliability and Diagnostics; Founder Secretary and Director General, Council of Vibration Specialists
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