I saw a meme abt an anime character being ruberbanded and so like it got me thinking
I’m also a fan of quips such as “all up in the koolaid and don’t even know the flavor”
The manufacturing process involved lots of machining coolant to prevent the high speed tool bits and the parts from overheating and fusing together, and help remove the massive quantity of metal chips/shavings from the drilling areas. The coolant is fantastic for the machining operation and metals in general, but it eats paint and embrittles plastic and rubber. Any cables that are in the exposure zone are in armored cables or metal tubing.
Some of the coolant ends up being aerosolized from the spray and while it is below OHSA's safety limit, it's still enough to slowly degrade the paint inside the facility over time. There are certain areas that have much higher concentration of the mists, but because people rarely work in those areas, the company wasn't concerned.
There was one cabinet full of industrial control systems and network switching gear in that rarely visited area. That thing had been there since the 1980's and saw many modifications (usually with more stuff being added in). Sometime ago, it started having problems and one of the technicians used a thermal imaging camera to confirm that it was an overheating problem.
In an ideal world, they would have either used a bigger electrical cabinet, move some of the stuff elsewhere to lower the thermal load concentration, or install a fan with a filter in front to catch the mists. Instead someone just left the cabinet open and informed their supervisor that the problem was solved.
Guess what coats the wires and cables in the cabinet? Rubber and plastic. And while the circuit boards in the electronics are laminated fiberglass, the components on those boards frequently use plastic shells to protect the silicon chips or other internal components, and are encased in more plastic.
There were also 480V cables and breakers inside of that cabinet as well.
More than a year down the road, the station starts having erratic behaviors and would randomly alarm out. The insulation on the wires in the cabinets were melting or flaking off, allowing bare copper to come in contact with each other. During the troubleshooting, they removed one of the swappable controls module and the plastic housing cracked, with a chunk falling out. Somehow the 480V cables hadn't lost their insulation yet, which would have been a problem if they had metal-to-metal contact somewhere.
And that was I how spent my Thanksgiving week a few years ago, replacing the entire system because everything was... keep reading on reddit ➡