Maintenance Improvement Process for Control Emission System in a Pharmaceutical Plant

Abstract

The Scrubber system SC-25 A/B is an emission control system that supports a manufacturing process of oral solid dosage in a pharmaceutical plant located in Barceloneta, Puerto Rico. Although the scrubber in subject is not an actual manufacturing system, it is responsible of removing 99% of volatile organic compound from the air exhausted from manufacturing process. While scrubber operations are highly regulated by the Environmental Protection Agency, several concerns were raised in the pharmaceutical plant due to consistent operational failures due to low flow rate alarms. Performing voice of the customer analysis, data gathering and field visit, the issue was assessed and addressed to provide a solution of improvement. Low flow rates in the scrubber are triggered by the following drivers: effluent water quality, pipe size capacity, and strainer capacity. As a result, short- and long-term improvement proposals were presented to the system owner which includes Preventive Maintenance Revision, Piping and Strainer resizing increase and propose the implementation of local water treatment using biocide for the scrubber. Key Terms ⎯ Emission Control System, Maintenance, Reliability, Scrubbers.