Validating a Disaster Recovery: Ongoing Testing After a Facility Fire

A client experienced a fire in May 2009, which produced corrosive gasses and soot that traveled throughout the large (50,000 sq. ft.) facility. As part of the restoration procedure, electronics (including CNC machine controller boards, PCs and servers) were cleaned by an outside service.

Subsequently, selected electronics hardware was sent to Foresite for evaluation. The key question: Was the hardware sufficiently clean for a normal product life?

We determined, through use of the C3 and ion chromatography (IC) testing, that while the prior cleaning had removed some of the contamination caused by the fire, ionic residues remained between components and the PCB surface, especially on low standoff components. The C3 is capable of extracting residues from high-density, fine-pitch, and low-standoff areas – areas that are especially susceptible to residue entrapment. The C3 test results indicated that the remaining residues were conductive and corrosive. IC identified the specific contaminants and their concentrations. It was concluded that detrimental residues existed in sufficient quantities to result in failures in a 6-18 month timeframe.

Foresite developed a cleaning protocol utilizing an inline cleaning system with heated saponifier, steam rinsing with de-ionized water, and an inline pressure rinse. A cross flow oven was used to dry the assemblies. Proof-of-cleaning testing confirmed the effectiveness of this process – ionic residue concentrations on “re-cleaned” electronics were well below our recommended limits.

However, the story doesn’t quite end there; occasional electronics failures were continuing to occur. Four years after the fire, frequent monitoring of HVAC filters from throughout the facility continued to show concerning levels of ionic contamination in the air. Again, C3 and IC testing (plus XRF testing, when needed) have been used by Foresite on both new (baseline) and exposed air filters. Through this monitoring, trouble areas, such as open space between drop ceilings and the roof, and susceptible electronics hardware have been identified and addressed.

Used Air Filter

New Air Filter

As testing continues to identify any remaining issues and documents the progress and resolution, the happy ending of this story is within reach.