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  • Preliminary Incident Report of BBS Leakage

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    Safrin Sangia
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    A preliminary incident report details a BBS leakage that occurred at a cement plant. On July 16th, a diaphragm pump was replaced due to leakage and tested with no issues. However, on July 17th the BBS system was stopped due to an overflow in the pump room from a loose bolt on a ball valve. Approximately 20 tons of BBS leaked into the area. Immediate actions taken included stopping the kiln, cleaning the overflow, and isolating drainage. Long term corrective actions proposed installing cameras, improving containment, training, and relocating facilities.

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    BBS Leakage.rev

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    A preliminary incident report details a BBS leakage that occurred at a cement plant. On July 16th, a diaphragm pump was replaced due to leakage and tested with no issues. However, on July 17th the BBS system was stopped due to an overflow in the pump room from a loose bolt on a ball valve. Approximately 20 tons of BBS leaked into the area. Immediate actions taken included stopping the kiln, cleaning the overflow, and isolating drainage. Long term corrective actions proposed installing cameras, improving containment, training, and relocating facilities.

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    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
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    16 views8 pages

    Preliminary Incident Report of BBS Leakage

    Uploaded by

    Safrin Sangia
    A preliminary incident report details a BBS leakage that occurred at a cement plant. On July 16th, a diaphragm pump was replaced due to leakage and tested with no issues. However, on July 17th the BBS system was stopped due to an overflow in the pump room from a loose bolt on a ball valve. Approximately 20 tons of BBS leaked into the area. Immediate actions taken included stopping the kiln, cleaning the overflow, and isolating drainage. Long term corrective actions proposed installing cameras, improving containment, training, and relocating facilities.

    Copyright:

    © All Rights Reserved
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    of 8

    Preliminary Incident Report

    NAR1
    1. Preliminary Incident Report of BBS Leakage
    Date 17.07.2012
     Symptom
    - 16 July 13:00 Start to replace diaphragm pump due to leakage in diaphragm
    flange area
    - 16 July 15:15 Repair done, BBS circulation test around 15 minutes by day shift
    crew. The result was no leakage
    - 16 July 17:46 start BBS to Kiln Burner, the range rate was 1.2 – 1.5 tph
    - 17 July 07:06 stop BBS due to information from local if BBS was overflowing in
    the pump room area
    - The leakage was about 20 tons, which identified from level drop very fast from
    04:46 to 07:06 about 23 % level (78 to 55 %)
    - Overflowing from pump room passed to the ditch behind BBS pump room via rest
    room drainage
     Root Cause
    - Leakage in BBS Pump room, which the current finding is due to ball valve bolt
    loose

    1
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt
    Preliminary Incident Report

     Action
    Immediate Action
    - Stop Kiln to reduce impact from dilute water
    - Cleaning overflow in pump room area, ditch, and settling pond
    - Isolated rest room drainage to stop BBS going to the ditch
    - Purchase oil skimmer
    - Conduct water analysis (pH, COD, TDS, and TSS) before and after settling pond
    every 2 hours (for next 48 hrs)
    Action Log
    - Install CCTV for BBS Pump room
    - Install higher dam to avoid overflow to shower and rest room
    - Increase routine inspection and improve awareness
    - Improve Emergency Response in Oil Spillage Procedure & Responsibility
    - Conduct training of emergency Response in Oil Leakage

    2
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt
    Preliminary Incident Report

    - Relocate Shower and rest room to outside BBS facility building


    - Install two permanent water gates equipped with ladders
    - Install material level sensor in the BBS Pump room
    - Review the water leakages source from all unit area to ditch

    3
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt
    Replaced
    diaphragm
    in 16 July
    Leakage
    position
    before repair
    16 July

    4
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt
    Leakage
    position at 17
    July morning
    due to this bolt
    was loose

    5
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt
    Location
    of leakage

    6
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt
    Overflow via
    rest room
    drainage

    7
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt
    Leakage
    Leakage found, BBS
    90 happen 3directly be
    stopped
    85
    Start 2.5
    80 BBS
    Tank 1 Level, ton

    BBS rate, tph


    2
    75
    70 1.5
    65
    1
    Unloading
    60
    BBS delivery
    0.5
    55
    50 0
    8:00
    9:00

    0:00
    1:00
    2:00
    3:00
    4:00
    5:00
    6:00
    7:00
    10:00
    11:00
    12:00
    13:00
    14:00
    15:00
    16:00
    17:00
    18:00
    19:00
    20:00
    21:00
    22:00
    23:00
    LA3-3B1.L1:PV_AVG Level indicator tanki 1 %
    LA3-VA3.F1:PV_AVG BBS rate to kiln (new log) t/h

    8
    6/17/2019/PP
    Holcim Indonesia Manufacturing Directorate Report.ppt

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