In a refinery, a leak was detected on a 1-inch steam line operating under high-pressure service. The line was carrying steam at 130 bar pressure and 160°C temperature, making the leakage a serious operational and personnel-safety concern. Although the line size was small, the operating pressure made the situation critical. At 130 bar, even a […]
In a chemical plant, a major leakage was observed from a large-diameter flange handling ammonia vapour and carbamate liquid. The flange had an outside diameter of approximately 1.8 metres, with a significant gap of around 32 mm between the flange faces. The equipment was operating at 75 bar pressure and 170°C temperature. Due to the […]
In a chemical plant, leakage was observed from the bolted cover / flange region of a Hot Ammonia Separator. The equipment was operating under high-pressure service, with a process gas mixture containing Hydrogen, Nitrogen and Ammonia. The operating pressure of 150 bar made the leakage a critical maintenance and safety concern. Although the operating temperature […]
An engineered online leak sealing solution using an in-house designed and fabricated ring clamp and NES–2F high-temperature sealing compound. In a renowned power plant in India, a severely corroded bonnet flange on a 6-inch safety valve was releasing high-temperature steam and condensate through a circumferential gap exceeding 14 mm. With the system operating at 14 […]
A gland leak on a valve operating in a high-pressure steam system is more than a maintenance issue. Apart from the continuous loss of steam and energy, an uncontrolled leak can create a serious personnel-safety concern and may progressively affect the surrounding valve components. At a major power plant in India, a severe steam leak […]
The Challenge A leading cement plant in India was experiencing severe abrasive wear on a section of its pulverised coal burner pipe. The pipe transports fine coal particles towards the combustion zone. Continuous exposure to fast-moving pulverised coal had gradually worn the pipe surface, particularly near the furnace-end section where the equipment was subjected to […]
A critical cooling water pipeline at a prominent refinery developed an active leak from a heavily corroded flanged connection. The line was operating at approximately 8 kg/cm² pressure and 50°C, making immediate intervention necessary to prevent further loss of cooling water and avoid disruption to plant operations. Visual inspection showed extensive external corrosion across the […]
The Challenge At a renowned refinery in India, a section of the plant air line had suffered extensive environmental corrosion following prolonged exposure to heat, moisture and outdoor operating conditions. During the initial inspection, Nicco Engineering’s Belzona service engineers observed severe deterioration across several sections of the pipeline. The original coating had broken down, exposing […]
The Challenge A power plant was facing a serious concrete deterioration issue on an external wall structure that had been in service for nearly 25 years. Over time, continuous exposure to the plant environment, elevated operating temperature, weathering, moisture ingress, and natural aging had caused significant degradation of the concrete surface. During inspection, the wall […]
This case happened in a prominent refinery in India, During routine operations, a critical leak was detected at a welded joint on a Venturi Flow Transmitter (FT) line handling Propylene. The defect posed a high-risk scenario, as even a minor failure could have led to a complete plant shutdown, resulting in significant production and financial loss. Key technical details of the line were as […]
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