Online Leak Sealing – NICCO ENGINEERING SERVICES LIMITED

Emergency Venturi FT Clamp Installation at Propylene Recovery Unit (PRU)

admin — Mon, 13 Apr 2026 07:22:33 +0000

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 follows:

Line Size: 34″ × ¾”, 300#

Media: Propylene

Operating Conditions:

Pressure: 12.0 kg/cm² (Operating) | 18.60 kg/cm² (Design)

Temperature: 30°C (Operating) | 84°C (Design)

Type of Defect: Crack at weld joint

Criticality: Extremely high (Shutdown imminent)

Conventional repair options such as line isolation or replacement were not feasible due to operational constraints and time sensitivity.

Solution Approach

Nicco Engineering proposed and executed a nonstandard, specially fabricated clamp solution, designed specifically for the geometry and constraints of the Venturi FT assembly.

Key aspects of the solution included:

Custom clamp design and fabrication without requiring any site modification

Precision dimensional control, ensuring a perfect fit on first installation

Online Leak Sealing (OLS) to eliminate the defect while the plant remained operational

The execution was carried out jointly with the Belzona technical team, utilizing proven composite repair materials:

NES5B for primary leak sealing

Belzona 1161 & Belzona 5841 for strengthening and complete peripheral sealing

Belzona 9371 reinforcement tape for additional structural integrity

Execution Highlights

Installation completed without any hot work or unit shutdown

Zero safety incidents during a highrisk operation

Successful OLS injections with no post-installation leakage

Flawless coordination between engineering, site execution, and sealing specialists

Outcome & Client Feedback

The intervention successfully averted a potential plant shutdown, safeguarding continuous operations and preventing major production losses.

Client formally acknowledged Nicco Engineering’s performance, highlighting:

Exceptional technical competence

Meticulous planning and preparation

Strict adherence to safety protocols

Precision execution under critical conditions

This project stands as a strong example of Nicco’s capability to deliver innovative, reliable, and safetydriven solutions for complex, highstakes industrial challenges.

NRV Bonnet leakage in a prominent power plant in India

admin — Thu, 14 Aug 2025 06:03:07 +0000

The Problem

In a critical steam-handling section of a prominent power plant in India, a sudden leakage was identified at the bonnet of a 6-inch Non-Return Valve (NRV). The leak was discharging steam and condensate at 8 bar pressure and 180°C temperature, posing serious hazards to nearby equipment, insulation, and most importantly, operational personnel.

The continuous leakage not only threatened to halt a key section of the process unit but was also incurring significant energy losses. Preliminary estimates indicated an hourly steam loss worth several thousand rupees, with risk of progressive damage to nearby components if left unchecked.

Inspection by NESL team & the Solution Offered

Upon immediate intimation, NESL’s Online Leak Sealing Response Team reached the site within hours and conducted an on-site inspection.

Leak Characteristics:

Leak Location: NRV Bonnet Joint
Line Size: 6 inches
Medium: High-temperature steam
Pressure: 8 bar
Temperature: 180°C
Leak Type: Continuous fissure around bonnet circumference

Proposed Solution:

NESL recommended an online sealing intervention using:

Brass wire peening to close open paths
Injection of high-temperature resistant sealing compound (NESL – ½ A) suitable for steam lines up to 200°C

This solution would ensure zero shutdown and minimum disturbance to plant operations.

4. Safety Mitigation Protocols

The job was executed in strict compliance with NESL’s Online Leak Sealing SOP and BIS IS 18159:2023 industrial safety norms:

PPE compliance: All technicians were equipped with fire-retardant overalls, insulated gloves, face shields, and steam-resistant boots.
Permit to Work (PTW) obtained from client maintenance.
Area isolation with barricading and caution signage
Standby safety observer to monitor team health and emergency response
Continuous temperature and pressure monitoring
Toolbox Talk (TBT) conducted before job initiation

5. Execution of the Job

The job was carried out under the supervision of a senior technician with support from two experienced team members. The leak area was first cleaned and checked for temperature to ensure proper bonding. Brass wire peening was then applied around the NRV bonnet to reduce the leak path and help retain the sealing compound. NESL- ½ A compound, suitable for high-temperature steam lines, was injected using a caulking gun in multiple passes to fully seal the area. The compound began curing within minutes, and the team monitored the zone for 30 minutes to ensure the seal held steady with no further leakage.

6. Re-check and Assurance

After full curing a joint inspection was carried out along with the client’s maintenance head.

The sealed area was visually inspected.
No vapor emission or temperature drop observed.

7. Before and After Images

8. Client Appreciation

The client expressed satisfaction over:

The timely response
Professional execution without shutdown
Cost savings by avoiding valve replacement and downtime

This case once again demonstrates NESL’s leadership inemergency online leak sealing services across Indian industries. By complying with BIS IS 18159:2023 standards, adopting zero-downtime repair techniques, and deploying field-proven sealing compounds, NESL helped the power plant avert serious operational and financial loss.

If you are facing a similar problem at your please feel free to reach out to us: https://www.niccoengineering.com/contact-us/

Efficient Online Leak Sealing of High-Pressure Ammonia Vapour & Carbamate Leak at a 1.8 m Flange

admin — Wed, 02 Jul 2025 06:08:34 +0000

In large-scale fertiliser plants, even a small flange leak can cascade into major safety, environmental, and financial consequences. When faced with an ammonia vapour and carbamate liquid leak at 75 bar and 170 °C, Nicco Engineering’s sealing specialists demonstrated how precise inspection, rigorous safety protocols, and the right sealing compound can arrest a critical leak—without a plant shutdown.

The Challenge

At a urea synthesis facility, a flange joint with an outer diameter of 1.8 m and a 32 mm gap began leaking under full operating conditions. Ammonia vapour posed a severe inhalation risk and environmental concern, while the carbamate liquid drained in volume per day—a significant loss to the client. Shutting down for repairs would have cost hundreds of thousands in lost production and restart logistics. An online sealing solution was essential.

Inspection & Detailed Assessment

Manual Inspection:

Visual confirmation of vapour plume and liquid droplets.
Measurement of flange gap uniformity.

Drawing Verification:

Cross-referenced plant piping and instrumentation diagram (P&ID) and mechanical drawings to verify flange dimensions and spacer alignment.
Identified asymmetry in spacer thickness and bolt-hole alignment as likely contributors to uneven sealing surfaces.

Safety Protocols & Site Preparation

Permit to Work (PTW): Secured hot-work and confined-space clearances.
Personal Protective Equipment: Full-face respirators with SCBA, ammonia-rated gas monitors, and acid-resistant suits and gloves.
Emergency Readiness: Standby spill-control and neutralizing agents on hand.

Sealing Solution & Execution

We selected Compound 2B, a BIS-approved material (per BIS IS 18159:2023) capable of withstanding temperatures to 300 °C. NES 2B was injected using an injection gun, gradually the sealant filled the flange gap thereby arresting the leak.

Results & Validation

Pressure Test: Gradual re-pressurization to 75 bar—no detectable leak or pressure drop.
24-Hour Monitoring: Stable pressure readings without deviation.

Impact & Client Feedback

By executing a rapid, well-orchestrated online seal, Nicco Engineering:

Prevented significant production loss during the shutdown.
Mitigated health and environmental hazards without interrupting plant operations.
Demonstrated compliance with national sealing standards.

“Nicco’s team delivered exceptional expertise and safety diligence—halting a critical leak in hours and saving us significant downtime. Their professionalism and the performance of Compound 2B were outstanding.”

Conclusion
This case underscores the value of detailed inspection, adherence to safety and standards, and the selection of a high-performance sealing compound in addressing severe, high-pressure leaks online—safeguarding both people and productivity.

Immediate Resolution of Hazardous Steam Leakage in a 660MW Power Plant

admin — Mon, 01 Jul 2024 09:14:13 +0000

A renowned 660MW power plant in India experienced a hazardous steam leakage incident. The affected line was operating at a high pressure of 140 bar, carrying steam at a temperature of 230°C. The leakage occurred on the body of the Turbine Driven Boiler Feed Pump (TDBFP) flange, posing a significant risk to the plant’s operations and safety.

Inspection and Solution

Upon receiving the emergency call, our service engineers promptly arrived on-site to assess the situation. After a thorough inspection, they identified that our proprietary compound NES 2C was the optimal solution to arrest the steam leakage instantly. The chosen method for application was the drill and tap technique, known for its effectiveness in sealing high-pressure leaks.

Safety Protocols

Safety is paramount in such high-risk situations. Our team ensured that all safety protocols were strictly adhered to before and during the execution of the job. This included isolating the affected area, wearing appropriate personal protective equipment (PPE), and closely monitoring the pressure and temperature of the steam line throughout the repair process.

Execution

Using the drill and tap method, our engineers carefully applied the NES 2C compound to the leaking flange. The compound’s excellent sealing properties and the precision of the drill and tap technique allowed for an immediate cessation of the steam leakage.

Recheck and Assurance

Following the repair, our team conducted a meticulous recheck to ensure that the leakage had been fully stopped. This inspection confirmed that the repair was successful and that the leak had been arrested effectively, providing a temporary but reliable solution until the next scheduled shutdown.

Client Appreciation

The swift and efficient response by the Nicco online leak sealing team was highly appreciated by the client. The quick resolution of the steam leakage not only ensured the safety of the plant but also prevented an expensive and unscheduled shutdown. The client commended our team for their professionalism, expertise, and the quality of service provided under pressure.

Emergency Online Leak Sealing at a prominent (2x800MW) Power Plant in India

admin — Wed, 29 May 2024 09:16:53 +0000

Introduction

In this case study, we examine a critical incident at a (2x800MW) prominent power plant in India that faced a severe steam leak from a valve gland. The leakage involved steam gushing out at an extreme temperature of 300°C and a pressure of 150 bar. The immediate and efficient response of our online leak sealing team played a pivotal role in resolving this high-risk situation.

Situation Overview

Incident Details

Location: A prominent (2x800MW) power plant in India
Issue: Valve gland leakage
Conditions: Steam leakage at 300°C and 150 bar

Emergency Response

Our service engineers promptly responded to the emergency call. Upon arrival, they identified that the valve gland was exposed to high temperatures and water, causing the leakage.

Challenges Faced

The primary challenges included:

High Temperature: The steam temperature of 300°C posed a significant risk to both personnel and equipment.
High Pressure: The pressure of 150 bar required specialized handling to prevent further damage and ensure safety.
Immediate Action Needed: The critical nature of the leak demanded an immediate and effective solution to prevent operational downtime and potential hazards.

Solution Implementation

Leak Sealing Compound: Our proprietary leak-sealing compound, NES-7A, was chosen to address the leakage. NES-7A is renowned for its effectiveness in sealing leaks under extreme conditions, such as high temperature and pressure.

Procedure

Assessment: The engineers assessed the leakage and surrounding conditions to plan the sealing process.
Preparation: Necessary safety measures were implemented to ensure the safety of the team and the plant.
Injection of NES-7A: The leak sealing compound NES-7A was injected into the valve gland area. Its properties ensure a robust seal even under the harshest conditions.
Monitoring: Post-injection, the area was monitored to ensure the leakage was arrested and no further issues arose.

Outcome

The application of NES-7A successfully sealed the leak. Key outcomes:

Immediate Leak Arrest: The leakage was stopped promptly, preventing potential damage.
Safety Ensured: The high temperature and pressure conditions were managed safely without any incidents.
Operational Continuity: The power plant operations continued without significant downtime, showcasing the effectiveness of the solution.

Our expertise and prompt action ensured the safety of personnel and equipment, while maintaining the power plant’s operational integrity. This incident reaffirms the reliability and efficacy of our leak sealing solutions in the most challenging industrial conditions.

Emergency Steam Leak Repair at a Prominent Power Plant in India

admin — Fri, 03 May 2024 07:21:12 +0000

A prominent power plant in India faced a critical issue with steam leakage from a 1″ pipe welding joint, causing concern due to the high pressure and temperature involved. This emergency required immediate attention to prevent further damage and ensure uninterrupted operation of the plant.

Challenge: The welding joint, exposed to high heat and water, had lost its integrity, leading to steam gushing out from a pinhole. This leakage posed a significant risk to the safety and efficiency of the power plant, requiring a rapid and effective solution.

Solution: Our service engineer was summoned to address the emergency promptly. Upon inspection, it was determined that the most effective way to stop the leak was by enclosing the leaking joint with a solid box clamp. This bespoke clamp was fabricated at client’s site, adhering to ASME Sec VIII Div I standards, ensuring it could withstand the operating pressure of 170 kg/cm2 and temperature of 330°C.

Implementation: Our team quickly measured the dimensions and fabricated the box clamp, ensuring a tight fit over the leaking joint. The clamp was installed with precision, and NES 2C was injected through designated points on the clamp to seal the leak effectively.

Result: The installation of the box clamp and injection of NES 2C successfully arrested the steam leakage, resolving the issue to the satisfaction of the client. The prompt response and efficient execution of the repair ensured minimal downtime for the power plant, preventing potential hazards and maintaining operational efficiency.

Safety Compliance: Throughout the repair process, all safety protocols were strictly adhered to, ensuring the safety of our team and compliance with industry standards. This commitment to safety reflects our dedication to providing effective solutions while prioritizing the well-being of our personnel and clients.

Emergency Leak Sealing at a Fertilizer Plant

admin — Tue, 19 Mar 2024 07:02:50 +0000

A prominent fertilizer plant in India, faced a critical syngas leakage from a pipeline joint, with the line operating at a temperature of 370°C and pressure of 134 Bar. The leak posed a significant threat of plant shutdown, which would have resulted in expensive downtime and production losses.

Nicco’s service engineer responded swiftly to the emergency call. Upon inspection, it was determined that the most effective solution was to install a bespoke box clamp around the leaking joint. Nicco’s proprietary leak sealing compound NES-2H, specially designed for syngas operating at high temperatures and pressures, was used to seal the leak.

Execution: Nicco’s design team promptly took precise measurements of the pipe joint, and the box clamp was fabricated in our workshop on an urgent basis. The leak sealing process was executed using the drill and tap method, which efficiently sealed the leak and prevented further damage to the pipeline.

Safety Mitigation: During the operation, Nicco’s team implemented stringent safety measures to ensure the safety of their personnel and the plant. This included the use of appropriate personal protective equipment (PPE), adherence to safety protocols, and the availability of an emergency response plan to address any unforeseen issues.

The Outcome: Nicco’s prompt response and effective leak sealing solution saved the plant from expensive downtime. The client appreciated Nicco’s professionalism and expertise in handling the emergency, which further strengthened their trust in Nicco’s services.

Emergency Valve Body Leak Sealing with NES-2C

admin — Wed, 17 Jan 2024 08:47:08 +0000

In a critical scenario faced by a prominent carbon black manufacturer in India, a 6-inch 1500 class valve body experienced a severe leakage, releasing steam at a pressure of 150 bar and a temperature soaring to 200°C. To tackle this emergency, our service engineers swiftly intervened, employing a bespoke clamp fabricated as per ASME standards. This case study delves into the measured approach and successful resolution of the situation.

NICCO’s team of experienced engineers took immediate action upon discovering the valve body leakage. Recognizing the urgency of the situation, they deployed their expertise to implement an effective solution, preventing potential hazards and minimizing downtime for the carbon black manufacturer. Our engineers chose to enclose the leaking valve by a bespoke clamp to arrest the leakage completely.

Prior to fabricating the bespoke clamp at our workshop, NICCO engineers conducted meticulous measurements. Precision in these measurements was crucial to ensure the clamp’s compatibility with the valve body’s specifications and the severity of the leakage. This approach was essential in crafting a tailored solution for the specific requirements of the emergency.

Our inhouse design team adhered to the ASME standards while designing the clamp by our proprietary design software.

Our engineers opted for the NES-2C compound to address the critical valve body leakage. NES-2C is known for its efficacy in high-temperature and high-pressure applications. Notably, this compound is certified by the Bureau of Indian Standards (BIS), emphasizing its compliance with rigorous industry standards and safety protocols.

The bespoke clamp fabricated by NICCO included strategically placed injection points. NES-2C, the chosen compound, was precisely injected through these points to seal the leakage promptly. This targeted approach ensured the effective application of the sealant without compromising the structural integrity of the valve body.

Throughout the leak-sealing process, NICCO engineers prioritized safety. Rigorous safety protocols were adhered to, including the use of specialized personal protective equipment, implementation of confined space entry procedures, and continuous environmental monitoring. Regular safety briefings ensured that the team remained vigilant and well-prepared for potential challenges.

This case study serves as a testament to NICCO’s capabilities in providing swift and effective solutions in critical scenarios.

Successful Intervention in Pipeline Leakage and Surface Rebuilding at a Leading Power Plant

admin — Tue, 03 Oct 2023 09:41:43 +0000

This case study examines a recent incident involving a pipeline leakage and surface rebuilding job at a prominent power plant. The NICCO Team was called upon to address the issue promptly and efficiently. This report outlines the equipment, operating conditions, and the team’s approach to resolving the problem, including a detailed explanation of the surface rebuilding process and the safety mitigation measures implemented.

1. Introduction:

The NICCO Team was tasked with handling a critical situation at a leading power plant. The incident involved a pipeline leakage and surface rebuilding job, requiring immediate attention to prevent disruption to plant operations and ensure the safety of personnel. This report provides a comprehensive overview of the team’s response, focusing on the detailed surface rebuilding process and the safety measures taken.

2.Equipment and Operating Conditions:

2.1 Equipment:

The pipeline involved in the incident was part of the blast furnace system. Designed to transport water under ambient temperature and pressure, this pipeline plays a vital role in the plant’s operations.

2.2 Operating Conditions:

The line pressure during the incident was recorded at 10 bar and at Ambient temperature. The service fluid in the pipeline was water, which necessitated a swift response to prevent further leakage and potential damage to the surrounding infrastructure.

3. Assessment and Response:

3.1 Initial Assessment:

When the NICCO Team arrived to the power plant, they did a detailed inspection of the pipeline leak and the impacted surface. They pinpointed the source of the leak and assessed the degree of the damage to identify the best course of action. The environmental issue and continual exposure to water caused extensive surface erosion, according to our service engineer.

3.2 Leakage Mitigation and Safety Measures:

To address the pipeline leakage, the team employed a straight box clamp fabricated at Nicco’s workshop. The clamp was specifically designed to fit the pipeline dimensions and ensure a secure and reliable seal. It effectively halted the leakage and prevented any further loss of water. Nicco’s proprietary leak sealant NES-1/2A was injected through the injection points on the clamp to ensure no further leakage happens. During the job was carried out, the team implemented necessary safety measures to protect personnel and the surrounding environment. This included establishing a safe work zone, using appropriate personal protective equipment (PPE), and ensuring proper ventilation to mitigate any potential risks associated with the leakage.

3.3 Surface Rebuilding:

After mitigating the leakage, the NICCO Team focused on rebuilding the damaged surface of the pipeline. The process began with surface preparation, where the damaged area was cleaned and prepared for the application of preventive coating. The team utilized Belzona Polymeric Coating, which also acts as a bonding agent and provides a smooth surface for the subsequent application of strengthening materials.

3.4 Strengthening Support:

To reinforce the repaired surface, the team employed Belzona 9611, Belzona 1161, and Belzona 9341 reinforcement tape. These high-performance materials are specifically formulated for surface rebuilding and provide excellent adhesion, durability, and resistance to water and environmental factors. Belzona 9611 acted as a base coat to ensure proper adhesion, followed by the application of Belzona 9341 reinforcement tape for surface rebuilding. Finally, Belzona 1161 (Super UV-Metal) was applied as a topcoat to provide additional protection against corrosion and erosion.

Post-Repair Evaluation:

Following the pipeline repair and surface rebuilding, the NICCO Team conducted comprehensive tests and inspections to verify the effectiveness of the interventions. They monitored the pressure, flow rate, and system performance to ensure that the repaired pipeline operated efficiently and met safety standards. Furthermore, the team conducted rigorous quality checks to ensure the integrity and durability of the rebuilt surface.

Conclusion:

Through their swift response and expertise, the NICCO Team successfully addressed the pipeline leakage and surface rebuilding job at the leading power plant. Their utilization of a customized clamp, along with the application of appropriate compounds and strengthening support materials, ensured a reliable and long-lasting solution. The team’s commitment to safety

Nicco Online Leak Sealing Team Successfully Arrests Steam Leakage from Valve Body in an Indian Fertilizer Plant

admin — Tue, 03 Oct 2023 06:43:46 +0000

Nicco Online Leak Sealing Team was approached by a leading fertilizer plant in India to address a persistent steam leakage issue from a valve body. Valve body leakage is a common problem in such plants due to exposure to chemicals and unfavourable environmental conditions, leading to rusting and wear. The challenge was to seal the leak insitu, while the valve was under a line pressure of 70 bar and operating at a high temperature of 350 degrees centigrade. The technicians’ high level of skill and expertise, combined with adherence to strict safety and risk mitigation measures, played a crucial role in executing this challenging task successfully.

1. Background

Fertilizer plants are critical infrastructures, and any leakage in their equipment can lead to severe operational inefficiencies, environmental concerns, and safety risks. In this case, the valve body’s leakage was causing significant steam loss, affecting production and operational costs. Furthermore, the high temperature and pressure posed a significant hazard for any repair work, demanding a well-planned and risk-controlled solution.

2. Technical Approach

The Nicco Online Leak Sealing Team decided to enclose the leaking part of the valve using a bespoke clamp to create a safe environment for the repair work. The team fabricated the clamp in their own workshop in West Bengal, ensuring it met the required standards and specifications for the high-pressure and high-temperature conditions.

3. Selection of Sealant

Considering the challenging conditions, the team opted to use NES-2C as the sealing agent. NES-2C is a specialized sealant that has proven to work efficiently in high-temperature environments. It offers excellent resistance to chemicals and prevents further deterioration of the valve, making it an ideal choice for this application.

4. Execution of Repair

With the bespoke clamp fabricated and the NES-2C sealant ready, the highly skilled technicians prepared to carry out the insitu leak sealing. The team meticulously followed all safety protocols and risk mitigation measures to ensure the safety of personnel and the plant’s surroundings.

The repair process involved the following steps:

The area surrounding the valve body was secured, and access was restricted to authorized personnel only.
The bespoke clamp was carefully positioned around the leaking part of the valve body, ensuring a tight and secure fit.
The NES-2C sealant was injected into the valve body through a controlled process, effectively sealing the leakage point.
The technicians monitored the pressure and temperature continuously during the repair process to avoid any unexpected complications.

5. Successful Leak Arrest and Post-Repair Inspection

Upon completion of the leak sealing process, the steam leakage from the valve body was instantly arrested. The repair proved to be effective, as no further steam leakage was observed during the subsequent days of operation.

One month after the repair, a Nicco service engineer revisited the plant to conduct a post-repair inspection. The valve was carefully examined, and it was found to be in excellent condition, with no signs of leakage. The NES-2C sealant had withstood the high-pressure and high-temperature conditions without any degradation, validating its effectiveness in this challenging application.

The success of this insitu repair not only saved the plant from further steam losses and associated operational costs but also contributed to the overall safety and environmental sustainability of the facility.

Nicco’s dedication to safety, adherence to best practices, and commitment to providing innovative solutions make them a reliable partner for leak sealing and repair services in critical industrial settings.