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