NICCO ENGINEERING SERVICES LIMITED

Online Leak Sealing of a 1-Inch High-Pressure Steam Line in a Refinery

admin — Wed, 14 Oct 2026 09:13:56 +0000

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 minor leak can discharge steam at high velocity, creating burn hazards, equipment exposure risks and the possibility of progressive deterioration around the leak point.

Immediate shutdown and line isolation were not preferred due to the refinery’s operating requirements. The plant required an engineered online leak sealing solution that could arrest the leak safely while maintaining process continuity.

Nicco Engineering Services Limited carried out the repair using a solid box clamp fabricated in its own workshop and NES-2B sealing compound injected under controlled conditions.

The Engineering Challenge

High-pressure steam leaks demand immediate attention because of the risk they pose to personnel, nearby instruments, insulation and adjacent equipment.

In this case, the small line size did not reduce the seriousness of the job. A 1-inch line operating at 130 bar can release steam with considerable force. The repair arrangement had to provide reliable containment while allowing controlled injection of sealing compound into the leakage path.

The key challenges were:

sealing a high-pressure steam leak without shutdown;
designing a compact but robust clamp for a 1-inch line;
ensuring the clamp could withstand injection pressure and service conditions;
preventing uncontrolled steam escape during installation;
selecting a suitable compound for the pressure, temperature and service medium;
completing the work safely within refinery operating constraints.

Clamp Design and Fabrication

A solid box clamp was selected for this high-pressure application. Compared with light-duty enclosure arrangements, a solid box clamp provides a more robust sealing cavity and better mechanical containment for demanding pressure conditions.

The clamp was fabricated in NESL’s own workshop based on the line size, leak location, available access and required injection arrangement. The design allowed the clamp to fully enclose the affected section and create a controlled cavity for compound injection.

For high-pressure applications, the clamp is a critical part of the pressure-containing repair system. It must be suitable not only for the operating pressure and temperature, but also for the additional forces developed during compound injection.

The Online Leak Sealing Approach

After site assessment, the solid box clamp was installed around the leaking portion of the 1-inch steam line. The clamp was secured to establish a controlled sealing cavity around the leak point.

NES-2B sealing compound was then injected through the provided injection point under controlled pressure. The injection was carried out progressively so that the compound could enter the leak path, build resistance and gradually arrest the steam escape.

As the compound occupied the leakage route, the steam discharge reduced and was finally stopped. The work was completed online, without removing the line from service.

Result

The online leak sealing operation successfully arrested the high-pressure steam leak.

Following completion:

the leakage was stopped;
the 1-inch steam line remained in service;
refinery operation continued without interruption;
personnel exposure to high-pressure steam was reduced;
an unplanned shutdown was avoided;
the plant gained time to plan permanent repair during a suitable maintenance window.

Why This Repair Matters

In refinery operations, steam lines support critical heating, tracing and process functions. Even a small-bore line can become a major concern when it operates at high pressure.

This case demonstrates that successful online leak sealing depends on the complete engineered arrangement: site assessment, clamp design, workshop fabrication, compound selection and controlled field execution.

The sealing compound alone is not the solution. For high-pressure service, the clamp must be designed and fabricated to create a reliable containment cavity and withstand the combined service and injection loads.

Online Leak Sealing of Ammonia Vapour and Carbamate Liquid Leak from a 1.8 m Flange in a Chemical Plant

admin — Wed, 14 Oct 2026 08:54:25 +0000

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 hazardous nature of the process medium and the high operating pressure, the leakage presented a serious safety, environmental and production-continuity concern.

Conventional repair would have required shutdown, isolation, depressurisation and dismantling of the flange assembly. Given the equipment’s criticality and potential production loss, the plant required an engineered online leak-sealing solution that could arrest the leakage while the system remained in operation.

NESL responded with a bespoke clamp-based online leak sealing solution, supported by in-house clamp design, workshop fabrication and controlled injection of NES-2B sealing compound.

The Engineering Challenge

This was not a routine flange leak. The large flange diameter, wide flange gap and hazardous service made the job technically demanding.

A 32 mm gap between flange faces creates a substantial leakage path. At 75 bar, the escaping ammonia vapour and carbamate liquid could not be treated as a minor gasket leak. Any uncontrolled discharge had the potential to expose nearby personnel, accelerate corrosion around the joint, affect adjacent structures and force an unplanned shutdown.

The repair had to address several critical factors:

containment of a hazardous ammonia and carbamate service;
sealing of a wide leakage path around a large-diameter flange;
controlled injection without over-stressing the existing flange assembly;
compatibility of sealing compound with the process medium and temperature;
safe installation of the clamp under live plant conditions;
restoration of containment without disturbing plant operation.

The photographs show the scale of the flange and the complexity of the installed clamp arrangement. The solution required accurate site measurement, proper sealing cavity design and careful planning of injection points around the circumference.

Bespoke Clamp Design and Fabrication

Based on site dimensions and the leakage geometry, NESL designed a bespoke clamp suitable for installation around the 1.8 m OD flange.

The clamp was fabricated in NESL’s own workshop, allowing the repair to be tailored to the actual flange profile, available clearances, bolt layout and sealing requirement. The clamp was designed to create a controlled sealing cavity around the leaking joint and to provide multiple injection points for uniform distribution of the sealing compound.

For such applications, clamp design is an integral part of the repair. The clamp is not merely a cover; it becomes part of the temporary pressure-containing sealing system. Therefore, the design and fabrication approach considered the operating pressure, temperature, flange condition, installation constraints and compound injection requirements.

The Online Leak Sealing Approach

After fabrication, the bespoke clamp was transported to site and installed around the leaking flange. Once the clamp was secured in position, injection fittings were prepared for controlled introduction of the sealing compound.

NES-2B compound was selected for the application considering the process medium, operating pressure and temperature.

The compound was injected progressively through the installed injection points. The objective was to allow the compound to travel through the sealing cavity and occupy the leakage path between the flange faces. Injection was carried out in a controlled sequence to build sealing resistance gradually and avoid sudden pressure imbalance within the clamp cavity.

As the compound filled the leakage path, the discharge of ammonia vapour and carbamate liquid reduced progressively. Injection continued until the leakage was fully arrested and the joint condition was stabilised.

The repair was completed online, without dismantling the flange and without requiring immediate shutdown of the equipment.

Result

The online leak sealing intervention successfully arrested the ammonia vapour and carbamate liquid leakage from the large-diameter flange.

Following completion:

the hazardous leak was contained;
the equipment remained in service;
an unplanned shutdown was avoided;
exposure risk to operating personnel was reduced;
process loss and environmental risk were controlled;
the plant gained time to plan permanent maintenance during a scheduled shutdown.

Why This Repair Matters

Large-diameter flange leaks in ammonia and carbamate service are among the more challenging online leak sealing applications. The risk is not limited to product loss. Such leaks directly affect plant safety, equipment integrity, environmental compliance and production reliability.

This case demonstrates the importance of combining field assessment, engineered clamp design, in-house fabrication and controlled compound injection. The sealing compound alone is not the solution. Successful online leak sealing depends on the complete engineered arrangement: clamp design, sealing cavity, injection strategy, compound selection and safe field execution.

For chemical and fertilizer plants, this approach provides a practical means of maintaining containment and avoiding costly production interruption where shutdown-based repair is not immediately feasible.

Standards and Engineering Reference

Online leak sealing of pressure equipment should be approached as an engineered temporary repair. The repair philosophy should consider applicable pressure containment principles, ASME PCC-2 guidance for repair of pressure equipment and piping, and relevant Indian requirements such as BIS IS 18159:2023 covering online leak sealing compounds and clamp / enclosure design.

In this case, the bespoke clamp and NES-2B injection system were applied as an engineered sealing arrangement to restore containment under live operating conditions.

Online Leak Sealing of Hot Ammonia Separator Flange in a Chemical Plant

admin — Wed, 14 Oct 2026 08:36:01 +0000

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 was moderate at 40°C, the nature of the process medium made the job highly sensitive. The gas mixture contained approximately 54.85% Hydrogen, 18.235% Nitrogen and 12.959% Ammonia, requiring a carefully controlled sealing operation under strict site safety conditions.

For the plant team, immediate shutdown and dismantling of the flange assembly was not a preferred option due to the production impact and the complexity of isolating high-pressure process equipment. NESL was called upon to carry out an online leak sealing intervention while the equipment remained in service.

The Engineering Challenge

A leak on a high-pressure ammonia separator presents a different level of risk compared with ordinary utility leaks.

The concern was not only the visible loss of process gas. The equipment was handling a hazardous gas mixture containing Hydrogen and Ammonia. Hydrogen introduces flammability concerns, while Ammonia exposure presents a direct personnel-safety and environmental hazard. At 150 bar, even a small leak path can discharge with significant velocity and may worsen if not addressed quickly.

The photographs show a heavily weathered bolted cover area with multiple injection fittings installed around the leakage zone. The sealing arrangement had to consider the existing flange geometry, available access around the cover, bolt layout, leakage path and the need to introduce sealing compound progressively without imposing uncontrolled stress on the joint

The repair therefore required:
– safe execution on pressurised equipment;
– identification of the active leakage path;
– controlled installation of injection points around the flange / cover region;
– selection of a compound compatible with the service and operating conditions;
– gradual injection to avoid sudden pressure imbalance;
– verification that the leak had been arrested before demobilisation.

The Online Leak Sealing Approach

NESL’s service team first assessed the leakage pattern, flange condition and accessibility around the separator cover. Since the equipment was in live service, the intervention had to be planned to maintain containment throughout the operation.
Injection fittings were positioned around the affected region to create a controlled path for introducing the sealing compound into the leakage zone. NES-2B compound was selected for the application based on the service conditions and the nature of the process medium.

The sealing compound was injected in a controlled and sequential manner. Rather than applying excessive force at one point, the compound was progressively introduced through the prepared injection points so that it could migrate into the available leak path and build resistance within the joint cavity.

As the compound occupied the leakage path, the gas discharge was gradually reduced. Injection was continued until the leakage was fully arrested and stable sealing was achieved.

The work was carried out online, without dismantling the equipment and without requiring an immediate shutdown of the plant.

Result
The online leak sealing intervention successfully restored containment at the hot ammonia separator.

Following completion:
– the leakage from the separator cover / flange region was arrested;
– the equipment continued to remain in operation;
– an unplanned shutdown was avoided;
– exposure risk to personnel was reduced;
– loss of process gas was stopped;
– the plant gained time to plan permanent inspection and maintenance during a scheduled shutdown.

Why This Repair Matters

In chemical and fertilizer plants, high-pressure equipment leaks can have consequences far beyond the visible leak point. A leak involving Hydrogen and Ammonia can create safety, environmental, reliability and production risks within a very short time.

This case demonstrates the value of engineered online leak sealing when immediate shutdown is impractical. The sealing compound alone is not the solution. Successful online leak sealing depends on correct assessment of the leak geometry, appropriate compound selection, controlled injection pressure, safe execution practices and experienced field judgement.
For plant maintenance and asset integrity teams, such interventions provide a practical way to regain containment and maintain process continuity until a permanent repair can be planned.

Standards and Engineering Reference

Online leak sealing should be treated as an engineered temporary repair and not as a casual maintenance activity. In such applications, the repair philosophy should consider the principles of ASME PCC-2 for pressure equipment repair, applicable pressure containment requirements, and relevant Indian practices such as BIS IS 18159:2023 for online leak sealing compounds and clamp / enclosure design.

In this case, the repair was executed with due consideration to the live operating condition, process hazard, pressure boundary and sealing compound performance.

Arresting a High-Temperature Steam Leak at a Severely Corroded Safety Valve Bonnet Flange

admin — Fri, 09 Oct 2026 09:02:59 +0000

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 kg/cm² and 350°C, the leakage represented an immediate personnel-safety concern, a significant source of energy loss and a potential trigger for an unplanned shutdown of a critical process unit.

For the plant’s maintenance and asset integrity team, the challenge was not simply to arrest the leakage. It was to find a technically suitable intervention that could address the deteriorated flange joint while preserving process continuity and avoiding the production losses associated with isolating the equipment.

Nicco Engineering Services Limited (NESL) responded with a bespoke online leak sealing solution, combining in-house clamp engineering and fabrication with a high-temperature sealing compound to contain the leakage without a planned process shutdown.

The Challenge: Severe Flange Deterioration Under Live Operating Conditions

The leakage originated at the bonnet flange joint of a 6-inch safety valve. Extensive corrosion had compromised the joint geometry, leaving a circumferential leakage path with a local opening exceeding 14 mm.

Unlike a conventional gasket leak, where controlled bolt tightening or gasket replacement may restore sealing under suitable isolated conditions, this case involved significant deterioration of the flange assembly itself.

The continuous discharge of steam and condensate created several operational concerns:

Personnel safety: Exposure to high-temperature steam and condensate presented a serious burn and scalding hazard.
Energy losses: Continuous steam escape represented a direct loss of thermal energy and boiler-generated steam, with preliminary estimates indicating losses worth several thousand rupees per hour.
Equipment deterioration: Prolonged leakage could accelerate damage to adjacent components, insulation and supporting structures.
Production continuity: Conventional flange repair would require equipment isolation and potentially a process interruption, depending on the plant configuration.
Escalating maintenance costs: Delaying corrective action could increase the scope and cost of eventual flange refurbishment or replacement.

With the equipment remaining in operation, conventional joint dismantling and gasket replacement were not immediately practical.

The plant therefore required a repair approach that could contain the leakage while avoiding an unscheduled shutdown, subject to engineering assessment and the site’s safety requirements.

Emergency Response and Technical Assessment

Following the emergency request, NESL’s Online Leak Sealing Response Team mobilised and arrived at the plant within a few hours.

The initial site assessment focused on understanding the leak geometry, the operating conditions and the feasibility of installing an external sealing enclosure around the damaged bonnet flange.

Operating and leakage conditions

Parameter	Site condition
Equipment	Safety Valve
Nominal valve size	6 inches
Leakage location	Bonnet flange joint
Process medium	High-temperature steam and condensate
Operating pressure	14 kg/cm² (approximately 13.7 bar)
Operating temperature	350°C
Nature of damage	Severe corrosion and flange deterioration
Leakage pattern	Continuous circumferential leakage
Local flange gap	Greater than 14 mm
Proposed intervention	Bespoke ring clamp with injected sealing compound

The size of the opening and the deterioration of the existing joint made the repair particularly challenging. An external enclosure had to accommodate the damaged geometry and provide an effective sealing boundary under elevated temperature and pressure.

The assessment also required consideration of the remaining integrity of the existing flange, the mechanical and thermal loads on the proposed enclosure, and the need to preserve the safety valve’s essential operating function.

Based on the site conditions, NESL proposed a custom-engineered ring clamp combined with an appropriate high-temperature sealing compound as the preferred containment methodology, subject to the necessary plant approvals.

NESL’s Engineered Solution: Bespoke Ring Clamp and High-Temperature Sealant

1. Custom Clamp Design and In-House Fabrication

The damaged flange geometry required a purpose-built enclosure rather than a standard off-the-shelf repair clamp.

NESL’s engineering team developed a bespoke ring clamp configured for the bonnet flange assembly and the observed leakage location.

The clamp design considered the operating pressure and temperature, the available installation envelope, the joint geometry, the mechanical loading of the enclosure and the requirements for an effective sealing boundary.

A key advantage was NESL’s in-house capability to design and fabricate custom-engineered clamps at its own workshop.

This integrated engineering and manufacturing capability enabled the proposed sealing arrangement to be tailored to the actual site conditions while reducing dependence on external fabrication vendors—an important consideration during time-sensitive industrial maintenance interventions.

The design approach was informed by established pressure-equipment repair principles, including:

BIS IS 18159:2023: Online Leakage Sealing Systems — Code of Practice.
ASME PCC-2, Article 306: Mechanical Clamp Repair, covering the engineering considerations applicable to mechanical repair clamps.
Applicable ASME pressure-equipment design provisions: Consideration of the relevant construction code and pressure-boundary design requirements for the specific application.

2. Selection of NESL–2F High-Temperature Sealing Compound

NESL selected its proprietary NESL–2F High-Temperature Leak Sealing Compound for the steam-service application.

The compound is specified by NESL for suitable high-temperature applications, with a stated temperature capability of up to 450°C, subject to the applicable product qualification and service limitations.

At an operating temperature of 350°C, the application demanded a sealing material capable of maintaining its intended performance in the presence of steam, elevated temperature and sustained operating pressure.

The selection of the sealing compound was an essential part of the overall repair methodology. The performance of an online sealing arrangement depends not only on the mechanical enclosure but also on the suitability of the sealant for the process conditions and the damaged joint geometry.

3. Controlled Online Sealing Intervention

Following the site safety review and necessary authorisations, the NESL team carried out the online sealing intervention using the purpose-built ring clamp and NES–2F sealing compound.

The repair was undertaken with the objective of establishing an effective containment barrier around the deteriorated bonnet flange without requiring a planned shutdown of the process unit.

The combination of a geometrically matched enclosure and a suitable sealing compound provided an alternative to immediate joint dismantling and gasket replacement.

The principal operational benefit was the ability to address the leakage while preserving plant operation, thereby avoiding the immediate production interruption that could otherwise have accompanied conventional maintenance.

Operational and Commercial Benefits

For plant management, the significance of this intervention extended beyond containing the steam leakage.

Avoidance of an Unplanned Shutdown

By undertaking the intervention online, the plant avoided the immediate need for a planned isolation solely to carry out conventional bonnet flange repair, subject to the continued safe operation of the equipment.

Reduction in Steam and Energy Losses

Containment of the leakage addressed an ongoing source of steam and thermal-energy loss. Preliminary estimates placed the financial impact at several thousand rupees per hour, making timely intervention commercially important.

Reduced Exposure to Escalating Maintenance Costs

Prompt containment reduced continued exposure of nearby equipment and insulation to the escaping steam and condensate, helping limit the potential for secondary deterioration.

Faster Maintenance Response Through In-House Engineering

NESL’s integrated capability for site assessment, bespoke clamp design and workshop fabrication supported a coordinated response to an emergency maintenance requirement.

Improved Shutdown Planning Flexibility

An engineered online intervention can provide the plant with an opportunity to schedule permanent flange refurbishment or replacement during an appropriate maintenance window, rather than allowing the leak alone to dictate an immediate shutdown.

Engineering Perspective: Why This Was Not a Routine Flange Leak

The distinguishing feature of this case was the extent of flange deterioration.

A gap exceeding 14 mm represents a substantially different engineering challenge from minor gasket seepage. It raises questions about the adequacy of the remaining joint, the ability of the proposed enclosure to retain pressure and the compatibility of the repair with the original equipment function.

For online sealing interventions of this nature, established industry practices emphasise the importance of assessing the damaged component, evaluating the suitability of the clamp and sealing system, considering applicable pressure and thermal loads, and establishing an appropriate repair life and follow-up inspection strategy.

ASME PCC-2 provides an internationally recognised technical framework for pressure-equipment repairs, while BIS IS 18159:2023 specifically addresses online leakage sealing systems in the Indian industrial context.

These engineering principles are especially important when repairs are undertaken on safety-critical equipment such as safety valves, where the sealing intervention must not compromise the valve’s protective function.

Conclusion: Containing the Leak Without Compromising Production Continuity

This case demonstrates the value of combining rapid site response, application-specific engineering, in-house clamp fabrication and appropriate high-temperature sealing technology.

By developing a bespoke ring clamp to address a severely deteriorated safety-valve bonnet flange, NESL offered the plant a practical alternative to immediate shutdown-based maintenance.

For asset integrity and maintenance managers, the broader lesson is clear: a properly assessed and engineered online leak sealing intervention can help control urgent leakage, reduce avoidable energy losses and protect production continuity while permanent maintenance is planned.

Through its integrated engineering, fabrication and field-service capabilities, Nicco Engineering Services Limited supports power plants in addressing challenging leakage problems with a focus on safety, equipment integrity and operational reliability.

Online Gland Leak Sealing of a 3-Inch Angle Seat Piston Valve

admin — Tue, 29 Sep 2026 08:53:17 +0000

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 developed from the gland area of a 3-inch Angle Seat Piston Valve. The leakage was traced to the gland packing around the valve stem.

The valve was part of an operating system and immediate isolation or shutdown was not considered feasible. The plant therefore required a repair method that could control the leakage while the valve remained in service.

Nicco Engineering Services Limited carried out an engineered Online Leak Sealing (OLS) intervention to arrest the leak without interrupting plant operation.

Operating Conditions

Equipment: Angle Seat Piston Valve
Nominal Size: 3 inch
Leak Location: Valve gland / gland packing area
Process Medium: Steam
Operating Pressure: 195 kg/cm²
Operating Temperature: 100°C
•
Existing Packing: Metallic gland packing
Leak Sealing Compound: NES Compound 7A

The Engineering Challenge

Gland leaks present a different sealing challenge from conventional flange or pipe-joint leaks.

The leakage path exists around a moving valve stem, and any sealing intervention has to control the escaping process medium without damaging the stem, restricting its movement, or placing uncontrolled loads on the gland assembly.

In this case, the challenge was intensified by the high operating pressure.

The repair therefore had to address several factors simultaneously:

containment of the escaping steam;
retention of the sealing material within the gland region;
controlled introduction of compound into the leak path;
protection of the valve stem and gland assembly; and
safe execution while the system remained pressurised and operational.

The Online Leak Sealing Approach

Before beginning the sealing operation, the gland arrangement and accessible sealing geometry were assessed by the service engineering team.

The existing metallic gland packing formed an important part of the sealing arrangement and provided the necessary mechanical resistance within the gland region.

A suitable injection arrangement was then established around the gland.

NES Compound 7A was introduced through a single injection point under carefully controlled injection pressure.

Rather than simply forcing compound into the gland, the injection was progressively controlled so that the material could migrate into the available leakage path and establish an effective seal around the stem.

As the compound occupied the leak path, the escaping steam was progressively reduced until the gland leakage was arrested.

The work was completed online, without shutting down the operating system.

Result

The intervention successfully restored containment at the valve gland.

Following completion:

the steam leakage was arrested;
the valve remained in continuous service;
an unplanned plant shutdown was avoided;
steam and associated energy losses were stopped;
the immediate personnel-exposure risk around the leaking valve was substantially reduced; and
the valve could remain operational until a permanent inspection and maintenance opportunity during a planned shutdown.

Why This Repair Matters

For power plants, the value of online leak sealing is not simply the elimination of a visible leak.

On critical steam systems, taking equipment out of service can affect generation availability, maintenance planning and plant operating continuity. Where the equipment condition and leak geometry are suitable for online intervention, an engineered leak sealing solution can provide a controlled means of maintaining containment until permanent maintenance can be undertaken during a scheduled outage.

This case also demonstrates an important principle of gland leak sealing: the repair has to be engineered around the existing valve construction, packing arrangement, operating pressure, process medium and available injection path.

The sealing compound alone is not the solution. Successful online leak sealing depends on the complete engineered arrangement and controlled field execution.

Conclusion

The successful sealing of the gland leak on this 3-inch Angle Seat Piston Valve demonstrates the applicability of Online Leak Sealing for selected high-pressure steam valve leaks where immediate shutdown is impractical.

Through assessment of the gland configuration, utilisation of the existing metallic packing arrangement and controlled injection of NES Compound 7A, Nicco Engineering was able to restore containment while keeping the system in operation.

For power plants where equipment availability and personnel safety are both critical, such interventions can provide an effective temporary engineered repair until the equipment can be properly inspected and overhauled during the next planned shutdown.

Belzona Protects a Pulverised Coal Burner Pipe Against Abrasive Wear

admin — Tue, 28 Jul 2026 06:22:34 +0000

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 intense abrasive conditions.

During inspection, the maintenance team identified:

Extensive wear over a substantial length of the pipe
Progressive deterioration of the exposed surface
A high risk of further material loss
The possibility of eventual perforation and premature replacement
An uneven surface profile requiring abrasion-resistant protection

Metal studs were already present on the pipe surface as part of the existing wear-protection arrangement. However, the exposed areas between and around the studs still required a durable protective system.

The Conventional Solution

The conventional repair approach would have involved extensive hardfacing, welding or replacement of the affected pipe section.

These methods could have resulted in:

Longer maintenance downtime
Extensive hot work
Possible heat distortion
Additional handling and alignment requirements
Higher fabrication and replacement costs
Recurring maintenance as the hardfaced surface continued to wear

The plant therefore required a cold-applied system that could utilise the existing studded surface and provide protection against fine-particle abrasion.

Why Belzona Was Recommended

Belzona was recommended because the application required an abrasion-resistant system capable of being applied around the existing metal studs without extensive welding or replacement.

Belzona 1812 and Belzona 1813 were selected according to the temperature conditions across the application area.

The system offered several advantages:

Resistance to fine-particle abrasion
Cold application without heat distortion
Application over irregular and studded surfaces
Reduced requirement for extensive hot work
Protection of the existing pipe structure
Selection of suitable materials according to operating temperature

The Belzona Solution

The existing metal studs were retained and used as part of the repair configuration.

Belzona 1812 and Belzona 1813 were applied over and around the studs to create a continuous abrasion-resistant protective layer. Product selection was based on the temperature criteria of the respective sections of the pipe.

The materials were carefully worked into the spaces between the studs to ensure full contact with the prepared steel surface and to minimise the possibility of voids.

Application Process

1. Inspection and assessment

The pipe section was inspected to determine the extent of abrasive wear and identify the areas requiring protection.

The condition and distribution of the existing metal studs were also reviewed before proceeding with the application.

2. Cleaning and degreasing

The repair area was thoroughly cleaned using an appropriate cleaner and degreaser.

This removed:

Oil and grease
Dust and loose contamination
Process deposits
Other substances that could affect adhesion

The surface was allowed to dry before further preparation.

3. Hand-tool surface preparation

As abrasive blasting was not used, the exposed metal surfaces were prepared using suitable hand tools.

The surface was mechanically roughened to:

Remove loose material and surface contamination
Create a coarse profile
Improve mechanical adhesion
Prepare the spaces around and between the existing studs

Particular care was taken to reach the restricted areas surrounding the metal studs.

4. Application of Belzona 1812 and Belzona 1813

The Belzona materials were mixed and applied in accordance with the temperature criteria of the respective pipe sections.

The materials were firmly pressed:

Around the existing metal studs
Between the studs
Into the prepared surface profile
Across the complete wear-prone area

Careful application ensured that the studded surface was encapsulated and that a continuous abrasion-resistant layer was formed.

5. Inspection and curing

The completed application was visually checked for:

Continuous coverage
Adequate encapsulation around the studs
Absence of visible gaps or voids
Suitable transition between repaired and unrepaired areas

The applied materials were then allowed to cure before the pipe was returned to service.

The Outcome

The completed Belzona system created a continuous abrasion-resistant barrier over the wear-prone section of the pulverised coal burner pipe.

The repair:

Utilised the existing metal studs
Protected the exposed steel between the studs
Reduced the rate of further abrasive wear
Avoided extensive hardfacing and replacement
Eliminated the need for additional heat during application
Allowed different Belzona materials to be selected according to temperature conditions
Extended the service life of the existing pipe section

The combined use of Belzona 1812 and Belzona 1813 provided the cement plant with a practical cold-applied solution for protecting a critical component against recurring fine-particle abrasion.

Online Cooling Water Leak Repaired with Belzona Composite Technology

admin — Tue, 21 Jul 2026 06:14:33 +0000

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 flange, bolts, adjoining pipework, and bend. Water was escaping under pressure from the joint area, while the surrounding metal surfaces displayed significant rusting, scaling, and coating deterioration.

The Challenge

A conventional repair would have required isolation, depressurisation, cutting, welding and replacement of the damaged section. To minimise downtime, the client required an online, cold-applied solution capable of controlling the leak and reinforcing the weakened connection.

The Belzona Solution

A specially designed 304 stainless-steel strip system was installed to provide mechanical restraint and control the active leakage. The affected area was then reinforced using:

Belzona 1161 (Super UW-Metal)
Belzona 9341 Reinforcement Tape

The repair followed a site-engineered adaptation of Belzona Know-How System Leaflet VPF-11a for high-pressure pipe repairs.

Surface Preparation and Application

Loose rust, scale, failed coating and other contaminants were removed using hand and power tools. Surface preparation was not possible due to thinning of the pipeline surface.

Belzona 1161 was mixed at:

2:1 by volume
4:1 by weight

An initial layer was pressed firmly into the prepared surface to fill corrosion pits and improve substrate contact. Belzona 9341 was then saturated with Belzona 1161, wrapped around the repair area with suitable overlap and fully encapsulated with an additional layer of material.

The external substrate temperature was verified before application because Belzona 1161 has a published application range of 5°C to 40°C. At a surface temperature of approximately 40°C, the system required around 12 hours before full mechanical or thermal loading.

Safety and Quality Control

The work was carried out under the site’s permit-to-work procedure with a task-specific risk assessment, controlled access, suitable PPE and continuous coordination with plant operations. No welding or hot work was required.

The completed repair was inspected to confirm secure reinforcement, full encapsulation, sound edges, absence of visible voids and control of the leakage.

The Result

The combined stainless-steel and Belzona repair system successfully controlled the cooling water leak and reinforced the corroded connection without immediate pipeline replacement.

The client benefited from:

Online leak control
No hot work
Reduced shutdown requirements
Faster maintenance response
Reinforcement of the damaged pipeline connection

Conclusion

By combining a 304 stainless-steel strip system with Belzona 1161 and Belzona 9341, the maintenance team delivered a practical cold-repair solution for a critical cooling water leak under demanding operating conditions.

Restoring a Severely Corroded Air Line at a Power Plant with Belzona

admin — Tue, 14 Jul 2026 06:45:35 +0000

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 metal substrate to continuous corrosive attack.

More critically:

Extensive surface corrosion was visible along the air line.
Localised pitting had developed at several locations.
Considerable metal loss was observed in the affected areas.
Some sections had deteriorated to the point of developing air leaks.
The remaining pipeline wall was significantly weakened at critical locations.

The condition of the line made conventional abrasive surface preparation particularly challenging. Aggressive blasting or mechanical preparation of the already thinned pipeline presented a risk of further damaging the substrate and potentially enlarging existing perforations.

The plant therefore required a cold-applied repair solution capable of rebuilding the deteriorated areas and protecting the pipeline against continued environmental corrosion.

The Conventional Solution

The conventional approach would have involved identifying the severely corroded sections and replacing the affected pipework.

This could have required:

Isolation of the air line.
Cutting and removal of damaged pipeline sections.
Fabrication and installation of replacement pipework.
Welding and associated hot work controls.
Inspection and testing before returning the line to service.

Apart from the cost of replacement, the process could significantly increase maintenance time and introduce additional operational and safety requirements within the plant.

Applying a conventional protective coating alone was also not considered sufficient. The pipeline had already suffered substantial metal loss and deep pitting, meaning the deteriorated areas first required rebuilding before an environmental protective coating could be applied.

Why Belzona Was Recommended

The Belzona system was recommended because the repair required more than simply painting the corroded pipeline.

The service engineers needed a solution capable of addressing two separate problems:

1. Restoring deteriorated and pitted areas of the pipeline

Belzona 1161 was selected as the repair material to rebuild areas affected by corrosion and metal loss.

2. Providing long-term environmental corrosion protection

Belzona 5841 was selected as the protective coating system for the repaired pipeline, helping provide a barrier against the heat- and moisture-related environment responsible for the original deterioration.

Most importantly, the cold-applied Belzona repair approach enabled the engineers to restore the affected sections without welding or extensive replacement of the pipeline.

The Belzona Solution

A combination of Belzona 1161 and Belzona 5841 was used to restore and protect the damaged air line.

Belzona 1161

The material was applied to the severely deteriorated areas to rebuild the damaged substrate, fill corrosion pits and restore the profile of the affected pipeline sections.

Particular attention was given to areas where extensive corrosion and localised leakage had been identified.

Belzona 5841

Following the repair of the deteriorated areas, Belzona 5841 was applied as the protective coating system.

The coating provided a barrier between the pipeline substrate and the surrounding environment, helping protect the repaired air line from further corrosion caused by persistent moisture and elevated environmental temperatures.

Application Process

The application was carried out by Nicco Engineering’s trained Belzona service engineers.

1. Initial Inspection

The complete affected air line was inspected to identify:

Severely corroded sections.
Areas of localised pitting.
Locations showing substantial wall loss.
Active leakage points.
Areas requiring rebuilding and protective coating.

The inspection confirmed that aggressive surface preparation was not advisable at several locations because of the reduced remaining metal thickness.

2. Controlled Surface Preparation

The affected sections were carefully prepared to remove loose corrosion, degraded coating and surface contamination.

Unlike a conventional coating application where extensive abrasive blasting may be possible, the preparation process had to be carefully controlled due to the fragile condition of the remaining pipeline wall.

Care was taken not to further damage the severely thinned substrate.

3. Rebuilding with Belzona 1161

Belzona 1161 was applied to the deteriorated sections of the air line.

The material was used to:

Fill deep corrosion pits.
Rebuild areas affected by substantial metal loss.
Restore the profile around damaged pipeline sections.
Reinforce the locally deteriorated areas prior to protective coating.

The material was carefully formed around bends, joints and irregular pipeline geometries to achieve complete coverage of the required repair areas.

4. Protection with Belzona 5841

Following completion of the rebuilding work, Belzona 5841 was applied to the prepared and repaired pipeline surfaces.

The coating system created a continuous protective barrier over the air line, isolating the substrate from the environmental conditions that had contributed to the original corrosion.

The Outcome

The Belzona repair system successfully restored the severely corroded air line without the need for extensive pipe replacement or welding.

The completed repair:

Rebuilt areas affected by severe pitting and metal loss.
Addressed the locally deteriorated and leaking sections.
Restored the profile of the damaged pipeline.
Provided environmental corrosion protection to the repaired surfaces.
Avoided extensive cutting and replacement of the affected air line.
Offered the plant a practical cold-applied repair alternative.

The before-and-after condition of the pipeline clearly demonstrates the extent of deterioration and the transformation achieved using the Belzona composite repair and protective coating system.

From a severely corroded, pitted and leaking air line to a rebuilt and protected pipeline—the repair demonstrated how the correct combination of Belzona materials can address both existing metal loss and the environmental conditions responsible for corrosion.

Restoring an Aged Concrete Wall in a Power Plant with Belzona 4111

admin — Tue, 05 May 2026 08:34:45 +0000

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 showed visible signs of distress, including surface cracking, spalling, exposed and damaged concrete sections, staining, and large areas of uneven, weakened substrate. In some areas, the deterioration had progressed deeply, creating an irregular surface profile and raising concern over further damage if left untreated.

The operating temperature in the area was approximately 120°C, making it essential to select a repair material capable of withstanding the service conditions while restoring the damaged concrete profile.

Conventional Repair Concern

A conventional civil repair would have required extensive surface removal, rebuilding, curing time, and possible disruption to nearby plant operations. The client required a practical, in-situ repair method that could restore the damaged concrete area without a lengthy outage or complex reconstruction work.

Why Belzona?

Belzona offered a cold-applied repair alternative that could be carried out directly on site. The solution allowed the damaged concrete surface to be rebuilt and profiled without hot work, helping the plant avoid unnecessary operational disruption while improving the condition of the aged wall.

Belzona 4111 was selected for the repair due to its suitability for rebuilding and resurfacing damaged concrete surfaces. The material provided a strong repair system for restoring the uneven and deteriorated wall section and creating a smoother, more protected surface.

The Belzona Solution

The damaged concrete wall was first inspected to identify loose, cracked, and weakened areas. All loose concrete, contaminants, dust, and friable material were removed from the repair zone to achieve a sound substrate for application.

After surface preparation, Belzona 4111 was mixed and applied to the damaged areas of the concrete wall. The material was used to rebuild the lost profile, fill irregular sections, and restore the surface geometry. Special attention was given to the severely degraded zones, cracks, edges, and uneven areas to ensure proper coverage and continuity of the repair.

The application was carried out in situ around the plant structure and nearby pipe supports. The Belzona material was carefully spread and finished to provide a uniform repaired surface over the affected concrete section.

Products Used

Belzona 4111 – Used for rebuilding, resurfacing, and repairing the deteriorated concrete wall.

Application Area

The repair was performed on a concrete wall structure in a power plant that had been in service for approximately 25 years.

Operating Conditions

The repaired area was exposed to an operating temperature of approximately 120°C.

The Outcome

The Belzona repair restored the damaged concrete wall surface and improved the condition of the deteriorated area without the need for major civil reconstruction. The before photographs showed heavy surface degradation, cracking, staining, and loss of concrete profile. After application, the affected areas were rebuilt with a smoother and more uniform finish using Belzona 4111.

The repair helped the plant address the aging-related concrete damage in a practical and cost-effective manner while avoiding the delays typically associated with conventional repair methods.

Key Benefits

✅ In-situ repair – Work was completed directly at site without major dismantling or reconstruction.
✅ Cold-applied solution – No hot work was required during the repair process.
✅ Profile restoration – Damaged and uneven concrete areas were rebuilt with Belzona 4111.
✅ Reduced downtime – The repair approach helped avoid a lengthy conventional civil repair process.
✅ Improved surface condition – The deteriorated wall section was restored to a smoother, more protected finish.

Conclusion

This application demonstrates how Belzona 4111 can be used as an effective solution for restoring aged and damaged concrete structures in demanding industrial environments. For this power plant, the repair provided a practical way to address deterioration on a 25-year-old concrete wall exposed to high operating temperature, helping extend the serviceability of the structure and reduce the need for extensive civil replacement work.

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.