NICCO ENGINEERING SERVICES LIMITED

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.

Belzona Seals Persistent Cooling Tower Leak at Outlet Pipe Interface

admin — Mon, 16 Mar 2026 07:38:11 +0000

A cooling tower at a leading industrial gas producing facility in India had developed a profuse leakage at the peripheral junction of the concrete wall and the outlet pipe section. The ongoing leakage created a maintenance concern for the plant and required a practical sealing solution that could be applied effectively on site.

The application was carried out in 2025 for an industrial gas producing facility asset with a concrete & metal substrate.

The Challenge

Leakage had been observed on the cooling tower wall throughout the periphery of the outlet pipe section, indicating a failure at the interface between the pipe and the surrounding concrete. Left unresolved, this type of leak can continue to undermine asset condition and leads to plant shutdown. Plant engineers needed a reliable, long-term repair approach that would address the leak without resorting to more disruptive remedial work followed by wrapping of the metal pipeline which was thinned out as well.

The Belzona Solution

Working closely with plant engineers, our Belzona sales engineer recommended a repair strategy using Belzona 4211 in combination with Belzona 4111 (Magma Quartz) for leakage arresting & Belzona 1161- Super UW Metal in conjunction with Belzona –9341 Reinforcement Tape for pipe surface restoration. The system was selected to seal the gap between the pipe and the concrete and create a durable protective layer over the repaired area.

Application Method

The repair was completed in accordance with Belzona Know-How System Leaflets TCC-9. Surface preparation began with chipping off the loose mortor of the concrete followed by manual abrading to ensure the area was properly prepared for application. The cracks and gap between the pipe and concrete were then sealed using Belzona 4211. Once this had been forced into the void, Belzona 4111 was applied over the treated area to complete the repair and provide a robust sealed finish.

Visual Repair Progress

The project photographs show the progression of the repair from visible leakage on the cooling tower wall near the outlet pipe section, through the insertion of Belzona 4211 into the gap, to the final over-application of Belzona 4111 across the repaired area. The completed repair presents a sealed and uniform finish around the pipe interface.

Result

By combining effective surface preparation with a proven Belzona sealing system, the plant was able to address a long-term leak at a critical cooling tower location. The repair delivered a practical in-situ solution and demonstrated how Belzona materials can be used to restore integrity and improve reliability in concrete cooling tower structures.

DM Water Drainage Line Reclamation Using Belzona Solutions

admin — Mon, 17 Nov 2025 10:00:35 +0000

The DM (Demineralized) Water Drainage Pipeline in a critical utility section had suffered extensive corrosion damage due to prolonged exposure to water and environmental factors. Upon inspection, NESL’s service engineers identified severe metal loss and pitting corrosion on both the inner and outer surfaces of the carbon steel line.

Challenge

Replacing the damaged section of the drainage line would have required shutdown of the water treatment unit, extensive cutting, welding, and hydro-testing—making it a costly and time-consuming process. The client therefore sought a cold-applied repair solution that could:

Be executed in situ while the plant remained in operation.
Provide long-term corrosion protection against continuous exposure to DM water.
Eliminate the need for hot work and replacement.

Proposed Solution

NESL recommended a Belzona polymeric repair and protection system comprising:

Belzona 1161 (Super UW-Metal) – for rebuilding and profiling the heavily pitted surface.
Belzona 1321 (Ceramic S-Metal) – as a corrosion-resistant topcoat providing a smooth, hydrophobic finish.
Belzona 9341 Reinforcement Sheet – used to strengthen the repair in high-stress or structural areas.

Application Procedure

All work was carried out by NESL’s certified Belzona applicators under live plant conditions.

Surface Preparation

The pipeline surface was mechanically cleaned using power tools and abrasive blasting (where accessible) to achieve a minimum SA 2.5 surface cleanliness and a surface roughness of 75–125 microns.
All corrosion products and loose scales were removed, and the area was thoroughly degreased using Belzona 9111 (Cleaner/Degreaser).

Rebuilding of Metal Loss

Deep pitting and wall thinning were rebuilt using Belzona 1161.
The material was mixed in the prescribed ratio and applied using a steel spatula to rebuild the original profile of the pipeline.
In areas where the pitting exceeded 3 mm depth, Belzona 9341 reinforcement sheet was embedded into the first layer to provide additional mechanical strength.

Surface Smoothing and Coating

After initial curing, the surface was lightly abraded to achieve a smooth transition.
A full overcoat of Belzona 1321 (Ceramic S-Metal) was then applied in two coats, with contrasting colors to ensure uniform coverage and desired DFT (Dry Film Thickness).
This coating provided an impermeable, corrosion-resistant barrier against DM water and environmental moisture.

Quality Checks and Curing

Coating thickness was verified using a DFT gauge, ensuring consistent coverage (minimum 500 µm total).
After full cure, a spark test was conducted to confirm coating integrity.
The system was then allowed to cure before exposure to service conditions.

Results

The Belzona-applied section was reinstated within 24 hours, avoiding any production loss.
The pipeline integrity was fully restored without any hot work or welding.
The client achieved significant cost savings—over 70% compared to replacement—and gained a durable corrosion protection system expected to last over 5 years in continuous service.

Conclusion

The use of Belzona 1161 & 1321 with 9341 reinforcement provided a cold, safe, and efficient repair method for the DM water drainage line.

This case highlights how NESL’s expertise in polymeric repair technology enables industrial plants to restore critical assets without costly shutdowns, ensuring operational continuity, safety, and sustainability.

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.

In-Situ Repair of Worn Coal Mill Shaft Using Belzona 1111

admin — Wed, 28 May 2025 06:50:46 +0000

The Challenge

A leading thermal power plant in India experienced severe wear at the bearing area of a coal mill shaft. Upon initial inspection, our service engineer observed:

Significant material loss and surface degradation around the bearing zone

Irregular shaft diameter causing potential misalignment with bearings

Signs of accelerated wear likely due to abrasive conditions and operational stress

Risk of imminent failure if left unaddressed, which would lead to extended downtime

This wear was causing operational inefficiencies and posed a risk of unexpected shaft failure, demanding urgent intervention.

Conventional Solution

The traditional repair involved welding metal buildup followed by machining to restore shaft dimensions. This method would require at least 72 hours of downtime and Involves heat input, risking shaft distortion and misalignment. Considering the time and cost constraint involved in replacement of the shaft, client choose to go with cold repair method.

The Belzona Solution

Our service engineer recommended Belzona 1111 (Super Metal). Belzona 1111 is a 2-part epoxy-based repair composite designed for metal repair and protection. It Cures rapidly, minimizing downtime and provides strong adhesion and excellent wear resistance suitable for heavy industrial use.

Application Process

The repair was carried out adhering strictly to Belzona System Leaflets:

Thorough degreasing and cleaning of the shaft surface

Abrasive blasting to near-white metal cleanliness (SA 2.5), ensuring optimal surface profile for adhesion

Verification of surface roughness and cleanliness per Belzona standards

On-site mixing and application of Belzona 1111 by our trained technicians

Entire process completed within 12 hours, allowing fast return to service

The Outcome

60 hours of downtime saved compared to traditional welding and machining

No heat input, so no risk of shaft distortion or misalignment

Shaft restored to precise dimensions with improved wear resistance

Avoided costly shaft replacement and extended operational disruptions

Thermal power plant resumed production promptly with confidence in the repair’s reliability