Belzona 1161 – NICCO ENGINEERING SERVICES LIMITED

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

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

This case happened in a prominent refinery in India, During routine operations, a critical leak was detected at a welded joint on a Venturi Flow Transmitter (FT) line handling Propylene. The defect posed a high-risk scenario, as even a minor failure could have led to a complete plant shutdown, resulting in significant production and financial loss.

Key technical details of the line were as follows:

Line Size: 34″ × ¾”, 300#

Media: Propylene

Operating Conditions:

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

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

Type of Defect: Crack at weld joint

Criticality: Extremely high (Shutdown imminent)

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

Solution Approach

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

Key aspects of the solution included:

Custom clamp design and fabrication without requiring any site modification

Precision dimensional control, ensuring a perfect fit on first installation

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

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

NES5B for primary leak sealing

Belzona 1161 & Belzona 5841 for strengthening and complete peripheral sealing

Belzona 9371 reinforcement tape for additional structural integrity

Execution Highlights

Installation completed without any hot work or unit shutdown

Zero safety incidents during a highrisk operation

Successful OLS injections with no post-installation leakage

Flawless coordination between engineering, site execution, and sealing specialists

Outcome & Client Feedback

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

Client formally acknowledged Nicco Engineering’s performance, highlighting:

Exceptional technical competence

Meticulous planning and preparation

Strict adherence to safety protocols

Precision execution under critical conditions

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

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.

Nicco Online Leak Sealing Team’s Intervention in an Irrigation Line Leakage and Surface Rebuilding at a 900MW Pump Storage Project

admin — Sun, 09 Jul 2023 17:15:43 +0000

This case study showcases the successful intervention by the Nicco Online Leak Sealing Team to address a leakage issue in the Irrigation Line of a 900MW Pump Storage Project. The team conducted a thorough inspection, identified the problem, and implemented a bespoke solution involving the fabrication of a specialized clamp. By utilizing Nicco’s proprietary leak sealant, NES 1/2A, and reinforcing the clamp with Belzona 1161, the team effectively sealed the leakage and ensured the structural integrity of the pipeline.

1. Problem Identification:

During the inspection conducted by Nicco’s service engineer, it was observed that the pipeline suffered from a puncture, and the diameter of the pipe varied from 265 mm to 273 mm, resulting in irregularity. This irregularity posed a challenge during the fixation of the clamp, as gaps were present between the pipe and the clamp bore.

2. Bespoke Clamp Design & Fabrication:

Accurate measurements were taken to fabricate a bespoke clamp that would tightly fit around the leaky pipeline, ensuring a secure enclosure. The fabrication process ensured a precise fit and eliminated any gaps or irregularities between the clamp and the pipeline.

3. Clamp Installation:

The specially fabricated straight box clamp was installed to enclose the leaky pipeline. This clamp provided structural support and ensured a tight seal over the punctured area, effectively preventing further leakage.

4. Injection of NES 1/2A Leak Sealant:

Nicco’s proprietary leak sealant, NES 1/2A, was injected through the injection points on the box clamp. NES 1/2A is a blend of synthetic rubber with non-staining properties mixed with organic and strong inorganic fillers that generate heat resistance behavior. To facilitate this process, EN8 grade injection gun adaptors, manufactured in Nicco’s workshop using advanced CNC machines and modern fabrication systems, were utilized. This step resulted in the instantaneous arrest of the leakage, effectively sealing the damaged section of the pipeline.

5. Surface rebuilding: Application of Belzona 1161:

To reinforce the integrity of the clamp and prevent any potential leakage from the edges, Belzona 1161, a high-performance epoxy coating, was applied along the edge of the box clamp. This application ensured a secure and durable seal, further enhancing the pipeline’s resistance to erosion, corrosion, and chemical attack.

6.1 Why Belzona 1161 was chosen?

Belzona 1161 was chosen for surface rebuilding due to its exceptional qualities and benefits:

a) Adhesion: Belzona 1161 exhibits excellent adhesion to various substrates, including metal, ensuring a strong bond and long-lasting protection.

b) Durability: This epoxy coating provides exceptional resistance to erosion, corrosion, chemical attack, and mechanical stress, enhancing the surface’s durability and preventing further damage.

c) Flexibility: Belzona 1161 can accommodate substrate movement and thermal cycling, making it suitable for applications where flexibility is required.

d) Versatility: The versatility of Belzona 1161 allows for its application in a wide range of environments and service fluids, making it a reliable choice for surface rebuilding projects.

7. Safety Mitigation Steps Implemented:

Prioritizing safety, the Nicco Online Leak Sealing Team implemented the following measures:

a) Risk Assessment: A thorough risk assessment was performed to identify potential hazards associated with the leakage issue, including pressure risks, water exposure, and potential damage to surrounding infrastructure.

b) Safety Equipment: The team ensured they had the appropriate personal protective equipment (PPE) for the job, including safety glasses, gloves, and protective clothing, to safeguard themselves from any potential risks.

c) Safety Procedures: Strict adherence to safety protocols, such as lockout/tagout procedures and work permits, was maintained to minimize risks during the repair process.

Nicco’s expertise in leak sealing, along with their advanced workshop infrastructure and proprietary solutions, demonstrates their commitment to delivering effective and reliable solutions for critical infrastructure projects.