Nicco Online Leak Sealing Team – NICCO ENGINEERING SERVICES LIMITED

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

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

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

The Challenge

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

Inspection & Detailed Assessment

Manual Inspection:

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

Drawing Verification:

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

Safety Protocols & Site Preparation

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

Sealing Solution & Execution

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

Results & Validation

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

Impact & Client Feedback

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

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

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

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

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

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

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

Inspection and Solution

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

Safety Protocols

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

Execution

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

Recheck and Assurance

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

Client Appreciation

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

Emergency Steam Leak Repair at a Prominent Power Plant in India

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

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

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

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

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

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

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

Emergency Valve Body Leak Sealing with NES-2C

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

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

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

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

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

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

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

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

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

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

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

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

1. Introduction:

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

2.Equipment and Operating Conditions:

2.1 Equipment:

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

2.2 Operating Conditions:

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

3. Assessment and Response:

3.1 Initial Assessment:

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

3.2 Leakage Mitigation and Safety Measures:

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

3.3 Surface Rebuilding:

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

3.4 Strengthening Support:

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

Post-Repair Evaluation:

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

Conclusion:

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

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

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

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

1. Background

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

2. Technical Approach

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

3. Selection of Sealant

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

4. Execution of Repair

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

The repair process involved the following steps:

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

5. Successful Leak Arrest and Post-Repair Inspection

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

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

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

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

Nicco Online Leak Sealing Team’s Success in Resolving 14-Inch Valve Gland Leakage at a Thermal Power Plant in India

admin — Tue, 25 Jul 2023 05:26:42 +0000

Valve gland leakage in Boilers is a common issue faced by power plants, this case study highlights how the Nicco Online Leak Sealing Team effectively addressed a critical 14-inch valve gland leakage at a prominent thermal power plant in India.

The valve gland leakage was occurring under extreme operating conditions with a line pressure of 140 bar and a temperature of 540ºC , involving super-heated steam. Prior to contacting Nicco, other leak sealing companies had refused to undertake the task due to its complexity. The power plant was left with no choice but to plan for an expensive and inconvenient shutdown. However, after communication with Nicco, they discovered a viable solution to resolve the issue without disrupting operations.

Leaking Equipment:

The thermal power plant, a key electricity generator, faced a critical issue with a 14-inch valve gland leakage. The leaking valve was responsible for controlling the flow of super-heated steam, leading to substantial steam loss and a potential decrease in plant efficiency. Concerned about the implications of the leak, the plant management sought immediate assistance from Nicco’s Online Leak Sealing Team, known for their expertise in handling complex leak sealing challenges.

2. Safety Precautions:

Understanding the inherent risks associated with attending a high-temperature steam leakage, the Online Leak Sealing Team prioritized safety measures throughout the project. The safety precautions included:

Comprehensive Risk Assessment: Before commencing any remedial actions, the team performed a thorough risk assessment, identifying potential hazards and implementing strategies to mitigate them.

Specialized PPE and Equipment: All team members were equipped with specialized personal protective equipment (PPE), including heat-resistant suits, gloves, goggles, and face shields, to safeguard against exposure to extreme temperatures and steam.

Safety Training: The team underwent extensive safety training to enhance their awareness of high-temperature steam hazards and emergency procedures.

Heat Resistant Barriers: Heat-resistant barriers were erected around the work area to protect the surrounding personnel and equipment from the high-temperature environment.

Continuous Monitoring: Throughout the leak sealing process, the team continuously monitored pressure, temperature, and other critical parameters to detect any abnormal changes promptly.

Emergency Response Plan: A comprehensive emergency response plan was in place, outlining evacuation procedures and immediate medical support in the event of any unforeseen incidents.

3. Leak Sealing Procedure:

The Nicco Online Leak Sealing Team executed a meticulous approach to address the 14-inch valve gland leakage:

Site Assessment: The team thoroughly assessed the leak site, evaluating the severity of the leakage and its impact on plant operations.

NES-2H Leak Sealant Injection: Utilizing their proprietary NES-2H leak sealant, specially formulated for high-temperature and high-pressure applications, the team injected it into the valve gland through EN-8 grade injection gun adaptors. The NES-2H sealant swiftly filled and sealed the leakage path.

Quality Control and Cure Validation: After the injection process, the team ensured the proper curing of the NES-2H sealant to form a durable and reliable seal. Rigorous quality control measures were implemented to verify the effectiveness of the leak sealant.

4. Results and Conclusion:

This successful case study exemplifies Nicco’s capability in handling critical leak sealing challenges in demanding industrial settings. The company’s dedication to safety, advanced leak sealing technology, and skilled professionals solidify their position as a trusted partner for maintenance and repair solutions in the power generation industry in India.

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.