Risk Assessment – NICCO ENGINEERING SERVICES LIMITED

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.

Safety Training at Mumbai Branch & Various Client Locations

admin — Tue, 19 Sep 2023 10:47:37 +0000

Safety is not just a priority; it’s our unwavering commitment. We understand that our dedicated technicians and service engineers often find themselves working in hazardous environments. That’s why we leave no stone unturned when it comes to their safety.

Our Safety department plays a pivotal role in ensuring the zero tolerance of accident to our team members along with injury free working environment. Here’s why they deserve our heartfelt appreciation:

Integral Part of Our Operation: Safety training forms the bedrock of our operations in hazardous environments. We don’t compromise when it comes to preparing our workforce for any challenge they may face.

Client-Centric Approach: Our safety training extends far beyond our headquarters. Technicians and service engineers receive comprehensive training at various client locations, ensuring they are well-prepared no matter where they are.

Attention to Detail: Every aspect of the safety training program is meticulously designed. We leave no room for error because we understand that even the smallest oversight can have significant consequences for health and Safety.

We owe it to our Safety Manager Mr. Subrata Das for his dedication, expertise, and tireless efforts in making sure our team operates in the safest possible manner.

Let’s continue to prioritize the well-being of our employees and the preservation of our environment.

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.