Sealant Application – 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.

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’s Online Leak Sealing Team at a Hazardous Steam Leakage from Valve Gland of Hot Water Drain Line in a Power Plant in India

admin — Tue, 01 Aug 2023 07:21:20 +0000

A hazardous steam leak occurred in the valve gland of hot water drain line at a prominent power plant in India. The leak was located at the valve gland, operating at an elevated pressure of 200 bar and a scorching temperature of 360 degrees centigrade. The severity of the leak posed a significant safety risk and potential operational disruption for the power plant. To address the issue promptly and effectively, Nicco’s Online Leak Sealing Team was called in to provide a solution that ensured safety, minimized downtime, and prevented any further damage.

1. Challenges:

Handling a steam leak of this magnitude in a high-pressure, high-temperature environment required a systematic approach to mitigate risks and safeguard the personnel involved. The key challenges faced by the team included:

Safety Concerns: Dealing with steam leaks at such extreme conditions demanded utmost caution to protect the technicians and the plant equipment.

Operational Continuity: The power plant’s uninterrupted operation was vital, necessitating a solution that allowed repair without shutting down the entire system.

Leak Mitigation: The primary objective was to seal the leak effectively, preventing any further release of steam and avoiding any potential hazards or adverse impacts on the plant’s operation.

2. The Solution:

Nicco’s Online Leak Sealing Team, well-equipped with skilled technicians and advanced tools, arrived at the power plant to address the critical situation. The carefully planned solution involved the following steps:

Risk Assessment and Safety Measures: Before proceeding with any repair work, the team conducted a thorough risk assessment. Proper safety protocols, including personal protective equipment (PPE) and safety guidelines, were followed to ensure the well-being of the technicians.

Online Leak Sealing Process: The video footage captured at the site showed the steam leak emanating from the valve gland. The team decided to utilize a specialized sealant, NES-7A, for sealing the leak effectively. The sealant was chosen for its capability to withstand high pressures and temperatures.

Injection of Sealant: Nicco’s technicians employed a controlled injection technique to deliver the sealant through the valve gland directly into the leak path. The sealant quickly filled the voids and cracks, forming a reliable seal, and stopping any further steam leakage.

Ongoing Safety and Monitoring: Throughout the sealing process, the team continued to monitor the pressure and temperature conditions closely. Regular inspections and safety checks were conducted to ensure no additional leaks or risks arose during the operation.

3. The Outcome:

Nicco’s Online Leak Sealing Team successfully arrested the hazardous steam leak at the hot water drain line valve gland. The prompt and efficient response prevented further steam loss, minimized operational downtime, and ensured the power plant’s continuous functioning. The timely intervention and skillful application of the sealant, NES-7A, safeguarded the personnel and equipment from potential harm.

4. Follow-up Inspection:

To validate the effectiveness of the leak sealing operation, Nicco’s service engineer revisited the power plant after one month. The inspection confirmed that the sealant had maintained its integrity, and there were no signs of leakage during the interim period. The team also rechecked all safety measures and ensured that the repaired section was functioning optimally.