Steam Leak Hazards – 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.

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.

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.