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