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