OLS Presentation online leak sealing by nicco

Online leak sealing today is the leak-sealing solution of choice as it saves energy, prevents an expensive and unwanted shutdown, and can address a wide variety of leaks. Through continuous R&D, NESL has developed its own range of proprietary leak sealants that can address a wide variety of steam, chemical, hydrocarbon, and gas leaks at temperatures ranging from -100°C to 850°C and pressures up to 250 bar. Our sealants have been tested in thousands of applications over several years and you can be confident of their performance. We design, test, and manufacture our leak sealing products in-house at our ISO 9001 and ISO 14001 compliant facility, thus assuring quality to the utmost.

1. NICCO ENGINEERING SERVICES LIMITED An ISO Certified Organisation ISO 9001:2015 ISO 14001:2015 ISO 45001:2018 www.niccoengineering.com ONLINE LEAK SEALING

2. Online Leak Sealing Technology, Specification & Safety Parameters www.niccoengineering.com

3. The Following Industries suffer due to Leakages in the Process Equipment REFINERY PETROCHEMICAL POWER FERTILIZER CEMENT STEEL CHEMICALS etc. www.niccoengineering.com

4. Failure of Flanges / Bonnet Gasket Failure of Gland Packing Pin Holes in Weld Joints Cracks in Pipe Line Corrosion, Erosion, Abrasion Caused Thin Down of Pipe Lines Resulting Leakages Galvanic Corrosion in Heat Exchangers / In any Bi-metallic Joints Causes of Leakage www.niccoengineering.com

5. Water Air Steam Oil Nature of Fluids Hydrocarbon Gases Various Chemicals Temperature - 100 ° C to 850 ° C www.niccoengineering.com

6. Injection Process Compound flows into the cavity and forms a secondary gasket. Injection of compound through injection point (opposite to leak area). www.niccoengineering.com

7. Injection Process Injection of compound from 2 nd injection point www.niccoengineering.com

8. Injection Process Injection of compound from 3 rd injection point www.niccoengineering.com

9. Injection Process Final stage of injection www.niccoengineering.com

10. Need Safety Assessment / Design & Testing of Equipment Being Used in Online Leak Sealing Process Online Leak Sealing is the most hazardous process in the industry www.niccoengineering.com

11. Major Items Needed for Online Leak Sealing Process Adaptors / Restrictors Clamps Leak Sealing Compounds Theses Items become part of process system during and after Leak Sealing Process www.niccoengineering.com

12. Adaptor Design & QA Plan All material to be tested for chemical composition and tensile strength to ascertain the quality. Adaptor to used from 100% tested quality of material of EN8/EN24/SS grade based service condition. Type test for pressure withstanding capacity. In process QA plan & control is required during manufacturing of adopter to remove any hair crack. Adaptor www.niccoengineering.com

13. Adaptor / Restrictor www.niccoengineering.com Allows compound to flow inside only

14. Clamp design & fabrication ASME Standard PCC-2 provides general guideline for design, installation and repair of pressure equipment and piping. ASME B31.3 and ASME BPVC Sec. VIII Div. I and Sec. II part D provide the allowable stress loads along with necessary design calculations.  Applicable Codes and Standards for Design of Clamp www.niccoengineering.com

15. Design criteria of a clamp Clamps are designed based on pressure, temperature and leaking media. Design is based on Boiler & Pressure Vessel Code, ASME Section VIII. All welding are done as per deep penetration fillet welding. All welding should have NDT Test. Special clamp can be recommended for Radiography Test. www.niccoengineering.com

16. Types of Clamp Ring Clamp Box Clamp Tee Clamp www.niccoengineering.com Bend Clamp Clamp for mightier bend Special Clamp for critical site condition

17. 17 Design of Ring Clamp Design Parameters Line Size Design Pressure Operating Pressure www.niccoengineering.com Design Temperature Operating Temperature Min. Gap Between Flange

18. Typical Design / Drawing of Ring Clamp www.niccoengineering.com

19. Ring Clamp www.niccoengineering.com

20. Line Size Design Pressure Operating Pressure Design of Box Clamp Design Parameters Design Temperature Operating Temperature www.niccoengineering.com

21. Typical Design / Drawing of Box Clamp www.niccoengineering.com

22. Box Clamp www.niccoengineering.com

23. Leak Sealing Compound Design www.niccoengineering.com Steps of compound development: Select suitable Polymers / Blend Design compound formulation with different ingredients Lab evaluation / Shop floor processing trial Testing in the lab / R&D to meet objectives Evaluate processability Compound to make environment friendly Field trial

24. Physical Properties of Polymers www.niccoengineering.com Large permanent deformations without breaking, some are stiff and strong, some are soft and flexible and others can withstand impact without breaking. All those “mechanical properties” are peculiar to the polymer. The magnitude of interactions is dependent upon the nature of the intermolecular bonding forces and the molecular weight. The amount of interaction is different in different polymers and quite often different in different samples of the same polymer.

25. Chemical Properties of Polymers www.niccoengineering.com The chemical properties of polymers are very similar to those of analogous small molecules. A functional group attached to a polymer chain generally reacts. The rates at which these pendent groups undergo reactions , however, can be quite different. The reactivity of pendent functional groups can be substantially increased by the presence of suitable neighboring groups and environment.

26. Compounds Compounds are selected based on temperature, pressure and leaking medium Compounds are subject to following test for safe use Specific Gravity Rheological Study Auto Ignition Temperature Thermo-gravimetric Analysis (Degradation properties) www.niccoengineering.com

27. Characteristics of compound Specific Gravity Ratio of the weight of a given substance, to the weight of an equal volume of water, at a given temperature (Tested as per IS3400 Part 3 - 2003) Should be in the range of 1.25 to 2.10 Defines the flowability of the Compound www.niccoengineering.com

28. Characteristics of compound Rheological Study Rheometer describes curing & processing characteristics of compounds. Defines the curing time and flow. Curing rate kept in the range of 15 to 30 min depending upon the nature of application. www.niccoengineering.com

29. Auto-Ignition The auto-ignition temperature of a substance is the lowest temperature at which it will spontaneously ignite in a normal atmosphere without an external source of ignition, such as flame or spark (as per ASTM E659). Auto-ignition temperature of a compound defines its safe use at that temperature , pressure & presence of Oxygen. Characteristics of compound www.niccoengineering.com

30. Thermo-gravimetric Analysis TGA measures the amount and rate of change of weight of a material as a function of temperature or time in a controlled atmosphere. This is done to predict the thermal stability of the compound at the specified temperature (as per ASTM E1131). Max 25% of degradation of compounds at the specific temperature is the acceptable limit. Characteristics of compound www.niccoengineering.com

31. Compound Code Features Temperature NES ½ A Blend of synthetic rubber with non-staining properties mixed with organic and strong inorganic fillers generate heat resistance behavior. Suitable for Steam, Boiler feed water and wide rages of chemicals. 100 C– 250 C NES 1 B Blend of synthetic rubbers with non-staining polymers mixed with special chemicals and active inorganic filler enhance heat resistance properties. Suitable for Feed water, Ammonia gas. 80 C– 200 C Compound Selection Guide

32. Compound Selection Guide Compound Code Features Temperature NES 2 B Blend of rubbers with polar group and strong covalent chain mixed with active inorganic fillers offer excellent resistance to chemicals. Suitable for Hydrocarbon, Sea water, Higher Aniline Point Mineral Oil above 100 Bar. 160 – 300 C NES 2 C Blend of rubbers with non staining polymers mixed with organic, inorganic fillers and heat resistant fiber offer chemical resistance behavior. Suitable for Hydrocarbon, Higher Aniline Point Mineral Oil upto 100 Bar 160 – 350 C

33. Compound Code Features Temperature NES 2 F Inorganic based synthetic rubber having high bond strength in the chain reinforced with filler of heat resistant fiber produce high heat resistant compound. Suitable for Super Heated Steam, Hydrogen gas, Hydrocarbons and Flu gas. 250 – 450 C NES 2 G Special fluro polymer mixed with organic filler and heat resistant fiber generate resistance to petrochemical and derivatives. Suitable to Naphtha, Kerosene, Diesel, Petrol, CO, Flu gas. Amb . – 220 C Compound Selection Guide

34. Compound Code Features Temperature NES 2H Halogenated Inorganic rubber blended with high heat resistance inorganic filler imparts high heat resistant properties. Suitable for Super heated Steam, Hydrocarbon and Air. 450 - 850 C NES 2J Blend of synthetic rubber with active polar group and internal polymer configuration mixed with organic and active inorganic filler generate excellent oil and fuel resistance properties . Suitable for LPG. Max 300 C Compound Selection Guide

35. Compound Code Features Temperature NES 3 A Blend of synthetic rubber with suitable structural configuration and non staining properties mixed with organic and inorganic fillers offer heat ozone and chemical resistance behavior . Suitable to General purpose, Inorganic Acid and Steam. 160 – 300 C NES 4 A Inorganic rubbers with high bond strength in the chain used for heat and chemical resistance properties. Suitable for Thermic Fluid. Max 350 C Compound Selection Guide

36. Compound Code Features Temperature NES 5 A Blend of a strong, tough waxy and non-flammable synthetic Polymers generate chemical resistance properties. Suitable for wide range of Chemicals including Hydrocarbon derivatives upto 120 bars. (-100) to 240 C NES 5 B Mix of a strong, tough waxy and non-flammable synthetic Polymer and very low volatile plasticizer generate chemical resistance properties. Suitable for wide range of Chemicals including Hydrocarbon derivatives upto 40 bars. (-85) to 240 C Compound Selection Guide

37. Compound Code Features Temperature NES 5 D Blend of mainly saturated polymer with other synthetic rubbers and mixed with active inorganic fillers generated chemical resistance properties. Suitable for Di-ethanol Amine, Mixed Amines. Max 160 C NES 5 E Blend of synthetic rubbers and halogenated rubber mixed with organic filler generate ability for resistance to many derived alcohol by nature. Suitable for Ethylene Glycol, HCl 45%, Ethyl Alcohol, Methyl Alcohol, Butyl Alcohol Max 100 C Compound Selection Guide

38. Compound Code Features Temperature NES 6 B Inorganic synthetic rubber having high bond strength polymer chain mixed with inorganic filler generate high heat resistance properties. Suitable for Transformer Oil Leakage, Acetic Acid. 160 – 450 C NES 6 C Blend of rubbers with polar group and strong covalent bond mixed with organic and inorganic filler generate excellent resistant to Hydrocarbon and derived fluids. Suitable for Kerosene, Diesel, Petrol and Other derived fluids. 80 – 300 C Compound Selection Guide

39. Compound Code Features Temperature NES 8 A Inorganic saturated rubber having high bond strength polymer chain mixed with inorganic & organic filler generate chemical resistance properties. Suitable for glacial & concentrated Acetic Acid. Ambt . – 140 C NES 9 E Halogenated inorganic polymer mixed with organic and inorganic filler generate excellent chemical resistant to inorganic chemical including HCl . Suitable for concentrate HCl and other inorganic chemical. (- 40 C) – 160 C Compound Selection Guide

40. Compound Code Features Temperature NES R2 Re-injection for NES 6C, NES 2B, NES 2C, NES 2J 160 C-300 C NES R3 Re-injection for NES 2F, NES 6B 300 C – 550 C Compound Selection Guide

41. NICCO ENGINEERING SERVICES LIMITED Head Office: Infinium Digispace , 4 th Floor CP-15, Sector-V, Salt Lake City, Kolkata 700091. Tel: [phone] Fax: [phone] Email: [email protected] THANK YOU