If your site has had leaks in the past, fluid has likely leaked into walls or floors, which can cause severe damage over time. Online leak sealing prevents this by filling holes in pipes with a rubber material to prevent the contents of the pipe from getting through them. This is an easy fix and comes with the benefit of not having to replace any of your pipes! To find out more about online leak sealing, read on or contact our team today. 

Online leak sealing has become a critical part of many industries, from energy production to manufacturing. The process of online leak sealing can be utilized in any situation that has pressurized pipework containing fluid or gas. During a leakage in a high-pressure pipe, repairs can be seen as almost impossible due to the high velocity of the leak and potentially extreme temperatures of the contents of the pipe.  Online leak sealing is the process of resealing and reinforcing the leaking pipe in situ without depressurizing or draining the pipe itself. If you would like to discuss online leak sealing further, contact our professional team today and we will be happy to help with any of your needs. 

The process of online leak sealing begins with an initial consultation; this is a crucial step to ensure the best possible solution to the leak. Given the incredible variety of pipe designs and sizes, every leak will require a custom and bespoke solution. During the initial plan, time will be spent to determine the best material to seal the pipe; this decision will be determined by the material of the pipe that is leaking, the contents, temperature, and pressure of the pipe. If any bespoke brackets are needed, these will now be manufactured as a priority. Once the actual process of sealing the leak begins, the chosen sealant will be introduced, and any bracketry required will also be fitted. In some cases, the bracket can be removed at a later date. In others, this will remain in place long term. Following the sealing procedure, regular checks on the repair will often be undertaken to ensure complete sealing.  Contact our team today if you would like to discuss a leak you are experiencing or simply discuss the process.

LEAK SEALING SERVICES

We offer the best solutions for leakage problems safe, speedy, cost-effective, and reliable. The idea is to prevent unwanted shutdown and downtime.

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, EMBARK has developed its own range of proprietary leak-sealing compounds that can address a wide variety of steam, chemical, hydrocarbon, and gas leaks at temperatures ranging from -100C to 850C and pressures up to 250 bars. Our compounds have been tested in thousands of applications over several years and you can be confident of their performance. We design, test, and manufacture our compounds in-house at our ISO 9001 and ISO 14001 compliant facility, thus assuring quality to the utmost.

HOT STEAM LEAKAGE

A recent case of hot steam leakage of 20 TPDS HEATER FLANGE LEAKAGE near the control room was addressed by our service engineer Mr. Soumya Deep Chatterjee.

The leakage was at a temperature of 350C and a Pressure of 15 Bar. Online Leak Sealing by Brass Wire Peening Method was adopted. Leak Sealing Compound 2B was injected through specially designed adaptors. The leakage was arrested instantly.

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.

 SUPERHEATED STEAM LEAKAGE

One of our clients faced Super-heated Steam Leakage from a Hot Re-Heater line crack. Pressure 110 bar and Temperature 600C.

Our engineers analyzed the root cause of the leakage, took precise measurements, and engineered a box clamp. The clamp was installed over the leak and special-purpose Leak-Sealing compound 2H was injected. The leakage was arrested instantly.

Now the 460MW power plant has been running successfully and a shutdown was averted.

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 

LEAKING FLANGE JOINT

A leading power plant faced a leakage issue due to a gasket failure of the Boiler Feed Water Pump.
Clients could not afford to shut down due to heavy production loss and thus asked EMBARK for an online leak-sealing solution.
Our engineers took precise measurements of the Flange Joint Line and fabricated and installed a clamp. EMBARK Leak-Sealing compound was injected, and due to the quick response of the leak-sealing compound, the leakage was arrested instantly. This saved time and heavy production loss. Now, the power plant has been running successfully.
EMBARK'S history of developing innovative technologies continues with the addition of online leak-sealing services, helping to avoid production losses and unscheduled plant shutdowns. 

LEAK SEALING SERVICES

Leak Sealing is the process of sealing pressurized leaks while under continuous pressure to avoid costly shutdowns or unscheduled maintenance downtime. EMBARK has been successfully sealing leaks operating pressure and temperature, ranging from vacuum to 400 bar and from -60C to 600C.

Valve Packing: This is the most common application for under-pressure leak sealing services for many reasons. Valve packing can be repacked online very quickly and economically without shutdown or having to isolate the valve itself. The sealant used to seal these leaks is very similar to the original packing material supplied by the valve manufacturer and will not harden or ruin the valve. Some common applications for these valve-packing repairs are steam, superheated steam, water, condensate, chemical, vacuum, air, or almost any process.

Flange Joint Leaks

There are many different leak sealing services and ways of achieving a seal on a flange depending on the gap between flanges and also temperature and pressure. For flange gaps below 6mm, a wire insert technique is normally performed. This process is excellent for low-pressure leaks. Since almost all flanges are built to standard sizes, a two-piece flange clamp can be installed and then injected to arrest the leak. Standard size Flange Clamps for sizes  thru 24, class 150#, 300#, and 600# rated flanges are normally stocked for a quick turnaround response time to meet client emergency requirements. Clamps for other sizes can normally be designed and manufactured in less than 24 hours. The same techniques can be used for Heat Exchanger Joints, Turbine Joints, etc.

Elbow Leaks

EMBARK designs and manufactures Elbow Box Clamps, to suit pipe configurations. The leak sealing method can be either an injectable groove or the EMBARK-developed combination seal.

Weld Leaks / Pinholes

Straight-Line Box Clamps are used regularly to repair these leaks. Manufactured to the required pipe sizes, these are installed and injected very quickly to eliminate your leak problems.  Variations of these include T-Box clamps for sealing Tees, Reducer (Concentric/eccentric) Box Clamps, and even clamps that encapsulate and seal pipes combined with fittings, flanges, valves, etc.

Other frequent operations covered by this service include Pipe Crimping to kill lines, Sealing of Screwed Couplings, Ball Valve Seals, Wellhead Pack-Off areas, Resin Injection of clamp annulus for reinforcing corroded/pitted lines & wall thinning.

LEAK SEALING SERVICES

On-Line Leak Sealing is a temporary solution to tackle process system leakage problems whilst the process line is in full operation. Leak sealing solutions can tackle almost all kinds of leaking substances, for example, steam, water, air, oil, hydrocarbon, and chemical products. This innovative technology can be used in the process with pressure ratings up to 380 bar and temperatures ranging from cryogenic to 600C.

A serious leak from a pipeline in a continuous process plant calls for a choice between three courses of action. First, the pipeline can be shut down for conventional repair; secondary, the leak can be left to blow, usually only for a limited time; thirdly, by means of a process, the leak can be cured while the line remains at full pressure and temperature.

The pipeline leak may occur at the flanges, straight pipe, elbows, tees, valve gland, etc. This is due to the nature of the pipeline contents where the flow is turbulent and the pipeline is subjected to corrosion and/or erosion e.g., near elbows and tees, or at a flange joint or a valve. It can also occur at the pipeline weld joints where the pipeline material is not homogeneous.

Our Online leak sealing services are supported by experienced engineers and technicians on leak sealing repairs and design. At NPSSB, we strive to provide the most cost-effective and reliable leak repair solution to meet our client's requirements. Whether it is a pipe leak, valve leak, or flange leak, we promise to provide the right repair solution to solve our client's problem with a fast response.

Valve Packing Leak

• This is the most common application for under-pressure leak-sealing services for many reasons.
• These valve packing leaks can be repacked online very quickly and economically without shutdown or having to insulate the valve itself.

Flange Joint Leak

• Flange leaks are an unfortunate common appearance in many facilities and can be easily sealed by using online leak sealing technology.
• There are many ways to achieve a seal on a flange depending on the gap of the flange and temperature and pressure.

Pipe Fitting Leak

• The box enclosure clamps are manufactured to the standard pipe size and are fabricated in short-radius or long-radius applications.
• Once the box enclosures are installed, they are injected with a suitable sealant to perform a 100% guaranteed seal injection groove/cavity-filled sealing method depending on pipe conditions.