Category: INSONO™ Composite Inspection

Benefits

• Provided independent assurance of repair quality.

• Established a robust baseline.

• Supported risk-based maintenance planning.

Scope

An onshore gas terminal engaged ICR to undertake a non-destructive inspection of four engineered composite repairs installed on a high-pressure dry gas pipeline. The repairs had been designed and installed to arrest external corrosion associated with localised wall thinning and restore the structural integrity of the pipeline in accordance with the original design requirements.

The client required an initial post-installation inspection to establish a baseline condition for each repair and to provide independent verification that the repairs had been installed to an acceptable standard and were suitable for continued service.

Solution

Using the INSONO™ inspection system, an ICR Level 2 Inspector assessed each repair for laminate quality, bondline integrity and the presence of any internal anomalies. The inspection also confirmed the repair dimensions and laminate thickness, providing a comprehensive record of the condition of each repair at the time of inspection.

The inspection identified no bondline anomalies, confirming that the composite repairs remained well bonded to the parent steel substrate. Where interlaminar anomalies were identified, these were documented, measured and assessed to provide a baseline against which future inspections can be compared. The inspection findings concluded that the repairs were suitable for continued service at the time of inspection.

By establishing a detailed baseline immediately following installation, the asset operator can now monitor the condition of each repair throughout its design life. Repeat inspections can be used to identify any changes in the size or distribution of internal anomalies, providing objective evidence to support integrity management decisions and optimise future inspection intervals.

Result

• Independent verification of four engineered composite repairs following installation.

• Confirmation that the repairs were suitable for continued service.

• Comprehensive baseline condition assessment for future comparison.

• Identification and mapping of internal anomalies to support long-term monitoring.

• Increased confidence in the integrity and performance of the composite repairs throughout their design life.

Contact ICR

Please complete the form below, and a member of our team will get in touch as soon as possible.

Benefits

• Improved asset integrity management.

• Reduced operational risk and uncertainty.

• Completed assessment in minimal time, with no disruption to operations.

Scope

An offshore operator engaged ICR to perform a baseline non-destructive inspection of two engineered composite repairs installed on a live asset. The scope included a thick glass fibre composite repair and a carbon fibre composite repair, both installed to restore the integrity of degraded pipework.

Solution

Using the INSONO™ inspection system, an ICR Level 2 Inspector completed a detailed assessment of each repair, recording the condition of the laminate, bondline integrity and the location and size of any internal anomalies. The inspection provided a comprehensive baseline dataset following installation.

The primary objective of the inspection was to establish a reference point from which the repairs can be monitored throughout their operational design life. By comparing future inspection data against the baseline, the operator will be able to identify any changes in the condition of the composite laminate, monitor the stability of identified anomalies and make informed engineering decisions regarding the continued serviceability of the repairs.

The inspection was completed offshore without affecting production and demonstrated the value of periodic condition monitoring as part of a proactive composite repair management strategy. By establishing an accurate baseline at an early stage, the operator has increased confidence in the long-term performance of the repairs while reducing uncertainty associated with future integrity assessments.

Result

• Established a comprehensive baseline condition for both glass fibre and carbon fibre repairs.

• Enabled future trend analysis through repeat inspections.

• Supported informed integrity management and life-extension decisions.

• Reduced uncertainty associated with the long-term performance of engineered composite repairs.

• Demonstrated the capability of INSONO™ to inspect both glass fibre and carbon fibre repair systems in an offshore environment.

Contact Us

To find out more about INSONO™ composite repair inspection, please submit an enquiry using the form below, and a member of our team will be in touch as soon as possible.

Client: Operator 

Asset: Onshore terminal 

Location: UK mainland 

Result: INSONO™ inspection completed on production critical pipework. Results were fed back into WSE allowing continuous monitoring. 

Client challenge 

For many clients, ensuring the integrity of your repairs is an essential factor in establishing a baseline for future inspections and is integral to the Written Scheme of Examination (WSE)/ Risk Based Inspection (RBI) process. When an energy operator approached our team to conduct a comprehensive visual inspection and non-intrusive inspection (NII) on a repair, we utilised our extensive experience to accurately identify any potential anomalies that could jeopardise the suitability of the repair for service. 

What we did 

To address our client’s challenge, we conducted a meticulous close visual inspection covering 100% of the composite repair area, focusing on the external condition of the wrap. Following this, we used INSONO™, a proven non-intrusive technique that utilises soundwaves for a baseline NII examination. This comprehensive assessment evaluated the internal body of the composite wrap and substrate, recording any anomalies that might impact its integrity and life cycle. The established baseline serves as a reference point for future inspections/ examinations, aligning with the RBI and WSE. 

Results 

By using INSONO™ we effectively located, measured, recorded, and monitored anomalies associated with the wrap repair and substrate. By employing this technique, we provided the client with a robust solution for assessing composite repairs in areas with challenging accessibility or complex geometries, including bends, valves, multiple pipework connections, headers, pipe racks, vessels, and various structural locations. Our examination not only addressed the current concerns but also set the stage for ongoing monitoring and maintenance.

Client: Operator

Asset: Offshore asset

Location: Southern North Sea

Result: Two anomalies were identified and can be monitored over the design life of the repair

Client challenge

A major oil and gas producer approached us looking for continued assurance in the integrity of a pre-existing composite repair used in their infrastructure. They required a comprehensive visual inspection and non-intrusive inspection (NII) to assess the current condition of the repair wrap. The primary objective was to identify, quantify, and record any anomalies that could compromise the pressure-retaining capacity of the repair and substrate for inclusion in the framework of their Risk-Based Inspection (RBI)/Written Scheme of Examination (WSE).

What we did

Our team conducted a close visual inspection to evaluate the external condition of the repair wrap. Subsequently, we performed a non-intrusive examination using INSONO™, a technology that uses the principles of acoustic inspection to assess the entire volume of the composite wrap and substrate. This technique was chosen for its capability to detect anomalies in critical areas such as the bond line, interlaminar dis-bonds, and the steel substrate. The goal was to identify any features that could – if left unmonitored – impact the integrity and life cycle of the repair wrap and assess its suitability for continued use.

Results

The examination successfully located two delaminations (voids) within the wrap. Following a thorough technical assessment by the composite design team’s technical authority and fitness-for-service evaluation against defined acceptance criteria, it was determined that these anomalies likely occurred during the application of the wrap. Engineering assessments confirmed that these features had no detrimental significance to the integrity of the wrap repair.

As a result, the client’s Written Scheme of Examination (WSE) was updated in accordance with their Risk Based Inspection (RBI) process. The composite repair wrap was deemed fit for continued service, and a valid justification for extension was provided.

Conclusion

Our composite repair examination, played a crucial role in providing data driven justification for the continued classification of the composite repair as fit for service. The repeatability of this inspection method positions the client well for future life extensions, as potential concerns can be consistently addressed and mitigated. This case underscores the importance of advanced inspection techniques in ensuring the ongoing integrity and safety of critical infrastructure components in the oil and gas industry.

Client: Operator 

Asset: Offshore asset 

Location: Southern North Sea 

Result: The INSONO™ inspection was completed to assess the integrity of wraps applied to a series of off-takes.

Client challenge 

Our client, an energy operator, faced the challenge of ensuring the integrity and reliability of their composite wrap processes. They needed a solution that would deliver confidence and assurance in Fitness for Service (FFS)/Risk-Based Inspection (RBI) schemes. The specific challenge was to locate, measure, record, and monitor anomalies associated with both baseline/new wrap surveys and in situ wraps. It is important to identify any anomalies associated with any composite repair and monitor them over time to ensure continued safe operation and minimise risk to the overall infrastructure. 

What we did 

To address the client’s challenge, we implemented our non-intrusive technique INSONO™ into the FFS/RBI schemes. INSONO™ utilises a non-intrusive (NII) examination technique incorporating low-frequency sound waves to assess the internal body of the composite wrap and substrate. This method locates, quantifies, and records anomalies that could compromise the suitability for service. 

The versatility of INSONO™ as a proven non-intrusive technique made it particularly suitable for inspecting wraps in challenging and unconventional areas. This included leaks or damaged areas that tend to arise during production, as well as bends, valves, multiple pipework connections, headers, pipe racks, vessels, and various structural locations. The adaptability enabled it to address the client’s specific concerns and requirements, showcasing its effectiveness in diverse configurations. 

Our inspection established a baseline reference for future wrap inspections as part of the Written Scheme of Examination/ Risk-Based Inspection (WSE/RBI) process, ensuring continued service in line with RBI/WSE standards. 

Results

The incorporation of INSONO™ as an inspection tool proved to be highly successful. It provided a robust solution for locating, measuring, recording, and monitoring anomalies associated with wrap repairs and substrates. This method demonstrated its efficacy in both baseline, new wrap surveys and current in situ wraps, offering repeatability for ongoing assessments. Our client gained confidence and assurance in the composite wrap process, knowing that potential issues affecting integrity and life cycle were systematically identified and addressed.