We are pleased to announce that our composite inspection technology, INSONO™, has received accreditation from UKAS (The United Kingdom Accreditation Service). UKAS supports the delivery of quality assessment and conformity processes, benefiting businesses and organisations that specify or use accredited tests, measurements, inspections, or certification schemes. UKAS has granted accreditation to our organistion against the requirements of ISO/IEC 17020:2012. Accreditation provides consumers with confidence in an increasingly complex, dynamic, and global marketplace by ensuring consistently high standards in the quality of purchased products or services.
Our clients can have confidence in our ability to meet their needs and deliver services with competence, impartiality, and independence in accordance with recognised international standards and best practices.
What is INSONO™?
INSONO™ is a solution that allows for the extension of defined life repairs, reducing waste and avoiding high-carbon emissions associated with traditional steel replacement alternatives. Developed by ICR, INSONO™ validates the condition and integrity of composite repairs, providing operators with assurance in the installation, long-term performance, and evidence to support life extension of the repair.
INSONO™ complements ICR’s Technowrap™ range and assures operators that their composite repairs are fit for purpose and comply with regulatory body guidelines on inspection criteria.
INSONO™ can detect defects in three main areas of concern: the bond line, interlaminar dis-bonds, and the steel substrate. A scanner provides 3D models and visual representations of the repair, allowing for precise dimensions to be used. Subsequently, an automated visual inspection report and 3D model are provided.
This technology may also enable composite repairs to be carried out in higher-risk locations, subject to risk assessment and engineering validation, where this may not have been previously considered.
Contact Antonio Caraballo, Inspection and Integrity Management Services Director to find out more antonio.caraballo@icr-world.com
ICR Group has recorded its highest turnover since the business was launched in 2011 – with the Middle East playing a key role in the firm’s success.
ICR, a technology-focused provider of specialist maintenance, inspection and integrity solutions across multiple sectors, has seen increased demand across its core energy sector operations, following the roll-out of an internationalisation strategy and diversification into other sectors.
The UK firm’s turnover for its 2022-23 year-end was £41.7m, a 20% increase on its previous financial year. Headcount has increased globally by 15%, from 204 to 235, since May 2022, and the company expects to create around 50 jobs across its operations during the next phase of its strategy.
Jim Beveridge, Chief Executive Officer at ICR, said: “Our presence in the Middle East has been particularly noteworthy, with recent high-value projects completed in the United Arab Emirates, Qatar and Saudi Arabia. We have also solidified our presence in the region by appointing a new partner in Abu Dhabi.
“Our ongoing international expansion not only bolsters our long-term sustainability but also plays a vital role in creating meaningful and enduring employment opportunities, rightly positioning us as a contributor to the energy transition.
“The Middle East is a dynamic market, brimming with potential for innovative companies such as ICR. At ADIPEC, we are eager to foster deeper relationships with our partners and engage with organisations striving to achieve their net-zero objectives. With COP28 on the horizon, our industry must remain steadfast in its commitment to facilitating a just transition toward a lower-carbon future.”
ICR’s established technological solutions continue to play a significant part in its growth. Technowrap provides life-long repairs that can be applied to internal, external and through-wall defects on complex geometries, while INSONO is an innovative NDT (non-destructive testing) technique for the inspection of engineered composite repairs. The Technowrap repair system reduces emissions by 66% compared to the traditional replacement methods.
Quickflange offers cold work solutions with weldless, high-performance flange-to-pipe connections. It provides a permanent repair option for improving pipeline integrity and flow assurance, eliminating the need for welding or hot work. ICR’s drone division, Sky-Futures, has also secured further international work.
NAMA Development Enterprises is ICR Group’s sponsor in Abu Dhabi, while its new execution partner in Abu Dhabi is APS.
ICR Group and NAMA Development Enterprises will be exhibiting at Stand 6210 at ADIPEC.
ICR Group is set to highlight its innovative technologies by contributing to a broader conversation on decarbonisation strategies at Offshore Europe.
Ross McHardy, Group Director at ICR, will be hosting a session entitled ‘Small Steps for a Bigger Change: Decarbonisation Through Technology’. The event on Tuesday, September 5 (10am-11.15am) at Aberdeen’s P&J Live will also feature other industry leaders.
This seminar is part of the Collaboration Zone, an initiative organised by the Energy Industries Council (EIC). Running throughout the week, the programme offers an avenue for speakers and attendees to exchange knowledge, explore smarter operational methods and present valuable insights gained from past experiences.
In addition’s, ICR’s innovations will be showcased at the same venue on Wednesday, September 6 (10am-10.30am) during a dedicated Technology Spotlight Session. This EIC event, hosted by Josh Cannell, Interim Head of Sales – Quickflange™, and Calum Macnaughton, Inspection and Integrity Engineer at ICR, will put the focus on Quickflange™ and INSONO™. Day 2 of the EIC Collaboration Zone – Navigating Net Zero – is sponsored by ICR.
Ross said: “Offshore Europe serves as an excellent platform to engage with the industry and share best practice and innovative ideas. Decarbonisation stands as a pivotal element in ICR’s strategy for fostering sustainable growth and both these EIC events provide a first-rate opportunity to highlight our ethos and smart technology.”
ICR’s Quickflange™, a weldless connector solution, offers an alternative for cold work applications, particularly for high-performance flange-to-pipe connections. This technology facilitates permanent repairs, enhancing pipeline integrity and ensuring fluid flow, all without the need for welding or hot work. With its wide range of applications, Quickflange™ has proven to be both cost-effective and efficient, reducing repair times by up to 80% compared to traditional methods. Remarkably, it also contributes to a 57% reduction in greenhouse gas emissions when contrasted with conventional welding practices.
INSONO™ is an innovative NDT (non-destructive testing) technique for the inspection of engineered composite repairs. It is a solution that allows for the extension of defined life repairs, reducing waste while avoiding high-carbon emissions from traditional steel replacement alternatives. INSONO™ complements ICR’s Technowrap™ range and provides operators with the assurance their composite repairs are fit for purpose and satisfy regulatory body guidelines on inspection criteria.
Technowrap™, a lifelong repair system, boasts the capability to address internal, external, and through-wall defects, even when dealing with complex geometries. This innovative solution has demonstrated a remarkable 66% reduction in emissions when compared to conventional replacement methods.
In his capacity as Group Director, Ross oversees the ICR repair division, which encompasses Technowrap™, Quickflange™, mechanical services and leak sealing business lines. He holds a BEng in Civil Engineering and an MSc in Offshore Engineering and is a chartered structural engineer. With 30 years of industry experience, he has held senior positions in various companies, including TAQA, EnQuest, and EnerMech.
Offshore Europe is celebrating its 50th anniversary. For more information about the conference & exhibition, please visit https://www.offshore-europe.co.uk/en-gb.html
This integrated approach to implementing composite repair solutions can reduce carbon emissions by 66% compared to traditional methods, says Antonio Caraballo, Inspection & Integrity Management Services Director, ICR, UK
The repair and maintenance of assets has always been an important element in the oil and gas industry and is essential to ensuring the reliability and safety of operations. Continuing to be a priority in today’s energy industry, throughout the transition to explore greener energy alternatives, the importance of corrosion control remains at the forefront of operator’s minds. Inadequate or infrequent inspection and management of assets can lead to a range of risks including production failure and loss of containment, potentially leading to catastrophic impacts on the personnel, plant and environment. As a vital factor in optimising the productivity, production, and downtime of operations whilst mitigating potential risks, corrosion control is essential to minimising operational and repair costs and extending asset life.
With the risk of health and safety issues and disruption to operations, corrosion can also compromise the appearance, performance, strength, and load-bearing ability of assets. Corrosion management will allow the operator to mitigate any safety and environmental hazards, as well as prevent any production and financial losses. As a key challenge facing the industry today, corrosion can lead to production delays, equipment failure, operational expenditure and safety hazards.
ICR Integrity is an industry-leading, technology-enabled provider of specialist repair, inspection and integrity management solutions to a diverse range of industries. The company’s well-established repair and maintenance division offers clients world class repair solutions providing greater asset uptime and reliability while saving time and cost compared to traditional repairs. The newly formed specialist inspection and integrity division reflects the company’s focus on innovation and technology advancements in support of its global clients’ integrity management requirements.
The traditional oil and gas industry, which ICR has a strong presence in, requires solutions that provide validation and assurance on the condition of their assets, as well as any repairs that have been undertaken. With a strong focus on the environment when carrying out testing, avoiding carbon intensive techniques is essential to the sector. Many ageing assets have composite repairs reaching the end of their design life, meaning there is an increased requirement to revalidate or extend the life of the repairs, allowing operators to avoid costly replacement options that may require a full shutdown of the asset. Regulatory bodies, have a strong focus on the integrity management and condition monitoring of repairs. Being able to inspect the defined life repairs is therefore a key enabler in ensuring safe and reliable operations for extended time periods.
Based on the principles of acoustic inspection methods with pitch and catch, ICR Integrity’s innovative new Non-Destructive Testing (NDT) technique, called INSONO. It provides resonance and mechanical impedance analysis to detect and size any flaws in the inspection of engineered composite repairs. The technology has been validated by The Welding Institute (TWI) and has patent and UKAS accreditation pending. A hand-held scanner creates 3D models and visual representation of the composite repair, allowing for precise dimensions to be used in the assessment. Any defects in three main areas of concern can then be detected – in the bond line, the interlaminar and the steel substrate.
With over 30 years’ experience, ICR is internationally recognised as a service-leader and a key-player in the ongoing development and adoption of composite technology. INSONO complements its industry renowned Technowrap™ range of engineered composite repairs and assures operators that their composite repairs are fit for purpose, satisfying regulatory body guidelines regarding inspection criteria. It also allows for the extension of defined life repairs reducing waste whilst avoiding high-carbon emissions from traditional steel replacement alternatives.
Inspection techniques currently available are not practical to deploy in the field and many are unable to access complex geometries with a single technique or product. INSONO is hand-carried and requires only one Technician, meaning inspections can be carried out in higher risk areas where they may not have been previously considered.
ICR is internationally recognised as a service-leader and a key player in the ongoing development and adoption of composite technology. The versatile product range offers practical and cost-effective rehabilitation of pressure systems and structural components with minimal disruption to operations, typically delivering valuable cost savings. The repair systems can not only be applied to live systems with no impact on production, but also offer a low greenhouse gas (GHG) emissions alternative to steel replacement. Replacing large steel equipment is energy intensive and requires the production of a new part. By repairing their equipment, ICR’s clients avoid the emissions associated with steel production and transportation as well as the energy required to perform the replacement.
Technowrap™ repair solutions can be engineered for anywhere between 2 and 20 years, which can be equal to the lifetime of a traditional replacement and as such are directly comparable to a replacement solution, depending on the anomaly type. ICR compared the carbon impact of using its repair system technology for the repair of a 2-metre section of 8” carbon steel pipework (85.1 kg) located 225 miles offshore from Aberdeen. The findings established that the repair system reduced emissions by 66% compared to the traditional replacement method.
On a recent project in the Northern North Sea, an operator client asked ICR to review various sections of pipework that had sustained severe corrosion resulting in wall thinning below the minimum allowable wall thickness of the pipework. Due to the location of the pipework being underneath the helideck, the client required minimal impact on production and an engineered Technowrap™ composite solution was chosen as the most efficient, engineered solution. The scope of work saw the delivery of the repair with a 20 year repair lifetime. Technowrap™ trained personnel installed the 2K materials, completing the repair with a design temperature of the line of 90ºC.
As there was no shutdown required, the solution offered was extremely cost effective. Due to the complexity of the location (under the helideck), ICR mobilised a multi skilled rope access trained composite repair team who implemented the repairs, removing scaffolding requirements. The appropriate risk assessments were carried out to minimise any potential risks associated with the work. In order to achieve the required adhesion grit blasting to the cleanliness standard of SA 2.5 was completed prior to the application.. As a result, the scope was delivered on time, within budget and with no incidents or accidents. The client was given the further assurance through the bespoke engineering and design calculations for each repair, carried out to code requirements in accordance with ISO 24817 and ASME PCC-2.
With safety, environment, efficiency and reliability as a top priority in the industry, ICR is leading the ongoing development and adoption of composite technology to support operators globally. Actively working in close collaboration with clients to ensure the structural integrity of assets is maintained with minimal disruption to operations, ICR is able to support clients on their journey to sustainability.
With extensive experience dealing with some of the most challenging projects in the industry, ICR’s integrated approach to implementing composite repair solutions and specialist engineered clamp designs can reduce emissions by 66% compared to other methods. With sustainable operations at the forefront of the industry’s agenda, this further allows clients to repair and maintain their assets to avoid costly operational disruption and potential safety and environmental hazards.
To view this article in World Pipelines click here
