Composites Technology Used Onshore With Synergy to Offshore Applications
Authors: Williams J.G. , Silverman S.A. 
Published: October 2008

The use of Fiberglass Reinforced Plastic (FRP) composites on offshore platforms is rapidly growing, particularly for low pressure piping and secondary structure such as grating. Onshore, FRP pipe systems have been used for over thirty-five years with overall good experiences. In recent years most research and development activity in composites in the oilfield has been directed toward offshore applications. Some of this technology also has the potential to improve the profitability and safety of onshore operations. With this in mind, the Composites Engineering and Applications Center recently conducted a study to review the status of FRP technology and consider how corrosion-resistant composite products could better be utilized in onshore petroleum production operations. Applications considered included line pipe, tubing, casing, tanks and vessels, and sucker rods. New products such as spoolable pipe and other emerging technologies were also reviewed for possible onshore applications. Two applications which appear to offer opportunity to use FRP pipe include replacing aging infrastructure in mature waterflood fields and the use of FRP pipe for carbon dioxide injection in enhanced recovery projects. Several advancements made in recent years are discussed in the paper including advanced resin formulations which provide improved damage tolerance and chemical and fire resistance. Good experiences recorded in the study encourages economic incentive for oil companies to increase their utilization of FRP products in onshore oil and gas production operations. Life cycle cost savings of up to 70 percent, for example, have been recorded for some applications using FRP pipe.

Introduction

Composite structures are resistant to corrosion and their high specific strength and stiffness permit them to be designed to carry load with significantly less weight than similarly designed metal components. When corrosion is a serious issue for metals, composites can often provide reliable long term service at reduced cost. Fiberglass reinforced plastic (FRP) piping systems have been used in onshore operation for over thirty-five years. The largest growth period for FRP products in the United States was during the late 1960's through the early 1980's when U.S. oil companies began large salt water injection projects and corrosion resistant FRP pipe in 3 in. and 4 in. sizes were used for injection lines. FRP products were later qualified for use in large carbon dioxide projects which further expanded the application of FRP pipe. FRP pipe has also been used for flow lines and downhole as casing and tubing. A brief bibliography of the history of onshore applications of FRP products is contained in references 1–15.

The study validated that there are thousands of miles of FRP pipe and other composite products serving successfully throughout the world. United States domestic use of FRP line pipe and tubing is estimated at about $60 million per year compared to a total market of $200 million worldwide. The emphasis of many of the major oil companies has shifted away from domestic onshore developments toward deepwater and international projects. However, recent advancements and affordability of 3D seismic and horizontal drilling technology are providing new opportunities for profitable onshore oil and gas development in the United States which could create a demand for more FRP products. Additionally, there is continued expansion of carbon dioxide injection in tertiary recovery projects, particularly in the West Texas area, which could increase the use of FRP products. These two activities along with the replacement of aging infrastructure in mature waterflood fields are seen as the major drivers for growth in the us