Oil Industry Experiences With Fiberglass Components (1987)

ABSTRACT The results of a survey of oil company experiences with Fiberglass Reinforced Plastic (FRP) products indicate good experiences both onshore and offshore for numerous facility applications. This report reviews the current state of FRP technology and highlights the experiences reported in the survey. The lower cost, corrosion resistance and lighter weight of FRP components make them very attractive for expanded application, especially in the North Sea where FRP use is currently very limited. INTRODUCTION Fiberglass Reinforced Plastics (FRP) had their beginning with a commercial venture in 1938 by Owens Corning to make glass fibers for use as insulation and acoustical isolation material. The development of plastic resins subsequently led to the development of structural uses for FRP. Over the past two decades FRP composites have been used throughout the world for a wide variety of oil industry applications. The lighter weight, fatigue and corrosion resistance and associated low life cycle costs (Figure 1) make FRP components very attractive for expanded oil industry application both onshore and offshore. Glass fibers are resistant to most chemicals and resin materials are available which are compatible with most environments experienced in the oil industry. FRP composites are approximately 66 percent lighter weight (weigh one-third as much) than equivalent steel components. FRP's lighter weight often permits FRP pipe to be installed by work crews unassisted by mechanical hoists. This convenience is especially helpful for installing pipe in tight locations. Complex spool assemblies can be made in the factory and assembled in the field saving valuable on-site installation time. FRP joints require no welding and the experience level required to make quality joints can be learned very quickly. Facility modifications are also easier and less expensive with FRP. FRP composites can offer significant cost savings relative to metal by providing lower initial installed cost, reduced maintenance and longer life. A survey was conducted recently to determine the experiences of the oil industry concerning FRP components. The survey was by no means comprehensive; however, it is believed to be representative of current experience. Overall, the results show strong approval for existing FRP pipe and tank components and include recommendations for expanded utilization. Many oil companies are very aggressive in their utilization of FRP. Operators off the coast of Africa, for example, use FRP extensively for water management systems including fire water lines. Conoco has used FRP tanks and pipe for approximately 20 years and currently uses considerable amounts offshore for low pressure waterflood systems. Limited amounts of FRP are used in the North Sea where operators and regulatory agencies have been much more conservative. In the last few years, however, this region has begun to give serious consideration to utilizing FRP products. This paper highlights the response of oil operations personnel concerning their experiences with FRP components. Discussions are presented on the current status of FRP technology and on issues which concern potential users of FRP products. In addition, cost comparisons between FRP and metal components are discussed as well as cost effective opportunities for expanded applications of FRP components.