Datadriven Guide Enhances Thermoplastic Piping Selection

Imagine a world where oil and gas pipelines no longer require frequent replacements due to corrosion, where operational costs are significantly reduced, and safety risks are dramatically minimized. This vision is becoming reality through Reinforced Thermoplastic Pipes (RTP), now more commonly referred to as Flexible Composite Pipes (FCP). This article examines the technological evolution, performance advantages, application scenarios, and selection strategies for RTP/FCP systems, providing data-driven insights for informed decision-making.

From Innovation to Industry Standard

RTP technology emerged in the early 1990s as a solution to the corrosion limitations of traditional metal pipelines, initially serving as an alternative to medium-pressure steel pipes in onshore oil and gas operations, particularly in the Middle East. Early RTP systems utilized synthetic fiber reinforcement.

A significant milestone occurred in 1998 when Pipelife Nederland B.V. participated in a joint industrial project to develop Long-Length Reinforced Thermoplastic Pipe (LLRTP). Leveraging decades of pipe manufacturing expertise, the company introduced the SoluForce branded RTP system, marking a new phase in pipeline technology.

The original LLRTP design modified flexible thermoplastic pipes that Pipelife had produced since the 1960s by adding reinforcement layers to withstand higher pressures, hence the name "Reinforced Thermoplastic Pipe." As adoption grew across the oil and gas industry, the technology evolved with various reinforcement methods. In 2010, industry associations standardized the terminology to "Flexible Composite Pipe" (FCP) to encompass all reinforcement materials.

Terminology and Applications

FCP systems are known by several names including "flexible flowlines," "spoolable pipe," "reinforced line pipe," and in offshore applications as "flexible risers" or "umbilicals."

While initially developed for oil and gas, SoluForce FCP now serves multiple industries:

• Residential gas distribution
• Potable water systems
• Mining operations
• CO ₂ transportation
• Hydrogen infrastructure

The technology has proven resilient in extreme environments from Kuwait's desert heat to Indonesian jungle humidity and subsea installations at 80-meter depths off Africa's west coast.

Structural Advantages

A typical FCP features a multilayer construction. SoluForce pipes consist of three primary layers: HDPE liner, reinforcement layer, and HDPE protective coating. The Gas Tight variant adds an aluminum barrier to prevent permeation of light components.

SoluForce distinguishes itself through fully bonded layers creating a monolithic structure rather than stacked components. This design, combined with non-metallic connection systems, delivers superior corrosion resistance, flexibility, installation speed, and reusability compared to steel pipes or conventional FCP alternatives.

The system's white outer coating provides UV stability and protection against environmental factors without bearing structural loads. Certified for pressures up to 450 bar (6,527 psi), SoluForce serves both onshore and offshore applications.

Material Selection

SoluForce offers three reinforcement options:

• Light: Aramid fiber for maximum flexibility
• Classic: High-strength synthetic fiber
• Heavy: Steel wire for extreme pressures

The Gas Tight version incorporates an aluminum layer, while the High Temperature variant withstands continuous operation at 85°C (185°F) - unmatched by competing FCP products. The HDPE liner resists all oilfield fluids and gases including H ₂ S, CO ₂ , strong acids, and caustics while providing corrosion immunity, scale resistance, and lower flow friction than steel.

Selection Framework

Choosing optimal RTP/FCP solutions requires systematic evaluation:

Application Requirements

• Media composition (corrosives, contaminants)
• Operating pressure/temperature ranges
• Flow capacity needs
• Design lifespan
• Installation environment (terrain, subsea, etc.)

Performance Parameters

• Material properties (HDPE, PA, PVDF comparisons)
• Reinforcement type tradeoffs (fiber vs. wire)
• Connection method suitability (flanged, fused, mechanical)
• Compliance with ISO, API and other standards

Cost Analysis

Evaluate total cost of ownership including:

• Initial material and installation expenses
• Maintenance requirements
• Operational efficiencies (energy savings, leakage reduction)
• Lifecycle cost modeling

Monitoring and Optimization

• Installation quality verification
• Real-time operational monitoring
• Predictive maintenance analytics
• Performance tuning based on operational data

Implementation Case Study

An oilfield gathering system plagued by chronic corrosion adopted SoluForce Classic FCP to replace steel piping. The synthetic fiber-reinforced solution delivered:

• Elimination of corrosion-related failures
• 60% reduction in maintenance costs
• 40% faster installation
• Enhanced safety through leak prevention

Future Outlook

FCP technology continues advancing through material science innovations and manufacturing improvements. Emerging developments include:

• High-strength fiber reinforcements for deeper offshore applications
• Smart pipe systems with embedded monitoring capabilities
• Advanced composite materials for extreme service conditions

As these innovations mature, FCP adoption is expected to expand across energy, water, and industrial sectors, offering safer, more reliable, and cost-effective pipeline solutions.