Different hybrid composite pipe solutions have been proposed and evaluated for use in ultra-deepwater applications. This includes composite and hybrid composite/metallic pipe designs made from both a thermoplastic and thermosetting matrix. Each of these designs target a proportion of the future deep sea market and will require a leveraging of present logistics and infrastructure or new developments for deployment. These design concepts primarily focus on deepwater (hence, a higher collapse load) in combination with higher pressure and/or sour service requirements. A section of this hybrid composite pipe design targets the larger diameter high through-put (low or high pressure) FLNG market.

GE Oil & Gas has proposed hybrid metallic/composite pipelines which use composite layers for both hoop and tensile loads. This paper discusses and compares several different design concepts i.e. bonded composite pressure armor, composite tensile armor and both. Although the use of composite pipe will reduce the overall weight, consideration should be given to the buoyancy versus drag requirements of each composite pipe design. Further, consideration needs to be given to manufacturing, reeling, transportation and installation for each of these different design concepts. Acceptability of these individual designs by the end customer requires detailed FMECA, qualification and testing. This paper therefore compares detailed advantages of each composite pipe design for ultra-deepwater applications, presents the latest developments and compares future applications.

Considerations have been given to development of continuous quality control procedures for the manufacture of these composite pipelines and working prototypes. In addition, the latest results are discussed. The possibilities of defects correction and repair mechanism are also explored. This paper aims to show an appreciation of various composite pipe design concepts and addresses key concerns from both a manufacturing and customer acceptability point of view.

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