A recent project initiative in Brunei Shell Petroleum (BSP) landed a decision to change the initial basis for design of a fully Carbon Steel (CS) facility system, onto a combination of Corrosion Resistant Alloys (CRA) and Flexible Composite Pipe system (FCP, also commonly known as spoolable RTP: Reinforced Thermoplastic Pipe). This is due to high expected corrosion rates and the consequent challenges that follows in design and the imminent CS system operations.

Updated production parameters from the initial design basis called for materials selection and corrosion studies reassessment. Following the industry design engineering practices and philosophy, technical evaluation of materials including FCP and comparison among potential material concepts were exercised. This is mainly between corrosion resistant materials and various CS options. The former was evaluated to be feasible with added benefits in reducing corrosion maintenance and management needs. The concept consists of utilising FCP for the production flowlines and CRAs for the piping systems.

Hardwares and barriers normally required for CS system such as Corrosion Inhibition (CI) injection skids and requirements, pig traps for cleaning and intelligent pigging, are removed from the project scope. Furthermore, with high corrosion expected, non-standard piping class needs to be developed to give thicker Corrosion Allowances (CA). These in turn results in a competitive cost saving advantage as reflected in the cost studies.

Non-metallic material selection of FCP is demonstrated, manufacturers' specifications assessed and evaluated. This paper intends to provide sets of learning points gathered during the project phase which focuses on the use of FCP for production lines.

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