Understanding the damage mechanisms and developing failure analysis protocol for RTR pipes
Status: Project
Date Announced: February, 2026
The scope of the JIP concerns failures of RTR pipelines and non-metallic components in RTR pipe and joint systems, such as, adhesive bonds and elastomer O-rings. Failures of RTR pipes, which occur adjacent to metallic fittings, such as, valves and couplers, where the metallic component may have contributed to failure would also be included but not failures of metallic components themselves.
Summary
Reinforced thermoset resin (RTR) pipes and pipelines have been employed in oil & gas operations for the transport of hydrocarbons, water and harsh chemicals for over 50 years. RTR pipes and joints are recognised for their excellent corrosion resistance, which reduces frequency of pipe inspection and maintenance, leading to significant cost savings over the operational lifetime. Capital expense is also reduced as need for replacement of pipework is reduced.
Despite best efforts in designing robust, long service life, RTR pipeline installations – failures do sometimes occur. Determining the cause of failures is essential in understanding what went wrong and how to prevent similar failures occurring in the future.
In the first instance, issues related to design, materials selection and/or manufacturing, might affect pipe performance and durability. For example, resin and curing agent, voids and inclusions, reinforcement material, winding angle, layup, etc. However, to focus solely on pipe materials and manufacturing would ignore many extrinsic factors, which may feature through transport, installation, commissioning and operation. External influences might include unintended defects introduced during installation (or maintenance) or perhaps transient deviations from standard conditions which occasionally push the pipeline beyond the intended operational envelope. Indeed, a confluence of intrinsic and extrinsic factors may ultimately lead to a failure and each case is likely to present its own unique set of circumstances.
Initial uncertainties when establishing a failure investigation can result in delays, misinformed actions and considerable expense being incurred to resolve issues. In this regard, it is expected that understanding and subsequent exploitation of commonalities in previous pipeline failures could lead to a more streamlined investigative approach, delivering both time and cost efficiencies.
Objectives
- Understand the most frequently observed failure modes, failure mechanisms and root causes of damage to RTR pipes and joints which impact Sponsors in operations;
- Review the current Body of Knowledge for failure modes and effects analysis (FMEA) concerning RTR pipe and joint systems;
- Define a specification for information and documents required upfront prior to commencing a failure investigation;
- Construct a root-cause failure analysis (RCFA) method to link failure modes and potential root causes;
- Define analytical methods and tests required to support failure investigations to efficiently resolve the root cause(s) for specific failure modes;
- Develop a failure investigation protocol for root cause analysis of failures in RTR pipes and joints;
- Develop a provisional database of failures in RTR pipes and joints using data provided by Sponsors.
If you are interested in finding out more, download the PDF Summary Outline using the following link