Thermoplastic Composite Pipe Enables Fast-tracked Pipeline Replacement Offshore Egypt

A collaborative approach to pipeline installation was the driving force behind a fast-tracked pipeline replacement solution, with Oceaneering installing one of Strohm’s thermoplastic composite pipe (TCP) flowlines at one of the West Delta Deep Marine (WDDM) project gas wells in Mediterranean.

In recent years, Egypt has been seeking to increase domestic natural gas production to help meet rising demand, strengthen energy security, and reduce reliance on imported liquefied natural gas during seasons of peak demand. The WDDM project is important for Egypt’s energy security, providing a reliable domestic source of natural gas to the domestic grid and therefore reducing the country’s exposure to global supply disruptions.

The Engineering Challenge: Restoring Production Under a Compressed schedule

The original field development relied on rigid subsea infrastructure for production. Due to observed asset integrity flow line challenges, the Sepia well was taken off stream as a precautionary measure early 2025 when a targeted replacement program was initiated by the operator.

Egypt’s peak electricity demand typically occurs through July and August, when domestic gas consumption spikes during heat waves, creating a firm deadline for the infrastructure to be replaced and the well to be brought onstream.

Alternative proposals involved replacing the pipeline with a conventional unbonded flexible pipe, which would be installed using a specialized lay vessel. However, this option was associated with higher costs, and due to the limited availability of these specialized vessels, the installation could not have been completed before Q4 at the earliest, resulting in a critical and costly delay.

Developing a Faster Alternative

To meet the required timeline, Strohm’s non-metallic thermoplastic composite pipe (TCP) was identified as a suitable solution. The flexible, field-proven pipeline is lightweight, immune to corrosion, and can be installed with smaller vessels which are readily available.

The carbon fiber and PA12 polymer TCP flowline used for gas production has a design pressure of 5,000 psi and it is qualified to DNV-ST-F119 standard. Due to the use of carbon fibers, it is resistant to fatigue-based failures, making it a suitable choice for dynamic applications, from jumpers to flowlines and risers, including sweet and sour hydrocarbon, water, CO2 and gas service.

The high stiffness of carbon fibers paired with the load transfer capability of PA12 as matrix also makes it well suited for deepwater service and operating pressures up to 700 bar and temperatures up to 80°C. The material has been qualified for a lifetime of up to 30 years.

“TCP was the perfect choice for this accelerated project, and several factors came together to make this timeline possible,” said Martin van Onna, Strohm’s CEO. “The front-end engineering work for the pipeline, end fittings, bend restrictors, and ballast modules was completed within one month following a huge effort from our engineering teams. Furthermore, engineering and manufacturing activities were completed in parallel where possible, allowing us to start manufacturing as soon as possible to fit with the tight schedule.

“Throughout the project, our focus was on finding the most efficient way to deliver without compromising on quality, safety, or reliability. For example, we had 50 wooden crates containing ballast modules and bend restrictors which were consolidated into seven open-top steel containers, significantly reducing the number of lifts required during vessel loading.”

“TCP products have always been designed with reliability at the forefront. With more than a decade of real-world field performance, no documented failures across our installed base, and a flawless record across all factory acceptance tests conducted, our track record speaks for itself. That proven performance, our experienced engineers, combined with the trust we have built with independent third-party verification bodies, give us confidence in our products and the ability to fast-track solutions without compromising on quality or reliability.”

Fast-tracked installation using vessel of opportunity

The flowline was installed by Oceaneering at water depths of almost 600m, using the offshore construction vessel Energy Savanah. The vessel was equipped with a flexible, horizontal lay and reel drive system, enabling installation without the need for a specialized lay vessel.

Christopher Boler, senior manager at Oceaneering’s Offshore Project Group, commented: “The team successfully mobilized and delivered the offshore campaign in a new operating environment, in what was our first installation project in the region. Through close coordination across teams and geographies, we successfully navigated regional permitting, customs, and complex logistics to execute the campaign safely and efficiently.

“The TCP installation presented its own set of challenges. The product's lightweight, yet stiff characteristics required the use of ballast weights to achieve the required seabed stability. Installation tolerances were tight, with the vertical connection system allowing virtually no margin for error. Early engagement with Strohm and the installation contractor during the design and procurement phases helped identify technical challenges, evaluate installation approaches, and uncover opportunities to accelerate the project schedule. This early collaboration, combined with careful planning, detailed engineering, and ongoing communication between the project teams, established a strong foundation for successful offshore execution

“With the installation vessel confirmed late in the project lifecycle, engineering rework was required, including updates to installation methodologies and analyses. The flexibility and responsiveness of the engineering and project teams, supported by the close collaboration between the two companies, ensured the project remained on track.”

Offshore operations included deployment of the flowline, installation of ballast modules, subsea connection activities, and verification of system integrity prior to handover. The controlled installation sequence, combined with detailed engineering preparation and close coordination between offshore and onshore teams, enabled safe execution while maintaining schedule objectives.

The operation was completed safely and efficiently. The controlled installation sequence, combined with modular ballast, precise tension management and continuous integrity testing, minimized deck handling time and maintained pipe alignment throughout the process, demonstrating once again the viability of using smaller vessels to install TCP pipelines.

Results

“The project was an excellent example of leveraging collaboration to meet schedule constraints for the operator”, added Christopher Boler. “As we were able to use a smaller chartered vessel to perform the flowline replacement, it allowed the work to be aligned with an umbilical replacement in the same field to further increase efficiencies. Despite a demanding schedule, the team delivered a complex project involving the installation of multiple products from a new vessel, operating in a region where Oceaneering had not previously executed an installation campaign.”

Martin van Onna added: “TCP technology provides a strong, corrosion free, and field-proven solution for operators Our products can help fast-track offshore energy projects, as TCP pipelines can be manufactured quickly, terminated on-site and deployed using light construction vessels to meet tight client schedules.

“The close collaboration between our companies was key to this fast-tracked installation. The teams’ ability to work with vessels of opportunity, rapidly mobilize equipment and crews, and adapt installation methods to local operating conditions, reduced mobilization time and costs. The entire project, from contract to the pipeline becoming operational, was achieved within ten months, representing a five month advantage over conventional solutions and a total cost saving of roughly 25% when compared to traditional approaches.”

Technologies such as TCP that can be deployed from a broader range of vessels enable operators to access available capacity in the market and respond quickly when conventional installation resources are unavailable. Combined with modular equipment, established procedures, and experienced project teams, this approach can provide a faster route from project award to installation while maintaining the highest safety, quality, and technical requirements.