COMPOSITES
IN CIVIL APPLICATIONS
NOTE: From
1994-1998, the bulk of ATP funding was applied
to specific focused program areasmulti-year
efforts aimed at achieving specific technology
and business goals as defined by industry. ATP
revised its competition model in 1999 and opened
Competitions to all areas of technology. For more
information on previously funded ATP Focused Programs,
visit our website at http://www.atp.nist.gov/atp/focusprg.htm. |
Dr.
H. Felix Wu, Program Manager
TEL
301-975-4685
FAX 301-548-1087
felix.wu@nist.gov
|
National
Institute of Standards and Technology
A225 Administration Building
Gaithersburg, MD 20899 |
EXECUTIVE
SUMMARY
The proposed focused
program, Composites in Civil Applications, will catalyze
industry efforts in civil/construction, composites/materials, chemicals/petrochemicals,
and offshore oil production to foster the development of new approaches
and technologies for our nation's infrastructure. Industry has identified
three major new application areas for composite materials: Infrastructure,
Industrial Facilities, and Offshore Exploration & Production.
These application areas are the focus of this program. NIST/ATP will provide
an opportunity to leverage resources from government and industry in a
cost-shared partnership to accelerate the development and dissemination
of composite technology in civil applications.
Infrastructure
systems are integral to the economic and social well being of our nation.
Such systems affect our daily lives ranging from the ability to move from
one location to another, the use of electrical power, and the disposal
of waste to such fundamental issues as the quality of air and water. Because
these systems are so pervasive and complex, they are often taken for granted,
resulting in low levels of maintenance and uneven levels of attention
from policy makers and technologists alike. The level of investment in
the nation's infrastructure is massive, and keeping these assets in usable
condition is one of the major challenges facing the nation over the coming
decades. For example, the Federal Highway Administration (FHWA) estimates
that the federal government alone has invested over $1 trillion in the
nation's highway system. Of concern, over 40% of the nation's bridges
are structurally or functionally deficient. In California alone, over
$3.5 billion is required for seismic retrofitting of bridges. Because
of this need, FHWA is stressing the use of asset management systems that
will target the most economical allocation of resources in upgrading the
nation's transportation system.
Other infrastructure
systems as well are facing stress. Environmental Protection Agency (EPA)
has estimated that billions of dollars must be spent to provide sewer
and water treatment facilities for the nation's urban areas. Additional
billions of dollars will be spent by the private sector in providing pipelines,
tracks, and other network elements that are part of the nation's power
and transportation grid. Technical challenges associated with aging structures
include: time dependent materials degradation, widespread fatigue damage
from increased usage, poor initial selection of materials, or initial
flaws in design and/or fabrication. Industry/government/university collaboration
can produce new materials and technologies that can extend the service
life of constructed facilities with reduced maintenance and improved durability.
For example, applications of advanced composite materials such as glass,
aramid or carbon fibers in polymer matrices are becoming increasingly
important to extend the service life of infrastructure.
Industrial
facilities often operate in severely corrosive environments with
stringent worker safety requirements for structural reliability, fire
suppression and electrical isolation. Composite materials can provide
lightweight, corrosion resistant, and non-conductive structures and components.
Consequently, composites are already in limited use in industrial operations;
however, major efforts at manufacturing affordability could make their
use more encompassing. The general category of industrial facilities includes
a wide range of functions and associated design and performance requirements.
It could consist of refineries, chemical and processing plants, power
generation and transmission facilities, and mining facilities.
Although composites
have been extensively developed and used in the aerospace and marine industries,
these technologies do not meet the specific needs of civil applications.
Infrastructure and industrial applications are characterized by large
scale and rapid construction. Compared to aircraft and marine component
manufacture, civil applications deal in tons of product per project and
thousands of projects per year, and at significantly more locations than
a few aircraft plants and shipyards. While it is necessary to address
the resolution of many outstanding issues such as reparability, flame
and smoke toxicity, durability, environmental impact, and the availability
of validated design codes, standards, and guidelines for civil applications,
the NIST/ATP program can have a major impact on the composite's industries
response to the problems of scale and production volume. Key program issues
are the extent to which automation of the manufacturing process can reduce
cost and increase volume and the degree of quality control and quality
assurance that can be developed and provided during the manufacturing
and installation phase utilizing the typical civil construction work force.
Specific issues to
be addressed are:
- the development
of continuous composite fabrication processes, from fiber placement
through resin impregnation and cure,
- automated methods
of component assembly into large scale structures,
- the impact of
automation and production volume on raw material and production costs,
- methodologies
for design and utilization of pre-manufactured structural elements assembled
at the worksite instead of the build in place model used today, and
- methods to build
in health monitoring systems for subsequent field inspection.
Lastly, it is necessary
to develop and validate a body of analytical and design tools which move
beyond the mature methods for calculating material and structural response
and extend the understanding into critical problems associated with application
include issues of attachments, flexible joints, and field connections
which characterize civil constuction.
The industry/government/university
partnership in this program will utilize the strengths of each partner.
The NIST/ATP program acts as a facilitator, providing two valuable services
- it brings together the construction and composites industry to address
a common technical challenge and it provides funding to leverage activities
that industry is not willing to undertake alone thereby providing the
critical level of resources for success. University research personnel
and laboratories, often uniquely qualified for research in composites,
can direct their efforts to address critical technical problems that inhibit
the successful introduction of products into civil infrastructure applications.
The industry-led program will provide the technology advancements needed
to solve critical civil infrastructure problems and improve the U.S. economy
by creating jobs in the composites and infrastructure service industries
and improving the international trade balance of payments by exporting
new products and services.
Composites utilization
on offshore platform will help to enable/accelerate cost
effective oil and gas production in the Gulf of Mexico (GOM), in the ultra
deepwater (>4000 ft.) regions and in environmentally sensitive areas
along the coast line. Increased oil and gas production in the GOM will
provide new job opportunities and create new business for the composites
and oil and gas related industries. Composites for offshore operations
will require a good balance between material utilization, cost, design
tailoring, manufacturing, and other issues not faced before by the composite
industry in other application areas. For example, the use of short pitch
based carbon fiber for composite tension leg platform (TLP) tendons, will
not only provide a technical challenge to design and material tailoring,
but also for developing innovative manufacturing methods that can provide
the high degree of reliability required for offshore construction. Promising
new composite applications that would be created with advanced technology
include: TLP tendons; synthetic fiber floating production system (FPS)
mooring ropes; thick-walled tubulars for ultra high pressure; double-wall
insulated subsea pipes; long-length, large-diameter pipes; extended reach
smart drill pipes; linerless high-performance fiber-reinforced thermoplastic
pipes; primary platform structures; pressure vessels and tanks; and metal/composite
hybrid structures.
Although composite
materials can offer many positive attributes, affordability achieved by
reaching low-cost manufacturing and integration of new low-cost carbon
fibers will be a crucial issue in this arena. The offshore oil and gas
industry encouraged by the need defined by the U.S. government to reduce
reliance on foreign oil imports is committed to develop Gulf of Mexico
resources. Without support for U.S. based development, the industry will
import technology from overseas. This could lead to loss of job opportunities
and overseas technology dependency, which would not be beneficial to the
U.S. industry as a whole. While heavy collaborative effort in composites
is strongly encouraged by government agencies overseas, the U.S. composites
industry is just recovering from the downturns in the late eighties and
early nineties. Without NIST/ATP commitment for funding, many composite
manufacturers will not venture into long term, high-risk projects with
the oil and gas industry (which is also known, at times, to be as volatile
as the composite industry). The NIST/ATP support provides the stability
to ensure a continuous path of high-risk technology development where
return of investment could be tremendous. In addition, the NIST/ATP not
only will help reduce dependency on imported oil, but also help efficiently
accelerate the pace of composite technology and encourage cost-effective
development of future ultra deepwater Gulf of Mexico hydrocarbon resources.
POTENTIAL
FOR U.S. ECONOMIC BENEFIT
Civil infrastructure
including bridges and buildings forms a significant aspect of the nation's
investment. Although our use of highways has increased dramatically over
the past decade there has been chronic under investment in both maintenance
and upgrading facilities resulting in the current situation wherein more
than half our urban and rural roadways are in poor, mediocre or fair condition
and 31.4% of our bridges are rated as structurally deficient or functionally
obsolete. The FHWA estimates that over $80 billion will be needed to just
eliminate the current deficiencies in bridge structures and to maintain
current repair levels. The introduction of methods of renewal (including
new construction) using high performance composite materials that are
light and durable present the opportunity for immense economic benefits
both in real terms and in intangibles. In real terms repairs could cost
less and be conducted faster enabling a net savings to the nation while
upgrading or maintaining our current infrastructure. New construction
using these technologies would have a significantly longer life-time and
technical issues related to dead weight which have often restricted functionality
would be resolved. The durability of composite decks for example would
significantly reduce the overall maintenance costs borne by state DOTs
(for example some DOTs expend over 50% of their annual budget on maintenance
of bridge decks).
Besides the tangible
economic benefits there are myriad intangible benefits related to savings
of GDP resulting from on-time delivery of goods and services that are
currently delayed due to slow moving traffic over posted bridges and roads,
traffic jams due to insufficient access etc. Further as traffic needs
increase (including those related to higher speeds) losses due to old
and deteriorating infrastructure will result in losses in the billions
of dollars annually.
Civil transportation
infrastructure is an important aspect of the world economy and contracts
worth billions of dollars are let annually on a global basis. Without
the development of the technology, U.S. companies will be at a disadvantage
in competing in a global economy. Already U.S. primes are losing to Japanese
and European companies due to the lack of such advances and their deployment
in the U.S. Further foreign companies are even conducting rehabilitation
jobs in the U.S. due to the lack of U.S. firms with similar technologies,
resulting in a further economic loss.
Fiber-reinforced polymer
(FRP) have greater strength capabilities and are less susceptible to environmental
deterioration than steel. FRP composites do not deteriorate in the presence
of road salts, which shorten the life of a conventional structure. Additionally,
FRP has weight to strength ratios of 50 times that of concrete and 18
times that of steel. An example for future use of FRP is in Ohio. Ohio
has 42,865 bridges, 24,551 of those are currently rated inadequate to
support today design loads. Nationwide out of the 600,000+ bridge
structures there are 30% to 40% that are structurally deficient or functionally
obsolete. It has been estimated by FHWA that it would cost approximately
$212 billion to eliminate these highway deficiencies. AASHTO has estimated
approximately $263 billion to eliminate the deficiencies and $94 billion
just to make modest repairs or upgrades. Ohio DOT alone spends approximately
$200 million yearly to replace or rehabilitate bridge structures. All
of these structures will gradually have to be replaced and composites
could play a significant role. It is conceivable that with the good attributes
composites have to offer the construction industry, and if high risk composite
systems or products were developed they could have some impact on 10%
of these structures. This would represent $20 billion nationwide and $20
million annually in Ohio.
The technology needed
to safely and economically develop deepwater petroleum bearing reservoirs
is extremely complex and will require advancements in several different
disciplines. Technology is playing a vital role in reducing the cost of
finding and producing oil and gas. Important advancements have been made
in seismic technology, directional drilling, multiple completions, subsea
systems, and production techniques. Composite materials are another technology,
which could provide important enabling solutions for safe, affordable
deepwater development. Floating platforms are the only practical configurations
for deepwater and are commonly used in combination with subsea wells.
Floating platforms are tied to the ocean floor by moorings or tethers,
or for drilling can be dynamically positioned using thrusters. Saving
weight is an important design consideration for floating platforms with
more cost benefit for some configurations such as Tension Leg Platforms
(TLPs) than others and corrosion prevention is also important. Successful
introduction of secondary composite structures, such as gratings, hard
rails, and ladders, on recent GOM TLPs and NIST/ATP research programs
have positioned the oil industry to be receptive to composites for primary
structural components. Low-cost manufacturing methods and utilization
of hybrid materials to minimize cost are two examples of ways composite
manufacturers are addressing the cost issue.
The ATP program initiated
by NIST in 1995, which focused on composite manufacturing for the oil
industry, provided significant stimulus to get composites acceptability
within the broader petroleum industry. Products such as composite production
risers, drilling risers, and spoolable pipe are being considered in project
planning exercises. A significant amount of scientific technology has
also been developed under these programs such as complex metal to composite
joints, hybrid material design methods, and composite structure reliability
analytical methods.
The oil industry is
currently developing the deepwater solutions that will be implemented
in the 1st decade of the 21st century. Many issues
are multi-disciplinary in which a solution for one problem affects the
design of many related components. Weight savings fall into this category
and if composites are not considered in the early planning stage, the
benefits will not be captured and the industry will become entrenched
in an alternative inefficient solution. Advanced composites technology
needs to be developed now and be ready for application during the introductory
window of opportunity which for ultra deepwater GOM will be during the
next five years.
GOOD TECHNICAL
IDEAS
It is noted that the
quality of construction strongly affects the wealth and productivity of
a nation. More than 60% of the fixed reproducible wealth of the U.S. is
invested in publicly and privately owned constructed facilities. Infrastructure
represents approximately 25% of the nation's stock of physical capital.
However, the quality, durability and flexibility of the construction materials
and systems used restrict this investment. Current estimates place the
value of the nation public works infrastructure at $2.7 trillion with
the bulk of these assets (86%) in the hands of state and local governments.
Also, infrastructure comprises approximately 25% of the current national
construction related expenditures estimated at $450 billion annually.
U.S. infrastructure, however, is perilously close to the limit of its
design life because of a consistent history of inadequate maintenance
and lack of motivation for rapid implementation of innovation in this
area.
The visible consequences
of the state of U.S. civil infrastructure are evident in structurally
deficient bridges and deteriorating highway pavements. At the minimum,
ten percent (60,000 miles) of the federal-aid pavement falls below minimum
engineering standards. The Road Information Program (TRIP) notes that
60% of the nation's pavements require substantial rehabilitation. In the
U.S., an estimated 40% of all bridges are judged to be structurally deficient
or obsolete and require repair, strengthening or replacement. The cost
to eliminate deficiencies as noted in 1993 was $78 billion, with the average
annual cost to just maintain our deteriorating status-quo being $5.2 billion.
Current estimates for repairing only bridges and roads that are seriously
deficient or about to fall below minimum acceptable standards are projected
at $167 billion. Another $90 billion is required for repairs to the 238,000
highway bridges. Similar levels of distress are also seen in pipelines
used for the distribution of potable water and sewage with repair and
replacement costs being estimated at the same level of magnitude (e.g.
repair to major aqueducts in California alone are estimated to cost over
$1 billion. Serious deterioration to de-icing salts is present in more
than 55,000 parking garages, and a significant percentage of industrial
facilities and multi-story homes fall below minimum acceptable standards
for safety. The costs of an inadequate infrastructure are enormous. One
study estimates that by the year 2005, traffic delays caused by inadequate
roads and highways will cost the nation a staggering $50 billion in lost
wages and wasted fuel. More than inconvenience, such losses are a fatal
blow to the nation's economy and to its competitiveness in a global economy.
Infrastructure is the single most pervasive element that affects a nation's
economic competitiveness, and in today's world, it's national security.
Approximately 65%
of United States energy needs are supplied by petroleum. Domestic oil
and gas production, however, is declining and in 1998 the United States
will import approximately 4 billion barrels of oil accounting for 56%
of consumption and add approximately $63 billion annually to the international
trade deficit. In 1972, just prior to the oil embargo, the United States
imported 1.7 billion barrels of oil, which were only 29% of total consumption.
One promising new source for petroleum in the United States is from reservoirs
located beneath deepwater in the Gulf of Mexico (GOM). It will be a significant
challenge to produce petroleum from reservoirs located beneath ultra-deepwater
(up to13,000 feet of water depth). Lightweight, corrosion-resistant composite
materials could provide an important contribution to the safe, economical
development of deepwater petroleum resources. In addition, if composite
products are developed by U.S. manufacturers rather than overseas, they
could be deployed in deepwater basins in other parts of the world to provide
a valuable market for U.S. products. The export of composite products
for the oil industry will help make U.S. oil and service companies more
competitive in international exploration and production services and has
a significant positive impact on the U.S. balance of payments. Based on
the needs and opportunities identified, NIST/ATP established a focused
program on Manufacturing Composite Structures for the
oil industry and six programs addressing oil exploration and production
applications were initiated in 1995. These programs will finish their
third year of development in 1998 and several programs have made sufficient
progress to move toward commercialization. The technology developed is
also being used to develop alternative oil application products based
on current market demands. NIST/ATP support helped create a critical mass
of interested parties involving all the stake holders, the end users (oil
companies), technology developers (industry and universities), and potential
suppliers (materials and manufacturers). These interdisciplinary teams
worked together to define the functional requirements, resolve critical
technology barriers, conduct validation tests and establish specifications
in preparation for the introduction of new products into service. Without
NIST/ATP support, the oil industry would be much less prepared to accept
and apply composite materials.
STRONG COMMITMENT
OF INDUSTRY
Two Working Group
Committee meetings occurred on January 29 and March 5, 1998, in which
five technical areas were identified by industries during the planning
meetings. Eight white papers have been submitted to ATP Program Manager
by industry recommending three major industries needing ATP program stimulus:
Infrastructure, Industrial Facilities,
and Offshore Exploration & Production. The recent
ATP Workshop on Composites in Civil Applications on June
17-18 has shown that these industries have great interest and enthusiasm
about participating in the recommended focused program. This ATP Workshop
attracted more than 140 participants from industry, governmental agencies,
and academia. The industries represented included civil/construction,
composites/materials, chemical/petrochemical, and offshore industries.
Using offshore E&P as an example: the oil industry provided strong
support to first NIST/ATP composite focused program. The oil industry
appreciates the potential of composites to provide economic and technical
enabling contributions in ultra deepwater developments. From the first
solicitation of the composite focused program, it is clear that composite
manufacturers have good ideas to incorporate in proposals for new ATP
programs. Major oil and oil service companies can be expected to participate
in high payoff programs if ATP focused program is offered. The timing
of the need for a new focused program for industry is now. The industry
can be expected to submit proposals to the Composites in Civil Applications
focused program competition whenever ATP composite focused program becomes
available.
OPPORTUNITY
FOR ATP FUNDING TO MAKE A DIFFERENCE NOW
It should be noted
that the civil and construction industries are fragmented and although
willing to use and implement new technologies, have historically needed
facilitation from other sectors. The NIST/ATP program functions as a facilitator,
providing two valuable services (1) It brings together the construction
and composites industry under a common umbrella with a common goal, and
(2) it provides funding to leverage activities that industry is willing
to undertake thereby providing the critical level of resources for success.
Substantial progress has been made over the past five years in the development
of composites for civil infrastructure applications ranging from reinforcing
and dowel bars, to cables, bridge decks and girders, retrofit, repair
and strengthening techniques, and even full structural systems. The civil
engineering industry has a far greater understanding and degree of comfort
associated with the use of these materials and this predicates a higher
degree of success for programs initiated now over those initiated a few
years ago.
Although ATP has previously
funded a more general competition in this area aimed at low-cost manufacturing
previously, it should be stressed that with a few exceptions the programs
funded were not focused strictly on civil infrastructure but rather were
aimed at the development of manufacturing methods in general with civil
infrastructure components being used as technical demonstrators only.
The needs of civil infrastructure are such that specific materials systems,
design approaches and manufacturing methods need to be developed that
focus on the technical needs, functionality and economic criteria specific
to civil infrastructure. The adaptation of methods for other areas to
civil infrastructure is likely to end in a more costly product with little
value in terms of that component or in terms of spin-off advantages.
The civil infrastructure
industry routinely and generally has a high commitment to technologies
that meet their needs. It has only been with in the past several years
that the civil infrastructure has shown interest in composites as alternatives
to or in use with steel and concrete to solve various needs. There are
several organizations or committees now that state DOT's engineering firms
and contractor companies have organized or sit on that reflect their interest
in using composite. Several of these are American Concrete Institute (ACI440)
which deals with composites in concrete, AASHTO for the state DOT's has
a new committee designated solely for composites in infrastructure, Highway
Innovative Technology (HITEC) which sets up panel evaluations for company
products and is evaluated by state DOTs. The Composite Institute has their
Market Development Alliances (MDA) for bridge applications, which has
members from the resin industry, fiber industry, contractors and manufactures.
It is generally accepted
that light-weight, fiber-reinforced, composite materials could play a
major role in facilitating the safe, reliable, economical production of
oil and gas from deepwater reservoirs; however, significant work needs
to be done to make the technology ready. Steel is the primary material
used in the construction of offshore platforms and infrastructure and
tubulars are the most common structural element. Steel is relatively inexpensive,
but heavy and susceptible to corrosion. Low-density and corrosion resistance
are the primary properties which make composites attractive for offshore
developments. In deepwater, the value credited to saving weight increases
and composites become more economically attractive.
Unlike the aerospace
area, the oil industry does not have a strong sponsor for development
work in the materials area, either within oil companies or the oil service
industry. In the modern highly competitive commodity market driven by
stockholder expectations of ever increasing profits, most oil companies
have in the last 5 years reduced or eliminated in-house research in the
materials area. Oil companies have downsized or closed materials laboratories
with the expectation that the oil service industry and universities would
fill the need. The net result is that in the last five years much less
research has been sponsored in the materials area. Fortunately for composite
materials, the NIST/ATP programs have helped keep active a critical level
of research and development activity in support of oil E&P applications.
By the time project
engineers enter the planning stage to develop the supporting infrastructure
of field developments, it is usually too late to develop new technology
unless it is impossible to accomplish the objective otherwise. Project
teams focus their attention on existing technology, even if it is more
expensive or less efficient. The uncertainty of changing development scenarios
during such long lead times is a primary concern for product manufacturers
and becomes one of the primary reasons government support is needed to
help accelerate the pace of development and ensure that products are available
when they are needed.
A successful development
program spurred by a NIST/ATP initiative will have a significant impact
on the economic development of ultra deepwater in the GOM. The increased
utilization of composites will have an extensive impact on the composites
supply and manufacturing industries. An expansion of the composites industry
will result in a large net increase in needs for skilled labor in the
U.S. to supply materials and products. A new market for composite materials
will be developed. The increase in the market for carbon fiber over the
next ten years, for example, could be on the order of 250 million pounds.
This market will also consume large quantities of aramid fiber, glass
fiber, matrix resins and other associated materials used in the manufacture
of composite structure. The potential market for new components for the
GOM offshore market over the next ten years could exceed $5 billion. The
global market could be even larger.
Realistically, however,
the composites industry has little capital to invest in new product development
and oil companies allocate little resources to the materials development
area. Without a NIST/ATP or other external stimulus, only a portion of
the needed development will occur and such efforts will not be at the
pace needed to meet the window of opportunity concurrent with the early
development of ultra deepwater resources.
TECHNICAL
AND BUSINESS SCOPE
The key advantages
of fiber-reinforced composites, such as free-form and tailored design
characteristics, strength/weight and stiffness/weight ratios which significantly
exceed those of conventional civil engineering materials, high fatigue
resistance, and a high degree of inertness to chemical and environmental
factors, are often overridden by high materials and manufacturing costs,
particularly in direct comparison with conventional structural materials
such as steel and concrete. However, the recent downturn in defense spending
and the resulting need for new markets has spurred renewed efforts in
reducing the costs of both raw materials and manufacturing processes,
making composites more competitive to use in civil infrastructure applications.
In addition, the anticipated availability of low-cost carbon fiber will
allow composite composites to be competitively applied to a much larger
class of civil infrastructure and offshore applications. These materials,
are easily applied to a variety of civil infrastructure, industrial facilities,
and offshore E&P problems and their application can generically be
classified as in the following diagram.
Although composites have been extensively developed and used in the aerospace
industry, they need to be developed further in specific directions for
use in civil infrastructure and industrial facilities. In fact, the extent
of these applications are used will depend on (1) the resolution of outstanding
issues such as repairability, fire, durability and environmental concerns,
(2) the extent to which automation in the manufacturing process can reduce
cost, (3) the development of composite material based design concepts
that optimize the use of the material, (4) the availability of validated
codes, standards, and guidelines which can be used as design references
and tools by the civil engineering community, and (5) the degree of quality
control and quality assurance which can be developed and provided during
the manufacturing/installation phase utilizing unskilled general construction
labor.
Similarly, although
composite technology applied to the oil industry has much in common with
aerospace, infrastructure and automotive, it also is driven by unique
requirements, both technical and economic. Some applications will benefit
significantly from technology transfer while other applications or issues
require unique new developments to succeed. In addition, technology transfer
can propagate in two directions. Research conducted in support of oil
industry applications has generated several advanced capabilities, which
could be helpful to other industries. Examples of frontier areas of research
conducted for the oil industry include understanding of the mechanics
of hybrid structures, design of ultra high strain components, and design
of thick-walled tubulars. In addition, very advanced failure prediction
analytical methods have been developed in support of NIST/ATP composite
production riser and spoolable tubing projects. Through complementary
teaming arrangements with universities and small companies, an ideal model
for ATP programs is to encourage participation by the academic community
to ensure that good engineering principles are applied and advanced technology
capabilities are developed as needed.
There are several
areas in which more research is needed to advance the state of understanding
to support the design of future oil industry applications. More work needs
to be done on hybrid structures. Most of the advanced applications will
rely on combinations of carbon and glass to meet high performance requirements
at minimum cost. The availability of low cost carbon will move toward
greater carbon utilization. Another interesting area which has surfaced
in the development of certain applications is the requirement to resist
ultra high impact loads. The hull of a TLP, for example, must resist impact
by 2500 kJ and the drilling riser must resist a 250 kJ impact. These are
extremely large energies and work needs to be done to be able to survive
this level of impact load safely. Sensor technology is rapidly advancing
in drilling and logging operations. It is not only possible to integrate
fiber optics into the wall of composite tubes as transmission lines, but
to better use the sensors themselves for structural integrity monitoring.
The area of damage tolerance and repair are important as well as inspection
and nondestructive test methods. The use of new materials and combinations
of materials means that design allowables are not well established and
safety factors have not been well defined. In addition, much work remains
to be done to develop and translate advanced analytical methods into more
automated design procedures. Low-cost manufacturing will continue to play
an important role in the successful economical development of new composite
applications as will creative structural engineering to take advantage
of the design flexibility offered by composite materials.
The ultimate goal
of this program is that the technology developed will encourage and enable
a broad range of new applications for composite technology in civil infrastructure,
industrial facilities, and offshore oil and gas operations. Some of these
potential new applications include creative concepts for long-life, low-cost,
large structures/joining technology for bridge construction; growing design/manufacturing/construction
with new materials/shapes/manufacturing technologies with safer, corrosion-free,
and more cost-effective for industrial facilities; and a whole new series
of products for the oil industry to enable the cost-effective development
of ultra deepwater petroleum resources. It is also anticipated that these
advancements will improve the economy of the United States by creating
jobs and reducing the international trade deficit through the export of
products and services and decreased dependence on foreign oil. A NIST/ATP
focused program is key to making certain that a critical level of effort
is deployed in the United States to capture these advantages.
Exclusions from technical
scope include the following:
- Demonstration
projects.
- Development of
design codes and standards/specifications.
Date created: October
1999
Last updated:
April 12, 2005
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