Effect of Material and Stacking Sequence on the Global Analysis of Oil and Gas Wells with Thermoplastic Composite Pipe Tubing

The growing demand for materials that combine lightweight characteristics with high strength has driven the development of alternatives to steel in the oil and gas industry, particularly in challenging environments such as pre-salt and post-salt fields. In this context, the present study investigates the feasibility of using thermoplastic composite pipes (TCPs) as tubing in oil and gas wells. A parametric study was conducted to evaluate the impact of material selection and laminate stacking sequences on load distribution. Structural performance was assessed using finite element method (FEM) simulations with beam elements, considering interactions with casing, gravitational effects, internal and external pressures, and thermal loads. Classical Laminate Theory was employed to convert local anisotropic properties into global stiffness matrices, enabling the analysis of various loading scenarios for PEEK/FC and PVDF/FC composite pipes. The results indicate that, while steel remains a reliable baseline, TCPs can reduce axial loads at the tubing hanger by up to 50% due to their lower density. Laminates with intermediate fiber orientations promote a more uniform stress distribution, mitigating peak loads in transition zones. FC/PEEK exhibited lower sensitivity to angular variations compared to FC/PVDF, primarily due to the characteristics of its polymer matrix. Stacking sequences with intermediate fiber orientations, demonstrated greater efficiency under combined loading conditions than extreme configurations. These results reinforce the potential of TCPs as a promising alternative for lighter, safer, and more resilient offshore production systems.