When building a new pipeline, there is a need to work close to existing piping systems that are live and carrying flammable hydrocarbon fluids. Some of those pipes are steel and some are nonmetallic composite pipes. Although all live pipes are vulnerable and can be damaged during excavation to build a crossing pipeline or cable. Nonmetallic pipes that are made of thermosetting resin and glass fibers are much easier to be damaged due to impact and can cause future failures in service, even if they were not live during excavation. To address this problem and to protect existing pipes, a protection method was designed, prototyped and successfully deployed. This method consists of a covering tool of 1.5 meters long, or longer as needed, placed firmly over the existing pipe to protect it from any direct impact resulting from external forces while excavation is in progress. The cover consists of two halves, on the top and bottom of the pipe fastened together using stud bolts. The weight of this cover is supported independently from the pipeline being protected. The two ends of the cover sit on the ground and steel dowels can be used to hold the cover in place around the pipe and to resist any movement that may apply load on the pipe. This protection system encourages the use of nonmetallic composite pipes that are primarily used to combat corrosion. This technology also protects coating on steel pipe to prevent corrosion. The method is granted as a US patent # 11,549,633 for Saudi Aramco.
The challenge that faces constructing new pipelines is the need to work close to existing piping systems that are live and carrying flammable hydrocarbon fluids. Recently, there has been a need to also work near nonmetallic pipelines that are more vulnerable to damage than steel pipes. On-demand shutdown of a pipeline system is usually very difficult to obtain from the respective area responsible operation department. Industry standards and work procedures mandate that when a new pipeline is crossing an existing pipeline, the new line should cross below the existing line with a minimum clearance of 600 mm between the bottom of the existing and the top of the new pipe [1]. This method of construction becomes very challenging when the existing ground consists of solid rocks that require heavy machinery to excavate. Project management records show that there are thousands of pipelines crossings are encountered every year.
