[0001] Iliis application claims priority from U.S. Provisional Application No. 63/350,228 (the ‘228 application) filed June 08, 2022. The ‘228 application is incorporated by reference.

[0002) This application relates to the subject matter of the family of patents for SMARTPIPE TECHNOLOGIES® (herein referred to as “Smartpipe”), and it is applicable to Smartpipe multi layered flexible composite pipelines including:

U.S. Pat. No. 5,551,484 “Pipe Lines* and Monitoring System,

U.S. Pat. No. 7,374,127 “System and Methods for Making Pipe Liners”

U.S. Pat. No. 7,258,141 “Pipe Liner Apparatus and Methods”

U.S. Pat, No. 8,567,448B2 “Methods and Systems for In-Situ Pipe Lining”

U.S. Pat. No. 8,567,450132 “In-Situ High Pressure Pipe Manufacture”

U.S. Pat. No. 9,310,014B2 “Pipe and Systems and Methods for Making Pipe for Installation in a Pipeline*

U.S. Pat. No. 9,453,606 “Movable Factory for Simultaneous Mobile Field Manufacturing and Installation of Non-Metallic Pipe”

U.S. Pat. No. 10,288,207 B2 “In Line Inspection Method and Apparatus Performing In Line Inspections”

U.S. Pat, No. 10,436,667 “In Line Inspection Method and Apparatus

Performing In Line Inspections”

U.S. Pat. No. 629811 55 “In Line Inspection Strain Device Method and Apparatus for

Performing In Line Joints Inspections”

U.S. Pat, No. 1112049 “System and Methods for Transient Mitigation Device in Continuous Pipelines for Surge Impact Control”

629811 55, PCT/US2021/019723 “In Line Inspection Strain Device Method and Apparatus for Performing In Line Joints Inspections”

[0003] The present invention addresses the current technology gap that exists for the management and mitigation of gaseous permeation through non-metallic and partially metallic composite pipe structures, termed Reinforced Thermoplastic Pipe (“RTP”). This novel Gaseous Zero Emissions Device (“ G-ZED”) is specifically designed for the inspection, detection, and management of the potential permeation of the gaseous medium within the RTP layers and beyond.

Currently, there is no such system available in the composite pipeline industry, other than in the Smartpipe suite of technologies. Other Smartpipe patents are applicable to leak detection, continuous monitoring, periodic inline inspection of line pipe and connectors, and mitigation of high-pressure transient events.

[0004] The high-strength structurally layered materials of the Smartpipe RTP are unbonded, allowing any volume of the permeated gas, however small to flow freely through the layers between the inner plastic core pipe and the protective outer cover, until it reaches a collection point, the .G*ZED. The accumulation of the gaseous medium is controlled and collected to be processed, reused, or disposed of. The Gaseous Zero Emissions Device is functional for multiple forms and uses of RTP pipelines. This G-ZED novelty represents a completion of Smartpipe's monitoring system by combining Smartpipe’s patented Fiber Optic and multiple embedded discrete sensors with integrated reader/activator, this novel device for monitoring and managing permeation of the gaseous substances in a .single apparatus.

[0005] Other Smartpipe patents are incorporated here by reference. It should be noted that the specific product “Smartpipe” RTP is a patented invention, and that the present patent application conforms to the extended art of the invention where this invention compliments the original product, adding a novel application to fill an existing industry technology gap: the monitoring, collection and control of composite pipeline permeation of gaseous substances utilizing a composite pipe-based device, the G-ZED. It is important to note that the system is in continual monitoring mode where it is possible for the operator to obtain the data at any time. This novel system has not been available in the composite pipe (RTP) industry until now. This novel system is designed to be integrated with the industry’s existing and future R'lP pipeline systems, to be installed on new RTP pipe or retrofitted onto an existing installed RTP pipeline.

BACKGROUND

[0006] The Reinforced Thermoplastic Pipe industry has grown exponentially over the past 25 years. These flexible, high-pressure systems transport most anything that has been traditionally transported by steel pipelines. RTP has many advantages over steel pipelines, including flexibility, constructability in difficult environments, light weight, non-corroding materials and in the case of Smartpipe, fiber-optic monitoring cables and embedded sensors along the full length of the pipeline to monitor and inspect its structural health. There is _? however, a feature of composite pipe that is not a positive,, the permeation of gas through the composite structure, which releases to atmosphere or, in the case of RTP installed inside a steel pipe, accumulation of the gas in the steel pipe’s annular space. This accumulation poses significant safety risk, and the industry has previously vented the gas to the atmosphere by strategically placed vents along the length of the steel pipe. '1'his procedure is no longer acceptable to the public dr the industry regulatory bodies. While some RTP products have reduced or claimed to eliminate in its entirety the permeation of gases, due to unforeseen quality control or manufacturing defects, will go undetected, as there is no other process to detect or safely remediate the presence of gases and no other RTP products are monitored or inspected while in operation.

[0007] This invention is designed to address these problems that are known to presently exist in the composite RTP pipeline industry. The engineered G-ZED system functions to prevent gaseous substances’ uncontrolled accumulation, release to the atmosphere and potential catastrophic failure of the pipeline. Personal safety and environmental security are threatened by pipelines that cannot be monitored and periodically inspected by operators and pipeline regulators. This invention relates to a method and structurally inventive system-construction or mechanism to facilitate such monitoring and inspection of the composite pipe, and channels permeated gases to a collection point where they are then re-injected into the pipeline, re-used to power necessary appurtenances, or disposed of. This invention contains embedded sensors for detection, monitoring, equipment activation and deactivation for gaseous substances’ containment, reuse, or removal. The system’s components are designed and assembled as a package that includes sensors,: method of attachments designed to the specific pipeline requirements, and are user friendly for installation and operation in existing and new pipelines.

[00081 This novel G-ZED device is not currently available in the industry. The novelty of this invention is found to be most useful in RTP pipelines where there is a need to detect and eliminate gaseous substances feat permeate through the wall of the pipelines. Industry standards or performance allowances by authorities that regulate pipelines require zero emissivity performance for fee pipelines. Uncontrolled accumulation and release of gaseous permeation, due to the absence of continuous monitoring and effective management of the accumulated gas is unacceptable and as a result becomes a serious safety hazard to both the public and environment. [0009] The G-ZED inventive system is equipped with electronic monitoring sensors which determine the permeated gaseous accumulated quantities, pressure; or potential leaks as a part of the pipeline’s total monitoring and inspection dataset. The G-ZED is tested and certified as part of the system’s manufacturing and subsequent operational procedures.

[0010] The Smartpipe G-ZED system for detection and management is a method of detecting the presence and volume of the gaseous accumulation, where the G-ZED device collects such data and either automatically evacuates the accumulated gas, or transmits the data to the operator, who then activates the system to eliminate the gaseous containment.

[0011] This safeguards and informs the G-ZED operator to recognize the condition of the gaseous permeation and accumulation and the performance of the necessary steps for its containment, reuse, or removal. The system can be programmed to automatically perform the removal, reuse or containment functions, or the operator can manually perform the operations based on predetermined metrics.

[0012] Additionally, due to the high-strength and flexibility of the composite pipelines, it is also feasible to install multiple nested pipes within pipes, and as such the annular spaces become safe containment and flow channels for the permeated gases, This is especially important for pipelines in hard to access, high consequence locations.

SUMMARY OF THE INVENTION

[0013] The inventive system and methods for net zero fugitive emissions in pipelines by means of the G-ZED is a novel method and apparatus which is presently non-existent in the pipeline industry. The G-ZED is an addition to the previously issued patent for the ILI monitoring system, and it applies to RTP pipe and the outside environment in monitoring of the pipelines for hazardous gases.

(0014] The G-ZED completes the Smartpipe composite pipe system as a self-contained, connected, state of the art pipeline, incorporating the monitoring, collection, reuse, or disposal of permeated gas of any type. This novel system channels the permeant through the reinforcement layers, sealing it inside Smartpipe’s outer cover until it reaches a collection point, thereby eliminating fugitive emissions of hazardous gases of any type from the Smartpipe or other RTP system. [0015] The inventive G-ZED system is a non-intrusive component device, and as a fully assembled piece, it is installed at one or more locations along the pipeline; The G-ZED will monitor and transmit data relative to the volume, flow, and pressure of the collected gas. The designed G-ZED system is equipped with multiple sensor devices, positioned in the best configuration to provide crucial information to the operator for appropriate action to be taken, maintaining optimal structural health of the pipeline. The G-ZED device cooperates with the in-line inspection system to provide full control of the pipeline, The system is replaceable, if necessary. The system can be installed outside of the pipeline performing the same function if the operator of the pipeline deems it necessary for such operation.

[0016] The inventive system provides the G-ZED as a pre-manufactured device for pipelines as may be required by customers,

[0017] An important feature of this inventi ve G-ZED device is to function as the mechanism for facilitating use of the gaseous substances as accumulated, removed, contained, stored, processed by catalytic converter or other relevant methods, re-used or reinjected into an operating pipeline. The G-ZED device will address current and future regulatory codes that require net-zero-emissions. The G-ZED product can be implemented at the time of the original construction of a pipeline, or at any time requiring the pipeline to be equipped with such a device.

[0018] The inventive G-ZED system for pipelines is described with the inclusions of the drawings and items or components of this ‘"first-to-file” document designated as the figures from 1 through 12. The final submission proposes additions if needed to complete a full function of this application.

[0019] It is an objective of this G-ZED invention to integrate this system with the entire inline inspection system and all its components.

[0020 The novel G-ZED device is assembled, ready for transportation to the site for installation, constructed at the connecting point with a pipeline and conduits in continuation, which may be a new, rehabilitated, reconstructed, or stand-alone pipeline.

[0021] It is further intended: that multiple installation configurations are possible, such as above ground, within a host pipeline, direct buried underground, in multiple conduits, culverts, subsea, and in a variety of industrial applications in conduits and other industrial applications.

[0022] It is further intended that the novel use of this inventive system Is also applicable in Smartpipe “C”-shape reduced cross sections for later processing in the pipelines, and in a multiple configuration of concentric, multiple smaller pipes within pipe combinations, and of the shapes in reduction as documented in other Smartpipe patents.

[0023] It is further intended that the novel method of the new pipeline designed structures may requite a multiplicity of the inner composite liners in a concentric configuration. G-ZED devices may be installed inside the layers, above or below layers, on the host pipe, and inside the cavities, to assess the condition of the pipe and related spaces around the pipeline to its position underground, above ground and in an extraneous condition, such as liquids.

[0024) It is further intended that proprietary computer hardware and software is also a part of the inventive system.

[0025] It is further intended that this novel method of the invention, its engineering and mechanics are applicable to specific requirements in a specific connection in a pipeline and can be calculated in advance to demonstrate such function of the pipeline. A custom made In Line Inspection Strain Device (“ILISD”) will allow for variable combination of the constructed elements.

NOVELTIES OF THE INVENTION AND INNOVATION

[0026] The present state of the RTP industry has no provision for the types of devices constructed with pipelines for gaseous permeation collection, reuse, and containment. The reference is noted that a prior art invention Smartpipe is used in the manufacturing of the G-ZED product. The system is suitable for reinforced thermoplastic composite pipe and other non-metallic or partially metallic pipelines and conduits. This novel G-ZED device has not been previously available in the industry.

[0027] The novelty of this inventive system is that the G-ZED device structure and its component members are designed specifically for the acceptance of the connectors suitable and specific to RTP pipes, specifically Smartpipe.

[0028] The novelty of the structure of G-ZED device is that it is constructed in a multiplicity of combinations and connections to Smartpipe.

[0029] The inventive G-ZED sy stem's data collection allows for the assessment of the condition of the gaseous accumulation indicating the need for means of reuse or disposal.

[0030] The novelty of this inventive G-ZED system is in its advantage where unbonded composite pipelines’ reinforcement layers contain voids, as a primary permeation flow channel and containment, and the heist pipelines’ annular space as the secondary containment. Bonded composite pipe has no such reinforcement layer flow channel, and the permeated gases are collected and channeled through the host pipe annular space, if installed in a host pipeline. The flow and elimination of the gaseous containment is collected by the G-ZED device from within the RTP layers and the annular space of the host pipe, to be facilitated within the same device. The critical features of such a system are not currently available in today’s industry'.

[0031] The novelty of the invention is in the ability of the G-ZED system to perform its function in separate and combined interactive work with the reinjection into a pipeline, collection, reuse, or disposal by other means.

BACKGROUND OF THE INVENTION AND INNOVATION

[0031] The invention relates to the G-ZED devices made from CRA (corrosion resistant alloy) or non-metallic composite pipe chamber, or combined concentric chambers, with sensors and compartments for collection of the gases, differential pressurization, and various means of reclaimed gas reintroduction into the existing pipeline, The other options are to remove and contain in system storage chambers the collected gaseous substance, or to transfer into a separate pipeline system.

[0033] The G-ZED technology is made available in conjunction with the prior art for making the composite pipelines.

[8034] This technology, as it relates to the composite pipelines, develop as line pipes in the “C" formed sections as well as other patented cross sections, as referenced here as ‘form shaped sections”, and specifically noted in the Smartpipe patents. The free standing RTP pipes are also the subject for use of this G-ZED device.

[0035] The form shaped Smartpipe RTP pipes are made with a reduced area in cross section from the host pipe. They replace a full function of the host pipe, but the host pipe provides in situ annulus that is a barrier to the permeation of the gaseous substance to the surrounding ground, The G-ZED device is primarily designed to contain the permeation from the RTP pipe alone, but the device also allows for collection of the gaseous substance from both spaces.

[0036] Ibis inventive system of G-ZED devices, is capable of being installed in a variety of ways, such as at the end of the continuous RTP pipe, terminating with a special connector; and connected to the CRA (corrosion resistant alloy) or non-metallic composite pipe section, where a portion of the free standing RTP pipe is exposed to the cavity of the chamber, allowing for the free flow of gas permeation into the chamber. The collected gaseous substance would then be conveyed into the CRA (Corrosion resistant alloy) or non-metallic composite fitting section of the continuous pipe, which can be lined with another section of the RTP pipe. The Intermediate means of the gaseous substance evacuation can be also devised by means of the outside collection chamber or redirection of the collected gaseous substance into a separate pipeline.

BRIEF DESCRIPTION OF THE DRAWINGS

[0037] FIG. 1 is a longitudinal cross section of the permeation stem installation. The existing pipe is fitted with a connector specific to RTP connectivity.

[0038] FIG. 2 is an isometric depiction of a typical profile of RTP with a cross section of “shape formed” pipe in “C” formation .

[0039] FIG, 2a is an expanded cross section of the RTP depicted in FIG. 2.

[0040] FIG. 3 is a longitudinal cross-sectional detail of the permeation stem installation showing the RTP configured within the proprietary connector, The illustration represents the flow of the gaseous substance permeating through the pipe.

[0041] FIG. 4 is a depiction of the permeation gas chamber assembly with the inventive G-ZED device engaged over the assembly with several components of the pipeline.

[0042] FIG. 5 is a longitudinal section of the permeation gas chamber assembly with venturi concentric pressurization showing the position of the G-ZED device parallel to the primary device.

[0043] FIG. 6 is a flow diagram depiction of the G-ZED device permeation processing system with embedded sensors, electronics and fiber optics for receiving, processing and gathering information at the connected ports via the Scada or other computerized means.

[0044] FIG. 7 is a longitudinal cross sectional depiction of the Smartpipe In Line Inspection Strain Device (“ILISD”) device combined with utilization of the G-ZED permeation device chamber where the continuation of the monitoring system is fully functional within the CRA (corrosion resistant alloy) or non-metallic composite chamber, and the gaseous substance is collected within the same chamber.

[0045] FIG. 8 is a longitudinal cross sectional depiction of the Smartpipe Transient Mitigation Device (“TMD”) device positioned within the concentric chamber for gaseous substance containment of the G-ZED permeation device.

[0046] FIG. 9 is a cross sectional depiction of the G-ZED continuous pipe chamber as a concentric pipe in single and multiple configurations, providing for the annulus spaces evacuation of the gaseous substances, which may escape from inner pipeline into each subsequent cavity.

[0047] FIG. 10 is a cross sectional depiction of the G-ZED continuous pipe combining multiple pipes within the pipe and the multiple annulus spaces that can sequentially collect gaseous substances, and safely provide for their fell evacuation.

[0048] FIG. 11 is a depiction of the G-ZED continuous free-standing pipe with a single containment chamber.

[0049] FIG. 12 is a depiction of the G-ZED continuous free-standing pipe with two or more containment chambers.

DETAILED DESCRIPTION OF THE INVENTION

(0050] FIG. I shows the installation of a permeation stem by connecting a section of existing steel pipe 1 into a connector 2 specific to an RTP.

[0051] FIGS. 2 and 2a provide details on the multi-layered components of a composite Smartpipe RTP product including a cross section of “shape formed” pipe in “C” formation with cross section for later processing into pipelines. FIGS. 2 and 2a represent Smartpipe technology and show a typical section of the composite layers from the interior line pipe, high strength tapes, and the protective layer. The components are depicted as follows: a. Interior liner pipe; b. High strength reinforced Smartpipe RTP; c. High strength pulling tapes with embedded woven fabric sensors; d. Wrapping layers helical and circular; e. Covering assembly tapes; f. Sensors and readers for various pipeline functions; g, “shape formed” pipe in "C" formation; h. Protective layer with instrumentation fiber optics, full containment no permeation into annulus (host pipe or stand-alone pipe); i. Metallic non permeable component of the protective layer; impregnated flexible layer cured post installation; high strength nano enhanced barrier, composed layer to contain gas within the RTP.

(0052] The illustration of FIG. 3 is an enlarged detail from FIG. 1 represents the flow of the gaseous substance permeating through the RTP and provides a detail 3 of a free standing pipe with gas permeation 6 contained within the reinforcement layers. The detail 4 shows the reinforcement layers permeated by the gas within the voids and sensors 5 at the outer cover layer detecting the gas permeation. The gas flow movement is towards a containment chamber. Detail 6 indicates gas permeation beyond reinforcement layers migrating to the containment chamber. Direction of continuous gas flow in the pipe is shown by the arrow 11.

[0053] A typical permeation gas chamber assembly as part of the inventive G-ZBD system is shown in FIG. 4. with a CRA (corrosion resistant alloy) or non-metallic composite pipe chamber 9 concentrically engaged to collect gas permeation beyond the reinforcement layers 7 of the section of RTP exposed within the chamber 9. Also shown is the inlet part of the steel pipe 1 connected to and extending into the CRA (corrosion resistant alloy) or non-metallie composite pipe chamber 9. The steel pipe extending into the CRA (corrosion resistant alloy) or non-metallic composite pipe chamber 9 is supported by centralizers 8, The RTP section exposed within the chamber 9 joins the existing steel pipe 1 by a connector 2. Further in continuation is the steel pipe connected piece to the exit end from the CRA (corrosion resistant alloy) or non-metallic composite chamber and connected to another connector-fitting the continuation of the pipeline. The section of the steel fitting is the point of directing the reclaimed gaseous substance 16 to be pressurized from the G-ZED into an active pipeline.

[0054] As further shown in Figure 4, the CRA (corrosion resistant alloy) or non-metallic composite pipe chamber 9 has an inlet end 9a and an exit end 9b. At the inlet end 9a a steel host pipe 14a containing an RTF would be affixed with the RTP extending into the chamber 9 to join the existing steel pipe I by a connector 2. At the inlet end 9a annulus gas flow 14 between the RTP and steel host pipe 14a would merge and flow into the chamber 9; Continuous gas flow 11 moves from the inlet end 9a io the exit end 9b. Further in continuation is the steel pipe connected piece 1 from the exit end 9b of the CRA (corrosion resistant alloy) or non-metallic composite chamber and connected to another connector-fitting to the continuation of the pipeline 1. The connector-fitting is the point of the reclaimed gaseous substance 16 to be pressurized from the G-ZED into an active pipeline. Non-reversible gas flow 13 from the chamber 9 would be piped to an assembly of fittings and equipment 10 to facilitate gas evacuation from the chamber 9 and direction to buster compression chambers 17 to provide for separation of pressure before directing the reclaimed gas pressurized 16 back into the existing steel pipe 1. Pressure monitoring 15 for SC AD A (Supervisory Control and Data Acquisition) would be provided at the assembly of fittings and equipment 10 and the chamber 9 as well as vacuum pressure inducement 12 for flow increase of the permeated gas and multiple embedded discrete sensors 28 are shown in the chamber.

[0055) FIG. 5 shows an alternative embodiment of the permeation gas chamber with venturi concentric pressurization 17, providing a second continuous chamber for gaseous substance containment, pressurization, and evacuation to one of the means of the collection or continuation with the medium in transport.

[0056] The flow diagram depiction in FIG. 6 shows a permeation processing system as would be applied to the inventive G-ZED system generally as shown in FIG. 4. Shown are micro packs 18 used in conjunction with data and fiber optic transmission 19. This system of monitoring has several technological features where it could be combined with sensors, fiber optics and other means available in contemporary technologies. Shown is a control system algorithm 20, computer system 21, SCADA 22 and response alarm 23.

[0057) FIG. 7 shows a Smartpipe In Line Inspection Strain Device (“ILISD”) device 24 used in combination with the inventive G-ZED system within the penneation chamber 9 to afford continuous pipeline monitoring with combined data for permeation. Likewise in FIG 8, a Smartpipe Transient Mitigation Device ("TMD") device 25 is used in combination within the permeation chamber 9 to function for pressure mitigation.

[0058) In FIGS. 9 and 10 are shown permeation sections of both singular and multiple RTFs with singular and multiple annulus areas. In the ease of a singular annulus non-reversible gas flow 13 can be routed through the host pipe to an assembly 10 to facilitate gas evacuation, and in the ease of multiple annular spaces, each space will collect gas and evacuate the gas toward a collection chamber.

[0059] A permeation gas chamber assembly as part of the inventive G-ZED system is shown in FIG. 11 with a free standing RTP 7 and a single containment chamber 9, for the gaseous substances collected from the specially composed reinforcement cover assembly, which provides for all gaseous substances conveyed only through the voids within the reinforcing layers, The collection nonreversible device 13 at the beginning of the chamber 7 serves as a transitional piece to revert the gaseous substance from the permeable reinforcing layers of the pipe cover, which conveys the gaseous substance into the chamber for evacuation or reinjection, while the free-standing pipeline 7 remains functional. The gaseous substances then can be injected or evacuated from the pipeline by means of pressurization or elimination by the outside equipment. This free-standing pipe is self-dependent.

[0060] A permeation gas chamber assembly as part of the inventive G-ZBD system is shown in FIG. 12 with continuous free-standing pipe and two or more containment chambers 17, for the gaseous substances collected from the specially composed reinforcement cover assembly, which contains at least one permeation barrier layer of metallic or non-metallic material, providing for all gaseous substances to be safely conveyed through the voids within the reinforcing layers. The compression chambers are increased to provide for the separation of pressures. The cross sectional blow up of the RTP layers shows the metallic non-permeable component i of the protective layer h. It should be noted that the RTP full containment within the layers have variable densities and voids up to 40%