At the 2024 International Pipeline Conference in Calgary, Rebrov et. al. accurately summed up the current challenge within the crack arrestor industry by writing:

“Pipelines repurposed for…dense phase CO2 are particularly susceptible to the threat of ductile running fractures due to the specific properties of CO2 and the existing transmission lines. Further, high-pressure natural gas transmission lines…can also be vulnerable to ductile running fractures…Using…composite materials for…externally applied arrestors has the potential to provide substantial cost advantages…and has led to significant interest in employing this advancing technology. Despite [this]…industry has not achieved consensus on the most appropriate design methodology for composite crack arrestors."

TCI designed Envirolock to resolve just this type of tough challenge.

Its distinctiveness lies it its composition as well as its application. Instead of weaker glass-fiber based constructions, our system features stronger carbon fiber materials. Sun et. al, 2024 recently noted that “Carbon fiber-reinforced composite material is one of the best candidates for crack arrestors” but that industry lacks “clear design criteria” due to material performance variations. Our system addresses this challenge and reduces costs by avoiding mats/tapes. Rather, TCI is using innovative in-trench robotically wound tow which can deliver the needed precision and consistency. In turn, this makes our crack-arresting systems capable of serving not only traditional natural gas pipelines, but it would also make CO2 repurposing feasible for the first time.

Companies can adaptably deploy Envirolock either as a series of recurring standalone crack arrestors (ECA) or as a systematic solution applied to long lengths of pipeline (EPRS). Thus, operators can customize their crack arresting methods to optimize them for safety and cost-efficiency. For example, they could select ECAs for remote and excellent condition pipelines, and then install EPRS where integrity threats are more acute or it traverses sensitive areas.

Competing crack arrest options are currently constrained to thicker-walled pipe segment replacements, the deployment of steel fracture collars, or the use of glass-fiber crack arrestors that are largely limited to lower pressure applications. Relative to TCI's EPRS option, existing crack-arrestor options are more narrowly scoped and do not offer additional benefits such as resistance to external corrosion, third-party strikes, and ground movement (EPRS). Both ECAs and EPRS offer significant cost advantages as well, especially when compared to segment cut-outs or new line installations. Envirolock therefore offers superior value to operators looking for protection against natural gas and CO2 pipeline running fractures.