Load–Deformation Behavior and Risk Zoning of Shallow-Buried Gas Pipelines in High-Intensity Longwall Mining-Induced Subsidence Zones

In recent years, controlling the integrity of shallow-buried natural gas pipelines within surface subsidence zones caused by high-intensity underground longwall mining in the Daniudi Gas Field of China’s Ordos Basin has emerged as a critical challenge impacting both mine planning and the safe, efficient co-exploitation of coal and deep natural gas resources. This study included field measurements and an analysis of surface subsidence data from high-intensity longwall mining operations at the Xiaobaodang No. 2 Coal Mine, revealing characteristic ground movement patterns under intensive extraction conditions. The subsidence basin was systematically divided into pipeline hazard zones using three key deformation indicators: horizontal strain, tilt, and curvature. Through ABAQUS-based 3D numerical modeling of coupled pipeline–coal seam mining systems, this research elucidated the spatiotemporal evolution of pipeline Von Mises stress under varying mining parameters, including working face advance rates, mining thicknesses, and pipeline orientation angles relative to the advance direction. The simulations further uncovered non-synchronous deformation behavior between the pipeline and its surrounding sand and soil, identifying two distinct evolutionary phases and three characteristic response patterns. Based on these findings, targeted pipeline integrity preservation measures were developed, with numerical validation demonstrating that maintaining advance rates below 10 m/d, restricting mining heights to under 2.5 m within the 260 m pre-mining influence zone, and where geotechnically feasible, the maximum stress of the pipeline laid perpendicular to the propulsion direction (90°) can be controlled below 480 MPa, and the separation amount between the pipe and the sand and soil can be controlled below 8.69 mm, which can effectively reduce the interference caused by mining. These results provide significant engineering guidance for optimizing longwall mining parameters while ensuring the structural integrity of shallow-buried pipelines in high-intensity extraction environments.