BBS Bumper for Bundled Bores - Included Components

 BBS Bumpers for Pipe Bundles - What is Included?

     Sometimes called Multi-Pipe Pullbacks; bundled road bores occur when more than one pipe is pulled through a bore hole.  It is a new tweak on a long time technology; the only difference is:  the bore hole is large enough to fit more than one pipeline.  In those cases, two things have to be considered:

1.   How do we make sure they pipelines don't damage one another during the pull through?  Pipes do jolt at times as they encounter rock, roots, etc.  You certainly don't want those lines that you are never going to see again experiencing damage to their corrosion coatings!
2.   How do we make sure we don't have pipelines resting upon one another?  We've supplied bumpers on bundles with as many as 11 pipelines involved.  Imagine 11 pipeline all resting on one another (picture a handful of uncooked spaghetti).  How is CP going to get to the line that is stuck in the middle of that bundle surrounded by a literal pipe wall keeping soil, water and current away from the line?  How about the "inside" sides of those pipes that are making up the "wall"?  You need to make sure there is space between those pipelines so that soil can ultimately fill those areas; creating a path for the CP. 

If you're curious - you can see a case study HERE.

     Now with nearly one hundred thousand bumpers installed and pulled through bore holes; we've yet to hear of a single bumper failure.  Yet to hear of a single bumper that disappeared during transit (the bumpers on the leading edge of the bundle always show up on the other end of the bore).   We've got a proven product, using our specially formulated bumper material --- and our proven system for making certain the bumper stays in place.  Many other folks have used this product successfully; so you can be confident you aren't taking any chances at all.

     So what comes in the system? See below:

Our specially formulated bumper material.  We are also working on new shapes to offer some advantages in the field.  Hopefully those evaluations will be completed in the months to come!

The epoxy bonding agent that gives fantastic shear and peel resistance to the bumper holding system.

The main component that holds the bumper in place with nowhere to go.  Tens of thousands installed with no reported failures.

Finally, the leading edge strip.  Probably not needed in all honesty, but this, installed on the leading edge of the system gives even more protection against some kind of peel back.

Bundled Pipe Bumpers: A Comprehensive Case Study

 Bundled Pipe Bumpers: A Comprehensive Case Study

Frequently, we receive calls from customers seeking assistance with challenging problems, and it is always gratifying to offer them simple and effective solutions. In this particular case study, a customer approached us with a bundled directional drilling project in Texas. Although the pipes had already been strung up, they were concerned about potential pipe collisions during the pull-through process. Complicating matters further, they were pulling four pipelines simultaneously, measuring 16", 16", 12", and 10" in diameter. The customer needed a swift and reliable solution. After multiple discussions, emails, and an in-person meeting, the customer was convinced that our BBS system was the answer. With the urgency of the situation in mind, we promptly coordinated with suppliers, mobilized additional labor, and commenced manufacturing to ensure the timely delivery of the required materials. Thus, the problem was successfully resolved.

Collaborative Efforts

Like any pipeline project, unexpected challenges emerged along the way. Fortunately, this project boasted an exceptional crew, consisting of a quality-focused contractor, a meticulous inspector scrutinizing every detail, an engaged end user, and a seasoned road bore team. Moreover, our company, Joint Specialists, contributed decades of experience in pipeline construction materials, further strengthening the collaborative approach.

Bundled Pipe Bumper Installation Process

The four pipes were aligned side by side, and markings were made to indicate the precise locations for bumper installation. Preheating the pipes to 140°F, we carefully placed the bumpers in their designated spots. Next, a two-part epoxy was mixed and applied to the warmed pipe surface. Finally, the heat shrink, which serves as the primary anchor for the bumpers, was carefully shrunk in place. Overall, each bumper installation required a mere 3-5 minutes. Once all the BBS systems were installed, the pipes were bundled and ready for the subsequent pulling operation.

Unforeseen Obstacles

However, during the initial 400-foot segment of the pull-through, the pipe-grabbing mechanism unexpectedly snapped. Although such incidents were rare, it presented a significant challenge. Consequently, the pipe bundle that had reached 400 feet underground needed to be extracted in the opposite direction, necessitating a complex maneuver using side booms. This unexpected turn of events provided an exceptional opportunity to test the resilience of our BBS system. Notably, the subsequent operations involved pulling the pipe back 400 feet, then pushing it 1,700 feet back through the hole. Furthermore, this situation offered a unique chance to inspect our system after its 400-foot round trip into the depths of the Earth. The question lingered: would our system prove as effective as we believed? The ensuing inspection would yield the answer.

Thorough Inspection and Evaluation

The inspectors and representatives from the end user's team shared our excitement about this rare opportunity to closely examine several dozen BBS systems. The inspection aimed to determine if any bumpers were missing, whether any had been left behind in the mud, and whether any collisions had occurred among the pipes. Despite the layers of mud obscuring the bumpers, the inspectors meticulously examined each BBS system. Running their fingers along each side of the bumper, they ensured its presence, stability, and functionality. Remarkably, we achieved a 100% success rate in this evaluation.

Conclusion

In conclusion, the BBS system demonstrated its efficacy without a doubt. Its reliable performance and ability to prevent pipe collisions were reaffirmed through this case study. We confidently invite anyone claiming to possess alternative solutions to provide documented photographic evidence supporting their claims. Based on our extensive experience and the results of this study, we firmly believe that no other system can rival the effectiveness and reliability of our BBS system.

Pipe Spacer for Bundled Road Bores

 

BBS - Bundled Bore System for Protecting Your Pipelines

Reach out for more info:  steve@jsicoatings.com

Bundled directional drilling applications present a unique challenge in the pipeline industry as different pipe sections can damage each other during installation. Joint Specialists, a leader in pipeline solutions, has developed a solution to address this problem. The Bore Bumper System (BBS) is a proven and reliable solution for preventing pipeline damage during bundled directional drilling applications.

The BBS system is primarily composed of two components - a specially formulated and designed rubber bumper material and a heat shrinkable vehicle. The rubber bumper material is carefully selected, evaluated, and proven to provide a cushion and space between the pipelines during installation. The heat shrinkable vehicle is a reliable component with a long history of use, ensuring that the bumper stays in place throughout the pulling process and beyond.

In the past, other solutions, such as rope with duct tape, have been used to prevent pipe collisions, but these solutions are not reliable. Some solutions are intricately complicated, with additional products on a pipeline that are designed to withstand the forces of road bore, introducing metal bands on the pipeline, which is a risky approach. In contrast, the BBS system is a proven and simple solution that only uses products specifically designed to withstand road bore forces. It offers abrasion resistance, penetration resistance, shear, and impact resistance values that are top of the line.

Each BBS kit includes two specially formulated bumpers, a suitable amount of S1301M Two Part Epoxy Primer, a high shear heat shrinkable sleeve, a high shear heat shrinkable leader strip, and duct tape to hold the bumpers in place until the sleeves have been installed. The spacing of BBS bumpers and sleeves is determined by the end user guidelines.

To install the BBS system, all pipe surfaces involved in the application must be free of all oils, dust, dirt, mud, or any other substance that would reduce or prevent a proper bond. The pipe surfaces should be preheated to a temperature between 140F and 160F, and the bumpers should be wrapped around the pipe quickly and secured in place using a small amount of duct tape. The S1301M Epoxy should be mixed and applied in a thin coat covering all parts of the pipe that will be in contact with the shrink sleeve. The wider shrink sleeve should be wrapped around the pipe quickly and centered on the bumpers. Finally, the closure strip should be secured using the propane torch and a gloved hand.

In conclusion, the Bore Bumper System is a proven solution to prevent pipeline damage during bundled directional drilling applications. Joint Specialists has developed a reliable and straightforward system that is designed to keep space between pipelines involved in a bundled directional drill. The BBS system is easy to install, using products that are specifically designed to withstand road bore forces, making it the best choice for anyone looking for a reliable solution to pipeline damage during bundled directional drilling applications.

Pipe Bumpers (BBS or BBS/CCS)

Pipe Bumpers (BBS and BBS/CCS Bumper Systems)

     As the United States becomes more and more saturated with existing pipelines, and as securing right of ways becomes more and more difficult; it seems the industry is seeing surprising growth in the area of bundled directional drilling projects.  If you're unfamiliar with this technology, it is exactly the same as your standard road bore or directional drill; but you pull more than one pipeline through the bore hole at the same time.  We've been involved in projects where two lines were pulled through the same hole; and we've been involved with projects where as many as 11 pipelines per pulled through the bore hole at the same time!  Hard to believe?  Yes.  Incredible to see?  Absolutely (sorry, no photos were allowed on that job site).  One problem to tackle there:  how do you prevent the pipelines from damaging one another as they are pulled through the hole?  Also, how do you insure that you don't have pipe resting on pipe through out the life of the line?  The answer is fairly simple: BBS bumper systems. 

    

     Seems simple, right?  It is.  Kind of.  You see our bumpers are held in place by materials that are specifically designed to survive the enormous shear and peel forces that are associated with a road bore.  Picture a bumper wedged between three different pipelines being pulled through a mountain of mud.  That bumper is going to act like a sail - seeing tremendous forces.  That is why it is so important to use a 'road bore rated' product to hold that bumper in place.  How do we know ours works?  We've seen before and after photos after a thorough evaluation:  Pipe Bumper Case History

    It is important, when selecting a system, that you select a system where all components are approved for use by the manufacturer as road bore approved.  Some systems utilize components that are not road bore approved.  What happens to those bumpers when they are being dragged beneath a road, beneath the ship channel, or beneath a reservoir of some kind?  Nobody knows!  Does it make sense to use a system with components that the product manufacturer would say NO WAY!  You absolutely cannot use our product for that application and expect it to work!  No, it doesn't make any sense at all -- yet there are still people who use it.  I can't figure it out! 

     For help with your next bundled road bore project, give me a call.  Let's have a chat.  Let us help figure out how you're going to keep those pipelines from damaging one another so that you can spend your time and attention on one of the other hundreds of details you'll need to make decisions on.

Pipe Doughnuts on Polypropylene Coated Pipe

Bore Bumpers for PP Coated Pipelines

     Had a recent phone call from a contractor who had a large problem.  He had been awarded a project to complete a directional drilling bundle where the pipe was factory coated with polypropylene...and company he was working for had commissioned him to find a a spacer system to insure that the two pipelines did not damage one another during the pull through process.  We seem to get a lot of telephone calls where someone out in the pipeline world is asking us to engineer a solution for them.  We love it when that happens because it is one of the most exciting aspects of our jobs.

Here you see one of our BBS Bundled Bore Bumper sleeves installed in the field (not on PP).

     In this case, things were a little bit different, because we have the product (BBS - Bundled Bumper System) and it has been thoroughly evaluated.  In fact, we had the amazing opportunity to evaluate our product in true "before" and worse than "after" fashion when the pipe bundle entered the bore and then had to be pulled back out after a malfunction (and amazingly, in that case, how did they pull the pipe out?  by strapping onto our bumpers and pulling...which we would never recommend...but hey, they had to get that pipe out of there and it actually held up very well).  

     So what was the problem then?  If you're reading this blog, you almost certainly know that polypropylene is notoriously difficult to bond to unless you are using a stick, aggressive mastic sealant.  At the same time, a sticky aggressive mastic sealant does not offer great shear properties (when evaluated in light of a 20+" multi pipeline directional drill).  This left the question:  Would our shrink sleeve material that has successfully been used numerous times in bundle bore applications bond well enough to a PP coating to complete its mission?  (The mission being to hold that bumper in place until the pipelines reach their final resting places). A good question. 

     One of the challenges with polypropylene in my experience (and some polyethylenes to a lesser degree) is that there are many different types of polypropylene and not all polypropylenes interact with our adhesives in the same manner.  This was going to present a problem.  Fortunately, the contractor was able to send us a small sample of the exact PP that was coated on his line (by stripping it from an unneeded section of pipe).  Great!  No need to speculate...we can evaluate this ourselves without even needing to leave our own warehouse!

     But first, let's take a closer look at the function of our BBS bundled bore sleeve system.  The purpose of the system is to hold our special formulated bumper in place, so that bumper can prevent two or more pipelines from colliding during the pull through.  Sounds fairly simple:

- Put bumper on

- Lock bumper in place

- Survive

     That is important to keep in mind.  Beyond that, it is important to fully understand what types of forces will be exerted on this system.  Let's look at and evaluate some of the different material properties associated with our product and determine whether they are or are not going to come into play in this particular application.

1. Peel Strength - based on our experience with the product, we don't believe peel is any factor here at all.  For the system to be put into peel would require a set of circumstances that are pretty much unimaginable. 
2. Impact Resistance - the system has excellent impact resistance of course, but we don't believe this characteristic will come into play here.
3. Penetration Resistance - again, not a factor.  This system has excellent penetration resistance (I would say unmatched) but the chance that a penetration occurs that is somehow eventually able to dislodge and/or move the bumper is very difficult to imagine.  
4. Cathodic Disbondment Resistance - again, not a factor.  This material is not acting as a coating (but when it does act as a coating it exhibits excellent CD resistance). 
5. Shear Resistance - Bingo.  We have a winner.  The forces exhibited on the profile of the bumper will put front edge of the sleeve under shear forces.  The front of the sleeve will see shear forces and the weight of the other pipelines along with the force of the pull will exhibit shear forces.  

     So going through all of that, we arrived at the conclusion that the single largest factor when determining (in this particular case) whether our system would properly hold the bumper in place through the duration of the pull through is shear resistance.  Now we have a road map toward proper product evaluation.

     The samples came in and we began determining the best way to evaluate shear strength.  The contractor already had a system in place that required abrading and heat treating the polypropylene for his field joint coating procedures, so the first simple step was to expect that same treatment for the areas where our BBS sleeves would be bonding to the factory applied polypropylene.  Clearly step one was going to be: prepare the PP samples with abrasion and heat treating.

     Next we bonded stamps of our material onto the PP samples.  Our base bonding product exhibits shear values that pass at 80 pounds per square inch when installed on epoxies and dual layer FBE.  DIRAX (the product in question) has been used successfully hundreds of thousands of times, there is no question that the shear resistance values of DIRAX are more than sufficient to survive the forces associated with a directional drill. 

     Using a testing system that we developed here, we were able to determine that our material samples installed directly on the PP samples held up at 80 pounds per inch without failure.  The bond could have taken more than 80 pounds, but we saw no real reason to test to failure.  In any case, given that the single most important technical value in this application is shear resistance, and given that our product exhibits exemplary shear resistance; as high as has been successfully used many, many times in directional drilling applications, we felt incredibly comfortable to approve the use of our product for this specific application.  I am hoping we will be able to get photos from the field of the project which is going on as we speak.  If I can - check back in as they will be posted here.

Pipeline Spacer Ring

Directional Drill Spacer Rings

 

     Pulling more than one pipe at a time through a bore hole as a means of reducing pipeline construction costs seems to be something that is getting more and more common every month.  It creates a unique problem though:  how do you prevent the pipe sections from damaging one another both during the 'staging' and during the bore itself?  Good news: we know how.

 

     They go by many names:  bundle bumper sleeves; pipe spacer rings, pipeline doughnuts, pipeline donuts, or any number of other options.  We've sold our spacer rings for pipe as small as 4" and for pipe as large as 20".  We've sold our spacer rings to be used on a two pipe bore -- and we've sold our bumpers to be used on four pipe bores.  There really is no limit.

 

     If you're interested in more information, please send me an email to steve@jsicoatings.com and I will get you a copy of our electronic product guide.  I'm confident it will answer all of your questions (and then some).  

Directional Drilling and Road Bore of a Pipeline

Directional Drilling of a Pipeline

      Isn't it an amazing thing?  Drilling a hole through the ground that goes underneath a road...or a lake...or the ship channel...and then reaching through that hole and pulling a stinking PIPELINE through that hole.  WOW.  It is easy to wrap my brain around a cable being pulled like that....but a steel pipeline that might weight thousands of pounds per foot?? Incredible.

 

     If you've never had the opportunity to view a pipe pull in person; then today is your lucky day!  But wait...there's more.  Not only does this video show a pipe being pulled through a bore hole; this video shows FOUR (yes 4) pipelines being pulled through the bore hole at the same time!  In this specific case, there are two 16" lines and two smaller lines all bundled together.  This is a somewhat short bore coming in just over a quarter mile.

 

     As you might imagine, dragging four long, heavy, steel pipelines through the ground is likely to cause some damage.  Surely those pipelines will be banging into one another.  Surely there will be roots, rocks, clay and other possible obstacles down 8-10 feet beneath the surface.  In addition, the pipelines don't all lay next to one another like they do on a pipe truck...instead they are all free to go wherever they would like to go.  To paint the picture even further - we've got a 48" OD hole that has been drilled -- and 52" (outside diameter) combined inches of pipeline.  At least one of those pipelines is going to be surfing on the other three throughout the process!  Scary!

 

     This presents the other side of the problem:  how is a pipeline....that is literally RIDING ON TOP OF three other pipelines going to travel 1/4 mile without getting or causing damage??  FBE and ARO coatings like Powercrete are very reliable external pipeline coatings; but they are not really designed for pipe surfing by other pipes...

 

     In this particular case, the customer chose to use our BBS bumper system to protect the pipelines during the boring process (even the surfing pipeline).  Based on the BBS performance - they were THRILLED that they did.  But more on that later. 

 

     Now on to the show.  I hope I haven't built it up too much.  Before I'd ever seen a road bore, I expected some kind of speed to it like you might see when you pull the string from the top of a top.  I was wrong! 

 



Bumper Doughnut Sleeve for Bundled Directional Bore

    Question:  I have a bundled directional drill that includes a 6" pipe.  What can I use to hold a doughnut in place to prevent the pipes from bumping into and damaging one another?

     Answer:  When you're dealing with a 6" pipe; that presents a challenge.  In the world of heat shrink sleeves, the important dimensions are 6.625" (the OD of the pipe) and 8.625" (the OD of the substrate which is the 6" pipe plus two layers of 1" thick rubber.  Unfortunately, that 8.625" down to 6.625" would require just a bit more shrink ratio than the DIRAX is able to provide.  So in case like that, we must use a different product that is still fiber sheet reinforced; but is also a high expansion product. 

Bundle Bumper Sleeve for Smaller Diameter Pipe

     What you see here is our BBS/CCS for a 6" pipe.  The doughnut is 2" wide (along the pipe) and 1" tall (two 1" x 1" doughnuts pushed together).  An excellent product and those doughnuts are not going to be going anywhere!