METHODS AND SYSTEMS FOR PULLING BUNDLES OF CONDUITS

The present disclosure describes a pulling device that is used to attach to a non-circular bundle of conduits during installation of micro-duct bundles using horizontal directional drilling (HDD). According to some embodiments, the pulling device includes an interior pocket at a distal end to receive one end of the bundle of conduits and is shaped to constrain a rotational orientation of the bundle of conduits within the pulling device. Additionally, the pulling device includes a pulling eye configured to provide for the pulling device to be pulled through a bore hole in order to be installed underground. The pulling device includes one or more apertures on the exterior surface that receive a fastener to attach the bundle of conduits for pulling through the bore hole.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to infrastructure (e.g., conduit) systems, and more specifically to methods, systems, and devices for pulling a bundle of conduits.

2. Discussion of the Related Art

Infrastructure systems, and more specifically conduit systems, may facilitate various use cases such as transportation, communication, utility distribution, etc. For instance, some systems may implement underground conduits (e.g., such as underground plastic pipes or ducts) to support various utilities such as telecommunications, water supply, sewerage, etc. Such systems may demand efficient and precise placement of underground conduits, for example, to minimize disruption to surface activities and minimize environmental impact. Some techniques, such as Horizontal Directional Drilling (HDD), may be implemented to install underground conduits. HDD techniques may include creating a bore underground using a drill rig and subsequently drawing one or more conduit(s) into position using the HDD drill rig. HDD techniques, or other conduit placement techniques, may thus be implemented to install and enable various conduits, such as plastic pipes, micro-ducts, etc.

However, in some cases, friction within the drilled hole and/or improper attachment of the conduit to a pulling device (or puller) may impede the smooth pulling of conduits through the bore. Existing conduit pulling systems are deficient. For example, pulling systems (or pullers) that grip the inside of plastic pipes may not be able to firmly, or securely, attach to multiple micro-duct bundles. Moreover, in some cases, conduits with small diameters, and/or a tight packing of a bundle of conduits, may make it difficult for conventional pullers to grip the conduits from the inside. Such deficiencies of conventional systems may result in improper attachment of conduit(s) to a pulling device, improper placement of conduits, installation delays, etc.

Accordingly, there is a need in the art for improved conduit pulling systems (e.g., an improved puller for a bundle of conduits) that are capable of effectively grabbing and pulling bundles of conduits (e.g., for installation via HDD techniques).

SUMMARY

The present disclosure describes methods, systems, and devices for pulling a bundle of conduits (e.g., a bundle of multiple small plastic pipes, or micro-ducts, that are bundled together such that the bundle has a non-circular exterior profile). Embodiments of the present disclosure include a pulling device with an interior pocket configured to secure (e.g., grab, constrain, etc.) a bundle of conduits. At least a portion of the interior pocket is non-circular in shape to match the exterior shape of bundle of conduits. In other words, the interior pocket of the pulling device is configured to match the cross section of the bundle of conduits to securely constrain the bundle of conduits. Additionally, fasteners (e.g., screws) are driven through the pulling device and intersect at least a portion of the individual conduits within the bundle, approximately through the centers of the individual conduits. Accordingly, embodiments of the present disclosure are able to create a strong connection between the pulling device and the bundle of conduits which provides a secure system for underground installation of the bundle of conduits.

An apparatus, system, and method for pulling a bundle of conduits are described. One or more aspects of the apparatus and system include an interior pocket at a distal end to receive one end of the bundle of conduits, with at least a portion of the interior pocket having a non-circular profile, shaped to constrain a rotational orientation of the bundle of conduits within the pulling device, wherein the interior pocket has one open end and one closed end; a pulling eye configured to allow the pulling device to be pulled through a bore hole; and one or more apertures extend from an exterior of the pulling device to the interior pocket, sized and located around a perimeter surface of the exterior the pulling device to receive a fastener or fasteners, where the one or more apertures are at one or more angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device.

A method for pulling a bundle of conduits is described. One or more aspects of the method include providing a pulling device comprising an interior pocket at a distal end to receive one end of the bundle of conduits, with at least a portion of the interior pocket having a non-circular profile, shaped to constrain a rotational orientation of the bundle of conduits within the pulling device, wherein the interior pocket has one open end and one closed end; inserting one end of the bundle of conduits into the interior pocket of the pulling device; attaching the pulling device to a pulling mechanism via a pulling eye configured to allow the pulling device to be pulled through a bore hole; and pulling the pulling device and the bundle of conduits having been attached to the pulling mechanism through the bore hole using the pulling mechanism. In some aspects, the pulling device further comprises one or more apertures extending from a perimeter surface of an exterior of the pulling device to the interior pocket, the one or more apertures being sized and located to receive a fastener or fasteners, wherein the one or more apertures are at one or more angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device.

A method for making a pulling device for a bundle of conduits is described. One or more aspects of the method include forming an interior pocket at a distal end of the pulling device to receive one end of the bundle of conduits; shaping at least a portion of the interior pocket to have a non-circular profile to constrain rotational orientation of the bundle of conduits within the pulling device; and creating one or more apertures extending from a perimeter surface of an exterior of the pulling device to the interior pocket, sized and located to receive a fastener fastener. In some aspects, the one or more apertures are at angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device.

DETAILED DESCRIPTION

Conduits (e.g., plastic pipes, micro-ducts, cables, etc.) may be installed and utilized underground to support various use cases as such electrical utilities, telecommunications, water supply, gas supply, sewerage, etc.

The present disclosure describes methods, systems, and devices for pulling a bundle of conduits. An example embodiment includes a pulling device for installation of non-circular bundles of conduits (e.g., a bundle or grouping of small plastic pipes or micro-ducts that together have a non-circular exterior shape). In some cases, the pulling device may be used for installation of bundles of conduits (e.g., underground installation of conduits using horizontal directional drilling (HDD)). In some aspects, as described in more detail herein, the pulling device includes a non-circular interior pocket shaped to match at least a gripping portion of the exterior shape of the bundle of conduits. For instance, the non-circular shaped portion of the interior pocket may rotationally orient the pulling device such that fasteners (i.e., screws) may be driven through the pulling device to intersect at least a portion of the individual conduits (e.g., approximately through the centers of the individual conduits). Accordingly, by using fasteners to intersect at least a portion of the individual conduits, embodiments of the present disclosure may be implemented create a strong connection between the pulling device and the bundle of conduits.

As such, the present disclosure provides improved methods, systems, and devices for installing bundles of conduits. The techniques and systems described herein may result in more secure attachment of conduit(s) to a pulling device, which may generally enable improved infrastructure systems. For instance, more diverse conduit configurations (e.g., more numerous conduits, conduits with smaller diameters, more tightly packed bundles of conduits, and more precise placement of conduits) may be deployed/installed according to one or more aspects of the present disclosure.

A process of Horizontal Directional Drilling (HDD) commonly includes installing plastic pipes or ducts underground. The HDD process involves the drill rig first drilling a “pilot bore” which establishes the path of the bore and the location of the pipes to be installed underground. Next, the plastic pipe(s) are pulled into place by the HDD drill rig. In some cases, friction in the drilled hole may create resistance to pulling the plastic pipe back through the hole.

A plurality of methods are used to attach a puller to the plastic pipe(s) so that the plastic pipe(s) can be pulled appropriately in place. For instance, a common method involves utilizing a wire mesh grip affixed to the exterior of the pipe, which relies on friction to secure the pipe. Alternatively, some approaches involve gripping the pipe internally, using expanding jaws or by threading the pipe. In certain scenarios, a tube with cross holes can be slid over the duct, after which holes are drilled through the plastic pipe, and bolts or screws are employed to fasten it to the metal tube puller.

Additionally, in certain scenarios, a plastic duct installation may involve a multiple micro-duct bundle or a bundle of conduits. The bundle typically comprises more than one small (e.g., less than 25 mm in diameter), round ducts, referred to as micro-ducts, encased within a plastic sheath. For example, such bundles may include 2 or more conduits (e.g., ducts), which may vary in diameter. The diameters may range, e.g., from 10 to 14 mm.

The plastic sheath surrounding the duct bundle results in a non-circular exterior shape (e.g., which may be referred to as a non-circular cross section of the bundle).

The shape may take various forms, such as triangular, square, or hexagonal, etc. However, the non-circular configuration may pose challenges when using wire mesh grip-style pullers, as the pullers may struggle to securely grip the exterior of the bundle of conduits. Furthermore, the wire mesh grips may only engage with the outer sheath of the pipe bundle, failing to distribute any load to the internal ducts.

Moreover, pullers designed to grip the inside of plastic pipes may not be compatible with multi micro-duct bundles or bundle conduits. The tight packing of the individual ducts within the bundle can make it difficult to use pullers intended to grip the ducts from the inside, as they may struggle to maneuver within such densely packed configurations.

Accordingly, embodiments of the present disclosure describe a secure method of attaching the pulling device and the bundle of conduits. In some cases, the pulling device is slid over the end of the bundle of conduits (or multiple micro-duct bundle). The non-circular cross-section of the interior pocket of the pulling device matches, and hence rotationally constrains, the pulling device to the bundle of conduits. Fasteners (such as screws) may be received at apertures present over the exterior surface of the pulling device and installed inside the pulling device using the bundle of conduits.

In some cases, the fasteners may be installed such that the fasteners may cut threads into and pass through the exterior sidewalls of at least a portion of the micro-ducts of the bundle of conduits. In some cases, the apertures in the pulling device can be located such that the fasteners intersect the exterior sidewalls of one or more of the individual micro-ducts of the bundle of conduits and pass approximately through the centers of the individual micro-ducts, or in other locations. Accordingly, use of fasteners in the apertures (as described herein) and the non-circular interior pocket of the pulling device constrains the device with respect to the bundle of conduits to provide a strong connection with the bundle of micro-ducts and/or individual micro-ducts.

An embodiment of the present disclosure describes a method that can be used to seal the micro-ducts. In some cases, the individual micro-ducts in the bundle of conduits may be sealed to prevent drilling fluid or other debris from entering the micro-ducts during the pullback process.

In some cases, after the HDD drill rig pulls the bundle of conduits through the bore hole, the pulling device may be removed from the bundle of conduits. The fasteners may be unthreaded from the pulling device and the bundle of conduits (having been attached to one another) and then removed from the pulling device and the bundle of conduits. Thus, the pulling device may be removed from the bundle of conduits after the bundle of conduits is pulled through the bore hole.

An embodiment of the present disclosure includes an insert or spacer that may be used to increase the versatility of a pulling device. In some cases, the spacer may be suitable for interposition between an interior of the pulling device and an exterior of the bundle of conduits. As such, the interior space of the spacer may be able to fit, while rotationally constraining, a bundle of conduits that is smaller than a bundle of conduits that may be engaged in the interior of the pulling device (e.g., without the spacer).

Accordingly, the present disclosure provides a pulling device used for pulling a bundle of conduits that includes non-circular multiple micro-ducts. In some cases, a non-circular shape of the interior pocket of the pulling device constrains the position of the bundle of conduits in the interior pocket of the pulling device. Additionally, a plurality of fasteners can be threaded into the individual micro-ducts of the bundle of conduits which may improve the pullback capacity of the pulling device. According to an embodiment, spacers may be used to adapt the pulling device for use with additional sizes and configurations of bundle of conduits.

Conduits may generally refer to any structure, pathway, or channel (e.g., used to carry various utilities or services). For instance, conduits may generally include pipes, channels, tubes, cables, plastic pipes, ducts, micro-ducts, telecommunication conduits, water supply conduits, and electrical conduits, among various other examples. In certain aspects of the present disclosure, some descriptions or embodiments may use some of the above terminology interchangeably, without limiting the scope of the present disclosure. For instance, certain examples may be described with reference to pipes or ducts, but may more generally apply to any conduit by analogy, without departing from the scope of the present disclosure. Embodiments of the present disclosure can be used in the context of infrastructure systems. For example, the pulling system based on the present disclosure pulls a bundle of conduits including multiple micro-ducts for underground installation using HDD. Details regarding the design of the pulling device are provided with reference toFIGS.1-13. Details regarding the method of using the pulling device for pulling the bundle of conduits are provided with reference toFIGS.14-15.

A Pulling Device

Embodiments of the present disclosure include a pulling device designed for a bundle of conduits. In some cases, the bundle of conduits may include multiple micro-duct bundles with a non-circular shaped exterior. According to an embodiment, the pulling device may be made of steel or other durable materials. A first end of the pulling device includes a pulling eye, a shackle, or other means to attach the device to the HDD drill string assembly for pulling back towards the HDD drill rig. A second end (i.e., opposite to the first end) of the pulling device includes an interior pocket or cavity designed to slide over the exterior of the bundle of conduits.

FIG.1shows an example of a pulling device100according to aspects of the present disclosure. The example shown includes pulling device100and bundle of conduits130(e.g., a bundle of one or more conduits125).

An embodiment of the present disclosure describes a method of attaching the pulling device100and the bundle of conduits130. In some cases, the pulling device100is slid over the end of the bundle of conduits130(or multiple micro-duct bundle). The non-circular cross-section of the interior pocket of the pulling device100rotationally constrains the pulling device100to the bundle of conduits130. Fasteners115(or screws) may be received at the apertures110in the pulling device100and installed inside the pulling device100to attach the bundle of conduits130. In some cases, the fasteners115may be installed such that the fasteners115may cut threads into and through the walls of each of the micro-ducts (e.g., micro-ducts125) of the bundle of conduits130.

In some cases, the apertures110in the pulling device100can be located such that the fasteners115intersect the exterior sidewalls of one or more of the individual micro-ducts (i.e., micro-duct125) of the bundle of conduits130approximately through the centers of at least apportion of the individual micro-ducts125, or in other locations. Additionally or alternatively, fasteners115such as bolts may be used to pass completely through the apertures110in the pulling device100and holes drilled in the periphery of the bundle of conduits130. The bolts may be secured at the distal end with nuts.

Accordingly, use of fasteners115in the apertures110(as described herein) and the non-circular interior pocket of the pulling device100constrains the device with respect to the bundle of conduits130to provide a strong connection to the individual micro-ducts (i.e., micro-duct125). In some cases, the strength of the connections may vary as a function of the forces applied to the bundle of conduits130as it may be pulled through the pilot bore. Therefore, the fasteners115may not be over-tightened which may strip the threads cut into the exterior sidewalls of micro-duct125of the bundle of conduits130, which may be, for example, made of a plastic material.

In some cases, the pulling device100may be attached to the bundle of conduits130at an end of the pilot bore. For example, the pulling device100may be attached opposite an HDD drill rig used to drill the pilot bore. The pulling device100, once attached to the bundle of conduits130, may be pulled back through the pilot bore. In some cases, a reamer may be attached to an HDD drill string and then connected to a pulling eye105at one end of the pulling device100by a pulling head and swivel. For example, the swivel provides for the reamer to turn without turning the pulling device100. The HDD drill string is then pulled back through the pilot hole by the HDD drill rig.

According to some aspects, the present disclosure provides a pulling device100including an interior pocket at a distal end to receive one end of the bundle of conduits130, with at least a portion of the interior pocket having a non-circular profile, shaped to constrain a rotational orientation of the bundle of conduits130within the pulling device100, where the interior pocket has one open end and one closed end. In some examples, pulling device100inserts one end of the bundle of conduits130into the interior pocket of the pulling device100.

In some examples, pulling device100attaches the pulling device100to a pulling mechanism via a pulling eye105configured to allow the pulling device100to be pulled through a bore hole. In some examples, pulling device100pulls the pulling device100and the bundle of conduits130having been attached to the pulling mechanism through the bore hole using the pulling mechanism. In some aspects, the pulling device100further includes one or more apertures110extending from a perimeter surface of an exterior of the pulling device100to the interior pocket, the one or more apertures110being sized and located to receive a fastener115(or fasteners), where the one or more apertures110are at one or more angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device100. In some aspects, the pulling mechanism is a horizontal directional drilling rig.

In some aspects, the pulling device100includes (e.g., may be made of) steel. In some examples, pulling device100attaches the pulling device100to the bundle of conduits130by inserting the fastener115(or fasteners) through the one or more apertures110and into the conduits.

Pulling device100is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2-7, and10-12. In one aspect, pulling device100includes pulling eye105, aperture110, and fastener115. According to some aspects, pulling eye105is configured to provide for the pulling device100to be pulled through a bore hole. According to some aspects, pulling eye105forms a pulling eye105to provide for the pulling device100to be pulled through a borehole. Pulling eye105is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2,3,11, and12.

In some aspects, one or more apertures110extend from an exterior of the pulling device100to the interior pocket, sized and located around a perimeter surface of the exterior the pulling device100to receive a fastener115or fasteners115, where the one or more apertures110are at one or more angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device100.

According to some aspects, aperture110creates one or more apertures110extending from a perimeter surface of an exterior of the pulling device100to the interior pocket, sized and located to receive a fastener115or fasteners. In some aspects, the one or more apertures110are at angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device100. In some aspects, the one or more apertures110are created counterbored to match heads of the fastener115or fasteners115. Aperture110is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2,7,11, and12.

According to some aspects, one or more fasteners115are inserted through the one or more apertures110and into and through the exterior of the bundle of conduits130to secure the bundle of conduits130within the interior pocket of the pulling device100. According to some aspects, fastener115is or fasteners are screws. In some examples, fastener115is or fasteners are bolts and nuts. In some aspects, the fastener115or fasteners are high-strength self-tapping screws with a piloting drill point.

In some aspects, the fastener115or fasteners are wood screws, sheet metal screws, or cotter pins. Fastener115is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2,4, and10-12.

In some aspects, the bundle of conduits130includes a bundle of more than one small, round conduits contained within a plastic sheath120. In some cases, the bundle of conduits includes a plurality of (or multiple) micro-duct pipes or plastic pipes. According to some aspects, bundle of conduits130seals ends of individual conduits of the bundle of conduits130to prevent entry of drilling fluid or other debris. In some aspects, sealing the ends includes wrapping an exterior of the bundle of conduits130with one or more layers of tape.

In some aspects (e.g., as described in more detail with reference toFIG.9), bundle of conduits130may refer to both the grouping of multiple conduits125and a surrounding sheath130. Bundle of conduits130is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2, and11-13. In one aspect, bundle of conduits130includes micro-duct125(e.g., a plurality of micro-ducts). Micro-duct125is an example of, or includes aspects of, the corresponding element described with reference toFIG.13.

FIG.2shows an example of an exploded view of a pulling device200according to aspects of the present disclosure. The example shown includes pulling device200and bundle of conduits225.

The present disclosure provides systems and methods of a pulling device used for pulling a bundle of conduits that includes multiple micro-ducts. In some examples, the interior pocket may include a non-circular shape. In some examples, the micro-ducts may include plastic pipes with a non-circular outer shape.

As shown inFIG.2, the non-circular shape of the interior pocket210of the pulling device200constrains the position of the bundle of conduits225in the interior pocket210of the pulling device200. In some aspects (e.g., as described in more detail with reference toFIGS.1and9), bundle of conduits225may refer to both the grouping of multiple conduits and a surrounding sheath. In other words, according to different embodiments, the interior pocket210may be shaped to match the bundle of conduits225including the cross section (or exterior shape) of just a grouping of multiple conduits, or of a grouping of multiple conduits and a surrounding sheath.

In some cases, a plurality of fasteners220can be threaded into the individual micro-ducts of the bundle of conduits225which may improve the pullback capacity of the pulling device200.

Additionally,FIG.2shows an example of an exploded view of a pulling device200. The example shown includes a pulling device200with multiple metal fasteners220and a bundle of conduits225with multiple micro-ducts or plastic pipes.

Pulling device200is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,3-7, and10-12. In one aspect, pulling device200includes pulling eye205, interior pocket210, aperture215, and fastener220. Pulling eye205is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,3,11, and12. Aperture215is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,7,11, and12. Fastener220is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,4, and10-12.

According to some aspects, interior pocket210is at a distal end to receive one end of the bundle of conduits225, with at least a portion of the interior pocket210having a non-circular profile, shaped to constrain a rotational orientation of the bundle of conduits225within the pulling device200, wherein the interior pocket210has one open end and one closed end (as shown inFIG.2). In some aspects, the non-circular profile of the interior pocket210is shaped to match at least a portion of a cross-section of the exterior of the bundle of conduits225. Interior pocket210is an example of, or includes aspects of, the corresponding element described with reference toFIGS.5,6,10, and11. Bundle of conduits225is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1, and11-13.

FIG.3shows an example of a top view of a pulling device300according to aspects of the present disclosure.FIG.3shows the overall profile of the pulling device300, a pulling eye305(i.e., through-hole), and the angled and parallel apertures for attachment of fasteners (or screws) to the bundle of conduits.

Pulling device300is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,4-7, and10-12. In one aspect, pulling device300includes pulling eye305. Pulling eye305is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,11, and12.

In some cases, a reamer may be attached to an HDD drill string and then connected to a pulling eye305at one end of the pulling device300. For example, as shown inFIG.3, an end of the pulling device300includes a pulling eye305to provide for the pulling device300to be pulled through a bore hole. Additionally, the pulling device300has multiple apertures310(or cross holes) extending from exterior surface of the pulling device300to the interior pocket. The apertures310are designed to accept fasteners (e.g., screws) as described with reference toFIGS.1-2.

In some cases, apertures310may be counterbored to match the fasteners (e.g., heads of the screws). According to an exemplary embodiment, one or more fasteners may be used. In some examples, the fasteners may be high-strength self-tapping screws. In some cases, the self-tapping screws may include a piloting drill point. However, embodiments are not limited thereto, and other types of fasteners, including wood screws, sheet metal screws, bolts, cotter pins, etc. may be used.

FIG.4shows an example of a side view of a pulling device400according to aspects of the present disclosure.FIG.4shows the overall profile of the pulling device400including angled and parallel apertures (such as aperture405) for attachment of fasteners (or screws) to the bundle of conduits. In some cases, the bundle of conduits includes a plurality of (or multiple) micro-duct pipes or plastic pipes.

As shown inFIG.4, the pulling device400has multiple apertures (such as aperture405) (or cross holes) extending on the exterior surface of the pulling device400. For example, in some cases, the apertures may be extending at angles between plus and minus 60 degrees (i.e., ±60°)from the central axis of the pulling device400. The apertures are designed to accept fasteners (e.g., screws) and may be counterbored to match the fasteners (e.g., heads of the screws).

Pulling device400is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-3,5-7, and10-12. In one aspect, pulling device400includes fastener405. Fastener405is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2, and10-12.FIG.5shows an example of a sectional side view of a pulling device500according to aspects of the present disclosure.FIG.5shows an internal profile of the pulling device500. For example, the profile inFIG.5corresponds to a side sectional view taken along the line AA′ ofFIG.4on a scale of 1:2. As shown inFIG.5, an internal profile of the pulling device500is illustrated that enables attachment with bundle of conduits.

Pulling device500is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-4,6,7, and10-12. In one aspect, pulling device500includes interior pocket505. Interior pocket505is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2,6,10, and11.

Embodiments of the present disclosure include a pulling device500with an interior pocket505of which at least a portion is non-circular in shape to match at least a portion of the exterior shape of bundle of conduits (i.e., micro-duct bundle). A first end of the pulling device500includes a pulling eye510, a shackle, or other means to attach the device to the HDD drill string assembly for pulling back towards the HDD drill rig.

A second end (i.e., opposite to the first end) of the pulling device500includes an interior pocket505or cavity designed to slide over the exterior of the bundle of conduits. In some cases, the non-circular shaped portion of the interior pocket505rotationally orients the pulling device500such that fasteners (i.e., screws) driven through the pulling device500intersect at least a portion of the individual conduits. For example, the interior walls of the interior pocket505may be made to engage with, e.g., match, at least a portion of the cross-section of the exterior shape of the bundle of conduits.

In some examples, a cross-section of a portion of the interior pocket505in the pulling device500may be a non-circularly-packed shape and slightly larger than the cross-section of the bundle of conduits. A profile of the interior pocket505may outline multiple geometric shapes. Further details regarding the shapes of the interior pocket are provided with reference toFIG.8.

FIG.6shows an example of a rear view of a pulling device600according to aspects of the present disclosure.FIG.6shows an internal profile of the pulling device600. For example,FIG.6illustrates a shape of an interior pocket605of the pulling device600. Further details regardingFIG.6are provided with reference toFIG.7which shows a section ofFIG.6along line BB′.

Pulling device600is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-5,7, and10-12. In one aspect, pulling device600includes interior pocket605. Interior pocket605is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2,5,10, and11.

In some cases, at least a portion of the interior walls of the interior pocket605have a non-circular cross-sectional shape. The interior walls of the interior pocket605may be made to engage with, e.g., match, at least a portion of the cross-section of the exterior shape of the bundle of conduits including multiple micro-ducts. In some examples, as shown inFIG.6, the cross-section of a portion of the interior pocket605in the pulling device600may be a hexagonal circularly-packed shape or a hexagon shape and slightly larger than the cross-section of the bundle of conduits.

FIG.7shows an example of a cross sectional view of a pulling device700according to aspects of the present disclosure.FIG.7shows an internal profile of the pulling device700. For example,FIG.7depicts a section along line BB′ ofFIG.6on a scale of 1:2.

Pulling device700is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-6, and10-12. In one aspect, pulling device700includes aperture705. Aperture705is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,11, and12.

As seen inFIG.7, a plurality of apertures (e.g., aperture705) are present on the pulling device700. In some cases, the apertures705may extend from the exterior of the pulling device700to a surface of the interior pocket. For example, the apertures705(also referred to as cross holes) may be at angles between plus and minus 60 degrees (i.e.,) ±60° from the central axis of the pulling device700. The apertures705are designed to accept fasteners (e.g., screws) and may be counterbored to match the fasteners (e.g., heads of the screws).

FIG.8shows an example of a rear profile of a pulling device according to aspects of the present disclosure. The example shown includes first pulling device800, second pulling device810, and third pulling device820.

As shown inFIG.8, each of the three examples show an internal profile of the pulling device. Accordingly, in one aspect, first pulling device800includes first interior pocket805, second pulling device810includes second interior pocket815, and third pulling device820includes third interior pocket825.

In some cases, the internal profile comprising the internal pocket (i.e., first interior pocket805, second interior pocket815, and third interior pocket825) of the pulling device (i. e., first pulling device800, second pulling device810, and third pulling device820, respectively) enables attachment with bundles of conduits.

A bundle of conduits having multiple (i.e., different) shapes and sizes may be attached to the pulling devices shown inFIG.8. For example, sizes of the bundle of conduits may be affected by the shape and size of the pipes included in the bundle (e.g., micro-duct pipes or plastic pipes).

FIG.8shows a non-circular interior pocket of the pulling device. In some cases, the bundle of conduits (i.e., including multiple micro-duct or plastic pipes) enters and may be seated in the interior pocket (e.g., any of the first interior pocket805, second interior pocket815, or third interior pocket825). As shown with reference toFIG.8, a profile of the non-circular interior pocket in the pulling device may outline multiple geometric shapes, as illustrated with reference to first pulling device800, second pulling device810, and third pulling device820.

The profiles of the interior pocket may include different forms such as a plurality of sides and/or feature shapes and/or only one side feature/shape on a circular or non-circular profile, etc. For example, the interior pockets, as shown inFIG.8, may be able to accommodate bundles of conduits that may include different numbers of micro-ducts of circular (or non-circular) cross-sections (e.g., having equal diameter) in a non-circularly-packed shape. As a result, the cross-section of a portion of the interior pocket in the pulling device may vary based on the number of micro-ducts.

In some cases, the cross-section of a portion of the interior pocket in the pulling device may be slightly larger than the cross-section of the bundle of conduits. Accordingly, the pulling device can slide over the bundle of conduits and may be constrained rotationally (as desired). Further details regarding micro-ducts in the bundle of conduits and the size variations of the bundle of conduits are described with reference toFIGS.9and13.

FIG.9shows an example of a configuration of a bundle of conduits according to aspects of the present disclosure. The example shows a variety of bundles of conduits (e.g., multiple micro-duct bundle profiles) including first bundle of conduits900, second bundle of conduits905, third bundle of conduits910, and fourth bundle of conduits915. In each example variety, the bundle is shown positioned inside a pulling device such as described elsewhere herein as it would be positioned in practice.

Referring toFIG.9, a plurality of conduit bundle configurations (e.g., for the micro-duct pipes or plastic pipes) are illustrated. As shown inFIG.9, the bundles of conduits may differ in shape/size based on the sizes and shapes of the individual conduits (e.g., the size/shape of each of the multiple micro-duct pipes or plastic pipes) included in the bundle. In some cases, the bundles of conduits may differ in shape/size based on the sizes and shapes of a sheath surrounding the bundle of conduits. For example, each of the bundle of conduits (first bundle of conduits900, second bundle of conduits905, third bundle of conduits910, and fourth bundle of conduits915) illustrate different numbers and arrangement of micro-duct pipes resulting in different sizes and shapes of the bundle of conduits.

For example, as shown inFIG.9, in some cases, the bundle of conduits (such as first bundle of conduits900and second bundle of conduits905) may each include seven micro-ducts of circular cross-section having equal diameter in a hexagonal circularly-packed shape. As a result, the cross-section of a portion of the interior pocket in the pulling device may be a hexagonal circularly-packed shape or a hexagon shape. As shown inFIG.9, the first bundle of conduits900and second bundle of conduits905include micro-duct pipes of different sizes. For example, the micro-ducts in the first bundle of conduits900may be smaller (e.g., in diameter) than the micro-ducts in the second bundle of conduits905. Accordingly, the first bundle of conduits900is smaller than the second bundle of conduits905.

Additionally, for example, the third bundle of conduits910includes 15 micro-ducts and the fourth bundle of conduits915includes 10 micro-ducts. In some cases, as shown inFIG.9, the micro-ducts may be contained within an outer sheath (e.g., plastic sheath). However, embodiments are not limited thereto and another suitable material may be used for the outer sheath. The outer sheath around the duct bundle creates a non-circular exterior (such as approximately triangular, hexagonal, trapezoidal, etc. in shape). Additionally, in some cases, the interior pocket of the pulling device may be slightly larger than the cross-section of the bundle of conduits. Therefore, the pulling device can slide over the bundle of conduits and may be constrained rotationally (as desired).

FIG.10shows an example of a side sectional view of a pulling device1000according to aspects of the present disclosure. Pulling device1000is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-7,11, and12. In one aspect, pulling device1000includes interior pocket1005and fastener1010. Interior pocket1005is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2,5,6, and11. Fastener1010is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,4,11, and12.

In some cases, the bundle of conduits is fastened to the pulling device1000using the plurality of fasteners1010. Referring together toFIGS.7and9, multiple apertures (such as aperture1015) are present in the pulling device1000. In some cases, apertures are strategically placed for fastening the bundle of conduits. For example, a plurality of fasteners1010(such as, but not limited to, screws) may be used to attach the bundle of conduits (comprising multiple micro-duct or plastic pipes) to the pulling device1000.

In some embodiments, the angled apertures (e.g., aperture1015) may be counterbored, countersunk, or may be as a through hole. In some cases, the apertures1015may be located to ensure appropriate screw engagement between the pulling device1000and the bundle of conduits. Accordingly, for example, once the bundle of conduits is inserted into the pulling device1000, the bundle of conduits may be fastened by means of fasteners such as metal screws. However, embodiments are not limited thereto and other types of fasteners, including wood screws, sheet metal screws, bolts, cotter pins, etc. may be used.

FIG.11shows an example of an exploded view of a pulling device1100according to aspects of the present disclosure. The example shown includes pulling device1100, bundle of conduits1125, and spacer1130.

Pulling device1100is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-7,10, and12. In one aspect, pulling device1100includes pulling eye1105, interior pocket1110, aperture1115, and fastener1120. Pulling eye1105is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-3, and12.

Interior pocket1110is an example of, or includes aspects of, the corresponding element described with reference toFIGS.2,5,6, and10. Aperture1115is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,7, and12. Fastener1120is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,4,10, and12. Bundle of conduits1125is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,12, and13.

According to one or more embodiments, an insert or spacer1130may be used with the pulling device1100. In some cases, an insert or spacer1130may be used to increase the versatility of a pulling device1100. The spacer1130may be sized and shaped to fit a cavity inside the pulling device1100such that the spacer1130may be rotationally constrained. In some cases, the spacer1130may be suitable for interposition between an interior of the pulling device1100and an exterior of the bundle of conduits1125. For example, the spacer1130may include various materials such as plastic, fiberglass, carbon fiber, wood, and metal.

According to an example, an exterior shape of the spacer1130may be the same as an interior shape of the spacer1130. Additionally or alternatively, the exterior shape of the spacer1130may be different from the interior shape of the spacer1130. The external shape of the spacer1130may adapt to the non-circular interior pocket1110of a (e.g., large) pulling device1100. As used herein, a large pulling device may refer to a pulling device with an interior pocket that has a larger diameter than the external diameter of the bundle of conduits such that a rotational orientation of the bundle of conduits is not constrained.

Additionally or alternatively, the internal shape of the spacer1130adapts to the form of the non-circular profile of the accepting pipe. Accordingly, spacer1130may be used to adapt pulling device1100to be used with additional sizes and configurations of bundle of conduits1125. In some cases, the spacer1130may be attached and removed as desired.

In some aspects, the insert or spacer1130includes one or more holes, slots, or other apertures1115that align with the one or more apertures1115in the pulling device1100. According to some aspects, a spacer1130is inserted into the interior pocket1110of the pulling device1100before inserting the bundle of conduits1125, the spacer1130being configured to adapt the pulling device1100to receive the bundle of conduits1125. In some aspects, the spacer1130includes one or more apertures1115that align with the one or more apertures1115of the pulling device1100. Spacer1130is an example of, or includes aspects of, the corresponding element described with reference toFIG.12.

FIG.12shows an example of a pulling device1200with a spacer1225according to aspects of the present disclosure. The example shown includes pulling device1200, bundle of conduits1220, and spacer1225.

Pulling device1200is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-7,10, and11. In one aspect, pulling device1200includes pulling eye1205, aperture1210, and fastener1215. Pulling eye1205is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1-3, and11. Aperture1210is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,7, and11. Fastener1215is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,4,10, and11. Bundle of conduits1220is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,11, and13.

As shown inFIG.12, an insert or spacer1225may be inserted into the pulling device1200to enable bundle of conduits1220having different sizes and shapes to be accepted by (e.g., fastened to) the pulling device1200. The spacer1225may compress when being inserted into the pulling device1200which ensures a snug fit when seated into the pulling device1200. According to an embodiment, the spacer1225includes apertures that align with the apertures1210of pulling device1200for attachment to the pulling device1200into the bundle of conduits1220with multiple micro-ducts or plastic pipes.

As shown inFIG.12, the spacer1225may be suitable for interposition between an interior of the pulling device1200and an exterior of the bundle of conduits1220. In some examples, at least a portion of the interior space formed by the spacer1225may include a non-circular cross-section. Accordingly, the interior space of the spacer1225may be able to fit (e.g., while rotationally constraining) a bundle of conduits1220that is smaller than a bundle of conduits1220that may otherwise be engaged in the interior of the pulling device1200(e.g., without the spacer1225). According to an embodiment, spacers1225may be used to adapt the pulling device1200for use with additional sizes and configurations of bundle of conduits1220. Spacer1225is an example of, or includes aspects of, the corresponding element described with reference toFIG.11.

FIG.13shows an example of a bundle of conduits1300according to aspects of the present disclosure. Bundle of conduits1300is an example of, or includes aspects of, the corresponding element described with reference toFIGS.1,2,11, and12. In one aspect, bundle of conduits1300includes multiple (e.g., seven) micro-ducts1305. Micro-duct1305is an example of, or includes aspects of, the corresponding element described with reference toFIG.1.

Referring toFIG.13, a bundle of conduits1300is shown that includes a plurality of micro-ducts1305(and in some cases a sheath1310). For example, the bundles of conduits include multiple (i.e., different) shapes and sizes. In some examples, the shape and size of the bundle of conduits1300may be affected by the shape and size of the individual conduits1305and/or the shape and size of the surrounding sheath1310).

An embodiment of the present disclosure describes a method that can be used to seal the micro-ducts1305. In some cases, the micro-ducts1305may be sealed to prevent drilling fluid or other debris from entering the micro-ducts1305of the bundle of conduits1300during the pullback. A first sealing method may include wrapping the exterior of the bundle of conduits1300with one or more layers of tape which creates a tight fit to the interior of the pulling device. A second sealing method may install plugs into the ends of the individual micro-ducts1305. Additionally, a third sealing method may include taping the ends of the individual micro-ducts1305of the bundle of conduits1300to seal the ends of the individual micro-ducts1305.

Accordingly, an apparatus for multiple micro-duct pulling system is described. One or more aspects of the apparatus include an interior pocket at a distal end to receive one end of the bundle of conduits, with at least a portion of the interior pocket having a non-circular profile, shaped to constrain a rotational orientation of the bundle of conduits within the pulling device, wherein the interior pocket has one open end and one closed end; a pulling eye configured to allow the pulling device to be pulled through a bore hole; and one or more apertures extend from an exterior of the pulling device to the interior pocket, sized and located around a perimeter surface of the exterior the pulling device to receive a fastener or fasteners, where the one or more apertures are at one or more angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device.

Some examples of the apparatus and system further include one or more fasteners that are screws. Some examples of the apparatus, system, and method further include one or more fasteners that are bolts and nuts.

Some examples of the apparatus and system further include an insert or spacer configured to adapt the pulling device to multiple conduit bundle sizes and shapes. In some aspects, the insert or spacer comprises one or more holes, slots, or other apertures that align with the one or more apertures in the pulling device. In some aspects, the pulling device comprises steel.

In some aspects, the non-circular profile of the interior pocket is shaped to match at least a portion of a cross-section of the exterior of the bundle of conduits. In some aspects, the bundle of conduits comprises a bundle of more than one small, round conduits contained within a plastic sheath.

A Method of Pulling the Bundle of Conduits

A method for multiple micro-ducts pulling system is described. One or more aspects of the method include providing a pulling device comprising an interior pocket at a distal end to receive one end of the bundle of conduits, with at least a portion of the interior pocket having a non-circular profile, shaped to constrain a rotational orientation of the bundle of conduits within the pulling device, wherein the interior pocket has one open end and one closed end; inserting one end of the bundle of conduits into the interior pocket of the pulling device; attaching the pulling device to a pulling mechanism via a pulling eye configured to allow the pulling device to be pulled through a bore hole; and pulling the pulling device and the bundle of conduits having been attached to the pulling mechanism through the bore hole using the pulling mechanism. In some aspects, the pulling device further comprises one or more apertures extending from a perimeter surface of an exterior of the pulling device to the interior pocket, the one or more apertures being sized and located to receive a fastener or fasteners, wherein the one or more apertures are at one or more angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device.

Some examples of the method further include inserting one or more fasteners through the one or more apertures and into the bundle of conduits to secure the bundle of conduits within the interior pocket of the pulling device. In some aspects, the fastener or fasteners are screws. In some aspects, the fastener or fasteners are bolts and nuts.

Some examples of the method further include inserting a spacer into the interior pocket of the pulling device before inserting the bundle of conduits, the spacer being configured to adapt the pulling device to receive the bundle of conduits. In some aspects, the spacer comprises one or more apertures that align with the one or more apertures of the pulling device. In some aspects, the pulling mechanism is a horizontal directional drilling rig.

Some examples of the method further include sealing ends of individual conduits of the bundle of conduits to prevent entry of drilling fluid or other debris. In some aspects, sealing the ends comprises wrapping an exterior of the bundle of conduits with one or more layers of tape.

FIG.14shows an example of a method1400for infrastructure systems according to aspects of the present disclosure. In some examples, these operations are performed using special-purpose hardware. Generally, these operations are performed according to the methods and processes described in accordance with aspects of the present disclosure. In some cases, the operations described herein are composed of various substeps, or are performed in conjunction with other operations.

At operation1405, the method provides a pulling device including an interior pocket at a distal end to receive one end of the bundle of conduits, with at least a portion of the interior pocket having a non-circular profile, shaped to constrain a rotational orientation of the bundle of conduits within the pulling device, where the interior pocket has one open end and one closed end. In some cases, the operations of this step refer to, or may be performed by, a pulling device as described with reference toFIGS.1-7, and10-12.

At operation1410, the method inserts one end of the bundle of conduits into the interior pocket of the pulling device. In some cases, the operations of this step refer to, or may be performed by, a pulling device as described with reference toFIGS.1-7, and10-12.

At operation1412, the method inserts one or more fasteners through the one or more apertures in an exterior periphery of the pulling device and into the outside surface of one or more of the conduits to secure the bundle of conduits within the interior pocket of the pulling device.

At operation1415, the system attaches the pulling device to a pulling mechanism via a pulling eye configured to allow the pulling device to be pulled through a bore hole. In some cases, the operations of this step refer to, or may be performed by, a pulling device as described with reference toFIGS.1-7, and10-12.

At operation1420, the system pulls the pulling device and the bundle of conduits having been attached to the pulling mechanism through the bore hole using the pulling mechanism, where the pulling device further includes one or more apertures extending from a perimeter surface of an exterior of the pulling device to the interior pocket, the one or more apertures being sized and located to receive a fastener or fasteners, where the one or more apertures are at one or more angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device. In some cases, the operations of this step refer to, or may be performed by, a pulling device as described with reference toFIGS.1-7, and10-12.

Additionally, a method for pulling a bundle of conduits is described. One or more aspects of the method include forming an interior pocket at a distal end of the pulling device to receive one end of the bundle of conduits; shaping at least a portion of the interior pocket to have a non-circular profile to constrain rotational orientation of the bundle of conduits within the pulling device; and creating one or more apertures extending from a perimeter surface of an exterior of the pulling device to the interior pocket, sized and located to receive a fastener or fasteners. In some aspects, the one or more apertures are at angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device. In some aspects, the non-circular profile of the interior pocket is shaped to match the non-circular exterior profile of the bundle of conduits.

In some aspects, the fastener or fasteners are screws. In some aspects, the fastener or fasteners are bolts and nuts.

Some examples of the method further include forming a pulling eye to allow the pulling device to be pulled through a borehole. In some aspects, the pulling device is made of steel.

In some aspects, the creating the one or more apertures comprises creating the one or more apertures counterbored to match heads of the fastener or fasteners. In some aspects, the fastener or fasteners are high-strength self-tapping screws with a piloting drill point. In some aspects, the fastener or fasteners are wood screws, sheet metal screws, or cotter pins. Some examples of the method further include attaching the pulling device to the bundle of conduits by inserting the fastener or fasteners through the one or more apertures and into the conduits.

FIG.15shows an example of a method1500for infrastructure systems according to aspects of the present disclosure. In some examples, these operations are performed using special-purpose hardware. Generally, these operations are performed according to the methods and processes described in accordance with aspects of the present disclosure. In some cases, the operations described herein are composed of various substeps, or are performed in conjunction with other operations.

At operation1505, the system forms an interior pocket at a distal end of the pulling device to receive one end of the bundle of conduits. In some cases, the operations of this step refer to, or may be performed by, an interior pocket as described with reference toFIGS.2,5,6,10, and11.

At operation1510, the system shapes at least a portion of the interior pocket to have a non-circular profile to constrain rotational orientation of the bundle of conduits within the pulling device, and. In some cases, the operations of this step refer to, or may be performed by, an interior pocket as described with reference toFIGS.2,5,6,10, and11.

At operation1515, the system creates one or more apertures extending from a perimeter surface of an exterior of the pulling device to the interior pocket, sized and located to receive a fastener or fasteners, where the one or more apertures are at angles between positive and negative 60 degrees from normal relative to a central axis of the pulling device. In some cases, the operations of this step refer to, or may be performed by, an aperture as described with reference toFIGS.1,2,7,11, and12.