Method and apparatus to repair flexible fiber-reinforced pipe

1. A method of repair comprising:

removing damaged stacks from a flexible fiber-reinforced pipe comprising a plurality of helically-wrapped stacks of laminated strips of material from a damage location;

enhancing a direct contact surface of replacement stacks to be installed at the damage location to increase bond ability of the replacement stacks;

applying an adhesive to the surface of the replacement stacks;

installing the replacement stacks to the damage location; and

binding the replacement stacks to remaining existing stacks with the applied adhesive.

2. The method of claim 1 , further comprising: installing a replacement jacket over the replacement stacks.

3. The method of claim 1 , further comprising:

installing a first single strip of material below the replacement stacks, wherein the length of the first single strip of material extends to a first distance of overlap; and

installing a second single strip of material above the replacement stacks, wherein the length of the second single strip of material extends a second distance of overlap.

4. The method of claim 3 , wherein installing replacement stacks comprises:

disposing U-tape below the undamaged portions and covering the damage location for a width of one stack; and

sealing the U-tape around the first single strip of material, the replacement stack, and the second single strip of material.

5. The method of claim 4 , further comprising:

abrading surfaces of contact of at least one of the U-tape, the first single strip of material, and the second single strip of material; and

applying an adhesive to one or more of the abraded surfaces to allow for binding between the contact surfaces.

6. The method of claim 1 , further comprising:

grinding at least one exposed end of the existing stacks to form a stair-step surface; and

grinding at least one end of the replacement stack to form a corresponding stair-step surface to correspond with the stair-step surface of the existing stacks.

7. The method of claim 1 , wherein the abrading contact surfaces comprises at least one of physical and chemical abrasion.

8. The method of claim 1 , further comprising:

cutting away an exterior jacket of the pipe around the damage location;

removing sections of damaged stacks from the damage location; abrading an exposed surface of the damage location;

installing cover U-tape in the damage location;

laying the replacement stacks in the cover U-tape; and

wrapping the replacement stacks with the U-tape.

9. The method of claim 8 , wherein the exposed surface of the damage location comprises at least four inches of an undamaged stack of the pipe.

10. The method of claim 1 , wherein the installing the replacement jacket comprises plastic welding the replacement jacket to a surface of the pipe.

11. The method of claim 1 , wherein the installing the replacement jacket comprises extruding a plastic material to seal the replacement jacket to a surface of the pipe.

12. The method of claim 1 , further comprising covering the pipe around the damage location with a protective layer.

13. The method of claim 12 , wherein the protective layer comprises ethylene propylene copolymer tape.

14. The method of claim 1 , wherein the installing replacement stacks comprises:

bending and securing undamaged stacks of the pipe away from the damage location;

applying epoxy to the replacement stacks and to undersides of the bent undamaged stacks;

releasing the bent undamaged stacks; and

applying epoxy to the replacement stacks and to upper sides of the released undamaged stacks.

15. The method of claim 1 , wherein the repair is performed in-situ.

16. The method of claim 1 , further comprising:

removing at least one of tensile loads, compression loads, and internal pressure loads from the pipe prior to performing the repair.

17. The method of claim 1 , further comprising applying a barrier tape to undamaged stacks exposed by the removed damaged portions of the damaged stacks prior to installing the replacement stacks.

18. The method of claim 1 , further comprising applying a barrier material to the installed replacement stacks prior to installing the replacement jacket.

19. The method of claim 1 , wherein the replacement stacks comprise protective tape wrapped there around.

20. A method of repair comprising:

removing damaged stacks from a flexible fiber-reinforced pipe comprising a plurality of helically-wrapped stacks of laminated strips of material;

installing a first single strip in a void created by the removed damaged stacks;

enhancing a direct contact surface of a replacement stack to be installed at a location previously occupied by the damaged stacks to increase bond ability of the replacement stack;

installing the replacement stack in a void created by the removed damaged stacks; and

installing a second single strip over the replacement stack.

21. The method of claim 19 , further comprising installing U-tape around the first single strip, the replacement layer, and the second single strip.