Repair system and method

1. A method of repairing a flexible pipe that is disposed within a bore of a carrier pipe, comprising:

increasing an area of a first hole formed in the carrier pipe, wherein the first hole in the carrier pipe is aligned with a second hole formed in an outer layer of the flexible pipe, a third hole formed in a middle layer of the flexible pipe, and a fourth hole formed in an inner layer of the flexible pipe;

bending material around the third hole in the middle layer of the flexible pipe via the first hole in the carrier pipe to increase an area of the third hole and to form one or more protrusions that extend beyond the outer layer of the flexible pipe; and

patching the fourth hole in the inner layer of the flexible pipe via the third hole in the middle layer of the flexible pipe.

2. The method of claim 1 , comprising sealing the first hole in the carrier pipe.

3. The method of claim 2 , wherein sealing the first hole in the carrier pipe comprises coupling a seal system to the carrier pipe over the first hole.

4. The method of claim 1 , wherein bending material around the third hole in the middle layer of the flexible pipe comprises bending a portion of a metal strip in the middle layer to form a protrusion that extends beyond the outer layer of the flexible pipe.

5. The method of claim 1 , wherein patching the fourth hole in the inner layer of the flexible pipe comprises:

electrofusing the inner layer of the flexible pipe;

welding a patch over the fourth hole in the inner layer of the flexible pipe;

inserting a plug into the fourth hole in the inner layer of the flexible pipe;

placing a gasket over the fourth hole in the inner layer of the flexible pipe and securing a clamp to the flexible pipe over the gasket; or

any combination thereof.

6. The method of claim 1 , comprising drilling or trimming material around the fourth hole in the inner layer of the flexible pipe before patching the fourth hole in the inner layer.

7. The method of claim 1 , comprising increasing area of the second hole in the outer layer of the flexible pipe via the first hole in the carrier pipe, wherein bending the material around the third hole in the middle layer of the flexible pipe comprises bending the material around the third hole in the middle layer of the flexible pipe via the second hole in the outer layer of the flexible pipe.

8. The method of claim 1 , wherein increasing area of the first hole in the carrier pipe comprises cold cutting or hot cutting material around the first hole in the carrier pipe.

9. The method of claim 1 , comprising:

disposing a first seal within an annular space between the carrier pipe and the outer layer of the flexible pipe upstream of the fourth hole in the inner layer of the flexible pipe; and

disposing a second seal within the annular space between the carrier pipe and the outer layer of the flexible pipe downstream of the third hole in the inner layer of the flexible pipe.

10. The method of claim 9 , comprising:

injecting another material into the annular space between the outer layer of the flexible pipe and the carrier pipe; and

curing the other material within the annular space.

11. The method of claim 10 , wherein injecting the other material into the annular space comprises injecting cement or epoxy into the annular space.

12. The method of claim 10 , comprising placing a leak detection pipe into the annular space before injecting the other material into the annular space to facilitate detecting subsequent hole formation in the carrier pipe.

13. The method of claim 10 , wherein curing the other material within the annular space comprises hardening the other material around the one or more protrusions formed in the middle layer to facilitate supporting tensile loads exerted on the flexible pipe.

14. The method of claim 9 , wherein:

disposing the first seal within the annular space comprises inserting a first foam seal or a first swellable seal into the annular space via the first hole in the carrier pipe; and

disposing the second seal within the annular space comprises inserting a second foam seal or a second swellable seal into the annular space via the first hole in the carrier pipe.

15. The method of claim 9 , wherein:

disposing the first seal within the annular space comprises:

forming a first aperture in the carrier pipe upstream of the first hole in the carrier pipe; and

inserting the first seal into the annular space via the first aperture in the carrier pipe; and

disposing the second seal within the annular space comprises:

forming a second aperture in the carrier pipe downstream of the first hole in the carrier pipe; and

inserting the second seal into the annular space via the second aperture in the carrier pipe.

16. A method of repairing a flexible pipe within a carrier pipe, comprising:

increasing an area of a first hole in the carrier pipe;

bending a first layer of the flexible pipe around a second hole in the first layer; and

patching a third hole in a second layer of the flexible pipe.

17. The method of claim 16 , comprising sealing the first hole in the carrier pipe.

18. The method of claim 16 , wherein bending the first layer of the flexible pipe comprises bending portions of metal strips that form the first layer.

19. The method of claim 16 , wherein patching the third hole comprises:

electrofusing the second layer;

welding a patch over the third hole;

inserting a plug into the third hole;

placing a gasket over the third hole and coupling a clamp to the flexible pipe over the gasket; or

any combination thereof.

20. The method of claim 16 , comprising:

inserting a first seal upstream of the third hole and a second seal downstream of the third hole; and

injecting a material into an annular space formed between the first seal, the second seal, the flexible pipe, and the carrier pipe.