System and method for trepanation of submarine hydraulic pipes

Description

1 / 26 SYSTEM AND METHOD FOR TREPANATION OF SUBMARINE HYDRAULIC PIPES Field of invention

[001] The present invention is applied to the area of ​​technologies for maintenance of subsea equipment used in the oil and gas industry and, more particularly, refers to a system and a method for trepanning subsea hydraulic tubes (tubings), responsible for carrying out the hydraulic control of subsea equipment by means of valves. Fundamentals of the invention

[002] The offshore oil and gas industry is a highly complex and challenging environment, in which the operation of subsea equipment is fundamental to the production and exploration of these natural resources. In offshore production systems, hydraulic control is widely used to control the functions of this subsea equipment, through subsea valves that often comprise safety elements of wells and subsea systems.

[003] Although widely used in the oil and gas industry, umbilicals with thermoplastic hoses have a commonly observed failure mode when operating in deep and ultra-deep water, namely the premature rupture of the control hoses. This failure leads to the loss of hydraulic actuation of the subsea valves, which can compromise the operational continuity of the system.

[004] Although there are some options available to maintain the safe operation of a subsea system when a hydraulic line fails; such as the use of backup functions, sharing of hydraulic functions and operation of valves in override - forced opening, replacement of the control umbilical may be necessary.

[005] Such maintenance (umbilical cord replacement) is a complex, costly and time-consuming process, involving the acquisition of Petition 870250013949, dated 20 / 02 / 2025, page 39 / 84 2 / 26 a new umbilical, use of special launching vessels, mobilization and installation of the new control umbilical, in addition to the loss of production during these activities and other direct and indirect costs.

[006] Therefore, there is a latent need in the State of the Art for the development of a system that is capable of solving the problems caused by failures of hydraulic control umbilical hoses, without the need for immediate replacement of the component, allowing proper realignment of the hydraulic circuit in Wet Christmas Tree (WCT) caps that do not have the alignment flexibility present in more modern logic caps.

[007] Thus, the present invention provides a system and a method for performing hydraulic tubing trepanning, which allows for the quick and efficient construction of a hydraulic bypass line, in order to bypass damaged hydraulic lines, without the need to replace the entire control umbilical. This makes it possible to significantly reduce production or injection downtime and, above all, the costs associated with replacing the control umbilical, while maintaining the safe and efficient operation of subsea equipment. The system and method developed by the present invention are applicable to any offshore production system, especially systems located in deep and ultra-deep water, where the problem of hose ruptures is more prevalent. State of the Art

[008] The State of the Art shows some documents that reveal matters within the technological field of the present invention.

[009] Document KR102669799 B1 refers to a method of constructing an uninterrupted water lock, characterized by comprising the following steps: (A) installing fixing modules Petition 870250013949, dated 20 / 02 / 2025, p. 40 / 84 3 / 26 for intermittent drilling on the inlet and outlet sides of the target section of the pipe through which the fluid flows; (B) install a drilling device on the clamping module to drill a pipe; (C) protect the drilled part of the pipe by means of a clamping module; (D) remove the drilling device from the clamping module and install a fluid cutting device; (E) Install a bypass tube between the fluid blocking devices installed on the inlet and outlet sides, respectively; and (F) Open the bore through the clamping module and close the inlet and outlet sides of the target section of the tube using the fluid blocking device to form a flow path through the bypass tube. The method has the effect of preventing damage to the tube while completely blocking the flow of fluid within the tube.

[010] However, document KR102669799 B1 shows a solution typically used for large diameter ducts (greater than 4 inches). Furthermore, this document shows an alternative configuration of a mechanical isolation system. The system presented by KR102669799 B1 shows a section of the original duct wall cut out, which needs to be removed, requiring a more complex method. The present invention, in turn, is mainly applied to pipes between 12.7 mm (1 / 2 inch) and 19.05 mm (3 / 4 inch), so that, instead of using a rotary tool, as is traditionally done in the State of the Art, a static tool (knife) is used that cuts the hydraulic pipe (tubing) and bends the cut part so that the resulting geometry prevents the passage of fluid, isolating the branch that leads to damage in the umbilical. At the other point, the cutting and crushing are such that the communication of fluid pressure is permitted.In this way, the fluid from the intact hose feeds both circuits.

[011] In addition, document US11156319 B2 refers to a flow restriction system for restricting fluid flow. Petition 870250013949, dated 20 / 02 / 2025, p. 41 / 84 4 / 26 through a pipe, and includes an anchor and an inflatable plug. The anchor includes an alignment body, a shielding body, and a first fluid passage defined in the alignment body and the shielding body. The shielding body extends from the alignment body and has an upstream face and a downstream face. The downstream face is opposite the upstream face. The shielding body is configured to block at least part of the fluid flow through the pipe. The inflatable plug is attached to the downstream face of the shielding body. The inflatable plug includes an internal chamber that is in fluid communication with the first fluid passage.

[012] However, document US11156319 B2 presents an inflatable element as a mechanical blocking element, which would not have the same efficiency as the mechanical element used by document KR102669799 B1, for example, but which would serve to reduce the flow rate in a section by restricting the bypass channel and a possible passage through the isolation element itself. This document does not reveal, or even suggest, the use of a static tool that cuts the hydraulic tubing and bends the cut part so that the resulting geometry prevents the passage of fluid, isolating the branch that leads to the umbilical damage, and causing the fluid from an intact line to feed two different lines.

[013] Furthermore, document AU2018209072 B2 discloses a tool for hot tapping (trepanning) an underwater pipe. The tool includes a hydraulically activated clamp to secure the tool to the pipe, and a punch with a chamfered end designed to create a hole in a side wall of the pipe. A hydraulic access point is provided to allow fluid connection within the pipe.

[014] However, document AU2018209072 B2 addresses the provision of a hydraulic line drilling tool to promote new access, without going into the merits of the concept of Petition 870250013949, dated 20 / 02 / 2025, p. 42 / 84 5 / 26 complete solution, which enables the restoration or maintenance of operation through a bypass of the damaged line, as is the case with the present invention. Furthermore, the mechanism of the tool proposed in the aforementioned document presents relevant differences compared to the tool of the present invention regarding the cutting / drilling and sealing methods indicated in the two systems. Moreover, document AU2018209072 B2 does not disclose or suggest application to subsea chemical transport and injection systems. In general, the control umbilical of subsea wells and equipment shares hydraulic functions with chemical injection functions. The present invention may also have application in the maintenance of chemical injection lines, in case of failure of the original line, or in case of need to create bypasses or branches in one of these lines.Additionally, the tubing or hydraulic line penetration mechanism of the present invention differs from the tool proposal detailed in AU2018209072 B2. In the present invention, a knife cuts the line, while in the aforementioned document, a punch perforates the line.

[015] Thus, based on the foregoing, the system and method of the present invention relate to the comprehensive concept of bypassing control lines or chemical injection lines, in order to enable the maintenance of hydraulic control operation or subsea chemical injection in wells and equipment. Brief description of the invention

[016] The solution of the present invention to the technical problem mentioned above consists in the development of a system for trepanning submarine hydraulic pipes (tubings) that allows the quick and efficient construction of a hydraulic bypass line, in order to bypass damaged hydraulic lines, without the need to replace the entire control umbilical. Petition 870250013949, dated 20 / 02 / 2025, page 43 / 84 6 / 26

[017] The present invention has application in offshore production systems, especially those located in deep and ultra-deep water and which use thermoplastic umbilicals for the control of wells and subsea equipment. These umbilicals are more susceptible to failures, which prevents them from maintaining the system pressurized and therefore operational. Typically, the system and method of the present invention can be used in subsea oil or gas production collection systems, subsea water or gas injection systems, and subsea oil or gas production flow or transfer systems.

[018] As part of a collection system, the technology developed in the present invention can be combined with state-of-the-art solutions, such as the use of reserve functions, sharing of hydraulic functions, operation of valves in override, and use of chemical injection lines as control lines to increase the range of options, so as to avoid replacing the electro-hydraulic umbilical for controlling wells and subsea equipment.

[019] Additionally, the present invention also has application in the recovery of control lines that have suffered damage to their connectors or at some other point, and which no longer exhibit tightness, preventing their return to operation without intervention with a Pipe Laying Support Vessel (PLSV), Subsea Equipment Support Vessel (SESV), or drilling rig, depending on the point of leakage. The system of the present invention also provides a mini clamp, with a diameter suitable for gripping / encasing the hydraulic pipe of interest, materials of high mechanical strength and corrosion resistance, and sealing in a suitable material (e.g., Viton), to ensure tightness at high working pressures. Petition 870250013949, dated 20 / 02 / 2025, page 44 / 84 7 / 26

[020] Thus, the objectives and advantages of the present invention are achieved by providing a system for trepanning subsea hydraulic pipes comprising: a first pipe having a first clamp that encases a portion of the first pipe; a second pipe having a second clamp that encases a portion of the second pipe; each of the first clamp and the second clamp having a corresponding branch, the branch of the first clamp being aligned with an orifice of the first pipe; wherein a knife having a curved lower portion and a cutting edge is connected to a hydraulic cylinder; wherein the hydraulic device is equipped with a directional valve and actuatable by a remotely operated vehicle (ROV), the hydraulic device acting on a piston, compressing the knife against the wall of the corresponding pipes, so as to form an orifice and a bend;where a branch tube is connected between the branches of the pair of clamps to form a fluid communication between the first tube and the second tube.

[021] Furthermore, the present invention also provides a method for trepanning submarine hydraulic pipes using the described system, wherein the method comprises: installing a first clamp on a portion of a first pipe; installing a second clamp on a portion of a second pipe, with the second clamp encasing the portion of the second pipe; using a ball valve to prevent the entry or exit of fluids in the system undergoing intervention; using a hydraulic system composed of a hydraulic cylinder and a directional valve to generate the displacement of the knives to perform the cutting and crushing; connecting a knife in position to perform the respective cutting and crushing; introducing a knife, having a curved lower portion and a cutting edge, through the ball valve and a branch of each of the clamps to cut and bend each of the pipes forming, Petition 870250013949, dated 20 / 02 / 2025, page 45 / 84 8 / 26 thus, a hole and a bend; and connect a branch pipe between the branches of each of the clamps or between the isolating ball valves, allowing pressurization of the damaged branch. Brief description of the figures

[022] The preferred embodiments of this invention will be better understood when read in conjunction with the accompanying drawings. It should be understood, however, that the invention in question is not limited only to the precise arrangements and instruments shown.

[023] Thus, the present invention will be described below with reference to its typical embodiments and with reference to the attached drawings, in which:

[024] Figure 1A shows a schematic view of a section of a first hydraulic pipe and a section of a second hydraulic pipe, each connected to its respective upstream hydraulic hose and to the downstream actuation equipment, wherein the arrows indicate the direction of hydraulic fluid flow within each pipe towards a corresponding subsea piece of equipment actuated by the hydraulic fluids (such as a valve), according to an embodiment of the present invention.

[025] Figure 1B shows a schematic view of the flow configuration in the two paths shown in Figure 1A, after each of them has been drilled to realign the pressurized circuit, isolating the section that presented leakage, using the proposed system for drilling subsea hydraulic pipes, in which the arrows indicate the direction of fluid flow from a first pipe that follows two flow paths, according to an embodiment of the present invention.

[026] Figure 1C shows an alternative configuration where the failure occurred in the tubing itself that is part of the subsea equipment, receiving an alternative route (by pass), according to an embodiment of the present invention. Petition 870250013949, dated 20 / 02 / 2025, p. 46 / 84 9 / 26

[027] Figure 2 shows a typical front view of one of the hydraulic tubes, according to an embodiment of the present invention.

[028] Figure 3 shows a simplified front view of one of the clamps to be used on each of the hydraulic tubes, according to an embodiment of the present invention.

[029] Figure 4A shows a simplified front view of a clamp installed around one of the hydraulic pipes, according to an embodiment of the present invention.

[030] Figure 4B shows a simplified side view of a clamp installed around one of the hydraulic tubes, according to an embodiment of the present invention.

[031] Figure 4C shows a simplified top view of a clamp installed around one of the hydraulic pipes, according to an embodiment of the present invention.

[032] Figure 5A shows a simplified side view of a knife, according to an embodiment of the present invention.

[033] Figure 5B shows a simplified front view of a knife, according to an embodiment of the present invention.

[034] Figure 6A shows a schematic view of a knife before it is inserted into the branch of a clamp installed on one of the hydraulic pipes, according to an embodiment of the present invention.

[035] Figure 6B shows a schematic view of a knife after being inserted into the branch of a clamp and before cutting one of the tubes to create a hole and a bend, according to an embodiment of the present invention.

[036] Figure 6C shows a schematic view of a knife after it has made a cut in one of the tubes and while it is crushing the cut wall part of one of the tubes to create the bend, according to an embodiment of the present invention. Petition 870250013949, dated 20 / 02 / 2025, p. 47 / 84 10 / 26

[037] Figure 6D shows the final configuration of a portion of one of the tubes after removing the knife from the clamp branch, according to an embodiment of the present invention.

[038] Figure 7A shows a simplified front view of a knife configuration to be used for cutting and kneading, such that the circuit allows the flow of hydraulic fluid through the tube where it is applied, according to an embodiment of the present invention.

[039] Figure 7B shows a simplified side view of the same knife shown in Figure 7A, according to an embodiment of the present invention.

[040] Figure 7C shows a side view of the appearance of the cut and crease, demonstrating that the passage will not be obstructed, according to one embodiment of the present invention.

[041] Figure 7D shows a front view of the same section of the pipe shown in Figure 7C, according to an embodiment of the present invention.

[042] Figure 8 shows the detail of the clamp opening to be coupled to each of the tubes, according to one embodiment of the present invention.

[043] Figure 9A shows in greater detail the clamp in its configuration of use, when installed on a pipe, according to an embodiment of the present invention.

[044] Figure 9B shows the same clamp with two nuts installed to compress the clamp against the pipe, ensuring the tightness of the system, according to one embodiment of the present invention.

[045] Figure 10 shows two alternative configurations of means to be used as a bypass, the one on the left being the configuration using a hose and the one on the right using a steel pipe, according to an embodiment of the present invention. Petition 870250013949, dated 20 / 02 / 2025, page 48 / 84 11 / 26

[046] Figure 11 shows the complete device installed, including the closed clamp and a ball valve installed on it to ensure the tightness of the system during the trepanning process, as well as the trepanning device itself, which has a hydraulic actuator with an attached directional valve to perform the trepanning itself, according to an embodiment of the present invention.

[047] Figure 12 shows the device in an alternative configuration with the use of a float and ROV handling handle, according to an embodiment of the present invention. Detailed description of the invention

[048] Reference is made in detail to preferred embodiments of the present invention, illustrated in the accompanying drawings. Wherever possible, the same or similar reference numbers will be used throughout the drawings to refer to identical or similar features. It should be noted that the drawings are in simplified form and are not represented to precise scale, so minor variations are expected.

[049] Currently, when ruptures of subsea hydraulic hoses or pipes occur, there are some possible technical solutions; such as the use of a spare hose. Although it is a simple solution, it does not completely solve the problem, since the spare hose is also subject to the failure mechanism. Furthermore, for older Wet Christmas Trees (WCTs), there is a limitation in the configuration possibilities of the spare hoses, so that if the spare hose ruptures, the operational flexibility of the hydraulic actuation is completely lost.

[050] Furthermore, other solutions involve aligning more than one subsea valve for a given hydraulic function (“chicken foot”). This solution implies a reduction in operational flexibility, with the independence of Petition 870250013949, dated 20 / 02 / 2025, page 49 / 84 12 / 26 valve operation compromised, potentially leading to two to four valves operating simultaneously, when ideally they should be operated in sequences more convenient for the process and flow development.

[051] Another solution provided consists of re-instrumenting the umbilical for the use of chemical injection hoses acting as a hydraulic control function. This is a simple solution, but it has limitations and a high cost, since it must be carried out by a pipe-laying support vessel (PLSV), in addition to the system having a hose with a high potential for particulate generation, resulting from the friction of the metallic strip that exists internally in the hose and which provides resistance to collapse in chemical injection hoses (a requirement not demanded in hydraulic control hoses). This effect generates contamination, which can compromise the functionality of subsea components, typically directional valves that align the hydraulic functions to the actuators of the subsea valves, as well as the actuators themselves.

[052] Furthermore, a commonly employed solution is the placement of a valve in forced opening (override). Considering that subsea valves generally form well safety barriers, the placement of valves in override should be avoided, as it makes the system vulnerable during events that require automatic valve closure, such as shutdowns, which may be caused by leaks and fires. This ultimately requires, within a timeframe specified by the standard, the need to replace the umbilical to restore operational capability.

[053] Finally, it may be preferable to replace the entire umbilical. However, this is the most extreme and costly solution, as it requires a new umbilical, which can be several kilometers long, in addition to the low availability and high cost of naval resources for its installation. Such resources compete with development projects, Petition 870250013949, dated 20 / 02 / 2025, page 50 / 84 13 / 26 impacting production in other fields, in addition to the one that requires maintenance services.

[054] Therefore, aiming to solve the technical problem related to failures in umbilicals or subsea hydraulic tubes, the present invention provides a simple application system, aimed at the trepanation of a hydraulic tube used in a subsea hydraulic tunnel (for example), which makes it possible to make the tube that will act as a backup more flexible, allowing total versatility in hose correlation configuration. This allows subsea tunnels that do not have a recoverable logic cover by ROV the same flexibility as more modern subsea tunnels, which have a recoverable logic cover. This flexibility avoids the need to place valves in override (increased operational risk), which allows operational continuity and avoids premature replacement of the well control umbilical or equipment.

[055] According to the present invention, the system and its associated method allow redirecting the flow of hydraulic fluid that runs through the interior of an intact hydraulic pipe (or hose) to an auxiliary line (bypass pipe) and, subsequently, to another pipe that has a fault or leak in some section of hose, typically located upstream of this point, so that the operation of the valve associated with the faulty hydraulic pipe is not interrupted or impaired.

[056] Thus, reference is made to Figures 1A, 1B and 1C, which show a solution involving the trepanation of subsea hydraulic tubes, according to an embodiment of the present invention. In particular, Figure 1A shows portions of a first hydraulic tube (1) and a second hydraulic tube (2) close to each other, typically located in the same subsea equipment, each carrying hydraulic fluid for actuation of a corresponding valve. In Figures 1B and 1C it is possible to visualize Petition 870250013949, dated 20 / 02 / 2025, page 51 / 84 14 / 26 the system, after intervention, with its main components, while Figure 2 shows, in a front view, the cross-section of a typical hydraulic pipe, according to the present invention. Thus, the configuration of the solution represented by the system for trepanning submarine hydraulic pipes comprises a first pipe (1) interconnected to an intact system (i.e., without faults), responsible for conducting a fluid inside it towards a valve (not shown) actuated by the fluid. Similarly, a second pipe (2) also carries a hydraulic fluid inside it to actuate a second valve (not shown), corresponding to the second pipe (2). A fault in some section along the circuit in which the second pipe (2) is inserted (such as: rupture of a hose installed upstream, leakage in a connection, etc.)), configured by loss of pressure in the branch, which will cause loss of hydraulic fluid with or without loss of functionality of the actuated valve, may be detected, prompting intervention to solve the problem. To avoid replacing the umbilical when it is not possible to align the spare hose, a time-consuming and costly process, the system is assembled so that the hydraulic fluid from the first pipe (1) is also distributed to the second pipe (2) by means of a bypass line (3), so that pressure communication between the fluids is permitted and the hydraulic fluid feeds both the circuit responsible for actuating the valve of the first pipe (1) and the circuit that actuates the valve of the second pipe (2).

[057] Thus, the system comprises a first clamp, (20) which encases a portion of the first tube (1) and a second clamp (20) which encases a portion of the second tube (2), as seen in Figures 4A to 4C. Each of the clamps (20) has a general inverted T shape, having a corresponding branch (21), as shown in an exemplary manner. Petition 870250013949, dated 20 / 02 / 2025, page 52 / 84 15 / 26 as Figures 3, 4A, 4B and 4C. In addition, each of the clamps (20) is mounted or installed on the corresponding pipe section, preferably by means of a remotely operated vehicle (ROV). Alternatively, the clamps (20) can be installed by a diver.

[058] In the example given, the circuit of the first tube (1) does not have faults, the hydraulic fluid transported by it should not have its flow completely blocked towards the corresponding valve fed by the first tube (1), so that the high-pressure fluid should also be conducted or distributed to another branch line (3) until it reaches the portion of the second tube (2) where the second clamp (20) is mounted. The branch line (3) can be rigid (3a) or flexible (3b), as shown in Figure 10, depending on the complexity of the configuration of the tubes (1) and (2), allowing greater maneuverability of this component.

[059] To isolate the damaged section, allowing the proposed repair, a hydraulic cutting device (70), shown in Figure 11, consisting of a hydraulic cylinder (54) is alternatively coupled via a “quick coupling” (52), but not limited to this configuration, to a ball valve (50), which in turn is coupled to the clamp (20), by threading onto the thread (30, 30a), as shown in Figures 9A and 9B, while the knife (4) is coupled to the shaft (56) of the cylinder (54), to perform the cutting and crushing or bending (23), generating the access or hole (22) in the tube (2).

[060] The use of the ball valve (50), convenient for preventing seawater from entering the circuit, by actuating its handle (51), is optional and its presence will depend on the dimensioning of the shaft (56) of the cylinder (54) and the length of the blades (4) and (5) themselves.

[061] A similar procedure should be performed on tube (1), but using the knife (5), shaped to generate the cut and Petition 870250013949, dated 20 / 02 / 2025, page 53 / 84 16 / 26 crushing (24), providing the same access or orifice (22), but without isolating the branch, allowing virtually full passage.

[062] It should be noted that cutting using knives (4) and (5) does not generate waste such as filings, nor does it require the removal of scrap, which could make the process more complex or bring potential risks of jamming of the actuated components, due to contamination by particulate matter, also allowing an opening with a maximum diameter (22), which does not occur in conventional trepanning operations.

[063] Figure 1C shows an alternative configuration, where the proposed invention is used to make a bypass (31) in the pipe (2) itself, considering damage to it. In this case, clamps (20) are also used, but with the same knife (4) for both trepanning operations, in a suitable position to isolate the section between the clamps. The flow direction is highlighted, indicated by arrows.

[064] Both knives (4) and (5), and the cylinder (54) have keyways, respectively (42) and (53), so that they are installed in a suitable position for performing the trepanning, with the desired effects of full passage (24) or blocking (23). Special care must be taken in dimensioning the knives (4) and (5) and the shaft (56) of the cylinder (54), so that the cutting stroke respects the limits for the solution to be effective.

[065] Both accesses (22) are created by shearing from the pressure exerted by the blades of the knives (4) and (5), when compressed by the cylinder (54), from hydraulic power supplied by an external source (ROV or carried by the diver).

[066] In the proposed invention, the directional valve (57), fixed to the cylinder structure (54) by fasteners (60), actuated by solenoids (58), allows the alignment of the hydraulic pressure. Petition 870250013949, dated 20 / 02 / 2025, p. 54 / 84 17 / 26 for one of the channels (59), which pressurize the cylinder chamber (54), confined by the pistons (55), allowing it to advance (cutting) and retract (retracting the knife (4) or (5), depending on the case). In addition, the hydraulic cylinder (70) and the directional valve (57) are coupled.

[067] The branch (21) is also used to guide the knives (4) and (5), depending on the case.

[068] Thus, it should be noted that each type of knife (4) or (5) has distinct applications, namely, to cut and generate a dent or bend (23) such that it causes insulation with the part of the circuit that lacks tightness and to cut and generate a dent or bend (24) such that it allows passage through the largest possible remaining section of tube.

[069] Furthermore, each knife (4) and (5), with a circular cross-section, as shown in Figures 5A and 5B, and 7A and 7B, respectively, is introduced into the branch (21) of the corresponding clamp (20), to cut and bend the tubes (1) and (2), as the case may be. In this way, a hole (22) and a bend (23) and (24), respectively, are formed in the tubes (2) and (1), respectively. It should be noted that knives (4) and (5) have a curved lower portion (40) and a cutting edge (41), so that, as the edge (41) of knife (4) or (5) advances together with the curved lower portion (40) transversely into the interior of the respective tube (2) or (1), a part of the wall of this tube (2) or (1) is sheared and folded, forming the hole (22) and the fold (23) or (24), respectively, due to the cutting and crushing of the wall part of the tube in question (2) or (1).The introduction of one of the knife configurations (4) into the branch (21) of the clamp (20) and its progression, forming the hole (22) and the bend (23) in the tube (2), are illustrated in Figures 6A, 6B and 6C.

[070] Furthermore, according to one embodiment of the present invention, a branch tube (3) is connected to the branch Petition 870250013949, dated 20 / 02 / 2025, page 55 / 84 18 / 26 (21) of the first clamp (20) and in the branch (21) of the second clamp (20), to connect the first tube (1) to the second tube (2). This connection forms a fluid communication between the first tube (1) and the second tube (2), so that the high-pressure hydraulic fluid coming from the first tube (1), in addition to following the longitudinal path along the first tube (1) to the corresponding valve, is diverted to the branch tube (3), through the hole (22) and branch (21) of the first clamp (20) towards the first tube (1), through the branch (21) and hole (22) of the second clamp (20).

[071] In the second tube (2) the hydraulic fluid passes through the orifice (22) and is prevented from returning to the leak point by the concave part of the bend (23), being directed to the actuated valve from the second tube (2). The arrows in Figures 1A to 1C show the direction of the hydraulic fluid flow coming from the first tube (1) and, from the first clamp (20), being directed by two paths, in Figure 1B: A - following the first tube (1) to the subsea equipment (valve, for example); and B - following the branch tube (3) to the second clamp (20) and being redirected by the bend (23) then through the intact section of the second tube (2) to a second subsea equipment (valve, for example).

[072] Figure 1C shows the alternative configuration where the damage is located in the tube itself (2). In this case, both trepanning interventions involve the use of the knife (4) positioned conveniently, so that the crushing or bending (23) prevents pressurization between the two points where the clamps (20) are installed.

[073] Note, therefore, that the bend (23) formed in the second tube (2), in addition to redirecting the fluid coming from the branch tube (3) to an intact section of the second tube (2), prevents the fluid from going to the damaged section in the circuit of the second tube (2), providing tightness to the system. Petition 870250013949, dated 20 / 02 / 2025, pp. 56 / 84 19 / 26

[074] In addition, the system's pipes (1, 2, 3) have diameters ranging from about 0.0127 m (1 / 2 inch) to about 0.01905 m (3 / 4 inch).

[075] Next, the implementation of a method for trepanning subsea hydraulic pipes will be described in greater detail, in which the synergistic operation between the components of the present invention will become even more evident to a person skilled in the art.

[076] Thus, the method comprises a first step of installing a first clamp (20) on a portion of a first tube (1), so that the first clamp (20) encases the portion of the first tube (1). Such encasement is made possible by the fact that the clamp is split in two (Figure 8).

[077] As shown in greater detail in Figure 8, the clamp (20) has a joint (25) and a sealing surface (26), which must be dimensioned to provide tightness at pressures that can reach 5000 psi (approximately 345 bar). Seals must also be employed on the longitudinal part (27) of the clamp (20), housed in a cavity (27a), as well as on the radial part (28) of the branch (21), housed in a cavity (28a). The cavities (27a) and (28a) appear highlighted in Figure 8. The branch (21) also has, alternatively, a pair of tapered threads (29) and (30). Alternatively, the thread (30) can be replaced by a quick coupling profile (52), similar to that shown in Figure 11. Both the profile, if adopted, and the thread (30) must be of a smaller gauge than that of the thread (29), so that it is possible to close the branch (21) by threading and compressing the thread (29).The use of nuts (29a) and (30) is foreseen for threads (29) and (30a), respectively, as shown in Figure 9B.

[078] Thus, the branch (21) of each of the clamps (20) can be joined by a set of nuts (29a, 30a) in Petition 870250013949, dated 20 / 02 / 2025, page 57 / 84 20 / 26 tapered threads (29, 30) with different gauges, providing sealing between clamp (20) and tube (1, 2), between clamp (20) and ball valve (50), between ball valve (50) and hydraulic cylinder (70) and between ball valve (50) and branch tube (3)

[079] Similarly, a second clamp (20) is installed on a portion of a second tube (2), with the second clamp (20) encasing the portion of the second tube (2). The installation of both clamps (20) is preferably done by means of an ROV or, less preferably, by means of a diver.

[080] After installing each of the clamps (20), in a location that allows the installation of the compact system, composed of the hydraulic cylinder (70), the closed shut-off ball valve (50) is installed, operated by the handle (51). Next, the hydraulic cylinder (70) is mounted, using a quick coupling (52) or, alternatively, using a threaded joint, so that a keyway (53) allows the correct relative positioning of the parts.

[081] Similarly, a knife (4) or (5), depending on the case, having a curved lower portion (40) and a cutting edge (41) is introduced into the cylinder (70) and connected to the shaft (56), positioned through the keyway (42), present in the knife (4) or (5). It is important to note that this keyway (42) is not shown in Figures 5A to 6C and 7A to 7B, since these Figures present a simplified configuration to facilitate understanding.

[082] With the system assembled and tested, the ROV operator or diver, depending on the case, can activate one of the solenoids (58) to advance the piston (55) and, consequently, perform trepanning with shearing and crushing of the cut part of the wall of the respective tube (1) or (2), through access via the branch (21) of the clamp (20). This Petition 870250013949, dated 20 / 02 / 2025, p. 58 / 84 21 / 26 way, an orifice (22) and a watertight (23) or communicating (24) fold are formed, depending on the case.

[083] After the trepanation is performed, the ROV activates the other solenoid (58), responsible for the retraction of the piston (55) of the cylinder (70), which causes the knife (4) or (5), depending on the case, to be retracted, allowing the ball valve (50) to close, by actuating the handle (51).

[084] When performing the two trepanations, in the tubes (1) and (2), with their respective clamps (20) installed and fixed by means of the nuts (29a) and, preferably, keeping the valves (50) interconnected to the branch (21) of each of the clamps (20), although omitted in Figures 1B and 1C, the method also includes the connection of a bypass tube (3) or (31) depending on the case. This bypass tube may adopt configuration (3a) or (3b), with the rigid configuration (3a) being manufactured after surveying the exact geometry of the points where the clamps (20) were installed, so that they are manufactured and installed correctly. In either case, there must be a rigid end with a housing (32) for a sealing layer which must be sized to withstand the typical pressures of underwater hydraulic actuation (up to 5000 psi).

[085] This bypass tube is then positioned and connected by means of a nut (30a) or, alternatively, by means of a quick connector, which must be fitted to the valve(s) (50), if the same is / are maintained.

[086] Thus, with the bypass pipe (3) connected (new control line in operation), the hydraulic functions targeted for maintenance are restored and the equipment (valve) or well can continue to operate normally. In this way, the present invention allows, through its system and associated method, the problem of loss of hydraulic functions in control systems of subsea equipment to be solved in a way Petition 870250013949, dated 20 / 02 / 2025, page 59 / 84 22 / 26 fast and efficient, without the need for complete replacement of the hydraulic tube or control umbilical.

[087] The clamps (20) and the bypass tube (3) (hydraulic bypass line) allow the creation of the new control line, while the knife (4) or (5) allows the creation of the new desired alignment (new fluid flow path).

[088] Furthermore, the present invention can also be applied to subsea chemical transport and injection systems. In general, the well control tube or umbilical and subsea equipment share hydraulic functions with chemical injection functions. The system and method of the present invention can also be applied to the maintenance of chemical injection lines, in case of failure of the original line, or in case of need to create diversions or branches in one of these lines.

[089] Alternatively, it is still possible to adopt some type of floating element (71) and / or handle (72), as illustrated in Figure 12, to facilitate handling of the device (70) by the ROV. The floating element aims to provide slightly negative buoyancy and adjust the center of gravity of the system.

[090] It is also important to mention that the system of the present invention has access for pressure testing after installation.

[091] Thus, in one embodiment, the present invention provides a system for trepanning subsea hydraulic pipes comprising: a first pipe (1) having a first clamp (20) that encases a portion of the first pipe (1); a second pipe (2) having a second clamp (20) that encases a portion of the second pipe (2); each of the first clamp (20) and the second clamp (20) having a corresponding branch (21), the branch (21) of the first clamp (20) being aligned with an orifice (22) of the first pipe (1); wherein a knife (4, 5) having a lower portion Petition 870250013949, dated 20 / 02 / 2025, pp. 60 / 84 23 / 26 curve (40) and a cutting edge (41) is connected to a hydraulic cylinder (70); wherein the hydraulic device (70) is fitted with a directional valve (57) and actuatable by a remotely operated vehicle (ROV), the hydraulic device (70) acting on a piston, compressing the knife (4,5) on the wall of the corresponding tubes (1, 2), so as to form an orifice (22) and a bend (23, 24); wherein a branch tube (3) is connected between the branches (21) of the pair of clamps (20) to form a fluid communication between the first tube (1) and the second tube (2).

[092] Furthermore, according to one embodiment of the present invention, a method is provided for trepanning submarine hydraulic pipes using the described system, wherein the method comprises: installing a first clamp (20) on a portion of a first pipe (1); installing a second clamp (20) on a portion of a second pipe (2), with the second clamp (20) encasing the portion of the second pipe (2); using a ball valve (50) to prevent the entry or exit of fluids in the system undergoing intervention; using a hydraulic system composed of a hydraulic cylinder (70) and a directional valve (57) to generate the displacement of the knives (4, 5) to perform the cutting and crushing; connecting a knife (4, 5) in position to perform the respective cutting and crushing;introduce a knife (4) or (5) having a curved lower portion (40) and a cutting edge (41), through the ball valve (50) and a branch (21) of each of the clamps (20) to cut and bend each of the tubes (1, 2) thus forming a hole (22) and a bend (23, 24); and connect a branch tube (3) between the branches (21) of each of the clamps (20) or between the isolating ball valves (50), allowing pressurization of the damaged branch.; Petition 870250013949, dated 20 / 02 / 2025, pp. 61 / 84 24 / 26

[093] Some advantages are observed from the implementation of the system and method disclosed by the present invention, as described below.

[094] One of the related advantages concerns productivity, since the invention results in a significant reduction in direct and indirect costs, as it minimizes the need to replace subsea control pipes or umbilicals. The use of the system and method of the present invention reduces the costs associated with the acquisition, mobilization and installation of new control pipes or umbilicals, as well as the production downtime during the period of supply of the new pipe or umbilical and mobilization of the launching vessel (PLSV). These factors result in significant financial savings and reduced production downtime in the operation of an offshore production system.For example, comparing a current scenario of umbilical replacement, where the supply process has been initiated following the last critical failure, there is usually a period of approximately 740 days between contracting and supplying the materials, plus about 90 days for PLSV mobilization, resulting in approximately 830 days of lost production, injection, or, if operation is possible, loss of hydraulic fluid to the environment. Considering an average potential of producing wells (608 m3 / d), this represents a gross revenue loss of approximately US$ 222 million during this period, assuming the oil price remains constant at US$ 70.00 / bbl.With the use of the system and method of the present invention, the repair time would be limited to approximately 180 days, for the preparation of procedures and planning of operations with a remotely operated vehicle (ROV Support Vessel - RSV) support vessel, a significantly cheaper resource, so that such a loss would be on the order of US$ 48 million, considering the same previous assumptions. Considering a minimum length of 5 km of electro-hydraulic umbilical (UEH), in the current situation... Petition 870250013949, dated 20 / 02 / 2025, pp. 62 / 84 25 / 26 a saving of US$ 1.5 million in materials and around US$ 7.0 million in interconnection services, when compared to the cost of approximately 7 days of RSV operation using the system and method of the present invention, which would result in a cost of US$ 0.4 million in services. Thus, the use of the present invention has a potential overall gain of approximately US$ 182 million per operation in the current scenario.

[095] Furthermore, the safety gain provided by the present invention is also noticeable, since the use of the system and method of the invention reduces the exposure of the workforce to accident risks, since the entire repair operation is carried out remotely by the ROV, which eliminates the exposure of people to operations considered to be of greater risk, such as moving loads or positioning close to pressurized systems.

[096] Furthermore, the present invention allows for the rapid and safe execution of repairs to subsea hydraulic control systems. The solution obtained enables a reduction in mean time to repair (MTTR), an important factor for the operational efficiency of subsea systems. With the high productivity typical of offshore wells, the impact of increased efficiency represents a significant economic gain. By using the system and method of the present invention, repair time is significantly reduced because, when a critical control function fails, it is not necessary to wait for long periods to acquire a new hydraulic pipe or umbilical, or even to mobilize flexible line laying vessels (PLSV) to carry out the repair, competing with the interconnection of new wells, typically more productive (in their early life), in which losses related to the prioritization of activities are frequently observed.

[097] Those versed in the art will appreciate the knowledge presented here and will be able to reproduce the invention in the following ways. Petition 870250013949, dated 20 / 02 / 2025, pp. 63 / 84 26 / 26 presented and in other variants, covered within the scope of the attached claims. Petition 870250013949, dated 20 / 02 / 2025, pp. 64 / 84

Claims

1 / 4 CLAIMS 1. System for trepanning submarine hydraulic pipes, characterized in that it comprises: a first pipe (1) having a first clamp (20) that encases a portion of the first pipe (1); a second pipe (2) having a second clamp (20) that encases a portion of the second pipe (2); each of the first clamp (20) and the second clamp (20) having a corresponding branch (21), the branch (21) of the first clamp (20) being aligned with an orifice (22) of the first pipe (1); wherein a knife (4, 5) having a curved lower portion (40) and a cutting edge (41) is connected to a hydraulic cylinder (70); wherein the hydraulic device (70) is equipped with a directional valve (57) and actuatable by a remotely operated vehicle (ROV), the hydraulic device (70) acting on a piston, compressing the knife (4,5) on the wall of the corresponding tubes (1, 2), so as to form an orifice (22) and a bend (23, 24);wherein a branch tube (3) is connected between the branches (21) of the pair of clamps (20) to form a fluid communication between the first tube (1) and the second tube (2).; 2. System, according to claim 1, characterized in that each of the clamps (20) is split in two and positioned over the tubes (1, 2) to be interconnected, closed and locked using a nut (29a) with tapered thread (29).

3. System according to claim 1 or 2, characterized in that each of the branches (21) of the clamps (20) is connected to a ball valve (50) for isolating the system. Petition 870250013949, dated 20 / 02 / 2025, page 65 / 84 2 / 4 4. System according to claim 3, characterized in that at least one of the ball valves (50) can be connected to the hydraulic device (70).

5. System, according to any of the preceding claims, characterized in that the knives (4, 5) have a circular cross-section.

6. System, according to any of the preceding claims, characterized in that, as the edge (41) of the knives (4, 5) advances together with the curved lower portion (40) transversely into the interior of the tubes to be trepanned (1, 2), a part of the wall of the respective tube is opened and bent to form a hole (22) and the bend (23, 24).

7. System, according to any of the preceding claims, characterized in that the bend (23) is configured to redirect the hydraulic fluid coming from the bypass tube (3) to an intact section of the second tube circuit (2) and to prevent the hydraulic fluid from going to a damaged section of the second tube circuit (2).

8. System, according to any of the preceding claims, characterized in that the tubes (1, 2, 3) have diameters ranging from 0.0127 mm (1 / 2 inch) to 0.01905 mm (3 / 4 inch).

9. System, according to any of the preceding claims, characterized by the fact that it allows the arrangement of the bypass tube (3) in a damaged section of the tube (2) itself that is undergoing intervention.

10. System, according to any of the preceding claims, characterized in that the split clamps (20) have a sealing layer (26) and cavities (27a, 28a) with seals (27, 28) to allow the repaired system to operate at high pressures without leakage. Petition 870250013949, dated 20 / 02 / 2025, page 66 / 84 3 / 4 11. System, according to any of the preceding claims, characterized in that the branch (21) of each of the clamps (20) can be joined by a set of nuts (29a, 30a) in tapered threads (29, 30) with different gauges, providing sealing between clamp (20) and tube (1, 2), between clamp (20) and ball valve (50), between the ball valve (50) and the hydraulic cylinder (70) and between the ball valve (50) and the branch tube (3).

12. System, according to any of the preceding claims, characterized by using quick connection (52) instead of threaded connection (30).

13. System, according to any of the preceding claims, characterized in that the branch tube (3) is rigid (3a) or flexible (3b).

14. System, according to any of the preceding claims, characterized by having a set of keyways (42, 53) so as to allow the relative positioning of the knives (4, 5) to be suitable for carrying out the work.

15. System, according to any of the preceding claims, characterized in that it is operable by ROV.

16. System, according to any of the preceding claims, characterized in that it has access for pressure testing after installation.

17. System, according to any of the preceding claims, characterized in that it has a float (71) to facilitate handling by ROV.

18. System, according to any of the preceding claims, characterized in that it has a handle (72) that allows for easy, gravity-fed ROV connection.

19. Method for trepanning submarine hydraulic pipes, using the system as defined in any of the previous claims, the method being characterized in that it comprises: installing a first clamp (20) on a portion of a first pipe (1); installing a second clamp (20) on a portion of a second pipe (2), with the second clamp (20) encasing the portion of the second pipe (2); using a ball valve (50) to prevent the entry or exit of fluids in the system undergoing intervention; using a hydraulic system composed of a hydraulic cylinder (70) and a directional valve (57), to generate the displacement of the knives (4, 5) to perform the cutting and crushing; connecting a knife (4, 5) in position for performing the respective cutting and crushing;introduce a knife (4) or (5) having a curved lower portion (40) and a cutting edge (41), through the ball valve (50) and a branch (21) of each of the clamps (20) to cut and bend each of the tubes (1, 2) thus forming a hole (22) and a bend (23, 24); and connect a branch tube (3) between the branches (21) of each of the clamps (20) or between the isolating ball valves (50), allowing pressurization of the damaged branch. Petition 870250013949, dated 20 / 02 / 2025, page 68 / 84;

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