Case Study: DeepFlex achieves optimized all-composite deepwater pipeline design and validation with Dassault Systemes (Abaqus FEA)

Abaqus Finite Element Analysis helps DeepFlex customize pipeline for offshore applications

DeepFlex, a Houston-based developer of patented all-composite flexible fiber-reinforced pipe (FFRP), faced the challenge of designing lightweight, nonmetallic subsea pipe that could survive extreme deepwater conditions—very high external hydrostatic pressures, internal wellhead pressures and temperature swings—without metallic reinforcement. To gain detailed insight into layer-by-layer behavior and optimize cross‑section layouts, DeepFlex worked with MMI Engineering using Abaqus FEA software from Dassault Systemes to model the complex composite interactions and loading scenarios.

Using Dassault Systemes’ Abaqus/CAE with Abaqus/Explicit and Abaqus/Standard, MMI built 3D contact models (nearly one million degrees of freedom) and ran overnight analyses to simulate burst, collapse, bending, torsion and axial loads, validating results against prototype tests. The Abaqus-driven simulations clarified failure mechanisms and load redistribution, enabling DeepFlex to tailor layer designs, support product ratings up to 10,000 psi working/collapse test performance (4‑inch tested to 10,000 psi collapse; 2‑inch survived Marianas Trench pressures), and integrate FEA into its ongoing design process.

DeepFlex

Mike Bryant

Chief Technical Officer