Design and Analysis of Composite Overwrapped Pressure Vessels Course

Composite Overwrapped Pressure Vessels (COPVs) are a type of pressure vessel that are commonly used in aerospace and other high-performance applications.  They are made by wrapping a thin liner of aluminum, plastic, or other materials with high-strength carbon fibers. This combination of materials allows COPVs to be lightweight while still being able to withstand high pressures. COPVs are often used to store and transport compressed gases, such as oxygen or nitrogen, and are also used in rocket propulsion systems.

If a COPV fails, it can result in the release of hazardous fluids and the loss of the contained fluid that is no longer available for its intended purpose. This can pose safety risks and potential disruptions to systems or processes that rely on the stored fluid. It is crucial to address COPV failures promptly to mitigate any potential consequences and ensure the safety of the surrounding environment and equipment.

To produce safe and secure COPV, it is essential to undergo a detailed design and analysis stage.

In the design stage, various aspects need to be considered. This includes selecting high-quality composite materials, determining the geometry and thickness of the overwrap layer, designing the vessel’s end closures, and integrating fittings and connections to minimize potential weak points. Additionally, it is crucial to account for expected operating conditions such as pressure, temperature, and load to ensure the COPV is designed to safely withstand these environments.

During the analysis phase, detailed simulations should be conducted to evaluate the structural performance of the COPV under different loading conditions. This may involve finite element analysis to assess the vessel’s strength, stiffness, and fatigue resistance. Furthermore, safety analyses should be performed to identify potential failure points and ensure that the COPV meets safety standards and applicable regulations.

By incorporating a robust design process and detailed analysis in the production of COPVs, it is possible to ensure that these vessels are safe, reliable, and capable of effectively withstanding the required operational conditions.

Modeling the performance of Composite Overwrapped Pressure Vessels (COPVs) through finite element analysis presents a difficulty due to the complex material structures and the elaborate setup demands for modeling, making it a challenging task.

This course is structured with lectures, demonstrations, and workshops. The workshops are crucial for the training as they aim to solidify the ideas covered in the lectures and demonstrations. Their purpose is to give participants hands-on experience in conducting and troubleshooting real FEA analyses.

What you’ll learn

In this course, you will learn about the design and analysis of composite overwrapped pressure vessels using Abaqus and ASME BPVC Section X.

Upon successfully finishing this course, every participant will have the ability to:

• Safety factors to prevent stress rupture failure modes of the COPV, as well as assessments like Leak-Before-Burst and Damage Tolerance Life for the liner.
• Utilization of computational design tools, specifically the Abaqus FEA product suite and associated Wound Composite Modeler plugin from Dassault Systems, for analyzing COPVs. It will delve into computational results obtained with this tool to emphasize the significance of correct design, manufacturing, and operational practices in averting different failure modes.

As part of the course, The downloadable version of ASME BPVC Section X standard will be available, at no cost.

Overview of the course

Lecture 1 Overview of Standards

• ASME BPVC Section X Standard Overview

Lecture 2  Determining Operational Envelope
Lecture 3  Modeling of Pressure Vessels with Abaqus FEA and WCM Plugin

• Workshop 1: Generating Axisymmetric COPV Models
• Workshop 2: Generating 3D COPV Models
• Workshop 3: Autofrettage Analysis
• Workshop 4: Design Factors (Including wind angle and stack sequence)
• Workshop 5: Buckling and Debonding

Knowledge Prerequisites

None

Who Should Attend

This course targets engineers and engineering managers involved in designing, analyzing, and developing of COPV vessels. Participants should possess a Bachelor of Science degree or equivalent engineering experience. A basic understanding of stress analysis, materials behavior, and fracture mechanics is advantageous.

This course is available offline with 24/7 online support.

A certificate of completion will be provided to participants who successfully attend and finish the course.

Targeted Audience

• Integrity Assessment Engineers
• Maintenance Engineers
• Safety, Reliability, and Quality Engineers
• Piping Engineers
• Mechanical Engineers
• Simulation Analysts
• Process Engineers
• Project Managers
• HSEQ Personnel

Available Releases

2024

Duration

8 hours

Discipline

Design and Analysis of Composite Overwrapped Pressure Vessels (COPV) Course is designed to cover the utilization of ASME BPVC Section X Standard. It is aimed at engineers involved in FEA simulation who wish to enhance their comprehension of the intricate mechanical and failure behavior associated with composite pressure vessels.