Date: 25th to 29th May 2015
Location: Midlands Innovation & Research Centre, Athlone, Ireland
Background to the Course
High performance Composite Overwrapped Pressure Vessels (COPVs) have been utilized in the aerospace and automotive industries for many years, providing an inherently safe, lightweight and cost effective storage source for pressurized fluids. COPVs are commonly used for gas and propellant storage in spacecraft and launch vehicles. The consequence of a COPV rupture can include the release of caustic fluids, loss of necessary fluids and the release of stored energy equivalent to several pounds of trinitrotoluene (TNT) depending on the quantity, pressure and fluid contained in the COPV.
In the aerospace sector, the development of a commercial space industry has reinforced the need for light and low cost yet safe and reliable pressure vessels. In the automotive sector, new demands for alternative fuel vehicles driven by changes in the energy sector have given rise to opportunities for durable and low cost, and also safe and reliable pressure vessels, particularly for hydrogen and compressed natural gas. Safety and high reliability are achieved by adhering to rigorous processes throughout the life cycle of a pressure vessel, including the design, manufacture, testing, handling, and operation phases.
Scope of the course
This course will provide an introduction to the basic principles governing the design and operation of Composite Overwrapped Pressure Vessels (COPV). The comprehensive overview of current technological understanding will provide both engineering mechanics fundamentals and practical applications drawn from experience to educate program managers, design engineers, ground and flight operators, safety analysts, quality engineers and users/customers.
Fundamental to the use of COPVs in space applications is the relevant failure modes and the design techniques introduced to ensure safe operation. Flight safety can only be properly understood through appropriate engineering design and quality throughout the vessel lifecycle from design, qualification, manufacturing, acceptance testing, handling and finally operational use. Each step of the product lifecycle has relevant safety considerations, which will ultimately affect the likelihood for catastrophic failure resulting in loss of life during operations… < Read More >
Course Length and Duration
32 hrs in 5 days
Who Should Attend?
- Engineers and Managers who are interested in the latest techniques for COPV design, development manufacturing and testing
- Quality and Safety Assurance practitioners with no previous COPV experience
- Ground operators and those who write design requirements for COPV safe handling.
What You Will Learn?
- Failure modes in COPVs and requirements for safe operation in space environments
- Designing for Maximum Operational Pressure and Relevant Factors of Safety
- Approaches to Liner Fatigue Modeling under Pressure Cycling
- Liner Buckling: Models, Trigger and Methods of Prevention
- Composite Stress-Rupture Phenomenon and Reliability Modeling
- Nondestructive Evaluation (NDE
- Considerations for Ground Operations and Damage Control Mitigation Techniques.
How You Will Learn It ?
- Interactive Verbal instruction using Power Point
- Videos and Photographs.
- Case studies
- Interactive experience with Finite Element Analysis simulation with the Abaqus FEA program.
What You Will Take With You?
- The course book with all presentations and documents
- Student version of Abaqus FEA (of Dassault Systèmes)
- Certificate of Course Completion
The course instructors are internationally recognized experts in the field of COPV Design and Operations:
Leigh Phoenix (PhD Cornell) is professor of Mechanical and Aerospace Engineering at Cornell University (USA), where he has been on the faculty since 1974, and teaches courses in composite materials, solid mechanics and applied mathematics. Much of his research involves micromechanically– based statistical modeling and experiments on long-term reliability of fibrous composites (e.g., aramids, carbon, S-glass, PBO) under high stress in difficult environments. Examples include composite-overwrapped pressure vessels, pressurized hydraulic lines and wind turbine blades. He also models ballistic impact into fibrous materials in support of developing improved materials and architectures for soft body armor, flexible composite panels and military and police helmets. In 1983 Phoenix received the Fiber Society Award for Distinguished Achievement in Basic or Applied Fiber Science, and in 1992 he won the ASTM Harold DeWitt Smith Award in fiber mechanics. In 2005 he was awarded the NASA-NESC Engineering Excellence Award for his pressure vessel work in support of the Shuttle’s Return to Flight.
Michael T. Kezirian (PhD MIT) is an Associate Technical Fellow with the Boeing Company. He has brought extensive experience in composite materials, propulsion systems and system safety to address safety concerns for the Space Shuttle and Space Station Programs. Currently, he is supporting the Boeing Commercial Crew Development (CCDEV) Program on the design of the CST-100. As an Adjunct Associate Professor of Astronautical Engineering at the University of Southern California, he teaches a graduate elective, Safety of Space Systems and Space Missions. Previously, he taught undergraduate and graduate classes in Polymer Science and Spacecraft Dynamics. Dr. Kezirian is Associate Fellow of the AIAA and Fellow Member of the IAASS. In 2009 he was awarded the NASA Astronaut Personal Achievement Award (Silver Snoopy). Dr. Kezirian is the editor-in-chief of the newly introduced, Journal of Space Safety Engineering, published by the IAASS.
Course Syllabus Day 1 – Afternoon
- General introduction to geometry and structure of high-pressure COPV
- COPV safety considerations
- Failure modes
- Certification standards
Day 2 Morning COPV Safety test and analyses Day 2 Afternoon
- Damage Control Plans
- Ground Safety Considerations
- Design Considerations
Day 3 Morning
- Winding pattern design
- Autofrettage, purpose and risks in implementation
Day 3 Afternoon Approaches to liner fatigue modeling under pressure cycling
Day 4 Morning
- Liner buckling
- Overwrap stress-rupture phenomena and reliability modelling
Day 4 Afternoon
- Nondestructive evaluation (NDE) of liner, and crack and flaw detection techniques
- Overwrap NDE to detect broken tows, wraps and delamination
Day 5 Morning
- Special Considerations: Operating COPVs in the Space Environment:
- Special Topic: USC Rocket Propulsion Laboratory
- New concepts in pressure vessel standards
- Standards for the Automotive Industry
Computational Workshop: Students will be provided the student version of Abaqus FEA (Dassault Systèmes (3DS) ) and workbooks on the Wound Composite Modeler (WCM). Results of Abaqus simulations are used throughout the course.
Computational Workbook A In this workshop, the user step through the process of generating an axisymmetric model of a COPV and post processing the results using the Wound Composite Modeler (WCM). The model will consist of both helical and hoop layers.
Computational Workbook B In this workshop, the user steps through the process of generating a three-dimensional model of a COPV and post processing the results using the WCM.
Computational Workbook C The focus of this workshop is the use of the WCM as a COPV design tool. The WCM will be used to gauge the effect of parameters such as wind angle, number of layers, and liner materials on the stresses during operations (changes in COPV pressure).
Computational Workbook D This workshop explores the concept of autofrettage. An autofrettage analysis will be performed to demonstrate how tensile stresses in the liner may be reduced in order to extend the fatigue life of a COPV.
Course Fee – Design and Operations of Composite Overwrapped Pressure Vessels
The fees for the 5 day Design and Operations of Composite Overwrapped Pressure Vessels training course are;
IAASS Member = €1550 per Participant
IAASS Non-Member = €1650 per Participant
Space Industry Skillnet Member: POA
Note: A discount is available to organisations who send more than 2 participants, where each additional participants will be charged at the rate of an IAASS Member. This fee includes all course materiial and lunches and course banquet on Wednesday evening.
Eligibility for Job Seekers Job-seekers can participate in Skillnets training programmes subject to the eligibility criteria listed at the following link; http://www.skillnets.ie/job-seekers/eligibility-criteria
Registration Please register for attendance at the course by sending a completed Design & Operations of COPV 2015 – Booking Form to the Network Manager, Catherine Lenehan by e-mail: email@example.com
Contact & Directions Participants requiring assistance with directions to the Space Industry Skillnets training venue in the Midlands Innovation & Research Centre, Athlone Institute of Technology, Athlone, Co. Westmeath, Ireland, should contact the Network Manager, Catherine Lenehan at firstname.lastname@example.org
Accommodation There is a wide variety of accomodation in Athlone to suit all levels of taste & expense. Please see http://www.athlone.ie for a range of options in the region.
Who are the IAASS?
The International Association for the Advancement of Space Safety, is a non-profit organisation dedicated to furthering international cooperation and scientific advancement in the field of space systems safety. In October 2004 IAASS became member of the International Astronautical Federation (IAF). For more information please visit http://www.iaass.org. The philosophy of the IAASS is best summed up in the following: “Over the long run the safety of all human beings in the global commons of space is a responsibility that must be shared by all space-faring powers” (G. Rodney, NASA Associated Administrator S&MA 40th IAF Congress, October 1989, Beijing – China)