A comprehensive non-linear finite element model is developed for predicting the behavior of composite hydrogen storage cylinders subjected to high pressure and localized flame impingements. The model is formulated in an axi-symmetric coordinate system and incorporates with various sub-models to describe the behavior of the composite cylinder under extreme thermo-mechanical loadings. A heat transfer sub-model is employed to predict the temperature evolution of the composite cylinder wall and accounts for heat transport due to decomposition and mass loss. A composite decomposition sub-model described by Arrhenius's law is implemented to predict the residual resin content of thermal damaged area. A sub-model for material degradation is implemented to account for the loss of mechanical properties. A progressive failure model is adopted to detect various types of mechanical failure. These sub-models are implemented in ABAQUS commercial finite element code using user subroutines. Numerical results are presented for thermal damage, residual properties and profile of resin content in the cylinder. The developed model provides a useful tool for safe design and structural assessment of high pressure composite hydrogen storage cylinders. (c) 2008 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.