Tim Marker FAA Technical Center Discussion of Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials

Tim Marker

FAA Technical Center

Discussion of Test Method to Determine the BurnthroughResistance of Thermal/Acoustic Insulation Materials

INTERNATIONAL AIRCRAFT MATERIALS FIRE TEST WORKING GROUP MEETING

Held at Airbus Industries, Hamburg, Germany

June 23-24, 2003

TUESDAY, JUNE 24, 2003

Task Group Meetings

Burnthrough – Noel Spurlock (Boeing) presented Boeing’s Thermal Acoustic Insulation Material Burnthrough Test Procedure. This will be sent to Tim Marker for review/comments, etc., and then sent out to the labs to set their test equipment up. Once labs are set up to these specs, a Round Robin will be conducted on two materials, and then Tim or someone from the FAA Technical Center will visit each lab to ensure all labs have their test apparatus set up the same.

Jim Davis and Noel Spurlock will jointly research the creation of a “new” airflow meter (?) and send their findings to FAATC for review and prepare a presentation for the fall 2003 Materials Meeting.

Advisory Material: Randy Smith will put together a list of odd areas in the airplane and Boeing’s proposed methods for complying with the proposed Rule and send it to Tim Marker to review and to possibly be added to the advisory material as soon as possible. Randy will talk to Peter Busch of Airbus to try to collaborate this project with Airbus.


Held at Airbus Industries, Hamburg, Germany

June 23-24, 2003

TUESDAY, JUNE 24, 2003

Task Group Summaries

Burnthrough Task Group (Dick Hill): Boeing presented its Thermal Acoustic Insulation test procedure. Tim Marker will review this information. If he agrees with it, this information will be sent to each participating lab and a Round Robin will be conducted on a couple of materials with a representative from the FAA Technical Center present during each set of tests to ensure every lab sets up and conducts the tests in the same manner.

Burnthrough Task Group Report – R. Hill A number of topics were addressed. The definition of ‘halfway’ as written in the rule was discussed. A presentation was given on alternate definitions that were thought to be similar to the one in the rule. The FAATC will discuss these other interpretations of the rule with the FAA regulatory side. The FAATC will try to address some of the issues brought up during this Task Group meeting under “Burnthrough” on its website as updates, etc., once these issues are discussed with the regulatory side.


November 19-20, 2003

Hosted by Boeing Commercial Airplane Group, Seattle, Washington, USA

Task Group Reports

THURSDAY, NOVEMBER 20, 2003

FAATC Review of

Thermal Acoustic Insulation MaterialBurnthrough Test Procedure

THERMAL ACOUSTICINSULATION MATERIAL

BURNTHROUGHTEST PROCEDURE

NOEL L SPURLOCK

BOEING COMMERCIAL AIRPLANESAERO / NOISE / PROPULSION LABORATORY

SEATTLE, WASHINGTON

1 Verify burner assembly – Park Model DPL

1.1 Components

1.1.1 Blower – 5.25” diameter X 3.50” deep 1

1.1.2 Fuel nozzle – Monarch, 6.0 GPM, 80o, PL 1

( PL - hollow cone or PLP - semi-hollow NO! )

1.1.3 Stator – Monarch H215, CCW, 4” diameter 1

1.1.4 Turbulator – Monarch F124, CCW, 4 X 23/4

1( 4.00” diameter 3/4OD X 2.75” diameter ID )

1.1.5 Burner cone – 6” H X 11” W ( R3.0 ) X 12” L ( All dimensions ± .125” 2 )

THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH TEST PROCEDURE

X

(1) Test Burner. The arrangement of the test apparatus is shown in figures 1 and 2and must include the capability of swinging the burner away from the test specimenduring warm-up.

(i) Nozzle. A nozzle must maintain the fuel pressure to yield a nominal 6.0gal/hr (0.378 L/min) fuel flow. A Monarch-manufactured 80o PL (hollow cone)nozzle nominally rated at 6.0 gal/hr at 100 lb/in2 (0.71 MPa) delivers a properspray pattern.

(ii) Fuel Rail. The fuel rail must be adjusted to position the fuel nozzle at adepth of 0.3125 inch (8 mm) from the end plane of the exit stator, whichmust be mounted in the end of the draft tube.

Part VII – Test Method to Determine the Burnthrough Resistance ofThermal/Acoustic Insulation Materials

(2) Test Burner. Must be a modified gun-type such as the Park Model DPL 3400.flame characteristics are highly dependent on actual burner set-up. Parameterssuch as fuel pressure, nozzle depth, stator position, and intake airflow must beproperly adjusted to achieve the correct flame output.

b. Apparatus

Calibration Temperature ComparisonSemi Solid vs Hollow Cone Nozzle @ FAATC

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

Tem

pe

ratu

re (

oF

)

Semi Solid (PLP or SS) Hollow Cone (PL)

July 2001

Calibration Heat Flux ComparisonSemi Solid vs Hollow Cone Nozzle @ FAATC

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

He

at

Flu

x (

Btu

/ft2 s

ec

)

Semi Solid (PLP or SS) Hollow Cone (PL)

July 2001

1 Verify burner assembly – Park Model DPL

1.2 Configuration

1.2.5 Draft tube to cone exit plane – 12.0” 2

1.2.6 Draft tube angle – 30o 3 ( from horizontal )

1.3 Operation

1.3.1 Fuel flow = 6 ± 0.2 GPM 1

1.3.2 Fuel pressure = 100 psig

1.3.3 Air flow = 2150 ± 50 ft/min 1 (adjust with blower and hose-end dampers NO!- see 2.4 )


(3) Calibration Rig and Equipment (con’t)

(v) Air Velocity Meter. Use a vane-type air velocity meter to calibrate thevelocity of air entering the burner. An Omega Engineering Model HH30Ais satisfactory. Use a suitable adapter to attach the measuring device to theinlet side of the burner to prevent air from entering the burner other thanthrough the measuring device, which would produce erroneously low readings.Use a flexible duct, measuring 4 inches wide (102 mm) by 20 feet (6.1 meters)long, to supply fresh air to the burner intake, to prevent damage to the airvelocity meter from ingested soot. An optional airbox permanently mountedto the burner intake area can effectively house the air velocity meter andprovide a mounting port for the flexible intake duct.


b. Apparatus

June 2001

2 Adjust test Apparatus

2.1 Thermocouple rake

2.1.1 Thermocouples – seven 1/8”, grounded,type K, metal sheathed 3 24 AWG, Ceramic Packed

2.1.2 Rake configuration● 30o from vertical● 1” between T/C w/ 3” exposure to flame 3

2.1.3 Rake position● T/C tips 1” above cone horizontal CL● Middle T/C on cone vertical center line● T/C plane 4” from cone exit plane 3


(3) Calibration Rig and Equipment (con’t)

(iii) Calorimeter Mounting. Mount the calorimeter in a 6- by 12- +0.125inch (152- by 305- +3 mm) by 0.75 +0.125 inch (19 mm +3 mm) thickinsulating block which is attached to the heat flux calibration rig duringcalibration (figure 4). Monitor the insulating block for deterioration andreplace it when necessary. Adjust the mounting as necessary to ensure thatthe calorimeter face is parallel to the exit plane of the test burner cone.

(iv) Thermocouples. Provide seven 1/8-inch (3.2 mm) ceramic packed,metal sheathed, type K (Chromel-Alumel), grounded junction thermocoupleswith a nominal 24 American Wire Gauge (AWG) size conductor forcalibration. Attach the thermocouples to a steel angle bracket to form athermocouple rake for placement in the calibration rig during burnercalibration (figure 5).


b. Apparatus

2 Adjust test Apparatus

2.4 Burner air flow● Hose-end damper set to 50% NO!

● Blower damper set to 2150 ± 50 ft/min 1

2.5 Vent Hood

2.5.1 Vertical air flow = 100 ± 50 ft/min 5

2.5.2 Horizontal air flow < 50 ft/min 5

2.6 Calorimeter cooling water

2.6.1 Water temperature = 120o F ( 48.8o C )

2.6.2 Water flow rate > 1 GPM


4 Calibrate Burner

4.1 Two minute warm-up

4.2 Thermocouple rake

3.2.1 Thirty seconds to stabilize NO!

3.2.2 Record data for thirty seconds

4.3 Calorimeter

3.3.1 Thirty seconds to stabilize NO!

3.3.2 Record data for thirty seconds

4.4 Examine data – burner adjustments if required


(5) Warm-up and Temperature Check

Position the burner in front of the thermocouple rake. After checking for properalignment, rotate the burner to the warm-up position, turn on the blower/motor,igniters and fuel flow, and light the burner. Allow it to warm up for a period of2 minutes. Move the burner into the calibration position and allow 1 minute forthermocouple stabilization, then record the temperature of each of the 7 thermo-couples once every second for a period of 30 seconds. Turn off burner, rotateout of position, and allow to cool. Calculate the average temperature of eachthermocouple over this 30- second period and record. The average temperatureof each of the 7 thermocouples should be 1900oF + 100oF (1038 + 56oC).


e. Calibration

(4) Warm-up and Heat Flux Check

While the burner is still rotated to the warm-up position, turn on theblower/motor, igniters and fuel flow, and light the burner. Allow it to warmup for a period of 2 minutes. Move the burner into the calibration positionand allow 1 minute for calorimeter stabilization, then record the heat fluxonce every second for a period of 30 seconds. Turn off burner, rotate outof position, and allow to cool. Calculate the average heat flux over this30-second duration. The average heat flux should be 16.0 +0.8 Btu/ft2 sec(18.2 +0.9 W/cm2).


e. Calibration

Average Rake Temperature Vs. TimeAt Various Air Velocity Settings

1600

1700

1800

1900

2000

0 2 4 6 8 10

Time (minutes)

Te

mp

era

ture

(oF

)

1900 ft/min

2000 ft/min2100 ft/min

2200 ft/min2400 ft/min

Nov 1999

Effect of Soot Buildup on Calorimeter Performance(2 minute warm-up away from calorimeter surface)

10

11

12

13

14

15

16

17

0 2 4 6 8 10 12

Time (minutes)

He

at

Flu

x (

Btu

/ft2 s

ec

)

1900 ft/min

2000 ft/min

2100 ft/min

2200 ft/min

2400 ft/min

2600 ft/min

Date: 11/24/99

Nov 1999

2 ADJUST TEST APPARATUS2.4 Burner Air Flow Adjustment and Verification

Set hose-end damper to 50% NO! Set burner damper

to 2150 ft/min

Monitor air flow with an Omega HH-30 air velocity meter

4 CALIBRATE BURNER4.1 Two Minute Warm-up (position 1):

Allow burner to stabilize – check air flow 4.2 Move burner to T/C rake (position 2):

Stabilize 30 seconds – record data 30 seconds 4.3 Move burner to calorimeter (position 3): NO! COOL

Stabilize 30 seconds – record data 30 seconds

Burner Position 3Burner Position 2Burner Position 1

(4) Warm-up and Heat Flux Check

While the burner is still rotated to the warm-up position, turn on theblower/motor, igniters and fuel flow, and light the burner. Allow it to warmup for a period of 2 minutes. Move the burner into the calibration positionand allow 1 minute for calorimeter stabilization, then record the heat fluxonce every second for a period of 30 seconds. Turn off burner, rotate outof position, and allow to cool. Calculate the average heat flux over this30-second duration. The average heat flux should be 16.0 +0.8 Btu/ft2 sec(18.2 +0.9 W/cm2).


e. Calibration

(5) Warm-up and temperature Check

Position the burner in front of the thermocouple rake. After checking for properalignment, rotate the burner to the warm-up position, turn on the blower/motor,igniters and fuel flow, and light the burner. Allow it to warm up for a period of2 minutes. Move the burner into the calibration position and allow 1 minute forthermocouple stabilization, then record the temperature of each of the 7 thermo-couples once every second for a period of 30 seconds. Turn off burner, rotateout of position, and allow to cool. Calculate the average temperature of eachthermocouple over this 30- second period and record. The average temperatureof each of the 7 thermocouples should be 1900oF + 100oF (1038 + 56oC).


e. Calibration

5 PREPARE TEST SPECIMEN5.2 Mount Test Specimen in Holder

• Flat against stringers• Tuck into frame/stringer corner• Clip to frame picture shows OEM clips, not 1” by 2” clips

(3) Construction (con’t)

(iv) Installation on Test Frame. Attach the blanket test specimens to the testframe using 12 steel spring-type clamps as shown in figure 7. Use the clampsto hold the blankets in place in both of the outer vertical formers, as well asthe center vertical former (4 clamps per former). The clamp surfaces shouldmeasure 1 inch by 2 inches (25 by 51 mm). Place the top and bottom clamps6 inches (15.2 cm) from the top and bottom of the test frame, respectively.Place the middle clamps 8 inches (20.3 cm) from the top and bottom clamps.

(Note: For blanket materials that cannot be installed in accordance withfigure 7, the blankets must be installed in a manner approved by the FAA.)


c. Test Specimens

Installation of Test Samples on Test Frame

Discussion of Test Method to Determine the BurnthroughResistance of Thermal/Acoustic Insulation Materials

Step 1: Install Left Blanket, Squeeze Onto Former

Step 2: Install Right Blanket, Clip To Frame

Step 3: Tuck Blanket Into Corners @ Center

Tuck Tuck

Step 4: Tuck Blanket Into Corners @ Sides, Clip

Tuck Tuck

Desired Blanket Installation on Test Frame

Desired Blanket Installation on Test Frame

Round Robin VI

Blanket I.D.

Blanket Construction* Supplier

Thickness per Layer

(inch)

Blanket Density

(lb/ft3)

Barrier Material

**

A

2 Layer Fiberglass/ TexTech

Aramid Felt JM/TexTech 1.0 0.42

Aramid Felt

7641R

B

2 Layer Fiberglass/

Dupont Nomex Paper JM/Dupont 1.0 0.42

4 mil Nomex Paper

C 1 Layer OPF Osaka Gas 1.0 0.47 N/A

Round Robin VI Materials

Round Robin VI Testing Sequence

A1, B1, C1, B2, C2, A2, C3, A3

Initial Calibration

Second Calibration

B3, A4, B4, C4, B5, C5, A5, C6

Third Calibration

A6, B6, A7, B7, C7, B8, C8, A8

Round Robin VI Tasks

FAATC witnessing of burnthrough testing using RRVI samples

Completion of all test samples needed

Refine test spreadsheet

Update Calibration Guidelines document

Use Boeing-manufactured calibration tools to check labs

Documents

Tim Marker FAA Technical Center Discussion of Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials