Tim Marker

1
Discussion of Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
Tim Marker
FAA Technical Center
2
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
Boeings 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 Boeings
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.
3
INTERNATIONAL AIRCRAFT MATERIALS FIRE TEST
WORKING GROUP MEETING   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.
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INTERNATIONAL AIRCRAFT MATERIALS FIRE TEST
WORKING GROUP MEETING   November 19-20,
2003   Hosted by Boeing Commercial Airplane
Group, Seattle, Washington, USA
THURSDAY, NOVEMBER 20, 2003
Task Group Reports
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.
5
FAATC Review of
Thermal Acoustic Insulation Material Burnthrough
Test Procedure
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THERMAL ACOUSTICINSULATION MATERIALBURNTHROUGHT
EST PROCEDURE

• NOEL L SPURLOCK
• BOEING COMMERCIAL AIRPLANES
• AERO / NOISE / PROPULSION LABORATORY
• SEATTLE, WASHINGTON

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THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
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 Turbulato
r 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 )
X
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Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
b. Apparatus
(1) Test Burner. The arrangement of the test
apparatus is shown in figures 1 and 2 and must
include the capability of swinging the burner
away from the test specimen during warm-up.
(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. Parameters such as fuel pressure,
nozzle depth, stator position, and intake airflow
must be properly adjusted to achieve the correct
flame output.
(i) Nozzle. A nozzle must maintain the fuel
pressure to yield a nominal 6.0 gal/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
proper spray pattern.
(ii) Fuel Rail. The fuel rail must be adjusted to
position the fuel nozzle at a depth of 0.3125
inch (8 mm) from the end plane of the exit
stator, which must be mounted in the end of the
draft tube.
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July 2001
10
July 2001
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THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
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 F
uel 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 )
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Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
b. Apparatus
(3) Calibration Rig and Equipment (cont)
(v) Air Velocity Meter. Use a vane-type air
velocity meter to calibrate the velocity of air
entering the burner. An Omega Engineering Model
HH30A is satisfactory. Use a suitable adapter to
attach the measuring device to the inlet side of
the burner to prevent air from entering the
burner other than through 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
air velocity meter from ingested soot. An
optional airbox permanently mounted to the burner
intake area can effectively house the air
velocity meter and provide a mounting port for
the flexible intake duct.
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June 2001
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THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
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
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Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
b. Apparatus
(3) Calibration Rig and Equipment (cont)
(iii) Calorimeter Mounting. Mount the
calorimeter in a 6- by 12- 0.125 inch (152- by
305- 3 mm) by 0.75 0.125 inch (19 mm 3 mm)
thick insulating block which is attached to the
heat flux calibration rig during calibration
(figure 4). Monitor the insulating block for
deterioration and replace it when necessary.
Adjust the mounting as necessary to ensure
that the 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
thermocouples with a nominal 24 American Wire
Gauge (AWG) size conductor for calibration.
Attach the thermocouples to a steel angle bracket
to form a thermocouple rake for placement in the
calibration rig during burner calibration (figure
5).
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THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
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 lt 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 gt 1 GPM
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THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
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
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Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
e. Calibration
(5) Warm-up and Temperature Check
Position the burner in front of the thermocouple
rake. After checking for proper alignment,
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 of 2 minutes. Move the burner into the
calibration position and allow 1 minute
for thermocouple stabilization, then record the
temperature of each of the 7 thermo- couples once
every second for a period of 30 seconds. Turn
off burner, rotate out of position, and allow to
cool. Calculate the average temperature of
each thermocouple over this 30- second period and
record. The average temperature of each of the 7
thermocouples should be 1900oF 100oF (1038
56oC).
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Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
e. Calibration
(4) Warm-up and Heat Flux Check
While the burner is still rotated 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 of 2 minutes. Move the
burner into the calibration position and allow 1
minute for calorimeter stabilization, then record
the heat flux once every second for a period of
30 seconds. Turn off burner, rotate out of
position, and allow to cool. Calculate the
average heat flux over this 30-second duration.
The average heat flux should be 16.0 0.8 Btu/ft2
sec (18.2 0.9 W/cm2).
20
Nov 1999
21
Nov 1999
Date 11/24/99
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2 ADJUST TEST APPARATUS
2.4 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
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4 CALIBRATE BURNER
4.1 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 3
Burner Position 2
Burner Position 1
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Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
e. Calibration
(4) Warm-up and Heat Flux Check
While the burner is still rotated 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 of 2 minutes. Move the
burner into the calibration position and allow 1
minute for calorimeter stabilization, then record
the heat flux once every second for a period of
30 seconds. Turn off burner, rotate out of
position, and allow to cool. Calculate the
average heat flux over this 30-second duration.
The average heat flux should be 16.0 0.8 Btu/ft2
sec (18.2 0.9 W/cm2).
25
Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
e. Calibration
(5) Warm-up and temperature Check
Position the burner in front of the thermocouple
rake. After checking for proper alignment,
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 of 2 minutes. Move the burner into the
calibration position and allow 1 minute
for thermocouple stabilization, then record the
temperature of each of the 7 thermo- couples once
every second for a period of 30 seconds. Turn
off burner, rotate out of position, and allow to
cool. Calculate the average temperature of
each thermocouple over this 30- second period and
record. The average temperature of each of the 7
thermocouples should be 1900oF 100oF (1038
56oC).
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5 PREPARE TEST SPECIMEN
5.2 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

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Part VII Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
c. Test Specimens
(3) Construction (cont)
(iv) Installation on Test Frame. Attach the
blanket test specimens to the test frame using 12
steel spring-type clamps as shown in figure 7.
Use the clamps to hold the blankets in place in
both of the outer vertical formers, as well
as the center vertical former (4 clamps per
former). The clamp surfaces should measure 1
inch by 2 inches (25 by 51 mm). Place the top
and bottom clamps 6 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
with figure 7, the blankets must be installed in
a manner approved by the FAA.)
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Discussion of Test Method to Determine the
Burnthrough Resistance of Thermal/Acoustic
Insulation Materials
Installation of Test Samples on Test Frame
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Step 1 Install Left Blanket, Squeeze Onto Former
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Step 2 Install Right Blanket, Clip To Frame
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Step 3 Tuck Blanket Into Corners _at_ Center
Tuck
Tuck
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Step 4 Tuck Blanket Into Corners _at_ Sides, Clip
Tuck
Tuck
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Desired Blanket Installation on Test Frame
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Desired Blanket Installation on Test Frame
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Round Robin VI
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Round Robin VI Materials
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Round Robin VI Testing Sequence
Initial Calibration
A1, B1, C1, B2, C2, A2, C3, A3
Second Calibration
B3, A4, B4, C4, B5, C5, A5, C6
Third Calibration
A6, B6, A7, B7, C7, B8, C8, A8
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Round Robin VI Tasks
Completion of all test samples needed
Refine test spreadsheet
Update Calibration Guidelines document
FAATC witnessing of burnthrough testing using
RRVI samples
Use Boeing-manufactured calibration tools to
check labs