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Title: THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH TEST PROCEDURE


1
THERMAL ACOUSTICINSULATION MATERIALBURNTHROUGHT
EST PROCEDURE
  • NOEL L SPURLOCK
  • BOEING COMMERCIAL AIRPLANES
  • AERO / NOISE / PROPULSION LABORATORY
  • SEATTLE, WASHINGTON

2
FIRE AND HAZARDOUSTEST FACILITY
FIRE BARRIER TEST GROUPBUILDING 3-322NORTH
BOEING FIELD
3
PURPOSE OF DEVELOPINGA TEST PROCEDURE
FORTHERMAL ACOUSTICINSULATION MATERIALS
? CLEARLY DEFINED TEST METHOD? DOCUMENTED
PROCESS OF TEST PERFORMED IN FACILITY?
CONSISTENT PROCESS USED BY ALL TEST ENGINEERS
IN LAB? SINGLE SOURCE FOR TEST INFORMATION?
PREPARATION FOR BOEING SPECIFICATION SUPPORT
STANDARD
4
SEVEN ELEMENTS OF BURNTHROUGH TEST PROCEDURE
THERMAL ACOUSTICINSULATION MATERIALS
1. VERIFY BURNER ASSEMBLY2. ADJUST TEST
APPARATUS3. SETUP DATA SYSTEM4. CALIBRATE
BURNER5. PREPARE TEST SPECIMEN6. PERFORM
BURNTHROUGH TEST7. PROCESS DATA
5
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 ) 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 )
6
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
1 Verify burner assembly Park Model
DPL 1.2 Configuration 1.2.1 Stator / Ignitor
clocking 1030 ( 1000 to 1100 per FAA
instructions 1 ) 1.2.2 Ignitor position 1/8
between ignitor tips, 1/8 forward of fuel
nozzle, 1/2 from fuel nozzle center line
1.2.2 Turbulator to fuel nozzle 5/16 1 (
0.313 ) 1.2.3 Fuel nozzle to stator 3.75
1 1.2.4 Draft tube to turbulator face 5/16 1
7
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 - see
2.4 )
8
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 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
9
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
2 Adjust test Apparatus 2.2 Calorimeters 2.2.1
Calibration heat flux ? 30o from
vertical ? 4 from cone exit
plane ? 1 above cone horizontal center
line ? On cone vertical center
line 2.2.2 Back-face heat flux ? 30o
from vertical ? 12 from specimen
holder ( flame-side ) ? 4 each side of
burner vertical center line ? On cone
horizontal center line
10
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
2 Adjust test Apparatus 2.3 Test Specimen
Holder 2.3.1 Construction and orientation
Fabricate per FAA specification
3 2.3.2 Holder position ? 30o from
vertical ? 4 to burner cone exit
plane ? Center on burner vertical center
line ? Bottom stringer 14 below burner cone
horizontal center line 3
11
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
2 Adjust test Apparatus 2.4 Burner air
flow ? Hose-end damper set to
50 ? 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
12
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
3 Setup Data System 3.1 Verify
instrumentation 3.1.1 T/C and calorimeter type
3.1.2 Current calibration 3.2 Initialize data
acquisition system 3.2.1 Input response for
calorimeters 3.2.2 Set scan rate to 1 sample
per second 3.2.3 Set period to 30 seconds for
calibration 3.2.4 Set period to 6 minutes for
test
13
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 3.2.2 Record data for
thirty seconds 4.3 Calorimeter 3.3.1 Thirty
seconds to stabilize 3.3.2 Record data for
thirty seconds 4.4 Examine data burner
adjustments if required
14
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
5 Prepare Test Specimen 5.1 Condition test
specimen ? 70o 5o F ? 55 10
RH ? 24 hours 5 5.2 Mount in test specimen
holder ? Wrap around frame ? Clip
blankets to frame ? Keep flat against
stringers ? Tuck into stringer / frame corners
15
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
6 Perform Burnthrough Test 6.1 Two minute
warm-up away from test specimen 6.2 Move burner
to test specimen 6.2.1 Start timer, record
data, start video 6.2.2 Monitor burner air
flow 6.2.3 Monitor backside calorimeters 6.2.4
End test ? At specimen
burnthrough ? Back-face heat flux over
limit ? 6 minutes
16
THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH
TEST PROCEDURE
7 Process Data 7.1 Transfer data to file
server (or permanent storage
medium) 7.2 Plot data ? Pre-test T/C
rake ? Pre-test Calorimeter ? Test
backside calorimeter ? Post-test T/C
rake ? Post-test calorimeter 7.3 Analyze
data
17
BURNER AND TEST APPARATUS ADJUSTMENT AND
DIMENSIONING TOOLS
TOOLS DEVELOPED AND FABRICATED AT THE FIRE AND
HAZARDOUS TEST FACILITY AND CURRENTLY USED FOR
BURNER CHECKOUT AND TEST SETUP
BOEING COMMERCIAL AIRPLANES AERO / NOISE /
PROPULSION LABORATORY SEATTLE, WASHINGTON
18
BURNER ADJUSTMENT TOOLS
Nozzle / Stator / Cone Location Tool
Set turbulator to fuel nozzle dimension Set fuel
nozzle to stator dimension Set burner cone to
turbulator dimension
19
BURNER ADJUSTMENT TOOLS
Ignitor Position and Clocking Tool
Adjust ignitor position without removing hardware
from burner assembly Repeatability with ignitor
clocking plate Clear view of ignitors
20
BURNER ADJUSTMENT TOOLS
Turbulator Position and Clocking Tool
Adjust turbulator position without removing
hardware from burner assembly Repeatability with
turbulator clocking disk Clocks turbulator
relative to ignitors
21
TEST APPARATUS ADJUSTMENT TOOLS
T/C Rake / Calorimeter / Test Specimen Position
Tool
One tool to check and adjust T/C rake and all
thermocouples, calorimeter, test specimen fixture
and burner cone orientation
22
BURNTHROUGH TEST PROCEDURE AS CONDUCTED AT
THEFIRE AND HAZARDOUS TEST FACILITY
THERMAL ACOUSTICINSULATION MATERIALSBURNTHROUGH
TEST METHOD
BOEING COMMERCIAL AIRPLANES AERO / NOISE /
PROPULSION LABORATORY SEATTLE, WASHINGTON
23
1 VERIFY BURNER ASSEMBLY
Burner Position 1
1.1 Components 1.2 Configuration 1.3 Operation
24
2 ADJUST TEST APPARATUS
Burner Position 2
2.1 Thermocouple Rake
25
2 ADJUST TEST APPARATUS
Burner Position 3
2.2 Calorimeter
26
2 ADJUST TEST APPARATUS
Burner Position 4
2.3 Test Specimen Holder
27
2 ADJUST TEST APPARATUS
2.4 Burner Air Flow Adjustment and Verification
Set hose-end damper to 50
Set burner damper to 2150 ft/min
Monitor air flow with an Omega HH-30 air velocity
meter
28
2 ADJUST TEST APPARATUS
2.5 Vent Hood Airflow Adjustment and Verification
Verify air velocity ? Vertical 100 50
ft/min ? Horizontal lt 50 ft/min Adjust vent hood
airflow as required
29
2 ADJUST TEST APPARATUS
2.6 Calorimeter Cooling Water Temp and Flow Rate
Set NESLAB temperature bath to 48.8 deg C (120
deg F) Verify water flow gt 1 GPM
1/4 GPM per calorimeter 3 calorimeters Assume
unequal flow through cooling circuit
30
3 SETUP DATA SYSTEM
3.1 3.2 System Verification and Initialization
Verify instrumentation is correct type and
calibrations are current Input response for
calibration calorimeter and backside
calorimeters Set to record at 1 sample per
second Set for 30 second calibration run and 6
minute test run
31
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)
Stabilize 30 seconds record data 30 seconds
Burner Position 3
Burner Position 2
Burner Position 1
32
5 PREPARE TEST SPECIMEN
5.1 Condition Test Specimen
? 70o 5o F ? 55 10 RH ? 24 hours
33
5 PREPARE TEST SPECIMEN
5.2 Mount Test Specimen in Holder
  • Flat against stringers
  • Tuck into frame/stringer corner
  • Clip to frame

34
6 PERFORM BURNTHROUGH TEST
6.1 Two minute warm-up 6.2 Move burner to
test specimen 6.2.1 Start data acquisition,
start timer, start video 6.2.2 Monitor
airflow 6.2.3 Monitor backside calorimeter
6.2.4 End test
  • Specimen burnthrough
  • Back-face gt 2 BTU/ft2sec
  • Reach 6 minute limit

35
7 PROCESS DATA
7.2 PLOT DATA
Back-face Calorimeter and Thermocouple Plot
36
REFERENCES
1. FAA Burner Calibration Guidelines, Burnthrough
Round Robin Task Group, PowerPoint Presentation
by Timothy Marker, William J Hughes FAA
Technical Center, September 2000 2. FAA Document,
DOT/FAA/AR-00/12, Aircraft Materials Fire
Test Handbook, April 2000 3. FAA Document,
Federal Register, Vol. 65, No. 183, Proposed
Rule, Improved Flammability Standards for
Thermal/Acoustic Insulation Materials Used in
Transport Category Airplanes, September
2000 4. FAA Document, DOT/FAA/AR-99/44,
Development of Improved Flammability Criteria
for Aircraft Thermal Acoustic Insulation,
by Timothy Marker, William J Hughes FAA
Technical Center, September 2000 5. Reference 4,
Appendix B Proposed Post-crash Burnthrough
Test Standard Hazardous Test Facility capability
exists but not currently employed included in
procedure in anticipation of certification test
requirements
37
BURNER AND TEST APPARATUS ADJUSTMENT AND
DIMENSIONING TOOLS
DRAWINGS OF THE TOOLS DEVELOPED AND FABRICATED AT
THE FIRE AND HAZARDOUS TEST FACILITY
BOEING COMMERCIAL AIRPLANES AERO / NOISE /
PROPULSION LABORATORY SEATTLE, WASHINGTON
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Noel L. Spurlock, BSME Test Engineer - Hazardous
Test Facility Aero / Noise / Propulsion
Laboratory Boeing Commercial Airplanes Seattle,
Washington noel.l.spurlock_at_boeing.com
47
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