Tim Marker FAA Technical Center Discussion of Test Method to Determine the Burnthrough Resistance 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.

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.

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. INTERNATIONAL AIRCRAFT MATERIALS FIRE TEST WORKING GROUP MEETING 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 Material Burnthrough Test Procedure

THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH TEST PROCEDURE NOEL L SPURLOCK BOEING COMMERCIAL AIRPLANES AERO / NOISE / PROPULSION LABORATORY SEATTLE, WASHINGTON

1Verify burner assembly – Park Model DPL 1.1Components 1.1.1Blower – 5.25” diameter X 3.50” deep Fuel nozzle – Monarch, 6.0 GPM, 80 o, PL 1 ( PL - hollow cone or PLP - semi-hollow NO! ) 1.1.3Stator – Monarch H215, CCW, 4” diameter Turbulator – Monarch F124, CCW, 4 X 2 3 / 4 1 ( 4.00” diameter 3/4OD X 2.75” diameter ID ) 1.1.5Burner 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 2 and must include the capability of swinging the burner away from the test specimen during warm-up. (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 80 o PL (hollow cone) nozzle nominally rated at 6.0 gal/hr at 100 lb/in 2 (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 inch (8 mm) from the end plane of the exit stator, which must be mounted in the end of the draft tube. Part VII – Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials (2) Test Burner. Must be a modified gun-type such as the Park Model DPL 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. b. Apparatus

July 2001

1Verify burner assembly – Park Model DPL 1.2Configuration 1.2.5Draft tube to cone exit plane – 12.0” Draft tube angle – 30 o 3 ( from horizontal ) 1.3Operation 1.3.1Fuel flow = 6 ± 0.2 GPM Fuel pressure = 100 psig 1.3.3Air flow = 2150 ± 50 ft/min 1 (adjust with blower and hose-end dampers NO!- see 2.4 ) THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH TEST PROCEDURE

(3) Calibration Rig and Equipment (con’t) (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. Part VII – Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials b. Apparatus

June 2001

2Adjust test Apparatus 2.1Thermocouple rake 2.1.1Thermocouples – seven 1/8”, grounded, type K, metal sheathed 3 24 AWG, Ceramic Packed 2.1.2Rake configuration ●30 o from vertical ●1” between T/C w/ 3” exposure to flame 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 THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH TEST PROCEDURE

(3) Calibration Rig and Equipment (con’t) (iii) Calorimeter Mounting. Mount the calorimeter in a 6- by inch (152- by mm) by 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). Part VII – Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials b. Apparatus

2Adjust test Apparatus 2.4Burner air flow ●Hose-end damper set to 50% NO!●Blower damper set to 2150 ± 50 ft/min 1 2.5Vent Hood 2.5.1Vertical air flow = 100 ± 50 ft/min Horizontal air flow < 50 ft/min 5 2.6Calorimeter cooling water 2.6.1Water temperature = 120 o F ( 48.8 o C ) 2.6.2Water flow rate > 1 GPM THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH TEST PROCEDURE

4Calibrate Burner 4.1Two minute warm-up 4.2Thermocouple rake 3.2.1Thirty seconds to stabilize NO! 3.2.2Record data for thirty seconds 4.3Calorimeter 3.3.1Thirty seconds to stabilize NO! 3.3.2Record data for thirty seconds 4.4Examine data – burner adjustments if required THERMAL ACOUSTIC INSULATION MATERIAL BURNTHROUGH TEST PROCEDURE

(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 1900 o F o F ( o C). 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 Btu/ft 2 sec ( W/cm 2 ). Part VII – Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials e. Calibration

Nov 1999

Date: 11/24/99 Nov 1999

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

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 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 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 Btu/ft 2 sec ( W/cm 2 ). 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 1900 o F o F ( o C). Part VII – Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials e. Calibration

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

(3) Construction (con’t) (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.) Part VII – Test Method to Determine the Burnthrough Resistance of Thermal/Acoustic Insulation Materials c. Test Specimens

Installation of Test Samples on Test Frame Discussion of Test Method to Determine the Burnthrough Resistance 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 Center Tuck

Step 4: Tuck Blanket Into Sides, Clip Tuck

Desired Blanket Installation on Test Frame

Round Robin VI

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