1. Modeling In-flight Inert Gas Distribution in a 747 Center-Wing Fuel Tank William Cavage AAR-440 Fire Safety Branch Wm. J. Hughes Technical Center Federal Aviation Administration International Systems Fire Protection Working Group CAA House London, England UK June 23-24, 2005

2. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Outline Background Previous Work Plywood Scale Test Article Analytical Model Results –Cascading Inerting –747 SCA Test Simulations Summary

3. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Background To support the OBIGGS development work, Fire Safety Research has been developing models of ullage inerting given inert gas deposited and flight cycle –Assists in the development process and allows for system development, cost analysis, and trade studies –Models have to be simple to be useful for these applications Would like to be able to model the distribution of inert gas in compartmentalized tanks –Help determine the necessary distribution needed to meet future requirements for reducing oxygen concentration –Want to capitalize on previous modeling work done in support of ground-based inerting research (see AIAA Paper 2002-3032)

4. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Previous Work – Multi-Bay GBI Inerting Models FAA developed analytical model that calculates inert gas distribution, in terms of [O 2 ], in 6-bay tank at sea level –Based on previous work and tracks oxygen in and out of each bay at each time step, given inert gas deposited, assumes perfect mixing FAA built and performed tests in 24% scale 747SP CWT and measured inert gas distribution –Inerted with scaled flow and measured [O 2 ] in each bay Boeing Phantom Works created a CFD Model of a Boeing 747SP center-wing fuel tank and solved for a single, GBI flow case –Used CFD Fluent TM Solver and assumed no turbulent mixing Results gave varying degrees of agreement with aircraft data –Scale tank had excellent agreement, all duplicated bulk average well

5. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Analytical Model Inerting Data Comparison

6. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Scale Model Inerting Data Comparison

7. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D CFD Model Inerting Data Comparison

8. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D CFD Model Inerting Data Comparison

9. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Previous Work – In-flight Tank Inerting Modeling Developed analytical model of ullage oxygen concentration in a single bay tank based on inert gas added and altitude change –Model uses system performance (NEA flow and purity) in terms of time and altitude and calculates mass of oxygen added and removed from one bay at each time step, assuming perfect mixing, and given tank volume and starting oxygen concentration –Calculates ullage gas removed from tank due to increase in altitude (mass of O 2 ) and air entering tank due to decrease in altitude (mass of O 2 ) FAA built and performed tests in 50% scale Airbus A320 center- wing fuel tank using altitude chamber –Made from plywood using drawings given to FAA by Airbus –Mass flow controller and NEA mixer used to inert the tank with scaled flow in altitude chamber and measured ullage with oxygen analyzer

10. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D A320 Flight Test Descent Data Compared with Model Results

11. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Scale 747 SCA CWT In-flight Testing FAA used existing 24% scale model in an altitude chamber to simulate 747 SCA flight test scenario –Used model from previous GBI experiments –Test personnel controlled the altitude/time flight cycle to simulate particular flight test –Inerting system simulated by additional test personnel using mass flow controller and NEA mixer to inert the tank with scaled flow in altitude chamber –8-channel altitude oxygen analyzer used to track each bay ullage oxygen concentration as well as additional basic instrumentation to monitor experiment –See Report DOT/FAA/AR-04/41 for details of 747 SCA flight tests

12. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Developed analytical model of multi-bay inerting in-flight based on previous model to simulate 747 SCA flight test scenario Model Method - Multi Bay Analytical Model –First developed more simple “cascading” inerting model which has very few assumptions and is more easily validated –Model has one inert gas deposit (bay 1) and one vent (bay n) –Next, modified model to split flow to several bays and vent flow from several bays using flight test data for ratios

13. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Results – Cascading Inerting Reconfigured the 747 scale tank to perform cascading inerting tests to compare results of scale tank with analytical model –Changed deposit and venting configuration and made holes between bays small to promote mixing –Results good but had significant discrepancies during descent –Differences contributed to scale tank lid leaking air in due to worn seal –Bulk average data matched identically further supporting conclusion

14. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Results – 747 SCA Ground Test Used data from a single flight test to tweak analytical model and make small change to scale tank –Both models agreed well with ground test results –Scale tank still had some differences –Bulk average data matched well

15. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D Results – 747 SCA Descent Simulation Duplicated several descents using both analytical model and scale tank simulations –Used measured OBIGGS performance and flight cycle as input to scale tank and analytical model to simulate a test descent –Results of both simple models illustrated good agreement with the data trends with several large discrepancies in values at individual times, peak and resulting values of the critical bays 1, 2, & 3 had deviations of about +/- 1% oxygen (other bays larger) –Bulk average of the different models agreed well with measured flight test data –Limitations of analytical model evident when comparing all flight test descent – simplistic nature of the model gives limited capabilities –Scale tank needs to be looked at more to determine why it has difficulty in predicting the measured results

16. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D 747 SCA Flight Test Descent Data Compared with Model Results

17. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D 747 SCA Flight Test Descent Data Compared with Model Results

18. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D 747 SCA Flight Test Descent Data Compared with Model Results

19. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D 747 SCA Flight Test Descent Data Compared with Model Results

20. Modeling of Fuel Tank Inerting ____________________________________ AAR-440 Fire Safety R&D An analytical model of ullage oxygen concentration distribution has been developed for a 6-bay compartmentalized tank and can duplicate flight test trend data in a fairly accurate manner given experimental data is available to develop bay-to- bay flow ratios –Peak and resulting values agree fair to good depending on case A scale model can be used with an altitude facility in a relatively cost effective way to give fair agreement with peak and resulting flight test [O 2 ] values –Some specialized instrumentation and facilities needed –More work is needed to see the effect on small scale tank fidelity on the ability of the model to duplicate flight test data Summary