PROPOSED BURNTHROUGH TEST

METHOD CALIBRATION GUIDELINES

Objective of Testing:

• Establish Similar Calibration Procedure

• Produce Similar Exposure From Burner

• Achieve Similar Test Results

Factors That Can Influence Calibration

• Air Intake Velocity

• Air Intake Temperature

• Fuel Flowrate

• Fuel Temperature

• Instrumentation (type/size of thermocouple, calorimeter type)

• Other Adjustments (position of igniters, static disc, tabs)

• Fuel Type (Jet A, Diesel, Fuel Oil)

• Environmental Conditions (relative humidity, barometric pressure)

Individual Calibration Rigs

Protective Heat Shield for Burner Components

Protective Heat Shield for Burner Components

Conditioned Intake Air

Conditioned Intake Air

Intake Airbox

Intake Airbox Mounted to Burner

Fuel Temperature

Intake Airbox Holding Air Velocity Meter

Measurement of Intake Air and Fuel Temperature

Temperature Rake Using 1/8” Closed Bead Thermocouples

Factory Mounted Static Disc

Static Disc Mounted to Igniter Assembly

Temperature Profile Bias

Backside Heat Flux MeasurementsCalorimeters Mounted at 4 Inches from Centerline

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

0 60 120 180 240 300 360

Time (seconds)

He

at F

lux

(Btu

/ft2

se

c)

Cal #1 Baseline

Cal #2 Baseline

Cal #1 Nextel Test

Cal #2 Nextel Test

Use of Deflection Tabs at Draft Tube End

Air Velocity = 2000 ft/minIgniters @ 6:00Average Temp = 1912oFResult: Low on ends, too hot in middle

Air Velocity = 2000 ft/minIgniters @ 6:00Average Temp = 1927oFResult: Too hot in middle

Air Velocity = 2000 ft/minIgniters @ 6:00Average Temp = 1890oFResult: Low on ends, too hot in middle

Effect of Tab Positioning on Temperature

Air Velocity = 2000 ft/minIgniters @ 6:00Average Temp = 1957oFResult: Low on ends, too hot in middle

Air Velocity = 1900 ft/minIgniters @ 6:00Average Temp = 1951oFResult: Low on ends, too hot in middle

Air Velocity = 2000 ft/minIgniters @ 9:00Average Temp = 1860oFResult: All temperatures in range

Effect of Tab Positioning on Temperature

Location of Flame Enhancement Tab

Air Velocity = 1900 ft/minIgniters @ 9:00Average Temp = 1846oFResult: All temperatures in range

Air Velocity = 2000 ft/minIgniters @ 9:00Average Temp = 1860oFResult: All temperatures in range

Air Velocity = 2100 ft/minIgniters @ 9:00Average Temp = 1882oFResult: All temperatures in range

Air Velocity = 2200 ft/minIgniters @ 9:00Average Temp = 1896oFResult: All temperatures in range

Day 1 Temperature Calibration @ Various Air Velocity Settings

Air Velocity = 2000 ft/minIgniters @ 9:00Average Temp = 1826oFResult: All temperatures in range

Air Velocity = 2100 ft/minIgniters @ 9:00Average Temp = 1832oFResult: All temperatures in range

Air Velocity = 2200 ft/minIgniters @ 9:00Average Temp = 1864oFResult: All temperatures in range

Day 2 Temperature Calibration @ Various Air Velocity Settings

Air Velocity = 1900 ft/minIgniters @ 9:00Average Temp = 1863oFResult: All temperatures in range

Air Velocity = 2000 ft/minIgniters @ 9:00Average Temp = 1887oFResult: All temperatures in range

Air Velocity = 2100 ft/minIgniters @ 9:00Average Temp = 1913oFResult: Middle temperatures slightly high

Day 3 Temperature Calibration @ Various Air Velocity Settings

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

1900 2000 21002 minute 14.76 14.65 13.843 minute 15.03 14.63 14.014 minute 15.08 14.42 13.985 minute 15.14 14.26 13.886 minute 14.90 14.14 13.79Average 14.98 14.42 13.90

1900 2000 21002 minute 12.82 12.64 13.053 minute 13.00 12.81 13.134 minute 12.74 12.85 13.155 minute 12.64 12.81 13.276 minute 12.44 12.87 13.35Average 12.73 12.80 13.19

Day 1 Heat Flux Calibration @ Various Air Velocity Settings

12

13

14

15

16

1900 2000 2100

Air Velocity (ft/min)

He

at

Flu

x (

Btu

/ft2 s

ec

)

12

13

14

15

16

1900 2000 2100

Air Velocity (ft/min)

He

at

Flu

x (

Btu

/ft2 s

ec)

Date: 11/17/99

Day 2 Heat Flux Calibration @ Various Air Velocity Settings

2100 2000 19002 minute 12.49 12.86 12.643 minute 12.54 12.93 12.734 minute 12.58 13.00 12.805 minute 12.68 12.90 12.726 minute 12.69 12.83 12.65Average 12.60 12.90 12.71

12

13

14

15

16

2100 2000 1900

Air Velocity (ft/min)

He

at

Flu

x (

Btu

/ft2 s

ec)

2100 2000 19002 minute 12.93 13.28 13.163 minute 13.19 13.29 13.134 minute 13.33 13.37 12.995 minute 13.49 13.36 12.936 minute 13.60 13.23 12.86Average 13.31 13.31 13.01

12

13

14

15

16

2100 2000 1900

Air Velocity (ft/min)

He

at

Flu

x (

Btu

/ft2

se

c)

Date: 11/18/99

Day 3 Heat Flux Calibration @ Various Air Velocity Settings

2100 2000 19002 minute 12.06 12.73 12.563 minute 12.39 12.74 12.664 minute 12.57 12.95 12.725 minute 12.77 13.01 12.726 minute 12.80 13.06 12.68Average 12.52 12.90 12.67

12

13

14

15

16

2100 2000 1900

Air Velocity (ft/min)

He

at

Flu

x (

Btu

/ft2 s

ec)

2100 2000 19002 minute 12.97 13.06 12.863 minute 13.14 13.16 12.874 minute 13.28 13.15 12.805 minute 13.27 13.29 12.696 minute 13.48 13.17 12.69Average 13.23 13.17 12.78

12

13

14

15

16

2100 2000 1900

Air Velocity (ft/min)

He

at

Flu

x (

Btu

/ft2 s

ec)

Date: 11/19/99

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

10

11

12

13

14

15

16

0 2 4 6 8 10 12

Time (minutes)

Re

co

rde

d H

ea

t F

lux

(B

tu/f

t2 se

c)

1900 ft/min

2000 ft/min

2100 ft/min

2200 ft/min

Date: 11/23/99

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

Latest Calibration Procedure

Temperature: (1850oF +/- 100oF)

Adjust Fuel Flowrate to 6.0 gal/hr

Adjust Burner Intake Air Velocity to 2200 ft/min

Heat Flux: (15.2 Btu/ft2 sec +/- 0.8 Btu/ft2 sec)

•After 2-minute warm-up, swing burner into position, •allow 1 minute stabilization, •take reading for 30 seconds (once per second) and average, •swing burner away from flame

•After 2-minute warm-up, swing burner into position, •allow 1 minute stabilization, •take reading for 30 seconds (once per second) and average, •swing burner away from flame

DateSkin

Material

Skin Thickness (inches)

Sample Size

(inches)

Bolt Holes in CTR Vertical

FormerAir Velocity

(ft/min)Intake Air Temp (F)

Fuel Temp (F)

Initial Burnthrough Time (sec)

Final Burnthrough Time (sec)

9/27/99 Alum 5052 0.05 36 x 39 6 2000 NR NR 32 379/27/99 Alum 5052 0.05 36 x 39 6 2025 to 2036 NR NR 39 459/27/99 Alum 5052 0.05 36 x 39 6 2011 to 2023 NR NR 35 409/28/99 Alclad 2024 0.063 36 x 36 6 2011 to 2028 87 72 46 559/28/99 Alclad 2024 0.063 36 x 36 6 2011 to 2025 88 75 26 529/28/99 Alclad 2024 0.063 36 x 36 6 2010 to 2026 84 72 41 549/29/99 Alclad 2024 0.063 36 x 36 4 2010 to 2017 85 75 64 699/30/99 Alclad 2024 0.063 36 x 36 4 2203 to 2215 90 65 62 6810/1/99 Alclad 2024 0.063 36 x 36 4 2325 to 2330 86 70 40 5210/1/99 Alclad 2024 0.063 36 x 36 4 2201 to 2211 88 72 46 5510/1/99 Alclad 2024 0.063 36 x 36 4 2200 to 2205 86 73 49 6610/5/99 Alclad 2024 0.063 36 x 36 4 2198 to 2214 78 68 47 5210/6/99 Alclad 2024 0.063 36 x 36 4 2182 to 2190 77 63 47 5110/6/99 Alclad 2024 0.063 36 x 36 4 2190 to 2206 74 65 64 7010/6/99 Alclad 2024 0.063 36 x 36 4 2185 to 2203 76 70 66 6910/7/99 5052 Alum 0.05 36 x 36 4 2203 to 2214 76 66 39 40

10/13/99 5052 Alum 0.05 36 x 36 4 2182 to 2190 93 76 44 5610/14/99 5052 Alum 0.05 36 x 36 4 2225 to 2244 77 69 41 51

Calibration Tests Using Aluminum Skin

Round Robin Burnthrough TestingMaterial Selection

• Quick-Failing Material (< 1 minute)

• Long Duration Passing Material (> 5 minutes)

• 1-2 Minute Material Combination

• 2-3 Minute Material Combination

Round Robin Burnthrough Testing

Purpose

To identify problems encountered during calibration of test equipment to ensure similarity between labs

To prove similarity of test equipment through testing of identical samples

Cataloguing Method for Identifying Materials

Ins Thickness (in) - Ins Density (lb/ft3) - Ins Type - Add Barrier - Film - Weight Class (Thickness)

60=0.6042=0.4234=0.34

FG=FiberglassOPF=Oxidized Polyacrylonitrile FiberPAN=Polyacrylonitrile FiberRPI=Rigid Polyimide Foam

NEX=Nextel Ceramic PaperFOP=Felted OPFNQZ=Needled QuartzCFS=Carbon Fiber Skrim

PET1=class 1 polyethylene terepthalatePVF2=class 2 polyvinyl fluoridePI=polyimideFC=fluoropolymer composite

Example: 2-42-FG-NEX-PET-1

0

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420

Lab A Lab B Lab C Lab D

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Material 1

Material 2

Material 3

Material 4

Burnthrough Round Robin Test Results (Imaginary)

Burnthrough Test Method Round Robin Task Group

Test Facilities Material Suppliers

• FAATC - Tim Marker• CEAT - Anne Mansuet• Darchem Flare - Darren Dodd• CTA - Anna Villate• Boeing - Hank Lutz• Daimler Chrysler - Bernd Menken• Johns Manville - Becky Wulliman• 3M - Tom Tompkins• Mexmil - Dave Indyke• Accufleet - Jim Davis• Akro Fireguard - George Danker• International Aero - John Brooks• No Fire - Sam Gottfried

• Orcon - Sherm Smith

• 3M - Tom Tompkins

• Johns Manville - Becky Wulliman

• Mexmil - Dave Indyke

• Osaka Gas - Yo Ishikawa

• Inspec Foams - Dan Trahan

• Schneller - Dale Onderak

• Facile - Paul Harencak

• Lamart - Dave Shields

• Jeheir - Jacques Maillard

Recent Burnthrough Test Results

0

60

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480

540

600

IntumescentCoated

AluminumSkin (.063

inch)

3 Layers TTIInsulation

(MC8-7688B99)12908A

2 Layers TTIInsulation

(MC8-7688B99)12908A

1 Layers TTIFelt (MC8-

7689)

2 Layers TTIFelt (MC8-

7689)

IntumescentCoated

AluminumSkin (.063

inch)

2 Layers TTIInsulation

1 Layer TTIInsulation

1 Layer TTIInsulation

2 Layers0.42 lb/ft3Fiberglass

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