Federal Aviation Development of an Administration Improved ... · Federal Aviation Development of...

Presented to:

Federal AviationAdministrationDevelopment of an

Improved Fire Test Method and Criteria for Aircraft Electrical Wiring

The International Aircraft Material Fire Testing Working Group

By: John Reinhardt, Project Manager, PMP

Date: June 17-18, 2008

Location: Niagara Falls, NY

22 of 39Federal AviationAdministration

Development of an Improved Fire Test Method and Criteria for Aircraft Electrical Wiring

Outline

• Project Initiating Process

Project Charter

Scope Statement

• Planning Process

Work Breakdown Structure

• Execution Process

Review Historical Information

Meet with Stakeholders

Definition of Fire Threat

Test Methods Selection

Material Selection

Material Testing

• Project Status & Final Words



• Objectives:

Develop a fire test method for aircraft electrical wiring that could adequately discriminate between poorly performing wire insulation materials and fire worthy ones when exposed to a realistic fire scenario.

• Requirements:

Submit a final report documenting the developmental project and the new test method.

• Due Date (milestone):

30 June 2009: Draft Final Report

Initiating Process

PROJECT CHARTER



Initiating Process



SCOPE STATEMENT• This project will focus on the flammability characteristics of aircraft wiring insulation only.

• It will consider the Radiant Heat Panel test apparatus as a candidate replacement.

• Excluded: wire arcing, design issues, installation issues, maintenance issues, FAA policies, etc.

Initiating Process



Work Breakdown Structure

1. NEW FLAMMABILITY TEST FOR AIRCRAFT WIRING

1.1 Review Historical Information

1.2 Meet with Stakeholders

1.4 Test Methods Selection

1.5 Material Selection

1.3 Define Fire Threat

1.6 Material Testing

1.7 Evaluate Test Methods

1.8 Select/Modify Selected Test Method

1.9 Verify Test Method

1.10 Publish Test Method

Completed

In Progress

Planning Process: Scope



WBS 1.1 Review Historical Information

Go BackGo Back

Execution Process: WBS 1.1

Organization Document Flammability Test Method

Federal Aviation Administration

Appendix F Part I of 14 CFR Part 23 & 25, and Aircraft Materials Fire Test Handbook DOT/FAA/AR-00/12 Chapter 4

Sixty Degree Bunsen Burner Test

Horizontal Flammability (Method No. 5211)Vertical Flammability (Method No. 5221) for MIL-

W rated wiresSpark Method Flammability (Method No. 5231)

International Electrotechnical Commission IEC 60332-3 Tests on Electric Cables Under Fire Conditions Part 3-10

National Fire Protection Association NFPA 262Standard Method of Test for Flame Travel and Smoke of Wires and Cables for Use in Air-Handling Spaces

SAE Aerospace Standard Method 801 Sixty Degree Bunsen Burner Test

UL 1666Test for Flame Propagation Height of Electrical and Optical-Fiber Cables Installed Vertically in

Shafts

UL 1685Vertical-Tray Fire-Propagation and Smoke-Release Test for Electrical and Optical-Fiber Cables

General Services Administration Federal Test Method Standard 228

Underwriter Laboratory



WBS 1.2 Meet with Stakeholders• FAA Sponsor

• FAA Program Manager

• FAA Fire Safety Researchers

• International Aircraft Materials Fire Test Working Group

• OEMs

• Other

Go Back




WBS 1.3 Define Fire Threat• Report DOT/FAA/AR-99/44 – “Development of Improved Flammability Criteria for Aircraft Thermal Acoustic Insulation,” September 2000

• And, Report DOT/FAA/AR-08/4 –“Development of an Improved Fire Test Method for Aircraft Ducting,” February 2008

• Fire Threat: 101.6 by 101.6 by 228.6-mm Urethane Foam Block (Density: 16.02 kg/m3)

• Environment:

Sea Level

Narrow-body attic

Insulation blankets in attic

Insulated duct in attic

Quasi-Std Ambient Temperature




INTERMEDIATE-SCALE FIRE TEST OF WIRES/CABLESIgnition Source Temperature Profile (Baseline)

0

100

200

300

400

500

600

700

800

900

1000

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Time (Min)

Tem

pera

ture

(Deg

C)

Test 1Test 2Test 3Test 4

Tmax = 857 degCTavg = 810 degCt peak avg = 1.12 min



INTERMEDIATE-SCALE FIRE TEST OF WIRES/CABLESIgnition Source Heat Flux Profile (Baseline)

0

10

20

30

40

50

60

70

80

90

100

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Time (Min)

Hea

t Flu

x (W

/cm

2 )


q. max = 90 W/cm2

q. avg = 77 W/cm2

t peak avg = 1.14 min

Go Back



WBS 1.4 Test Methods Selection

60-Degree Bunsen Burner Test

Intermediate-Scale

Microscale Combustion Calorimeter

Radiant Heat Panel

Fire PropagationBurn AreaAfter Flame TimeDrip Flame TimeTotal Heat ReleaseHeat Release RateOnset TemperatureCombustion Temperature% Char

MEASUREMENTMATERIAL TEST METHOD


Go Back




Go Back

Item No. Wire Specification AWG Insulation Material Jacket Material Temp Rating (degC) Comments

1 Hitachi Riser Cable Cat 3 PVC Fire Retardant Thermoplastic 60 Other Industry Usage

2 Hitachi Riser Cable (Cat 5e: ) Polyolefin Fire Retardant Thermoplastic 60 Use in other Industries; POLYOLEFIN: Polyethylene, Polypropylene, Cellular Polyolefin, Flame Retardant PE?

3Computer Cable Polypropylene Insulated, Belden 9804, 28 AWG, 2 pairs, shield: 90% overall foil/braid, drain wire overall

Polypropelene PVC 60 Use in other Industries

4 M17/28-RG58 (Coaxial Cable Type IIIA) PE PVC 80 Use in other Industries5 Neoprene Hook-up Wire Neoprene - 90 Use in other Industries6 MS 5086/1 (~ BMS13-13) 20 PVC Nylon 105 Past Aircraft Production7 Fiber Optic Riser Cable - PVC 105 Use in other Industries8 Hypalon Hook-up Wire Hypalon - 105 Use in other Industries

9 SAE AS 22759/14 20 Extruded FEP PVDF 135 Aircraft acceptable protected wire listed on FAA's Adisory Circular 43.13-1B Table 11-12, Past Aircraft Production

10 MS22759/16 20 ETFE - 150 Aircraft acceptable open wire listed on FAA's Adisory Circular 43.13-1B Table 11-11

11 MS 22759/32 20 Zelrad 150-S, XL-ETFE - 150Aircraft acceptable protected wire listed on FAA's Adisory

Circular 43.13-1B Table 11-12; Current In-Flight Entertainment/Other Passenger Systems

12 BMS13-48 (~ MS 22759/34) 20 ETFE - 150Aircraft acceptable open wire listed on Adisory Circular 43.13-1B

Table 11-11; Current Aircraft Production; Aircraft, In-Flight Entertainment/Other Passenger Systems

13 BMS13-60T01C01 20 Polyimide PTFE 150 Current Aircraft Production

14 MS 81044/6 (~ BMS13-38) 20 Crosslinked Polyalkene PVDF 150 Aircraft acceptable open wire listed on FAA's Adisory Circular 43.13-1B Table 11-11; Past Aircraft Production

15 MS 81381/21 20 Polyimide Tape Polyimide Resin 150 Aircraft acceptable protected wire listed on Adisory Circular 43.13-1B Table 11-12; Past Aircraft Production

16 Radix Braidless Silicone 150 Lead Wire Silicone Rubber - 150 Use in other Industries

17 SAE AS22759/33 20 Crosslinked ETFE Single Layer - 200Aircraft acceptable protected wire listed on FAA's Adisory

Circular 43.13-1B Table 11-12; Current In-Flight Entertainment/Other Passenger Systems

18 BMS13-55 20 Impregnated Inorganic Fiber PTFE 200 Current Aircraft Production19 BMS13-72 20 PTFE FEP 200 Current Aircraft Production

20 SAE AS 22759/5 20 Extruded PTFE - 200 Aircraft acceptable open wire listed on FAA's Adisory Circular 43.13-1B Table 11-11; Past Aircraft Production

21 SAE AS 22759/11 20 TFE - 200 Aircraft acceptable protected wire listed on FAA's Adisory Circular 43.13-1B Table 11-12; Past Aircraft Production

22 SAE AS22729 (MS 22759/86) 20 Composite: Fluoropolymer/Polyimide Tape - 260 Current Aircraft Production; Current In-Flight

Entertainment/Other Passenger Systems



WBS 1.6 Material Testing• Tests to be conducted:

• 60-Degree Bunsen Burner Test

• Micro-Scale Combustion Calorimeter

• Intermediate-Scale Fire Test

• Radiant Heat Panel Test

• Other (as needed).





Wire Specification Intermediate Scale Test 60 Degree Test MSCC Test RHP TestBaseline X N/A N/A

Belden 9804 Cable(PVC-PP) X X XBMS13-48 (Ex-XL-ETFE) X X

BMS13-55 (PTFE) X XBMS13-60 (PTFE-PI) X X X

BMS13-72 (FEP-PTFE) X XBraidless Silicone 200 Lead Wire X X XFiber Optic Cable M9B037 (PVC) X X X

Hitachi Riser Cable Cat 3 (FR-PVC) X XHitachi Riser Cable Cat 5e: (FR-PO) X X

Hypalon Hook-up Wire X X XM17/28-RG58 (PVC-PE) X X X

MS 22759/16 (ETFE) X XMS 22759/32 (Z-XL-M-ETFE) X X

MS 5086/1 (Nylon-PVC) X X XMS 81044/6 (XL-PA) X X X

MS 81381/21 (PI) X XNeoprene Hook-up Wire X XSAE AS 22759/11 (TFE) X X X

SAE AS 22759/14 (FEP-PVF2) X XSAE AS 22759/5 (Ar-TFE) X X

SAE AS22729 (FP-PI) X XSAE AS22759/33 (XL-ETFE) X X



WBS 1.6 Material Testing• 60-DEGREE BUNSEN BURNER TEST FOR ELECTRIC WIRE

– Test Protocol: Chapter 4 of DOT/FAA/AR-00/12 “Aircraft Materials Fire Test Handbook”

– Sample Size: 76.2 cm (mark: 20.3 cm); mounted at 60 degrees from horizon

– Heat Source: Methane Flame (T>954C), perpendicular to wire sample

– Heat Source Exposure: 30 seconds

– Flame Extinguishing Time: <30 secs

– Burn Length: <7.6 cm

– Drip Extinguishing Time: <3 sec




Wire Sample: BMS13-60 (Passed B.L. = 2.9 cm, FET = 0 sec)



Wire Sample: MIL-17/28-RG58 (Passed, B.L. = 5.6 cm, FET = 3 sec)



Wire Sample: MS5086/1 (PVC/Nylon, Failed: B.L. = 39.5 cm, FET = 156 sec)



Execution Process: Material TestingFAA 60-DEGREE BUNSEN BURNER TEST FOR ELECTRIC WIRE

0

5

10

15

20

25

30

35

40

45

50

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180

Average Extinguishing Time (sec)

Ave

rage

Bur

n Le

ngth

(cm

)

Radix Silicone 200

MS5086/1 (PVC/Nylon)

Note: All wire samples had zero second drip extinguishing time

Requirements: Average Extinguishing Time <= 30 seconds, Average Burn Length <=7.6 cm

Go to IST Chart




0

1

2

3

4

5

6

7

8

9

10

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Average Extinguishing Time (sec)

Ave

rage

Bur

n Le

ngth

(cm

)

MS81044/6 (XL-PA)

MIL17/28-RG58 (PVC/PE)

Note: All wire samples had zero second drip extinguishing time

Requirements: Average Extinguishing Time <= 30 seconds, Average Burn Length <=7.6 cm

Hypalon

Belden 9804 Cable (PVC-PP)Fiber Optic M9B037 (PVC)

MS22759/33 (XL-ETFE)MS22759/16 (ETFE)

BMS13-48 (EX-XL-ETFE)BMS13-55 (PTFE)MS22759/5 (TFE)

MS22759/14 (FEP-PVF2)MS22759/32 (Z-XL-M-ETFE)

MS22759/11 (TFE)BMS13-72 (FEP-PTFE)

MS81381/21 (PI)BMS13-60 (PTFE-PI)MS22759/86 (FP-PI)

Hitachi CAT 5eHitachi CAT 3




0.03 0.03 0.03 0.030.07 0.07 0.07

0.10 0.10 0.10 0.100.13

0.20 0.200.23

0.30 0.30 0.30

0.60

0.70

1.10

0.00

0.20

0.40

0.60

0.80

1.00

1.20

BMS13-72

(FEP-P

TFE)

BMS13-60

(PTFE-P

I)

MS2275

9/32 (

Z-XL-M

-ETFE)

MS2275

9/5 (A

R-TFE)

BMS13-48

(EX-X

L-ETFE)

BMS13-55

(PTFE)

MS2275

9/33 (

XL-ETFE)

MS2275

9/14 (

FEP-PVF2)

MS2275

9/86 (

FP-PI)

MS2275

9/11 (

TFE)

Belden

9804

Cab

le (P

VC/PP)

MS8104

4/6 (X

L-PA)

MS2275

9/16 (

ETFE)

MS8138

1/21 (

PI)

MIL17/2

8-RG58

(PVC/P

E)

Hitach

i Cat

5e (F

R/Polyole

fin)

Hypalo

n

Fiber O

ptic M

9B03

7 (PVC)

Radix

Silicon

e 200

Hitach

i Cat

3 (FR/P

VC)

MS5086

/1 (N

ylon-P

VC)

Material ID

Mas

s Lo

ss (g

)

Note: Black color denotes that the conductor was exposed after the test; the Blue color denotes that it did not.



WBS 1.6 Material Testing• MICRO-SCALE COMBUSTION CALORIMETER TEST


– Test Protocol: FAA Report DOT/FAA/AR-01/117 “A Micro-scale Combustion Calorimeter”

– Sample Size: milligram range

– Heat Source: Heating Coils (ramps up from 21 to 900 ºC)

– Heat Source Exposure: 1ºC per sec to effect pyrolysis

– Not a compliance test



MICRO-SCALE COMBUSTION CALORIMETER TEST OF WIRES/CABLES

0

200

400

600

800

1000

1200

1400

272 284 292 294 300 306 317 319 344 491 498 499 501 501 502 505 517 534 534 604 612 615 626 627

Minimum Combustion Temperature (degC)

Hea

t Rel

ease

Cap

acity

(J/g

-K)

Hyp

alon

Mil1

7/28

-RG

58 (P

E)

Fibe

r Opt

ic (P

VC)

Neo

pren

e

9804

Cab

le (P

P/PV

C)

MS5

086

(Nyl

on/P

VC)

MS2

2759

/14

(FEP

/PVF

2)

Silic

one

200

BMS1

3-48

(EX-

XL-E

TFE)

MS2

2759

/32

(Zel

rad-

XL-E

TFE)

MS8

1044

/6 (P

VDF-

PA)

MS2

2759

/33

(XL-

ETFE

)

BMS1

3-55

(PTF

E)

BMS1

3-72

(FEP

-PTF

E)

MS2

2759

/5 (E

X-PT

FE)

BMS1

3-60

(PTF

E-PI

-PTF

E)

MS2

2759

/86

(FP-

PI)

MS8

1381

/21

(PI)

MS2

2759

/11

(TFE

)

MS2

2759

/16

(ETF

E)

Hita

chi C

AT 3

(Ins

ulat

ion)

Hita

chi C

AT 5

e (In

sula

tion)

Hita

chi C

AT 5

e (J

acke

t)

Hita

chi C

AT 3

(Jac

ket)




0

5

10

15

20

25

30

35

40

45

MS8138

1/21 (

PI)

MS2275

9/86 (

FP-PI)

BMS13-60

(PTFE-P

I))

MS2275

9/11 (

TFE)

MS2275

9/5 (E

X-PTFE)

BMS13-55

(PTFE)

BMS13-72

(FEP-P

TFE)

MS2275

9/14 (

FEP-PVF2)

BMS13-48

(EX-X

L-ETFE)

MS2275

9/32 (

ZELRAD 15

0-S, X

L-ETFE)

MS2275

9/33 (

XL-ETFE)

Neopre

ne

MS2275

9/16 (

ETFE)

MS2275

9/16 (

ETFE)

Hitach

i Cat

3 (Ins

ulatio

n)Silic

one 2

00

Hitach

i Cat

3 (Ja

cket)

9804

Cab

le (P

P/PVC)

Hypalo

n

Hitach

i Cat

5 (Ja

cket)

Fiber O

ptic (

PVC)

MS8104

4-6 (P

VDF/XL P

olyalk

ene)

MS5086

-1 (N

ylon/P

VC)

MIL17/2

8-RG58

(PE)

Hitach

i Cat

5 (Ins

ulatio

n)

Material ID

Tota

l Hea

t Rel

ease

(kJ/

g)




0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

BMS13-55

(PTFE)

BMS13-72

(FEP-P

TFE)

MS2275

9/11 (

TFE)

Hitach

i Cat

5 (Ins

ulatio

n)

MS2275

9/5 (E

xtrud

ed PTFE)

MIL17/2

8-RG58

(PE)

MS2275

9/16 (

ETFE)

MS2275

9/16 (

ETFE)

MS2275

9/14 (

FEP-PVF2)

MS2275

9/33 (

XL-ETFE)

MS2275

9/32 (

ZELRAD 15

0-S, X

L-ETFE)

MS5086

-1 (N

ylon/P

VC)

BMS13-60

(PTFE-P

I))

MS2275

9/86 (

FP-PI)

Fiber O

ptic (

PVC)

BMS13-48

(EX-X

L-ETFE)

MS8104

4-6 (P

VDF/XL P

olyalk

ene)

9804

Cab

le (P

P/PVC)

Hitach

i Cat

3 (Ja

cket)

Hitach

i Cat

3 (Ins

ulatio

n)

Material ID

Perc

ent C

har (

%)



WBS 1.6 Material Testing• INTERMEDIATE-SCALE FIRE TEST


– Test Protocol: FAA Report DOT/FAA/AR-08/4 – “Development of an Improved Fire Test Method for Aircraft Ducting,” February 2008

– Sample Size: bundle of wire, 1.27 cm in diameter, 330.2 cm long

– Heat Source: Polyurethane Foam Block + 10 cc of Heptane (Avg HF = 77 kW/m2, and Avg T = 810 ºC)

– Heat Source Exposure: ~8 minutes; peak occurrence ~ 1min

– Test Duration: 15 minutes

– Not a compliance test




Intermediate-Scale Fire Test Setup – Front View

Composite Ceiling Panel

(Nomex)

Fire Ignition Source(Urethane Foam Block

Soaked with 10 cc of Heptane)0.31 cm from Duct

TC1, TC2, TC3, TC4, TC5, TC6, Tc7C1, C2, C3

Note: TC: Thermocouple (2.54 cm below ceiling) C: Calorimeter Sensors 2.54 cm apart- Two more cameras (wide view)

Thermoacoustic InsulationBlanket (Polyimide film and Two 0.34 PCS FiberglassBlanket)

Insulated (PI/FG Blanket) Small Duct

(15.24 cm Height)

30.48 cm

Port Side Starboard Side

Narrow-body Transport Aircraft Fuselage Section



365.76 cm

30.48 cm(Typical DistanceBetween TCs2-6)

11.43 cm

Fwd TC1, C1

Camera 3

15.24 cm

147.32 cm

13.33 cm

Forward

Aft

Mid TC4, C2

TC2

TC3

TC5

TC6

Wire/Cable Bundle (~½” Diameter)

Aft TC7, C3

313.69 cm

Fire Ignition Source

Camera 1

Camera 2

Intermediate-Scale Fire Test Setup – Top View





Wire Sample: BMS13-60 (B.L. = 29.5 cm, FET = 1.33 min)




Wire Sample: MIL-17/28-RG58 (B.L. = 109.8 cm, FET = 17.9 min, dripped)




Wire Sample: MS5086/1 (B.L. = 101.7 cm, FET = 9.45 min)



INTERMEDIATE-SCALE FIRE TEST OF WIRES/CABLES

0

100

200

300

400

500

600

700

800

900

1000

Baseline Belden 9804Cable (PVC-

PP)

BMS13-60(PTFE-PI)

MS22759/11(TFE)

MS81044/6(XL-PA)

Silicone 200 MIL17/28-RG58 (PVC-

PE)

Hypalon Fiber Optic(PVC)

MS5086/1(Nylon-PVC)

Material ID

Tem

pera

ture

(Deg

C)

Test 1

Test 2

Test 3

Test 4




0

20

40

60

80

100

120

Baseli

neMS22

759/1

1 (TFE)

MS8104

4/6 (X

L-PA)

BMS13-60

(PTFE-P

I)Fibe

r Opti

c (PVC)

Belden

9804

Cab

le (P

VC-PP)

Silicon

e 200

Hypalo

n

MIL17/2

8-RG58

(PVC-P

E)MS50

86/1

(Nylo

n-PVC)

Material ID

Hea

t Flu

x (W

/cm

2 )





0

20

40

60

80

100

120

140

0 2 4 6 8 10 12 14 16 18 20

Maximum Extinguishing Time (min)

Max

imum

Bur

n Le

ngth

(cm

)

MS5086/1 (PVC/Nylon)MIL17/28-RG58 (PVC-PE)

Belden 9804 Cable (PVC-PP)

MS22759/11 (TFE)

MS81044/6 (XL-PA)

BMS13-60 (PTFE-PI)Legend: Green Diamond - Passed FAA 60 Deg Fire Test Red Diamond - Failed FAA 60 Deg Fire Test

Silicone 200

Fiber Optic (PVC/Kevlar)

Hypalon

Go to 60 Degree Chart




0

20

40

60

80

100

120

MS22759/11(TFE)

BMS13-60(Composite)

MS81044/6 Fiber Optic(PVC)

Silicone 200 Belden 9804Cable (PVC-

PP)

MIL17/28-RG58(PVC/PE)

MS5086/1-20-9 Hypalon

Material ID

Mas

s Lo

ss (g

)

Note: Black color denotes that the conductor was exposed after the test; the Blue color denotes that it did not.



Project Tasks % Completion = 61%Cost Performance Index = 1.02Schedule Performance Index = 0.99

Project Status



Questions?Anyone interested in joining this task group? Task group (participatory discussion) meeting tomorrow.

Final Words

Go Back

Federal Aviation Development of an Administration Improved ... · Federal Aviation Development of...

Documents

Transcript of Federal Aviation Development of an Administration Improved ... · Federal Aviation Development of...