presented to: iamftwg by: tim salter date: october 19-20, 2011, atlantic city, nj federal aviation...
DESCRIPTION
3 Federal Aviation Administration Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ 3 Summary Flow testing new nozzles –Checking for consistency in flow rates Testing nozzles in sonic burner –Nozzle clocking to check for uniform flame temperature distribution using thermocouple rake Seat cushion tests using sonic burner –Data collected using old Park burner and Monarch nozzles will be compared to data taken using new nozzles and sonic burner –Check for similarity, and adjust sonic burner to reproduce Park data resultsTRANSCRIPT
Presented to: IAMFTWG
By: Tim Salter
Date: October 19-20, 2011, Atlantic City, NJ
Federal AviationAdministrationSeat Cushion Test
Method Update
2 2Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Introduction
• Have been working to setup sonic burner for use with seat cushion test method for the purpose of replacing older style Park Burner
• Testing has been ongoing in an attempt to setup the sonic burner such that it will reproduce Park burner test results
• The advantage of the sonic burner is that it is capable of producing more consistent results than the Park burner
3 3Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Summary
• Flow testing new nozzles– Checking for consistency in flow rates
• Testing nozzles in sonic burner– Nozzle clocking to check for uniform flame
temperature distribution using thermocouple rake• Seat cushion tests using sonic burner
– Data collected using old Park burner and Monarch nozzles will be compared to data taken using new nozzles and sonic burner
– Check for similarity, and adjust sonic burner to reproduce Park data results
4 4Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
2.0 gph NexGen Burner Set-up
• Fuel Pressure: 2.0 gph (+/- 0.1 gph)• 1/8” sheathed ceramic packed K type TCs• Test using an air pressure of 45 psi
– Based on previous seat cushion test results using a 2.0 gph NexGen burner that were comparable to the Park Burner test results
5 5Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
2.0 gph NexGen Burner Setup Continued• Stator Positioning: Results
– Rotational Location• Igniter centerline located 330 degrees clockwise from zero
degrees (igniter vertical centerline)
– Axial Location• Front face of stator located 3.375 inches from front face of
turbulator
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Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
2.0 gph NexGen Burner Set-up Continued• Configuration: Muffler and 90 degree elbow
– The burner was fitted with a 90 degree elbow at the rear of the draft tube to reduce the space needed to run the device. This seemed to have an impact on the operation of the burner, and resulted in reduced TC temperatures, and erratic results. The muffler on the burner was repositioned in between the elbow and the draft tube. The muffler acts to smooth out the flow which was being disrupted by the 90 degree elbow.
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Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Muffler and Elbow Configuration
Before After
8 8Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Proposed Burner Settings
• Delevan B 2.0 gph fuel nozzle– 2.0 gph (+/- 0.1 gph)
• Air pressure: 45 psi• Stator rotation: 330 degrees from vertical
centerline• Stator location: 3.375” from turbulator exit
plane • Muffler between burner tube and elbow
9 9Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Fuel Nozzle Flow Test Rig
• Fuel is pressurized to 100 psi, and fuel is collected for one minute then stopped. The reading on the graduated cylinder shows the number of milliliters that flow in one minute. This is then converted to gallons per hour. The actual fuel flow rate can then be compared to the rated flow rate of the nozzle. A higher quality nozzle will show a lower difference between actual and rated flow rates.
10 10Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Fuel Nozzle Flow Rate• Delevan Nozzle Flow Check
– The Delevan nozzles were checked on a bench top flow testing rig. The results show, that compared to the typical Monarch nozzles, the Delevan nozzles have a much lower percent error.
– Delevan 2.0 gph error: 4.09%– Monarch 2.25 gph error: 13.59%– Further testing with different nozzles is
ongoing. • 25 Everloy 2.0 gph-rated hollow cone
nozzles were also tested, and produced results similar to the Delevan nozzles.
Average Flow Rate
1.93
1.91
1.92
1.94
1.88
1.89
1.90
1.91
1.92
1.93
1.94
1.95
1
Nozzle Type
gallo
ns/h
our
Delavan AR-DDelavan R-DDelavan BMonarch AR
Average Percent Standard Deviation of Flow Rate
2.79
1.55
0.85
4.15
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
1
Nozzle Type
% S
tand
ard
Dev
iatio
n
Delavan AR-DDelavan R-DDelavan BMonarch AR
11 11Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Delavan Nozzle Flow Test Results
• Average = 1.92• Std Dev = 0.04• %SD = 1.89%
1.871.89 1.89
1.90 1.90 1.90 1.90 1.90 1.901.92
1.93 1.93 1.93 1.93 1.931.95
1.97
2.03
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.00 8
0° R
-D 7
2.00 8
0° A
R-D 3
2.00 8
0° R
-D 11
2.00 8
0° A
R-D 2
2.00 8
0° A
R-D 4
2.00 8
0° R
-D 10
2.00 8
0° R
-D 12
2.00 8
0° B
16
2.00 8
0° B
18
2.00 8
0° A
R-D 1
2.00 8
0° R
-D 8
2.00 8
0° B
13
2.00 8
0° B
14
2.00 8
0° B
15
2.00 8
0° B
17
2.00 8
0° R
-D 9
2.00 8
0° A
R-D 5
2.00 8
0° A
R-D 6
Nozzle ID
Flow
rate
, GPH
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Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Nozzle Clocking Summary
• Monarch nozzles are not uniform around the spray cone periphery
• Delavan nozzles seem to provide more uniform spray pattern through 360° nozzle rotation– Delevan flame temperatures are lower (~100°F)
than Monarch flame– Previously recorded lower temperatures partially due
to old thermocouples– Temperatures for the Delevan nozzles increased
after replacing old thermocouples with new ones
13 13Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Burner and Nozzle Calibration
Comparison of Temperature Minimums and Maximums
1200.0
1300.0
1400.0
1500.0
1600.0
1700.0
1800.0
Monarch AR Delevan AR-D Delevan R-D Delevan B
Tem
pera
ture
(F)
14 14Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Burner and Nozzle Calibration
Average Flame Temperatures
1200.0
1300.0
1400.0
1500.0
1600.0
1700.0
1800.0
Monarch AR Delevan AR-D Delevan R-D Delevan B
Tem
pera
ture
(F)
15 15Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Seat Testing with Burner
• Sonic Burner was then used to burn seat test cushions using Delevan and Everloy Nozzles
• The Park burner was also used to test seat cushions with the Monarch nozzle
• The goal is to adjust the sonic burner such that it produces similar results as the Park burner
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Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Results
Seat Cushion Weight Loss %
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
Airflex Dax Fireblock
Cushion Type
Perc
ent W
eigh
t Los
s
Park w/Monarch 80 PLP Sonic w/Delavan AR-D
Sonic w/Delavan R-DSonic w/Delavan BSonic w/Everloy
17 17Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Thermocouple Temperature Drift
• Extreme thermal cycling can cause thermocouples to display an increased error in readings
• Exposing a SS sheathed 1/8” TC to a flame over 7 separate temperature tests showed a decrease in temperature reading of ~80 degrees Fahrenheit
• Met with representatives from TC supplier, and are working on a solution to the problem– Develop new thermocouple more suited to withstand extreme
thermal cycling• Type K thermocouples remain accurate under
constant temperatures, or conditions where temperatures do not change by hundreds of degrees in a time period of only a few seconds
18 18Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Thermocouple Average Temperatures During Burner Calibration
1200
1300
1400
1500
1600
1700
1800
1900
TC 1TC 2
TC 3TC 4
TC 5TC 6
TC 7
Avera
ge
Tem
pera
ture
(F)
Park 1/16" TC Avg
Sonic 1/16" TC Avg
Sonic 1/8" TC Avg
19 19Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Thermocouple Temperature Drift
Thermocouple #2 Temperatures for Park 1/16" TCs, Sonic 1/16" TCs, and Sonic 1/8" TCs
1600
1650
1700
1750
1800
1850
1900
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Tem
pera
ture
(F)
20 20Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
New Air and Fuel Cooling System
• Ice chest filled with ice water was not cold enough to keep fuel temperatures within specification
• New freezer setup keeps fuel temperatures within spec during summer months– Fuel not stored in temperature controlled area
• Simplified operation, longer operating periods– No longer have to keep filling chest with ice, and not
limited by capacity of ice maker
21 21Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
New Air and Fuel Cooling System
22 22Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Future Adjustments and Testing
• Continue to test using thermocouples and seat test articles
• Adjust sonic burner based on test results• Keep in consideration that not all seat test
articles are manufactured the same• Fiberboard seat cushion testing
– Fiberboard seat cushion fitted with 40 thermocouples will be used to generate a 3D temperature model
23 23Federal AviationAdministration
Seat Cushion Test Method Update IAMFTWG, October 19-20, 2011, Atlantic City, NJ
Questions?