Systems Fire Protection Working Group Taj Mahal - Atlantic City, NJ November 4, 2003 FAA Concept OBIGG System Flight Testing on NASA 747 SCA William Cavage AAR-440 Fire Safety Research Federal Aviation Administration

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Outline Goals and Objectives OBIGGs Architecture OBIGGs Installation –Pallet –NEA Deposit Instrumentation / DAS –CWT –System –OBOAS / FAS –Data Acquisition –Power Distribution Status

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Testing Goals and Objectives Prove the simplified inerting concept and validate/expand upon existing system performance models Develop/validate system sizing data Validate previous in flight inert gas distribution modeling done by FAA Measure the progression of flammability in the CWT of a typical commercial transport airplane

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D OBIGGS - System Architecture 400 deg F bleed air enters electrically controlled & operated Shut-off Valve on OBIGGS Control Box Air goes through heat exchanger by a cooling air throttling valve to control temperature manually using a ASM air input temperature sensor –Some bleed air can bypass the heat exchanger if selected Conditioned air passes through dust/oil contaminant filter Air enters ASM and has OEA separated and dumped overboard

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D OBIGGS - System Architecture (cont’d) NEA passes through high flow shut-off valve (Parker Box operator) and High/Low flow metering valves System controlled by control box in cabin that is connected to system with cable routed through wheel well –Turns system on/off –Select heat exchanger bypass on/off –Select fan on/off –Select high/low flow mode –ASM input air temperature readout

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Assembled FAA OBIGGs Drawing

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D OBIGGS - System Installation System installed in aft, right side fairing area (empty pack bay) System is mostly assembled before installation in the aircraft –Total Weight = 165 lbs System attaches to fairing structure at six locations with specially design mounting brackets –Brackets designed by Shaw for canceled FAA joint flight test with Boeing –4 main brackets pick up existing fastener holes but two secondary brackets need to have holes drilled in stringer System wired to control box in cabin via a cable which attaches to the system 41-pin connector –Powers/controls system components

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D OBIGGS - System Installation (cont’d) System interfaces with bleed system via a main bleed duct manifold in that area –4-foot segment from SCA is removed and FAA segment installed –Needs to align precisely with system bleed air input fitting System cooling air passes in a scoop and out the outflow box –Two FAA panels with these parts already mated with aircraft

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Top View of System Installed Inboard Aircraft Structure Outboard Aircraft Structure

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Simplified OBIGG System Installation

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Empty Pack Bay Before/After System Installation

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D OBIGGS - Deposit System Install deposit “T” and dual isolation valves allows for improved functionality of testing (counter-wire valves) –Install a “T” in system NEA deposit –1 side of “T” goes to outflow box via a normally closed isolation valve –Other side of “T” goes to flow meter, check valve, and a second normally open isolation valve Install AN bulkhead fitting in replaced pack bay canted bulkhead panel –Route NEA from check valve to fitting with flexible hose

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Deposit System Overview

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D NEA Deposit “T”

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Flow Meter/Deposit Installation

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D NEA Diversion Valve Installation

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D To deposit NEA in tank without permanent modification replaced purge door with “instrumentation panel” that passes the NEA, thermocouples, and gas samples (not FAS) into the tank from the wheel well adjacent to the pack bay –NEA fitting is 1” SwageLok Bulkhead Fitting NEA routed to deposit nozzle mounted in the top of tank in Bay 6 (aft, right bay) via a 1-inch flexible line –nozzle mounted in bracket attached to aircraft stiffener bracket between strings at top of tank Also Blocked Half Vent System OBIGGS - Deposit System (cont’d)

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Install Instrumentation Port

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Existing Stringer/Stiffener/Bracket Assembly

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Install NEA Deposit Nozzle and Associate Hardware

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Install Vent Blocking Plates

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Instrumentation and Data Acquisition Various thermocouples and pressure transducers used –Evaluate system performance –Measure tank flammability parameters OBIGGS system flow meter and 2-channel oxygen analyzer for NEA and OEA analysis Onboard Oxygen Analysis System (OBOAS) most critical measurements –8-channel system analyzes 8 locations in tank Flammability Analysis System (FAS) will measure progression of CWT flammability in flight –1 location in forward section of tank

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D CWT Instrumentation Installation Instrumentation in the CWT of the NASA SCA –Install Instrumentation Panel in Place of Purge Door –Route and Mount Thermocouples –Install Sample Port Float Valve Assembly and Route Lines as well as sample return lines Sub-Contractor (FFC) supported FAA installation –Highly experienced in this type of work –Statement of Work gives more details

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Route and Mount Thermocouples

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Install Sample Port Float Valve Assembly

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Instrumentation - Additional Thermocouples Use 16th Inch SS Sheath T-Type Thermocouple Probes Install one in each used pack bay and one in the OBIGGS pack bay Install 4 in the area of the bleed air connection –Monitor for Bleed Air Leaks System has 6 thermocouples installed Thermocouple in cabin Thermocouples in measurement systems (OBOAS/FAS)

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Measure Absolute Pressure at 4 locations on OBIGGS and measure static pressure in pack bay –Potential to add 1 to bleed manifold if possible Purchase off-the-shelf lab pressure transducers –Sensotec TJE Precision, Absolute series –Run on 28 VDC, 12 VDC nominal bridge voltage, internally regulated –0-5 VDC output Mount transducers on panel in cabin –Run 5 sense lines to pack bay Instrumentation - Pressure Transducers

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Thermocouple Probe and Pressure Transducer

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Instrumentation - NEA Flow Meter Engineered Specifically for The FAA OBIGGS –Designed from Existing Commercial and Military Assemblies by FCI –Flight worthy instrumentation (No TSO) –Uses vortex shedding heat release principal –Also measures absolute temperature and pressure of flow 1” diameter flow tube integrates with existing deposit system on pallet

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Flow Meter

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D System Instrumentation Diagram Static Pressure Temperature Spare [O 2 ] Static Pressure Temperature OEA [O 2 ] Temperature Static Pressure Temperature Temperature (FAA Reader) Static Pressure Temperature NEA [O 2 ] Penetration Hole

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Instrumentation - OBOAS Two 4-Channel Systems Measure Oxygen Concentration Continuous at 8 Different Fuel Tank Locations –Large diaphragm pump draws sample –Actively controls sample inlet and outlet pressure. –Flow through sensor design –Fluid traps, Ejector/Evacuator, Flame Suppressors for Safety Mounts in standard 19” flight test half rack including sample system (OBUSS) contained in large, purged box

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D OBOAS Block Diagram Fuel Tank Vapor Fuel Tank Liquid Pressurized Air Electrical Power Electronic Signals

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D OBOAS Mounted in FAA AMCO Racks

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Instrumentation - FAS System uses a Non-Dispersive Infrared Analyzer (NDIR) to measure fuel tank flammability in the form of total hydrocarbons (THC) Sample stream must be heated at all points leading to the NDIR to prevent condensation of fuel vapors –This is achieved in part via three heated hoses Installs in a rack and pallet for flight test

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Cabin Instrumentation/Rack Diagram

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Power Distributed to the Various Equipment from Utility Rack at ST. 990 –3-Phase 115 VAC 400Hz to Each OBOAS (13 amps/leg) –20 Amps of 115 VAC 60 Hz to FAS –5 Amps of 115 VAC 60 Hz to DAS and Computer –OBIGGS takes 5 Amps 28 VDC and 3-Phase 115 VAC, 400Hz (5 Amps/ Leg) Each OBOAS converter is tied to a switching unit that allows for power to be distributed between racks and to the OBIGGS O 2 analyzer Instrumentation - Power Distribution

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Power Distribution Diagram

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D IOtech Ethernet Based Daqbook –16-bit 200 kHz A/D Converter –Daisy chains slave units with 3-boards each –Expandable up to 256 channels Specified approximately 78 channels of data –CWT / OBOAS/ FAS - 48 channels –System Instrumentation - 15 channels –Misc. Temperatures - 9 channels –Aircraft Parameters - 2 channels Data Acquisition System

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D Data Acquisition System Data Daqbook / 2000E DBK60 Expansion

FAA-NASA 747 Inerting Flight Test ___________________________________ AAR-440 Fire Safety R&D CWT installation approved and completed OBIGGs, OBOAS, FAS, instrumentation/racks, & DAS installation approved –One sticking point OBOAS modified from Airbus testing and FAS completed Additional parts purchased NEA deposit completed, Instrumentation racks built up Preparing to ship all equipment for installation Status