Progress report of TFG 7 “Fire resistance test” May 14, 2014 Korea Transportation Safty Authority (TS) Korea Automobile Testing & Research Institute (KATRI) Hyuk JUNG, Chief Researcher 5 th EVS Informal Meeting

Table of Contents Future Plan of TFG Progress Report of KATRI Research 2 2 Status of TFG 7 Activity 1 1

Study and discuss component based fire resistance test procedure of REESS which has been proposed by Korea as an alternative. Specification of optimized test equipment to fire resistance test conditions Justification for the temperature and thermal energy of fire resistance test(A) compared to those of GTR draft(B) Allowance of installation of additional protection device on REESS pack during the test Any issues addressed in the process of discussion about fire resistance Review the applicability of fire resistance test(A) to vehicle based test 1. Status of TFG 7 Activity Task 1/27

We had started discussion by from 13th Feb. We aggregated comments and questions from member of TFG 7 and reflect those to KATRI’s study scope. Circulate the draft of TFG TOR by leader with members : 13th Feb. Collect an opinion about the draft of TFG TOR from members : ~March. KATRI give members feedback on members’ responses : 8th Apr. Collecting an additional opinion Comment by Japan(JARI) : 21st Apr. Comment by China(CATRC) : 29th Apr. 1. Status of TFG 7 Activity Activity 2/27

Japan The fire resistance test should simulate a catching fire from the road surface The height of flame to the battery pack Vehicle-based test procedures are necessary OICA The motives/justification for the changes in the ECE R test procedure Equivalency between two component based test procedures, A and B Material/data explaining and justifying the threshold of 800°C Necessity of applying test(A) to vehicle based test China Equivalency between two component based test procedures, A and B The height of flame to the battery pack IF the test A is suitable for components, we can consider Vehicle-based test 1. Status of TFG 7 Activity Member’s Opinion 3/27

1) CFD simulation about current test-equipment of KATRI : Finished 2) Study on justification for the temperature and thermal energy of the fire resistance test(A) compared to those of GTR draft(B) : Ongoing 3)Develop an optimized solution of current test equipment by CFD simulation : Ongoing 4) Modify the current test equipment and performance test : Not yet 5) Allowance of installation of additional protection device on REESS pack during the test : Finished 6) Review the applicability of test(A) to vehicle based test : Not yet ☞ IF the test A is suitable for components, we will consider this 4/27 In Component based test, test-device should include additional protection device while fire resistance test which is stated as [3.35. "Tested-Device" means either the complete REESS or the subsystem of a REESS that is subjected to the tests prescribed by this regulation.] and [3.30 The REESS may include subsystem(s) together with the necessary ancillary systems for physical support, thermal management, electronic control and casing] 1. Status of TFG 7 Activity Study Status of TFG 7

2. Progress Report of KATRI Research Study Process 5/27  Study Item #1 Study on justification for the temperature and thermal energy of the fire resistance test(A) compared to those of GTR draft(B) CFD simulation about current test equipment of KATRI Verify CFD simulation result of test (A) (Using the temp. data of KATRI’s fire resistance test A) Develop a optimized solution of current test equipment of KATRI by CFD simulation Modify the current test-equipment according to total optimization solution Verify performance of modified test-equipment (Fire resistance test A with mockup, Temp. measuring) CFD simulation about test A & B in same condition (with Mockup) KATRI indoor fire resistance test (B) Verify CFD simulation result of test (B) (Using the temp. data of KATRI’s fire resistance test B) CFD simulation about test A & B in same condition (with Mockup) CFD simulation about fire resistance test (B) condition Temperature and thermal energy of the fire resistance test(A) compared to those of GTR draft(B)

KATRI indoor fire resistance test (B) 6/27 2. Progress Report of KATRI Research Test Site : Korea Institute of Construction Technology (KICT) / Fire Research Center Size : 30m(W) × 38m(L) × 39m(H), - Floor area : 1,140㎡ Dust collection equipment : 150,000 m 3 /hr Hood : Ø 10 m Test configurations Descriptions * Mock-up simulates real REESS size - Small : 300×200×300 mm, Floor area : 0.06 ㎡ - Large : 1,000×1,000×200 mm, Floor area : 1 ㎡ * Pool size & Fuel quantity(25ℓ/m 2 ) - Small (0.42㎡) : 700 × 600 × 130 mm, 10.5ℓ - Large (2.25㎡) : 1,500 × 1,500 × 130 mm, 56.25ℓ - water 25 mm, Fuel 25 mm * DAQ get 25 temp. channel -10, 30, 50, 70, 100cm above the Fuel surface - horizontally 5 points at each height - K-Type Thermocouple : ∅1.6mm, L: 1300mm

7/27 2. Progress Report of KATRI Research Horizontally 5 points

8/27 2. Progress Report of KATRI Research Test condition Small & Large pool / Free burning & with Mock-up condition: total 4 conditions Flame temperature measuring continuously from ignition to natural extinguishing Ambient Temperature : about 20 ℃ Test scene Hood height : 6m Frame height : 2~3m Hood height : 7m Frame height : 4~6m Air flow : 0.02~0.33 m/s

9/27 2. Progress Report of KATRI Research Test result

10/27 2. Progress Report of KATRI Research Test result

11/27 Test Equipment (Front view) Test Equipment (Rear view) Part of burning Nozzle Mock-up DUT x 605 x 206 mm Install of Thermocouple - K-Type, 1.5 mm - place : 25 mm Measuring of Temp. - 5 point Temp. distribution ℃ Reaching : 14 sec -Total Avg. Temp. : 914 ℃ - Temp. Range : 840 ~ 1050 ℃ 2. Progress Report of KATRI Research KATRI test result of test (A) ( Reference EVS )

12/27 3. Progress Report of KATRI Research - FDS software: The Fire Dynamics Simulator (FDS) and Smoke view are the products of an international collaborative effort led by the National Institute of Standards and Technology (NIST) and VTT Technical Research Centre of Finland. Fire Dynamics Simulator is a computational fluid dynamics (CFD) model of fire-driven fluid flow. FDS solves numerically a form of the Navier-Stokes equations appropriate for low-speed (Ma < 0.3), thermally-driven flow with an emphasis on smoke and heat transport from fires. FDS has been aimed at solving practical fire problems in fire protection engineering, while at the same time providing a tool to study fundamental fire dynamics and combustion. This software is used for simulating the gasoline pool-burning. - ANSYS FLUENT software: ANSYS Fluent software contains the broad physical modeling capabilities needed to model flow, turbulence, heat transfer, and reactions for industrial applications ranging from air flow over an aircraft wing to combustion in a furnace, from bubble columns to oil platforms, from blood flow to semiconductor manufacturing, and from clean room design to wastewater treatment plants. ANSYS Fluent incorporates a comprehensive suite of reacting flow-modeling capabilities and simulate gaseous reactions using either reduced or complex chemistry. Pollutant models are built in to allow easy and accurate pollution emission predictions for NO, SO and soot. This software is used for simulating the LPG burner-burning. Introduction of CFD simulation tools CFD simulation

Verify CFD simulation result of test (B) 13/27 2. Progress Report of KATRI Research Small pool-Free burning Simulation [By FDS Software]

14/27 2. Progress Report of KATRI Research Small pool-Free burning Small pool- Burning with Mockup

15/27 3. Progress Report of KATRI Research Large pool-Free burning Large pool- Burning with Mockup

Develop an optimized solution of current test equipment by CFD simulation - Ongoing 16/27 3. Progress Report of KATRI Research LPG Burner-Burning with Mockup Simulation <LPG Burner-Burning with Small Mockup CFD simulation result (Middle of Mockup)> <LPG Burner-Burning with Large Mockup CFD simulation result (Middle of Mockup)> [By ANSYS FLUENT Software]

Develop a totally optimized solution of current test equipment of KATRI by CFD simulation 17/27 2. Progress Report of KATRI Research LPG Burner-Burning with Mockup Simulation

18/27 2. Progress Report of KATRI Research Test (B)Heat Flow[kW] at 50cm ParameterPhase BPhase C Small Mockup2620 Large Mockup Test (A)Heat Flow[kW] ParameterDirect exposure Small Mockup16.50 Large Mockup Phase B Phase C Phase B Phase C Heat Flow by CFD simulation in the pool-burning and LPG Burner-Burning with Mockup Heat flow is defined: where c p is specific heat, T is temperature and ρu∙dS is mass flow rate. Thermal energy comparison of test(A) with GTR draft(B)

Thermal energy comparison of test(A) with GTR draft(B 19/27 2. Progress Report of KATRI Research Test (A)Direct exposure, 120[s]Pre-heating15[s] ☜ 800 ℃ Reaching Time SUM Parameter Heat Flux [kW/m 2 ] Thermal Energy [kJ/m 2 ] Thermal Energy [kJ/m 2 ] Total Energy [kJ/m 2 ] Small Mockup27532,9924,12437,116 Large Mockup11814,1581,77015,928 Total Energy per unit area by CFD simulation Test (B)Phase B, 70[s]Phase C, 60[s]SUM Parameter Heat Flux [kW/m 2 ] Thermal Energy [kJ/m 2 ] Heat Flux [kW/m 2 ] Thermal Energy [kJ/m 2 ] Total Energy [kJ/m 2 ] Small Pool43330, ,33353,667 Large Pool16011, ,35018,550

2. Progress Report of KATRI Research Study Process 20/27  Study Item #2 Study on Specification of optimized test equipment to test conditions of fire resistance test(A) CFD simulation about current test equipment of KATRI Verify CFD simulation result (Using the temp. data of KATRI’s fire resistance test A) Develop a optimized solution of current test equipment of KATRI by CFD simulati on : Ongoing Modify the current test-equipment according to total optimization solution Verify performance of modified test-equipment (Fire resistance test A with mockup, Temp. measuring) Present the results of intermediate study Expected to be finished by June

2. Progress Report of KATRI Research Specification of optimized test equipment – Not yet 21/27 The height from the nozzle to the bottom of DUT : 300 mm

2. Progress Report of KATRI Research 22/27 Optimized conditions Nozzle spacing : 75 mm Number of Nozzle : 500 EA LPG mass flow rate: 120 kg/h LPG Supply Pressure : 2,215 Pa

Result for KATRI indoor fire resistance Test(B) This test shows a large deviation of flame temperature from 500℃ to 1000℃, according to measured positions at the same height. The average temperature of center area at each height is a little bit higher then or similar to frame temperature of “Technical Justification No 45” on EVS GTR draft. At EVS-02-07, the flame temperature of Test(A) is 840~1050 ℃ during 2 minutes and average flame temperature is 940 ℃. Verify CFD analysis result of test(B) The flame pattern and the temperature is similar to actual data of KATRI. CFD simulation result of test(A) Some area under 800℃ can be solved the improvement of test equipment by fuel quantity control later. 23/27 Comments for ‘Fire resistance test’ 2. Progress Report of KATRI Research

CFD analysis result of total thermal energy per unit area of mockup The total thermal energy of test (A) is 37,000 kJ/m 2 for small size mockup and 16,000 kJ/m 2 for large size mockup and in the case of test (B) is 54,000 kJ/m 2 at small and 18,000 kJ/m 2 at large. The thermal energy per unit area of test (B) is 44% higher than test (A) for the small, the test (B) is 16% higher than test (A) for the large. Both of total thermal energy per unit area of test (A) and (B) for small mockup are higher than the result for large mockup. In case of test (A), the test result can be changed when the CFD analysis finishes after optimization of test equipment and test conditions.. 24/27 Comments for ‘Fire resistance test’ 2. Progress Report of KATRI Research

3. Future Plan of TFG 7 25/27 Open issues 1. Study on Specification of optimized test equipment to test conditions of fire resistance test (A) Decision of the height of flame to the battery pack and the horizontal areas of flame 2.Modify the current test equipment according to total optimization solution 3. Verify performance of modified test-equipment (Fire resistance test A with mockup, Temp. measuring) 4. Review the applicability of test(A) to vehicle based test 5. Propose the equivalent test conditions of test A and B

3. Future Plan of TFG 7 26/27 Future Work After the end of KATRI's research, TFG 7 will discuss all issues of fire resistance test through teleconference or F2F meeting - From June or July And then TFG 7 propose the equivalent test conditions of test A and B with specification of optimized test equipment to test A conditions : - In 6 th EVS informal meeting.

Thank you!