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Tim MarkerFAA Technical Center
Development of a Lab-Scale Test For Evaluating Toxicity of Burnthrough Compliant
Insulation Systems
Fuselage Burnthrough Chronology
Full-sale test article built at FAATC in mid 1990’s for evaluating performance ofburnthrough-resistant thermal acoustic insulation materials.
Testing indicated burnthrough-resistant insulation provided a much moresurvivable cabin atmosphere when compared to current insulation materials.
Although burnthrough resistant materials provide a benefit, the ingress of toxicgases resulting from decomposition of the insulation needs to be quantified.
FAA issued NPRM, 2003 Final Rule issued, 2009 compliance.
2005 FAATC began development of a lab-scale test for evaluating toxicgas decomposition products that could be generated inside fuselageduring a postcrash fire.
It is anticipated that this test method could be used to evaluate the potential toxicity of insulation constructions and innovations meetingthe new burnthrough test requirements, in order to ensure that an adverse condition will not result inside an intact fuselage when exposed to an external fuel fire, despite the high burnthrough performance associated with a particular system.
Development of Lab-Scale Toxicity Test ForDecomposition Products During a Postcrash Fire
This test method could also be used to evaluate the toxic contribution of the basic fuselage structure, whenever a nonmetallic material is used as the primary component.
Conduct lab-scale burnthrough test on 2 types of burnthrough resistantinsulation, and 1 type of structural composite material (without insulation).Measured the build-up of toxic and flammable gases within an enclosuresimulating a fuselage
Conduct subsequent full-scale tests with identical insulation materials toestablish realistic baseline data using FTIR.
Methodology
Determine concentration scaling factor between lab and full-scale tests inorder to develop appropriate pass/fail criteria for lab-scale test.
complete
complete
pending
Apparatus for Evaluating Toxic Gas Decomposition Products
catch pan for melted aluminum skin
Apparatus for Evaluating Toxic Gas Decomposition Products
Fourier Transform Infrared (FTIR)/Total Hydrocarbon Gas analysis systemused to collect and measure toxic and flammable gases yielded during tests.
Burner configuration according to 25.856(b) Appendix F, Part VII.
Steel cube box simulates intact fuselage and serves as enclosure to collectemitted gases.
Additional analyzers measured the concentration of carbon monoxide,carbon dioxide, oxygen, and total hydrocarbons (THC) as propane.
Lab-Scale Apparatus for Evaluating Toxic Gas Decomposition Products
FTIR and THC Sampling System Used in Lab-Scale Testing
What is FTIR Spectroscopy?
What is FTIR Spectroscopy?
What is FTIR Spectroscopy?
Calibration Spectra and Selected Regions for FTIR Analysis
CO
CO2
H2O
Hydrocarbons
COF2COS
C3H8
HBr, HCl, HFHCN
NH3
Aniline, Acrolein, Benzene, Phenol
N2O, NO and NO2
COCl2
SO2
Gases Measured By FTIR
Flammable Gases
C2H2 Acetylene
C2H4 Ethylene
C2H6 Ethane
C3H8 Propane
C6H5NH2 Aniline
C6H5OH Phenol
C6H6 Benzene
CH2CHCHO Acrolein
CH4 Methane
Other Gases
CO2 Carbon Dioxide
H2O Water
N2O Nitrous Oxide
Sulfur DioxideSO2
Nitrogen DioxideNO2
Nitrogen OxideNO
AmmoniaNH3
Hydrofluoric AcidHF
Hydrogen CyanideHCN
Hydrogen ChlorideHCL
Hydrogen BromideHBr
Carbonyl SulfideCOS
Carbonyl FluorideCOF2
PhosgeneCOCl2
Carbon DioxideCO2
Carbon MonoxideCO
MethaneCH4
AcroleinCH2CHCHO
BenzeneC6H6
PhenolC6H5OH
AnilineC6H5NH2
Toxic Gases
Material Systems Tested in Lab-Scale Apparatus
Spectra at 5 Minutes
SO2
051213 ACM-- Box Test 6-- Open Box
0
50
100
150
200
250
0 10 20 30 40 50
Time (seconds)
Oth
er G
ases
(pp
m)
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
H2O
and CO
2 (ppm)
C2H2 C2H4 C2H6 C3H8 C6H5NH2 C6H5OH C6H6 CH2CHCHO CH4 CO COCl2 COF2 COS HBr HClHCN HF N20 NH3 NO NO2 SO2 CO2 water
Open Box (Baseline) Test Using FTIR Analysis
051213 Box Test 6- Open Box
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0 5 10 15 20 25 30 35Time (seconds)
Oth
er G
ases
(Pe
rcen
t)
0
2
4
6
8
10
12
14
16
18
CO
2 and O2 D
epletion (Percent)
COTHC as Propane CO2O2 Depletion
Open Box (Baseline) Test Using Gas Analyzers
Comparison of FTIR and Gas Analyzers for Open Box (Baseline) Test Lab Scale Test Open Box (Baseline)
Comparison of FTIR and Gas Analyzers @ 35 Seconds
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
CO CO2 THC
Gas
Yie
lds
@ 3
5 Se
cond
s (p
pm)
FTIRGas Analyzers
051213 Box Test 5-- PAN/ Metalized PVF
0
50
100
150
200
250
300
350
400
450
500
0 60 120 180 240 300
Time (seconds)
Oth
er G
ases
(pp
m)
0
5,000
10,000
15,000
20,000
25,000
CO
, CO
2 and H2O
(ppm)
C2H2 C2H4 C2H6 C3H8 C6H5NH2 C6H5OH C6H6 CH2CHCHO CH4 COCl2 COF2 COS HBr HClHCN HF N20 NH3 NO NO2 SO2 CO CO2 water
PAN Insulation Test Using FTIR Analysis
051213 Box Test 5- PAN/Metalized PVF
0
1
2
3
0 60 120 180 240 300Time (seconds)
CO
, CO
2 an
d O
2 D
eple
tion
(Per
cent
)
0
0.02
0.04
0.06
0.08
0.1
0.12
Total Hydrocarbons as Propane
(Percent)
CO CO2 O2 depletion THC as Propane
PAN Insulation Test Using Gas Analyzers
051212 Box Test 2-- FG/Ceramic Barrier/Metalized PVF
0
50
100
150
200
250
300
350
400
450
500
0 60 120 180 240 300Time (seconds)
Oth
er G
ases
(pp
m)
0
5,000
10,000
15,000
20,000
25,000
CO
, CO
2 and H2O
(ppm)
C2H2 C2H4 C2H6 C3H8 C6H5NH2 C6H5OH C6H6 CH2CHCHO CH4 COCl2 COF2 COS HBr HClHCN HF N20 NH3 NO NO2 SO2 CO CO2 water
FG/Ceramic Barrier Insulation Test Using FTIR Analysis
051208 ACM-- Box Test 1
0
10
20
30
40
50
60
70
80
0 60 120 180 240 300T ime (seconds)
Oth
er G
ases
(pp
m)
0
500
1000
1500
2000
2500
3000
3500
4000
H2O
and CO
2 (ppm)
C 2H 2 C 2H 4 C 2H 6 C 3H 8 C 6H 5NH 2 C 6H 5OH C 6H 6 C H 2C H C H O C H 4 C O C OC l2 C OF2 C OS H B r H C lH C N H F N 20 N H 3 N O N O2 SO2 C O2 w ater
Structural Composite Material Test Using FTIR Analysis
Comparison of Box Test Results at 5 Minutes
0
5,000
10,000
15,000
20,000
25,000
CO CO2 H20 THC as Propane
Gas
Yie
lds
(ppm
)
PAN/Metallized PVFFG/Ceramic Barrier/Metallized PVFStructural Composite
Comparison of Box Test Results at 5 Minutes
0
50
100
150
200
250
300
350
400
450
500
C6H5N
H2 C6H
5OH
C6H6
CH2CHCHO COCl2 COF2
COS HBr HClHCN
HF N20
NH3
NO NO2 SO2
Gas
Yie
lds
(ppm
)
PAN/Metallized PVFFG/Ceramic Barrier/Metallized PVFStructural Composite
Development of a Laboratory-Scale Test for Evaluating the Decomposition Products Generated Inside an Intact Fuselage During a Simulated Postcrash Fuel Fire Timothy R. Marker Louise C. Speitel April 2007 DOT/FAA/AR-TN07/15 This document is available to the public through the National Technical Information Services (NTIS), Springfield, Virginia 22161
U.S. Department of Transportation Federal Aviation Administration te
tec
hnic
al n
ote
tech
nica
Full-Scale Test Article for Evaluating Toxicity of BurnthroughCompliant Insulation Systems and Non-Metallic Fuselage Structure
Full-Scale Test Article for Evaluating Toxicity of BurnthroughCompliant Insulation Systems and Non-Metallic Fuselage Structure
Full-Scale Test Article for Evaluating Toxicity of BurnthroughCompliant Insulation Systems and Non-Metallic Fuselage Structure
Full-Scale Test Article for Evaluating Toxicity of BurnthroughCompliant Insulation Systems and Non-Metallic Fuselage Structure
FTIR and THC Sampling System Used in Full-Scale Testing
Full-Scale Test ResultsPAN Insulation System
Full-Scale Test Results, PAN Insulation System
Full-Scale Test Results, PAN Insulation SystemPre-test
Full-Scale Test Results, PAN Insulation SystemPost-test
Full-Scale Test Results, PAN Insulation SystemPost-test
Full-Scale Results, PAN Insulation, Gas AnalyzersCarbon Monoxide Levels
0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
0.045
0.050
0 60 120 180 240 300 360 420
Time (Seconds)
% C
arbo
n M
onox
ide
% CO Mid 5'6"% CO Fwd 5'6"% CO Fwd 3'6"
PAN Insulation, already corrected
Carbon Dioxide Levels
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
0 60 120 180 240 300 360 420
Time (Seconds)
% C
arbo
n D
ioxi
de
% CO2 Mid 5'6"% CO2 Fwd 3'6"
PAN Insulation, already corrected
Full-Scale Results, PAN Insulation, Gas Analyzers
Full-Scale Test PAN Metallized PVF (10/25/2007)Mid Station at 5' 6"
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
0 60 120 180 240 300 360
Time (Seconds)
Oth
er G
ases
(ppm
)
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
CO
, CO
2 , and H2 O
(ppm)
C2H2 C2H4 C2H6 C3H8 C6H5NH2 C6H5OH C6H6 CH2CHCHO CH4 COCl2 COF2 COS HBR HCL HCN HF N20 NH3 NO NO2 SO2 CO CO2 water
Full-Scale Results, PAN Insulation, FTIR
Full-Scale Test PAN Metallized PVF (10/25/2007)Forward Station at 5'6"
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
0 60 120 180 240 300 360
Time (Seconds)
Oth
er G
ases
(ppm
)
0
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
CO
, CO
2, an
d H
2O (p
pm)
C2H2 C2H4 C2H6 C3H8 C6H5NH2 C6H5OH C6H6 CH2CHCHO CH4 COCl2 COF2 COS HBR HCL HCN HF N20 NH3 NO NO2 SO2 CO CO2 water
Full-Scale Results, PAN Insulation, FTIR
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
CO CO2 H20 THC asPropane
OxygenDepletion
Gases
Gas
Yie
lds
@ 5
Min
utes
(ppm
)Mid Station at 5'6"
Fwd Station at 5'6"
Full Scale Test PAN/ Met PVF (10/25/2007)
Full-Scale Results, PAN Insulation, FTIR
Full Scale Test PAN/Met PVF (10/25/2007)Comparision of FTIR and Gas Analyzer Results at 300 Seconds
Mid Station at 5'6"
0
200
400
600
800
1000
1200
1400
1600
1800
2000
CO CO2 THC as Propane
Gases
Gas
Yie
lds
(ppm
)
FTIR Gas Analysers
Full-Scale Results, PAN Insulation, Comparison
Full-Scale Test ResultsCeramic Barrier Insulation System
(Initial Configuration)
Full-Scale Test Results, Ceramic Barrier Insulation System IPre-test
Full-Scale Test Results, Ceramic Barrier Insulation System IPost-test
Full-Scale Test Results, Ceramic Barrier Insulation System IPost-test
Full-Scale Test ResultsCeramic Barrier Insulation System
(Modified Configuration)
Full-Scale Test Results, Ceramic Barrier Insulation System IIPre-test
Full-Scale Test Results, Ceramic Barrier Insulation System II
Full-Scale Test Results, Ceramic Barrier Insulation System IIPost-test
Full-Scale Test Results, Ceramic Barrier Insulation System IIPost-test
Full-Scale Test Results, Ceramic Barrier Insulation System IIPost-test
Full-Scale Test Results, Ceramic Barrier Insulation System IIPost-test
Full-Scale Results, Ceramic Barrier Insulation II, Gas Analyzer Carbon Monoxide Levels
0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
0.045
0.050
0 60 120 180 240 300 360
Time (Seconds)
Car
bon
Mon
oxid
e (%
)
CO MID 5'6"CO FWD 5'6"CO FWD 3'6"
FG/Nextel 2nd test, already corrected for lag
Carbon Dioxide Levels
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0 60 120 180 240 300 360
Time (Seconds)
Car
bon
Dio
xide
(%)
CO2 MID 5'6"CO2 MID 3'6"CO2 FWD 5'6"CO2 FWD 3'6"
FG/Nextel 2nd test, already corrected for lag
Full-Scale Results, Ceramic Barrier Insulation II, Gas Analyzer
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
CO CO2 H20 THC asPropane
OxygenDepletion
Gases
Gas
Yie
lds
@ 2
60 S
econ
ds (p
pm)
Mid Station at 5'6"
Fwd Station at 5'6"
Full Scale Test Nextel/FG/met PVF (2/22/2008)
Full-Scale Results, Ceramic Barrier Insulation II, FTIR
Full Scale Test Nextel/FG/Met PVF (2/22/2008)Comparision of FTIR and Gas Analyzer Results at 260 Seconds
Mid Station at 5'6"
0
500
1000
1500
2000
2500
3000
CO CO2 THC as Propane
Gases
Gas
Yie
lds
(ppm
)
FTIR Gas Analysers
Full-Scale Results, Ceramic Barrier Insulation II, Comparison
Full-Scale Test ResultsStructural Composite System
Full-Scale Test Results, Structural Composite SystemPre-test
Full-Scale Test Results, Structural Composite System
Full-Scale Test Results, Structural Composite System
Full-Scale Test Results, Structural Composite SystemPost-test
Full-Scale Test Results, Structural Composite SystemPost-test
Full-Scale Test Results, Structural Composite SystemPost-test
Full-Scale Results, Structural Composite, Gas AnalyzerCarbon Monoxide
0.000
0.002
0.004
0.006
0.008
0.010
0.012
0.014
0.016
0.018
0.020
0 60 120 180 240 300 360 420 480
Time (Seconds)
Car
bon
Mon
oxid
e (%
)
CO Mid 5'6"CO FWD 5'6"CO FWD 3'6"
Carbon/Epoxy, already corrected for lag
Carbon Dioxide Levels
0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
0.045
0.050
0 60 120 180 240 300 360 420 480
Time (Seconds)
Car
bon
Dio
xide
(%)
CO2 Mid 5'6"CO2 FWD 3'6"
Carbon/Epoxy, already corrected for lag
Full-Scale Results, Structural Composite, Gas Analyzer
Full Scale Test Structural Composite (11/28/2007)Mid Station at 5'6"
0
5
10
15
20
0 60 120 180 240 300 360 420Time ( Seconds)
Oth
er G
ases
(ppm
)
0
500
1000
1500
2000
2500
3000
3500
4000
CO
2 and H20 (ppm
)
C2H2 C2H4 C2H6 C3H8 C6H5NH2 C6H5OH C6H6 CH2CHCHO CH4 CO COCl2 COF2 COS HBR HCL HCN HF N20 NH3 NO NO2 SO2 CO2 water
Full-Scale Results, Structural Composite, FTIR
0
100
200
300
400
500
600
700
CO CO2 H20 THC asPropane
OxygenDepletion
Gases
Gas
Yie
lds
@ 5
Min
utes
(ppm
)Mid Station at 5'6"
Fwd Station at 5'6"
Full Scale Test Structural Composite (11/28/2007)
Full-Scale Results, Structural Composite, FTIR
Full Scale Test Structural Composite (11/28/2007)Comparision of FTIR and Gas Analyzer Results at 5 Minutes
Mid Station at 5'6"
0
20
40
60
80
100
120
140
160
CO CO2 THC as Propane
Gases
Gas
Yie
lds
(ppm
)FTIR Gas Analysers
Full-Scale Results, Structural Composite, Comparison
Full-Scale Results, Comparison of 3 Insulation Systems
0
500
1000
1500
2000
2500
3000
CO CO2 THC as Propane HCN
Gas
Yie
lds
@ 5
Min
utes
(ppm
)
PAN/ Metallized PVFCeramic Barrier/ FG/ Matallized PVFStructural Composite
What do we do with all this data?
How does data compare to small scale results?
Determination of Full Scale Test Article Volume
Determination of Gas Concentration Scaling Factor
Ratio of VolumeBox to Burn AreaBox = 60.33 ft3 / 9.25 ft2 = 6.52
Ratio of VolumeFSTest to Burn AreaFSTest = 9258.1 ft3 / 64 ft2 = 144.7
Ratio of Full Scale to Lab Scale = 144.7 / 6.52 = 22.2
Theoretical Lab Scale Box Concentration is 22.2 Times Greater than Full Scale Concentration
Full-Scale Test Article has 22.2 Times More Volume per Burn Area than Lab Scale Box
Gas Concentration Scaling, PAN Insulation System
0
10
20
30
40
50
60
70
80
90
100
C6H5N
H2 C6H
5OH
C6H6
CH2CHCHO COCl2 COF2
COS HBr HClHCN
HF N20
NH3 NO NO2 SO2
COCO2H20
THC as Pro
pane
Oxygen
Dep
letion
Gases
Box
Tes
t Yie
lds/
Ful
l Sca
le Y
ield
sFire Side at 5'6"Forward at 5'6"
PAN/Met PVFScaling Divisors @ 5 Minutes
Gas Concentration Scaling, Ceramic Barrier Insulation System
05
1015202530354045505560657075808590
C6H5N
H2 C6H
5OH
C6H6
CH2CHCHO COCl2 COF2
COS HBr HClHCN
HF N20
NH3 NO NO2 SO2
COCO2H20
THC as Pro
pane
Oxygen
Dep
letion
Gases
Box
Tes
t Yie
lds/
Ful
l Sca
le Y
ield
s
Mid Station at 5'6"Fwd Station at 5'6"
Nextel/FG/met PVFScaling Divisors @ 260 Seconds
Gas Concentration Scaling, Structural Composite System
0
5
10
15
20
25
30
35
40
45
50
C6H5N
H2 C6H
5OH
C6H6
CH2CHCHO COCl2 COF2
COS HBr HClHCN
HF N20
NH3 NO NO2 SO2
COCO2H20
THC as Pro
pane
Oxygen
Dep
letion
Gases
Box
Tes
t Yie
lds/
Ful
l Sca
le Y
ield
s Mid Station at 5'6"Fwd Station at 5'6"
Structural CompositeScaling Divisors @ 5 Minutes
Gas Concentration Scaling, Findings
Analysis only considers volumetric aspects
Analysis assumes perfect mixing
Analysis does not consider surface area effects
Not all of gases scale similarly (example: COS)
Primary intoxicants (CO, HCN) scaled similarly
