Systems Fire Protection Working Group Taj Mahal - Atlantic City, NJ November 4, 2003

1. FAA Concept OBIGG System Flight Testing on NASA 747 SCA William CavageAAR-440 Fire Safety ResearchFederal Aviation Administration Systems Fire Protection Working Group Taj Mahal - Atlantic City, NJ November 4, 2003

2. Outline • Goals and Objectives • OBIGGs Architecture • OBIGGs Installation • Pallet • NEA Deposit • Instrumentation / DAS • CWT • System • OBOAS / FAS • Data Acquisition • Power Distribution • Status AAR-440 Fire Safety R&D

3. 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 AAR-440 Fire Safety R&D

4. 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 AAR-440 Fire Safety R&D

5. 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 AAR-440 Fire Safety R&D

6. Assembled FAA OBIGGs Drawing AAR-440 Fire Safety R&D

7. 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 AAR-440 Fire Safety R&D

8. 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 AAR-440 Fire Safety R&D

9. Top View of System Installed Inboard Aircraft Structure Outboard Aircraft Structure AAR-440 Fire Safety R&D

10. Simplified OBIGG System Installation AAR-440 Fire Safety R&D

11. Empty Pack Bay Before/After System Installation AAR-440 Fire Safety R&D

12. 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 AAR-440 Fire Safety R&D

13. Deposit System Overview AAR-440 Fire Safety R&D

14. NEA Deposit “T” AAR-440 Fire Safety R&D

15. Flow Meter/Deposit Installation AAR-440 Fire Safety R&D

16. NEA Diversion Valve Installation AAR-440 Fire Safety R&D

17. OBIGGS - Deposit System (cont’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 AAR-440 Fire Safety R&D

18. Install Instrumentation Port AAR-440 Fire Safety R&D

19. Existing Stringer/Stiffener/Bracket Assembly AAR-440 Fire Safety R&D

20. Install NEA Deposit Nozzle and Associate Hardware AAR-440 Fire Safety R&D

21. Install Vent Blocking Plates AAR-440 Fire Safety R&D

22. 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 AAR-440 Fire Safety R&D

23. 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 AAR-440 Fire Safety R&D

24. Route and Mount Thermocouples AAR-440 Fire Safety R&D

25. Install Sample Port Float Valve Assembly AAR-440 Fire Safety R&D

26. 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) AAR-440 Fire Safety R&D

27. Instrumentation - Pressure Transducers • 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 AAR-440 Fire Safety R&D

28. Thermocouple Probe and Pressure Transducer AAR-440 Fire Safety R&D

29. 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 AAR-440 Fire Safety R&D

30. Flow Meter AAR-440 Fire Safety R&D

31. System Instrumentation Diagram Spare [O2] Temperature Static Pressure Static Pressure Temperature NEA [O2] Static Pressure Temperature OEA [O2] Temperature Static Pressure Temperature Temperature (FAA Reader) Penetration Hole AAR-440 Fire Safety R&D

32. 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 AAR-440 Fire Safety R&D

33. OBOAS Block Diagram Fuel Tank Vapor Fuel Tank Liquid Pressurized Air Electrical Power Electronic Signals AAR-440 Fire Safety R&D

34. OBOAS Mounted in FAA AMCO Racks AAR-440 Fire Safety R&D

35. 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 AAR-440 Fire Safety R&D

36. Cabin Instrumentation/Rack Diagram AAR-440 Fire Safety R&D

37. Instrumentation - Power Distribution • 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 O2 analyzer AAR-440 Fire Safety R&D

38. Power Distribution Diagram AAR-440 Fire Safety R&D

39. Data Acquisition System • 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 AAR-440 Fire Safety R&D

40. Data Acquisition System Daqbook / 2000E DBK60 Expansion Data Data AAR-440 Fire Safety R&D

41. Status • 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 AAR-440 Fire Safety R&D