Flammability & Fire ProtectionMark Bathie – Airworthiness EngineerDesign & Manufacturing Seminar, Melbourne, 6th May 2010

AWB 25-16Part IV & V Special ConditionsAD/General/68 & 70AD/General/84FAA Research & Policy Developments

NextGen BurnerMagnesiumCompositesElectrical Wiring

RTCA DO-160FHalon

Halon ReplacementFAA AC 20-42DContaminated Halon

Fuel Tank Flammability Reduction Means

Overview

DuctingInsulation ContaminationSmall Parts

AWB 25-16

“Cabin Interior & Cargo Flammability”Replaced AAC 1-114Written at the request of AWIs & industry.Aimed mostly at non-technical (owners/pilots) and industry outsiders (automotive upholsterers).Covers historical information, terminology, test guidance and foreign NAA weblinks.Special mentions – small parts, role equipment.Revision required shortly for CASR Part 90.

Part IV & V Special Conditions

Numerous Boeing and Airbus aircraft now have FAA special conditions “Seats With Non-Traditional, Large, Non-Metallic Panels”When original FAR 25.853(c) rule developed, seats were made from metal and foam.Definition of a Large, Non-Metallic Panel –

1.5 square feet installed per seat place

AD/General/68 & 70

AD/General/68 – Part IV & V Burn TestsCompliance – “Before issue of Australian CofA…..on, or after 20 August 1990”

AD/General/70 – Mandates Cargo LinersCompliance - “Prior to 21 March 1992”

Compliance must be maintained after these dates!Some Industry interpreting it applies once.

AD/General/84

Thermal/Acoustic Insulation MaterialsFAR 25.856 (a) Fire propagation requirements now effective 5 years.FAR 25.856 (b) Fire penetration requirements now effective 6 months.

Fuselage Liners required in the lower half.Continuity must be maintained.Repairs to blankets and fasteners must consider 25.856 (b) for affected aircraft.

FAA Research & Policy Developments

NextGen BurnerPark Oil Burner for Part II, III, & VII no longer manufactured.FAA designed new burner featuring:

Simple machined partsRegulated Air-compressorAir mass flow regulated by a sonic choke.

NextGen Burner available for Part VII testing.Currently assessing Part II test compatability.

FAA Research & Policy Developments

MagnesiumTSO-C127a/SAE 8049A Para 3.3.3 “Magnesium alloys shall not be used”Aircraft/Seat/Alloy manufacturer’s pushing for allowance using new alloys.Initially for seat use followed by ducting, galley insert & carts, etc.FAA conducting full scale fire testsAssessment Halon and Water Extinguishment.

FAA Research & Policy Developments

Composites fuselagesGood burnthrough/penetration resistant propertiesAssessment of propagation properties

Requires pre-heat to propagate flamePanel edges “candle”Ply drop off a problem ???Development of Lab scale test

FAA Research & Policy Developments

“Previously, the FAA had demonstrated that the 12 second Vertical Bunsen Burner test was unable to properly discriminate materials that will or will not prevent fire propagation when exposed to a standard fire threat.”

FAA Research & Policy Developments

Electrical WiringLab and intermediate scale testsAviation wiring compliant, however -60º wire flammability test shown to pass wires the propagate for up to 17 minutes in intermediate scale tests!New test being developed

30º wire orientation60 second radiant panel pre-heat 15 second pilot flame application.flame out by 30 seconds or 3 inch

(similar to Part VI test)

See Report DOT/FAA/AR-10/2

FAA Research & Policy Developments

Ducting Ability to transport fire rapidlyAll ducting material tested in a program met the current 12-VBB certification fire test, yet….some performed poorly in the intermediate-scale fire test.A modified version of the Radiant Heat Panel test was able to predict the behaviour of ducting materials in the Intermediate Scale tests. See Report DOT/FAA/AR-08/4

FAA Research & Policy Developments

Insulation ContaminationMaterials pass certification tests……butMaterials age, andGet contaminated

How much contamination is too much?EVA Air Flight BR67 (B747), Bangkok, Thailand After landing smoke coming out of sidewalls next to seats.Burnt Insulation blankets contained:- dried liquid corrosion inhibiting compounds and particulate matter - glass fibres, synthetic and natural fibres, animal hair, cotton fibres, mineral particles, plastic, Styrofoam, metal fragments, and insects. Up 167 grams/sq metre.Heat of combustion determined to be 13 kJ/g (PET ~ 24kJ/g)

FAA Research & Policy Developments

Insulation Contamination Flame spread mechanisms

Lowers ignition energyIncreases fuel loadCan reduce shrinking away from flame source.Wicking.

See Tech Note DOT/FAA/AR-TN09/43

FAA Research & Policy Developments

Small Parts“small parts…that would not contribute significantly to the propagation of a fire….”

LocationFireworthiness of surrounding materialsMass or amount of small parts per unit area or volume

Examples given“knobs, handles, rollers, fasteners, clips, grommets, rub strips,pulleys, and small electrical parts”

AWB 25-16 advice“can be considered to be any part where the greatest dimension isno longer than 50mm.” – except small long thin things!“Multiple items in close proximity do not qualify for this exception.”

FAA developing further guidance.

RTCA DO-160F

AC 21-16F RTCA Document DO-160 versions D, E and F, “Environmental Conditions and Test Procedures for Airborne Equipment”DO-160E added Section 26 “Fire, Flammability”AC 21-16E allowed its use.AC 21-16F “RTCA/DO-160, Section 26, Fire, Flammability, is not sufficient for 14 CFR parts 25 & 33.FAA working with RTCA for suitable requirements in DO-160G.

Halon Replacement

ICAOAssembly Resolution A36-12: Halon replacement –“urgent need to develop and implement Halon replacements for civil aviation.”

ICAO and EU have timetable for replacement.Current situation:

Lavatories – replacements available.Engine – non-gaseous replacement.Hand held – replacements nearly available.Cargo – no solutions (Water mist/OBIGGS ???)

Halon Replacement

HalocarbonsHydrochlorofluorocarbon (HCFC) Blend B (Halotron 1),Hydrofluorocarbon (HFC)-227ea (FM-200), and HFC-236fa (Dupont FE-36)

All clean agentsAll are low Ozone Depleting Substances.However:

All agents are heavier, andTwo have higher Global Warming Potentials (GWP),

than Halon.

FAA AC 20-42D

“Hand Fire Extinguishers for use in aircraft”Due to replace AC 20-42C soon….Will approve Halon Equivalents.Contains guidance on agent selection, toxicity, etc.AWB 26-2 will be revised to reflect this.www.fire.tc.faa.gov/systems/handheld/handheld.asp

Contaminated Halon

Initially indentified LyonTech Engineering Ltd. supplied contaminated Halon to Fire Fighting Enterprises Ltd.Subsequently discovered other manufacturers affected.Currently four EASA ADs.Contaminated Halon to become a bigger issue. Africa also has contaminated supplies. Will increase push to replace Halons.At least one Australian aircraft affected.

Fuel Tank Flammability Reduction Means

Read –> Fuel Tank Inerting.FAA has:

Certification requirements – effectiveProduction requirements – effectiveRetrofit requirements – 50% of fleet by 12/2014

100% by 12/2017.

EASA has:Certification requirements – effectiveProduction requirements – 31 December 2011Retrofit requirements – NPA coming.

CASA:Considering our position.

Just before Questions –CASR Part 90

“Additional Airworthiness Requirements”.Replaces 18 AD/General series Airworthiness Directives.Effective 1 July 2010 with no changes.Minor changes effective 1 March 2012

Landing Gear Aural WarningFloor Proximity Escape Path Marking SystemsLavatory smoke detectors and fire extinguishers

2nd minor change effective 1 January 2016Seat cushion flammability test (Part II)

Just before Questions #2 –A quick Advertisement

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