Anthony Tellier

Installations and Externals Specialist

93-46/503-3J

· 231-5781 ·

'

CERTIFICATION SIMILARITY REPORT

Fireproof Testing

of

RCF Seals and Couplings, Inc.

TABLE OF CONTENTS

• Abstract i

• Introduction 1

• Applicable CFE738-1 RCF Parts 2

• Test Material 3

• Test Requirements 4

• Tested Configuration 5

• Test Methods 6

• Test Summary 7

• CFE738-Specific Testing 8

• Summary 9

• Conclusions 10

APPENDICES

• Flammability Test Report: GTCP331-350 Compressor Inlet Duct Air Seal, GAPD P/N 3810510

• Flammability Test Report: RCF #328 3-ply material II

• Fireproof Test Report: #328 3-ply material III

• Front Engine Mount Fire Seals IV

• Bulkhead Fire Shield - 3051052 V

• Aft Mount Bulb Seal - 3051055 VI

• Aft Mount Lip Seal - 3051056 VII

ABSTRACT

INTRODUCTION

The use of RCF Seals and Couplings #328 type fireshields, couplings, and Zone II seal material on the CFE738-1 has been based upon several successful fire tests performed by independent testing labs.

SUMMARY

Several configurations of RCF #328 fireseal material have been tested at a number of independent testing laboratories to demonstrate concurrence with the fire safety requirements specified in FAA Advisory Circular Document Number 20-135.

CONCLUSION

This Report meets the requirements of FAR Part 33.17 by demonstrating that the RCF Fireproof and Flammability testing was successful no matter what the fireseal shape or configuration. Based upon the close similarity of RCF’s #328 silicone rubber/fiberglass sandwich material and the applications, all such seals should be judged fireproof.

INTRODUCTION

The use of RCF Seals and Couplings, FMSC 53949, (Oxnard, CA) fireshields, couplings, and Zone II seals on the CFE738-1 has been based upon several successful fire tests performed by independent testing labs. The results were reported in short, to-the-point transmittals. Copies of the labs reports are available in the Appendices.

APPLICABLE CFE738-1 RCF PARTS

The RCF seals on the CFE738 engine are all located in the same general region: between the engine cases and the fan bypass annulus, and around the main thrust mount. These parts are listed in Table I.

Table I

CFE738 RCF PARTS

TEST MATERIAL

RCF’s #328 silicone/fiberglass material is a composite - a compression-molded, silicone rubber-impregnated fabric - which can be manufactured in various plies. RCF states that the 3-ply material is the minimum sandwich configuration that meets the fireproof requirements of FAA Advisory Circular Document Number 20-135 (RCF’s lighter-weight two-ply material is only fire resistant).

The seals are constructed around a series of plies which are laid up in a mold. The rubber is then injected, the mold pressurized, followed by heating and holding at the rubber’s cure temperature. Post-molding operations may include such procedures as hole drilling, slitting, and trimming.

TEST REQUIREMENTS

Fireseal materials shall meet fire safety requirements per FAA Advisory Circular Document Number 20-135.

Fireproof is defined as “the capability of a material or component to withstand, as well as or better than steel, a 2000 ·F flame (± 150 ·F) for 15 minutes minimum “

The test for demonstrating compliance with the criteria for “fireproof” materials . . . is to expose the specimen to the required flame temperature (15 minutes) time. The specimen shall withstand flame penetration and not exhibit backside ignition.

“Sheet materials and panels shall be tested by exposing a sample size approximately 10 inches on a side to a flame . . . The flame size and temperature shall be sufficient to maintain the required test temperature and heat flux density over an area approximately 5”x5” . . .”

TESTED CONFIGURATION

Fire testing of the RCF materials has been performed in three configurations of RCF #328 material:

1) generic sheet samples;

2) a GAPD part and;

3) a CFE738 part

The stand-alone generic test panels closely resemble actual engine parts, as the various fire seals used between fire zones I and II are all comprised of flat RCF sheet material differing only by the several configurations, number and sizes, of pass-through holes.

The GAPD part, Compressor Inlet Duct Air Seal, P/N 3810510, for the GTCP331-350, is a flat strip of plied RCF material.

The compressible bulb seal on the CFE738 composite inner ducts is a hollow P-shaped lay-up that is riveted to the ducts though the P’s leg. A source-controlled part purchased through duct supplier Wyman-Gordon, various lengths are found on ducts 3051061 through 3051064. Manufacturing definition is supplied though PSC 3051060.

TEST METHODS

In all instances, a 2000 ·F flame (± 150 ·F) was applied for 15 minutes minimum in accordance with aforementioned FAA requirements.

The generic samples were tested at American Research and Testing, Inc., Gardena, CA on 3-ply panels of RCF’s “#328” material. Both Fireproof and Flammability tests were performed. The three ignition test panels were tested; while the one 10” x 10” Fireproof Test piece was as specified in AC 20-135.

The GAPD Inlet Duct Air Seal was Flammability tested at Helium Leak Testing, Inc., Northridge, CA

The Inner Duct’s seals were tested as part of the Duct assembly under the auspices of Wyman-Gordon at the Boeing Commercial Aircraft Company facility in Seattle. This fireproof test was performed over April 13 - 14, 1993 and witnessed by AsPE Engineer Bernard Schaack.

TEST SUMMARY

The testing performed on non-CFE738 RCF parts is listed in Table II.

Table II

RCF TESTING

CFE738-SPECIFIC TESTING

The testing performed on CFE738 RCF parts is listed in Table III.

Table III

CFE738 RCF TESTING

SUMMARY

All of the parts listed in Table I are of similar construction, similar size; and located in similar places on the engine. All testing was performed by the direct application of a two thousand degree (F) flame per AC 20-135 and in all instances the flame not penetrate the test material nor did the material ignite.

CONCLUSIONS

This Report meets the requirements of FAR Part 33.17. No further test is required to substantiate these parts. Similarity and applicability has been shown and proven to be valid by virtue of the concurrence with AC 20-135. The RCF seal material has been extensively tested and shown to be categorically “fireproof” per FAA regulations and requirements and should be cleared for unqualified use.

APPENDIX I

Flammability Test Report: RCF GTCP331-350 Compressor Inlet Duct Air Seal, GAPD P/N 3810510

APPENDIX II

Flammability Test Report: RCF #328 3-ply material

APPENDIX III

Fireproof Test Report: RCF #328 3-ply material

APPENDIX IV

RCF Air Line Couplings

APPENDIX V

RCF LPT Baffle Seal

APPENDIX VI

RCF Forward Mount Bulb Seals

APPENDIX VII

RCF Inner Duct "C" Seals

APPENDIX VIII

RCF Service Extension Fire Shields