A Study of Transport Airplane Crash Resistant
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DOT/FAA/AR-01/76 A Study of Helicopter Crash- Office of Aviation Research Washington, D.C. 20591 Resistant Fuel Systems February 2002 Final Report This document is available to the U.S. public through the National Technical Information Service (NTIS), Springfield, Virginia 22161. U.S. Department of Transportation Federal Aviation Administration NOTICE This document is disseminated under the sponsorship of the U.S. Department of Transportation in the interest of information exchange. The United States Government assumes no liability for the contents or use thereof. The United States Government does not endorse products or manufacturers. Trade or manufacturer's names appear herein solely because they are considered essential to the objective of this report. This document does not constitute FAA certification policy. Consult your local FAA aircraft certification office as to its use. This report is available at the Federal Aviation Administration William J. Hughes Technical Center's Full-Text Technical Reports page: actlibrary.tc.faa.gov in Adobe Acrobat portable document format (PDF). Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. DOT/FAA/AR-01/76 4. Title and Subtitle 5. Report Date A STUDY OF HELICOPTER CRASH-RESISTANT FUEL SYSTEMS February 2002 6. Performing Organization Code 7. Author(s) 8. Performing Organization Report No. S.H. Robertson, N.B. Johnson, D.S. Hall and I.J. Rimson RA-FAA-01-130 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) Robertson Aviation, L.L.C. 1024 East Vista Del Cerro Drive Tempe, AZ 85281 11. Contract or Grant No. DTFA03-98-C-00016 12. Sponsoring Agency Name and Address 13. Type of Report and Period Covered U.S. Department of Transportation Final Report Federal Aviation Administration Office of Aviation Research 14. Sponsoring Agency Code Washington, DC 20591 ASW-110 15. Supplementary Notes The FAA William J. Hughes Technical Center Technical Monitor was Mr. Gary Frings. 16. Abstract This report presents the results of a study, funded by the Federal Aviation Administration (FAA), of helicopter Crash-Resistant Fuel Systems (CRFS). It covers the historical efforts that led to the current state of the art in military helicopter fuel systems and the more recent modifications to civil certification standards in Title 14 Code of Federal Regulations (CFR) Part 27 (Normal Category Rotorcraft) and Part 29 (Transport Category Rotorcraft). It describes the basic research, testing, field investigations, and production efforts that have led to the highly successful CRFS, that have saved many lives and have reduced the costs of accidents. While the hardware and fabrics are available today to create the CRFS, the adequacy of the integration of these items into existing and new civil fuel system designs cannot be assessed because of the lack of current field investigation data on civil helicopter crashes. This report reviews this problem, including the forms used for reporting and the current level of available data, which is essentially nonexistent. Training of field investigators in specific crashworthiness technology is of great importance, as well as the need for trained engineers in the design and certification process. A discussion of the civil and military crash environments is provided to give a background for the discussion of the need for re- evaluation of the rationale used in establishing the current civil regulatory standards. The value of full-scale crash testing during the early development of the military CRFS is reviewed. The lack of any planned tests for the CRFS in current civil helicopters is an area of concern. A section of the study discusses the individual components of a CRFS, with guidance on the application of each item to the overall system design. This report provides guidance to designers looking for information about CRFS design problems and analytical tools for use in product improvements. A summary of the changes currently taking place in the regulatory environment (specifications, standards, and regulations) for both military and civil rotorcraft development is included. This is also an area of concern. This report provides information to the FAA and other governmental organizations that can help them plan their efforts to improve the state of postcrash fire protection in the civil helicopter fleet. 17. Key Words 18. Distribution Statement Fuel systems, Rotorcraft Fuel systems, Crash-resistant fuel This document is available to the public through the National systems, Rotorcraft, Helicopters, Helicopter fuel systems Technical Information Service (NTIS) Springfield, Virginia 22161. 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unclassified 170 Form DOT F1700.7 (8-72) Reproduction of completed page authorized PREFACE This research effort and report was prepared by Robertson Aviation, L.L.C. (RA) under Contract No. DTFA03-98-C-00016 with the Federal Aviation Administration (FAA) William J. Hughes Technical Center, where Mr. Gary Frings served as the Technical Representative. The RA Program Manager for this work was S. Harry Robertson. Major research and writing tasks were provided at RA by crashworthiness engineers Neva B. Johnson, David Hall, and Jeffrey Bracken. Additional research support at RA was provided by David Stover, William York, and Ira Rimson, and by the Aviation Safety Center at Embry-Riddle Aeronautical University in Prescott, Arizona. Technical assistance was provided by a number of individuals and organizations actively involved in the Aviation Safety field, including the FAA; the NTSB; the Air Line Pilots Association (ALPA); Simula, Inc.; Dr. Dennis Shannahan; Roy Fox of Bell Helicopter; Dan Sydow of Engineered Fabrics Corporation in Rockmart, Georgia; Brian Carnell, retired crashworthiness engineer from Sikorsky Aircraft in Stratford, Connecticut; Dr. James W. Turnbow, retired engineering professor from Arizona State University and Chief Scientist from the Aviation Safety Engineering Research (AvSER) team of crashworthiness researchers in Phoenix, Arizona; and various engineers from the Aeroquip Corporation in Jackson, Michigan, and The Aviation Safety Center at Fort Rucker, Alabama. iii/iv TABLE OF CONTENTS Page EXECUTIVE SUMMARY ix 1. INTRODUCTION 1-1 2. HISTORY OF HELICOPTER CRASH-RESISTANT FUEL SYSTEMS 2-1 2.1 Background 2-1 2.2 Defining the Postcrash Fire Problem 2-1 2.2.1 Airplane Crash Testing 2-1 2.2.2 Helicopter Crash Testing 2-2 2.2.3 The Postcrash Fire Environment 2-4 2.3 Development of the Crash-Resistant Fuel System (CRFS) 2-4 2.3.1 Early Developments 2-4 2.3.2 Helicopter Fuel System Development 2-6 2.3.3 Implementation of CRFS in Military Helicopters 2-9 2.3.4 Crash-Resistant Fuel System in Civil Helicopters 2-13 3. ACCIDENT DATA 3-1 3.1 Military Helicopters 3-1 3.2 Civil Helicopters 3-2 3.3 Accident Report Forms 3-10 3.3.1 Civil Accident Investigation Forms 3-10 3.3.2 U.S. Army Accident Investigation Forms 3-12 3.4 Comparison of Military and Civil Crash Environments 3-13 4. STATUS OF CURRENT TECHNOLOGY AND IMPLEMENTATION OF CRFS 4-1 4.1 Crash-Resistant Fuel System Design Issues 4-1 4.2 General System Design Criteria 4-1 4.2.1 Aircraft Performance 4-2 4.2.2 Overall Fuel System Design 4-3 4.2.3 Individual Component Design 4-4 4.2.4 Tanks and Fittings 4-4 4.2.5 Self-Sealing Breakaway Valves 4-7 4.2.6 Fuel Lines 4-10 4.2.7 Vent Valves 4-11 v 4.2.8 Drain Valves 4-13 4.2.9 Spillage Control Valve 4-13 4.3 Assessment of Current Status of CRFS Design 4-15 5. CURRENT CRFS STANDARDS(MILITARY AND CIVIL) 5-1 5.1 Overall System 5-1 5.2 Military Standardsand Specifications 5-1 5.2.1 MIL-STD-1290 (series): Light Fixed- and Rotary-Wing Aircraft Crash Resistance 5-1 5.2.2 ADS-11 (series): Survivability Program, Rotary Wing 5-2 5.2.3 ADS-36: Rotary Wing Aircraft Crash Resistance 5-3 5.2.4 Aircraft Crash-Survival Design Guide (TR-89-D-22E) 5-4 5.2.5 Military Specifications (MIL-SPECs) 5-4 5.2.6 Joint Service Specifications 5-5 5.2.7 JSSG-2009: Air Vehicle Subsystems Specification Guide 5-7 5.2.8 MIL-STD-882D, Dated 10 February 2000: “Standard Practice for System Safety” 5-9 5.3 Civil Specifications 5-9 5.3.1 Normal Category Rotorcraft 5-9 5.3.2 Transport Category Rotorcraft 5-13 6. FUEL SYSTEM CRASH-SURVIVABILITY EVALUATION 6-1 6.1 Postcrash Fire Potential Rating System 6-1 6.1.1 Spillage Control 6-3 6.1.2 Ignition Control 6-5 6.2 Fuel System Fire Hazard Level Reduction 6-7 6.2.1 Evaluation Criteria and Process 6-7 6.2.2 Example Fuel System Fire Hazard Level Evaluation 6-13 7. AC 29-2B DISCUSSION 7-1 7.1 Background 7-1 vi 7.2 AC 29-2B, 29.952, General Comments 7-1 7.3 AC 29-2B, 29.952, Increasing the CRFS Capability 7-6 8. CONCLUSIONS 8-1 9. RECOMMENDATIONS 9-1 10. REFERENCES 10-1 11. BIBLIOGRAPHY 11-1 APPENDICES A—Accident Investigation Forms B—AC 29-2B Original Advisory Circular LIST OF FIGURES Figure Page 2-1 UH-1A Crash-Resistant Fuel System 2-9 2-2 Resistance to Tear for Tank Materials 2-10 2-3 Crash-Resistant UH-1D/H Fuel System 2-13 3-1 Percentage of All Helicopter Crashes That Are Survivable and Nonsurvivable 3-14 3-2 Severity Scale of All Helicopter Crashes 3-14 4-1 Frangible Type Self-Sealing Breakaway Valve 4-7 4-2 Quick Disconnect Valve Installed to Operate a Self-Sealing Breakaway Valve 4-7 4-3 Cable Lanyard Used to Transmit the High Load Required to Separate a Typical Self-Sealing Breakaway Valve 4-9 4-4 Cable Lanyard Used to Transmit Load to Pull Release Ring That Uncouples Quick-Disconnect Valve 4-9