SAE AIR 4023C-2016 Aircraft Turbine Fuel Contamination History and Endurance Test Requirements.pdf

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4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR4023C AEROSPACE INFORMATION REPORT AIR4023 REV. C Issued 1988-03 Revised 2016-

5、04 Superseding AIR4023B Aircraft Turbine Fuel Contamination History and Endurance Test Requirements RATIONALE This document has been revised to: (1) Add reference to JSSG 2007, (2) Include the EASA CS-E670 requirements for contaminated fuel testing, (3) Include a paragraph discussing SAP contaminati

6、on from Filter Monitors, (4) Update paragraph 3.9 to reference biofuels and FAME contamination, (5) Clarify the cyclic endurance test time for the 92 hour Cold testing in specification XPP-36C, (6) Add footnotes on the current status of the referenced MIL standards, and (7) Include editorial changes

7、 for clarity. FOREWORD Information for this document was provided by members of SAE Committee AE-5, Aerospace Fuel, Inerting for example, carbon fibers can pass through relatively fine filters, end on, whereas other polymeric fibers (such as Kevlar) could matt and block filters. Specifications requi

8、ring the addition of carbon fiber contamination to traditional fuel contamination are emerging, and future specifications may include other types of contaminants referenced above. Other fuel contamination issues include: (1) Copper contamination in jet fuel and its impact on fuel thermal stability,

9、(2) The impact of contamination in low lubricity fuels (low sulfur fuels, synthetic fuels such as Fischer Tropsch fuels, or potential bio-fuels) on fuel system components and operation, and (3) The impact of filter monitor media migration on fuel control systems. It should be noted that there is a d

10、iversity of test requirements and an unlikelihood of agreement on what the universal test and contamination requirements should be for the near future. SAE INTERNATIONAL AIR4023C Page 3 of 26 TABLE OF CONTENTS 1. SCOPE 4 1.1 Evolution 4 1.2 Field of Application 4 2. APPLICABLE DOCUMENTS 4 2.1 SAE Pu

11、blications . 4 2.2 Military Publications . 4 2.3 ISO Publications 5 2.4 ASTM Publications 5 2.5 Other Publications . 5 3. HISTORY AND DISCUSSION 6 3.1 Events That Influenced Early Turbine Engine Specifications 6 3.1.1 1940s . 6 3.1.2 1950-51 . 6 3.1.3 1959 6 3.1.4 1965 6 3.1.5 1973 6 3.1.6 1977 7 3.

12、2 Test Contaminants 7 3.2.1 Contaminant Requirements 7 3.2.2 Laboratory Analysis of Test Fuel Contaminant Samples 16 3.3 Endurance Test Requirements . 19 3.3.1 Military Test Requirements 19 3.3.2 Civilian Test Requirements . 22 4. FUTURE TEST REQUIREMENTS . 23 4.1 Carbon Fiber Contamination . 24 4.2

13、 Replacement Contaminants for AC Produced Arizona Fine and Coarse Test Dusts . 24 4.3 Replacement Standards for Cotton Linters Contaminant . 25 4.4 Copper Contamination 25 4.5 Filter Monitor Medium (SAP) Contamination . 25 4.6 Other Factors 25 5. NOTES 26 5.1 Revision Indicator 26 TABLE 1 FINE ARIZO

14、NA ROAD DUST . 7 TABLE 2 PARAGRAPH 4.1.1 - FUEL CONTAMINATION . 8 TABLE 3 FUEL CONTAMINATION IN MIL-E-5007B, TABLE I 8 TABLE 4 FUEL CONTAMINATION IN MIL-E-5007C, TABLE I . 9 TABLE 5 FUEL CONTAMINATION IN MIL-E-5007D, TABLE X 9 TABLE 6 FUEL CONTAMINATION IN MIL-E-8593A, TABLE X 10 TABLE 7 FUEL CONTAM

15、INATION IN AS/AV-E-8593C, TABLE X . 11 TABLE 8 AS/AV-E-8593C-2 FUEL CONTAMINANT, TABLE XI 12 TABLE 9 FUEL CONTAMINATION IN MIL-E-005007E(AS), TABLE X . 12 TABLE 10 FUEL CONTAMINANTS FOR CONTINUOUS OPERATION, TABLE XII, MIL-E-87231 . 13 TABLE 11 FUEL CONTAMINANTS FOR EQUIVALENT MISSION TIME, MIL-E-87

16、231, TABLE XIII 13 TABLE 12 CONTAMINANT MIXTURE IN MIL-F-8615D, TABLE V . 14 TABLE 13 CONTAMINANT MIXTURE IN JSSG-2009, APPENDIX E . 15 TABLE 14 VARIABILITY IN TEST CONTAMINANT SAMPLES 16 TABLE 14 VARIABILITY IN TEST CONTAMINANT SAMPLES (CONTINUED) . 17 TABLE 14 VARIABILITY IN TEST CONTAMINANT SAMPL

17、ES (CONTINUED) . 18 TABLE 15 ADDITIONAL FUEL CONTAMINANTS. 23 TABLE 16 CARBON FIBER CONTAMINATION 24 TABLE 17 PARTICLE SIZE DISTRIBUTION OF ISO FINE AND COARSE TEST DUSTS FROM ISO 12103-1 . 24 SAE INTERNATIONAL AIR4023C Page 4 of 26 1. SCOPE 1.1 Evolution This document discusses the history and deve

18、lopment of endurance requirements, provides an analysis of test contaminant material and includes a discussion of future requirements. 1.2 Field of Application This document provides the reader with a background of aircraft turbine engine fuel system component endurance test requirements needed by e

19、ngineers working on component design evaluation. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of th

20、e purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1 SAE Publications Avai

21、lable from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. MAP749 Aircraft Turbine Engine Fuel System Component Endurance Test Procedure (Room Temperature Contaminated Fuel) AIR790 Consider

22、ations on Ice Formation in Aircraft Fuel Systems AIR4246 Contaminants for Aircraft Turbine Engine Fuel System Component Testing ARP8615 Fuel System Components: General Specification For 2.2 Military Publications Available from DLA Document Services, Building 4/D, 700 Robbins Avenue, Philadelphia, PA

23、 19111-5094, Tel: 215-697-6396, http:/quicksearch.dla.mil/. JSSG-2009 Air Vehicles Subsystems JSSG-2007 Engines, Aircraft, Turbine MIL-E-005007E(AS) Engines, Aircraft, Turbojet and Turbofan, General Specification for MIL-E-5007 Engines, Aircraft, Turbojet and Turbofan, General Specification for MIL-

24、E-5009 Engines, Aircraft, Turbojet and Turbofan, Tests for MIL-E-5007A Engines, Aircraft, Turbojet and Turbofan, General Specification for MIL-E-5007B Engines, Aircraft, Turbojet and Turbofan, General Specification for MIL-E-5007C Engines, Aircraft, Turbojet and Turbofan, General Specification for M

25、IL-E-5007D Engines, Aircraft, Turbojet and Turbofan, General Specification for MIL-E-5009A Engines, Aircraft, Turbojet and Turbofan, Tests for SAE INTERNATIONAL AIR4023C Page 5 of 26 MIL-E-5009B Engines, Aircraft, Turbojet and Turbofan, Tests for MIL-E-5009C Engines, Aircraft, Turbojet and Turbofan,

26、 Tests for MIL-E-5009D Engines, Aircraft, Turbojet and Turbofan, Tests for MIL-E-8593 Engines, Aircraft, Turboprop, General Specification for MIL-E-8595 Engines, Aircraft, Turboprop, Qualification Tests for MIL-E-5009A AMENDMENT-1 MIL-E-8593A Engines, Aircraft, Turboshaft and Turboprop, General Spec

27、ification for MIL-E-87231 Engines, Aircraft, Turbojet and Turbofan MIL-F-8615D Fuel System Components, General Specification For (ASG) MIL-DTL-5624V Turbine Fuel, Aviation, Grades JP-4 and JP-5 MIL-DTL-83133J Turbine Fuels, Aviation, Kerosene Types, Nato F-34 (JP-8), Nato F-35, And JP-8 + 100 NOTES:

28、 1. MIL-E-5009 (all revisions) is inactive. MIL-E-5009D has been superseded by MIL-E-5007D. 2. MIL-E-5007 (all revisions) is inactive for new engine designs. 3. MIL-E-87231 is cancelled and replaced by JSSG 2007. 4. MIL-E-8593 (all revisions) is inactive. 5. MIL-E-8595 is cancelled and superseded by

29、 MIL-E-8593. 6. MIL-F-8615D is cancelled and superseded by ARP8615. 2.3 ISO Publications Available from International Organization for Standardization, ISO Central Secretariat, 1, ch. de la Voie-Creuse, CP 56, CH-1211 Geneva 20, Switzerland, Tel: +41 22 749 01 11, www.iso.org. ISO 12103-1 Road vehic

30、les - Test dust for filter evaluation; Part 1: Arizona test dust 2.4 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM D1655-06d Standard Specification for Aviation Turbine Fuels ASTM D66

31、15-06 Standard Specification for Jet B Wide-Cut Aviation Turbine Fuel 2.5 Other Publications XPP-36C Endurance Tests of Fuel Metering Components for Advanced Application NAMC-AEL-1670 Naval Air Engineering Center, Proposed Optimum Method of Conducting Contaminated Fuel Tests on Engine Components Per

32、 Specifications MIL-E-5007B and MIL-E-5009B EN 4106 Woodward Governor Company, Contaminated Fuel Test Method to MIL-E-5007B and MIL-E-5009B 63-AHGT-42 American Society of Mechanical Engineers, Contaminated Fuel Testing of Engine Controls to MIL-E-5009B Using the USN Aeronautical Engine Laboratory Te

33、chnique SAE INTERNATIONAL AIR4023C Page 6 of 26 EN 4106 Supp I Woodward Governor Company, Improved Method for Testing Components per MIL-E-5007B and MIL-E-5009B NAEC-AEL-1791 Naval Air Engineering Center, Proposed Revision to MIL-E-5007B and MIL-E-5009B Standardized Method of Conducting Contaminated

34、 Fuel Tests Nov/Dec 1972 Filtration & Separation, Fuel Filters for Aero Gas Turbine Engines Volume XXXIV Douglas Service AFLRL No. 90 Definition of Aviation Turbine Fuel Contamination Under Simulated Combat Conditions Letter Report Majac Division, Donaldson Corporation, Analysis of SAE Test Samples,

35、 MIL-E-5007 Report #266 Scientific and Laboratory Services Dept., Pall Corporation, Evaluation of MIL-E-05007D Test Contaminant NAPC-P-79002 Engines, Aircraft, Turbojet and Turbofan, General Specification for AS/AV-E-8593C-2 Engines, Aircraft, Turboshaft and Turboprop, General Specification for 3. H

36、ISTORY AND DISCUSSION 3.1 Events That Influenced Early Turbine Engine Specifications 3.1.1 1940s Two F-80s crashed because of contamination that plugged the fuel filters and caused dirty fuel to bypass the filter, thus contaminating the engine fuel system. A need was created for testing requirements

37、 to address these problems. 3.1.2 1950-51 Engine failures led to a USAF study of turbine fuel supplies. Contamination consisting of iron oxides, aluminum oxides, and silica sand with concentrations of 1.7 to 34.5 gm/1000 U.S. gallons were found during the study. Endurance requirements were generated

38、 for MIL-E-5007A and MIL-E-5009A that called for 150 hours of contaminated endurance, with 148 hours at 8 gm/1000 gallons and the last 2 hours at 80 gm/1000 gallons. The test contaminant was silica (fine Arizona road dust). A separate 50 minute salt water slug test and 72 hour soak was included. 3.1

39、.3 1959 A USN study of 126 JP-4 and JP-5 fuel samples found contaminants of iron oxide, silica, and linters in the 0 to 200 m range. The result of this and the previous USAF study, was MIL-E-5007B and MIL-E-5009B, which introduced the level of 41 gm/1000 gallons for an entire 300 hour endurance test

40、. Contaminants were iron oxides, silica (coarse Arizona road dust), cotton linters, and saltwater. The separate salt water slug and soak test was eliminated. 3.1.4 1965 A USAF study of fuel samples from receiving, storage, refuelers, and aircraft at SAC bases revealed contamination levels of 1.0 to

41、7.2 gm/1000 gallons. This resulted in revisions MIL-E-5007C and MIL-E-5009C, which reduced the cotton linter quantity to one tenth that of MIL-E-5007B and introduced the term “micron“ rather than “mesh size“ for describing large particles. 3.1.5 1973 Specifications MIL-E-5007C, MIL-E-5009C, and MIL-

42、E-5009D were combined into MIL-E-5007D. The total quantity of contaminants was increased from 40.1 gm/1000 gallons to 42.6 gm/1000 gallons and the iron oxides were erroneously split 50/50 into 14.5 gm Fe3O4 magnetite and 14.5 gm Fe2O3 hematite. Three controlled-environment shutdowns were added to th

43、e engine control system test. The reason they were added could not be determined. SAE INTERNATIONAL AIR4023C Page 7 of 26 3.1.6 1977 A joint industry and military conference held at Wright-Patterson AFB, Ohio to review the component endurance testing requirements in MIL-E-5007D concluded the followi

44、ng: a. The correct split for the iron oxides should have been 1.5 gm magnetite and 27 gm hematite. b. The 420- to 1500- m crushed quartz should be moved to a “to be created“ slug test. c. The crushed quartz was intended to represent aluminum chips frequently found in fuel samples and supposedly “dif

45、ficult“ to obtain in graded form. d. The naphthenic acid requirement should be eliminated in tests where service fuel is used. e. Test cycles should be the same for all components and should be mission-oriented. f. A dirt slug test and a low-lubricity-fuel endurance test should be added as separate

46、requirements. g. The three 120 hour engine control system shutdowns, introduced in MIL-E-5007D, should be replaced with a maximum of two overnight shutdowns. This requirement should be applied to all fuel system components including fuel nozzles. h. The military should continue to review and refine

47、endurance requirements based on field experience. 3.2 Test Contaminants 3.2.1 Contaminant Requirements The following pages tabulate significant fuel-contamination-material requirements that were imposed on turbine engine fuel system components. While the emphasis of this AIR is on solid contaminatio

48、n (in conjunction with salt water in many specifications), a more comprehensive background on water contamination and icing in aircraft fuel systems due to free water in fuel, and proper simulation of aircraft fuel systems in icing tests of fuel systems, is discussed in AIR790. 1. MIL-E-5007A, 27 Ju

49、ly 1951 and 2. MIL-E-8593, 3 September 1954 Table 1 - Fine Arizona road dust Particle Size-Microns Percent of Total 0-5 39 2 by weight 5-10 18 3 by weight 10-20 16 3 by weight 20-40 18 3 by weight Over 40 9 3 by weight Through a 200-mesh screen 100 by weight SAE INTERNATIONAL AIR4023C Page 8 of 26 3. XPP-36C, 3 June 1957 Table 2 - Paragraph 4.1.1 - fuel contamination Contaminant Particle Size Quantity Iron Oxid