Summary of Particle Count from C2A1 Canisters

7 Mar 2012
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Lockheed Martin Aeronautics Company The Boeing Company 1

Background
Sep 2011 As part of RTF, the CRU-122/P was outfitted with a C2A1 Canister. One C2A1 used for each Flight
CRU-122/P CRU-122/P RAPTOR2

C2A1 Canister

Aircraft Flying in CRU-122/P RAPTOR2 Configuration

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Background
Nov 2011 Elmendorf reported black dust found in a pilot breathing hose.

Elemental Analysis Determined Dust has the same element composition as particles from C2A1 canister.

Dust Analysis Determined Same as C2A1 Charcoal

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Background
Dec 2011 Langley reported black dust found in a pilot mask. Swab Samples provided to Boeing Analysis, via picked particles and Fourier Transform Infrared (FTIR) spectroscopy, Determined that dark particles appeared to be charcoal

Analysis Determined Particles Appeared to be Charcoal

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Test Objective
Feb 2012 Requested to Provide a quick evaluation of the particle size and quantity of the charcoal dust from the C2A1 Canister which is utilized on the CRU-122/P.
Activated Charcoal

Airflow

C2A1 Filter Canister

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C2A1 Cross Section

Lockheed Martin Aeronautics Company The Boeing Company

C2A1 Utilizes Activated Charcoal

5

Test Plan
Test Plan Determine Test Set-Up Utilize Used C2A1 Canister provided during Nov 2011 Evaluation Run particulate count on used canister Set up on Horizontal Flow Bench Test New C2A1 Canisters (1) from Lot MMB11G-999-018 (1) from Lot TVI09A001-022 Test Set-up in Developmental Lab (non-clean room) Utilize BRAG Valve to limit airflow

Tested New C2A1 Canisters from Different Manufactures

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Test Equipment
Particulate Probe

CLiMET Model CI-500 PARTICLE COUNTER Ranges: > 0.3 m | > 0.5 m | > 1.0
> 5.0 m | > 10.0 m | > 25.0 m
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FLOW TUBES Left for 20 LPM; Right for 200 LPM

m|
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Determination of Test Set-Up

Test Set-Up of Used C2A1 on Flow Bench
AIR FLOW

Air flow from in-house compressed air line Test conducted in horizontal flow bench Two flow rates in this configuration 20 & 200 lpm Data acquired for 1 minute for each run 1 minute acquisition at 1.00 cfm for 1 cubic foot volume counted Standard flow configuration

Air Source Eliminates Background Air Particulate

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Evaluation of Test Set-Up

Used C2A1 Particle Counts
Canister from Nov 2011 Investigation (AK413920111116) Test Set-Up (Flow Bench, In-House Compressed Air Source) Testing Included: Background taken as reference only (no particulate contribution) 20 lpm Air Flow 20 lpm Air Flow & tap on Canister from a Sharpie Pen 200 lpm Air Flow (Particulate Values adjusted for Airflow)
SAMPLE DESCRIPTION BACKGROUND CHECK IN HORIZONTAL FLOW BENCH (NO FLOW) 20 lpm FLOW THROUGH C2A1 20 lpm FLOW THROUGH C2A1 WITH SINGLE "TAP" OF SHARPIE > 0.3 m 4 1,130 13,974 > 0.5 m 1 75 7,889 > 1.0 m 0 4 1,972 > 5.0 m > 10.0 m > 25.0 m 0 0 302 0 0 209 0 0 27 RH 32 32 32 TEMP F 74.2 74.2 74.2 CI-500 FLOW (cfm) 1.00 1.00 1.00

200 lpm AIR FLOW THROUGH C2A1 (Values adjusted for higher airflow (X7)) 108,353 68,782 24,157 2,814 NOTE: Filter Values adjusted to better approximate 1 cubic foot of air per minute at 200 lpm

1,498

217

32

74.2

1.00

Disruption of C2A1 Increases Particulate Count

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Particulate Test Set-Up

Test Schematic for New C2A1 Canisters Particulate Count BRAG Valve

Rubber Boot

Air Supply

C2A1 Canister

Particle Counter

Air Source Eliminates Background Air Particulate

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New C2A1 Canister Testing

Test (2) New C2A1 Canisters
(1) from Lot MMB11G-999-018 (1) from Lot TVI09A001-022 Test Set-up in Developmental Lab (non-clean room) Utilize BRAG Valve to limit airflow Utilize Compressed Bottled Nitrogen Testing Included: Background taken as reference only (no particulate contribution) Safety Pressure Air Flow from BRAG Safety Pressure Air Flow & tap on Canister from a Sharpie Pen Press to Test Air Flow from BRAG Valve (Particulate Values adjusted for Airflow) Volumetric Samples Attempted

Air Source Eliminates Background Air Particulate

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Developmental Lab Background

Background Particulate in Developmental Lab
NUMBER OF PARTICLES PER CUBIC FOOT Sample number >0.3 m >0.5 m >1.0 m >5.0 m >10.0 m >25.0 m Three room air counts for "background". Meets Class 100,000 Exceeds Class 100,000 (outlyer in bold)Meets Class 200,000 Exceeds Class 100,000 (outlyer in bold)Meets Class 200,000 Fed-Std-209E equivalence Class 100,000 Class 10,000 Class 1,000 Class 100 Unless otherwise noted (no air flow), all sampling was done with a 10 second (uncounted) air flow to stabilize conditions prior to testing. Comments / explanation of test parameters

578,884

93,647

5,860 7,029 7,065

613 719 656

266 316 316

25 20 41

612,036 108,993 548,262 104,010

100,000 10,000 1,000 100

700 70 7 0

Background is Reference Only No Test Contribution

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New C2A1 Canister Particulate

Particulate from Lot #MMB11G-999-018
NUMBER OF PARTICLES PER CUBIC FOOT SAMPLE NUMBER 2 Press to Test No Disruption Impact 3 4 5 > 0.3 m 685,758 564,949 385 109,746 14 Press to Test 6 110,271 280 No Disruption Impact 7 224 > 0.5 m 109,829 157,199 140 79,436 14 61,159 119 70 > 1.0 m 9,433 42,056 35 34,321 0 26,950 42 7 > 5.0 m > 10.0 m > 25.0 m 526 4,263 14 2,758 0 2,023 0 0 190 1,904 7 1,519 0 938 0 0 Comments / Explaination of Test Parameters 19 Background sample with filter in place - no air flow 686 Air flow for 15 seconds, then "Press to Test" 0 Air flow for 60 seconds, no filter manipulation Air flow for 10 seconds, Sharpie impact from 6 413 inches Count from above test at 9.5 seconds before 0 manipulation Air flow for 10 seconds, then "Press to Test" for 10 63 seconds Count from above test at 9.5 seconds before 0 manipulation

Press to Test

0 Air flow for 60 seconds, no filter manipulation Air flow for 10 seconds, Sharpie impact from 6 8 86,884 56,672 18,067 3,241 1,764 168 inches Count from above test at 9.5 seconds before 56 7 0 0 0 0 manipulation Air flow for 10 seconds, then "Press to Test" for 10 9 36,589 9,982 1,498 392 91 7 seconds Count from above test at 9.5 seconds before 392 91 7 0 0 0 manipulation NOTE: Filter Values adjusted to better approximate 1 cubic foot of air per minute Assumed: BRAG flow = 200 lpm => actual count x 7 Press to Test flow was higher but only for 10 seconds => acutal count x 7

Disruption of C2A1 Increases Particulate Count

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New C2A1 Canister Particulate

Particulate from Lot #TVI09A001-022
NUMBER OF PARTICLES PER CUBIC FOOT SAMPLE NUMBER 10 > 0.3 m 4,081 > 0.5 m 1,085 > 1.0 m > 5.0 m > 10.0 m > 25.0 m 168 28 7 Comments / Explaination of Test Parameters No Disruption Impact 0 Air flow for 60 seconds, no filter manipulation Air flow for 10 seconds, Sharpie impact from 6 11 106,442 73,745 32,228 2,583 1,631 511 inches Count from above test at 9.5 seconds before 56 0 0 0 0 0 manipulation Air flow for 10 seconds, then "Press to Test" for 10 12 102,515 54,971 15,904 1,211 588 70 seconds Count from above test at 9.5 seconds before 91 14 0 0 0 0 manipulation NOTE: Filter Values adjusted to better approximate 1 cubic foot of air per minute Assumed: BRAG flow = 200 lpm => actual count x 7 Press to Test flow was higher but only for 10 seconds

Press to Test

Disruption of C2A1 Increases Particulate Count

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Summary
Test was conducted to provide quick look data. Lab Background Particulate Count is for Reference Only & does not affect C2A1 Particulate Count. Volumetric Samples were attempted but high air flow blew particulate off the pad. Samples not considered valid and were not analyzed. Particle Counts reflect what is being expended by the C2A1 and not what is being seen downstream at the CRU-122 or Pilot Mask. Particle Counter results through the C2A1 are adjusted by a factor of 7 to approximate total particulate per cubic foot per minute for 200 lpm flow. Increased flow from 10 second Press to Test not factored. Disruption of the C2A1 by either tapping or rapidly changing airflow increases particle count. Similar Results for Different C2A1 Canisters. Further testing at inlet of CRU-122/P and at Pilot Mask under flight conditions (regulated airflow, and vibration environments) required to more closely quantify flight results. Disruption of C2A1 Increases Particulate Count Lockheed Martin Aeronautics Match Flight Further Testing Required F-22 Program Information Proprietary Information to More Closely Company The Boeing Company Environment 15