Proactive Mitigation of PCTFE-Related Ignition Hazards in Oxygen Systems: II. Testing of Inventoried “At-Risk” PCTFE Parts and Hazard Analyses of Corresponding Ground Service Equipment at the Kennedy Space Center

    Volume 3, Issue 9 (October 2006)

    ISSN: 1546-962X

    CODEN: JAIOAD

    Page Count: 12


    Waller, JM
    Materials Scientist, Honeywell Technology Solutions Inc., NASA Johnson Space Center White Sands Test Facility, Las Cruces, NM

    Murray, KA
    Engineers, United Space Alliance, NASA Kennedy Space Center, Cape Canaveral, FL

    Staveland, AR
    Engineering Specialist, United Space Alliance, NASA Kennedy Space Center, Cape Canaveral, FL

    Faughnan, PD
    Materials Engineer, NASA-Kennedy Space Center, FL

    Tyre, D
    Engineers, United Space Alliance, NASA Kennedy Space Center, Cape Canaveral, FL

    Smith, SR
    Mechanical Engineers, Honeywell Technology Solutions Inc., NASA Johnson Space Center White Sands Test Facility, Las Cruces, NM

    Gallus, T
    Mechanical Engineers, Honeywell Technology Solutions Inc., NASA Johnson Space Center White Sands Test Facility, Las Cruces, NM

    Newton, BE
    Engineer, Wendell Hull & Associates, Inc., Las Cruces, NM

    Hshieh, FY
    Special Projects Scientist, Honeywell Technology Solutions Inc., NASA Johnson Space Center White Sands Test Facility, Las Cruces, NM

    Beeson, HD
    Office Chief, NASA Johnson Space Center White Sands Test Facility, Las Cruces, NM

    (Received 28 October 2005; accepted 19 June 2006)

    Abstract

    Revelations of excessive property variation in polychlorotrifluoroethylene (PCTFE) semifinished and finished parts led to concerns that leaks or part failure could occur in service, possibly leading to catastrophic component or system failure by flow friction and/or kindling chain mechanisms. Such concerns led to the issuances of an internal Kennedy Space Center (KSC) Problem Advisory and a Government-Industry Data Exchange Program Materials Advisory on PCTFE. The advisories led to an engineering analysis review of PCTFE-containing ground support equipment used in “at-risk” high-pressure oxygen and air systems at KSC Representative PCTFE replacement parts used in “at-risk” systems were removed from inventory and tested. Tests included determination of (1) dimensional stability by thermomechanical analysis and metrology, (2) percent crystallinity by specific gravity, and (3) the effect of annealing on engineering tolerances. While dimensional instability was determined not to be a major issue in existing inventories, establishing traceability back to the semifinished article (starting rod or sheet stock) was often not possible. Percent crystallinity varied widely depending on part origin and thickness. Annealing was found to lead occasionally to out-of-tolerance parts. The pneumatic impact ignition threshold of PCTFE in enriched air was also determined at pressures up to 41.4 MPa. Results show that ignition does not occur at ambient oxygen concentrations. Last, hazard analyses were performed on “at-risk” systems. Two problematic designs were discovered, but based on operational histories, a recommendation was made to redesign or repair and replace on a noninterference basis.


    Paper ID: JAI13568

    DOI: 10.1520/JAI13568

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    Title Proactive Mitigation of PCTFE-Related Ignition Hazards in Oxygen Systems: II. Testing of Inventoried “At-Risk” PCTFE Parts and Hazard Analyses of Corresponding Ground Service Equipment at the Kennedy Space Center
    Symposium Flammability and Sensitivity of Materials in Oxygen-Enriched Atmospheres, 2006-10-20
    Committee G04