This report provides guidance on how to adjust temperature measurements from mineral- insulated, metal-sheathed (MIMS) thermocouples (TCs) mounted on metal plates to correct for slow transient response. This information is needed so that more accurate transient temperature measurements can be made. These more accurate temperature measurements are of benefit for both qualification of hardware and as data sets for model validation. The approach was to use a relatively simple first order adjustment to the MIMS TC reading, as compared to a more accurate metal plate temperature measurement. MIMS TCs are used to improve reliability. Results from four data sets were analyzed to determine the time constraint; an overall average of 5.0 s was obtained. ACKNOWLEDGEMENTS The author would like to acknowledge the support of N. R. Keltner during the original testing where the three flat shroud data sets came from, and for his support in writing this report. Financial support was provided by DOE-EM Packaging Certification Program: James Shuler and Lawrence Gelder, Program Managers. Their support is greatly appreciated. Also acknowledged is Jill Suo- Anttila for providing a test where we could add intrinsic TCs, and for allowing use of the ungrounded junction data for the cylindrical shroud tests. Last, thanks to Jeff Energer for his review of the document and for providing valuable comments.
Mineral-insulated, metal-sheathed, Type-K thermocouples are used to measure the temperature of various items in high-temperature environments, often exceeding 1000degC (1273 K). The thermocouple wires (chromel and alumel) are protected from the harsh environments by an Inconel sheath and magnesium oxide (MgO) insulation. The sheath and insulation are required for reliable measurements. Due to the sheath and MgO insulation, the temperature registered by the thermocouple is not the temperature of the surface of interest. In some cases, the error incurred is large enough to be of concern because these data are used for model validation, and thus the uncertainties of the data need to be well documented. This report documents the error using 0.062" and 0.040" diameter Inconel sheathed, Type-K thermocouples mounted on cylindrical surfaces (inside of a shroud, outside and inside of a mock test unit). After an initial transient, the thermocouple bias errors typically range only about +-1-2% of the reading in K. After all of the uncertainty sources have been included, the total uncertainty to 95% confidence, for shroud or test unit TCs in abnormal thermal environments, is about +-2% of the reading in K, lower than the +-3% typically used for flat shrouds. Recommendations are provided in Section 6 to facilitate interpretation and use of the results. .
The purpose of this report is to describe the methods commonly used to measure heat flux in fire applications at Sandia National Laboratories in both hydrocarbon (JP-8 jet fuel, diesel fuel, etc.) and propellant fires. Because these environments are very severe, many commercially available heat flux gauges do not survive the test, so alternative methods had to be developed. Specially built sensors include 'calorimeters' that use a temperature measurement to infer heat flux by use of a model (heat balance on the sensing surface) or by using an inverse heat conduction method. These specialty-built sensors are made rugged so they will survive the environment, so are not optimally designed for ease of use or accuracy. Other methods include radiometers, co-axial thermocouples, directional flame thermometers (DFTs), Sandia 'heat flux gauges', transpiration radiometers, and transverse Seebeck coefficient heat flux gauges. Typical applications are described and pros and cons of each method are listed.
In the fire safety community, the trend is toward implementing performance-based standards in place of existing prescriptive ones. Prescriptive standards can be difficult to adapt to changing design methods, materials, and application situations of systems that ultimately must perform well in unwanted fire situations. In general, this trend has produced positive results and is embraced by the fire protection community. The question arises as to whether this approach could be used to advantage in cook-off testing. Prescribed fuel fire cook-off tests have been instigated because of historical incidents that led to extensive damage to structures and loss of life. They are designed to evaluate the propensity for a violent response. The prescribed protocol has several advantages: it can be defined in terms of controllable parameters (wind speed, fuel type, pool size, etc.); and it may be conservative for a particular scenario. However, fires are inherently variable and prescribed tests are not necessarily representative of a particular accident scenario. Moreover, prescribed protocols are not necessarily adaptable and may not be conservative. We also consider performance-based testing. This requires more knowledge and thought regarding not only the fire environment, but the behavior of the munitions themselves. Sandia uses a performance based approach in assuring the safe behavior of systems of interest that contain energetic materials. Sandia also conducts prescriptive fire testing for the IAEA, NRC and the DOT. Here we comment on the strengths and weakness of both approaches and suggest a path forward should it be desirable to pursue a performance based cook-off standard.
The objective of this report is to develop uncertainty estimates for three heat flux measurement techniques used for the measurement of incident heat flux in a combined radiative and convective environment. This is related to the measurement of heat flux to objects placed inside hydrocarbon fuel (diesel, JP-8 jet fuel) fires, which is very difficult to make accurately (e.g., less than 10%). Three methods will be discussed: a Schmidt-Boelter heat flux gage; a calorimeter and inverse heat conduction method; and a thin plate and energy balance method. Steady state uncertainties were estimated for two types of fires (i.e., calm wind and high winds) at three times (early in the fire, late in the fire, and at an intermediate time). Results showed a large uncertainty for all three methods. Typical uncertainties for a Schmidt-Boelter gage ranged from {+-}23% for high wind fires to {+-}39% for low wind fires. For the calorimeter/inverse method the uncertainties were {+-}25% to {+-}40%. The thin plate/energy balance method the uncertainties ranged from {+-}21% to {+-}42%. The 23-39% uncertainties for the Schmidt-Boelter gage are much larger than the quoted uncertainty for a radiative only environment (i.e ., {+-}3%). This large difference is due to the convective contribution and because the gage sensitivities to radiative and convective environments are not equal. All these values are larger than desired, which suggests the need for improvements in heat flux measurements in fires.
A series of experiments was performed to better characterize the boundary conditions from an inconel heat source ('shroud') painted with Pyromark black paint. Quantifying uncertainties in this type of experimental setup is crucial to providing information for comparisons with code predictions. The characterization of this boundary condition has applications in many scenarios related to fire simulation experiments performed at Sandia National Laboratories Radiant Heat Facility (RHF). Four phases of experiments were performed. Phase 1 results showed that a nominal 1000 C shroud temperature is repeatable to about 2 C. Repeatability of temperatures at individual points on the shroud show that temperatures do not vary more than 10 C from experiment to experiment. This variation results in a 6% difference in heat flux to a target 4 inches away. IR camera images showed the shroud was not at a uniform temperature, although the control temperature was constant to about {+-}2 C during a test. These images showed that a circular shaped, flat shroud with its edges supported by an insulated plate has a temperature distribution with higher temperatures at the edges and lower temperatures in the center. Differences between the center and edge temperatures were up to 75 C. Phase 3 results showed that thermocouple (TC) bias errors are affected by coupling with the surrounding environment. The magnitude of TC error depends on the environment facing the TC. Phase 4 results were used to estimate correction factors for specific applications (40 and 63-mil diameter, ungrounded junction, mineral insulated, metal-sheathed TCs facing a cold surface). Correction factors of about 3.0-4.5% are recommended for 40 mil diameter TCs and 5.5-7.0% for 63 mil diameter TCs. When mounted on the cold side of the shroud, TCs read lower than the 'true' shroud temperature, and the TC reads high when on the hot side. An alternate method uses the average of a cold side and hot side TC of the same size to estimate the true shroud temperature. Phase 2 results compared IR camera measurements with TC measurements and measured values of Pyromark emissivity. Agreement was within measured uncertainties of the Pyromark paint emissivity and IR camera temperatures.
It would not be possible to confidently qualify weapon systems performance or validate computer codes without knowing the uncertainty of the experimental data used. This report provides uncertainty estimates associated with thermocouple data for temperature measurements from two of Sandia's large-scale thermal facilities. These two facilities (the Radiant Heat Facility (RHF) and the Lurance Canyon Burn Site (LCBS)) routinely gather data from normal and abnormal thermal environment experiments. They are managed by Fire Science & Technology Department 09132. Uncertainty analyses were performed for several thermocouple (TC) data acquisition systems (DASs) used at the RHF and LCBS. These analyses apply to Type K, chromel-alumel thermocouples of various types: fiberglass sheathed TC wire, mineral-insulated, metal-sheathed (MIMS) TC assemblies, and are easily extended to other TC materials (e.g., copper-constantan). Several DASs were analyzed: (1) A Hewlett-Packard (HP) 3852A system, and (2) several National Instrument (NI) systems. The uncertainty analyses were performed on the entire system from the TC to the DAS output file. Uncertainty sources include TC mounting errors, ANSI standard calibration uncertainty for Type K TC wire, potential errors due to temperature gradients inside connectors, extension wire uncertainty, DAS hardware uncertainties including noise, common mode rejection ratio, digital voltmeter accuracy, mV to temperature conversion, analog to digital conversion, and other possible sources. Typical results for 'normal' environments (e.g., maximum of 300-400 K) showed the total uncertainty to be about {+-}1% of the reading in absolute temperature. In high temperature or high heat flux ('abnormal') thermal environments, total uncertainties range up to {+-}2-3% of the reading (maximum of 1300 K). The higher uncertainties in abnormal thermal environments are caused by increased errors due to the effects of imperfect TC attachment to the test item. 'Best practices' are provided in Section 9 to help the user to obtain the best measurements possible.