BWT.pdf

ULTRA-LIGHTWEIGHT AIR DISTRIBUT

ON SYSTEMS

BWT

ULTRA-LIGHTWEIGHT AIR

DISTRIBUTION & INSULATION SYSTEMS

BWT

CONTENTS

Introduction 3

A flexible resource for ultra-lightweight systems 4

Leading edge solutions for ultra-lightweight systems 6

Flexible ducting & semi rigid ducting 8

Rigid ducting, acoustic silencers& insulation systems 11

Innovative solutions for complex design requirements 12

Technical specifications 14

Thermal insulation & acoustic insulation 18

For commitment to the environment 19

2

WORLD LEADER IN ULTRA-LIGHTWEIGHT AIR

DISTRIBUTION AND INSULATION SYSTEMS

Senior Aerospace BWT (formerly BaxterWoodhouse and Taylor) is recognised as aworld leader in the design andmanufacture of ultra-lightweight lowpressure air distribution and insulationsystems and has established a position ofpreferred supplier to the aerospaceindustry worldwide.

Senior Aerospace BWT have a globalreputation and an impressive customerbase across which they provide systemsfor fixed winged and rotary wingedaircraft, for all market sectors and for both civil and military applications.

Senior Aerospace BWT is a subsidiarycompany of Senior plc and its outstandingdesign and manufacturing expertisecomplement the activities of other group companies.

With manufacturing facilities and offices in 15 countries across all continents,Senior plc is the worlds leading supplierof thin-walled flexible tubing and related high performance products across anumber of specialised markets.

Senior Aerospace BWT continues itspolicy of major investment in productdevelopment, materials research,manufacturing process and integratedbusiness systems. Combined with thecapabilities of other Senior plc companies,Senior Aerospace BWT is firmly placed toretain and expand its market position.

ATION SYSTEMS

WORLD

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BWT

ENGINEERINGAs one of the most experiencedorganisations in this sector of theaerospace industry, Senior AerospaceBWT is committed to maintaining a multi-disciplined engineering team capable ofsupporting its customers needs.

The team has responsibility for allactivities from design conception throughto first-off production. Design activitiesare supported by a state of the artcomputer aided design capability,enabling the visualisation of componentsin advance of manufacture.

Commitment to customer support ispivotal to Senior Aerospace BWTssuccess. The engineering team offers on-site support at the customers facilitythrough initial design onto installation ofthe finalised system.

MANUFACTURINGSenior Aerospace BWTs manufacturingfacilities meet and exceed the demandingrequirements of its customers, providinghigh quality products in the shortestpossible lead-time.

The highly motivated, multi-skilled andflexible workforce are dedicated toexceeding their customers expectationsfor quality products delivered on time.

An integrated business operating systemprovides information to support front endsales & operations planning, productionscheduling , product tracking andbusiness performance monitoring data.

Continuous investment in productionprocesses and facilities enables SeniorAerospace BWT to strive toward meetingits goal; to provide customers with qualityproducts at competitive prices, deliveredon time.

QUALITYSenior Aerospace BWT is accredited withBS EN ISO9001, AS9100 and EASA PART21 Subpart G approvals. In selectingSenior Aerospace BWT, customers haveplaced their confidence in its ability todesign and manufacture products to thehighest standard of quality and reliability.

The company quality management systemcomplies with both military and civilquality assurance requirements and isimplemented through formal companyprocedures.

Senior Aerospace BWTs qualitymanagement team provides anindependent quality assurance authorityand product quality control system,responsible for product integritythroughout the manufacturing process.

CUSTOMER SERVICESenior Aerospace BWT is proud of theunrivalled service and support provided toits customers.

On day-to-day issues such as orderplacement, inquiries, progress, andchange notification, each customer isallocated a dedicated member of theCustomer Service Team. This single pointof contact provides the level of servicethat is both expected and demanded bythe customer.

For additional customer service a globalnetwork of sales offices is operated andsupported by Senior Aerospace BWTRegional Managers.

For AOG requirements Senior AerospaceBWT operates a 365 days a year 24 hourservice.

A FLEXIBLE RESOURCE FOR ULTRA-

LIGHTWEIGHT SYSTEMS

GHTWEIGHT SYSTEMS

A FLEXIBLE RESOURCE FOR ULTRA-LIGHTWE

4

BWT

5A FLEXIBLE RESOURCE FOR ULTRA-LIGHTWEIGHT SYSTEMS

A FLEXIBLE RESOURCE FOR ULTRA-LIGHTWEIGHT SYSTEMS







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LEADING EDGE SOLUTIONS FOR

ULTRA-LIGHTWEIGHT SYSTEMS

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A comprehensive range of products enablesSenior Aerospace BWT to provide integratedsystem solutions, both modular and aircraftspecific, which optimise weight, cost,installation time and effective use of thespace envelope.

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BWT

8Various connecting methods Shaped flexible ducts Flexible & semi-rigid duct combinations

Bespoke products Complex duct geometries ...simple solutions to demanding requirements

FLEXIBLE DUCTING, SEMI-RIGID DUCTINGMI-RIGID DUCTING,

FLEXIBLE DUCTING, SEMI-RIGID DUCTING, FLEXIBLE DUCTING, SE

Senior Aerospace BWTs range of flexibleand semi-rigid ducting provides systemsolutions, both modular and aircraftspecific, which optimise weight, cost,pressure loss, installation time andefficient use of the available spaceenvelope.

Flexible ducting is available withurethane/nylon or silicone basedconstructions, for low and hightemperature applications respectively.They can be supplied as standard circularor shaped profiles, incorporatingtransitions, set bends and various endinterface connections.

Ultra-lightweight flexible ductconstructions are designed to meet therequirements of the aerospace industry,

where light weight, flexibility, durability, lowmaintenance and ease of installation are essential considerations.

Semi-rigid ducting can be supplied asstandard connectors and branches ortailored to maximise air flow oninstallations with a restricted spaceenvelope. Used as part of the systemsolution, Senior Aerospace BWTs semi-rigid ducting is the ideal partner for the flexible range.

Manufactured from proprietary ultra-lightweight reinforced composite materials,offering smooth bore solutions, SeniorAerospace BWTs semi-rigid materials areideally suited for use in complex ductgeometries.

BWT

E9

FLEXIBLE DUCTING, SEMI-RIGID DUCTING








10

RIGID DUCTING, ACOUSTIC SILENCERS, INSULATION SYSTEMS








RIGID DUCTING, ACOUSTIC SILENCERS,

INSULATION SYSTEMS RIGID DUCTING, ACOUSTIC SILENCERS, INSULAT

ATION SYSTEMS

Senior Aerospace BWT is able to supplycomponents for more specialisedinstallations and applications.

Rigid components are available withcomposite or aluminium constructions,offering greater resilience to serviceand/or maintenance activities. As with thesemi-rigid components, the duct profilescan be tailored to optimise the use ofavailable space.

Thermal and acoustic insulation in aircraftair distribution systems is an area whereSenior Aerospace BWT can offer a rangeof options providing cost effective andpractical solutions.

These solutions minimise heat loss byproviding complete coverage of theducting system.

Noise transmitted through an airdistribution system is greatly reducedthrough the use of Senior Aerospace BWTsilencer ducting. These acousticallyinsulated ducts can be supplied in flexibleor semi-rigid constructions, incorporatinga wide range of profiles and endconnections.

Fuselage insulation systems combinethermal and acoustic properties tomaximise passenger and crew comfortwithin the flight compartment. Individuallytailored, they ensure coverage of theairframe throughout the aircraft, optimisingperformance.

11

Transition duct Rigid duct with metallic flange connectors Rigid duct with installation provision

Standard acoustic silencer Bespoke acoustic silencer Fuselage insulation panel with integral airdistribution ducting

BWT

12

ENGINEERING DESIGN CAPABILITIESAs one of the most experiencedorganisations in this sector of theaerospace industry, Senior AerospaceBWT takes pride in its capability to offer acomprehensive range of design andproduct support services.

Senior Aerospace BWT maintains itsposition as a world leader in the designand manufacture of ultra-lightweight airdistribution ducting and cabin insulationsystems through a commitment toengineering excellence.

Senior Aerospace BWT employs a multi-disciplined engineering team withextensive experience in the applicationand development of ultra-lightweightmaterial technology in the aerospacesector. This team has been influential inthe successful implementation of many ofthe air distribution and insulation systemscurrently in service.

Speed of response and the flexibility ofthe engineering function is achievedthrough the use of advanced technologiesand development techniques. State of theart computer aided design and analysiscapabilities, in-house toolingmanufacture, reverse engineering andskilled project management are just someof the attributes that contribute to SeniorAerospace BWTs unrivalled ability todesign components and systems.

Tools available to the engineering teaminclude:

- CATIA- AutoCAD- Flowmaster2 flow analysis

TECHNICAL SUPPORTSenior Aerospace BWT offers a range ofengineering services to support itscustomers throughout design, installation,qualification and certification phases.These include:

Technical representation on-site during theinitial design phase, providing knowledge andexperience of AMS/ECS ducting integration

and lightweight materials, assisting customersat the most beneficial stage of a project,optimising design considerations, reducingcosts.

Samples manufactured and tested to provedesign concepts.

A dedicated research and developmentteam committed to the investigation andimplementation of new materials and processes.

Airflow analysis thus reducing costly flightand development test programs.

QUALIFICATIONSenior Aerospace BWT through theirextensive experience can manage acomprehensive program to support thequalification process. Senior AerospaceBWT will compile documentation, plan, testand report on all relevant aspects ofproduct and material performance.

Testing may be customer specific or to setstandards, for example RTCA/DO-160, MIL-STD-810 or ASTM. Performance data hasbeen collected from a number of programsand includes:

Environmental High & Low Temperature,Temperature Variation, Humidity,Waterproofness, Salt Spray, Fluid Susceptibilityand Fungal Resistance.

Mechanical Vibration, Operational Shock,Crash Safety, Over Pressure and Endurance(Pressure Cycling).

Airworthiness Flame Resistance, RadiantPanel Flame Propagation, Smoke and Toxicity.

RIG TEST FACILITIESSenior Aerospace BWT has the capabilityto offer a cost effective solution to airflowtesting and balancing on distributionducting systems, by means of purposebuilt test rigs, thus aiding the qualificationand certification process.

Testing can be carried out on completeducting systems, or sections of the systemto define airflow balancing provisions.

The main distribution systems, avionicsventilation and recirculation systems aretypical of those that can be balanced andproven.

BWT

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INNOVATIVE SOLUTIONS FOR COMPLEX

DESIGN REQUIREMENTS

ESIGN REQUIREMENTS

INNOVATIVE SOLUTIONS FOR COMPLEX DES

TECHNICAL SPECIFICATION -

FLEXIBLE DUCTING, INTERFACE CONNECTORS

ERFACE CONNECTORS

TECHNICAL SPECIFIC

14

STANDARD INTERFACE CONNECTORS

PRESSURE CUFF STANDARD CUFF BEADED END

A push-on connector used inconjunction with a beaded endconnector where access is limited andquick installation is required. Eliminatesthe need for clamps or sleeves whichreduces the overall system weight.

An elastomeric end connection,produced as an integral part of the ductwhich improves installation times andreduces system weight by eliminatingthe need for an additional sleeve.

A beaded interface to AS5131compatible with both standard orpressure cuffs. Other bead styles, suchas shaped inserts, are available to suitcustomer applications, and can also beincorporated.

TEE CONNECTOR STUB CONNECTOR Y CONNECTOR

SEMI-RIGID COMPONENTSFully compatible with the standard flexible components, Senior Aerospace BWTs propriety ultra-lightweight composite constructionis a proven solution for low pressure air distribution components. The versatility of this range means that both modular andbespoke solutions, according to system requirements, can be provided as a complete package.

Senior Aerospace BWT has pioneeredthe use of ultra-lightweight compositeconstructions in the manufacture of acomprehensive range of standard semi-rigid connectors. Targeting lowpressure, medium temperature ECS airdistribution applications, the SeniorAerospace BWT range of PDconnectors has been designed to befully compatible with standard flexibles.They are available with two standardinterface styles: Threaded (or screw connection) - a simple, economic solution,eliminating the need of a clamp, forsmall diameter interfaces. Beaded (to AS5131) - for largerdiameters and applications requiringadditional restraint.

BESPOKE COMPONENTSThe design of aircraft and theincorporation of many modern features,means that space to install any aircraftsystem is at a premium. Coupled with theneed to minimize weight and pressuredrop, Senior Aerospace BWT are able tocall on many years experience of designingducting systems, to design andmanufacture products to almost anycomplex geometry whilst maintainingperformance integrity.

This complexity is achieved by theutilisation of a propriety ultra-lightweight,smooth bore, semi-rigid compositeconstruction. The manufacturing processallows the product to be formed intoalmost any shape, thus making ultimateuse of the space envelope.

With the unique ability to combine ultra-lightweight product types, SeniorAerospace BWTs innovative design teamhas unrivalled options when developingsolutions to particular problemsassociated with installation andperformance constraints.

As well as designing bespoke systemsolutions, Senior Aerospace BWT are alsoable to utilise a number of standardconnectors manufactured from the ultra-lightweight semi-rigid compositeconstruction. These connectors are fullycompatible with the standard flexibleproducts offered by Senior AerospaceBWT by making use of either threaded orbeaded end styles. The versatility of thisrange means that both modular andbespoke solutions, according to systemrequirements, can be provided.

ATION - FLEXIBLE DUCTING, INTERFACE CONNECTORS, FLEXIBLE DUCTING, INTERFACE

15

A flexible duct qualified to AS1591 forlow pressure, medium temperaturesystems. Primary applications arecold air distribution and PSU feeds.

Temperature Range -55 to 100C (-67 to 212F)

Material construction: urethane/nylonmembrane with nylon helix

Materials compatible to RTCA/DO-160 FST to ABD0031 (ATS1000.001) Pressure loss to SAE

1168/1 E/D = 0.002 Ultra-lightweight 92g/m (1oz/ft) at 2.0

diameter Standard diameter range 0.375 to 6 0.5D inner bend radius Standard colour: White

A flexible duct for low pressure, hightemperature systems. Primaryapplications are warm air distributionsystems. Can be lagged to reducethermal loss.

A flexible duct with excellentdeformation recovery for low pressure,high temperature systems. Primaryapplications are warm air distributionsystems. Can be lagged to reducethermal loss.

U62

CHARACTERISTICS

S4 SPS

NormalOperating

Short termOperating

OverrunMax

Min MaxNormal

OperatingShort termOperating

OverrunMax

Min MaxNormal


OverrunMax

Min Max

-55 100 110 120C


Material construction: silicone/glassclothmembrane with stainless steel helix


1168/1 E/D = 0.002 Ultra-lightweight 112g/m (1.2oz/ft) at 2.0

diameter Standard diameter range 0.5 to 6 0.5D inner bend radius Standard colour: Red or Black

CHARACTERISTICS

-55 200 225 250C


Material construction: silicone/glassclothmembrane with high performance non-metallic helix


1168/1 E/D = 0.002 Ultra-lightweight 92g/m (1oz/ft) at 2.0

diameter Standard diameter range 0.5 to 6 0.5D inner bend radius Standard colour: Red or Black

CHARACTERISTICS

-55 200 210 240C

PD PDS PDF

TECHNICAL SPECIFICATION -

SEMI-RIGID DUCTING, RIGID DUCTING

RIGID COMPONENTS

TECHNICAL SPECIFICATION

Proprietary ultra-lightweight glassreinforced composite laminate, forlow pressure high temperature airdistribution systems. Primaryapplications are for complex ductgeometries where low weight and lowpressure drops are essential.


Materials compatible to RTCA/DO-160 FST to ABD0031 (ATS1000.001) Pressure loss: Smooth bore makes PD ideal

for bends and complex shapes in duct runs Ultra-lightweight: Approx 0.11kg/m2

(0.023lb/ft2) per lamination Wall thickness: Each lamination is approx.

0.08mm (0.003) thick Durability: Excellent puncture resistance, its

ability to flex without fracturing allows easyinstallation

Standard colour: Off white. Other coloursare available. Compatible with many paintbases

CHARACTERISTICS

Proprietary ultra-lightweight glassreinforced composite laminate, with acontinuous spiral wound stainlesssteel reinforcing helix, for lowpressure high temperature airdistribution systems. Primaryapplications are for circular andstraight air supply ducting runs wherelow weight and low pressure dropsare essential.


Materials compatible to RTCA/DO-160 FST to ABD0031 (ATS1000.001) Pressure loss: Smooth bore makes PDS

ideal for long straight duct runs Ultra-lightweight: Approx 0.61kg/m2

(0.13lb/ft2) Wall thickness: Approx. 0.76mm

(0.03) thick Durability: Stainless steel reinforcement

provides crush resistance Standard colour: Off white. Other colours

are available. Compatible with manypaint bases

CHARACTERISTICS

Proprietary ultra-lightweight glassreinforced composite sandwich,incorporating a foam core, providingself insulating properties for lowpressure medium temperature airdistribution systems. Primaryapplications are for fabricatedavionics plenums where low weight is essential.


Materials compatible to RTCA/DO-160 FST to ABD0031 (ATS1000.001) Pressure loss: Smooth surface ensures

PDF provides minimal loss solutions Ultra-lightweight: Approx 0.61kg/m2

(0.13lb/ft2) Wall thickness: Approx. 4.5mm

(0.18) thick Durability: Double wall construction

ensures excellent puncture resistance Standard colour: Off white. Other

colours are available. Compatible withmany paint bases

CHARACTERISTICS

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NormalOperating

Short termOperating

OverrunMax

Min MaxNormal


OverrunMax

Min MaxNormal


OverrunMax

Min Max

-55 180 220 240C -55 180 220 240C -55 150 180 200C

- SEMI-RIGID DUCTING, RIGID DUCTING, TECHNICAL SPECIFICATION - SEMI-RIGID C

PDA

Proprietary ultra-lightweight glass andaramid reinforced composite laminate,providing high performance solutionsto specific ducting requirements.Suitable for low pressure hightemperature air distribution systems.Primary applications are for complexduct geometries where durability,toughness and resistance to higherpressures is essential.



PDA provides minimal loss solutions Ultra-lightweight: Approx 0.15kg/m2

(0.031lb/ft2) per lamination Wall thickness: Each lamination is

approx. 0.15mm (0.006) thick Durability: Extremely tough and puncture

resistant Standard colour: Yellow. Compatible

with many paint bases

CHARACTERISTICS

17

PDC

Proprietary ultra-lightweight glass andcarbon reinforced composite laminate,providing high performance solutionsto specific ducting requirements.Suitable for low pressure hightemperature air distribution systems.Primary applications are for complexduct geometries where high strengthand resistance to higher pressures isessential.



PDC provides minimal loss solutions Ultra-lightweight: Approx 0.16kg/m2

(0.033lb/ft2) per lamination Wall thickness: Each lamination is

approx. 0.18mm (0.007) thick Durability: Extremely strong. Usually

combined with other laminate materialsto enhance overall performance

Standard colour: Black. Compatible withmany paint bases

CHARACTERISTICS

ACOUSTIC DUCTING

Noise transmission is a feature of anyair distribution system. The installationof an acoustic silencer adjacent to thenoise source is a proven solution toreducing noise within the system.Attenuation is achieved byencapsulating sound absorbentmaterials between either a rigid orflexible duct outer wall and a porousinner membrane.


Materials compatible to RTCA/DO-160 FST to ABD0031 (ATS1000.001) Pressure loss: Designed to minimize loss

whilst maintaining acoustic performance Lightweight 490g/m (5.3oz/ft) at 2.0

diameter Standard wall thickness 0.5 Standard diameter range 0.75 to 6

CHARACTERISTICS

NormalOperating

Short termOperating

OverrunMax

Min MaxNormal


OverrunMax

Min MaxNormal


OverrunMax

Min Max

-55 180 220 240C -55 180 220 240C -55 200 225 250C

THERMAL INSULATION &

ACOUSTIC INSULATION

OUSTIC INSULATION

THERMAL INSULATION & ACOUSTIC INSULAT

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Fuselage insulation Roll-back duct insulation Acoustic silencer detail Thermal insulation

FUSELAGE, ACOUSTIC AND THERMALINSULATION PANELSFuselage insulation systems combine thebenefits of both thermal and acousticinsulation.

Senior Aerospace BWTs insulation panelsare tailored to accommodate the fuselageairframe sections. This ensures anexcellent fit, thus eliminating any heat lossor noise transmitting voids.

Senior Aerospace BWTs ultra-lightweightducting can be incorporated into theinsulation panel providing continuous airfrom the main feed duct into the cabinenvironment. This maximises the use of thespace envelope between the fuselage skinand interior side wall panel.

Senior Aerospace BWTs insulationprovides optimum thermal and acousticalperformance where space and weight areregarded as critical design parameters.

THERMAL INSULATIONSenior Aerospace BWTs thermal insulationensures a consistent air temperature flowis maintained throughout the ductingsystem, thus maximising efficiency. Theinsulation can be supplied as an integralpart of the duct or as an add-on sleeve.

Various material densities and thicknessesare available enabling the engineer tobalance performance, weight and costaccording to system requirements.

BWT

In recognition of its environmentalresponsibilities Senior Aerospace BWTsearched for an innovative solution tomeet the legislative requirements forsolvent emissions abatement. Notsatisfied with conventional methodsthat add to the growing problem of CO2in the atmosphere and global warming,Senior Aerospace BWT researched,piloted and eventually commissionedEuropes first bioreactor for biomassabatement of solvent emissions. Theprocess is inert, significantly reducesprocess emissions and produces noharmful secondary waste to be cleanedor disposed of.

Senior Aerospace BWTs commitmentto continuous improvement is furtherreflected in its drive to achieve leanand efficient manufacturing processesthat drive down the cost ofmanufacture to provide a competitiveadvantage to its customers. Ongoingcapital investment in equipment andfacilities complements the long termdevelopment of new materials andprocesses required to meet the everchanging demands of the aerospacemarket.

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WHERE TO FIND US

MANCHESTERAIRPORT

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MANCHESTER

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7 5

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M56

M62

M6

M62

M602

M60

M61

M66

M62

M60

M60

M67

M56

M6

M6

M60

TO PRESTONBOLTON

SALFORD

WILMSLOW

KNUTSFORD

HOLMESCHAPEL

CHELFORD

ALDERLEYEDGE

A34

A6

A6A34

A555 A5149

A5102

A628

A535

A523

A34

A536

A534

BURY

TO BURNLEY TO LEEDSM1/A1 (M)

OLDHAM

STOCKPORT

ASHTON-UNDER-LYNE

WARRINGTON

CONGLETON

MACCLESFIELD

POYNTON

ADLINGTON

TO BUXTON

ALTRINCHAM

TO PRESTON & THE NORTH

TO LIVERPOOL

TO CHESTER& NORTH WALES

TO BIRMINGHAM& SOUTH WALES

GLOSSOPA57

TO SHEFFIELD

& M1

M60

Senior Aerospace BWTs Adlingtonsite is located 15 miles southeastof Manchester, 4 miles north ofMacclesfield and 1 mile south ofPoynton off the A523. It is withineasy access of all major rail links,motorway routes and ManchesterInternational Airport.

Adlington Industrial Estate,

Adlington, Macclesfield

Cheshire, SK10 4NL,

United Kingdom.

Tel: +44 (0)1625 870700

Fax: +44 (0)1625 879472

Website: www.senior-bwt.com

E-mail: [email protected]

M1

M1

A1(M)M1

M180

M62

M6M54

M5

M50

M4M5

M4

M3M5

M40

M4

A1(M)

M25

LONDON

BIRMINGHAM

M42

M69

MANCHESTER

SHREWSBURY

LEEDS

BRISTOL

DERBY

LEICESTER

OXFORD

COVENTRYNORTHAMPTON

NOTTINGHAM

SHEFFIELD

M6

CARDIFF

M11

M62M61

M25

BWT

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