ARP4865A

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ARP4865 REV. A
AEROSPACE
RECOMMENDED PRACTICE Issued 1997-01
Reaffirmed 2007-11
Stabilized 2013-12
Superseding ARP4865
Gas Turbine Engine Fuel Nozzle Test Procedures
RATIONALE
This document has been determined to contain stable technology which is not dynamic in nature.
STABILIZED NOTICE
This document has been declared "Stabilized" by the SAE EG-1E Gas Turbine Test Facilities and Equipment Committee
and will no longer be subjected to periodic reviews for currency. Users are responsible for verifying references and
continued suitability of technical requirements. Newer technology may exist.
__________________________________________________________________________________________________________________________________________
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SAE INTERNATIONAL ARP4865A Page 1 of 31

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FOREWORD
Fuel nozzle performance requires measurement of fluid flow and pressure as well as the quality or
form and symmetry of the spray. The spray produced by most nozzles is measurable and must meet
certain criteria. The test equipment used for these measurements must meet specific accuracy
requirements for flow, pressure, and temperature. The test conditions, test fixturing for holding the
nozzle, and the methods used to measure the various spray acceptance criteria must also be
controlled.
There are two main categories of nozzle design; pressure atomizer and air blast. The pressure
atomizer uses fluid pressure as the main mechanism for breakup of the fluid into droplets. The outlet
orifice is small and a swirl device upstream of the outlet orifice establishes spray angle. This design
provides a very distinct spray angle and air is introduced into this angle without causing distortions.
Fluid pressure to the inlet of the nozzle nominally is between 25 to 550 psig. The air blast design uses
the air as the main mechanism for breakup of the fluid into droplets. The air is directed at the sheet of
fluid exiting from an internal prefilmer located at the exit of the nozzle. The spray angle is less
apparent and the fuel distribution is less concentrated. Fluid pressure to the inlet of the nozzle
nominally is between 2 to 50 psig. Both designs may incorporate flow divider valves that can change
the inlet pressure versus outlet flow curve. Flow divider valves are common on designs with a primary
and secondary flow channel. The valve secondary flow will begin at higher pressures after the engine
start sequence is completed.
1. SCOPE:
The intent of this SAE Aerospace Recommended Practice (ARP) is to define and recommend to
the Aerospace Industry standardized test procedures for establishing fuel nozzle operating
performance including types of tests, controlled and measured parameters, and test configurations.

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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 the 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:
Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.
ARP598 The Determination of Particulate Contamination in Liquids by the Particle Count

Method
ARP785 Procedure for the Determination of Particulate Contamination in Hydraulic Fluids by
the Control Filter Gravimetric Procedure
2.2 ANSI Publications: Available from ANSI, 11 West 42nd Street, New York, NY 10036-8002.
ISO 4402 Hydraulic Fluid Power. Calibration of Liquid Automatic Particle-Count Instruments-
Method Using Air Cleaner Fine Test Dust Contaminant
ISO 10012-1 Quality Assurance Requirements for Measuring Equipment, Part 1:
Meteorological Confirmation System for Measuring Equipment. This replaces the
cancelled MIL-STD-45662A.
2.3 U.S. Government Publications:

Available from DODSSP, Subscription Services Desk, Building 4D, 700 Robbins Avenue,
Philadelphia, PA 19111-5094.
MIL-C-7024 Type II, Military Specification. Calibration fluid for Aircraft Fuel Systems
Components
MIL-L-6081 Grade 1010, Military Specification. Preservative Oil
2.4 Terminology:
Use the following equalities for the purposes of this document, unless stated otherwise.
MIL-C-7024 Type II = Characteristics of this test fluid simulates jet fuel with less flammability
hazard.
PHR = Pounds Per Hour. Units for flow measurement. Recommended.
PPH = Another designation for flow units still in use. Not recommended for new
documents.
PSIG = Pounds per Square Inch Gauge. Units for pressure measurement.

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2.4 (Continued):
QD = Quick Disconnect. This two part device allows for a single action hydraulic
connection and disconnection between the test stand and UUT. The first
part called, the inlet adapter, is attached to the UUT to protect the inlet
supply section of the nozzle. The opposing end of inlet adapter then
inserts into the companion portion of the QD that is attached to the test
equipment.
SCFM = Standard Cubic Feet per Minute. Volumetric rate of airflow.
UUT = Unit Under Test or the nozzle under test.
3. TEST CONDITIONS:
3.1 Test Fluid:
Standard test fluid for aerospace manufacturers is MIL-C-7024 Type II. This is also known as
Stoddard solvent. Experience has shown that MIL-C-7024 Type II purchased from a single
supply source will maintain stable properties. However, when purchased from multiple sources,
these fluid properties can vary several percent. In comparing fuel property data taken from
different sources, the differences must be taken into consideration. The flow measuring
instrument calibration must account for the correct density and viscosity for the MIL-C-7024
Type II used or an equivalent fluid matching the MIL-C-7024 Type II properties.
The use of test fluids other than MIL-C-7024 Type II, such as actual jet fuels, is not
recommended. The wide variance in fuel properties precludes convenient correlation of test data
with other testing facilities. The use of jet fuels for fuel nozzle testing is also more hazardous,
requiring more stringent safety considerations.
3.2 Filtration:
The minimum acceptance Beta ratio for MIL-C-7024-II filtration systems shall be as shown in
Equation 1:
β 6 /11/15 = 2 / 20 / 75 (Eq.1)
See Appendix A.
3.3 Fuel Contamination Testing:
The acceptance level shall conform to the requirement MIL-C-7024 Type II fluid. The
recommended contaminant testing method is the International Standards Organization Solid
Contaminant Code (ISOSCC). The recommended ISOSCC rating acceptance level for all fuel
nozzle test stands is 16/13 (see Appendix B). It is recommended that the fluid contaminant level
be checked at intervals of 60 days.

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3.4 Temperature:
3.4.1 Fuel: The calibration fluid shall normally be maintained at a temperature of 80 °F (26.7 °C)
±2 °F (1.1 °C) measured at a point near as practical to the flow measurement device and not
closer than 10 diameters from the static pressure measuring tap. Deviation from this range is
allowed only if the measurement system contains corrections for the mass flow errors due to
specific gravity and viscosity variations with temperature.
3.4.2 Air: The air shall be maintained at a temperature of 50 to 95 °F (10 to 35 °C) measured at a
point not closer than 10 diameters from the static pressure measuring tap. The air supply shall
be clean and dry with a dew point of 40 °F (22 °C) or less.
4. EQUIPMENT ACCURACY:
4.1 Pressure Measurement:
The pressure measurement equipment shall be accurate to within ±0.5% OF READING for the
UUT (See Appendix C).
4.2 Pressure Sensing:
The pressure measuring taps shall indicate true static pressure at a point as close as practical to
the UUT inlet in a tube having a minimum internal diameter equal to the fitting to which it is
attached. The pressure tap should be located within 6 in of parallel height from the pressure
gauge reference plane. Establish the spray chamber height, with the UUT installed in the fixture.
If this is not possible a calibration must be performed to allow for positive or negative head
pressure.
4.2.1 Measuring Sections: Static pressure can be measured with a pressure measuring section
designed such that the pressure sensing passage is small relative to the diameter of the flow
passage and the pressure is sensed in the boundary layer of the fluid during normal operation.
The internal diameter must be large enough to assure a maximum velocity of no more than
20 ft/s (6.096 m/s) at the flow condition for fuel or Mach 0.2 for air such that the dynamic
pressure component is minimized. The pressure tap is placed a minimum of 10 diameters
downstream from the supply fitting connection and 2 diameters upstream from the exit. See
Figure 1 for fuel flow and Figure 2 for airflow.
4.2.2 Quick Disconnects (QD): If a QD is used during performance testing, the center check valve
should be removed. The inlet adapter must have at least the same internal diameter as the
UUT fitting. Periodic leakage checks should be performed on the inlet adapter and QD.
4.2.3 Calibration of QDs: If the test setup does not allow removal of the center check valve, then a
calibration must be performed to establish a correlation between pressure drop and flow rate.
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FIGURE 1 - Typical Fuel Flow Measuring Section
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FIGURE 2 - Typical Airflow Measuring Section

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4.2.4 Plenum Measurement (AIR): Static pressure can be measured in a Plenum chamber which
provides the working fluid to the test article. This is done with a small pressure sensing passage
at the periphery of the chamber. The internal volume must be large enough to assure a Plenum
feed of the test fluid to the test article. The maximum velocity at the inlet of the Plenum should
be no more than Mach 0.2 at the flow condition and no portion of the Plenum cross section shall
be smaller than the inlet. See Figure 3. The general shape of the air box is not critical if these
requirements are met.
4.3 Pressure or Flow Setting:
Pressure setting shall be within ±1% OF READING at all test points of the UUT. When
applicable, flow setting shall be within ±2.0% OF READING.
4.4 Fuel Flow Measurement:
The flow measurement shall be accurate to within ±0.5% OF READING at all test points of the
UUT.
4.5 Airflow Measurement:
The flow measurement equipment shall be accurate to within ±1.0% OF READING at all test
points.
4.6 Spray Angle Measurements:
The angle measuring device shall be accurate to within ±1° OF READING for overall angle and/or
±1% OF READING for linear width. The majority of sprays are conical in nature as they exit the
orifice of the UUT. The spray angle is measured at a point specified by the engine and nozzle
manufacturer. The spray cone is viewed as a two dimensional plane using simple fixturing and
measuring devices. The measured data can be either an angle and skew or linear dimensions
from centerline.
4.6.1 Spray Angle Test Fixturing: Test fixturing is normally mounted on or integral to spray chambers
which collect the spray dispensed, evacuate the fumes, and return the test fluid to the test
stand. The spray chamber and fixturing allow the spray to exit downward in a vertical plane and
is viewed by the operator through a transparent, nondistorting viewing aperture. Where spray
angle measurement or patternation is required, the UUT shall be mounted in a suitable fixture
such that, when installed in the measuring device, the UUT tip center-line is held within
±0.025 in (0.635 mm) of the angle device or patternator centerline. See Figures 4 and 5. The
theoretical spray cone apex, as defined by the appropriate control document, shall also be
placed at the measurement device reference plane, as defined by the device assembly
drawing, within ±0.025 in (0.635 mm). It is essential to establish the theoretical spray cone
apex and ensure the fixture dimensions are correct when installed in the spray angle device
being used.

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FIGURE 3 - Typical Air Box

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FIGURE 4 - Typical Spray Angle Device Front View
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FIGURE 5 - Typical Spray Angle Device Top View

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4.6.2 Plane -TS- For Test Fixtures: It is recommended that a reference plane called plane "-TS-" be
defined which is directly related to the UUT flange mounting holes. Thus, the measurement
plane is located relative to the flange datum on every UUT. The distance from "-TS-" to the
measurement plane is the nominal tip location plus the nominal defined location for
measurement of the spray angle and symmetry. Test tooling used to evaluate the spray must
be designed so the combination of the air box or UUT mounting fixture places the measurement
plane within 0.025 in (0.635 mm) of true position. Plane -TS- also becomes a standard
reference plane that should be added to the UUT envelope drawing. The tolerance specified
for -TS- to patternation devices should be ±0.050 in (1.270 mm). See Figures 6 and 7.
4.6.3 Visual Method: This method is very subjective and a procedure should be defined such that
repeatable results can be achieved. Normally there are two measurement indicators spaced
180° apart. The spray angle device indicators are moved slowly toward the conical spray. The
recommended practice is to read the position of these indicators when fluid droplets are
observed dripping at a constant rate. There are two types of indicator movement. The first
mechanism has the indicators in the horizontal plane located a known distance vertically from
the apex of the spray cone. These indicators move linearly towards the centerline of the spray.
See Figure 8. In the second mechanism, rotating indicators use the apex of the spray as the
axis of rotation. See Figure 9.
4.6.4 Calculation of Angle: The calculation of angle in the linear version is determined by
trigonometry. The fixture establishes the center axis of the spray and the required height from
the cone apex to the measurement plane. When the position of each indicator from the center
line is known, the two half angles of the spray are measured. Adding the two half angles yields
the total spray angle, sometimes referred to as combined angle. Subtracting the two half
angles and dividing by two, yields the skew angle which is a measure of the deviation from
centerline of the spray cone.
4.7 Circumferential Patternation:
The circumferential patternator is used to determine the variance of flow splits between a number
of defined segments of the spray. It is not considered a flow device and is used only to determine
deviation between the segments. See a typical device in Figure 7.
4.7.1 Collection of Fluid: The UUT is mounted directly above and centered on the collection device.
The device collects fluid when the UUT is spraying and guides it to individual measurement
segments.

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FIGURE 6 - Typical Plane


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FIGURE 7 - Typical Circumferential Patternator

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FIGURE 8 - Typical Spray Angle Device Top View

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FIGURE 9 - Typical Protractor Angle Device Top View


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4.7.2 Calculation of Patternation: Two methods are used to determine and display patternation data,
percent deviation from nominal and percent fuel per zone. Percent deviation from nominal is
obtained by adding the normalized collected volumes and dividing by the number of collection
segments to obtain a nominal value for each collection segment. Each individual collected
segment volume is subtracted from and divided by the nominal to give the segment's deviation
from nominal. This value is multiplied by 100 to give percent deviation from nominal. The total
spread percentage will be the difference between the minimum and maximum % deviations.
Percent fuel per zone is the collected volume, in percent, for each segment.
4.7.3 Spray Dissipation: A typical spray dissipation method for circumferential segmented
patternators uses randomly placed lock-wire in the individual segments. When the spray
strikes the lock-wire the droplets entrained in the air stream will coalesce on the lock-wire and
drain or drip to the bottom. Supporting the lock-wire with a large perforation mesh screen will
continue to coalesce the drain-off. Each segment should vent near the mesh screen at the
outside diameter of the patternator. Normal aspiration will suffice if the venting hole is large
enough. Use a forced evacuation system if a nonlaminar air stream or a nonrepeatable result
is evident. Measure the pressure in the chamber, referenced to atmosphere, and control the
exhaust air volume.
4.8 Radial Patternation:
The radial patternator is used to measure variances in flow collection segments arranged radially
from the spray cone apex of the UUT. The resulting data that is collected will provide a method
for determining spray angle and distribution of the spray. A typical collection device is shown in
Figure 10 and is described below. This device would normally be mounted directly below the
UUT spray centerline. The positioning can be seen in the top view of the device in Figure 5. This
description is not considered a recommended standard and is presented here only as a guide for
understanding. Similar radial patternators may have more or less segments and different
markings, but the general purpose is the same. The OEM nozzle manufacturers can provide the
exact information needed for each nozzle program.
An UUT is mounted directly above and centered on the centerline of the radial patternator
collector. A total of 14 segments on each side of centerline are lettered between A - P (I and O
are excluded). The center of the collection device is not lettered. The size of each collection
column or segment is 2.0 in high x 0.25 in wide x .25 in deep (50.8 mm high x 6.35 mm wide x
6.35 mm deep). The upper edge of the collector is located at a radius of 4 in (101.6 mm) from
the UUT apex. Each segment column is spaced 4.5° from each other. This will allow a
measurement of spray angle up to 126°. The transparent face of the collector has inscribed lines
that subdivide each segment column into eight units. These data are read when the meniscus of
the fluid passes the inscribed line. The collector utilizes a deflector shield that covers the
segments before measurement is started so that the proper flow and pressure can be set before
filling each segment. The shield is removed to begin filling the collector. The testing procedure
will specify either removing the shield for a specific time or until the last scribed line is reached in
the fastest filling segment. The shield is then returned to the deflecting position.

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FIGURE 10 - Typical Radial Patternator


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4.9 Spray Chamber:
The test chamber lighting and venting must be adequate to allow a clear view of the spray by the
operator. There shall be no obstructions that would distort the UUT spray within the
measurement plane.
4.9.1 Venting: The test chamber must provide for the safe venting of the UUT spray. The venting
flow rate must be adequate to keep the test chamber free from vapor that obscures the
operator's view of the UUT spray cone. The chamber pressure shall be within ±0.1 in of water
column when referenced to atmosphere. Location of the venting system shall not skew the
UUT spray which would cause inaccurate readings.
4.9.2 Lighting: A minimum of a 75 W collimated under-lighting and/or 300 W external indirect lighting
source should be used. Fiber-optic transmission of the light can be used to meet most safety
considerations. The under lighting apparatus shall not cause distortions to the spray.
4.9.3 Heat Transfer: Adequate safety precautions should be used to minimize the heat transfer from
the lighting source to the test fluid. A maximum surface temperature of 95 °F (35 °C) is
recommended for all surfaces that contact the test fluid.
4.9.4 Size: A minimum dimension of 9 in (228.6 mm) from the UUT centerline to the containment
wall is recommended. The format can be cylindrical or cubical. A minimum depth of 15 in
(381 mm) downstream from the UUT is recommended. Chamber sizing smaller than this can
cause distortions even at lower UUT flow conditions because of venting problems. Contact the
OEM to define what is allowable.
4.9.5 Spray Dissipation: One typical method for dissipating the spray is using fuel-cell foam
(SCOTFOAM-Orange) utilized in aircraft wings to prevent sloshing. Place a thickness of about
3 in (76 mm) at the bottom of the spray chamber. It can eliminate the splash back of the test
fluid and provide better visibility. Some systems provide an exhaust or evacuation system
below this fuel-cell foam layer. This will provide a laminar of air in a constant downward
direction and a stable system for reading spray angles. Another method for high velocity drops
is using lock-wire bent in a random pattern.
5. NOZZLE TESTING:
The testing of UUTs must be consistent with the same methods employed in a field service facility
as are performed at the OEM facility. The most important function of testing is performing tasks in
a consistent, repeatable manner. There may always be some amount of variance related to the
use of different testing systems, however, the differences between facilities can be more readily
evaluated and corrected with consistent test procedures.

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5.1 Operator Checklist:
The operator should have a checklist to run through before starting the test stand, allowing for
safety considerations and proper functioning. The test equipment shall state these requirements
in the operator's manual. The most important elements of operation can be outlined and
available near the operator's station. Also included in the checklist shall be a verification of the
calibration to the required standards.
5.2 Installing the UUT:
When installing the UUT into a fixture, ensure that the UUT is located correctly, particularly for
spray angle and patternation measurements. The fixturing should be adequately designed such
that it does not rely solely on the operator's expertise to correctly align the UUT. Most UUT test
systems use inlet adapters to protect the UUT fitting from damage. The inlet adapters are
typically designed to allow for a quick exchange of UUTs.
5.3 Setting the Pressure:
The pressure gauge is normally the most accurate measurement instrument, therefore, the
testing should be performed by setting a specific pressure whenever possible. The test operator
must increase the pressure to the test point without overshooting the test point. If a manually
operated test stand is used, the test operator must carefully increase or decrease pressure over
the last 10% of the test point to avoid the overshoot. Test articles with integral valves have test
points for Hysteresis values. The overshoot must be minimized such that valid Hysteresis values
can be obtained. Automated test equipment must provide accurate and repeatable control of the
pressure setting functions to limit overshoot to the required pressure setting tolerance.
5.4 Flow Reading:
The test operator or automated test procedure must allow a settling time for the flow
instrumentation. Most flow transducers require substantial settling time before accurate and
repeatable readings can be obtained. Not all test systems are the same and repeatability studies
should be performed to determine the correct settling time.
5.5 Data Record:
The data record must minimally include the following:
a. Test equipment used

b. Date
c. Test fluid
d. Pressure
e. Fluid flow
f. UUT part number
g. UUT serial number
h. Test operator identification

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5.6 Testing Procedure:
The testing procedure shall be documented and shall follow the original equipment manufacturers
test or overhaul procedures.
See Appendix D for an example of a general UUT test procedure.
5.7 Test Stand Noise:
The influences of the test stand noise to valve flow hysteresis must be considered. Some studies
indicate that excessive mechanical vibration near the nozzle will reduce hysteresis. It is
imperative that the amount of vibration be kept at a minimum repeatable hysteresis value.
Integral spray chambers attached directly to the test stand can receive this mechanical vibration
from the test stand and transmit it to the test fixture that holds the UUT. Engine companies may
require a specified amount of vibration to simulate the engine vibration. Suppliers must establish
what level of mechanical vibration is acceptable to the engine company.
PREPARED BY SAE SUBCOMMITTEE EG-1F, ENGINE ACCESSORY TEST EQUIPMENT

OF EG-1, AEROSPACE PROPULSION SYSTEMS SUPPORT EQUIPMENT

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APPENDIX A
FILTRATION
The filtration process itself is poorly understood. This causes terminology, concepts, and test methods
to improperly define or evaluate filters, filtration requirements, and filter performance. Filtration is the
separation of particles from a carrier fluid. This can be a mechanical separation at the surface or depth
filtration. Mechanical separation of particles occurs when a barrier, with openings smaller than the
particles being filtered, prevent the passage of such particles while allowing the passage of the carrier
fluid through the openings. Coarse strainers, fine wire mesh and membranes use this type of
separation which can be called "sifting" or "straining". Depth filtration, usually with lower micron
ratings, require separation throughout the depth of a filter by capturing the particles in a convoluted
pathway.
A.1 RATING SYSTEMS:
The filter system shall perform as follows:
a. β 6 = 2 (50.0% efficient @ 6 µm)

b. β 11 = 20 (95.0% efficient @ 11 µm)
c. β 15 = 75 (98.66% efficient @ 15 µm)
There are three rating systems in common use in the aerospace industry.
a. ABSOLUTE RATING: Defined as the size of the largest spherical glass particle which will
pass under laboratory conditions, this rating is often misunderstood and misused in the filter
industry and its customers. This rating means this is the largest size glass bead particle that
will be downstream of the element under very low pressure differentials and non-pulsating
flow conditions. This term should not be used in any test specification.
b. NOMINAL RATING: This value has no pertinent meaning. It does not signify any
characteristic of the filter which can be determined or measured against an accepted
standard. Nominal filter ratings have many limitations. First, they do not present a clear
indication of the largest size particle that can pass through a filter. Second, it is a
nonstandard system that lacks consistency; effectively an arbitrary value assigned to the filter
by the manufacturer. This term should be discouraged for use in any liquid test specification.
Due to these factors, nominal ratings have lost favor to the more sophisticated Beta filtration
rating systems.
c. DYNAMIC EFFICIENCY: Filter performance determined on the basis of simultaneously

counting particles in a number of preselected size ranges upstream and downstream of the
test filter.

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A.1 (Continued):
The preferred system for rating filters is dynamic efficiency. The ratio is determined by dividing
the number of particles entering by the number of particles leaving the test filter. This is usually
done by using an electronic automatic particle counting technique. The actual operating
conditions of the filters are used for this rating. The term for the resulting values is the Beta ratio
as defined in Equation A1:
β x = Nu x / Nd x (Eq.A1)
where:
x = the preselected particle size

Nu = number of particles of size x and greater upstream
Nd = number of particles of size x and greater downstream
The relationship between the Beta ratio and filter efficiency is shown in Equation A2:
% efficiency = 100 − 100 / β (Eq.A2)
Example:
Beta ratio: β 10 = 50
Expressed as efficiency: 100 - 100/50 = 98
Therefore: 98% of all particles greater than 10 µm are removed.
It would be impractical to compare beta rating's above 75, because you would be dealing with the
last 1% of efficiencies. We have adopted the 2/20/75 method which presents data as shown in
Equation A3:
β 6 /11/15 = 2 / 20 / 75 (Eq.A3)
The filter element performs as follows:
a. β 6 = 2 (50.0% efficient @ 6 µm)

b. β 11 = 20 (95.0% efficient @ 11 µm)
c. β 15 = 75 (98.66% efficient @ 15 µm)
NOTE: The filter industry is generally defining the particle size (x) at which β x = 2 as the nominal
rating and the particle size (x) where β x = 75 as the absolute rating of an element.

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APPENDIX B
FUEL CONTAMINATION TESTING
Contamination level measurement has historically used two basic methods. The first method
(ARP598) manually counts the particles in a given sample of fluid and classifies them as to the number
of counts in a given micron size range. The fluid sample size is 100 mL. The second method
(ARP785) weighs the particles collected in a given sample of fluid. This method (Gravimetric) is used
by the producer of the MIL-C-7024 Type II calibrating fluid. The acceptance level conforms to the
requirement of MIL-C-7024 Type II fluid.
A more recent testing method is the International Standards Organization Solid Contaminant Code
(ISOSCC) which is assigned on the basis of the number of particles per unit volume. This rating
system uses two numbers separated by a solidus. All particles greater than 5 µm are identified with
the first number and all particles greater than 15 µm are identified with the second number.

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APPENDIX C
CALIBRATION
There are two methods of determining accuracy of equipment. The first is full scale accuracy (%FS)
and the second is percent of reading (%R). The two methods can be defined as follows:
a. %FS: Full scale of the device used. The upper limit of the device is multiplied by the percentage
given (±) to specify the amount of uncertainty at any point on the scale.
b. %R: Percentage of reading. The nominal number value is multiplied by the percentage given
(±). This value is added and subtracted to the nominal value to determine the accuracy.
For a measurement device that is defined in %FS accuracy, the crossover point, where the %FS and
%R intersect, provides the lower limit for use of the device. This crossover point is the method for
determining the point to overlap %FS devices to comply with %R requirements. It is recommended
that pressure gauges have a minimum %FS of 0.11 and a %R of 0.5%. An easy method for finding the
crossover point is dividing the %FS by the %R to find the ratio, then times the upper limit to find the
intersect.
Example:
A pressure gauge with a 1000 psig range and %FS of 0.11% will divide the %FS (0.11) by the
recommended %R (0.5) to obtain a ratio of 0.22.
0.11 %FS / 0.50 %R = 0.22 ratio
Multiply the resultant ratio times the Full Scale range to find the crossover and the recommended lower
limit of the gauge.
0.22 ratio * 1000 psig = 220 psig
The next overlapping gauge with a range of 250 psig and %FS of 0.11% will extend %R to 55 psig to
maintain a recommended %R of 0.5.
0.22 ratio * 250 psig = 55 psig
This gauge would be usable down to 55 psig while maintaining %R.
C.1 CALIBRATION PROCEDURES:
All instrumentation will have calibration traceable to National Institute of Standards and
Technology (NIST) or appropriate national standard. The methods used for calibration of specific
instruments must be developed internally. Most government authorities (Military, FAA) and
engine companies require established written detailed procedures.

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TABLE C1 - Suggested Schedule for Calibration Intervals for the Instrumentation
Accuracy Accuracy
Nomenclature Frequency Required Method
Temperature indicators 180 days ±1 °F
Electrical instruments 180 days ±0.5% %FS
Airflow meters 180 days ±1.0% %R
Fuel flow meters 180 days ±0.5% %R
Pressure Gages 90 days ±0.5% %R
Specific gravity 60 days ±0.5% %R
1
Flow meters and readouts Daily ±0.5% %R
1
As described in C.2
C.2 DAILY AUDITS:
To ensure that daily calibration remains consistent and no problems develop, a daily check of the
test equipment should be performed. The most common form that is gaining acceptance is the
use of calibrated orifices. This system checks both the pressure and flow variables from a known
standard. The use of master nozzles is also acceptable, however problems can occur when
using UUTs with flow divider valves that are less repeatable than the flow measurement device.
C.3 ROUND ROBIN CALIBRATIONS:
A Round Robin is a calibration method used by the engine companies and facilities that overhaul
and/or test nozzles. Suppliers must ensure that all nozzles maintain close and consistent
calibration values. A sponsor will provide a “Master Nozzle” with nominal flow calibration values.
This “Master Nozzle” is sent to all Round Robin participants to their facility for calibration. A data
sheet may consist of:
a. Title of the test.

b. OEM test specification. This may include flow at several pressure settings, spray angle
measurements, patternation results, etc.
c. Test equipment used. Tracibility must be to a nationally recognized standard.
d. Part number and serial number of the nozzle.
e. Signatures of the calibrator and a witness.
f. Date of test.
Each participant will perform three calibrations of the test specification to establish repeatability.
A report will collate this information to provide the relative testing variations between the
participants. This method is very useful to identify and resolve a systemic problem. The OEM
shall determine the allowable correlation percentage between nozzle test stands in the same
facility and between different facilities.

_________________________________________________________________________________________________
APPENDIX D
SAMPLE FUEL NOZZLE TEST PROCEDURE
D.1 SEQUENCE:
All qualification testing specified herein shall be successfully completed after component final
assembly or after any rework, repair, or modification of the component. All tests shall be
performed in the assigned numerical order of the sub-paragraphs in this specification.
D.2 NOZZLE ASSEMBLY PREQUALIFICATION:
Measure the flow though the secondary circuit with the nozzle support and tip mounted in a
fixture that meets the requirements of ENGINEERING SPECIFICATION-XXX. The fixture shall
allow the testing of the secondary circuit separately from the primary circuit without the flow
divider valve installed. With and without the restrictor installed per the applicable assembly
drawing, the secondary circuit shall flow within the limits specified in Table D1 at the respective
inlet pressures.
TABLE D1 - Secondary Circuit Flow Limits
Test Fluid Flow (PPH) Test Fluid Flow (PPH)

Inlet Pressure (psig) Without Restrictor With Restrictor
XXX XXX-XXX XXX-XXX
XXX XXX-XXX XXX-XXX
D.3 NOZZLE ASSEMBLY QUALIFICATION:
D.3.1 Product Examination:
Each assembly shall be examined to assure that correct assembly has been made, that all
previous operations have been completed, and that the unit is ready for test.
D.3.2 Leakage Tests:
External leak tests shall be performed (as specified on the product drawing) prior to fluorescent
penetrate and radiographic inspection of final closure weld. Internal leak tests shall be
performed after all manufacturing operations have been completed.

_________________________________________________________________________________________________
D.3.3 Pneumatic External Leak Test:
Prior to the test, completely purge the nozzle assembly of liquid and cap all fluid escape
passages. To test, orient with the nozzle exit passages pointed upward and pressurize the
nozzle inlet and exit simultaneously with XXX-XXX psig nitrogen for XX seconds minimum while
submerged a passive test fluid. There shall be no bubbles indicating leakage from any external
surface. At the completion of the test, release the pressure from:
a. The nozzle tip exit end first or

b. The nozzle tip exit end simultaneously with the nozzle inlet
D.3.4 Hydraulic External Leak Test:
Prior to the test, completely fill the nozzle assembly with test fluid and cap all fluid escape
passages. To test, pressurize the nozzle inlet and exit simultaneously with XXXX-XXXX psig
test fluid for XX seconds minimum. There shall be no fluid indicating leakage from any external
surface. At the completion of the test, release the pressure from
a. The nozzle tip exit end first or

b. The nozzle tip exit end simultaneously with the nozzle inlet
D.3.5 Pneumatic Internal Leak Test:
Prior to the test, completely purge the nozzle primary circuit of liquid and cap the primary circuit
escape passages. To test, orient with the nozzle exit passages pointed upward and pressurize
the primary circuit nozzle inlet with XXX-XXX psig nitrogen for XX seconds minimum while
submerged in a passive test fluid. There shall be no bubbles indicating leakage from any
secondary flow passage.
D.3.6 Hydraulic Internal Leak Test:
Prior to the test, completely fill the nozzle primary circuit with test fluid and cap the primary
circuit escape passages. To test, pressurize the primary circuit nozzle inlet with XXXX-XXXX
psig test fluid for XX seconds minimum. There shall be no fluid indicating leakage from any
secondary flow passage.
D.3.7 Valve Hydraulic Reseat/Decay Test:
Prior to the test, cycle the assembly X times from a low pressure of XX psig (maximum) to a
high pressure of XXX to XXX psig to ensure removal of all trapped air. To test, set the inlet
pressure at XXX psig and close off the supply pressure. After X minutes, the fuel pressure
immediately upstream of the nozzle inlet shall be XXX psig minimum. The standard pressure
measurement requirements of ENGINEERING SPECIFICATION -XXX apply and the shutoff
valve must be upstream of the measurement section.

_________________________________________________________________________________________________
D.3.8 Valve Pneumatic Reseat Test:
To test, orient with the nozzle exit passages pointed upward and pressurize the nozzle inlet with
nitrogen to XXX-XXX psig while submerged in a passive test fluid. Verify that the valve is open
by observing a steady stream of bubbles leaving the exit passages. Reduce the inlet pressure
to XXX-XXX psig, with no overshoot, for XX seconds minimum. There shall be no bubbles
indicating leakage from any exit passage.
D.3.9 Flow Test:
Prior to the test, cycle the assembly X to X times from a low pressure of XX psig (maximum) to
a high pressure of XXX to XXX psig. The total fuel flow shall be within the limits specified
below at the respective inlet pressures in the order indicated.
TABLE D2 - Fuel Flow Limits
Test Fluid
Inlet Pressure Flow
(psig) (PPH)
XXXX XXX-XXX
XXXX XXX-XXX
D.3.10 Reference Information: Valve crack is nominally XXX psig across the valve. Secondary flow
across the tip, housing and restrictor less the valve is XXX pph nominal at XXX psig.
D.3.11 Hysteresis Test:
Prior to the test, cycle the assembly X to X times from a low pressure of XX psig (maximum)
to a high pressure of XXX to XXX psig. Measure the test fluid flow at the pressures specified
below when approached from a pressure of XXX to XXX psig. No overshoot of the tests
points is allowed. The difference in flow readings (as compared to the measurements at the
same pressures in 4.3.1) shall not exceed the limits below at the respective pressure. This
test may be performed in conjunction with the flow test in 4.3.1.
NOTE: The highest pressure test point in the Hysteresis testing must be approached from a
higher pressure point which is at least 10% above the test point. (See Table D3.)
TABLE D3
Inlet Pressure Maximum Hysteresis

(psig) (PPH)
XXXX XXX
XXXX XXX

_________________________________________________________________________________________________
D.3.12 Shroud Air Effective Area Test:
Measure the effective area of the shroud air circuit with the nozzle mounted in an airflow
fixture per the requirements of ENGINEERING SPECIFICATION -XXX. The effective area
shall be within the limits specified in Table D4 at the indicated pressure drop. The effective
area shall be calculated per ENGINEERING SPECIFICATION -XXX.
TABLE D4
Air Pressure Drop Effective Area Effective Area

(in H20) (in2) min (in2) max
XXXX XXX XXX
D.3.13 Reference: Limits are equivalent to XXX-XXX SCFM at a pressure ratio of XX.
D.3.14 Spray Profile Test:
Measure the spray profile and profile symmetry with the nozzle mounted in a spray profile
measuring device per the requirements of ENGINEERING SPECIFICATION -XXX. The
spray profile is defined as the horizontal separation between the tips of the probe apparatus
when they are in contact with the spray at a vertical distance of X.XX - X.XX inches from the
plane -TS- as defined in Figure X on page XX. The spray profile symmetry is defined as the
horizontal distance the center of the actual spray profile is located relative to the tip centerline.
Proper contact of the probe with the spray is defined as the point where a constant stream of
droplets are dripping off of the probes. The spray profile and profile symmetry shall be
measured in one radial plane of the nozzle spray. Radial location is optional; however, the
nozzle cannot be rotated until an acceptable result is obtained.
D.3.14.1 Spray Profile: To test, set the air and test fluid pressures as specified. The nozzle shall
provide a continuous fully developed conical spray pattern which shall be within the spray
profile and the profile symmetry limits below. These dimensions are a linear measure, but
can easily be converted to an angular value.
TABLE D5
Inlet Air Spray Spray Profile

Pressure Pressure Profile Profile Symmetry
(psig) (in H20) X Y (X-Y)/2
XXX XXX XXX-XXX XXX-XXX XXX-XXX
D.3.14.2 Spray Profile (Viscous Fluid): To test, using 12 centistoke fluid, set the primary inlet
pressure as specified. The primary nozzle shall provide a continuous fully developed
conical spray pattern which shall be within the spray profile, profile symmetry, and fluid flow
limits in Table D6.

_________________________________________________________________________________________________
TABLE D6
Inlet Spray Spray Profile Fluid

Pressure Profile Profile Symmetry Flow
(psig) X Y (X-Y)/2 (pph)
XXX XXX-XXX XXX-XXX XXX-XXX XXX MAX
D.3.15 Spray Quality Test:
At all conditions specified in paragraphs 4.5.1 and 4.5.2, spray quality shall meet the
requirements of drawing XXXXXXX.
D.3.16 Radial Distribution Test:
Measure the radial distribution of the nozzle spray with the nozzle mounted in a patternation
device per the requirements of ENGINEERING SPECIFICATION -XXX. The radial
distributions shall be measured in X radial plane(s) of the nozzle spray at a vertical distance of
X.X - X.X from plane -TS- as described in Figure X on sheet XX. Radial location of the nozzle
relative to the patternator is optional; however, the nozzle cannot be rotated until an
acceptable result is obtained.
To test, set the specified air and test fluid pressures for a period of time required to fill (within
2 graduations) the fastest filling collection tube. The patternator readings shall be within the
limits specified below. Specific distribution results need not be recorded.
TABLE D7
Inlet Pressure Air Pressure Patternator

(psig) (in H20) Reading
XXX XXX X-X
D.3.17 Circumferential Distribution Test:
Measure the Circumferential distribution of the nozzle spray with the nozzle mounted in a
circumferential patternation device per the requirements of ENGINEERING SPECIFICATION-
XXX. The circumferential distribution shall be measured at a vertical distance of X.X - X.X
from plane -TS- as defined in Figure X on page XX. The uniformity of the circumferential
distribution is defined as the percent difference between the maximum and minimum test fluid
samples relative to the fuel sample collected during the test.
To test, set the air and test fluid pressures as specified. The uniformity of the circumferential
distribution shall not exceed the specified limit.

_________________________________________________________________________________________________
TABLE D8
Inlet Air Circumferential

Pressure Pressure Uniformity
(psig) (In H20) (Percent)
XXX XXX XXXX MAX
MAX Fuel Sample - MIN Fuel Sample x 100
Circumferential =
Uniformity Fuel Sample (Average - -OR - -Max)
D.4 FINAL INSPECTION:
After successful completion of all test requirements, each assembly shall be examined to the
specific Quality Assurance plan to assure conformance to all requirements.
D.5 Preparation for Delivery:
Prior to shipment, each assembly shall be preserved as follows:
D.5.1 FLUSHING:
Flush with MIL-L-6081 Grade 1010 preservative oil per ENGINEERING SPECIFICATION -
XXX at an inlet pressure of XXX to XXX psig. Following flushing, allow excess fluid to drain.
D.5.2 Protective Covers:
Cover parts with protectors specified on the Parts List.

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Gas Turbine Engine Fuel Nozzle Test Procedures

SAE INTERNATIONAL ARP4865A Page 1 of 31

SAE INTERNATIONAL ARP4865A Page 2 of 31

2.1 SAE Publications:

Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.

ARP598 The Determination of Particulate Contamination in Liquids by the Particle Count

2.3 U.S. Government Publications:

SAE INTERNATIONAL ARP4865A Page 3 of 31

3.1 Test Fluid:

3.3 Fuel Contamination Testing:

SAE INTERNATIONAL ARP4865A Page 4 of 31

4.1 Pressure Measurement:

4.2 Pressure Sensing:

SAE INTERNATIONAL ARP4865A Page 7 of 31

4.3 Pressure or Flow Setting:

4.4 Fuel Flow Measurement:

4.5 Airflow Measurement:

4.6 Spray Angle Measurements:

SAE INTERNATIONAL ARP4865A Page 8 of 31

FIGURE 3 - Typical Air Box

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4.7 Circumferential Patternation:

SAE INTERNATIONAL ARP4865A Page 12 of 31

FIGURE 6 - Typical Plane

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FIGURE 7 - Typical Circumferential Patternator

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FIGURE 9 - Typical Protractor Angle Device Top View

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4.8 Radial Patternation:

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FIGURE 10 - Typical Radial Patternator

SAE INTERNATIONAL ARP4865A Page 18 of 31

4.9 Spray Chamber:

SAE INTERNATIONAL ARP4865A Page 19 of 31

5.1 Operator Checklist:

5.2 Installing the UUT:

5.3 Setting the Pressure:

5.4 Flow Reading:

5.5 Data Record:

The data record must minimally include the following:

a. Test equipment used

SAE INTERNATIONAL ARP4865A Page 20 of 31

5.6 Testing Procedure:

See Appendix D for an example of a general UUT test procedure.

5.7 Test Stand Noise:

PREPARED BY SAE SUBCOMMITTEE EG-1F, ENGINE ACCESSORY TEST EQUIPMENT

SAE INTERNATIONAL ARP4865A Page 21 of 31

A.1 RATING SYSTEMS:

The filter system shall perform as follows:

a. β 6 = 2 (50.0% efficient @ 6 µm)

c. DYNAMIC EFFICIENCY: Filter performance determined on the basis of simultaneously

SAE INTERNATIONAL ARP4865A Page 22 of 31

x = the preselected particle size

% efficiency = 100 − 100 / β (Eq.A2)

The filter element performs as follows:

a. β 6 = 2 (50.0% efficient @ 6 µm)

SAE INTERNATIONAL ARP4865A Page 23 of 31

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