Chapter 10: LIFE CYCLE COSTING

OF FIRE SUPPRESSION SYSTEMS

J. Michael Bennett, Ph.D. 

Bennettech, LLC 

TABLE OF CONTENTS

10.1 Background....................................................................................................................1025 

10.1.1 Technical Concept .............................................................................................1025 

10.1.2 NGP Tasks.........................................................................................................1026 

10.1.3 General Methodology ........................................................................................1027 

10.2 Agent properties.............................................................................................................1027 

10.3 Current System Description (Halon 1301) for Legacy Aircraft ....................................1028 

10.3.1 Cargo Aircraft ....................................................................................................1028 

10.3.2 Fighter Aircraft ..................................................................................................1034 

10.3.3 Rotary-wing Aircraft..........................................................................................1038 

10.4 Proposed System Description (HFC-125) for Future Aircraft.......................................1042 

10.4.1 Design Guide .....................................................................................................1042 

10.4.2 Cargo Aircraft ....................................................................................................1045 

10.4.3 Fighter Aircraft ..................................................................................................1048 

10.4.4 Rotary-wing Aircraft..........................................................................................1052 

10.5 Costs Of Current and Replacement Systems.................................................................1054 

10.5.1 Life Cycle Cost Estimate (LCCE) Summary for Legacy Aircraft.....................1056 

10.5.2 Life Cycle Cost Estimate (LCCE) Summary for Future Aircraft......................1058 

10.5.3 Detailed Cost Element Structure (CES).............................................................1061 

10.5.4 Cost Element Structure Data Development .......................................................1061 

10.6 Cost Savings...................................................................................................................1066 

10.7 Cost Analysis Using Altered Fire Suppression Performance ........................................1068 

10.7.1 Factor of Safety Testing.....................................................................................1068 

10.7.2 System Description ............................................................................................1069 

10.7.3 Altered Fire Suppression Performance ..............................................................1070 

10.7.4 Cost Analysis.....................................................................................................1073 

10.8 Conclusions....................................................................................................................1082 

10.9 References......................................................................................................................1083 

10.1 BACKGROUND 

10.1.1 Technical Concept 

Aircraft fires impose a significant cost impact on the military. Fire is either the primary cause or a 

contributing factor in a large portion of mishaps that result in injuries to personnel, material loss of 
1026 Life Cycle Costing of Fire Suppression Systems 

aircraft assets, and loss of mission capability. Methods and technologies to mitigate these costs or 

"design them out" are a major component in aircraft design, retrofit, and maintenance. 

To determine the preferred fire extinguishing medium, system or method for any application, the holistic 

approach is to compare alternatives based upon on an overall cost of ownership, or “life cycle cost,” 

either over an aircraft's projected useful life or some fixed period of use. This approach incorporates the 

various costs associated with procuring, installing and maintaining such equipment, including nonhardware costs such as development and certification, as well as repair and parts replacement. Fire 

protection equipment that functions successfully will prevent damage to personnel and property, resulting 

in an offsetting cost savings. The magnitude of these savings depends on the success rate and speed of 

suppression (thereby minimizing physical damage), and the cost of the protected assets themselves. The 

net cost or savings of each alternative can then be compared to determine the best choice, in this case as a 

replacement for the halon 1301 fire extinguishing chemicals. 

This process can also serve other purposes: 

• Estimation of whether a new fire protection technology is sufficiently superior to the state of 

the art, in cost effectiveness, to warrant further pursuit. 

• Justification of the use of any fire protection system at all for an application of interest. This 

entails a comparison of the cost savings in terms of assets preserved against the total life 

cycle cost of the fire protection technology. 

• Determination of the economics of an optimal degree of effectiveness of a firefighting 

system. Historically, fielded fire suppression systems have been less than 100 % effective. 

There are costs (dollars, mass carried, and volume occupied) that generally increase with an 

enhanced degree of surety that a firefighting system will protect the aircraft and its occupants. 

10.1.2 NGP Tasks 

To demonstrate the applications of life cycle costing to aircraft fire extinguishing systems, Bennett, 

Kolleck and co-workers at Booz Allen & Hamilton: 

1. Established a life cycle cost baseline for typical halon 1301 (CF3Br) fire extinguishing 

systems that are used on aircraft today, by considering several varied aircraft platform type 

representatives (both legacy (existing) and future platform types), to establish a life cycle cost 

equivalence goal for any halon 1301 replacement derived from or considered by the NGP. 

2. Performed a similar cost analysis for the same platforms using a different fire suppressant. 

These systems used the “first generation” halon 1301 replacement, HFC-125, C2HF5, (see 

below) for which extensive data existed. The HFC-125 system was sized to the same level of 

performance as the existing halon 1301 systems. This established a threshold cost-ofownership level that any halon 1301 replacement technology must exceed to be preferred 

over the pre-existing use of HFC-125 and thus maintain further interest for research and 

implementation. 

3. Performed cost of ownership studies by varying the performance levels of such systems, by 

adjusting the size capacities (with resultant weight and size impacts on life cycle cost), to 

determine an optimal performance level in terms of life cycle cost by balancing firefighting 

effectiveness with the size/capacity/cost implications. 
Background 1027

4. Evaluated the merits of halon 1301 and HFC-125 systems (and, by extension, or any other 

fire protection system) in terms of their ability to pay for themselves by determining if the 

cost savings in terms of assets saved historically actually exceeded the life cycle costs of 

developing, installing and supporting such systems in the field. This enabled confirming if 

the systems actually provide a tangible monetary benefit to their aircraft customers, to 

determine which aircraft configurations (if any) provide such benefits, and to quantify any 

perceived benefits. 

The methodologies developed, modified and demonstrated under the NGP have been documented in 

References 1, 2, and 3, whose distribution is restricted, and in References 4, 5, 6, 7, and 8, which are 

available to the public. The methodologies were fashioned to serve as stand-alone products, to provide 

the framework to build modified models for future halon 1301 replacements, and to serve as analysis 

tools to identify key indicators of desirable halon 1301 replacement properties to consider in later 

research on new technologies. Since their formulation, these methodologies have been used to perform 

trade-off studies and to assist in the selection of the most affordable halon replacement agent and system 

design for aircraft recently under development. 

10.1.3 General Methodology 

A methodology was developed to determine the net cost of the fire suppression system. This 

methodology incorporates the cost of the system, which is a function of system size/weight, and the cost 

savings provided by the system, which are a function of extinguishant effectiveness and the resultant 

aircraft saved and their value. The net cost is the cost of the system minus the cost savings. 

Fire system characterization was first necessary to understand and appreciate the system cost information 

fully. This was accomplished for the current halon 1301 systems and estimated for the proposed 

HFC-125 systems. Information regarding the current systems was available through previous NGP 

efforts.9,10 Estimates regarding the proposed systems were made using information generated as a part of 

the Halon Replacement Program for Aviation.11 Impact estimates (sensitivity analyses) were also made 

for the potential increase in bottle size/distribution plumbing. 

System cost information was developed utilizing the data contained in the Federal Logistics (FEDLOG) 

system and various traditional costing factors. The Defense Logistics Agency provided access to this 

system. It contains part numbers, suppliers, and other logistical information specifically for the Service of 

interest. It is not releasable to the general public because of the proprietary nature of some of the data. 

Cost savings information was obtained by utilizing the Annual Fire Protection Cost Model [1966-1995; 

1996-2025]12 and other peacetime incident data. 

10.2 AGENT PROPERTIES 

Halon 1301 is considered by many to be a nearly perfect compound for fire suppression in challenging 

and high performance applications, such as aircraft. This compound can be stored compactly as a 

liquefied gas at room temperature and a 1.61 MPa storage pressure, but quickly flash vaporizes at 

atmospheric pressure and ambient temperatures. It remains stable for years, which is important for 

satisfactory storage in fielded use. The electrical conductivity of the gas is low (permitting its use in 
1028 Life Cycle Costing of Fire Suppression Systems 

electrical and electronics areas), it is non-corrosive in its pure state, and it is an effective fire suppressant 

at concentrations well below levels that pose toxicity concerns to humans. 

HFC-125 was the “first generation” halon 1301 alternative chemical recommended for immediate use 

after intensive research efforts of the U.S. Air Force/Navy/Army/Federal Aviation Administration funded, 

multiyear Halon Replacement Program for Aviation to identify near-term substitutes for halon 1301 for 

aircraft platforms needing an immediate replacement.13 The selection had been made following testing in 

generic and reconfigurable engine nacelle and dry bay mockups, representing the wide range of aircraft 

fire zone configurations of interest to the sponsors. Statistical experimental design techniques were used 

to translate the experiments representing a subset of all the possible combinations of fire zones and 

scenarios into the determination of the extinguishant with the best firefighting performance i.e., lowest 

agent mass required to extinguish the fires, for all the applications and conditions of interest. In addition 

to fire suppression performance results, other data on the extinguishants’ storage and discharge 

characteristics, toxicity and materials compatibility traits were considered in the final decision. Once this 

decision was made, additional experiments were performed to develop a more precise system sizing 

model, again using statistical experimental design, for HFC-125 that would facilitate the sizing of 

extinguishing systems using it for various aircraft engine nacelle and dry bay applications. 

HFC-125 has many characteristics similar to halon 1301. It leaves no residue in the event of accidental 

discharge, and thus requires negligible cleanup support. It is non-reactive with steel, aluminum, or brass, 

and no adverse effects are expected on plastics. Most importantly, it fills heavily cluttered spaces quickly 

and easily, even at cold temperatures, and under high ventilation air flow conditions. Its atmospheric 

lifetime is 26.4 years.10

For these two chemicals, Table 10–1 lists the properties that were used in the cost estimates. 

10.3 CURRENT SYSTEM DESCRIPTION (HALON 1301) FOR LEGACY AIRCRAFT 

10.3.1 Cargo Aircraft 

The typical legacy cargo aircraft fire protection system layout is described below. The basic design 

approach placed emphasis on the prevention and containment of fire. The engine nacelle and APU 

compartments are designated as fire zones, where combustible fluids (fuel, hydraulic fluid, and engine 

oil) and ignition sources coexist, and a single failure in the combustible fluid system could result in a 

fire.14

Aircraft Engine Nacelle Fire Protection System Components and Procedures 

Provided below are realistic fire protection system configuration data for current (legacy) cargo aircraft 

currently being procured and operated by the USAF. It was assumed that fire protection systems for 

future cargo aircraft would be similar to these. Schematic drawings of the engine nacelle systems are 

shown in Figure 10–1 through Figure 10–3.
Current System Description (Halon 1301) for Legacy Aircraft 1029

Table 10–1. Properties of Halon 1301 and HFC-125 Used in Life Cycle Costing. 

Features Halon 1301 HFC-125 

Extinguishant Physical State (ambient) Gas Gas 

Mechanism of Extinguishment Chemical, some cooling, inerting Cooling, inerting 

Physical Properties 

Boiling Point (°C) at 101 kPa (1 atm) -57.8 -48.5 

Molecular Weight, g 149 120 

Liquid Density, kg/m3 (lb/ft3) at 70 ΕF 97.8 75.7 

Vapor Pressure, kPa (psia) at 298 K 249 190 

Freezing Point, °C (1 atm) -168 -103 

Critical Temperature, °C 4 72 

Critical Pressure, kPa (atm) 39 38 

Critical volume, cm3/mol 200 272 

Critical Density, g/cm3 0.75 0.44 

Liquid Density, g/ cm3 1.5 1.2 

Vapor Density, g/L 8.7 4.9 

Liquid Specific Heat, cal/g 0.21 0.3 

Vapor Specific Heat, cal/g 0.11 0.19 

Liquid Heat Capacity, cal/mol-K 30.9 36.1 

Vapor Heat Capacity, cal/mol-K 16.5 22.6 

Extinguishant Effectiveness 

Cup Burner Value, volume % 3.3 9.1 

Weight Impact (ratio to halon systems) 1 2.2 

Volume Impact (ratio to halon systems) 1 2.9 

Environmental Considerations 

Ozone Depletion Potential (ODP) 10 to 14 0 

Global Warming Potential (GWP) 1.9 0.58 

Fire extinguishing protection is provided for each engine by a fixed, high discharge rate, halon 1301 fire 

extinguishing system on each wing. Two engine vaporizing liquid fire extinguishers are located on the 

front spar of each wing inboard of the outboard pylon. Each extinguisher has two discharge ports, one 

directed to each engine on that wing. This arrangement allows either engine to receive fire extinguishing 

agent from either or both extinguishers (as a two-shot system) if needed. 

The distribution lines to the engine core and accessory compartments can terminate with discharge 

nozzles. However, for halon 1301, this is often a simple open pipe. A pylon fire extinguisher check 

valve, located in the engine distribution lines, isolates the two compartments from each other. The pylon 

fire extinguisher check valve opening pressure exceeds the differential pressure between the core and 

accessory compartments. 

Each engine's vaporizing liquid fire extinguisher has two engine aircraft fire extinguisher power device 

cartridges and one agent pressure switch. There are shutoff valves for each engine’s fuel and hydraulic 

fluid supplies. 
1030 Life Cycle Costing of Fire Suppression Systems 

When a fire is detected in an engine, the applicable FIRE PULL fire control handle assembly is pulled.

Signals are supplied through the handle assembly to close the applicable engine fire fuel and hydraulic 

shutoff valves, isolating the affected engine. 

The agent from the extinguishers is discharged by pulling out the applicable handle assembly. The handle 

assembly is rotated counterclockwise to discharge the agent from the inboard fire extinguisher and 

clockwise to discharge the agent from the outboard fire extinguisher. The handle assembly is springloaded to the center position. F the use of the first extinguisher does not put out the fire, agent is applied 

from the second bottle.14,15,16

Figure 10–1. 

Typical Cargo 

Aircraft Engine 

Nacelle Fire 

Protection 

System Location 

(Wing Leading 

Edge).16

Figure 10–2. Close-up of Typical Engine 

Nacelle Fire Protection System Bottle.16

(A: discharge heads)
Current System Description (Halon 1301) for Legacy Aircraft 1031

Figure 10–3. Typical Cargo Aircraft Engine Nacelle Fire Suppressant Storage and 

Distribution System (Wing Leading Edge).16

Additional Legacy Cargo Aircraft Fire Protection System Information 

Table 10–2 displays additional fire suppression system information (engine nacelle and APU) for a

typical legacy cargo aircraft.

1

Table 10–2. Additional Legacy Cargo Aircraft Fire Protection System Information. 

Engine Nacelle APU 

GENERIC

Number of aircraft 121 

Fire types Spray/pool

FIRE ZONE 

# of fire zones (# of compartments) 2 (4) 1 (1) 

Fire zone free volume (net volume), m3 (ft3) 7.45 (263) 0.623 (22)

Air ventilation at fire site, kg/s (lb/s) 0.29 (0.64) 0.29 (0.64)

EXTINGUISHANT

# of halon 1301 systems 2 1

Extinguisher trigger mode Remote Remote 

Extinguisher volume, cm3 (in3) 10,300 (630) 1400 (86)

Diameter of extinguishant container, cm (in) 27.7 (10.9) 14.2 (5.6) 
1032 Life Cycle Costing of Fire Suppression Systems 

Engine Nacelle APU 

Storage compartment for extinguishant bottle, m3 (ft3) 0.42 (15) 

Free volume in storage compartment, cm3 (in3) 0.43 (260) 

Normal charge and pressure of extinguisher container, 

MPa (psig) @ 21 °C (70 °F) with N2

5.6 (800) 4.24 (600) 

Max extinguisher container pressure (Burst range of 

safety disc), MPa (psig) 

13.2 to 15.6 

(1900 to 2300) 

@ 96 °C (205 °F) 

11.96 to 13.3 

(1720 to 1920) 

@ 96 °C (205 °F) 

Extinguisher container percent filled, % 67 69 

Extinguisher container orientation Upright with valves at bottom 

Dimensions of bottles with valves, cm x cm (in x in) 6.9 x 3.5 

Dimensions for present access to bottles 20 in x 13 in = 

260 in2

 = 1.81 ft2

Extinguisher container mass without halon 1301, kg (lb) 5.8 (12.8) 1.5 (3.2) 

Halon 1301 mass, kg (lb) 9.5 (21.0) 1.1 (2.5) 

Extinguisher container location, inside/outside fire zone Outside 

STRATEGY FOR USE 

 # of shots 2 1 

Manual/automatic Manual Manual 

Procedure for Activation Fire warning light is activated, pilot initiates 

firing of pyrotechnic squib which releases the 

contents of the bottle, the agent travels through 

the system plumbing to the engine nacelle/APU 

and is discharged as a gas. 

DISTRIBUTION SYSTEM 

Extinguisher dispersion method, @ 21 °C (70 °F) 5.6 MPa, 

N2 @ 800 psig 

4.24 MPa 

N2 @ 600 psig 

Extinguisher discharge rate (95 % in 0.9 s), 

kg/min (lb/min) 

544 (1200) 72 (158) 

Distribution system plumbing material Bottle to pylon stub: 

6061ALT6; all else: 

CRES. 

CRES 321 

 Inner diameter, cm (in) From bottle to pylon 

stub, 3.8 (1.5) ID; all 

else, 3.8 (1.5), 2.5 (1.0), 

and 1.9 (0.75) ID. Wall 

thickness, 0.24 (0.095) 

1.27 (0.5) ID. 

Wall thickness, 0.071 

(0.028) 

 Length, cm (in) 99.4 (39.14) from 

outboard bottle to both 

outlets in core 

compartments; 41.7 

(16.42); from outboard 

bottle to inboard pylon 

Straight length – 12.7 

(5) – 78.7 (31) 

 Shape, bends, elbows varies 1 bend, 1.5 radius 

 Number and nature of nozzles/pipe terminations Two nozzles One nozzle 

MODIFICATION POTENTIAL 

Restriction on alternative fluids, very/modest/slight slight slight 
Current System Description (Halon 1301) for Legacy Aircraft 1033

Engine Nacelle APU 

Ease of access of current distribution plumbing for 

retrofit (0 %-very difficult, 50 %-relatively easy, 100 

% easy) 

30 % difficult; 70 % 

easy. 

30 % difficult; 70 % 

easy. 

Access & available space for additional distribution 

plumbing or nozzle modification (0 %-very difficult, 

50 %-relatively easy, 100 % easy) 

30 % difficult; 70 % 

easy. 

30 % difficult; 70 % 

easy. 

OTHER 

Extinguisher system manufacturer Walter Kidde 

Evidence of halon 1301 distribution characteristics 

(from certification tests) 

6 % by volume for 0.5 s 

at cruising condition. 

Range of expected operating temperatures for the 

bottle and the plumbing, °C (°F) 

-60 to 93 (-77 to 200) 

Maximum Air Temperature in the Nacelle, °C (°F) 71 (160) 

MISCELLANEOUS 27.6 kPa (4 psi) is max pressure the protected 

volume can accept in nacelle. Max pressure in 

plumbing is 13.8 MPa (2000 psi) allowable. 

Potential fuels: Jet A and JP-8, Hydraulic Fluid 

Mil-H-83282, Lube Oil Mil-L-23699. 

Auxiliary Power Unit (APU) Fire Protection System Components and Procedures 

Fire extinguishing is provided for the APU by a fixed, high discharge rate, halon 1301 fire extinguishing 

system in the APU compartment. The APU fire extinguisher consists of the following components: 

• APU vaporizing liquid fire extinguisher, 

• APU fire extinguisher agent pressure switch, and 

• APU fire extinguisher power device cartridge. 

The APU extinguisher is externally mounted on the APU compartment forward firewall. The 

extinguisher has one discharge port. The discharge head, agent pressure switch and power device 

cartridge are located on the extinguisher. 

To extinguish a fire in the APU, the agent is discharged by any of the following switches: 

• AGENT DISCH switch on the APU control panel. 

• AGENT DISCH toggle switch on the aft loadmaster APU FIRE control panel assembly. 

• AGENT DISCH toggle switch on the ground refueling control panel APU FIRE panel.5

An APU fire is indicated by at as many as five signals in the aircraft, outside the aircraft, and on the APU 

itself.6

Figure 10–4 shows the typical auxiliary power unit fire protection system location for cargo aircraft.5, 7
1034 Life Cycle Costing of Fire Suppression Systems 

Figure 10–4. 

Typical 

Auxiliary

Power Unit 

Fire 

Protection 

System 

Location.16 

10.3.2 Fighter Aircraft 

Fire Protection System Components and Procedures 

The location for the representative legacy fighter aircraft fire protection system is in the aft fuselage 

between the engines, as shown in Figure 10–5 and Figure 10–6.

17 The single-bottle halon 1301 fire

suppression system is designed to provide fire protection for the left and right engine nacelles, the left and

right airframe mounted accessory drive (AMAD) bays, and the Auxiliary Power Unit (APU) bay.

1

 

Therefore, the first fire occurrence in either the engine/AMAD or APU bays will utilize all of the agent. 

The single cylindrical bottle is approximately 46 cm (18 in.) in length with a 11 cm (4.5 in.) diameter.18 

The general system installation is shown in Figure 10–7.19

Figure 10–5. Typical General Location of Fighter Aircraft Fire Extinguisher Bottle.17
Current System Description (Halon 1301) for Legacy Aircraft 1035

Figure 10–6. Schematic of Typical Fighter Aircraft Engine Bay.

17

Figure 10–7. Typical Fighter Aircraft Fire Suppression System Installation.19

The fire detection and extinguishing system is made up of three fire warning/extinguisher lights, a fire 

extinguisher pushbutton, one fire extinguisher bottle, a fire test switch and dual-loop fire detection

sensors. The extinguisher bottle is in the aft fuselage between the engines. The bottle provides a one-shot 
1036 Life Cycle Costing of Fire Suppression Systems 

extinguishing capability. The system provides engine/AMAD and APU fire warning, emergency 

shutdown and selective fire extinguishing.20

The three fire warning/extinguisher lights are pushbutton switch indicators which come on when a fire 

condition exists. Two of the fire warning/extinguisher lights are labeled FIRE. One, mounted on the top 

left corner indicates a fire condition in the left engine bay; the other, mounted on the top right corner of 

the instrument panel, indicates a fire condition in the right engine bay. The APU FIRE 

warning/extinguisher light is positioned inboard of the right FIRE light. A voice alert warning is 

activated anytime a fire warning light comes on. If more than one warning light comes on at the same 

time, the voice alert warning priority is ENGINE FIRE LEFT, ENGINE FIRE RIGHT, then APU FIRE.12

The fire extinguisher pushbutton switch is on the master arm panel and is labeled FIRE EXTGH. The 

switch has two lights. A yellow light is labeled READY and a green light labeled DISCH (discharge). 

When READY is on, the fire extinguisher bottle is armed. The READY light comes on when the 

appropriate fire warning/extinguisher light is pressed. Pressing an engine fire warning/extinguisher light 

shuts off fuel to the engine at the feed tank. With READY on, pressing the fire extinguisher pushbutton 

discharges the fire extinguisher bottle and turns on the DISCH light. There is no indication of actual 

discharge of the fire extinguisher bottle.12

The APU fire extinguishing system can be either manually or automatically actuated. To manually 

actuate the system, the fire extinguisher bottle is first armed and the APU shut down by pressing the APU 

FIRE warning/extinguisher light. When pressed, the APU FIRE light stays in and a barber pole indicator 

appears along side the light. The extinguisher bottle is then discharged into the APU bay by pressing the 

FIRE EXTGH pushbutton with the READY light on. Discharge of the bottle is delayed ten seconds after 

the light is pressed. This allows the APU time to spool down before the extinguishing agent is 

introduced. If the aircraft is on the ground, the APU fire extinguishing system is actuated automatically. 

The result is the same as with manual actuation, with the APU shutting down immediately after a fire is 

detected and the fire extinguisher discharging into the APU bay ten seconds later. The automatic system 

is prevented from operating by the action of a relay.12

Actuation of the engine/AMAD fire extinguisher can only be performed manually. Lifting the guard and 

pressing the affected FIRE warning/extinguisher light arms the system. This also shuts off fuel to the 

engine at the engine feed shutoff valves and closes the cross feed valve. When pressed, the FIRE light 

stays in, and a barber pole indicator appears in the switch guard. The extinguisher bottle is discharged 

into the affected engine bay by pressing the FIRE EXTGH pushbutton with the READY light on.12

Additional Legacy Fighter Aircraft Fire Suppression System Information 

Table 10–3 displays fire suppression system information (engine nacelle and APU) for the typical legacy 

fighter aircraft.9

Table 10–3. Additional Legacy Fighter Aircraft Fire Suppression System Information 

Parameter Engine Bay/APU 

FIRE TYPES (pool fires, mist) Spray/pool 

FIRE ZONE 

Number of fire zones 3 (2 engines/AMAD, 1 APU) 

Fire zone free volume, m3 (ft3) 1.14 (40.3) 
Current System Description (Halon 1301) for Legacy Aircraft 1037

Parameter Engine Bay/APU 

EXTINGUISHANT 

Number of halon 1301 systems 1 

Extinguisher trigger mode Pilot activated 

Extinguisher volume, cm3 (in3) 3031 (185) 

Size of cylindrical extinguishant container, cm (in) 11.4 cm (4.5 in) diameter, 46 cm (18 in.) long 

Storage compartment for extinguishant bottle, cm (in) 206 x 12.7 x 20.3 (81 x 5 x 8) 

Free volume in storage compartment, m3 (in3) 0.048 (2953) 

Normal charge and pressure of extinguisher container, 

MPa (psi) 

4.3 (625) @ 22.2 °C (72 °F) 

Max extinguisher container pressure, MPa (psi) 6.2 (900) @ 16 °C (60 °F) 

Extinguisher container percent filled, % 50 

Extinguisher container orientation (upright with valves 

at bottom) 

Lateral configuration 

Extinguisher container mass without agent, kg (lb) 2.7 (~6) 

Halon 1301 mass, kg (lb) 2.5 (5.5) 

Extinguisher container location (inside/outside fire zone) Outside 

STRATEGY FOR USE 

Number of shots 1 shot discharges into engine nacelle and 

AMAD bay or APU. 

Manual/automatic Manual 

Procedure for Activation Fire warning light is activated, pilot initiates 

firing of pyrotechnic squib which releases the 

contents of the bottle, the agent travels 

through the system plumbing to the engine 

nacelle/APU and is discharged as a gas. 

DISTRIBUTION SYSTEM 

Extinguisher dispersion method Cut-off pipe 

Extinguisher discharge rate, kg/s (lb/s) 0.99 (2.2) 

Distribution system plumbing Single pipe discharged into engine and 

AMAD simultaneously. APU has discharge 

port, but the first fire occurrence in either the 

engine/AMAD or APU bays will utilize all 

halon 1301 

Number and nature of nozzles/pipe terminations Cut-off pipe 

Tightness of the bottle space Only 12.7 cm (5 in) in height available for 

growth. 

Extinguisher Bottle Growth Potential 12.7 cm (5 in) in height 

OTHER 

Suppression success fraction Historical reports show 80% success. 

Evidence of halon 1301 distribution characteristics (from 

certification tests) 

Yes 

Range of expected operating temperatures for the bottle 

and the plumbing, °C (°F) 

-54 to 316 (-65 to 600) 
1038 Life Cycle Costing of Fire Suppression Systems 

Typical Legacy Fighter Aircraft Fire Suppression Concentration Tests 

The Certification Section of Chapter 2 describes the traditional methodology utilized to certify an aircraft 

fire suppression system. 

Historical Fire Suppression System Effectiveness 

As discussed in Chapter 2, data have been compiled on the effectiveness of the F/A-18 fire suppression 

system.21 The data show where, when, and why fires occurred from 1982 through 1993, as recorded by 

the Naval Safety Interactive Retrieval System (NSIRS). During this time period, seven F-18 aircraft were 

lost or destroyed due to fire. 

The engine halon 1301 fire suppression systems were shown to be 80 % successful in extinguishing inflight fires, and this effectiveness was the same for each engine. Eighty-nine percent of all fires in areas 

protected by halon 1301 fire suppression (engines and AMAD bays) occurred in flight. Fires in halon 

1301-protected areas accounted for 84 % of all in-flight fires. Engine fires accounted for 78 % of all inflight fires, with 19 occurring in the right engine, 15 occurring in the left engine, three in both engines, 

and three in unspecified engines. 

The preponderance (73 %) of F-18 aircraft fires occurred during a peak period between 1986 and 1989. 

Seventy-five percent of all engine fires occurred during this time period, and it was reported by 

Government fire protection engineers that the F-18 afterburner liners were faulty and the cause of at least 

25 incidents, not all of which were fire incidents. 

The majority (87 %) of F-18 fires were caused by material failures. Common material failures included 

afterburner liner and spray bar pigtail failures, high-pressure compressor failures, fuel leaks, electrical 

wire insulation breaches, fuel-filler cap mishaps, failures in the AMAD bay (e.g., hydraulic pump 

failures), as well as failures of various parts due to fatigue or foreign object debris (FOD).21 

These aforementioned “real world” effectiveness data were considered when estimating the realistic 

extinguishing “success rates” to be forecast in future use, and the resultant cost of assets saved, to offset 

the life cycle costs of developing, acquiring and maintaining a fire extinguishing system for an aircraft 

platform. This approach was used for all of the platform types studied.

10.3.3 Rotary-wing Aircraft 

Fire Protection System Components and Procedures 

The general location (between the two engines) of a legacy rotary-wing aircraft fire protection system is 

shown in Figure 10–8. 

The two-bottle halon 1301 fire suppression system is designed to provide dual-shot fire protection for the 

left and right engine nacelles. Each bottle is cylindrical in shape, and the two bottles are stacked 

vertically with the long axis of each bottle parallel to the engines themselves. 

There are two discharge locations in the engine nacelle, one at the forward firewall, the second at the side. 

The extinguishing lines truncate with open ended pipes. The inner diameter of the lines is 1.8 cm 
Current System Description (Halon 1301) for Legacy Aircraft 1039

(0.69 in. The flame detectors are required to detect a fire within 5 s. Additional time is needed for the 

pilot to initiate and activate the fire extinguishing system.

22

Locations of

bottles 

Figure 10–8. Typical General Location of 

Rotary-Wing Aircraft Fire Extinguisher 

Bottles.22

Each engine nacelle bay has a total volume of approximately 0.85 m3

 (30 ft3) and houses a single jet

turbine engine. Aside from the turbine engine, the bay is fairly cluttered with fuel lines, control systems,

etc. The resulting total free volume in each bay is approximately 0.46 m3

 (16.1 ft3). Each nacelle bay is 

independently ventilated via four apertures, which provide passive airflow that fluctuates with the 

helicopter’s airspeed and orientation. The airflows inside the nacelle bay range from about 0.54 kg/s to

1.6 kg/s (1.2 lb/s to 3.5 lb/s). 

Halon 1301 Design Guide Estimation 

The total mass of the current representative rotary-wing system is approximately 6.5 kg (14.3 lb). The

total extinguishing agent mass is 0.7 kg (1.5 lb) per platform or 0.3 kg (0.8 lb) for each bottle. The 

present system requires head space (vapor volume in the bottles above the liquid fill line) to pressurize the 

fluid to 4.1 MPa (600 psi) with nitrogen, and uses 0.3 cm (1/8 inch) thick 304 stainless steel bottles that 

weigh 0.8 kg (1.8 lb.) each, or 1.6 kg (3.5 lb) for the two bottles. The mass of the fluid distribution 

manifold, pyrotechnic valves, mounting hardware, and electrical connectors is about 4.2 kg (9.3 lb), with

the estimated mass of electrical cables and mounting hardware of 0.52 kg (1.1 lb) per installation (for a 

total of 1.0 kg (2.3 lb) per platform).23

However, it was unclear whether the current design’s halon 1301 mass (0.3 kg (0.8 lb) per bottle, for a 

total of 0.7 kg (1.5 lb) per platform, used by the rotary-wing representative was sufficient to maintain the 

necessary concentration of agent of at least 6 % by volume in air in all parts of the affected zone

simultaneously for at least 0.5 s at normal cruising condition. Due to this uncertainty, the required halon

1301 amount was calculated using the military specification for sizing systems, MIL-E-22285.24 This

specification applies to the installation of high-rate-discharge type fixed fire extinguishing systems for 
1040 Life Cycle Costing of Fire Suppression Systems 

engine spaces and other potential fire zones in aircraft. As a design guide, the following equations may 

be used to determine the minimum mass of agent to be discharged into each engine: 

1. For “rough” nacelle interior with low air flow, and for a smooth nacelle interior regardless of 

air flow, using whichever of the following two equations provides the larger value of W: 

W = 0.05V 

(10-1)

W = 0.02V + 0.25WA 

(10-2)

2. For “rough” nacelle interior with high air flow: 

W = 3(0.02V + 0.25WA) (10-3)

3. For a “deep frame” nacelle interior with high airflow: 

W = 0.16V+0.56WA 

(10-4)

where: 

W (lb) = mass of agent 

WA (lb/s) = mass flow air passing through the zone at normal cruising condition. 

V (ft3

) = net volume of the zone (gross volume of the zone less the volume of major items 

of equipment.24) 

Figure 10–4 shows the legacy rotary wing aircraft-specific parameters used to estimate the amount of 

halon 1301 required. 

Table 10–4. Legacy Rotary-wing Aircraft Specific Parameters. 

Parameter Value 

Airflow 0.54 kg/s to 1.59 kg/s (1.2 lb/s to 3.5 lb/s) 

fuel source MIL-H-83282, MIL-H-5606, JP-8 

Maximum air temperature 51.7 °C (125 °F) 

free volume 0.46 m3 (16.1 ft3) 

The resulting halon 1301 system agent capacity per platform ranges from 1.09 kg (2.39 lb.) to 3.26 kg 

(7.18 lb.), per the guidance of the aforementioned military sizing standards. 

Additional Legacy Rotary-Wing Aircraft Fire Suppression System Information 

Table 10–5 displays fire suppression system information (engine nacelle and APU) for a typical legacy 

rotary-wing aircraft.10
Current System Description (Halon 1301) for Legacy Aircraft 1041

Table 10–5. Additional Legacy Rotary-wing Aircraft Fire Suppression System 

Information. 

Parameter Value 

FIRE TYPES (pool fires, mist) Spray/pool 

FIRE ZONE 

Number of fire zones 2 

Fire zone free volume, m3 (ft3) 0.46 m3 (16.1 ft3) 

EXTINGUISHANT 

Number of halon 1301 systems 2 

Extinguisher trigger mode Pilot activated 

Extinguisher volume, cm3 (in3) 

Size of extinguishant container, cm, cm, cm (in, in, in) Cylindrical 

Normal charge and pressure of extinguisher container, 

MPa (psi) 

4.14 MPa (600 psi) 

Extinguisher container percent filled, % 60 

Extinguisher container orientation Stacked vertically and parallel to engines 

Extinguisher container mass without halon 1301, kg (lb) 0.79 kg (1.75 lb.) each or 1.59 kg (3.5 lb.) for 

the two bottles 

Halon 1301 mass, kg (lb) 0.68 kg (1.5 lb.) per platform or 0.34 kg 

(0.75 lb.) for each bottle 

Extinguisher container location (inside/outside fire zone) Outside 

STRATEGY FOR USE 

Number of shots 2 

Manual/automatic Manual 

Procedure for Activation Fire warning light is activated, pilot initiates 

firing of pyrotechnic squib which releases the 

contents of the bottle, the agent travels 

through the system plumbing to the engine 

nacelle and is discharged as a gas. 

DISTRIBUTION SYSTEM 

Extinguisher dispersion method The extinguishing lines end with open ends. 

Distribution system plumbing There are two discharge locations in the 

engine nacelle, one at the forward firewall, the 

second at the side. The inner diameter of the 

lines is 1.76 cm (0.694 in). 

Number and nature of nozzles/pipe terminations Two; The extinguishing lines end with open 

ends. 

Typical Legacy Rotary-Wing Aircraft Fire Extinguishing Concentration Tests 

The protocol for certifying and approving fire suppression systems for rotorcraft via concentration 

measurements during discharge is the same as previously described for the design of fighter aircraft 

systems. 
1042 Life Cycle Costing of Fire Suppression Systems 

Historical Fire Suppression System Effectiveness 

Reference 25 provides information on the historical effectiveness of rotary-wing aircraft fire suppression 

systems. It discusses where, when, and why fires occurred from 1977 through 1993, as recorded by the 

Naval Safety Interactive Retrieval System (NSIRS). During this period, 146 of 161 rotary aircraft fires 

(91 %) did not result in “destruction” of the aircraft – the fires were either extinguished by the on-board 

fire protection systems or ground crew, or self extinguished. The rotary aircraft fire suppression systems 

were reported as having extinguished 71% of all fire events in which the system was activated to attempt 

extinguishment. Analysis of the Safety Center data indicates that, when used, the rotary aircraft fire 

suppression systems were 71 % effective overall in extinguishing fires, and the engine fire suppression 

systems were 57 % effective.25

10.4 PROPOSED SYSTEM DESCRIPTION (HFC-125) FOR FUTURE AIRCRAFT 

10.4.1 Design Guide 

Since current (legacy) aircraft use halon 1301 (and not HFC-125), a potential system description and 

sizing for retrofit/future aircraft had to be estimated. The Halon Replacement Program for Aviation 

developed a Design Guide to assist in sizing systems using HFC-125.11 These systems are intended to 

provide extinguishant effectiveness equivalent to halon 1301 systems, which were designed using 

traditional approaches. This Design Guide was used to size a system for future aircraft platforms under 

consideration. The legacy aircraft-specific parameters were also used to estimate the mass of HFC-125 

required for their platforms. The Design Guide provides a two step design process to be used in sizing 

systems appropriately. 

The five-step approach to determine the required design concentration for certification and estimate the 

necessary mass of extinguishant to meet certification requirements consists of the following procedure: 

1. Calculate the customized design concentration required for the configuration of the platform 

of interest using Equation 5 in the Design Guide, using relevant operational values of air 

temperature, air mass flow rate, and fuel type used on the platform in the fire zone. 

a. If the range of air temperature and air mass flow varies considerably in the flight 

envelope, several combinations of relevant maximum air temperature and corresponding 

mass flow should be tried to assure the highest concentration calculated to be required 

over the flight envelope is achieved. In general, the application of the highest air 

temperature and minimum air mass flow (within acceptable data bounds, as governed by 

the Design Equation 5) will normally give a conservative worst-case estimate. 

b. For this equation, the values input for maximum air temperature and air mass flow should 

never be outside the range of the values upon which the equation was developed (37.8 °C 

to 135.0 °C (100 °F to 275 °F) and 0.4 kg/s to 1.2 kg/s (0.9 to 2.7 lb/s), respectively). If 

the actual maximum operating condition is outside of these ranges, the closest extreme 

value should be used. The impact on the accuracy of the results has been shown in 

experiments to be minimal. 

c. If more than one flammable fluid is present in the engine nacelle or APU (such as 

hydraulic fluids or oils), use the highest fuel constant (coefficient) value corresponding to 
Proposed System Description (HFC-125) for Future Aircraft 1043

the fluids present. (For example, the fuel constant = 0.4053 for hydraulic fluid would be 

used if it is present, since it has the highest constant.) 

d. If a single system protects one or more engine nacelles and an APU, calculate the 

required concentration and corresponding mass for either application independently and

use the higher of the two mass requirements. 

2. Calculate the expected extinguishant mass requirement via Equation 10-6, using the required

concentration calculated in Equation 10-5, the volume of the fire zone (nacelle or APU) and 

the actual air mass flow (even if outside the bounds considered in the previous step). 

3. Design the extinguishant container capacity consistent with current design practice and use 

the mass estimates in Equation 10-6 for use in design trade-study comparisons and as a

starting point for certification testing. 

4. Perform the certification discharge experiments (using existing Halonyzer or Statham

analyzer equipment to measure concentrations real-time, but recalibrated for HFC-125), with

the criteria being the attainment of the design concentration calculated in Equation 10-5 at all 

measurement points in the nacelle simultaneously for at least 0.5 s. 

5. If certification is not met, increase the container capacity or modify the distribution system to

eventually pass certification. 

The concentration calculated using Equation 10-5 will be the concentration used for certification testing 

of a HFC-125 system designed for engine nacelle or APU protection. Equation 10-5 can give a range of

concentration values from 14.5 % by volume to 26 %, by volume, 

Xe = 21.10 + 0.0185 AIRT - 3.124 WA + 5.174 (FUEL CONSTANT) + 0.0023 (AIRT) x 

(FUEL CONSTANT) + 1.597 (FUEL CONSTANT)11 (10-5)

where: 

Xe (% by volume) = Certification Design Concentration 

AIRT (°F) = maximum ventilation air temperature in the nacelle or APU during 

operations 

WA (lb/s) = internal air mass flow in the nacelle or APU during operations 

FUEL CONSTANT = coefficient to account for presence of JP fuel, hydraulic fluids, or oil 

The variable ranges permissible for use in Equation 5 are: 

AIRT 37.8 °C to 135.0 °C (100 °F to 75 °F) 

Wa 0.4 kg/s to 1.2 kg/s (0.9 lb/s to 2.7 lb/s) •

FUEL CONSTANT (Use highest coefficient of fluids present.) 

If JP fuel, use 0.3586 

If hydraulic fluid, use 0.4053 

If oil, use 0

If fire resistant hydraulic fluid (SKYDROL), use 0 
1044 Life Cycle Costing of Fire Suppression Systems 

Equation 10-6 below is a theoretically derived equation to estimate the minimum mass of extinguishant 

required for a system to pass the certification process while exhibiting at least the minimum design 

concentration Xe calculated from Equation 10-5, everywhere in the nacelle simultaneously. The equation 

was derived using physical flow modeling idealization presumably similar to that used to develop mass 

sizing formulas used for earlier halon 1301 certification, since the equations are similar in structure. Only 

one equation now exists for HFC-125, which accounts for the effects of high-speed airflow and

compartment obstructions (ribs and other structure), whereas the prior halon 1301 equations had multiple 

empirical sizing equations for various rib height and clutter classes, since it could exploit a large body of 

test data with these various configurations. Like its predecessor formula for halon 1301, this theoretical

estimation equation assumes optimal distribution and mixing of the extinguishant. It is useful for

preliminary sizing of systems for trade studies with other alternatives during the design process and as a

starting point to begin certification tests. If a distribution system is not designed to distribute the

extinguishant efficiently, certification tests may not be passed initially, and either the distribution system 

will require modification and improvement or the bottle capacity and extinguishant mass will need to be 

increased until certification is accomplished. Equation 10-6 will calculate system sizes that will range 

between 2.3 and 4.3 times the volume of optimally designed halon 1301 systems for identical 

applications, with a corresponding mass growth ratio only about 80 % of the volume growth ratio

compared to a halon 1301 system (due to the lower density of HFC-125 compared to halon 1301). The 

estimated HFC-125 system size and mass may actually be much closer in size to an existing halon 1301 

installation, due to the oversizing of many previous halon 1301 designs.11

(10-6)

W ACTUAL

Xe

Xe MASS lb XeV

•

− = +100 ( .) 0.003166 4.138

where: 

Xe (% by volume) = engine/APU concentration for certification (Equation 10-5) 

V (ft3

) = free volume of nacelle or APU--ft3

WACTUAL (lb/s) = actual maximum air mass flow (no experimental bounds) •

The two-step approach (per the Design Guide) was followed to determine the required design

concentration for certification and estimate the necessary mass of extinguishant to meet certification 

requirements. 

The Design Guide11 is limited to providing a mass estimate that assumes the HFC-125 is optimally 

distributed (with just the minimal required concentration at all sites simultaneously, and no wasted

excess), which may well be too optimistic, based upon experience with fielded systems. The following 

analysis was performed to provide an alternative method of estimating of the required mass and increased

container volume required, by attempting to replicate the amount of inefficiency currently observed with 

fielded legacy systems, due to simplifications and design limitations of their distribution systems, or even 

due to simple overdesigns, that result in excess or “wasted” extinguishant discharged that does not

directly satisfy the Design Guide criteria. This is accomplished simply by beginning with pre-existing

fielded legacy halon 1301 systems in use, and adjusting their size for HFC-125 (with a similar

overdesign, presumably), by merely adjusting their capacities and size by the ratios of the design
Proposed System Description (HFC-125) for Future Aircraft 1045

concentrations, liquid densities and molecular weights of HFC-125, compared to halon 1301. This 

alternative scaling approach (a “scale up” coefficient from halon 1301 to HFC-125, for equivalent 

protection) for realistic, “inefficient” systems is expressed in Equations 10-7 and 10-8 (illustrated for this 

application to require an HFC-125 design concentration of 24 %). 

(10-7)

WeightRatio

C

C

MW

MW

Halon

HFC

Halon

HFC ∗ = ∗ = = − − 3.2

6

23.8

149

120

[ ]

[ ]

1301

125

1301

125

(10-

8)

WeightRatio WeightRatio VolumeEstimate

HFC

HFC Halon

Halon

∗ = ∗ = = =

−

− 4.1

75.7

97.8 3.2 *

125

125 1301

1301 ρ

ρ

υ

υ

where: 

MW (g) = Molecular Weight 

[C] (% by volume) = Concentration determined by the Design Guide 

ρ (lb/ft3

) = Liquid Density @ 70 oF 

10.4.2 Cargo Aircraft 

Table 10–6 and Table 10–7 show the results of the Design Guide calculations (concentration and mass

estimation) for the future cargo aircraft engine nacelle and auxiliary power unit fire systems, respectively.

Table 10–6. Design Guide Estimates of HFC-125 Concentration and Mass for Future 

Cargo Aircraft Engine Nacelles. 

Maximum

Temperature

Air Mass Flow

kg/s (lb/s) Fuel Constant Concentration 

Mass 

Estimate 

(lb) 

Mass 

Estimate

(kg)

71.1 °C (160 °F) Maximum - 1.22 (2.7) Jet A (0.359) 17.8 N/A N/A 

71.1 °C (160 °F) Maximum - 1.22 (2.7) JP-8 (0.359) 17.8 N/A N/A 

71.1 °C (160 °F) Maximum - 1.22 (2.7) MIL-H-83282 (0.405) 18.1 N/A N/A

71.1 °C (160 °F) Maximum - 1.22 (2.7) MIL-L-23699 (0.0) 15.6 N/A N/A 

71.1 °C (160 °F) Minimum – 0.41 (0.9) Jet A (0.359) 23.4 N/A N/A 

71.1 °C (160 °F) Minimum – 0.41 (0.9) JP-8 (0.359) 23.4 N/A N/A 

71.1 °C (160 °F) Minimum – 0.41 (0.9) MIL-H-83282 (0.405) 23.8 N/A N/A

71.1 °C (160 °F) Minimum – 0.41 (0.9) MIL-L-23699 (0.0) 21.3 N/A N/A 

71.1 °C (160 °F) Actual – 0.29 (0.64) MIL-H-83282 (0.405) N/A 21.3 9.7 
1046 Life Cycle Costing of Fire Suppression Systems 

Table 10–7. Design Guide Estimates of HFC-125 Concentration and Mass for Future 

Cargo Aircraft Auxiliary Power Units. 

Maximum 

Temperature 

Air Mass Flow 

kg/s (lb/s) Fuel Constant Concentration 

Mass 

Estimate 

(lb) 

Mass 

Estimate

(kg) 

71.1 °C (160 °F) Maximum – 1.22 (2.7) Jet A (0.359) 17.8 N/A N/A 

71.1 °C (160 °F) Maximu .7) JP-8 m – 1.22 (2 (0.359) 17.8 N/A N/A 

71.1 °C (160 °F) Maximum – 1.22 (2.7) MIL-H-83282 (0.405) 18.1 N/A N/A 

71.1 °C (160 °F) Maximum – 1.22 (2.7) MIL-L-23699 (0.0) 15.6 N/A N/A 

71.1 °C (160 °F) Minimum – 0.41 (0.9) Jet A (0.359) 23.4 N/A N/A 

71.1 °C (160 °F) Minimum – 0.41 (0.9) JP-8 (0.359) 23.4 N/A N/A 

71.1 °C (160 °F) Minimum – 0.41 (0.9) MIL-H-83282 (0.405) 23.8 N/A N/A 

71.1 °C (160 °F) Minimum – 0.41 (0.9) MIL-L-23699 (0.0) 21.3 N/A N/A 

71.1 °C (160 °F) Actual – 0.29 (0.64) MIL-H-83282 (0.405) N/A 2.6 1.2 

Note that the con is base flow of 0.4 kg/s (0.9 lb/s) (within the 

ounds relevant for the equation) and the mass estimate is based upon the actual air mass flow of 

rease is given in Table 10–8. 

Table 10–9 shows the current and proposed system extinguishant and bottle masses. This is only an 

8. Future Cargo Aircraft Proposed System Estimates. 

centration estimate d upon an air mass 

b

0.27 kg/s (0.6 lb/s), as directed by the Design Guide. The first eight rows in each table are calculations of 

the maximum concentration required, evaluated over a range of air flows and fuel types, with the 

maximum concentration is denoted in bold face. The last row is the calculation of the required mass 

needed to hold the maximum required concentration, while accounting for airflow dilution at the highest 

actual operating mass flow, with the mass also being denoted in bold face. 

The estimate of the proposed system concentration, mass and volume inc

(proportional) estimate because the larger bottles would have to be designed by a fire suppression system 

manufacturer using factors such as agent density, agent pressure, percent liquid fill, and required 

container wall thickness. 

Table 10–

Aircraft Engine Nacelle Auxiliary Power Unit 

Conc. Mass Volume Conc. Mass Volume 

Total Agent 

Per Platform

% by vol. lb kg in3 L % by vol. lb kg in3 L lb kg 

Current halon 1301 

system 6.0 2 1.0 9.5 630 1 0.3 6.0 2.5 1.1 86.0 1.4 8 3 6.5 9.2 

Estimated HFC-125-

optimally distributed 23.8 21.3 9.7 814 13.3 23.8 2.6 1.2 110.9 1.8 87.9 39.9 

Estimated HFC-125- 

non-optimally 

distributed 23.8 67.2 30.5 2583 42.3 23.8 8.0 3.6 352.6 5.8 277.0 125.6
Proposed System Description (HFC-125) for Future Aircraft 1047

Table 10–9. Future Cargo Aircraft Extinguisher Container and Agent Mass. 

Current Halon 1301 System 

Estimated HFC-125-Optimally

Distributed 

Estimated HFC-125- NonOptimally Distributed 

AEN APU AEN APU AEN APU 

lb kg lb kg lb kg lb kg lb kg lb kg 

Bottle 

mass 12.8 5.8 3.2 1.5 13.0 5.9 3.3 1.5 41.0 18.6 10.1 4.6 

Agent 

mass 21.0 9.5 2.5 1.1 21.3 9.7 2.6 1.2 67.2 30.5 8.0 3.6 

Total 

mass 33.8 15.3 5.7 2.6 34.3 15.6 5.9 2.7 108 49.1 18.2 8.3 

Potential Airframe Impact 

Depending on the legacy cargo aircraft of interest, the potential airframe impact will vary. Issues to 

consider include: impact to the airframe weight/volume, maintenance, and modification. 

Weight/Volume Impact 

The weight/volume impact depends on the system optimization. As shown in the previous tables, a 

system that is optimally distributed can have a significant weight and volume reduction versus a nonoptimally distributed system. Increases in weight will cause an increase in the fuel required to haul the 

additional weight. Increases in volume will cause a reduction in weapon system capability (such as 

reduced storage for munitions). 

Maintenance Impact 

During this study, maintenance personnel were contacted for their insight and advice regarding the impact 

to maintenance procedures. The maintenance personnel provided the following maintenance time 

estimates and procedures. Two AFSC senior airmen are required to assist in access or removal of the 

items and to perform retrofit. Access to all five fire bottles requires one man-hour total. The fire bottles 

require weight checks every 10 years and the explosive actuating squibs are time change items and 

require time change every five years from date of manufacture or three years from the date of installation. 

Four man-hours total for all five fire bottles are required to remove the item. Six man-hours total for four 

fire bottles are required to reinstall and inspect the item. 

Current regulation Bottle requires that the bottle mass not exceed 17 kg (37 lb) if it is to be lifted 

overhead by one person. If the resulting design exceeds this limit, an additional maintenance person 

would be required and would result in additional operation and support costs. 

Any modification to the system must allow access to the fire bottles and distribution system. The areas 

accessed during normal fire suppression system maintenance include the wing leading edge and engine 

pylons. The access panels are routinely opened for other maintenance and there are no problems foreseen 

in removing any of the access panels. Typically, the access panels are the only components that have to 

be removed to access the fire protection system. The same access panels are typically used to access the 
1048 Life Cycle Costing of Fire Suppression Systems 

distribution system as are the fire bottles. Access panels may need to be made larger if a larger bottle is 

used. 

Modification Impact 

An estimate of the modification impact was difficult to ascertain and depends on the modification 

required. A more accurate assessment of the impact requires input from the airframe manufacturer, which 

was not available. Modification to the structure may be significant (and may be cost prohibitive). 

If the distribution system is optimally designed, HFC-125 may be able to fit in the existing space. 

However, if the distribution system is not optimally designed it will require a larger and heavier bottle, 

which may not be feasible in the current configuration. This may require either modification of the 

existing structure, a relocation of the bottles, or the optimization of the distribution system. It would need 

to be determined whether enough access/available space for additional distribution plumbing or nozzle 

modification exists. 

A poorly designed distribution system results in an unnecessary increase weight. Therefore, there is a 

strong incentive to optimize the system. It is recommended that a distribution optimization study (similar 

to the Navy's program for the F/A-18 E/F) be performed or else extensive aircraft modification will be 

required. 

Due to the current lack of airframer engineering assistance, the significant cost impact of modifying an 

aircraft (including structure) to accommodate fire system changes could not be estimated accurately. 

Therefore, those costs were not included in this study (since it requires a detailed, multi-faceted 

engineering assessment for engineers familiar with a specific platform and its design details and 

modification labor estimations, and performed on a case-by-case basis), and any estimates of retrofit costs 

in this study using larger systems that may require moderate or extensive structure modifications should 

be considered a very conservative underestimate of actual retrofit costs involved. 

Prior to the final design of an HFC-125 system, assistance from extinguisher system manufacturers and 

from the airframe manufacturer needs to be sought. 

10.4.3 Fighter Aircraft 

General Description 

Future fighter aircraft fire suppression systems will utilize a four-nozzle HFC-125 system in addition to 

the agent outlets in the AMAD and APU bays for enhanced agent distribution. The general location for 

the future fighter aircraft fire suppression system is similar to the legacy fighter aircraft fire suppression 

system. The extinguisher bottle is in the aft fuselage between the engines and provides a one-shot 

extinguishing capability. Future fighter aircraft fire suppression systems utilize a single bottle of 

HFC-125. The four-nozzle distribution system, shown schematically in Figure 10–9 is designed to swirl 

the agent into the incoming ventilation air and around the engine nacelle.26
Proposed System Description (HFC-125) for Future Aircraft 1049

To AMAD

ENGINE

Agent

AFT

OU TBOARD

Nozzle Location E

Nozzle Location D

Nozzle Location C

Nozzle Locations A & B

(TOP VIEW)

Figure 10–9. Typical Future Fighter Aircraft Agent Distribution System. 

The general characteristics of the enhanced plumbing highlight the significance of plumbing 

modifications. Compared with the much simpler legacy aircraft plumbing scheme, which employs a 

single discharge nozzle, the future aircraft four-nozzle system prepositions the HFC-125 throughout the 

nacelle. This pre-positioning, in concert with the prevailing nacelle airflows, optimizes agent presence at

any fire in the nacelle. The future fighter aircraft distribution system utilizes the same plumbing 

diameters as the legacy system.

27

Fire Protection System Components and Procedures 

It was assumed that the procedures for future fighter aircraft fire protection systems are similar to the

procedures for the legacy systems as described previously. Table 10-10 displays the components of the 

future aircraft engine nacelle fire suppression system.

 28

Fire Suppression System Optimization 

The Naval Air Systems Team conducted and participated in several varied halon 1301 replacement

programs. Each offered data that gave rise to the opportunity of successfully applying HFC-125 to the inservice fleet as an adequate alternative to halon 1301. The particular on-board retrofit applications being

promoted are the fixed halon 1301 fire protection systems protecting the engine nacelles aboard aircraft. 

Future fighter aircraft will not have the luxury of accepting any system larger than the halon 1301 system 

currently aboard earlier models. Future fighter aircraft utilized the same bottle compartment dimensions 

as their legacy fighter aircraft counterparts, which had only minimal growth opportunity for a new agent

cylinder.22 Consequently, the Navy invested in a system optimization program. This program focused on 

nacelle airflow analyses and plumbing optimization and proved that enhanced distribution of the less

effective chemical could, and did, deliver an HFC-125 system design capable of meeting the performance 

of the halon 1301 system it was replacing. This was extremely beneficial since original estimates 

predicted up to 200 % to 300 % system growth required.11 

Due to the early system optimization, the resulting future fighter aircraft Engine/AMAD/APU fire

extinguishing mass system mass only grew by 19 %, and the agent mass only grew by 27 %.

Table 10–11 shows a comparison of the fire extinguishing system masses. 
1050 Life Cycle Costing of Fire Suppression Systems 

Table 10–10. Future Fighter Aircraft Engine Nacelle Fire Protection System Components. 

Part Number Description 

Units Per 

Assembly 

2-100280-1 Fire Extinguisher Tank (4SQT109) Cartridge, Aircraft (Left Engine Cartridge) 

(05167) (McDonnell Douglas Corp Spec 74-500054-101) (4SQT109-J1) 

1 

M25988/1-905 O-Ring (Packing) (81349) 1 

33500009 Tank Fire Extinguisher (05167) (McDonnell Douglas Corp Spec 74-500052-

111) (4SQT109) 

1 

M25988/1-906 O-Ring (Packing) (81349) 1 

2-100280-3 Cartridge, Aircraft (APU Cartridge) (05167) (McDonnell Douglas Corp Spec 

74-500054-103) (4SQT109-J3) 

1 

M25988/1-905 O-Ring (Packing) (81349) 1 

2-100280-5 Squib, Electric (Right Engine Cartridge) (05167) (McDonnell Douglas Corp 

Spec 74-500054-105) (4SQT109-J2) 

1 

74A502115-1001 Tube Assembly (76301) 1 

74A502116-1003 Tube Assembly (76301) 1 

74A330710-2341 Shim (76301) 1 

4M36-02020 Washer, Flat (76301) 2 

NAS6604-4 Bolt, Shear (80205) 2 

AN894J10-8 Adapter, Straight, TU (88044) 1 

74A502106-1003 Tube Assembly (76301) 1 

74A330710-2339 Shim (76301) 1 

74D490106-1001 Dummy Connector, Plug (Shorting Plug) (76301) 3 

Table 10–11. Fighter Aircraft Fire Suppression System Mass Comparison.

Halon 1301 System 

(1 nozzle)a

HFC-125 System 

(4 nozzles)a

kg lb kg lb 

Bottle Mass 4.2 9.3 5.6 12.2 

Agent Mass 2.5 5.5 3.2 7.0 

Plumbing Mass 4.3 9.5 4.6 10.1 

Total Mass 11.0 24.3 13.4 29.3 

a

 in addition to the agent outlets in the AMAD and APU bays 

Design Guide Estimation 

To show the value of investment in system optimization, estimates were made during this program of the 

required mass and volume impact and the resulting costs of not utilizing an optimized system. These 

estimates were made using the referenced report generated as a part of the Halon Replacement Program 

for Aviation. 11
Proposed System Description (HFC-125) for Future Aircraft 1051

The intent of the design guide was to retain an equivalent level of fire fighting performance to the current 

halon 1301 systems. Like the halon 1301 systems they replace, the new systems incorporating HFC-125 

will not extinguish every imaginable fire condition created and if so, it could not be verified via 

experimentation. Historical data revealed an overall effectiveness of 60 % to 80 % for halon 1301 

systems. The HFC-125 design guidance demonstrates a validated 80 % to 100 % effectiveness. Systems 

designed using HFC-125 will generally require varying degrees of additional quantities per application 

compared to their halon 1301 counterparts for an identical application, assuming an optimized halon 1301 

system was used. Many fielded halon 1301 systems are not optimal in sizing, and the estimate of 

installing a replacement HFC-125 container has resulted in much smaller size increase impacts than 

expected. 

The design guide presumed optimal mixing. Less efficient distribution systems will require higher 

masses to achieve the required concentration simultaneously for a half second during certification, with 

the designer having the option of accepting higher mass requirements or modifying and improving the 

distribution system. 

Table 10–12 shows the future fighter aircraft specific parameters used to estimate the mass of HFC-125 

required. The concentration estimate is based upon an air mass flow of 0.4 kg/s (0.9 lb/s) (within the 

bounds of the equation), and the mass estimate is based upon the actual air mass flow of 0.96 kg/s 

(2.11 lb/s) as directed by the design guide. 

Table 10–12. Future Fighter Aircraft Specific Parameters. 

Parameter Value 

Airflow 0.96 kg/s (2.11 lb/s) 

Fuel Source JP-8, hydraulic fluid 

Maximum air temperature 104.4 oC (220 °F) 

Free Volume 1.10 m3 (38.8 ft3) 

Estimates of the HFC-125 system concentration, mass, and volume increase are given in Table 10–13. 

The resulting concentration and mass estimates were 25 % and 2.70 kg (5.96 lb), respectively, which 

differed somewhat from the Navy-generated results of 18 % and 2.21 kg (4.87 lb), respectively. 

Table 10–13. Estimates of System Parameters for Proposed Future Fighter Aircraft 

System Description. 

Concentration Mass Volume 

% by volume kg lb L in3

Legacy Fighter Aircraft 

(halon 1301) – (1 nozzle)b 6 2.5 5.5 3.0 185 

Future Fighter Aircraft 

(HFC-125) - (4 nozzles)b 9 3.2 7 4.0 242 

Estimated HFC-125- non-optimally distributed (this study) 25 8.4 18 13 800 

Estimated HFC-125- non-optimally distributed (Navy study) 18 6.2 14 10 600 

b in addition to the agent outlets in the AMAD and APU bays 

Table 10–14 shows the current and proposed system extinguishant and bottle masses. This is only an 

(proportional) estimate because the larger bottles would have to be designed by a fire suppression system 
1052 Life Cycle Costing of Fire Suppression Systems 

manufacturer using factors such as agent density, agent pressure, percent liquid fill, and required 

container wall thickness. 

Table 10–14. Future Fighter Aircraft Extinguisher Container and Agent Mass. 

Legacy Fighter Aircraft 

(Halon 1301) 

(1 nozzle)C

Future Fighter Aircraft 

(HFC-125) 

(4 nozzles)C

Future Fighter Aircraft 

Non-Optimally 

DistributedD

kg lb kg lb kg lb 

Bottle Mass 4.2 9.3 5.6 12.2 15.5 34.3 

Agent Mass 2.5 5.5 3.2 7.0 8.4 18.4 

Plumbing Mass 4.3 9.5 4.6 10.1 6.0 13.3 

Total Mass 11.0 24.3 13.2 29.3 29.9 66.0 

C in addition to the agent outlets in the AMAD and APU bays 

D Proportionally estimated 

As evidenced by the two previous tables, the Navy's investment in distribution system optimization 

realized a substantial payoff in weight and volume savings. 

10.4.4 Rotary-wing Aircraft 

System Description 

For these calculations, it was assumed that future rotary-wing aircraft would utilize a four-nozzle HFC125 fire suppression system. The location for the future rotary-wing aircraft fire suppression system is 

the same as in the legacy rotary-wing aircraft fire suppression system, i.e., between the engines. The 

single bottle provides a dual-shot extinguishing capability. 

Fire Protection System Components and Procedures 

It was assumed that the procedures for actuating the future rotary-wing aircraft fire protection systems are 

the same as the procedures for the legacy systems, as described previously. 

HFC-125 Design Guide Estimation 

At the time of these calculations, testing was underway to determine the required masses of various halon 

1301 alternative fire extinguishing agents for rotary-wing platforms. Thus, the mass of HFC-125 had to 

be estimated for the current purpose. The following is a description of that process and the resulting 

design guide.3

The intent of the design guide was to retain a level of fire fighting performance equivalent to the current 

halon 1301 systems. Like the halon 1301 systems they would replace, the new systems incorporating 

HFC-125 would not extinguish every imaginable fire condition created and if so, it could not be verified 

via experimentation, since finite (albeit even numerous) repeated successes in tests cannot statistically 

guarantee 100 % effectiveness in extended field use. Historical data revealed an overall fire suppression 

effectiveness of 60 % to 80 % for halon 1301 systems. The HFC-125 design guidance provides a 

validated 80 % to 100 % effectiveness. Systems designed using HFC-125 will generally require 
Proposed System Description (HFC-125) for Future Aircraft 1053

additional masses and volumes of agent, compared to their halon 1301 counterparts for an identical 

application. Fortunately, many fielded halon 1301 systems were overdesigned, so the replacement 

HFC-125 containers showed much smaller size increases than expected. 

The design guide presumes optimal mixing of the agent within the nacelle. Less efficient distribution 

systems will require higher masses to achieve the required concentration simultaneously for 0.5 s during 

certification, with the designer having the option of accepting higher mass requirements or modifying and 

improving the distribution system. 

Table 10–15 shows the future rotary-wing aircraft specific parameters used to estimate the amount of 

HFC-125 required. 

Table 10–15. Future Rotary-wing Aircraft Specific Parameters. 

Parameter Value 

Air flow 0.5 kg/s to 1.6 kg/s (1.2 lb/s to 3.5 lb/s) 

Fuel source MIL-H-83282, MIL-H-5606, JP-8 

Maximum air temperature 52 °C (125 °F) 

Free volume 0.5 m3 (16.1 ft3) 

The design guide yielded a platform HFC-125 mass estimate of kg 3.6 kg (7.9 lb.). However, the design 

guide assumes the HFC-125 is optimally distributed. The following analysis was performed to provide 

another estimate of the required mass required using the ratio of the molecular weights. This estimate 

assumes that the HFC-125 is not optimally distributed. The resulting platform HFC-125 mass estimate 

was 7.6 kg (16.8 lb.). 

Analysis of Increase in Total System Mass 

The representative rotary-wing platform provided a breakdown of the various fire suppression system 

component masses, as shown in Table 10-16; the “Other” includes distribution tubing, brackets, wiring, 

detectors and other miscellaneous components. However, it was unclear whether the provided bottle 

mass (Magent) (0.8 kg (1.8 lb)) included the squib. A process to determine the mass of the original bottle is 

described in detail in Reference 3. Within the representative rotary-wing platform, there is minimal room 

for an increase in the diameter of the fire suppression system cylinder. However, there is room for an 

increase in the cylinder length. Another process was used to analyze the increase in total fire suppression 

system mass and is also described in Reference 3. Table 10–16 shows the results of these analyses. 

Table 10–16. Future Rotary-wing Aircraft Analysis of Increase in Total Mass. 

Current Halon 

1301 Design 

Redesigned Halon 

1301 

(optimally 

distributed) 

Redesigned 

Halon 1301 

(not optimally 

distributed) 

HFC-125 

(optimally 

distributed) 

HFC-125 

(not optimally 

Mass per distributed) 

Platform kg lb kg lb kg lb kg lb kg lb 

Agent 0.7 1.5 1.1 2.4 3.3 7.2 3.6 7.9 7.6 16.8 

Bottle 2.6 5.7 4.0 8.9 11.8 26.0 15.9 35.1 33.4 73.7 

Other 4.2 9.3 4.2 9.3 4.2 9.3 4.2 9.3 4.2 9.3 

TOTAL 7.5 16.5 9.3 20.6 19.3 42.5 23.7 52.3 45.4 99.8 
1054 Life Cycle Costing of Fire Suppression Systems 

10.5 COSTS OF CURRENT AND REPLACEMENT SYSTEMS 

The life cycle cost of a system includes the acquisition, operation, and maintenance over the life of the 

system. Both the HFC-125 systems and halon 1301 systems are reusable and rechargeable. The pressure 

vessels must be hydrostatically tested periodically, and the explosive initiators used in the design must be 

changed periodically due to the limited propellant life. Support equipment and facilities required to 

service these units add to the life cycle cost. Costs associated with actual system utilization are generally 

low because of the infrequent need to use the system, although the rate of inadvertent discharge in some 

older aircraft may be significant. The life cycle cost of a system can be heavily impacted by the potential 

for increased mass that may result from incorporation of a non-ozone depleting fire extinguishing 

chemical.29

The costs estimated in this effort are those that would be incurred in the research, development, test and 

evaluation (RDT&E), procurement, and operations and maintenance (O&M) phases of an acquisition. 

RDT&E costs deal with all costs required to develop the fire suppression technology into a deployable 

system. Procurement (also called initial or nonrecurring) costs are those associated with the purchase of 

the fire suppression system (and associated hardware) and suppressant. O&M costs are broad and farreaching. Included in this category are those costs associated with program management support and life 

cycle sustainment management. 

There are some limitations to these cost estimates: 

• The significant cost impact of modifying an aircraft (including its structure) to accommodate 

fire system changes could not be accurately estimated and was thus not included 

• Dimensioned drawings of the aircraft were proprietary. As an alternative, technical orders 

were used. 

• Minimal FOS data existed. The data available were used and adapted. 

Prior to performing this cost analysis, the ground rules and assumptions (similar for all three platform 

assessments) were developed to bound this assessment: 

• Minimal FOS data existed. The data available were used and adapted. 

• This cost analysis was performed for the existing halon 1301 system and the off-the-shelfalternative (HFC-125) for both legacy and future cargo platforms and developed for a system 

with equivalent performance of halon 1301. 

• Raw Inflation Indices, dated 2001, from the Office of the Secretary of Defense were used to 

arrive at then-year (inflated) dollars. 

• This cost analysis assumes that each platform will be retrofitted for only one agent. 

• The maintenance concept assumed was the contractor logistics support (CLS). The average 

of CLS costs for analogous platforms was used. This estimate is assumed to be funded out of 

procurement dollars. 

• This cost analysis assumes a similar delivery schedule and number of aircraft to existing 

fielded aircraft. 

• Prime mission equipment (PME) unit costs for the legacy aircraft fire suppression system are 

based on Technical Orders (TOs) and FEDLOG pricing. 
Costs of Current and Replacement Systems 1055

• For the legacy aircraft, no RDT&E costs for the halon 1301 option were included since it was 

assumed that these were sunk costs. 

• HFC-125 is available at the time of retrofit. 

• The basic research data pertaining to HFC-125 is complete and available. Such information 

includes its chemical, thermophysical, thermodynamic, and transport properties. Other key 

items include: pressure, boiling point, molecular weight, liquid density, vapor pressure, 

critical temperature. 

• The following small- to medium-scale effectiveness experiments have been performed on 

HFC-125 and the data are complete and available: 

o ISO cup burner 

o Laminar opposed-flow diffusion flame (OFDF) 

o Turbulent spray flame 

o Propane inertion testing 

o Baffle-stabilized pool fire testing 

• The following small-scale environmental experiments have been performed on HFC-125 and 

that the data are complete and available: 

o Measurement of ozone depleting potential (ODP). 

o Measurement of global warming potential (GWP). 

o Measurement of acute toxicity (high-exposure, short-duration). 

o Evaluation of the production of acid gases and other hazardous by-products by smallscale R&D fire testing in a reasonably accurate simulation of the fire challenge or 

application under consideration. 

o Favorable completion of a typical corrosion test such as those conducted in the 

evaluation of new agents for aircraft engine fire suppression in accordance with 

ASTM Standard F1110-90, entitled "Standard Test Method for Sandwich Corrosion 

Test." 

• A full-scale testing of the suppressor in a military simulator has been performed and that the 

data are complete and available. 

• The agent meets the following time and concentration requirements as prescribed by the Air 

Force certification requirements specified in MIL-E-22285. For engine nacelles and APUs in 

USAF fixed wing aircraft, a certification test series is conducted using the calculated agent 

mass requirement as a starting point for discharge measurements using the calibrated 

concentration measurement equipment to insure the attainment of the required concentration 

for a prescribed time interval, usually 0.5 seconds. During this test series, adjustments in 

agent mass and/or distribution parameters are made until the system meets the requirement. 

• HFC-125 must leave no damaging residue to harm electronic or other components. For many 

applications, HFC-125 must fill a space to inert flammable or explosive atmospheres. With 

no damaging residue, HFC-125 cleanup would be with minimal effort. 

• HFC-125 is not electrically conductive. 

• According to DuPont, HFC-125 has an indefinite shelf life if the material is stored properly in 

a sealed container that prevents leakage as well as entering moisture. HFC-125 meets NFPA 
1056 Life Cycle Costing of Fire Suppression Systems 

2001 specifications for clean agents. These specifications are set to ensure product 

performance over long storage periods (many years). 

Additional details are available in References 1, 2, and 3. 

10.5.1 Life Cycle Cost Estimate (LCCE) Summary for Legacy Aircraft 

The following tables contain the life cycle cost estimate summary for the existing halon 1301 system and 

the off-the-shelf-alternative (HFC-125) for legacy cargo, fighter, and rotary-wing platforms and 

developed for a system with equivalent performance of halon 1301. 

Cargo Aircraft 

Table 10–17 shows the Life Cycle Cost Estimate (LCCE) for the legacy cargo aircraft halon 1301 and 

HFC-125 systems in FY00 constant dollars and then-year dollars by type of funding. 

Table 10–17. Comparison of Halon 1301 and HFC-125 System Life Cycle (FY00 to FY22) 

Cost Estimates for Legacy Cargo Aircraft ($ M). 

HFC-125 

126 kg (280 lb) 

HFC-125 

40 kg (88 lb) 

Description of Effort 

Halon 

1301 

Total 

Container 

Mod 

Container 

and 

Nozzle 

Mod 

Container 

and 

Distribution 

Sys Mod 

Container 

Mod 

Container 

and Nozzle 

Mod 

Container and 

Distribution 

Sys Mod 

FY2000 Constant 

Dollars 

1.0 RDT&E ($M) 0 0.3 0.3 0.4 0.3 0.3 0.3 

2.0 PROCUREMENT 10.3 20.1 21.2 21.8 18.3 19.4 19.9 

3.0 O&M 14.7 17.2 17.3 18.5 15.8 15.9 17.0 

4.0 MILITARY 

PERSONNEL 0.2 0.2 0.2 0.2 0.2 0.2 0.2 

5.0 MILITARY 

CONSTRUCTION 0 0 0 0 0 0 0 

TOTAL 25.2 37.9 39.1 40.8 34.5 35.7 37.5 

TOTAL COST PER 

AIRCRAFT 0.2 0.3 0.3 0.3 0.3 0.3 0.3 

Then Year Dollars 

1.0 RDT&E 0 0.3 0.3 0.4 0.2 0.3 0.3 

2.0 PROCUREMENT 11.0 22.2 23.5 24.1 20.2 21.4 22.1 

3.0 O&M 18.4 21.5 21.6 23.0 19.8 19.9 21.2 

4.0 MILITARY 

PERSONNEL 0.3 0.3 0.3 0.3 0.3 0.3 0.3 

5.0 MILITARY 

CONSTRUCTION 0 0 0 0 0 0 0 

TOTAL 29.7 44.4 45.8 47.8 40.5 41.9 44.0 
Costs of Current and Replacement Systems 1057

In terms of FY00 (Fiscal Year 2000) constant dollars, the legacy cargo aircraft halon 1301 fire 

suppression system cost is estimated to be $208 k per aircraft over a 23-year life cycle (FY00 to FY22), 

based on 121 aircraft. This is approximately 0.11 % of the total flyaway aircraft cost of $183 M. In 

FY00 constant dollars, the non-optimally distributed HFC-125 system, weighing 126 kg (280 lb) is 

estimated to range from $313 k to $338 k per aircraft. This is approximately 0.17 % to 0.18 % of the total 

flyaway aircraft cost. The optimally distributed HFC-125 system, weighing 40 kg (88 lb) ranges from 

$285 k to $310 k. This is approximately 0.16 % to 0.17 % of the total flyaway aircraft cost. 

Fighter Aircraft 

Table 10–18 shows the LCCE for the legacy fighter aircraft halon 1301 and HFC-125 systems in FY00 

constant dollars and then-year dollars by type of funding. In terms of FY00 constant dollars, the legacy 

fighter aircraft halon 1301 fire suppression system cost is estimated to be $20.5 k per aircraft over a 

29-year life cycle (FY00 to FY28), based on 549 aircraft. This is approximately 0.04 % of the total 

flyaway aircraft cost of $51.1 M. In FY00 constant dollars, the non-optimally distributed HFC-125 

system, weighing 8.4 kg (18.4 lb) is estimated to be $32.5 k per aircraft. This is approximately 0.06 % of 

the total flyaway aircraft cost. The optimally distributed HFC-125 system, weighing 3.2 kg (7.0 lb) is 

estimated to be $28.6 k. This is approximately 0.05 % of the total flyaway aircraft cost. Using the 

conservative value of 60 % system effectiveness, the breakpoint between cost and benefit is $282 k per 

aircraft. 

Table 10–18. Comparison of Halon 1301 and HFC-125 System Life Cycle (FY00 to FY28) 

Cost Estimates for Legacy Fighter Aircraft ($ M). 

Halon 1301 

HFC-125 

(optimally 

distributed) 

HFC-125 

(not optimally 

distributed) 

Description of Effort 2.5 kg (5.5 lb) 3.2 kg (7lb) 8.4 kg (18.4 lb)

FY2000 Constant Dollars 

1.0 RDT&E ($M) 0 2.0 2.0 

2.0 PROCUREMENT 8.1 9.5 9.6 

3.0 O&M 3.0 4.0 6.1 

4.0 MILITARY PERSONNEL 0.14 0.14 0.14 

5.0 MILITARY CONSTRUCTION 0 0 0 

TOTAL 11.2 15.7 17.8 

TOTAL COST PER AIRCRAFT 0.02 0.03 0.03 

Then Year Dollars 

1.0 RDT&E 0 2.0 2.0 

2.0 PROCUREMENT 9.1 10.9 11.0 

3.0 O&M 3.9 5.4 8.0 

4.0 MILITARY PERSONNEL 0.2 0.2 0.2 

5.0 MILITARY CONSTRUCTION 0 0 0 

TOTAL 13.3 18.5 21.3 
1058 Life Cycle Costing of Fire Suppression Systems 

Rotary-Wing Aircraft 

Table 10–19 shows the LCCE for the legacy rotary-wing aircraft halon 1301 and HFC-125 fire 

suppression systems in FY03 constant dollars and then-year dollars by type of funding. In terms of FY00 

constant dollars, the legacy rotary-wing aircraft non-optimally distributed halon 1301 system, weighing 

3.3 kg (7.18 lb) is estimated to be $30.3 k per aircraft over a 33-year life cycle (FY03 to FY35), based on 

1213 aircraft. This is approximately 0.18 % of the total flyaway aircraft cost. The optimally distributed 

halon 1301 system, weighing 1.1 kg (2.4 lb) is estimated to be $28.2 k per aircraft. This is approximately 

0.17 % of the total flyaway aircraft cost. In FY03 constant dollars, the non-optimally distributed 

HFC-125 system, weighing 7.6 kg (16.8 lb) is estimated to be $43.7 k per aircraft. This is approximately 

0.26 % of the total flyaway aircraft cost. The optimally distributed HFC-125 system, weighing 3.6 kg 

(7.9 lb) is estimated to be $39.5 k per aircraft. This is approximately 0.24 % of the total flyaway aircraft 

cost. Using the conservative value of 60 % system effectiveness, the breakpoint between cost and benefit 

is $306.8 k per aircraft. 

Table 10–19. Comparison of Halon 1301 and HFC-125 System Life Cycle (FY03 to FY35) 

Cost Estimates for Legacy Rotary-wing Aircraft ($ M). 

Halon 1301 

(optimally 

distributed) 

Halon 1301 

(not optimally 

distributed) 

HFC-125 

(optimally 

distributed) 

HFC-125 

(not optimally 

distributed) 

Description of Effort 1.1 kg (2.4 lb) 3.3 kg (7.2 lb) 3.6 kg (7.9 lb) 7.6 kg (16.8 lb) 

FY2003 Constant Dollars 

1.0 RDT&E ($M) 0 0 3.2 3.2 

2.0 PROCUREMENT 23.7 24.0 30.2 30.4 

3.0 O&M 10.3 12.6 14.3 19.2 

4.0 MILITARY PERSONNEL 0.19 0.19 0.18 0.18 

5.0 MILITARY CONSTRUCTION 0 0 0 0 

TOTAL 34.2 36.8 48.0 53.1 

TOTAL COST PER AIRCRAFT 0.03 0.03 0.04 0.04 

Then Year Dollars 

1.0 RDT&E 0 0 3.3 3.3 

2.0 PROCUREMENT 28.3 28.8 37.0 37.3 

3.0 O&M 14.1 17.3 19.6 26.4 

4.0 MILITARY PERSONNEL 0.32 0.32 0.32 0.32 

5.0 MILITARY CONSTRUCTION 0 0 0 0 

TOTAL 42.8 46.3 60.2 67.2 

10.5.2 Life Cycle Cost Estimate (LCCE) Summary for Future Aircraft 

The following tables contain the life cycle cost estimate summary for the existing halon 1301 system and 

the off-the-shelf-alternative (HFC-125) for future cargo, fighter, and rotary-wing platforms and developed 

for a system with equivalent performance of halon 1301. 
Costs of Current and Replacement Systems 1059

Cargo Aircraft 

Table 10–20 shows the LCCE for the future cargo aircraft halon 1301 and HFC-125 systems in FY00 

constant dollars and then-year dollars by type of funding. In terms of FY00 constant dollars, the future 

cargo aircraft halon 1301 fire suppression system cost is estimated to be $301 k per aircraft over a 32-year 

life cycle (FY00-31), based on 121 aircraft. This is approximately 0.16 % of the total flyaway aircraft 

cost of $183 M. In FY00 constant dollars, the non-optimally distributed HFC-125 system, weighing 

125.6 kg (276.8 lb) is estimated to range from $318 k to $366 k per aircraft. This is approximately 0.17% 

to 0.20 % of the total flyaway aircraft cost. The optimally distributed HFC-125 system, weighing 39.9 kg 

(87.9 lb) ranges from $288 k to $336 k. This is approximately 0.16 % to 0.18 % of the total flyaway 

aircraft cost. 

Table 10–20. Comparison of Halon 1301 and HFC-125 System Life Cycle (FY00 to FY31) 

Cost Estimates for Future Cargo Aircraft ($ M). 

HFC-125 

125.6 kg (276.8 lb) 

HFC-125 

39.9 kg (87.9 lb) 

Description of Effort 

Halon 

1301 

Total 

Container 

Mod 

Container 

and 

Nozzle 

Mod 

Container 

and 

Distribution

Sys Mod 

Container 

Mod 

Container 

and 

Nozzle 

Mod 

Container and 

Distribution Sys 

Mod 

FY2000 Constant Dollars 

1.0 RDT&E ($M) 0.56 0.61 0.69 0.75 0.54 0.62 0.68 

2.0 PROCUREMENT 18.3 17.8 20.2 22.0 15.9 18.2 20.0 

3.0 O&M 17.3 19.8 20.0 21.3 18.1 18.3 19.6 

4.0 MILITARY 

PERSONNEL 0.31 0.31 0.31 0.31 0.31 0.31 0.31 

5.0 MILITARY 

CONSTRUCTION 0 0 0 0 0 0 0 

TOTAL 36.5 38.5 41.1 44.3 34.9 37.5 40.6 

TOTAL COST PER 

AIRCRAFT 0.30 0.32 0.34 0.37 0.29 0.31 0.34 

Then Year Dollars 

1.0 RDT&E 0.57 0.62 0.70 0.77 0.55 0.63 0.70 

2.0 PROCUREMENT 22.3 21.7 24.6 26.8 19.4 22.2 24.4 

3.0 O&M 25.7 29.2 29.5 31.3 26.8 27.1 29.0 

4.0 MILITARY 

PERSONNEL 0.54 0.54 0.54 0.54 0.54 0.54 0.54 

5.0 MILITARY 

CONSTRUCTION 0 0 0 0 0 0 0 

TOTAL 49.1 52.1 55.3 59.4 47.3 50.5 54.6 

Fighter Aircraft 

Table 10–21 shows the LCCE for the future fighter aircraft halon 1301 and HFC-125 systems in FY00 

constant dollars and then-year dollars by type of funding. In terms of FY00 constant dollars, the future 
1060 Life Cycle Costing of Fire Suppression Systems 

fighter aircraft halon 1301 fire suppression system cost is estimated to be $26.3 k per aircraft over a 

33-year life cycle (FY00 to FY32), based on 549 aircraft. This is approximately 0.05 % of the total 

flyaway aircraft cost of $51.1M. In FY00 constant dollars, the non-optimally distributed HFC-125 

system, weighing 8.4 kg (18.4 lb) is estimated to be $32.7 k per aircraft. This is approximately 0.06 % of 

the total flyaway aircraft cost. The optimally distributed HFC-125 system, weighing 3.2 kg (7.0 lb) is 

estimated to be $28.7 k. This is approximately 0.05 % of the total flyaway aircraft cost. Using the 

conservative value of 60 % system effectiveness, the breakpoint between cost and benefit is $285 k per 

aircraft. 

Table 10–21. Comparison of Halon 1301 and HFC-125 System Life Cycle (FY00 to FY32) 

Cost Estimates for Fighter Cargo Aircraft ($ M). 

Halon 1301 HFC-125 HFC-125 

DESCRIPTION OF EFFORT 2.5 kg (5.5 lb) 3.2 kg (7lb) 8.4 kg (18.4 lb) 

FY2000 Constant Dollars 

1.0 RDT&E ($M) 2.0 2.0 2.0

2.0 PROCUREMENT 9.1 10.2 10.3

3.0 O&M 3.2 3.5 5.5

4.0 MILITARY PERSONNEL 0.16 0.16 0.16

5.0 MILITARY CONSTRUCTION 0 0 0

TOTAL 14.4 15.8 18.0

TOTAL COST PER AIRCRAFT 0.03 0.03 0.03

Then Year Dollars 

1.0 RDT&E 2.0 2.0 2.0

2.0 PROCUREMENT 11.0 12.3 12.5

3.0 O&M 4.5 4.8 7.8

4.0 MILITARY PERSONNEL 0.29 0.29 0.29

5.0 MILITARY CONSTRUCTION 0 0 0

TOTAL 17.8 19.4 22.5

Rotary-Wing Aircraft 

Table 10–22 shows the LCCE for the future rotary-wing aircraft halon 1301 and HFC-125 fire 

suppression systems in FY03 constant dollars and then-year dollars by type of funding. In terms of FY03 

constant dollars, the future rotary-wing aircraft non-optimally distributed halon 1301 system, weighing 

3.3 kg (7.2 lb) is estimated to be $35.9 k per aircraft over a 42-year life cycle of FY03 to FY41, based on 

1213 aircraft. This is approximately 0.22 % of the total flyaway aircraft cost. In terms of FY03 constant 

dollars, the future rotary-wing aircraft optimally distributed halon 1301 system, weighing 1.1 kg (2.4 lb) 

is estimated to be $33.7 k per aircraft over a 42-year life cycle of FY03 to FY41, based on 1213 aircraft. 

This is approximately 0.20 % of the total flyaway aircraft cost. In FY03 constant dollars, the nonoptimally distributed HFC-125 system, weighing 7.6 kg (16.8 lb) is estimated to be $41.4 k per aircraft. 

This is approximately 0.25 % of the total flyaway aircraft cost. The optimally distributed HFC-125 

system, weighing 3.6 kg (7.9 lb) is estimated to be $37.1 k per aircraft. This is approximately 0.22 % of 

the total flyaway aircraft cost. Using the conservative value of 60 % system effectiveness, the breakpoint 

between cost and benefit is $312.2 k per aircraft. 
Costs of Current and Replacement Systems 1061

Table 10–22. Comparison of Halon 1301 and HFC-125 System Life Cycle (FY03 to FY41) 

Cost Estimates for Future Rotary-wing Aircraft ($ M). 

Halon 1301 Halon 1301 HFC-125 HFC-125 

DESCRIPTION OF EFFORT 1.1 kg (2.4 lb) 3.3 kg (7.2 lb) 3.6 kg (7.90 lb) 7.6 kg (16.8 lb) 

FY2003 Constant Dollars 

1.0 RDT&E ($M) 3.2 3.2 3.1 3.1

2.0 PROCUREMENT 26.9 27.3 27.2 27.4

3.0 O&M 10.6 12.9 14.5 19.5

4.0 MILITARY PERSONNEL 0.22 0.22 0.22 0.22

5.0 MILITARY CONSTRUCTION 0 0 0 0

TOTAL 40.9 43.6 45.0 50.3

TOTAL COST PER AIRCRAFT 0.03 0.04 0.04 0.04

Then Year Dollars 

1.0 RDT&E 3.2 3.2 3.2 3.2

2.0 PROCUREMENT 35.4 35.9 35.8 36.1

3.0 O&M 16.2 19.8 22.2 29.9

4.0 MILITARY PERSONNEL 0.43 0.43 0.43 0.43

5.0 MILITARY CONSTRUCTION 0 0 0 0

TOTAL 55.2 59.4 61.6 69.6

10.5.3 Detailed Cost Element Structure (CES) 

This fire suppression system's detailed cost element structure (CES) given in Table 10–23 is based on the 

DoD 5000.4-M and MIL-HDBK-881 CES. It was customized for each system and approach. Due to 

space limitations and for clarity, only general information about the various cost elements is presented 

here. Additional details are available in References 1, 2, and 3. 

10.5.4 Cost Element Structure Data Development 

Cost factors used by government and industry were obtained from the Aeronautical Systems Center 

(ASC) Cost Library and ESC/FMC. These cost factors were then applied to the subsystem costs (Group 

A/Group B kits). A Group A Kit is defined as the hardware used to install/mount the fire suppression 

system while the Group B Kit is actually the fire suppression system itself, including the agent. The 

following sections are organized according to the Cost Element codes in Table 10–23. When no 

information was available for a given Element, a cost factor was used (multiplied by the appropriate 

Group A/Group B kit price) to estimate this element. However, cost factors were not available for every 

element. 
1062 Life Cycle Costing of Fire Suppression Systems 

Table 10–23. Detailed Cost Element Structure. 

Cost Elements 

1.0 RDT&E (3600) 

1.1 Concept Exploration 

1.2 Prototype Engineering And Manufacturing Development (EMD) Cost Sharing (Fire Suppression 

System Prototype) 

1.2.1 Subsystem 

1.2.1.1 Group A Kit (Hardware to install/mount fire suppression system) 

1.2.1.2 Group B Kit (Fire suppression system) 

1.2.2 Commercial-Off-The-Shelf (COTS)/Government-Off-The Shelf (GOTS) Software – N/A 

1.2.3 Development Software – N/A 

1.2.4 Integration, Assembly, Test and Checkout 

1.3 System/Platform Integration 

1.4 System Engineering/Program Management 

1.4.1 Systems Engineering 

1.4.2 Program Management 

1.4.3 Travel 

1.5 System Test and Evaluation 

1.5.1 Developmental Test and Evaluation (DT&E) 

1.5.2 Operational Test and Evaluation (OT&E) 

1.6 Data 

1.7 Training 

1.8 Evolutionary Technology Insertions (ETIs) - N/A 

1.8.1 Program Management 

1.8.2 Prototype and Test Bed 

1.8.3 Market Surveys 

1.9 Support Equipment 

1.9.1 Common Support Equipment 

1.9.2 Peculiar Support Equipment 

2.0 PROCUREMENT (3010) 

2.1 Prime Mission Product (Fire Suppression System) 

2.1.1 Subsystems 

2.1.1.1 Group A Kit (Hardware to install/mount fire suppression system) 

2.1.1.2 Group B Kit (Fire suppression system) 

2.1.2 Non-Recurring Engineering – N/A 

2.1.3 Software Integration – N/A 

2.1.4 Integration, Assembly, Test and Checkout 

2.2 System/Platform Integration and Assembly (Cost of installation) 

2.3 Systems Engineering/Program Management 

2.3.1 Systems Engineering 

2.3.2 Program Management 

2.3.3 Logistics Management 

2.4 System Test and Evaluation 

2.4.1 Operational Test and Evaluation 

2.5 Engineering Change Orders (ECOs) 

2.6 Initial Cadre Training 

2.7 Data 

2.8 Operational Fielding/Site Activation 

2.9 Depot Setup - N/A 

2.10 Support Equipment 

2.10.1 Common Support Equipment 
Costs of Current and Replacement Systems 1063

Cost Elements 

2.10.2 Peculiar Support Equipment 

2.11 Initial Spares and Repair Parts 

2.12 Warranty 

2.13 Evolutionary Technology Insertions (ETIs) - N/A 

2.14 Interim Contractor Support (ICS) 

2.15 Flexible Sustainment Support (Maintenance Support) 

3.0 OPERATIONS AND MAINTENANCE (3400) 

3.1 Program Administration 

3.1.1 Program Management Support 

3.1.1.1 Miscellaneous Contract Services 

3.1.1.2 Government Technical Support 

3.1.1.3 Travel 

3.1.2 Life Cycle Sustainment Management (LCSM) 

3.2 Program Operational Support 

3.2.1 Recurring Training 

3.2.2 Technical Data Revision 

3.2.3 Software Maintenance - N/A 

3.2.4 Hardware Maintenance 

3.2.4.1 Organic Support 

3.2.4.2 Contractor Maintenance 

3.2.5 Replenishment Spares 

3.2.6 Repair Parts and Materials 

3.2.7 Transportation, Packaging, and Handling 

3.2.8 Storage 

3.2.9 Disposal 

3.2.10 Facility Projects/Upgrades/Leases 

3.2.11 Operational O&M Impacts of ETIs - N/A 

3.2.12 Program Operations 

3.2.13 Unit Level Support 

3.2.13.1 Recurring Training (Unit Travel/TDY Costs) 

3.2.13.2 Operating Consumables 

3.2.13.3 Unit Level O&M Impacts of ETIs 

3.2.14 Depot Level Support 

3.2.15 Contractor Logistics Support (CLS) 

4.0 MILITARY PERSONNEL (3500) 

5.0 MILITARY CONSTRUCTION – N/A 

RDT&E (1.0) 

No cost information was available for the concept exploration (1.1). 

The prototype EMD cost sharing (1.2) is the hardware and software used to accomplish the primary 

mission and includes all integration, assembly, test and checkout, as well as all technical and management 

activities associated with individual hardware/software elements. ASC Avionics Support Cost Element 

Factors were used to estimate costs for systems engineering/program management, system test and 

evaluation, data, and training. 

The data used to derive these cost factors were extracted from Cost Performance Reports (CPR) and 

Cost/Schedule Status Report (C/SSR) reports. The other cost factors used in this estimate originated from 

Electronic Systems Center (ESC/FMC). Data used for these factors encompassed thirty-seven CPR and 
1064 Life Cycle Costing of Fire Suppression Systems 

C/SSR stored in the Automated Cost Estimating Integrated Tool's (ACE-IT) Automated Cost Data Base 

(ACDB). The data represent ESC production contract efforts occurring between 1974 and 1992. 

Technical orders and FEDLOG pricing were used to capture the cost of the Group A (1.2.1.1) and Group 

B (1.2.1.2) kits for the fire suppression system. The cost factors are applied to the Group A and Group B 

Kit costs. 

The integration, assembly, test and checkout (1.2.4) includes the effort associated with bending metal, 

mating surfaces, structures, equipment, parts, and materials required to assemble all equipment, 

components and subsystems into an operational system. Since specific cost information was not available, 

a multiplicative cost factor was used to estimate this element, as is common practice when such cost data 

is not available. 

System/platform integration (1.3) includes the efforts associated with integrating/installing systems or 

subsystems into an existing platform/weapon system. No cost information was available for this cost 

element. 

Systems engineering/program management (1.4) involves all associated elements to be reported, 

including the overall planning, directing, and controlling of the definition, development, and production 

of a system or program. Since specific cost information was not available, a cost factor was used to 

estimate this element. 

System test and evaluation (1.5) is the use of prototype, production, or specifically fabricated hardware 

and/or software to obtain or validate engineering data on the performance of the system during the 

development phase of the program. It includes detailed planning, conduct of, support for, data reduction, 

and reports from such testing, and all hardware/software items which are consumed or planned to be 

consumed in the conduct of such testing as well as all effort associated with the design and production of 

models, specimens, fixtures, and instrumentation in support of the system level test program. Since 

specific cost information was not available, a cost factor was used to estimate this element. 

Data (1.6) includes the effort required to develop technical and managerial data in support of the program. 

Since specific cost information was not available, a cost factor was used to estimate this element. 

Training (1.7) includes all efforts associated with the design, development, and production of deliverable 

training equipment as well as the execution of training services. Since specific cost information was not 

available, a cost factor was used to estimate this element. 

Support equipment (1.9) includes the effort required to design, develop and produce system peculiar and 

common support equipment. Since specific cost information was not available, the cost factors were used 

to estimate these elements. 

Procurement (2.0) 

The prime mission product (PMP) (2.1) is the hardware and software used to accomplish the primary 

mission and includes all integration, assembly, test and checkout, as well as all technical and management 

activities associated with individual hardware/software elements. Technical Orders (TOs) and FEDLOG 

pricing were used to capture the cost of the Group A/B Kits for the fire suppression system. 
Costs of Current and Replacement Systems 1065

The integration, assembly, test and checkout (2.1.4) includes the effort associated with bending metal, 

mating surfaces, structures, equipment, parts, and materials required to assemble all equipment, 

components and subsystems into an operational system. Since specific cost information was not available, 

a cost factor was used to estimate this element. 

System/platform integration and assembly (2.2) includes the efforts associated with integrating/installing 

systems or subsystems into an existing platform/weapon system. Depending on the alternative, labor was 

estimated for modifications to the container, nozzles, and the distribution system. 

Systems engineering/program management (2.3) includes the effort required for system definition; overall 

system design; design integrity, cost effectiveness, weight, and balance analyses; intra-system and intersystem compatibility; safety, security, and survivability requirements; human engineering; and 

performance specifications. Program management includes the effort required for configuration, contract, 

and data management; cost and schedule management; transportation and packaging management; vendor 

liaison; value engineering; and quality assurance. Logistics management includes the effort required for 

reliability, maintainability and logistics support integration. Since specific cost information was not 

available, a cost factor was used to estimate this element. 

System test and evaluation (2.4) includes the effort required for: all detailed test planning, support data 

consolidation and corresponding reports; hardware items consumed in the conduct of testing; and efforts 

associated with models, specimens, fixtures and instrumentation. No cost information was available for 

this cost element. 

Engineering change orders (2.5) includes the effort required for anticipated "in scope" contract 

engineering changes to the prime mission product. No cost information was available for this cost 

element. 

Initial cadre training (2.6) includes the effort required for the design, development, and production of 

training equipment, course material preparation, and travel costs associated with conducting training for 

an initial cadre of both operational and depot personnel. Since specific cost information was not available, 

a cost factor was used to estimate this element. 

Data (2.7) includes the effort required to develop technical and managerial data in support of the program. 

Since specific cost information was not available, a cost factor was used to estimate this element. 

Operational fielding/site activation (2.8) includes the real estate, construction, conversion, utilities, and 

equipment to provide all facilities required to house, service, and launch prime mission equipment at the 

organizational and intermediate level. Since specific cost information was not available, a cost factor was 

used to estimate this element. 

Common support equipment (2.10.1) involves the acquisition of additional support equipment, over and 

above existing support equipment inventories, required to support the acquisition of a new system or 

subsystems. Peculiar equipment (2.10.2) generally involves unique or special purpose vehicles, 

equipment or tools used to transport and hoist; service, repair, overhaul, assemble and disassemble; test 

and inspect; and to perform other maintenance on the prime mission product. Since specific cost 

information was not available, cost factors were used to estimate these elements. 
1066 Life Cycle Costing of Fire Suppression Systems 

Initial spares and repair parts (2.11) includes the effort required to procure modules, spare components 

and assemblies used for replacement purposes (building logistical pipeline) to support prime mission 

product. Since specific cost information was not available, a cost factor was used to estimate this element. 

The maintenance concept assumed was the contractor logistics support (CLS). Therefore, there are no 

costs associated with flexible sustainment support (2.15). 

Operations and Maintenance (O&M) (3.0) 

Program management support (3.1.1) includes the effort required for configuration, contract and data 

management, cost and schedule management, transportation and packaging management, vendor liaison, 

value engineering, and quality assurance. Since specific cost information was not available, a cost factor 

of 0.05 was used to estimate this element for the halon 1301 system and 0.10 for the HFC-125. The cost 

factor is varied depending on the maturity of the system; therefore, a higher factor was applied to the 

HFC-125 system since it is in the earliest stages for this platform. 

Hardware maintenance organic support (3.2.4.1) includes civilian labor, material, and overhead costs 

incurred after deployment. This cost element was estimated by taking the number of flying hours for a 

typical cargo platform (contained in the Air Force Instruction (AFI) 65-503 Attachment 42-1 for Aircraft 

Endstrengths) and multiplying by the average civilian hourly pay (contained in AFI 65-503 Attachment 

A28-1) and the average maintenance staff hour per flying hour. 

Replenishment spares include the cost of materials consumed in operation, maintenance, and support of 

the primary system and associated support at the unit level. Since specific cost information was not 

available, a cost factor in relation to initial spares and repair parts was used to estimate this element. 

The maintenance concept assumed was the CLS. The average of CLS costs (3.2.15) for analogous 

platforms was used. 

The tubing and brackets for the fire suppression system are nonrepairable and condemned at the field 

level, with a local manufacturing capability. The bottles are repaired (recharged) and condemned at the 

depot and have limited "O" and "I" level repair.30

Military Personnel (4.0) 

Military personnel support was estimated by taking the number of military personnel endstrengths 

(contained in the AFI 65-503 Attachment 42-1 for Aircraft Endstrengths) and multiplying by the average 

officer and enlisted pay (contained in AFI 65-503 Attachment A19-1) and the percentage of the fire 

suppression system to the total aircraft cost. 

10.6 COST SAVINGS 

In a previous study (Reference 31), the historical and projected costs to the U.S. Air Force aircraft fleet 

due to in-flight fires were determined. By combining the components which comprise the costs of 

peacetime aircraft losses due to fire, a resulting historical cost (over a 30 year period) of approximately 

$9.3 billion was determined, measured in 1995 dollars. The costs of combat aircraft losses due to fire 
Cost Savings 1067

were estimated to be approximately $5.9 billion (in 1995 dollars), based primarily on Southeast Asia 

experience. The costs of utilizing aircraft fire protection were estimated to be approximately $316 million 

(in 1995 dollars). Thus, the total historical costs of fire to the U.S. Air Force over the 1966 to 1995 time 

period was estimated to be $15.5 billion (in 1995 dollars). The total projected costs of fire to the U.S. Air 

Force over the 1996 to 2025 time period was estimated to be $16.0 billion (in 1996 dollars). A net 

present value of over $119 million was projected to be the benefit of fire suppression systems over the 

next 30 years, in terms of the reduction in casualty-related losses due to their presence, even with the 

costs of the protection systems themselves included. 

The cost savings for the life of the legacy and future aircraft were estimated by using the traditional 

extinguishing success rate for existing engine halon systems, the estimated fire costs per flight hour, and 

the number of flight hours for the legacy cargo aircraft. Field experience of existing engine halon systems 

on current aircraft, depending on the platform, shows that the systems have a 60 % to 80 % success rate. 

This study (Reference 31) postulated that future aircraft losses due to fire incidents were a function of the 

total number of flight hours (FH) for this period. An historical relationship between fire costs and flight 

hours was established. The resulting average fire cost per flight hour (in 2000 dollars) was $63.31

Table 10–24 through Table 10–26 show the estimated cost savings determined, while using on-board fire 

protection for legacy and future aircraft of the three types. 

Table 10–24. Cargo Aircraft Cost Savings Estimation. 

Cost Factors Legacy Aircraft Future Aircraft 

PAA Quantity Cumulative 121 121 

Flying Hours Cumulative 3.24 M 3.60 M 

Fire Cost Cumulative $204 M $226 M 

Cost Savings: 60 % effective system $122 M $136 M 

Cost Savings: 80 % effective $163 M $181 M 

Table 10–25. Fighter Aircraft Cost Savings Estimation. 

Cost Factors Legacy Aircraft Future Aircraft 

PAA Quantity Cumulative 549 549 

Flying Hours Cumulative 4.10 M 4.15 M 

Fire Cost Cumulative $258 M $261 M 

Cost Savings: 60 % effective system $155 M $157 M 

Cost Savings: 80 % effective $206 M $209 M 

Table 10–26. Rotary-wing Aircraft Costs Savings Estimation. 

Cost Factors Legacy Aircraft Future Aircraft 

PAA Quantity Cumulative 1,213 1,213 

Flying Hours Cumulative 9.9 M 10,0 M 

Fire Cost Cumulative $620 M $631 M 

Cost Savings: 60 % effective system $372 M $379 M 

Cost Savings: 80 % effective $496 M $505 M 
1068 Life Cycle Costing of Fire Suppression Systems 

10.7 COST ANALYSIS USING ALTERED FIRE SUPPRESSION PERFORMANCE 

Analyses discussed up to this stage in the cost analyses for halon 1301 and HFC-125 for legacy and future 

platforms have assumed a replacement HFC-125 system with an equivalent level of performance to 

legacy halon 1301 systems. For the next stage of this analysis, a methodology for legacy and future 

platforms utilizing systems with performance levels from traditional, fielded halon 1301 systems was 

developed. This allowed examination of whether there was an optimal performance or success rate that 

balances the costs of the system size (at that performance level) vs. the savings of the assets preserved at 

that success rate. Such a methodology could determine, for instance, if only a negligible increase in 

success rate resulted from doubling the size or cost of the system. 

To address the issue of a potential fire suppression system with altered performance, data from the Factor 

of Safety study performed during Phase III of the Halon Replacement Program for Aviation (HRPA) were 

used.11 Phase III was conducted in order to develop system sizing design equations for using HFC-125 as 

a halon replacement. As a final step in Phase III, the resulting design equations were "qualified" by 

performing Factor of Safety (FOS) tests. FOS testing provided an estimation of the fire protection 

effectiveness (as a percentage of fires successfully extinguished) of the amount of HFC-125 predicted by 

the design equation. Additional testing then determined the fire protection effectiveness percentages at 

agent capacities above and below the design equation amount. FOS data for the F-22 were used and 

adapted. These suppression system masses and corresponding effectiveness were correlated to the cargo 

and fighter aircraft platforms. The resulting systems’ costs, costs savings, and net costs were calculated. 

The relationship between varying the system size and system effectiveness (and therefore costs and 

savings) was determined. More detailed information regarding these cost analyses are available in 

References 25, 26, and 27. 

10.7.1 Factor of Safety Testing 

The resulting system sizing design formula from the HRPA was "qualified" by performing FOS tests 

under conditions similar to those of actual aircraft applications. The goals of FOS testing were twofold: 

• Determine the fire protection effectiveness (expressed as the success rate percentage in 

extinguishing fires) of the amount of HFC-125 predicted by the design equation for a typical 

aircraft application. 

• Compare the level of fire protection provided by the amount of HFC-125 predicted by the 

design equation with the level of fire protection offered by an aircraft's current halon 1301 

system. This comparison not only provided an estimate of how much HFC-125 is needed for 

equivalent protection to halon 1301 for the particular aircraft, but also provided a guideline 

for use in similar aircraft engine nacelles. 

The FOS testing and the need to estimate the effectiveness of the quantity of HFC-125 predicted by the 

design equation were driven by the fact that the bracketing technique used to determine the final 

successful mass in each test run could not consistently check the repeatability of the results. These FOS 

tests provided the data necessary to estimate the actual effectiveness of varying quantities of HFC-125. 

These tests were also performed to see if a suitable universal scale-up factor could be identified to 

estimate the masses of HFC-125 associated with near 100 % effectiveness, or to estimate masses of 

HFC-125 having the same effectiveness as current halon systems. 
Cost Analysis Using Altered Fire Suppression Performance 1069

Fire suppression engineers for various military aircraft systems were queried about "typical" operating 

conditions for their respective aircraft. These operating conditions were then translated into level settings 

for the parameters used in the testing. Information was gathered on three aircraft system engine nacelles 

in order to obtain a wide range of possible test conditions. The aircraft chosen were the RAH-66, F-22, 

V-22, and F-15. 

In keeping with the overall test strategy, the dependent variable was the observation of whether or not the 

fire was extinguished at the given agent amount. It was determined that at least ten shots at each agent 

amount of interest were required to capture the response of the system with sufficient precision of success 

rate, as measured by the percentage of fires extinguished.32

FOS data for the F-22 were used and adapted for this methodology. This methodology is explained in the 

next section. 

10.7.2 System Description 

Table 10–27 through Table 10–29 show the resulting system description for the actual cargo, fighter, and 

rotary-wing aircraft, respectively, selected and used for consideration and replication in the FOS tests. 

Table 10–27. Estimated Cargo Aircraft System Description. 

Aircraft Engine Nacelle Auxiliary Power Unit 

Conc. Mass Volume Conc. Mass Volume 

Total Agent 

Per 

Platform 

% by vol. lb kg in3 L % by vol. lb kg in3 L lb kg 

Current Halon 1301 

System 

6 21 9.5 630 10 6 2.5 1.1 86 1.4 86 39 

Estimated HFC-125-

Optimally Distributed 

24 21 9.7 810 13 24 2.6 1.2 111 1.8 88 40 

Estimated HFC-125- 

Non-Optimally 

Distributed 

24 67 30 2580 42 24 8 3.6 350 5.8 280 125 

Table 10–28. Estimated Fighter Aircraft System Description. 

Legacy Fighter Aircraft (Halon 1301) 

(1 nozzle)e

Future Fighter Aircraft (HFC-125) 

(4 nozzles)e

kg lb kg lb 

Bottle Mass 4.2 9.3 5.6 12.2 

Agent Mass 2.5 5.5 3.2 7.0 

Plumbing Mass 4.3 9.5 4.6 10.1 

Total Mass 11.1 24.4 13.3 29.4 

e

 in addition to the agent outlets in the AMAD and APU bays 
1070 Life Cycle Costing of Fire Suppression Systems 

Table 10–29. Estimated Rotary-wing Aircraft System Description. 

Current Halon 

1301 Design 

Redesigned

Halon 1301 –

small 

Redesigned

Halon 1301 –

large 

HFC-125 –

small 

HFC-125 –

large 

Mass per Platform kg lb kg lb kg lb kg lb kg lb 

Agent 0.7 1.5 1.1 2.4 3.3 7.2 3.6 7.9 7.6 16.8

Bottle 2.6 5.7 4.0 8.9 11.8 26.0 15.9 35.1 33.4 73.7

Other 4.2 9.3 4.2 9.3 4.2 9.3 4.2 9.3 4.2 9.3

TOTAL 7.5 16.5 9.3 20.6 19.3 42.5 23.7 52.3 45.3 99.8

10.7.3 Altered Fire Suppression Performance 

FOS data for the F-22 (shown in Figure 10–10) were used and adapted for this methodology.

Figure 10–10. F-22 Factor of Safety Data. 

These data were scaled from uired amount of HFC-125 

for the cargo, fighter, and rotary-wing aircraft, respectively, yielding an altered system description. For 

F-22 Factor of Safety Testing

0

1

2

3

4

5

6

7

8

9

10

0 1 234 5 6 7 8 9 10 11 12 13 14 15

Agent (lb.)

Fires Out

HFC-125

Halon

1301

the corresponding Design Guide amount to the req

example, the 40 % success rate for HFC-125 resulted in an estimated mass of 2.5 kg (5.4 lb). The 90 % 

success rate for HFC-125 in the F-22 FOS resulted in an estimated mass of 2.6 kg (5.6 lb). The resulting 
Cost Analysis Using Altered Fire Suppression Performance 1071

Design Guide amount was 6.4 lb. Thus, the ratio for 40 % success rate was 5.4/6.3 (or 0.9) of the Design 

Guide amount, and the 90 % success rate was 5.6/6.3 (or 0.9) of the Design Guide amount. These ratios 

were applied to the required amount of HFC-125 for the cargo, fighter, and rotary-wing aircraft, 

respectively. Table 10–30 through Table 10–32 show the resulting altered system descriptions for the 

cargo, fighter, and rotary-wing aircraft, respectively. These altered fire suppression system masses were 

used in the cost analysis for varied performance. 

Table 10–30. Cargo Aircraft Altered System Description. 

Aircraft Engine Nacelle Auxiliary Power Unit 

Design 

Conc. 

Mass 

Estimation

Volume 

Estimation

Design 

Conc. 

Mass 

Estimation 

Volume 

Estimation 

Total Agent 

Per Platform 

% by vol. kg lb L in3 % by vol. kg lb L in3 kg lb 

100 % Laboratory R Success ate 

Current lon ha 9 1 1 

1301 system 

6 .5 21 0 630 6 1.1 2.5 .4 86 39 86 

Estimated HFC

125-optimally

- 24 24 1

distributed 

9.7 21 13 810 1.2 2.6 1.8 10 40 88 

Estimated HFC

125- non-

- 24 30 67 42 2580 24 3.6 8 5.8 350 125 277 

optimally 

distributed 

90 % Laboratory Success Rate

Current halon 5.4 8.5 19 9 560 5.4 1.0 2.2 1.3 77 35 77 

1301 system 

Estimated HFC

125-optimally

- 1

distributed 

21 8.7 19 2 730 21 1.0 2.3 1.6 99 36 79 

Estimated HFC

125- non-

- 21 27 60 38 2310 21 3.2 7.2 5.2 315 112 248 

optimally 

Distributed 

40 % Laboratory Success Rate

Current halon 5.2 8.2 18 9 540 5.2 1.0 2.2 1.2 74 34 75 

1301 system 

Estimated HFC

125-optimally

- 1

distributed 

21 8.4 18 1 700 21 1.0 2.2 1.6 96 34 76 

Estimated HFC

125- non-

- 21 26 58 37 2230 21 3.1 6.9 5.0 300 110 240 

optimally 

distributed 
1072 Life Cycle Costing of Fire Suppression Systems 

Table 10–31. Fighter Aircraft Altered System Description. 

Halon 1301 HFC-125 Optimally Distributed

HFC-125 Non-optimally 

Distributed 

kg lb kg lb kg lb 

100% Laboratory Success Rate

Bottle m ss a 4.2 9.3 5.6 12.2 15.5 34.3

Agent mass 2.5 5.5 3.2 7 8.4 18.4 

Plumbing mass 4.3 9.5 4.6 10.1 6.0 13.3 

Total mass 1 2 1.1 4.4 13.3 29.4 29.9 65.9 

90 % Laboratory Success e Rat

Bottle mass 3.8 8.3 5.0 10.9 13.9 30.7 

Agent mass 2.2 4.9 2.8 6.3 7.5 16.5 

Plumbing mass 3.9 8.5 4.1 9.1 5.4 11.9 

Total mass 9.9 21.8 11.9 26.3 26.7 59 

40 % Laboratory Success Rate 

Bottle mass 3.7 8.1 4.8 10.6 13.4 29.6 

Agent mass 2.2 4.8 2.7 6.1 7.2 15.9 

Plumbing mass 3.7 8.2 4.0 8.8 5.2 11.5 

Total mass 9.6 21.1 11.5 25.4 25.9 57.0 

Table 10–32. Rotary-wing Aircraft Altered System Description. 

Mass per 

Platform 

Current Halon 

1301 Design 

Redesigned 

Halon 1301-small

Redesigned 

Halon 1301-

large HFC-125-small HFC-125-large 

kg lb kg lb kg lb kg lb kg lb 

100% ry Suc Laborato cess Rate 

Agent 0.7 1.5 4 1.1 2. 3.3 7.2 3.6 7.9 7.6 16.8 

Bottle 2.6 5.7 4.0 8.9 11.8 26.0 15.9 35.1 33.4 73.7 

Other 4.2 9.3 4.2 9.3 4.2 9.3 4.2 9.3 4.2 9.3 

TOTAL 7.5 16.5 9.3 20.6 19.3 42.5 23.7 52.3 45.3 99.8 

90 oratory Suc Rate % Lab cess

Agent 0.6 1.3 1.0 2.1 2.9 6.4 3.2 7.1 6.8 15.0 

Bottle 2.3 5.1 3.6 7.9 10.6 23.3 14.2 31.4 29.9 65.9 

Other 3.8 8.3 3.8 8.3 3.8 8.3 3.8 8.3 3.8 8.3 

TOTAL 6.7 14.7 8.3 18.4 17.2 38.0 21.2 46.7 40.5 89.2 

40 oratory Suc Rate % Lab cess

Agent 0.6 1.3 0.9 2.1 2.8 6.2 3.1 6.8 6.6 14.5 

Bottle 2.2 4.9 3.5 7.7 10.2 22.5 13.7 30.3 28.9 63.7 

Other 3.7 8.0 3.7 8.0 3.7 8.0 3.7 8.0 3.7 8.0 

TOTAL 6.5 14.2 8.1 17.8 16.7 36.7 20.5 45.2 39.1 86.3 
Cost Analysis Using Altered Fire Suppression Performance 1073

10.7.4 Cost Analysis 

 system masses and corresponding effectiveness were correlated to the cargo, 

rcraft for the cost studies using the methodology in References 1, 2, and 3. The 

Table 10–34 show the resulting net costs for the legacy and future cargo aircraft, 

M) divided by the percent system effectiveness, determined from 

These altered suppression

fighter, and rotary-wing ai

resulting systems costs (which are a function of system size/mass), costs savings (which are a function of 

extinguishant effectiveness and the resultant aircraft saved), and net costs (cost of the system minus the 

cost savings) were calculated. The relationship between varying the system size and system effectiveness 

(and therefore costs and savings) was determined. 

Cargo Aircraft 

Table 10–33 and 

respectively. “Slope” is the net cost ($

Figure 10–11, Figure 10–12, and Figure 10–13. The negative cost numbers indicate a net cost savings 

due to the presence of fire protection on board. Larger negative numbers mean a greater cost savings 

incurred. 

Table 10–33. Legacy Cargo Aircraft Net Costs ($ M). 

HFC-125 – non-optimized (276.8 lb) HFC-125 – optimized (87.9 lb) 

Effectiveness 

(%) 

Halon 

1301 

Container 

Mod 

Container 

and Nozzle 

Mod 

Container and 

Distribution Sys 

Mod 

Container 

Mod 

Container 

and Nozzle 

Mod 

Container and 

Distribution Sys 

Mod 

24 -23.9 -11.9 -10.7 -9.1 -14.1 -12.9 3 -11.

32 -40.2 -28.2 0 -27. -25.4 4 -30. -29.2 -27.6

54 -85.0 -72.5 -71.3 -69.7 -75.7 -74.5 -72.9

60 -97.0 -84.4 -83.2 -81.4 -87.7 -86.5 -84.8

72 - - 121.7 109.2 -108.0 - - 106.3 112.3 -111.2 -109.5

80 - - 137.8 125.1 -123.9 - - 122.2 128.5 -127.3 -125.6

s lope -2.03 -2.02 -2.02 -2.01 -2.04 -2.04 -2.04

Table 10–34. Future Cargo Aircraft Net Costs ($ M). 

HFC-125 – non-optimized (276.8 lb) HFC-125 – optimized (87.9 lb) 

Mod 1 Mod 2 Mod 3 Mod 4 Mod 5 Mod 6 

Effectiveness 

(%) 

Halon 

1301 

Container 

Mod 

Container 

an e d Nozzl

Mod 

Container and 

Distribution Sys 

Mod 

Container 

Mod 

Container 

an e d Nozzl

Mod 

Container and 

Dist Sys ribution

Mod 

24 -18.0 -16.7 -14.1 -11.1 -19.1 -16.5 -13.5

32 -36.1 8 1 -34. -32. -29.2 2 -37. -34.6 -31.6

54 -85.8 -83.9 -81.3 -78.3 -87.3 -84.7 -81.7

60 -99.1 -97.1 -94.4 -91.3 -100.7 -98.1 -95.0

72 -126.4 -124.6 -121.9 - - 118.9 128.0 -125.4 -122.4

80 -144.3 -142.3 -139.6 -136.5 -145.9 -143.3 -140.2

s lope -2.25 -2.24 -2.24 -2.23 -2.27 -2.27 -2.26
1074 Life Cycle Costing of Fire Suppression Systems 

-$137.8

-$121.7

-$97.0

-$85.0

-$40.2

-$23.9

-$144.3

-$126.4

-$99.1

-$85.8

-$36.1

-$18.0

-$160

-$140

-$120

-$100

-$80

-$60

-$40

-$20

$0

0 10 20 30 40 50 60 70 80 90

System Effectiveness (%)

Net Cost ($M)

Halon 1301 -

Legacy

Halon 1301 -

Future

Figure 10–11. Legacy and Future Cargo Aircraft Net Costs vs. System Effectiveness for 

Halon 1301. 

-$140

-$120

-$100

-$80

-$60

-$40

-$20

$0

0 10 20 30 0 60 70 80 90

System Effectiveness (%)

Net Cost ($M)

40 5

125 Mod1

125 Mod2

125 Mod3

125 Mod4

125 Mod5

125 Mod6

Figure 10–12. Legacy Cargo Aircraft Net Costs vs. System Effectiveness for HFC-125. 
Cost Analysis Using Altered Fire Suppression Performance 1075

-$160

-$140

-$120

-$100

-$80

-$60

-$40

-$20

$0

0 10 20 30 40 50 60 70 80 90

System Effectiveness (%)

Net Cost ($M)

125 Mod1

125 Mod2

125 Mod3

125 Mod4

125 Mod5

125 Mod6

Figure 10–13. Future Cargo Aircraft Net Costs vs. System Effectiveness for HFC-125. 

F

a

igure 10–14 shows the legacy and future cargo aircraft cost savings vs. system effectiveness. For cargo 

ircraft, the net cost change per single percent change in extinguishing of the fire system was

ap

system performance pays off in assets (costs) saved. 

Figure 10–14. Legacy and Future Cargo Aircraft Cost Savings vs. System Effectiveness. 

proximately -$2.0 M. These estimates showed that additional investment in optimizing fire suppression

$0

$50

$100

$150

$200

$250

0 10 20 30 40 50 60 70 80 90

System Effectiveness (%)

Cost Savings ($M)

Legacy Future
1076 Life Cycle Costing of Fire Suppression Systems 

Fighter Aircraft 

Table 10–35 and Table 10–36 show the net costs for the legacy and future fighter aircraft, respectively. 

Figure 10–15 and Figure 10–16 show the legacy and future fighter aircraft net costs vs. system 

effectiveness for halon 1301 and HFC-125, respectively. Figure 10–17 shows the legacy and future 

fighter aircraft cost savings vs. system effectiveness. 

Table 10–35. Legacy Fighter Aircraft Net Costs ($M). 

Net Costs 

Effectiveness (%) Halon 1301 (5.5 lb) HFC-125 (7 lb) HFC-125 (18.4 lb) 

24 -51 -475 -45 

32 -71 -67 -65 

54 -128 -124 -122 

60 -143 -139 -137 

72 -1756 -170 -168 

80 -195 -191 -188 

slope -2.57 -2.57 -2.57 

Table 10–36. Future Fighter Aircraft Net Costs ($M). 

Net Costs 

Effectiveness (%) Halon 1301 (5.5 lb) HFC-125 (7 lb) HFC-125 (18.4 lb) 

24 -48 -47 -45 

32 -69 -68 -66 

54 -127 -125 -123 

60 -142 -141 -138 

72 -174 -172 -170 

80 -194 -193 -191 

slope -2.60 -2.60 -2.60 

For fighter aircraft, the net cost change per single percent change in ex ishing effectiveness of the fire 

system was approx tely -$2.5 M. These estim howed that additional investment in optimizing fire 

suppression system rformance pays off in assets (costs) saved. 

tingu

ima ates s

 pe
Cost Analysis Using Altered Fire Suppression Performance 1077

-$250.0

-$200.0

-$150.0

-$100.0

-$50.0

$00.0

0 10 20 30 40 50 60 70 80 90 100

NET COSTS ($M)

HFC-125-

18.4LB

HALON 1301

HFC-125-7LB

Figure 10–15. Legacy Fighter Aircraft Net costs vs. m Effectivene

Figure 10–16. Future Fighter Aircraft Net Costs vs. System Effectiveness.

Syste ss.

-$250.0

-$200.0

-$150.0

-$100.0

-$50.0

$00.0

SYSTEM EFFECTIVENESS (%)

0 10 20 30 40 50 60 70 80 90 100

NET COSTS ($M)

HFC-125-

18.4LB

HALON 1301

HFC-125-7LB
1078 Life Cycle Costing of Fire Suppression Systems 

m

.

ng

Figure 10–17. Legacy and Future Fighter Aircraft Cost Savings vs. System Effectiveness. 

Rotary-Wing Aircraft 

Table 10–37 and Table 10–38 show the resulting net costs for the legacy and future rotary-wing aircraft, 

respectively. Figure 10–18 and Figure 10–19 show the legacy rotary-wing aircraft net costs vs. syste

effectiveness for halon 1301 and HFC-125, respectively. Figure 10–20 and Figure 10–21 show the future 

rotary-wing aircraft net costs vs. system effectiveness for halon 1301 and HFC-125, respectively

Figure 10–22 shows the legacy and future rotary-wing aircraft cost savings vs. system effectiveness. 

For legacy rotary-wing aircraft, the net cost change per single percent change in extinguishi

effectiveness (i.e., 91 % successful vs. 90 % in the field) of the fire system was approximately $-6.2M.

For future rotary-wing aircraft, the net cost change per single percent change in extinguishing

effectiveness of the fire system is estimated to be -$6.3 M. These estimates showed that additional 

investment in optimizing fire suppression system performance pays off in assets (costs) saved.

Table 10–37. Legacy Rotary-wing Aircraft Net Costs ($M). 

Net Costs 

Halon 1301 HFC-125

Effectiveness (%) 1.1 kg (2.4 lb) 3.3 kg (7.2 lb) 3.6 kg (7.9 lb) 7.6 kg (16.8 lb)

24 -115 -113 -102 -97

32 -165 -162 -151 -147

54 -301 -299 -287 -283

60 -338 -335 -324 -319

72 -413 -410 -399 -395

80 -462 -459 -448 -443

slope -6.19 -6.19 -6.18 -6.17 

$62

$83

$139

$155

$186

$206

$63

$83

$157

$188

$209

$141

$0

$50

$100

$150

$200

$250

0 10 20 30 40 50 60 70 80 90 100

SYSTEM EFFECTIVENESS (%)

COST SAVINGS ($M)

Legacy

Future
Cost Analysis Using Altered Fire Suppression Performance 1079

Table 10–38. Future Rotary-wing Aircraft Net Costs ($M). 

Net Costs 

Halon 1301 HFC-125 

Effectiveness % 1.1 kg (2.4 lb) 3.3 kg (7.2 lb) 3.6 kg (7.9lb) 7.6 kg (16.8 lb) 

24 -111 -109 -107 -103 

32 -161 -159 -158 -153 

54 -300 -298 -296 -292 

60 -338 -335 -334 -328 

72 -414 -411 -410 -405 

80 -464 -461 -460 -455 

Slope -6.30 -6.30 -6.29 -6.28 

Figure 10–18. Legacy Rotary-w Aircraft Net s vs. System

1301. 

ing Cost Effectiveness for Halon 

-115

-165

-3

-338

-462

-113

-162

-299

-335

-4

-

-500

-450

-350

-300

-250

-200

-150

-100

-50

0

20 40 60 8

em Effecti %)

Net Cost ($M)

01

10 -413

459

-400

0 0 100

Syst veness (

Halon 1301-small

Halon 1301 - Large
1080 Life Cycle Costing of Fire Suppression Systems 

Figure 10–19. Legacy Rotary-Wing Aircraft Net Costs vs. System Effectiveness for 

HFC-125. 

Figure 10–20. Future Rotary-Wing A osts vs. System Effectiveness for 

Halon 1301. 

-102

-151

-288-324

-399

-448

-97

-147

-283

-319

-395

-443

-500

-450

-400

-350

-300

-250

-200

-150

-100

-50

0

0 20 40 60 80 100

System Effectiveness (%)

Net Cost ($M)

HFC-125-small

HFC-125 - Large

-111

-161

-300

-338

-414

-464

-109

-159

-298

-335

-411

-461

-500

-450

-300

-250

-200

-150

-100

-50

0

0 20 40 60 80 100

-400

-350

System Effectiveness (%)

Net Cost ($M)

Halon 1301-small

Halon 1301 - Large

ircraft Net C
Cost Analysis Using Altered Fire Suppression Performance 1081

-107

-158

-296-334

-410

-460

-103

-153

-292

-328

-405

-455

-500

-450

-400

-350

-300

-250

-200

-150

-100

-50

0

0 20 40 60 80 100

System Effectiveness (%)

Net Cost ($M)

HFC-125-small

HFC-125 - Large

Figure 10–21. Future Rotary-Wing Aircraft Net Costs vs. System Effectiveness for 

Figure 10–22. Legacy and Future Rotary-Wing Aircraft Cost Savings vs. System

Effectiveness. 

HFC-125. 

149

198

447

496

151

202

454

505

0

100

200

300

400

500

600

0 20 40 60 80 100

System Effectiveness (%)

Cost Savings ($M)

335

379 372

341 Legacy

Future
1082 Life Cycle Costing of Fire Suppression Systems 

10.8 CONCLUSIONS 

The NGP adapted a life cycle cost model to estimate the cost benefits of carrying fire protection systems 

for engine nacelles and dry bays on board military aircraft and developed a methodology for estimating 

the total cost of either retrofitting existing aircraft or configuring future aircraft with new systems based

on a non-ozone-depleting fire suppressant. The calculations were performed for cargo, fighter, and rotary 

wing aircraft. The model replacement agent was HFC-125, since some data were available for such

systems. These estimates showed that additional investment in optimizing fire suppression system 

performance pays off in assets saved for all the platforms examined. Specifically: 

• It is highly cost effective for aircraft to carry fire protection systems, despite their life cycle

costs (about 0.05 % to 0.2 % of the total cost of the aircraft) and the infrequency of their use. 

This is largely due to the high cost of losing an aircraft. Based on historical data, the return

on investment in halon 1301 fire protection systems was estimated to be about 5:1 for cargo 

aircraft, 15:1 for fighter aircraft, and 12:1 for rotary-wing aircraft. 

• It would also have been highly cost effective for HFC-125 systems, of fire suppression 

effectiveness comparable to these halon 1301 systems, to have been installed on military 

aircraft. The return on investment would have been at least two-thirds that of the halon 1301

systems. 

125

installed in a future aircraft is a me as the net cost of a conventional halon 

1301 system. 

• The cost of replacing the halon 1301 system with one of equal effectiveness, using HFC-125, 

in a legacy cargo aircraft is of the order of $77 k to $120 k per aircraft, which amounts to

approximately 0.042 % to 0.066 % of the total cost of the aircraft. The estimates for fighter 

12.0 k (0.016 % to 0.023 %) and $9.2 k to $13.4 k

), respectively.

n system, for deciding 

among s

capacity of

aircraft, new

• For comparable fire suppression effectiveness, the net cost of a system using HFCpproximately the sa

and rotary-wing aircraft are $8.1 k to $

(0.055 % to 0.080 %

• Additional investment in a system of fire suppression performance above the historical levels 

is cost effective. For each 1 % increase in effectiveness (above the historical 60 % to 80 %), 

there is a net life cycle cost savings of about $5 k per fighter or rotary-wing aircraft and about 

$17 k per cargo aircraft. These estimates would be substantially improved were more 

extensive experimental data regarding factors of safety developed. 

Already, the team overseeing at least one aircraft platform in development has used this methodology for

estimating the costs associated with the selection of each alternative fire protectio

tho e alternatives, for selecting the preferable system performance level, and for sizing the 

the system. This methodology can be expanded to meet the additional challenges of new 

fire suppression technologies, and additional applications, such as fuel tank inerting. 
References 1083

10.9 

1. Kolleck,

Aircraft, SU amilton Inc., Dayton, Ohio, (2002). 

2. Kol k

Fighter Airc

3. Kolleck

Rotary-wing

4. Bennett, J.M., “Cost Analysis of Fire Suppression Systems,” 2006, in Gann, R.G., Burgess, S.R., 

chnical 

Working Conferences (HOTWC), CD-ROM, NIST SP 984-4, National Institute of Standards and 

echnology, Gaithersburg, MD, (2006). 

eck, M.L., “Cost Analysis of Fire Suppression Systems,” 2001, in Gann, R.G., 

urgess, S.R., Whisner, K.C., and Reneke, P.A., eds., Papers from 1991-2006 Halon Options Technical 

OTWC), CD-ROM, NIST SP 984-4, National Institute of Standards and 

echnology, Gaithersburg, MD, (2006). 

. Bennett, M.V., “Relative Benefit Assessment of Fire Protection System Changes,” 2000, in Gann, 

P.A., eds., Papers from 1991-2006 Halon Options 

Technical Working Conferences (HOTWC), CD-ROM, NIST SP 984-4, National Institute of Standards 

, MD, (2006). 

8. Bennett, M.V., “Relative Benefit Assessment of Fire Protection System Changes,” 1999, in Gann, 

 Systems In 

-TR-1999-3068, Wright-Patterson Air Force Base, OH, (1997). 

olleck, M.L., and Wheeler, J.A., Halon Replacement Program 

se, California, (1994). 

REFERENCES 

 M.L., Bennett, M.V., and Mercer, K.L., Cost Analysis of Fire Suppression Systems for Cargo 

RVIAC TR-00-006, Booz Allen & H

lec , M.L., Bennett, M.V., and Mercer, K.L., Cost Analysis of Fire Suppression Systems for 

raft, SURVIAC TR-01-005, Booz Allen & Hamilton Inc., Dayton, Ohio, (2002). 

, M.L., Bennett, M.V., and Mercer, K.L., Cost Analysis of Fire Suppression Systems for 

 Aircraft, SURVIAC TR-01-007, Booz Allen & Hamilton Inc., Dayton, Ohio, (2002). 

Whisner, K.C., and Reneke, P.A., eds., Papers from 1991-2006 Halon Options Technical Working 

Conferences (HOTWC), CD-ROM, NIST SP 984-4, National Institute of Standards and Technology, 

Gaithersburg, MD, (2006). 

5. Bennett, J.M., and Kolleck, M.L., “Cost Analysis of Fire Suppression Systems,” 2002, in Gann, R.G., 

Burgess, S.R., Whisner, K.C., and Reneke, P.A., eds., Papers from 1991-2006 Halon Options Te

T

6. Bennett, J.M., and Koll

B

Working Conferences (H

T

7

R.G., Burgess, S.R., Whisner, K.C., and Reneke, 

and Technology, Gaithersburg

R.G., Burgess, S.R., Whisner, K.C., and Reneke, P.A., eds., Papers from 1991-2006 Halon Options 

Technical Working Conferences (HOTWC), CD-ROM, NIST SP 984-4, National Institute of Standards 

and Technology, Gaithersburg, MD, (2006). 

9. Finnerty, A.E., Peregino, P.J., Vande Kieft, L.J., Tucker, J.R., Weiland, D.E., Sheinson, R.S., Gann, 

R.G., Bennett, M.V., and Wheeler, J.A., Fires Experienced and Halon 1301 Fire Suppression

Current Weapon Systems, Report TR-00-007, Survivability/Vulnerability Information Analysis Center 

(SURVIAC), Wright-Patterson Air Force Base, OH, (2003). 

10. Bennett, M.V., Relative Benefit Assessment of Fire Protection System Changes - Phase I, Task 1.1 – 

Analysis of Current Configurations, SURVIAC file number 20945, (August, 1999). 

11. Bennett, J.M., and Bennett, M.V., Aircraft Engine/APU Fire Extinguishing System Design Model 

(HFC-125), AFRL-VA-WP

12. Kolleck, M.L., Birghtsen, G.M., Bennett, M.V., and Wheeler, J.A., Annual Fire Protection Cost 

Model [1966-1995;1996-2025], SURVIAC 97-033, Booz Allen & Hamilton Inc., Dayton, OH, (1997). 

13. Bennett, J.M., Caggianelli, G.M., K

for Aviation, Aircraft Engine Nacelle Application Phase II – Operational Comparison of Selected 

Extinguishants, WL-TR-97-3076, Wright-Patterson Air Force Base, OH, (1997). 

14. Vogel, T.J., C-17A Fire Protection System Evaluation, Final Report, AFFTC-TR-94-03, Air Force 

Flight Test Center, Edwards Air Force Ba
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reakdown, Organizational Maintenance, Fire Protection, 

ehurst.navy.mil. 

e of Standards and 

 1-70-1-71. 

0 

 10-13, 2001. 

n from Marco Tedeschi, Naval Air Warfare Center to J. Michael Bennett, 

 T., “The Impact of Halon Replacement On Aircraft Engine Bay 

., 

, 

15 Technical Manual, Fault Isolation, Organizational Maintenance, Fire Protection, USAF Series, C17A, Aircraft, TO 1C-17A-26-FI-00-1, McDonnell Douglas Corporation, Military Transport Aircraft, 1 

June 1995. 

16. Technical Manual, Illustrated Parts B

USAF Series, C-17A, Aircraft, TO 1C-17A-4-26, McDonnell Douglas Corporation, Military Transport 

Aircraft, 1 September 1999. 

17. F/A-18E/F Interactive Electronic Technical Manuals (IETMs), Public Affairs Office, Naval Air 

Engineering Station, Lakehurst, NJ, www.lak

18. Sheinson, R.S., and Ash, L., “NAVAIR’s Response to NGP Program Element 1a Questions,” Public 

Affairs Office, Naval Air Engineering Station, Lakehurst, NJ, www.lakehurst.navy.mil, 1 December, 

1998. 

19. Leach, W., “Retrofit Opportunities For HFC-125 In Aircraft Engine Nacelles,” 1999, in Gann, R.G., 

Burgess, S.R., Whisner, K.C., and Reneke, P.A., eds., Papers from 1991-2006 Halon Options Technical 

Working Conferences (HOTWC), CD-ROM, NIST SP 984-4, National Institut

Technology, Gaithersburg, MD, (2006). 

20. A1-F-18AC-NFM-000, Technical Manual, “Fire Detection/Extinguishing Systems”, pp.

21. Tedeschi, M., Fixed-Wing Aircraft Fire Protection, Halon 1301 Fire Suppression Systems Effectivity 

Analysis, NAWCADLKE-MISC-05-SR-0146, US Naval Air System Team, Naval Air Warfare Center, 3

September 1994. 

22. Bubash, J., U.S. Army Tank Automotive Command, Memorandum for Bennett, J.M.,, and Steele, J., 

Wright Laboratory, WPAFB, WL/FIV, October 10, 1995. 

23. Haaland, P., Fire Suppression Options for the RAH-66 Comanche Helicopter, Huntington Research 

and Engineering, presentation to the Comanche PM IPT, October

24. MIL-E-22285, Military Specification, Extinguishing System, Fire, Aircraft, High-Rate-Discharge 

Type, Installation and Test of, April 27, 1960. 

25. Tedeschi, M., and Leach, W., Rotary Aircraft Fire Protection, Halon 1301 Fire Suppression Systems 

Effectivity Analysis, NAWCADLKE-MISC-05-SR-0132, Naval Air Warfare Center, May 26, 1994. 

26. Electronic communicatio

“F/A-18E/F Engine/AMAD/APU Production and EMD Fire Extinguishing System Information, p.2, 

February 8, 2001. 

27. Leach, W., “Retrofit Opportunity For HFC-125 Aircraft Engine Systems,” in Proceedings of the 

International Aircraft Fire & Cabin Safety Conference, CD-ROM, DOT/FAA Report No. 

DOT/FAA/AR-99/68, National Technical Information Service, Springfield, VA, (1998). 

28. (PS)A1-F-18EA-240-300, Technical Manual, Organizational Maintenance, System Maintenance with 

Illustrated Parts Breakdown, Fire Extinguisher Tank (4SQT109), Fire Extinguishing System, Public 

Affairs Office, Naval Air Engineering Station, Lakehurst, NJ, www.lakehurst.navy.mil. 

29. Roberts, G., Doria, G., and Breeden,

Fire Protection System Design,” 1999, in Gann, R.G., Burgess, S.R., Whisner, K.C., and Reneke, P.A

eds., Papers from 1991-2006 Halon Options Technical Working Conferences (HOTWC), CD-ROM

NIST SP 984-4, National Institute of Standards and Technology, Gaithersburg, MD, (2006). 

30. Electronic communication from Captain Brian M. Godfrey, ASC/YCLII, to J. Michael Bennett, 

October 2, 2000. 
References 1085

ety Conference, CD-ROM, DOT/FAA Report 

aboratory, WL/FIVS. 

31. Kolleck, M.L., and Bennett, J.M., “Assessing The Cost Impact Of Fire To The U.S. Air Force,” in 

Proceedings of the International Aircraft Fire & Cabin Saf

No. DOT/FAA/AR-99/68, National Technical Information Service, Springfield, VA, (1998). 

32. Presentation of Factor of Safety Testing – Aircraft Engine Nacelle, Wright L
1086 Life Cycle Costing of Fire Suppression Systems