1
ID# 20258, DISTRIBUTION A. Approved for public release: distribution unlimited.
Cost of Propane Fast Cook-Off Testing
Jon J. Yagla and David Hubble
Naval Surface Warfare Center Dahlgren Division, Dahlgren, Virginia
Ephraim Washburn
Naval Air Warfare Center Weapons Division, China Lake, California
ABSTRACT
The cost of fast cook-off testing with propane has been obtained by careful tracking of expenses
over a significant number of tests. These costs are compared to liquid fuel fire testing. The
costs consist of nonrecurring costs, the costs directly attributable to a given test, and recurring
costs of damage repair, maintenance, and environmental compliance. The nonrecurring costs
are design, siting, materials, chamber fabrication, fuel distribution systems, fabrication, and
calibration. The costs attributable to a given test are mainly planning, construction of test
stands, instrumentation, field crews, fuel, data analysis, and reporting. Recurring costs of
damage repair, maintenance of the cook-off facility including fuel equipment, and environmental
compliance are itemized.
These costs have been compared to the corresponding costs of liquid fuel fire testing. The cost
of testing with propane is shown to be significantly less than with liquid fuels. The total cost of
the propane fast cook-off test was found to be $25,886, compared to $36,791 for the liquid fuel
test. The paper explains the development of the cost model and cost of each item, and how the
costs were obtained.
INTRODUCTION
A cost assessment was performed to compare the total operating costs associated with
performing fast cook-off testing. Both the propane fast cook-off (FCO) burner and the traditional
jet fuel pool fire were analyzed (Figure 1 and Figure 2).
Figure 1. US Navy FCO 3.7 m by 3.7 m propane burner located in Dahlgren, Virginia
The total operating cost of the propane burner is based on data from the burners that were
developed and operated at Dahlgren (2.4 m by 2.4 m and 3.7 m by 3.7 m square burners).
Annualized recurring cost data are more limited, as the Dahlgren burners are the only ones that
have been operational long enough to obtain data. The regulatory compliance costs are very
site-specific, as regulations vary from state to state in the U.S., and by country internationally.
The per-test costs vary according to the test site’s labor rates and safety rules, but the hours of
work required should be accurate anywhere.
