Technical Guide.pdf

FOR OFFICIAL USE ONLY

USCG WHEC MDE FM 8 1/8 OPFOR OFFICIAL USE ONLY

MS Description: Fairbanks Morse 38 ND 8-1/8 Main Diesel Engine Lubricating Oil System And Engine

DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

DISTRIBUTION STATEMENT D.

Distribution authorized to DOD and DOD contractors only (Administrative / Operational use). Other requests shall be referred to COMNAVSEASYSCOM or higher DOD authority.

Table of Contents

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1 SAFETY PRECAUTIONS

2 MATERIALS

3 TOOLS / EQUIPMENT

4 PERFORMANCE SPECIFICATIONS FOR TOOLS / EQUIPMENT

FLUSHING PROCEDURE

1 PRELIMINARY PROCEDURES TO COMPLETE BEFORE

FLUSHING IS TO BEGIN

2 FLUSHING SEQUENCE

3 EXTERNAL PIPING

4 INTERNAL PIPING

5 FINAL FLUSH (COMBINED EXTERNAL AND INTERNAL)

6 LUBE OIL SYSTEM RESTORATION

7 IN-PLACE LUBE OIL COOLER FLUSH

LIST OF FIGURES

Figure 1, Scavenging Air Blower Lube Oil Line Location Figure 2: Valve Manifold Assembly Identification Figure 3: SSDG Lube Oil Flush Set Up Diagram

LIST OF ENCLOSURES

Enclosure 1: Ships Piping and Components Removal and Reinstallation Enclosure 2: Calibration Record Enclosure 3: Blank Flange and Plug Record Enclosure 4: Final Checkpoint Record Sheet 1 of 2 Enclosure 4: Final Checkpoint Record Sheet 2 of 2 Enclosure 5: Flushing Log Enclosure 6, General Flushing Log Enclosure 7: Final Checkpoint Summary Record Sheet 1 of 2 Enclosure 7: Final Checkpoint Summary Record Sheet 2 of 2

LIST OF TABLES

Table 1: Valve Alignment

GENERAL INFORMATION AND SAFETY PRECAUTIONS

Safety Summary The general safety precautions that are not related to any specific procedures will be provided and will not appear elsewhere in this procedure. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance.

KEEP AWAY FROM LIVE CIRCUITS – Operating personnel must observe all safety regulations at all times. Do not replace components or make adjustments inside the equipment with the high voltage supply turned on. Under certain conditions, dangerous potentials may exist when the power control switch is in the OFF position due to charges retained by capacitors. To avoid casualties, always remove power and discharge if necessary and ground a circuit before touching it. Tag applicable circuit breaker/equipment to indicate maintenance is being preformed.

DO NOT SERVICE OR ADJUST ALONE – Under no circumstances should any person reach into an enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable of rendering aid.

RESUSCITATION – Personnel working with or near high voltages should be familiar with modern methods of resuscitation. Such information may be obtained from the Bureau of Medicine and Surgery.

WARNINGS AND CAUTIONS – Failure to strictly follow the procedural step for all WARNINGS could result in serious injury or death of personnel. Failure to strictly follow the procedural step for all CAUTIONS could result in damage to, or destruction of equipment. The warnings and cautions that appear in the manual are listed below, with the location in the text shown by the page numbers.

WARNING SIGNS AND CONDUCTING MAINTENANCE DURING A FLUSH – All maintenance and repair work should be completed on an engine or the engine lubricating oil system before that cycle of the flush is to begin. If work must continue during a flush, permission must be given in writing from the flush supervisor to the appropriate maintenance supervisor. Personnel must comply with all warning signs and taped-off areas.

MAINTENANCE STANDARD

EQUIPMENT / COMPONENT

Fairbanks Morse 38 ND 8-1/8 Main Diesel Engine Lubricating Oil System And Engine

SYSTEM

WHEC MDE Propulsion Engines

RELATED MAINTENANCE

MS DESCRIPTION: COMPREHENSIVE MONITORED HOT LUBE OIL FLUSHING

PROCEDURE FOR WHEC MDE PROPULSION ENGINES, FAIRBANKS MORSE

DIESEL MODEL 8-1/8 12 CYLINDER.

NOTE 1: In many instances lube oil contamination is a primary cause or contributing factor in diesel engine failure. Overhaul and repair standards often do not include effective lube oil system cleaning procedures. Therefore, the potential for further engine failure remains due to particle contamination. During a casualty condition, such as bearing failure, metallic particles of the failed components are often dispersed throughout the lube oil system. This includes drilled oil passages, attached piping, and engine components. After complete overhaul, major repair of an engine, or engine casualty, the lube oil system internally and externally shall be thoroughly cleaned using the Hot Lube Oil flushing techniques IAW this document and the requirements of NSTM 233.

NOTE 2: This maintenance standard meets or exceeds the requirements of NSTM 233 (Diesel Engines)

1 SAFETY PRECAUTIONS

1-1 Forces afloat comply with NAVOSH Program Manual for Forces Afloat, OPNAVINST 5100.19 series.

1-2 Ensure all tag-out procedures are in accordance with current shipboard instructions.

1-3 Observe safety precautions in the areas of each rotating machinery and electrical equipment.

1-4 All electrical equipment, i.e. cable connection, control box and switch box shall be protected using weatherproof material.

2 MATERIALS

2-1 Commercial Grade (non-synthetic) SAE 10W High Detergent oil, with an API rating of SG or better.

2-2 Lubricating oil, engine, MIL-PRF-2104 Grade MS-HDO 10W: HMUG Group 11, Disposal Method 1.

NOTE 3: 2104 Grade MS-HDO 15-40W shall not be used.

3 TOOLS / EQUIPMENT

3-1 Comprehensive Flushing Module shall consist of the following components:

3-1.1 Positive displacement pump.

3-1.2 Electronic Variable Speed Control System with remote start-stop.

3-1.3 Digital Flow Meter.

3-1.4 Air Operated Diaphragm Pump minimum 1-inch.

3-1.5 Portable Pore Blockage Particle Counter.

3-1.6 Quadraplex Bag Filter System.

3-1.7 Cartridge Filtration System.

3-1.8 Magnetic Filter System.

3-1.9 Simplex Process Heating System Unit. (optional) 3-1.10 Triplex Process Heating System Unit.

3-1.11 Oil Spill Containment

3-2 Pneumatic Pipe Vibrators – six (6) each, sized to fit lube oil piping.

3-3 Hose Assemblies with locking style cam-locks.

3-4 Valve Manifold Assembly.

3-5 Flow Straightener.

3-6 Assorted hand tools.

3-7 Various Spool Pieces (“SP”).

3-8 Various sizes of Blank Flanges (“BF”).

3-9 Various sizes of Cam-lock Flanges (“CF”).

3-10 Various Jumper Lines (“JL”).

3-11 Various Temporary Valves (“TV”).

3-12 Pressure Gauges.

4 PERFORMANCE SPECIFICATIONS FOR TOOLS/EQUIPMENT: The Flushing Module shall have the following Performance Specifications:

4-1 Positive Displacement Pump shall:

4-1.1 Be capable of 500500 gallons per minute @ 120 PSI.

4-1.2 Have a minimum 3-inch threaded suction and discharge ports. Be driven by a (minimum) 20 HP 440V 3-phase motor in order to achieve the 500 GPM flow rate specification at the Quadraplex Bag Filter inlet.

4-1.3 Be controlled by an Electronic Variable Speed Control System with wired, remote start-stop capability to provide emergency start-stop capability simultaneously at the Flushing Module and in the engine room.

4-1.4 Be capable of a motor speed of 5-2000 RPM with digital read-out for RPM.

4-1.5 Have a minimum 3-inch “Y” strainer installed in the suction line to protect the pump.

5 Digital Flow Meter shall:

5-1 Be installed with a flow straightener consisting of a minimum 6 foot long, 3 inch diameter schedule 40 pipe connected to the Flushing Module with locking type cam-lock fittings.

5-2 Have current calibration and calibration log 5-3 Be sized to measure 450-550 GPM.

6 Air Operated Diaphragm Pump, minimum 1-inch connections, for the transfer, filling and draining of flushing fluid.

7 Portable Pore Blockage Particle Counter shall have current calibration and be capable of measuring fluid contamination with output in NAS code.

8 Quadraplex Bag Filter System shall consist of the following:

8-1 The Quadraplex Bag Filter Assembly is to be plumbed in parallel with individual isolation valves that allow filter/bag change-out while maintaining fluid flow, to allow for efficient filter change-outs.

8-2 Rated at a flow rate of 500 GPM or greater.

8-3 Fitted to accommodate 4 each, size 2, 25-micron commercial polyester-felt, full flow filter bags.

8-4 The Quadraplex Bag Filter assembly shall be equipped with pressure gages at inlet and outlet.

NOTE 4: Nylon bag filters are not an acceptable substitute and shall not be used.

9 Cartridge Filtration System shall include:

9-1 A minimum of 5 each, 36-inch tall filters in a parallel flow design with individual isolation valves to allow for efficient filter change-outs.

9-2 Rated at a flow rate of 500 GPM or greater.

9-3 Equipped with pressure gages at inlet and outlet.

9-4 A minimum filtration efficiency of the Cartridge filters shall be 3 microns with a beta ratio of 200.

9-5 Sufficient capacity to limit the clean pressure to 5 PSID while operating.

9-6 The Cartridge Filtration System shall be equipped with a check valve on the outlet to prevent filter damage/collapse during an emergency stop.

10 Magnetic Filter System shall consist of:

10-1 Three each (arranged in parallel) full flow magnetic filters.

10-2 A parallel flow design that provides a pressure drop of less than 1 PSID.

10-3 A minimum 2-inch inlet and outlet ports.

11 Process Heating System shall consist of a Simplex (optional) and a Triplex unit. Each unit shall have the following specifications:

11-1 Rated at a minimum of 35 KW with a watt density no greater than 28 watts per square inch.

11-2 3-inch inlet and outlet ports.

11-3 Redundant controls to prevent overheating and burning of the flushing medium.

11-4 Flow switches to allow the Process Heating Systems to only turn on when fluid flow is present at the outlet of the heaters.

11-5 Thermocouples attached to the heating elements to monitor the temperature of the elements.

11-6 Thermocouples to be attached to safety shutoff circuit to prevent overheating.

11-7 The Process Heating Systems shall be controlled using Proportional-

Integral-Derivative (PID) type, digital temperature controllers to accurately maintain 170-196 degrees F outlet temperatures.

12 Oil Spill Containment shall have the following:

12-1 Sufficient capacity to contain all modules of the Flushing Module including:

12-1.1 Quadraplex Filter System

12-1.2 Magnetic Filter System 12-1.3 Cartridge Filter System 12-1.4 Process Heating Systems 12-1.5 Miscellaneous pumps 12-1.6 The main pump when located in the engine room and the suction/return hoses are exempt from this line item.

12-2 Sufficient capacity to hold at least 75% of the flushing medium.

13 Hose Assemblies shall have the following:

13-1 Hoses shall at a minimum conform to MIL-H-24135.

13-2 4-inch suction/discharge hose to run as suction and discharge between the engine being flushed and the Flushing Module.

13-3 4-inch hose sections to connect Flushing Module components.

13-4 2-inch hoses to connect Flushing Module components.

13-5 All hoses shall be pressure tested and certified to 1.5 times working pressure annually and tagged with date of test and tested pressure.

13-6 All hose fittings shall be aluminum cam-lock style with self-locking mechanisms, equipped with barbed type fittings, and at a minimum shall conform to A-A-59326B (Army Specification) formerly MIL-C-27487.

13-7 All cam-lock fittings shall be attached to the hose with steel or stainless steel crimped ferrules.

13-8 All hose assemblies shall include caps and plugs to prevent any residual spillage of oil.

14 Valve Manifold Assembly shall have the following:

14-1 Each Valve Manifold Assembly shall consist of a minimum 3-inch pipe and minimum 4-inch ball or gate valves with locking cam-lock style fittings attached.

14-2 Each valve of the Manifold Assembly shall be numbered and each valve shall be identified in accordance with Figure 2.

15 Various sizes of Blank Flanges (“BF”) shall be constructed of a minimum of 1/4– inch thick steel blank flanges with gaskets to cover flanges in 3–inch, 4–inch, 5–inch, and 6–inch diameter pipe. All temporary blank flanges shall be painted with high visibility paint with the exception of the sealing side.

16 Various sizes of Cam-Lock Flanges (“CF”) shall be rated for a minimum 150 PSI and have cam-lock style fittings attached, with gaskets, to cover flanges in 3–inch, 4–inch, 5–inch, and 6–inch diameter pipe. All cam-lock flanges shall be painted with high visibility paint with the exception of the sealing side.

17 Various sizes of Pancake Blank Flanges (“PB”) shall be constructed of a minimum of 1/4–inch thick steel with gaskets to cover flanges in 3–inch, 4–inch, 5– inch, and 6–inch diameter pipe. All temporary pancake blank flanges shall have a minimum handle length of four (4) inches and a minimum handle width one-half (1/2) the distance between flange bolt holes. All temporary pancake blank flanges shall have the handle painted with high visibility paint with the exception of the sealing sides.

18 Pressure Gages. All Pressure Gages shall be sized to accurately read in 2 PSI increments with a range from 0 to 60 PSI, 0 to 100 PSI, 0 to 160 PSI, and 0 to 200 PSI as required.

19 MISCELLANEOUS

19-1 Caution or Danger Barrier tape.

19-2 Soft mallets.

19-3 Safety signs; 11 x 8-1/2-inch, stating at a minimum “Keep Clear. Hot Lube

Oil Flush in Progress.”

19-4 ID tags for blank flanges and any other removed Ships System components.

19-5 Oil Absorbent pads.

19-6 Lint free rags 19-7 Pails; 3-gallon minimum size.

19-8 Temporary Valve (TV) jumpers for the ship’s strainer and filter relief valves.

HAZARDOUS MATERIAL CONTROL STATEMENT

The Hazardous Material Users Guide (HMUG), OPNAV P-45-110-(), provides additional control measures, precautions, personal protective equipment (PPE), and spill controls for the hazardous material(s) identified in the Tools, Parts, Materials, Test, Equipment block. Maintenance personnel shall determine if additional PPE is necessary to accomplish the procedure and take appropriate action to obtain and wear such PPE to ensure the safety of maintenance personnel.

WARNING: Ensure all tag-out procedures are in accordance with current shipboard instructions.

NOTE 5: This Maintenance Standard shall be performed in full and in accordance with the specified sequence and procedures. Partial steps or step modification shall not be performed unless authorized by NSWCCD-SSES, Philadelphia Code 931.

All Enclosures shall be filled out and signed or initialed where required.

Enclosure 6 (General Flushing Log) shall be used for recording all events, inspections, shifting of Quadraplex Filters, valve line-ups, filter changes, or any conditions affecting the Lube Oil Flushing procedure.

NOTE 6: Checkpoints are designated as follows:

(V): Contractor Representative.

(G): Government Representative (Diesel Engine Inspector Preferred).

NOTE 7: Flushes shall always include External, Internal and Combined phases except when authorized by USCG on-site Representative.

NOTE 8: Any existing ship installed component or piping section removed shall be logged, removed and reinstalled, on Enclosure (1) of this procedure. A condition and / or cleanliness report shall be required for any item serviced by an outside activity, otherwise, record findings on Enclosure 6.

NOTE 9: Measuring equipment shall be calibrated in accordance with ISO 10012-1. Enter all calibration data on Enclosure (2) of this procedure.

NOTE 10: Discrepancies and/or deficiencies noted during the accomplishment of required steps shall stop further procedure(s) until the appropriate corrective action has been taken or continuation is approved by USCG on-site Representative.

NOTE 11: All blank or cam-lock flanges, pipe plugs, spool pieces, or any other temporary component shall be serialized, tagged and painted with highly visible paint and logged on Enclosure (3) of this procedure.

Provide copy of Enclosure (3) to ships force, Certified Diesel Engine Inspector (DEI) and job supervisor.

NOTE 12: All checkpoints shall be verified, logged on Enclosure (4) of this procedure and signed by performing activity representative and DEI before the next step can be performed. Verify with ship’s force representative only if required.

NOTE 13: The General Flushing Log, Enclosure (6) of this procedure, shall be maintained to document flushing of each component/segment of system.

NOTE 14: All spools shall be the same size or larger inside pipe diameter than the component it replaces.

NOTE 15: Spools Pieces for the ship’s strainers, filters and relief valves shall have built in valves and shall be installed in place of the relief valves for ship filters and strainers to achieve full flow during flush.

NOTE 16: All piping, pumps and components removed, disconnected or jumpered around, will have the lube oil flow areas hand cleaned completely before being blanked.

NOTE 17: Whenever a tank, inspection cover of engine, pipe or similar part of the lube oil system is opened for any length of time and not attended, the opening(s) shall be hard blanked or covered with ‘Herculite’ or equivalent, to prevent any entry of foreign material.

NOTE 18: Absorbent pads and lint free rags shall be readily available at the flushing job site and within the auxiliary spaces for the duration of the flushing evolution.

NOTE 19: Ships strainer baskets shall be removed during flush and the shifting levers shall be placed in the “BOTH” position, if applicable, and logged on the Flushing Log, Enclosure (1). Ships strainers that are not capable of being placed in the “BOTH” position shall be shifted midway during the accomplishment of the flush to insure a through flushing of the strainer assembly and piping. A sign shall be posted to indicate the on-line basket.

NOTE 20: Any removed pressure relief/by-pass or regulating valves not having a test data tag, expiring, or expired test date shall be tested in accordance with current maintenance documentation. The contractor shall notify the DEI, ships supervisor and ships force of any deficiencies regarding pressure relief/by-pass valves test dates.

Ensure system fluid and normal operating temperature is indicted on work request to insure proper testing.

NOTE 21: Ships Force or ship supervisor submit work request to have generator bearing lube oil supply pressure regulating valve disassembled, cleaned, tested, and reassembled in accordance with diesel engine technical manual.

NOTE 22: All system connection hoses (to and from the flushing module) shall have valves at low points to drain fluid.

NOTE 23: All engine and associated piping assembly hookups, from flushing module connection hoses to ship’s piping, shall have cam-lock style fittings with self-locking mechanisms attached to the flanges.

NOTE 24: All flushing module system components shall be fully isolatable.

FLUSHING PROCEDURE

1 PRELIMINARY PROCEDURES TO COMPLETE BEFORE FLUSHING IS TO

BEGIN:

1-1 Verify all cylinder test cocks are open.

1-2 Verify lube oil has been drained from engine sump, full flow filter, full flow strainer, , and all external lube oil piping.

1-3 Verify removal of lube oil filter elements before flushing.

1-4 Verify removal and hand cleaning of permanently installed duplex strainer baskets.

1-5 The following components shall be removed from the system: Record removal of existing ships components on Enclosure (1). Record temporary installed components on Enclosure (3). Ensure removed components are match-marked to insure correct orientation during reassembly.

1-5.1 Remove lube oil cooler temperature relief/by-pass valve and install temporary jumper from lube oil piping inlet to bypass piping, and blank Cooler outlet flange, see Figure 3 for TV-2 location.

1-5.2 Remove the lube oil cooler pressure relief/bypass valve and discharge piping to temperature regulating control valve. Install blank flange on pressure relief/bypass piping inlet to valve.

1-5.3 Install jumper with valve to by-pass the lube oil cooler, see Figure 3, TV-3 location.

NOTE 25: If lube oil cooler was not removed for independent cleaning, clean lube oil cooler in accordance with paragraph 7.

1-5.4 Remove lube oil filter elements before flushing.

1-5.5 Isolate the lube oil filter continuous vent valve ; see Figure 3 for BF-3 location.

NOTE 26: After removal of pump the DEI shall inspect pump for foreign material, debris and excessive wear. If pump requires disassembly for cleaning or additional maintenance, Ship’s Force shall submit a work request for additional work as required. Record condition and disposition on General Comment Sheet, Enclosure 6.

1-5.6 Remove attached lube oil pump pressure relief/by-pass valve and install TV-5, see Figure 3 for location, if required.

1-5.7 Remove and hand clean permanently installed duplex strainer baskets.

1-5.8 Remove the lube oil pump discharge piping connection from the attached lube oil pump to the bellows connection; and remove the attached lube oil pump, if required. Hand clean inlet and outflow areas and install blank flanges on the attached oil pump and mounting plate as required. Install camlock flange to remaining connection (inlet to external piping).

1-5.9 Remove the inlet piping from the sump draw to the attached lube oil pump.

Hand clean inlet and outflow areas and install blank flanges on removed piping. Install blank flange on inlet to the attached pump. Install camlock flanges on both the pre-lube draw and attached pump draw fittings of the tee fitting attached to the sump strainer.Remove inlet piping connection to pre-lube system; install camlock flanges.

NOTE 27: If removed, the DEI shall inspect pump for foreign material, debris and excessive wear. If pump requires disassembly for cleaning or additional maintenance, Ship’s Force shall submit a work request for additional work as required. Record condition and disposition on General Comment Sheet, Enclosure 6.

NOTE 28: After removal of pump the DEI shall inspect pump for foreign material, debris and excessive wear. If pump requires disassembly for cleaning or additional maintenance, Ship’s Force shall submit a work request for additional work as required. Record condition and disposition on General Comment Sheet, Enclosure 6.

1-5.10 Remove the pre-lube pump inlet and discharge piping connections to the pre-lube pump and remove pre-lube pump. Hand clean inlet and outflow areas and install blank flanges on the pre-lube pump, see location SP-2 on Figure 3.

NOTE 29: After removal of pump the DEI shall inspect pump for foreign material, debris and excessive wear. If pump requires disassembly for cleaning or additional maintenance, Ship’s Force shall submit a work request for additional work as required. Record condition and disposition on General Comment Sheet, Enclosure 6.

1-5.11 The pre-Lube / external piping system outlet flange shall be connected to the Valve Manifold Assembly. See Figures 2 and 3.

1-5.12 Disconnect the lube oil supply piping to the engine lube oil header. Hand clean oil flow areas and install cam-lock flanges, see location CF-3 and CF-4, Figure 3.

1-5.13 Remove turbocharger oil supply line at the external piping header connection. Install cap on header connection, and plug the turbocharger oil supply line connection.

1-5.14 Remove turbocharger exhaust piping between exhaust headers and turbocharger inlet. Install temporary FME on exposed exhaust header connections. Install FME on removed exhaust piping.

1-5.15 Remove all lube oil supply lines to internal components including: roller cam bearing supply lines, blower/generator pedestal bearing supply line, upper and lower vertical drive spray nozzle supply lines, governor/scavenging pump lube oil supply line, attached pump bearing lube oil supply line, outboard bearing lube oil supply line. Record removal of oil supply lines on Enclosure (1).

1-5.16 Install blanks on the Upper Header Main Bearing jumper line feed ports.

Record installation of blanks on Enclosure

1-6 Hose assemblies shall be connected to the Valve Manifold Assembly in accordance with Figures 2 and 3:

1-6.1 CF 1 to Valve 2; Pre-lube System Inlet piping.

1-6.2 CF 2 to Valve 3; Attached Pump Outlet or Attached Piping System Inlet.

1-6.3 CF 3 to Valve 5; Lube Oil Header.

1-6.4 CF 4 to Valve 7; Attached System Piping Outlet.

1-6.5 CF 6 to Valve 1; Sump via the Comprehensive Flushing Module.

1-7 Install 6 pneumatic pipe vibrators evenly spaced on the External Lube Oil System ensuring a minimum one each is installed on the Pre-Lube piping and Keep Warm piping.

CAUTION: Provide adequate ventilation in work spaces whenever cleaning solvent is being used.

NOTE 30: Prior to starting any flushing operations, verify engine sump, generator pedestal bearing lube oil drain tank, filter housing, and strainer housing have been drained. Verify cleanliness of the engine interior through all accessible areas by removing the coffin cover, crankcase inspection covers, etc. Verify the following surfaces have been cleaned:

Upper and lower crankcase.

Upper and lower crankshaft.

Upper and lower connecting rods.

Remove oil from upper pistons.

Upper and lower bearing caps.

Vertical drive and all gears, etc.

1-8 All internal engine surfaces and internal components shall be oil-wetted prior to heating flushing oil and commencing internal flushing operations.

CAUTION: Prior to use, insure all portable flushing equipment is clean and free of foreign material and that all instrumentation is properly calibrated.

CHECKPOINT: 1 (V) and (G). Verify Materials, Tools/Equipment, Miscellaneous items are ready for use and Preliminary Procedure Section 1 has been accomplished. Verify log sheets are available, properly filled-in and signed where appropriate up to this step.

CHECKPOINT: 2 (V) and (G). DEI or Ship Representative and the contractor shall inspect all accessible engine areas to verify all foreign material and debris has been removed.

2 FLUSHING SEQUENCE: Lube Oil Flushing shall be accomplished in the following sequence:

NOTE 31: Lubricating Oil Cooler flush can be accomplished anytime during the Flushing evolution.

NOTE 32: External Piping flush shall include within the twelve-hour flush the external piping, pre-lube piping, and lower header piping.

NOTE 33: All flushing connections shall be completed prior to commencing the flushing evolution.

2-1 External piping 2-1.1 External piping system (to include pre-lube piping and lower header)

2-2 Internal Flush; Upper header 2-3 Combined Flush

2-3.1 Internal piping and External piping, but not inclusive of the pre-lube circuit.

3 EXTERNAL PIPING

3-1 FLUSH EXTERNAL PIPING SYSTEM LOOP

3-1.1 Ensure that the engine sump and lubricating oil system is filled to the nominal operating level and maintained during the flushing evolution. The flushing medium shall be filtered through 25 micron commercial polyester felt full flow filter bag.

3-1.2 Install Portable Pore Blockage Particle Counter.

3-1.3 Align valves in accordance with Table 1, External Piping Loop.

CHECKPOINT: 3 (V).Verify that valves are aligned in accordance with Table 1 for External Piping System Loop.

3-1.4 Ensure new polyester bags are installed in the Quadraplex Filter Assembly.

3-1.5 Start the Flushing Module pump and begin oil circulation process at 20 gpm to confirm that connections are secure.

3-1.6 Energize the Triplex Portable Process Heating System unit.

3-1.7 Increase the Flushing Module pump flow to 125 gpm and reconfirm that connections are secure.

3-1.8 Increase Flushing Module pump flow rate to 500 gpm. The flush does not officially begin until a constant oil temperature is maintained at 172 - 180 degrees F at the inlet to the Quadraplex Filter Assembly.

3-1.9 Flush for 12 hours ensuring that the differential pressure on the Cartridge Filtration System does not exceed 20 PSID above initial clean pressure drop and the differential pressure on the Quadraplex Filtration System does not exceed 5 PSID above the initial clean pressure drop.

3-1.10 The External Piping Flush shall include the Lower Header Piping for the entire twelve (12) hour duration of the flush, and include the final two (2) hours of flushing as per paragraph 3-1.13 of this procedure.

3-1.11 Open Pre-lube flushing loop for four hours during the External Piping flush. Do not begin until the External Piping flush has elapsed for at least six hours. Secure Pre-lube Flushing loop after External Piping has elapsed for twelve hours. Do not open Pre-lube Flushing Loop during final two hour bag check of External Piping flush (12-14 hours).

NOTE 34: When the differential pressure on the Cartridge Filtration System exceeds 20 PSID above initial clean filter pressure drop or the differential pressure on the Quadraplex Filtration System exceeds 5 PSID above the initial clean bags pressure drop, replace Cartridge Filtration System elements or Quadraplex Filtration System elements, as required.

3-1.12 Replace the off-line Quadraplex Filtration System filter bags.

3-1.13 Flush for an additional 2 hours at 500 gpm and flushing oil temperature maintained at 172 - 180 degrees F at the inlet of Quadraplex Filter Assembly. During this two-hour flush, the fluid contamination level shall be tested every 15 minutes using the Portable Pore Blockage Particle Counter.

NOTE 35: If fluid contamination levels exceed NAS 9 at any time during the final two-hour flush, as indicated by the Portable Pore Blockage Particle Counter, the flush shall continue for another 2 hours from that point in time. This process will be repeated until the contamination levels, as indicated by the Portable Pore Blockage Particle Counter, are better than or equal to an NAS 9 for a 2-hour period.

NOTE 36: Solid-based contaminants are those that cannot be crushed between the thumbnail and the finger.

CHECKPOINT: 4 (V) and (G). Conduct a visual inspection of the Quadraplex filter bags. The sum total of solid based contaminants at the end of that 2-hour period shall not exceed a volume larger than one 25-cent piece. If the sum total exceeds the volume of a 25-cent piece, replace all Quadraplex filter bags and restart flush for an additional 2 hours beginning at paragraph 3-1.12. Record results on Enclosure (4).

3-1.14 Secure the Triplex Portable Process Heating System unit.

3-1.15 Secure the Flushing Module pump.

3-1.16 Secure all valves that could allow fluid to gravity flow back to the engine sump as noted in Table 1.

4 INTERNAL FLUSH; UPPER HEADER

4-1.1 Prior to the Internal Flush; Upper Header, reinstall end plugs (if removed) on the Lower Main Lube Oil header. Record installation of end plugs on Enclosure (1), if required.

4-2.1.1 If end plugs were not removed, visually inspect lower main lube oil header between end plate and jumper line feed port for debris, clean as required to remove debris.

4-1.2 Ensure FME plugs are removed and reinstall the Lower Header Main Bearing Jumper Lines. Record installation of lower header main bearing jumper lines on Enclosure (1).

NOTE 37: Do not “Lock wire” Lower Header Lube Oil Main Bearing jumper lines at this time. Jumper lines shall be lock wired at the completion and the acceptance of the Flush.

4-2.3 Remove blanks on the Upper Header Main Bearing jumper line feed ports.

Record removal of blanks on Enclosure (3).

4-2.4 Remove end plugs on Upper Main Lube Oil Header. Record removal of end plug on Enclosure (1).

4-2.4.1 If end plugs can not be removed, record on Enclosure (6) and proceed to paragraph 4-2.5.

4-2.5 Align valves in accordance with Table 1, Internal Flush.

CHECKPOINT: 5 (V). Verify that valves are aligned in accordance with Table 1 for Internal Flush.

4-2.6 Ensure sump level is at nominal operating level.

4-2.7 Ensure new polyester bags are installed in Quadraplex Filter Assembly.

4-2.8 Start the Flushing Module pump and begin oil circulation process at 20 gpm to confirm that connections are secure.

4-2.9 Energize the Triplex Portable Process Heating System unit.

4-2.10 Increase Flushing Module pump flow to 125 gpm and reconfirm that connections are secure.

4-2.11 Increase Flushing Module pump flow rate to 500 gpm. The flush does not officially begin until a constant oil temperature is maintained at 172 - 180 degrees F at the inlet to the Quadraplex Filter Assembly.

4-2.12 Flush for two hours ensuring that the differential pressure on the Cartridge Filtration System does not exceed 20 PSID above initial clean pressure drop and the differential pressure on the Quadraplex Filtration System does not exceed 5 PSID above the initial clean pressure drop.

NOTE 38: When the differential pressure on the Cartridge Filtration System exceeds 20 PSID above initial clean filter pressure drop or the differential pressure on the Quadraplex Filtration System exceeds 5 PSID above the initial clean bags pressure drop, replace Cartridge Filtration System elements or Quadraplex Filtration System elements, as required.

NOTE 39: Solid-based contaminants are those that cannot be crushed between the thumbnail and the finger.

CHECKPOINT: 6 (V) and (G). Conduct a visual inspection of the Quadraplex filter bags. The sum total of solid based contaminants at the end of that 2-hour period shall not exceed a volume larger than one 25-cent piece. If the sum total exceeds the volume of a 25-cent piece, replace all Quadraplex filter bags and restart flush for another 2 hours beginning at paragraph 4-2.12. Record results on Enclosure (4).

4-2.13 Secure the Triplex Portable Process Heating System unit.

4-2.14 Secure the Flushing Module pump.

4-2.15 Secure all valves that could allow fluid to gravity flow back to the engine sump as noted in Table 1.

4-2.16 At the end of the Internal Flush; Upper Header, reinstall upper crankshaft main bearing lube oil jumper lines, end plugs (if removed), and oil supply lines. Record reinstallation of existing ship items on Enclosure (1).

Record removal of temporary items on Enclosure (3).

4-2.16.1 If end plugs were not removed, visually inspect upper main lube oil header between end plate and jumper line feed port for debris, clean as required to remove debris.

NOTE 40: Do not “Lock wire” Lube Oil Main Bearing jumper lines at this time.

Jumper lines shall be lock wired at the completion and the acceptance of the Flush.

NOTE 41: Upper Crankcase Cover shall be in place for final flush, but it only requires minimal fasteners to prevent oil leakage during flush.

5 FINAL FLUSH (COMBINED EXTERNAL AND INTERNAL)

NOTE 42: Final flushing does not include Pre-Lube Loop.

NOTE 43: Turbocharger Exhaust Manifolds should be monitored during the

Final Combined Flush for fluid. Pump out or otherwise remove fluid from exhaust manifolds as fluid pools inside the Manifolds.

5-1 Final Flush (External and Internal systems) 5-1.1 Install new polyester bags in Quadraplex Filter Assembly.

5-1.2 Align valves in accordance with Table 1, Combined Final Flush.

CHECKPOINT: 7 (V). Verify that valves are aligned in accordance with Table 1 for Combined Final Flushing.

5-1.3 Start the Flushing Module pump and begin oil circulation at 20 gpm to confirm that connections are secure.

5-1.4 Energize the Triplex Portable Process Heating System unit.

5-1.5 Increase Flushing Module pump flow to 125 gpm and reconfirm that connections are secure.

5-1.6.1 Verify oil flow to all main, thrust, connecting rod, and camshaft bearings;

vertical drive, and oil-wetted components.

CHECKPOINT: 8 (V) and (G). Verify oil flow to all main, thrust, connecting rod, camshaft, and free end support bearings; vertical drive, gear train and oil-wetted components.

5-1.6 Increase Flushing Module pump flow rate to 500 gpm. The flush does not officially begin until a constant oil temperature is maintained at 172 - 180 degrees F at the inlet to the Quadraplex Filter Assembly.

5-1.7 Flush for 12 hours ensuring that the differential pressure on the Cartridge Filtration System does not exceed 20 PSID above initial clean pressure drop and the differential pressure on the Quadraplex Filtration System does not exceed 5 PSID above the initial clean pressure drop.

5-1.8.1 Isolate and break instrumentation lines (gages, pressure switches, pressure transducers, etc). Flush instrumentation lines into an appropriate container; minimum of 1-gallon flushed through instrumentation line. Restore instrumentation lines, open isolation valves as required.

5-1.8.2 Flush drain and vent piping into an appropriate container; minimum of 1-gallon flushed through drain / vent line, as required.

NOTE 44: When the differential pressure on the Cartridge Filtration System exceeds 20 PSID above initial clean filter pressure drop or the differential pressure on the Quadraplex Filtration System exceeds 5 PSID above the initial clean bags pressure drop, replace Cartridge Filtration System elements or Quadraplex Filtration System elements, as required.

5-1.8 Rotate crankshaft 90 degrees every 20 minutes during the initial 12-hour flush.

5-1.9 After the initial 12-hour flush, replace Quadraplex Filtration System elements.

5-1.10 Discontinue crankshaft rotation.

5-1.11 Continue flushing until a differential pressure increase of less than 2 PSIG higher than the differential of a clean Quadraplex Filtration System can be maintained for a period of 2 hours. During this 2-hour flush, the fluid contamination level shall be tested every 15 minutes using the Portable Pore Blockage Particle Counter.

CHECKPOINT: 9 (V) and (G). Verify oil flow to all main, thrust, connecting rod, camshaft, and free end support bearings; vertical drive, gear train and oil-wetted components.

NOTE 45: If fluid contamination levels exceed NAS 9 at any time during the final two-hour flush, as indicated by the Portable Pore Blockage Particle Counter the flush shall continue for another two hours from that point in time. This process will be repeated until the contamination levels, as indicated by the Portable Pore Blockage Particle Counter, are equal to or better than NAS 9 for a two-hour period.

NOTE 46: If a differential pressure increase of less than 2 PSIG higher than the differential of a clean Quadraplex Filtration System cannot be maintained for a period of 2 hours, continue flushing until the above criteria has been achieved.

NOTE 47: Solid-based contaminants are those that cannot be crushed between the thumbnail and the finger.

CHECKPOINT: 10 (V) and (G). Conduct a visual inspection of the Quadraplex filter bags after the criteria of Note 44 and Note 45 have been achieved. The sum total of solid based contaminants at the end of that 2-hour period shall not exceed a volume larger than one 10-cent piece. If the sum total exceeds the volume of a 10-cent piece, replace all Quadraplex filter bags and continue flush for an additional 2 hours beginning at paragraph 5-1.12. Record results on Enclosure (4).

5-1.12 Secure Triplex Portable Process Heating System unit.

5-1.13 Secure Flushing Module pump.

5-1.14 Secure all valves that could allow fluid to gravity flow back to the engine sump as noted in Table 1.

5-1.15 Remove flushing oil from sump, piping, hose assemblies, filter and strainer housings.

NOTE 48: Every effort shall be made to remove the flushing oil from the lube oil system. This will ensure a satisfactory NOAP report for viscosity, which will eliminate the need to change oil after a few hours of operation.

NOTE 49: Upon completion of the lube oil flushing, the flushing medium may be returned to clean containers and can be used for the next comprehensive monitored hot lube oil flush provided the cleanliness of the flushing medium can be maintained.

6 LUBE OIL SYSTEM RESTORATION

6-1 Restore the lube oil system to the original pre-flush configuration. Record installation of components on Enclosure (1).

6-2 Remove blank / cam-lock flanges, jumper lines, plugs, Valve Manifold Assembly, etc, used during the flushing procedure. Record removal on Enclosure (3).

6-3 Remove all main bearing jumper lines and gaskets.

6-4 Install new main bearing jumper line gaskets, P/N 16701840 (56 each), main bearing jumper lines and lockwire.

6-5 Open and inspect both exhaust belts; remove any excess oil as required 6-6 Clean engine sump with LINT FREE RAGS.

CHECKPOINT: 11 (V) and (G). Verify the engine sump is free of foreign material and debris.

6-7 Ships force shall hand clean filter housing prior to installing new filter elements.

CHECKPOINT: 12 (V) and (G). Verify the lube oil filter housing is clean and correct filter elements are available to be installed.

6-8 Ships force shall hand clean strainer housing prior to installing strainer baskets.

CHECKPOINT: 13 (V) and (G). Verify the lube oil strainer housing is clean and strainer baskets are clean and free of defects.

7 IN-PLACE LUBE OIL COOLER FLUSH.

NOTE 50: In-place flushing of the DLO cooler will be performed in three (3) stages. First step is flushing performed in the opposite direction of normal flow. Second step is flushing performed in the direction of normal flow. The third and final step is flushing performed in the opposite direction of normal flow. Due to the construction of the DLO cooler (baffles, low flow areas) and that this is an in-place flush, the three stage flushing procedure is necessary to provide the most effective method to remove contaminates. In addition, flushing oil temperature will be maintained at 180-190 degrees F to increase the effectiveness of the in-place Lube Oil Cooler Flush.

NOTE 51: When performing an in-place Lube Oil Cooler Flush, the Lube Oil Cooler shall not be included in the External Lube Oil Flushing procedure.

NOTE 52: When possible, rotating Lube Oil Cooler so that the inlet and outlet flanges are facing down will improve efficiency of the flushing evolution.

7-1 Drain the lube oil cooler to a suitable container.

7-2 Ensure lube oil cooler drain and vent valves are shut.

7-3 Disconnect the lube oil inlet and outlet piping to the lube oil cooler. Install blank flanges on inlet and outlet piping, if required.

7-4 Ensure that the engine sump is filled to the nominal operating level and maintained during the flushing evolution. The flushing medium shall be filtered through 25 micron commercial polyester felt full flow filter bag.

7-5 Connect the discharge hose from the Flushing Module to the outlet side of the lube oil cooler, using a 3-inch flange with a cam-lock style fitting with valves, on the cooler and on the connecting hose end to facilitate reverse flushing.

7-6 Connect the inlet hose of the Flushing Module to the lube oil cooler inlet, using a 3-inch flange with a cam-lock style fitting with valves, on the cooler and on the connecting hose end to facilitate reverse flushing.

7-7 Align valves or hoses to ensure flow path from cooler to the Flushing Module in the opposite direction to normal system flow.

7-8 Ensure new polyester bags are installed in the Quadraplex Filter Assembly.

7-9 Start the Flushing Module pump and begin oil circulation process at 20 gpm to confirm that connections are secure.

7-10 Vent the lube oil cooler into a suitable container to remove any air from the system.

7-11 Energize the Triplex Portable Process Heating System unit.

7-12 Increase Flushing Module pump flow to 125 gpm and reconfirm that connections are secure. Vent the lube oil cooler.

7-13 Increase Flushing Module pump flow rate to 500 gpm. The flush does not officially begin until a constant oil temperature is maintained at 180 - 190 degrees F at the inlet to the Quadraplex Filter Assembly.

7-14 Flush for 4 hours ensuring that the differential pressure on the Cartridge Filtration System does not exceed 20 PSID above initial clean pressure drop and the differential pressure on the Quadraplex Filtration System does not exceed 5 PSID above the initial clean pressure drop.

NOTE 53: When the differential pressure on the Cartridge Filtration System exceeds 20 PSID above initial clean filter pressure drop or the differential pressure on the Quadraplex Filtration System exceeds 5 PSID above the initial clean bags pressure drop, replace Cartridge Filtration System elements or Quadraplex Filtration System elements, as required.

7-14.1 Lightly shock lube oil cooler and end bells with a rubber mallet periodically, to dislodge any trapped contaminants.

7-14.2 Every 30 minutes, open vent / drain valve to insure removal of contaminates. Drain into suitable container.

7-14.3 Every 30 minutes, open vent / drain valve to insure lube oil cooler remains full. Drain into suitable container.

7-15 Secure the Triplex Portable Process Heating System unit.

7-16 Secure the Flushing Module pump.

7-17 Align valves or hoses to flush the lube oil cooler in the normal system direction of flow.

7-18 Ensure new polyester bags are installed in the Quadraplex Filter

Assembly.

7-19 Start the Flushing Module pump and begin oil circulation process at 20 gpm to confirm that connections are secure.

7-20 Energize the Triplex Portable Process Heating System unit.

7-21 Increase the Flushing Module pump flow to 125 gpm and reconfirm that connections are secure. Vent the lube oil cooler.

7-22 Increase Flushing Module pump flow rate to 500 gpm. The flush does not officially begin until a constant oil temperature is maintained at 180 - 190 degrees F at the inlet to the Quadraplex Filter Assembly.

7-23 Flush for 2 hours ensuring that the differential pressure on the Cartridge Filtration System does not exceed 20 PSID above initial clean pressure drop and the differential pressure on the Quadraplex Filtration System does not exceed 5 PSID above the initial clean pressure drop.

NOTE 54: When the differential pressure on the Cartridge Filtration System exceeds 20 PSID above initial clean filter pressure drop or the differential pressure on the Quadraplex Filtration System exceeds 5 PSID above the initial clean bags pressure drop, replace Cartridge Filtration System elements or Quadraplex Filtration System elements, as required.

7-23.1 Lightly shock lube oil cooler and end bells with a rubber mallet periodically, to dislodge any trapped contaminants.

7-23.2 Every 30 minutes, open vent / drain valve to insure removal of contaminates. Drain into suitable container.

7-23.3 Every 30 minutes, open vent / drain valve to insure lube oil cooler remains full. Drain into suitable container.

7-24 Secure the Triplex Portable Process Heating System unit.

7-25 Secure the Flushing Module pump.

7-26 Align valves or hoses to flush the lube oil cooler in the opposite direction of normal system flow.

7-27 Ensure new polyester bags are installed in the Quadraplex Filter

Assembly.

7-28 Start the Flushing Module pump and begin oil circulation process at 20 gpm to confirm that connections are secure.

7-29 Energize the Triplex Portable Process Heating System unit.

7-30 Increase the Flushing Module pump flow to 125 gpm and reconfirm that connections are secure. Vent the lube oil cooler.

7-31 Increase Flushing Module pump flow rate to 500 gpm. The flush does not officially begin until a constant oil temperature is maintained at 180 - 190 degrees F at the inlet to the Quadraplex Filter Assembly.

7-32 Flush for an additional 2 hours at 500 gpm and flushing oil temperature maintained at 180 - 190 degrees F at the inlet of Quadraplex Filter Assembly. During this two-hour flush, the fluid contamination level shall be tested every 15 minutes using the Portable Pore Blockage Particle Counter.

NOTE 55: If fluid contamination levels exceed NAS 9 at any time during the final two-hour flush, as indicated by the Portable Pore Blockage Particle Counter, the flush shall continue for another 2 hours from that point in time. This process will be repeated until the contamination levels, as indicated by the Portable Pore Blockage Particle Counter, are better than or equal to an NAS 9 for a 2-hour period.

NOTE 56: Solid-based contaminants are those that cannot be crushed between the thumbnail and the finger.

CHECKPOINT: 14 (V) and (G). Conduct a visual inspection of the Quadraplex filter bags. The sum total of solid based contaminants at the end of that 2-hour period shall not exceed a volume larger than one 10-cent piece. If the sum total exceeds the volume of a 10-cent piece, replace all Quadraplex filter bags and restart flush for an additional 2 hours beginning at paragraph 7-36. Record results on Enclosure (4).

7-33 Secure the Triplex Portable Process Heating System unit.

7-34 Secure the Flushing Module pump.

7-35 Drain lube oil cooler and hoses into a suitable container.

7-36 Remove flushing hoses and flanges.

7-37 Install blank flanges and record on Enclosure (3).

Figure 1, Scavenging Air Blower Lube Oil Line Location.

Figure 2, Valve Manifold Assembly Identification (EXAMPLE).

Figure 3, SSDG Lube Oil Flush Set Up Diagram (EXAMPLE).

SHIPS PIPING and COMPONENTS REMOVAL and REINSTALLATION

SHIP HULL NO.

CONTRACT NO. ITEM NO.

J.O.N. ENGINE NO.

START DATE OF FLUSH COMPLETION DATE:

PIPING SECTION/COMPONENT DESCRIPTION

(SIZE/LENGTH/NOMENCLATURE)

REMOVAL REINSTALLATION

Mech. Initial.

Date Mech. Initial.

Date

QA / WS.

Initial. Date

Enclosure 1: Ships Piping and Components Removal and Reinstallation Sheet __ of _____

CALIBRATION RECORD

SHIP HULL NO.

Equipment Serial Number Expiration date

Enclosure 2: Calibration Record

BLANK FLANGE and PLUG RECORD

BLANK FLANGE / PLUG DESCRIPTION / ID

NUMBER / LOCATION

INSTALLATION REMOVAL

Mech. Initial.

Date Mech. Initial.

Date

QA / WS.

Initial. Date

Enclosure 3: Blank Flange and Plug Record

FINAL CHECKPOINT RECORD

SHIP HULL NO.

CONTRACT NO. ITEM NO.

J.O.N. ENGINE NO.

START DATE OF FLUSH COMPLETION DATE:

Checkpoint

Number Date Time Contractor

Signature Ship’s Force Signature (if required)

DEI/Supervisor Signature

1 (V) 1 (G) 2 (V) 2 (G) 3 (V) 4 (V) 4 (G) 5 (V) 6 (V) 6 (G) 7 (V) 8 (V) 8 (G) 9 (V) 9 (G) 10 (V) 10 (G) 11 (V) 11 (G) 12 (V) 12 (G) 13 (V) 13 (G) 14 (V) 14 (G)

Enclosure 4: Final Checkpoint Record

FLUSHING LOG

CONTRACT NO. ITEM NO.

J.O.N. ENGINE NO.

START DATE OF FLUSH COMPLETION DATE:

Date Time

(24

HR)

Flow

(GPM)

Temp (F)

Quad

PSID

Cartridge Filter

PSID

NAS

Code

Comments Initial

Enclosure 5: Flushing Log

GENERAL FLUSHING LOG

SHIP HULL NO.

CONTRACT NO. ITEM NO.

J.O.N. ENGINE NO.

START DATE OF FLUSH COMPLETION DATE:

Time COMMENTS / REMARKS

Enclosure 6, General Flushing Log

FINAL CHECKPOINT SUMMARY RECORD

SHIP HULL NO.

CONTRACT NO. ITEM NO.

J.O.N. ENGINE NO.

START DATE OF FLUSH COMPLETION DATE:

Checkpoint

Number Estimated completion Date

Estimated completion

Time Checkpoint Description

1 (V) Verify Materials, Tools/Equipment, Miscellaneous items are ready for…