MIL-STD-1622B Change 1.pdf

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MIL-STD-1622B (SH)

w/CHANGE 1 15 November 2006

SUPERSEDING

MIL-STD-1622B (SH)

17 February 1999

DEPARTMENT OF DEFENSE

STANDARD PRACTICE FOR

CLEANING OF SHIPBOARD COMPRESSED

AIR SYSTEMS

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MIL-STD-1622B(SH)

w/ Change 1 ii

FOREWORD

1. This standard is approved for use by the Naval Sea Systems Command, Department of the Navy, and is available for use by all Departments and Agencies of the Department of Defense.

2. This standard is for use by naval activities and private firms performing services as prime or sub-contractors for Naval Sea Systems Command.

3. Comments, suggestions, or questions on this document should be addressed to Commander, Naval Sea Systems Command, ATTN: SEA 05Q, 1333 Isaac Hull Avenue, SE, Stop 5160, Washington Navy Yard DC 20376-5160 or emailed to commandstandards@navsea.navy.mil, with the subject line “Document Comment”.

Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at http://assist.daps.dla.mil.

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CONTENTS

PARAGRAPH PAGE

1. SCOPE

1.1 Scope

1.2 Applicability

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government documents

2.2.1 Specifications, standards, and handbooks

2.2.2 Other Government documents, drawings, and publications

2.3 Non-Government publications

2.4 Order of precedence

3. DEFINITIONS

3.1 Air

3.2 Aqueous cleaning solution

3.3 Bleed air system

3.4 Blue line

3.5 Clean

3.6 Cleaning solvent

3.7 Clean area

3.8 Clean cloth

3.9 Components

3.10 Critical applications

3.11 Deballast air system

3.12 Dew point

3.13 Dry air

3.14 Electronics dry air main

3.15 Emergency breathing air system

3.16 Final cleaner

3.17 General applications

3.18 Halogenated solvent

3.19 High pressure air system

3.20 Low pressure air system

3.21 Maximum operating pressure

3.22 Medium pressure air system

3.23 Nitrogen

3.24 Non-vital air main

3.25 Organic

3.26 Precleaner

3.27 Sample

3.28 Surfactant

3.29 Vital air main

3.30 Water

4. GENERAL REQUIREMENTS

4.1 Water

4.1.1 Applicability

4.1.2 Disposal

4.1.3 Compatibility

4.2 Cleaning solutions

4.2.1 Navy Oxygen Cleaner (NOC)

4.2.2 Tribasic Sodium Phosphate (TSP)

4.2.3 Non-Ionic Detergent (NID)

4.2.4 Isopropyl alcohol

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PARAGRAPH PAGE

4.2.5 NAVSEA approved halogenated solvents

4.3 Other cleaners

4.3.1 Other cleaners for general applications

4.3.2 Other final cleaners for critical applications

4.4 Other cleaner selection criteria

4.4.1 Cleaning performance

4.4.2 Health and safety

4.4.3 Material compatibility

4.4.4 Disposal

4.4.5 Process application

4.4.6 Cleaner quality

4.5 Gases

4.5.1 Safety precautions

4.5.2 Air

4.5.3 Nitrogen

4.5.4 Argon

4.6 Cleaning silver-brazed piping

4.7 Lubricants

5. DETAILED REQUIREMENTS

5.1 Facility requirements

5.2 Component cleaning process for general applications

5.2.1 Applicability

5.2.2 Material and equipment

5.2.3 Clean and rinse

5.2.4 Dry, reassemble and package

5.3 Component cleaning process for critical applications

5.3.1 Applicability

5.3.2 Objective

5.3.3 Material and equipment

5.3.4 Preclean and rinse

5.3.5 Final clean, verification and rinse

5.3.6 Dry, reassemble and package

5.4 Flask cleaning

5.4.1 Applicability

5.4.2 Material and equipment

5.4.3 Clean, verification, and rinse

5.4.4 Drying

5.4.5 Final inspection and end fitting installation

5.5 Instruments and gages

5.6 System aqueous cleaning process

5.6.1 Applicability

5.6.2 Material and equipment

5.6.3 System preparation

5.6.4 Leak-check

5.6.5 Preflush

5.6.6 Hydrostatic test

5.6.7 Final flush/pipe line cleaning

5.6.8 Rinsing and particulate flushing

5.6.9 Drying and reinstalling components

5.7 System solvent cleaning processes

5.7.1 Applicability

5.7.2 Nitrogen plants

5.7.3 Cryogenic nitrogen or oxygen-nitrogen plant piping

5.8 System blowdown

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PARAGRAPH PAGE

5.8.1 Applicability

5.8.2 System preparation

5.8.3 Leak-check

5.8.4 Blowdown

5.9 Hot or cold water flush

5.9.1 Applicability

5.9.2 System preparation

5.9.3 Hot water flush

5.9.4 Cold water flush

5.9.5 Inspection

5.9.6 Drying and reinstalling components

5.10 Testing

5.10.1 Pressure testing

5.10.2 Operational testing

5.10.3 Gas sampling and analysis

5.11 Removal and replacement of components

5.12 Piping repairs

5.12.1 Applicability

5.12.2 System Preparation

5.12.3 Maintenance of purge

5.12.4 Cutting/grinding of system

5.12.5 Cleaning

5.12.6 Inspection and testing

5.13 Loss of cleanliness

5.13.1 Definition

5.13.2 Method for determination of extent of contamination

5.13.3 Corrective action

5.13.4 Local cleaning

5.14 Process verification methods

5.14.1 Visual surface inspection methods

5.14.2 Shake test

5.14.3 Particulate and clarity inspection methods

5.14.4 Rinse water pH analysis

5.14.5 NOC alkalinity

5.14.6 Detection of hydrocarbon contamination by swipe

5.15 Personnel qualification and training

5.15.1 Applicability

5.15.2 Content of training

5.16 Packaging

5.16.1 Applicability

5.16.2 Internally and externally cleaned components

5.16.3 Internally cleaned items

5.16.4 Identification

5.16.5 Inspection of packaging

6. NOTES

6.1 Intended use

6.2 Issue of DoDISS

6.3 NAVSEA approval and direction

6.4 Safety precautions

6.5 Subject term (key word) listing

6.6 Changes from previous issue

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TABLES

I. Grades of water II. Testing requirements for other cleaners III. Flask cleaning matrix IV. Aqueous system cleaning matrix V. Applicability matrix for flush duration and back flush VI. Dryness level requirements VII. Solvent cleaning processes VIII. Inspection requirements A-I. Metallic material compatibility A-II. Rubber material compatibility A-III. Plastic material compatibility A-IV. Rubber compatibility criteria A-V. Plastic compatibility criteria B-I. NAVSEA approved halogenated solvents C-I. NAVSEA approved halogenated solvents for cleaning instruments ... 58

APPENDICES

A. Material Compatibility B. NAVSEA Approved Halogenated Solvents C. Cleaning Critical Application Instruments

1. SCOPE

1.1 Scope. This standard provides the requirements for cleaning of compressed air systems and components. Each activity should implement the applicable requirements of this document through a locally prepared and approved procedure. Activities subject to additional quality assurance requirements such as NAVSEA SS800-AG-MAN-010/P-9290 or NAVSEA SS521-AA-MAN-010 will obtain procedure approval from the applicable certifying activity. This standard does not apply to reactor plant air systems.

1.2 Applicability. This standard is applicable to all surface ships, submarines, and supporting shore base facilities which contain any of the following:

1.2.1 Compressed air systems and components. The cleanliness boundary includes all material designed for and normally wetted by low, medium, or high pressure air as specified in NAVSEA S9086-SY-STM-010/CH-551. Specific systems included are diver's life support air, air supplying oxygen generating equipment, emergency breathing air, emergency main ballast tank blow, electronics air, low pressure vital and non-vital air, and deballast air.

1.2.2 Compressed gaseous and liquid nitrogen systems and components supporting or interfacing with services containing 25% or less oxygen. The cleanliness boundary includes all material designed for and normally wetted by compressed gaseous or liquid nitrogen. For all cases, if the system or component interfaces with an oxygen or oxygen-enriched system or component, including gaseous or liquid oxygen generating equipment, containing greater than 25% by volume oxygen during normal operation, it will be cleaned as specified in MIL-STD-1330.

1.2.3 Equipment which comes in contact with or is used to transfer any fluid from its source to a system or component within any of the boundaries defined in 1.2.1 and 1.2.2 when such interface is intended to maintain the cleanliness requirements specified herein.

1.2.4 Open ended applications, other than air supplying diver's life support, will use best commercial practice to remove loose scale, dust, grit, filings, oil, and grease. Open ended applications supplying air for diver's life support will be cleaned as specified herein.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this standard, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2).

FEDERAL SPECIFICATIONS

O-S-642 - Sodium Phosphate, Tribasic, Anhydrous;

Dodecahydrate; and Monohydrate; Technical

COMMERCIAL ITEM DESCRIPTIONS

A-A-58020 - Drums, Shipping, Steel with Polyethylene Insert A-A-59155 - Nitrogen, High Purity, Special Purpose

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-D-16791 - Detergents, General Purpose (Liquid, Nonionic) MIL-G-18997 - Gauge, Pressure, Dial Indicating MIL-DTL-24800 - Cleaning Compound - Aqueous - Oxygen Systems Components MIL-PRF-27401 - Propellant Pressurizing Agent Nitrogen MIL-PRF-27415 - Propellant Pressurizing Agent Argon

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-1330 - Standard Practice For Precision Cleaning and Testing of Shipboard Oxygen, Helium, Helium- Oxygen, Nitrogen, and Hydrogen Systems

(Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or http://assist.daps.dla.mil or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

PUBLICATIONS

NAVAL SEA SYSTEMS COMMAND (NAVSEA)

SS521-AA-MAN-010 - U.S. Navy Diving and Manned Hyperbaric

Systems Safety Certification Manual S6430-AE-TED-010 - Technical Directive for Piping Devices, Flexible Hose Assemblies SS800-AG-MAN-010/ - System Certification Procedures and Criteria P-9290 Manual for Deep Submergence Systems 0900-LP-001-7000 - Fabrication and Inspection of Brazed Piping Systems 0902-018-2010 - General Overhaul Specifications for Deep Diving SSBN/SSN Submarines Repair 0987-LP-022-3010 - In-Place and On-Site Calibration of Pressure Instruments in Oxygen Gas Systems (Other Than Gas Generating Plants) S9086-H7-STM-010/ - NSTM, Lubricating Oils, Greases, Hydraulic CH-262 Fluids and Lubrication Systems S9086-RK-STM-010/ - NSTM, Piping Systems

CH-505

S9086-SY-STM-010/ - NSTM, Compressed Air Plants and Systems

CH-551

S9086-WK-STM-010/ - NSTM, Stowage, Handling, and Disposal CH-670 of Hazardous General Use Consumables

(Copies of this document are available from Commander, Naval Sea Systems Command, ATTN: SEA 05Z9, 1333 Isaac Hull Avenue, SE, Stop 5122, Washington Navy Yard DC 20376-5122.)

ENVIRONMENTAL PROTECTION AGENCY (EPA)

EPA-Method-1664 - N-Hexane Extractable Material (HEM) and Silica

Gel Treated N-Hexane Extractable Material (SGT- HEM) by Extraction and Gravimetry (Oil and Grease and Total Petroleum Hydrocarbons).

(Copies of this document are available from the Environmental Protection Agency, Ariel Rios Building, 1200 Pennsylvania Avenue, N.W., Washington DC 20460 or online at www.epa.gov.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract (see 6.2).

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI Z358.1 - Emergency Eyewash and Shower Equipment

(Copies of this document are available from the American National Standards Institute, 25 W. 43rd St, 4th Floor, New York, NY 10036 or online at http://webstore.ansi.org/.)

COMPRESSED GAS ASSOCIATION (CGA)

CGA G-7.1 - Commodity Specification for Air CGA G-10.1 - Commodity Specification for Nitrogen

(Copies of these documents are available from the Compressed Gas Association, Inc., 4221 Walney Road, 5th Floor, Chantilly, VA 20151-2923 or online at www.cganet.com.)

2.4 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. DEFINITIONS

3.1 Air. Air refers to gaseous air as specified in 4.5.2.

3.2 Aqueous cleaning solution. An aqueous cleaning solution is a water based cleaner whose constituents are soluble inorganic compounds such as silicates or phosphates or soluble organic compounds such as non-ionic surfactant or combinations thereof. Examples of aqueous cleaning solutions include commercial detergents which generally contain both soluble inorganic and organic compounds and Navy Oxygen Cleaner (NOC) which contains only soluble inorganic compounds.

3.3 Bleed air system. A bleed air system is a system in which air is supplied from the compression stage of a gas turbine generator or a propulsion gas turbine.

3.4 Blue line. When a cut for a pipe or fitting nears the inner wall, the outer surface turns blue which is referred to as cutting to the blue line.

The blue line results from oxidation caused by the reduced ability of the thinned pipe or fitting to dissipate heat generated by the power tool cutting the surface.

3.5 Clean. Clean refers to the absence of scale, particulate, oil and grease contaminants at a level below that which adversely affects the operation or reliability of the component or system. The process of cleaning shall not affect the form, fit or function of the item being cleaned.

3.6 Cleaning solvent. A cleaning solvent is any material that exhibits the capability to dissolve other substances through chemical action and, for the purposes of this document, are 100% volatile. Examples include halogenated solvents such as HFE-7100 which is non-flammable and hydrocarbon solvents such as isopropyl alcohol (IPA) which is very flammable.

3.7 Clean area. A clean area is an area that is free of air borne debris or contamination resulting from work accomplished in the immediate area.

3.8 Clean cloth. A clean cloth is used for local cleaning or wiping surfaces to evaluate loss of cleanliness. The cloth shall be adequately free of contaminants which could pose a compatibility, flammability, or toxicity hazard considering the specific application.

3.9 Components. Components refers to items such as valves, fittings, gauges and regulators in the systems.

3.10 Critical applications. Critical applications are systems or components requiring more detailed cleanliness requirements than general applications because of unique operating parameters and environments. Air systems supplying diver life support and air systems supplying oxygen generating equipment are classified as critical applications because of the increased toxicity hazard associated with high partial pressure environments for diver air, and flammability due to the interface with the oxygen system for air systems supplying oxygen generating equipment.

3.11 Deballast air system. A deballast air system is a low pressure air system which is used for deballasting amphibious assault ships.

3.12 Dew point. Dew point is the measure of dryness or wetness of a gas. It is defined as the temperature at which gas becomes saturated with water vapor causing condensation when cooled at constant pressure. Dew point temperatures listed in this standard are at atmospheric pressure.

3.13 Dry air. Dry air refers to air that has been dried to a dew point temperature low enough to prevent condensation. The dew point is application specific, and is based on the maximum pressure and minimum temperature that the application will normally experience. As an example, air that operates at 125 psig and is subjected to a 0oF operating environment would require a dew point temperature of about -35oF to prevent condensation.

3.14 Electronics dry air main. An electronics dry air main is that portion of the vital air main which is used for pressurization of various types of radar waveguides and antennas, electronic equipment, and transmission systems.

3.15 Emergency breathing air system. Emergency breathing air systems distribute emergency breathing air throughout submarines and to specified pump rooms and machinery spaces on surface ships.

3.16 Final cleaner. A final cleaner is an aqueous cleaning solution or a cleaning solvent used for final flushing of piping systems or final precision cleaning of components and parts.

3.17 General applications. General applications are systems or components not defined as a critical application.

3.18 Halogenated solvent. A halogenated solvent is any solvent whose chemical structure contains bromine, chlorine, fluorine, or iodine. Most halogenated solvents are non-flammable and many are very toxic. All NAVSEA approved halogenated solvents contain fluorine, some also contain chlorine, and none contain bromine or iodine.

3.19 High pressure air system. A high pressure air system is an air system which operates at pressures greater than or equal to 1000 lb/in2.

3.20 Low pressure air system. A low pressure air system is an air system which operates at pressures less than or equal to 150 lb/in2.

3.21 Maximum operating pressure. The maximum operating pressure is the highest pressure that can exist in a system or subsystem under normal (non-casualty) operating conditions. This pressure is determined by such influences as pressure regulating valve set pressure, maximum pressure at the system source such as compressed gas bank pressure or sea pressure, and pump shut-off pressure for closed systems. For constant pressure systems, such as regulated compressed gas systems, the term Nominal Operating Pressure has been used to designate the steady state operating condition. Where this type of pressure rating is applied, for the purpose of the requirements stated herein, it may be substituted as the maximum operating pressure.

3.22 Medium pressure air system. A medium pressure air system is an air system which operates at pressures greater than 150 lb/in2 and less than 1000 lb/in2.

3.23 Nitrogen. Nitrogen refers to gaseous nitrogen as specified in 4.5.3.

3.24 Non-vital air main. A non-vital air main is that portion of the ship service low pressure air system which serves other than vital users.

3.25 Organic. Organic refers to any chemical compound containing carbon. For the purposes of this document, the organic compounds of interest are hydrocarbon compounds containing carbon and hydrogen, and fluorocarbon compounds containing carbon and fluorine. Examples of hydrocarbon materials include most fuels and compressor lubricating oils, while examples of fluorocarbon materials include MIL-PRF-27617 grease used for lubricating high pressure o-rings.

3.26 Precleaner. A precleaner is any aqueous cleaning solution or cleaning solvent used to initially clean parts to visually clean. Examples include Navy Oxygen Cleaner (NOC), dissolved tribasic sodium phosphate (TSP), isopropyl alcohol (IPA), and non-ionic detergent (NID) mixed with water.

3.27 Sample. Sample is a representative amount of cleaning solvent, cleaning solution, rinse water or pressurized gas collected in clean containers at selected locations obtained to verify the performance of the cleaning process.

3.28 Surfactant. A surfactant is a surface wetting agent which reduces interfacial tension between a liquid and a solid.

3.29 Vital air main. A vital air main is that portion of the ship service low pressure air system which serves users whose continuous operation is essential for safety and mission capability of the ship.

3.30 Water. Water refers to water as specified in 4.1.

4. GENERAL REQUIREMENTS

4.1 Water.

4.1.1 Applicability. Three grades of water, A, B, and C, in descending order of purity, are associated with preparing and diluting cleaning solutions, flushing, rinsing, and testing, and are defined in Table I. Water purity requirements specified throughout this standard are minimum requirements and do not preclude the use of water of greater purity.

4.1.2 Disposal. Disposal of water shall be in accordance with local, state, and federal regulations.

4.1.3 Compatibility. Appendix A gives the compatibility of hot water with various materials. Where incompatibility exists, process changes such as rinsing with cooler water, shorter rinse durations, or immediate drying of wet surfaces may need to be considered. Where specific information is lacking, perform compatibility testing as specified in A.3 of Appendix A.

TABLE I. Grades of water.

Item Grade

A 1/ B 1/ C 2/

Chloride ion, maximum, ppm 0.1 1.0 35

Conductivity, maximum, micromhos/cm 3/ 2.5 20 550

Resistivity, minimum, ohms-cm 3/ 400K 50K 1.8K pH range 4/ 6.0 to 8.0 - -

Visual clarity No turbidity, oil, or sediment

1/ Demineralized water meeting the requirements of ASTM D 1193, type II, satisfies grade A or B requirements.

2/ Potable water and municipal water generally meets grade C requirements.

3/ Measure either conductivity or resistivity; resistivity is the inverse of conductivity.

4/ When the conductivity of grade A water is 0.25 micromhos/cm or less, pH measurements are not required.

4.2 Cleaning solutions.

4.2.1 Navy Oxygen Cleaner (NOC).

4.2.1.1 Applicability. NOC is an aqueous alkaline cleaning solution approved for use as a precleaner or final cleaner for all compatible piping and components. NOC shall be in accordance with MIL-DTL-24800.

4.2.1.2 Safety precautions. Follow the safety precautions recommended in the vendor's Material Safety Data Sheet (MSDS) and the following precautions recommended by the Navy Environmental Health Center (NEHC).

(a)Skin contact with NOC will result in irritation and chemical burns.

Wear impervious protection clothing constructed of neoprene or other material of equivalent resistance to penetration so as to prevent skin contact. Use elbow length gloves (with cuffs) as minimum protection any time open containers of the cleaning agent are handled. Wash potentially exposed skin areas with soap and water at breaks, and at the conclusion of the operation. Do not use organic solvents for this purpose. Thoroughly clean protective garments at the conclusion of the operation and store for reuse. Remove clothing which becomes contaminated as soon as possible and thoroughly clean before reuse. Seek prompt medical assistance should a rash, chemical burn, or other adverse effect be experienced which may be related to working with NOC. Do not store or consume food and tobacco in areas where they could be contaminated with NOC.

(b)Eye contact with NOC could result in chemical burns. Wear chemical worker's goggles for all operations where eye contact with NOC could occur. Use a full-length face shield for any operation where splashing of the material could occur. In the event of eye contact, personnel should flush their eyes thoroughly with fresh water for a minimum of 15 minutes, then seek prompt medical attention. An eye wash system conforming to the design requirements of the American National Standards Institute (ANSI) Z358.1 shall be in the immediate vicinity of all operations. Eye wash systems shall be capable of providing a minimum of 15 minutes of water for emergency flushing.

(c)Over exposure to mists or vapors from NOC may result in sneezing, coughing, respiratory system irritation, and possibly chemical burns and subsequent edema in the upper airways. Based on off-gas testing at temperatures up to 180oF, such a possibility is unlikely, considering the magnitude and frequency of use. If irritating solution mist is present, approved respirators shall be worn to avoid inhalation (see 6.4). In the event any adverse health effects are experienced, cease operations involving NOC and consult the cognizant medical department representative for additional guidance.

4.2.1.3 Disposal. Disposal of NOC shall be in accordance with local, state, and federal regulations. If neutralizing NOC, dilute at least 4:1 with water before adding acid to prevent forming a precipitate.

4.2.1.4 Compatibility. Appendix A gives the compatibility of NOC with various materials. Where specific information is lacking, perform compatibility testing as specified in A.3 of Appendix A. NOC used to clean aluminum or anodized aluminum should be diluted 50% with water.

4.2.1.5 Inspection prior to use. The following inspections shall be performed prior to using NOC.

(a)A shake test as specified in 5.14.2 and a visual clarity inspection as specified in 5.14.3.2 shall be performed. NOC which fails either inspection due to the presence of oil shall be rejected and returned to the vendor. NOC which fails the visual inspection due to the presence of particulate or fiber shall be either filtered with a 5 micron nominal or finer filter to remove the suspended particulate or fiber or rejected and returned to the vendor.

(b)Government purchases of NOC are origin inspected, origin accepted with a Certificate of Analysis for each lot maintained by Defense Supply Center Richmond. Other purchasers of NOC should request a Certificate of Analysis with each delivery. Any NOC returned to a vendor because of a quality deficiency shall be noted (see 6.3).

4.2.1.6 Dilution. NOC shall be diluted as follows:

(a)Concentration: NOC can be diluted with water up to 50%. NOC should be diluted 50% with grade B water when cleaning aluminum or anodized aluminum.

(b)Water quality: The preferred quality of water is 5 micron nominal or finer filtered grade A water. For long term use in cleaning equipment, such as an ultrasonic cleaning tank, parts washer, or flushing rig, grade B water may be used with a 5 micron filter installed. For short term use, such as a few hours, 10 micron filtered grade C water may be used.

(c)Order for mixing: In order to yield a more stable solution which will extend the life of the cleaner, water should be added to NOC rather than adding NOC to water.

4.2.1.7 Use of NOC in previously used equipment. For critical application cleaning equipment previously used with other than NOC, the following actions should be taken to minimize and evaluate for the possibility of the NOC reacting with the residue left behind.

(a)Fill the cleaning equipment with NOC diluted 25 to 50% with grade B water.

(b)Operate the cleaning equipment covered for 4 hours at 140 to 160oF.

(c)Visually inspect the NOC for foam and precipitate. Visually inspect the equipment for milky white deposits. Some white deposits at the fluid-air boundary are acceptable.

(d)If precipitate is visible in the NOC, the NOC foams, or milky white deposits are visible on the equipment in areas continuously wetted with NOC, discard the NOC solution, remove the deposits as specified in 4.2.1.7(e), and repeat the process.

(e)Deposits can be removed by soaking in hot water, or scrubbing and/or soaking with commercial white vinegar or a warm (up to 110oF) 10 to 16% citric acid solution, followed by a water rinse.

A 10 to 16% citric acid solution can be prepared by adding 12 to 20 ounces of powdered citric acid (CAS No. 77-92-9) to one gallon of water.

4.2.1.8 Use for extended periods. Extended use of NOC should be in covered equipment to minimize evaporation. Evaporative losses can be made-up with grade B water. NOC can be recycled using filtration, and continuously used or reused, provided the following conditions are satisfied:

(a)For critical applications, a shake test as specified in 5.14.2 reveals no excessive foam.

(b)For critical applications, a clarity inspection as specified in

5.14.3.2 reveals no oil, grease, or excessive particulate.

(c)An alkalinity test as specified in 5.14.5 indicates a satisfactory result. As the alkalinity of NOC is depleted in use, the volume of NOC required to obtain the blue end-point specified in 5.14.5 increases. When the alkalinity test measures 35 to 40 milliliters (mL) of NOC, the NOC is at risk of developing an insoluble precipitate. The NOC should either be replaced, or a portion of the low alkalinity NOC removed and replaced with fresh NOC to restore alkalinity. If evaporation concentrates the NOC causing the alkalinity test to measure less than 10 mL of NOC, the NOC should be diluted with water as specified in 4.2.1.6 to restore the alkalinity to a nominal measured range of 15 to 30 mL of NOC.

Do not attempt to adjust the alkalinity of 50 to 100 percent concentrated NOC by adding acid; an immediate gel or precipitate will develop. Alkalinity of NOC in use or stored in cleaning equipment should be checked weekly until the alkalinity test measures about 30 mL of NOC. Then, more frequent analysis should be performed to ensure an insoluble precipitate does not form.

4.2.1.9 Filtration. For long term use in cleaning equipment such as large ultrasonic tanks or parts washers, a filter sized at about 1 micrometer nominal should be installed. For use in a flushing rig, a 5 micrometer nominal or finer filter shall be installed, and it is recommended that a filter sized at about 1 micrometer nominal be installed. A 5 micrometer filter prevents introducing significant contamination back into the system. A 1 micrometer filter allows recycling and extending the use of NOC. It is also recommended that for flushing applications, a strainer be installed upstream of the filter to remove large debris that can prematurely clog the filter.

For critical applications, filters used for the first time shall be checked for extractable organic material. This is accomplished by recirculating through the filter with clean NOC at 140 to 160oF for no less than 1 hour and then checking for foam as specified in 5.14.2, and performing a visual inspection of the effluent as specified in 5.14.3.2. Checking for extractable organic material of filters is not required for filters from the same vendor and of the same material that previously tested satisfactorily. A suitable filter material is thermally bonded, pleated polypropylene containing no plasticizer or adhesive. The major advantage of disposable polypropylene filter cartridges is ease of use. Cleaning stainless steel reusable filters can be difficult and time consuming. The large soil holding capacity of disposable filter cartridges can often balance the cost of using smaller soil holding capacity stainless steel filters requiring frequent cleaning. Filter housings should be configured with a vent on the top of the housing to allow removing oil that has separated from the NOC. Verify with the filter manufacturer that the temperature, pressure and flow ratings of any filter are adequate for the intended application. Disposal of used filters or separated oil shall be in accordance with local, state and federal regulations.

4.2.1.10 Stowage. NOC should be stored in covered containers to minimize evaporative losses. Stowage of heated NOC for several days should only be in corrosion resistant metal, Teflon, or Teflon lined glass containers. Long term stowage of heated NOC in plastic (other than Teflon), rubber, or glass containers will result in cleaner degradation. For critical applications, unheated NOC may be stowed in plastic or plastic lined containers provided the container has been checked for extractable organic material. This is accomplished by filling the container with NOC for no less than 10 days then checking for foam as specified in 5.14.2, and performing a visual inspection as specified in 5.14.3.2. Checking for extractable organic material of containers is not required for containers from the same vendor and of the same material that previously tested satisfactorily. Experience indicates that NOC can be successfully stored in aged uncolored or clear high density polyethylene (HDPE) or polypropylene plastic containers. NOC can also be stored in steel containers having an unplasticized low density polyethylene (LDPE) liner which is not adhesively bonded to the steel container similar to A-A-58020. Stowage of NOC in colored plastic containers may contaminate the cleaner. NOC allowed to dry on glass will result in a hard insoluble residue.

Wide mouth glass sample bottles with external safety coatings and Teflon lined caps are acceptable, as are sampling containers manufactured from Teflon, Teflon lined glass, Teflon lined plastic, or stainless steel. Bulk shipboard stowage of NOC shall be in accordance with S9086-WK-STM-010/CH-670 for alkalies.

4.2.2 Tribasic Sodium Phosphate (TSP).

4.2.2.1 Applicability. TSP is a solid crystalline material mixed with water to prepare an aqueous alkaline cleaning solution approved for use as a precleaner or final cleaner for all compatible piping and components. TSP shall conform to O-S-642, type I or II, or equal. Type II is recommended because it is less susceptible to precipitation.

4.2.2.2 Safety precautions. Follow the safety precautions recommended in the vendor's Material Safety Data Sheet and the following:

(a)TSP is a solid, crystalline material which has a caustic action on skin, eyes, and mucous membranes. Repeated or prolonged contact with the solid material or its solution shall be avoided.

(b)Chemical safety goggles or face shield, rubber gloves, and rubber aprons or coveralls shall be worn to prevent skin contact. In the event of eye contact, personnel should flush their eyes thoroughly with fresh water for a minimum of 15 minutes, then seek prompt medical attention. An eye wash system conforming to the design requirements of the American National Standards Institute (ANSI) Z358.1 shall be in the immediate vicinity of all operations. Eye wash systems shall be capable of providing a minimum of 15 minutes of water for emergency flushing.

(c)If skin contact occurs, exposed areas shall be washed with large amounts of fresh water. If irritating dust or solution mist is present, approved respirators shall be worn to avoid inhalation (see 6.4).

(d)In the event any adverse health effects are experienced, cease operations involving TSP and consult the cognizant medical department representative for additional guidance.

4.2.2.3 Disposal. Disposal of TSP shall be in accordance with local, state, and federal regulations.

4.2.2.4 Compatibility. Appendix A gives the compatibility of TSP with various materials. Where specific information is lacking, perform compatibility testing as specified in A.3 of Appendix A.

4.2.2.5 Solution preparation. Prepare the TSP cleaning solution by dissolving 2 pounds of type I or 4.5 pounds of type II TSP with 5 gallons of grade B water at 160 to 180oF. In order to prevent a violent reaction and to better dissolve the TSP, add the TSP to the water; do not add water to the TSP. The solution shall be circulated until the TSP is dissolved prior to exposing the solution to a system or component.

4.2.2.6 Stowage. If a TSP stowage tank is not large enough, do not mix a solution stronger than as specified in 4.2.2.5 and attempt to dilute it in a piping system. Failure to maintain the temperature of a solution stronger than as specified in 4.2.2.5 at 160 to 180oF can result in the TSP precipitating and developing a hardened mass. This hardened mass is difficult, if not impossible, to remove. The preferred stowage tank material is stainless steel. Bulk shipboard stowage of TSP shall be in accordance with S9086-WK-STM-010/CH-670 for alkalies.

4.2.3 Non-Ionic Detergent (NID)

4.2.3.1 Applicability. NID is a concentrated non-ionic hydrocarbon surfactant that is mixed with water to prepare an aqueous detergent cleaning solution acceptable for use as a precleaner for critical applications and as a cleaner for general applications. NID shall conform to MIL-D-16791, type I, or commercial equivalent, such as Triton X-100.

4.2.3.2 Safety precautions. Follow the safety precautions recommended in the vendor's Material Safety Data Sheet (MSDS). If irritating solution mist is present, approved respirators shall be worn to avoid inhalation (see 6.4).

In the event any adverse health effects are experienced, cease operations involving NID and consult the cognizant medical department representative for additional guidance.

4.2.3.3 Disposal. Disposal of NID shall be in accordance with local, state, and federal regulations.

4.2.3.4 Compatibility. Appendix A gives the compatibility of NID solutions with various materials. Where specific information is lacking, perform compatibility testing as specified in A.3 of Appendix A.

4.2.3.5 Solution preparation. Prepare NID solution by adding 0.1 to

0.5 ounces of NID to each gallon of water. Use of higher concentrations of NID in water will not increase soil removal performance, and can cause difficulty in rinsing the NID solution from the surface. NID solutions shall be used at temperatures no greater than 140oF. At temperatures greater than 140oF, the solubility of NID will decrease leading to possible precipitation of NID.

4.2.4 Isopropyl alcohol (IPA).

4.2.4.1 Applicability. Isopropyl alcohol (IPA) is a cleaning solvent that is acceptable for use as a precleaner for critical applications and as a cleaner for general applications with compatible material. IPA shall not be used as a precleaner for Teflon in either a diver's air system or an air system supplying oxygen generating equipment. Any commercial grade of IPA is acceptable for use. IPA is soluble in water and commercial grades can have as much as 30% water.

4.2.4.2 Safety precautions. Follow the safety precautions recommended in the vendor's Material Safety Data Sheet and the following:

(a)IPA is a volatile hydrocarbon solvent with a boiling point of about

180oF. IPA is extremely flammable having a flash point of 56oF.

IPA vapors are toxic having a recommended 8-hour time weighted average exposure criteria of 400 ppm. Ingestion of IPA will cause burning of the gastrointestinal tract, nausea, vomiting, bleeding, CNS depression, hemolysis, and pulmonary damage. Ingestion of as little as 10 mL may cause serious injury, while ingestion of 240 mL can be fatal.

(b)An industrial hygienist, gas free engineer, gas free person, or other designated individual shall verify that ventilation in the space is adequate to keep the concentration of the solvent below the recommended exposure criteria during anticipated operations, excluding accidents or spills. If excessive solvent concentration is present, approved respirators shall be worn (see 6.4). Use caution when ventilating IPA vapors since the vapors are flammable. Explosion proof equipment may be necessary.

(c)IPA is absorbed by non-metallic material, such as Teflon, and unless carefully dried, may off-gas flammable and toxic material.

(d)In the event any adverse health effects are experienced, cease operations involving IPA and consult the cognizant medical department representative for additional guidance.

4.2.4.3 Disposal. Disposal of isopropyl alcohol shall be in accordance with local, state, and federal regulations.

4.2.4.4 Compatibility. Where specific information with respect to compatibility is lacking, perform compatibility testing as specified in A.3 of Appendix A.

4.2.5 NAVSEA approved halogenated solvents.

4.2.5.1 Applicability. A NAVSEA approved halogenated solvent, as specified and subject to the limitations in Appendix B, can be used as a cleaner for instruments as specified in 5.5, for cryogenic systems and piping as specified in 5.7, and for field wipe as specified in 5.13.4. Use of a NAVSEA approved halogenated solvent for any other application requires local engineering, environmental and industrial hygiene approval.

4.2.5.2 Safety precautions. For any NAVSEA approved halogenated solvent, follow the safety precautions recommended in the vendor's Material Safety Data Sheet and the following:

(a)An industrial hygienist, gas free engineer, gas free person, or other designated individual shall verify that ventilation in the space is adequate to keep the concentration of the solvent below the recommended exposure criteria during anticipated operations, excluding accidents or spills (see 6.4). If excessive solvent concentration will be present, approved respirators shall be worn (see 6.4). If necessary, use portable blowers. Exhaust ventilation is preferable to blowing air into the space. Solvent vapor should be captured as close as possible to the point of generation and discharged outside of the area in a manner that precludes recirculation and exposure to other personnel.

(b)At least two people shall be present at all times while solvent is being used. Do not leave the area unattended while cleaning is in progress.

(c)When a halogenated solvent is being transferred by hose or pipe from a remote location, communication shall be established between the pumping station and the space involved.

(d)To permit escape in the event of an accidental spill, a self-contained breathing device shall be immediately available to each person in any space where operations involving a halogenated solvent are taking place or occupied spaces where leaks may occur while systems containing halogenated solvents are being cleaned, tested, serviced, or repaired. Each person shall have received instruction and practice in the use of the particular self-contained breathing device to be used. When a spill occurs, a high concentration of solvent vapor may rapidly fill the space and dilute the air in the space. Breathing this diluted, contaminated air can result in rapid (10 to 15 seconds) loss of consciousness caused by oxygen being washed from the lungs. It is therefore necessary to stop breathing until the self-contained breathing device has been put on and is supplying air. The Navy "Emergency Escape Breathing Device" (EEBD) may be used for emergency escape.

(e)All hot work in the space shall be suspended before introducing the solvent into the system. An exception is that during overhaul in a shipyard, hot work may be performed on board a ship while systems are being flushed (not pressure tested) with halogenated solvents if each operation is authorized by a gas free engineer.

Personnel shall be instructed to leave the area immediately if anyone experiences any irritation of the eyes, nose or throat.

During specially authorized hot work, self-contained breathing devices for emergency escape are not required in spaces where all lines being flushed contain only welded joints (no flanges, valves or other fittings having mechanical joints). The following warning sign shall also be displayed at the entrance to all work spaces:

WARNING:

HALOGENATED SOLVENT OPERATION; DO NOT ENTER UNOCCUPIED SPACE

WITHOUT FIRST TESTING FOR SOLVENT; NO HOT WORK OR OPEN FLAMES

ALLOWED IN THIS SPACE EXCEPT WHEN AUTHORIZED BY A GAS FREE

ENGINEER; LEAVE SPACE IMMEDIATELY IF ANYONE NOTICES ANY EYE, NOSE

OR THROAT IRRITATION.

(f)Carefully check the system for leaks before pumping solvent through the system (see 5.7.3.2).

(g)Chemical safety goggles or a full-length face shield shall be used where eye contact is possible. A full-length face shield shall be worn over chemical safety goggles for any operation where splashing of the solvent may be a problem. In the event of eye contact, personnel should flush the eyes with fresh water for a minimum of 15 minutes, then seek prompt medical attention. An eye wash system conforming to the design requirements of the American National Standards Institute (ANSI) Z358.1 shall be in the immediate vicinity of all operations. Eye wash systems shall be capable of providing a minimum of 15 minutes of water for emergency flushing.

(h)Repeated contact with the skin may cause cracking and irritation.

Wear solvent resistant rubber gloves if contact with the hands cannot otherwise be prevented. Clothing that becomes saturated with solvent should be removed at once.

(i)The atmosphere in the space where the solvent is used shall be continuously monitored. An alarm shall be set on the instrument which will be activated when the solvent reaches its recommended exposure criteria. The concentration of the solvent shall not be allowed to exceed the recommended exposure criteria during a normal working day. If the alarm sounds, immediately put on the EEBD and promptly leave the space. Anyone re-entering the space should wear self-contained breathing apparatus operated in a pressure-demand mode.

(j)In the event of any adverse health effects are experienced, cease operations involving halogenated solvents and contact the cognizant medical department representative for additional guidance. Should someone be overcome in a space which lacks oxygen or because of the presence of a high solvent vapor concentration, the person should be removed immediately and given artificial respiration if necessary.

WARNING:

SOME HALOGENATED SOLVENTS CAN CAUSE CARDIAC SENSITIZATION. THE

ATTENDING PHYSICIAN MUST BE INFORMED OF THE HALOGENATED SOLVENT

IN-USE. ADMINISTERING AN INJECTION OF EPINEPHRINE OR SIMILAR

HEART STIMULANT CAN LEAD TO CARDIAC ARRHYTHMIA, INCLUDING

VENTRICULAR FIBRILLATION IF THE SOLVENT IN-USE CAUSES CARDIAC

SENSITIZATION. REGARDLESS OF THE SOLVENT IN-USE, THE PATIENT

SHOULD BE GIVEN FRESH AIR IMMEDIATELY AND SHOULD NOT BE ALLOWED TO

EXERT HIMSELF OR HERSELF.

(k)When drying with nitrogen, solvent vapors and nitrogen shall be externally vented away from populated areas. If this can not be accomplished, a gas free engineer shall be consulted. It may be necessary to use an oxygen monitor to ensure there is not an excessive dilution of oxygen in the air.

(l)Emergency rescue procedures shall be established, and proficiency documented to ensure that personnel can be safely removed in the event of hazardous exposures.

(m)Halogenated solvents used in contact with Diver Life Support Systems shall be completely drained and the components and piping placed in an oven and/or heated to assure all solvent is volatized and removed before assembly, test and operation. Samples as specified in 5.10.3 are required to confirm removal of all solvent.

4.2.5.3 Disposal. Disposal of NAVSEA approved halogenated solvents shall be in accordance with local, state, and federal regulations. Used or contaminated halogenated solvent should be reclaimed for use by distillation or other appropriate method and inspected as specified in applicable specifications (see 6.3).

4.2.5.4 Compatibility. Appendix B gives the compatibility of NAVSEA approved halogenated solvents with various non-metallic materials. Where specific information is lacking, perform compatibility testing as specified in A.3 of Appendix A.

4.2.5.5 Use of NAVSEA approved halogenated solvents. Follow the instructions provided by the vendor and as directed herein.

4.2.5.6 Water previously used in systems. Halogenated solvents containing chlorine can react with water forming corrosive acids. Systems previously known or believed to contain water or aqueous cleaning solutions shall be purged with nitrogen as specified in 4.5.3. An outlet dew point of a -40oF at atmospheric pressure shall be obtained prior to introducing any halogenated solvent that is known or believed to produce acids in contact with water.

4.3 Other cleaners.

4.3.1 Other cleaners for general applications. Any materially compatible aqueous cleaning solution or cleaning solvent may be used for general applications with local engineering and environmental approval.

Directions for use, safety precautions, disposal and compatibility are the responsibility of the approving activity. For all naval activities, review by the cognizant medical department or industrial hygienist shall be obtained prior to locally approving the use of any aqueous cleaning solution or cleaning solvent other than those specified in 4.2. The selection criteria for approving alternative cleaners is specified in 4.4.

4.3.2 Other final cleaners for critical applications. No aqueous cleaning solution other than TSP solutions, or MIL-DTL-24800 compositions, shall be used as a final cleaner. Use of pre-cleaners shall be as specified in 4.3.1. Other than NAVSEA approved halogenated solvents specified in Appendix B, approval shall be obtained prior to using any cleaning solvent as a final cleaner (see 6.3). Activities interested in obtaining approval of other final cleaning solvents or processes shall obtain direction (see 6.3).

4.4 Other cleaner selection criteria. The selection of a cleaner for precleaning of critical applications or cleaning of general applications shall consist of an evaluation of each requirement specified in Table II. Failure to complete the evaluation as specified in Table II can result in component damage or personal injury.

4.4.1 Cleaning performance. The cleaner shall be tested to verify acceptable cleaning performance with target soil, substrates and processes.

Examples of test methods to determine cleaning performance by soaking, using ultrasonic tanks or by pipe flushing are in MIL-DTL-24800.

TABLE II. Testing requirements for other cleaners.

Requirement Paragraph

Cleaning performance 4.4.1

Health and safety 4.4.2

Material compatibility 4.4.3

Disposal 4.4.4

Process application 4.4.5

Cleaner quality 4.4.6

4.4.2 Health and safety. Data on the cleaner, including the Material Safety Data Sheet (MSDS) shall be reviewed by cognizant health and safety personnel to determine the following:

(a)Flammability of the cleaner to include flash point, and upper and lower explosion limits if applicable. The fire hazard resulting from leaving the cleaner in a system shall be evaluated and mitigated.

(b)Toxicity of the cleaner to the worker. Vendors should have either tested the cleaner or reviewed each constituent of the cleaner with an acceptable toxicology data base such as Registry of Toxic Effects of Chemicals (RTECs). Activities are cautioned that biodegradability is not a measure of toxicity, and should never be substituted as such.