Attachment_11_ABO_Guide.pdf

A6-332AO-GYD-000

1 SEPTEMBER 2007

TECHNICAL MANUAL

LABORATORY AND FIELD GUIDE

AVIATORS BREATHING OXYGEN

(ABO)

SURVEILLANCE PROGRAM

LABORATORY AND FIELD GUIDE

CFA: NAVAL AIR WARFARE CENTER AIRCRAFT DIVISION,LAKEHURST, NJ 08733-5000

THIS PUBLICATION SUPERSEDES A6-332AO-GYD-000, DATED 1 JUNE 1997

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3. PURPOSE OF CHANGE: TO UPDATE THE MANUAL TO PROVIDE THE CORRECT

AMOUNT OF TIMES A YEAR FOR CORRELATION SAMPLES.

4. DETAILED INFORMATION: PEN AND INK CHANGES TO THE TECHNICAL

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A. SECTION V, PAGE 5-1, PARAGRAPH 5-1.2, REMOVE THE FIRST SENTENCE "A

MINIMUM OF FOUR TIMES A YEAR, IDENTICAL

SAMPLES ARE MAILED TO EACH TEST SITE" AND REPLACE WITH "A MINIMUM OF

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GENTEXT/REMARKS/1. INTERIM RAPID ACTION CHANGE (IRAC) NR 02 TO

TECHNICAL MANUAL NAVAIR A6-332AO-GYD-000, AVIATORS BREATHING OXYGEN

(ABO) SURVEILLANCE PROGRAM LABORATORY AND FIELD GUIDE, DATED 1

SEPTEMBER 2007, WAS PREPARED IAW REF A.

2. RESPONSIBLE CODES:

A. IN-SERVICE ENGINEERING: DAVID GUTHRIE, NAVAIR LAKEHURST,

4.8.6.10, COMM: 732-323-1433, DSN: 624-1433, EMAIL:

DAVID.H.GUTHRIE@NAVY.MIL.

B. LOGISTICS: KEVIN MCCARTHY, NAVAIR LAKEHURST NJ, CODE: 6.6.4.9,

COMM: 732-323-2356, DSN: 624-2356, FAX: 732-323-7402, EMAIL:

KEVIN.MCCARTHY2@NAVY.MIL.

3. PURPOSE OF CHANGE: TO UPDATE MANUAL TO PROVIDE CORRECT OXYGEN

PURITY REQUIREMENTS.

4. DETAILED INFORMATION:

A. PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF THE TECHNICAL

MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE

INFORMATION APPLIES TO THE FOLLOWING REFERENCE PAGES AND PARAGRAPHS

OF THE SUBJECT MANUAL UNTIL A FORMAL CHANGE IS RELEASED.

B. SECTION IV, PAGE 4-1, ADD PARAGRAPH 4-2.1.1.1 PERSONNEL MUST

INTERPRET ABO SAMPLES BY PERFORMING ANALYSIS AT A MINIMUM OF EVERY

24 MONTHS TO BE CONSIDERED ACTIVELY INVOLVED WITH ABO ANALYSIS.

PERSONNEL WHO GO BEYOND 24 MONTHS BETWEEN ANALYSIS SHALL COMPLETE

ALL INITIAL CERTIFICATION REQUIREMENTS.

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GENTEXT/REMARKS/1. INTERIM RAPID ACTION CHANGE (IRAC) NR 01 TO

TECHNICAL MANUAL NAVAIR A6‐332AO‐GYD‐000, AVIATORS BREATHING OXYGEN

(ABO) SURVEILLANCE PROGRAM LABORATORY AND FIELD GUIDE, DATED 1

SEPTEMBER 2007, WAS PREPARED IAW REF A.

2. RESPONSIBLE CODE: KATIE WILSON, NAVAIR LAKEHURST NJ, CODE:

6.6.4.9, TEL: 732‐323‐2887, DSN: 624‐2887, FAX: 732‐323‐2897, EMAIL:

KATIE.A.WILSON@NAVY.MIL.

3. PURPOSE OF CHANGE: TO UPDATE MANUAL TO PROVIDE CORRECT OXYGEN

PURITY REQUIREMENTS TO TABLE 2‐1, REVISE SECTION III, PARAGRAPHS

3‐10.2 AND 3‐10.3, AND ADD CORRECT PAGE NUMBERS.

4. DETAILED INFORMATION:

A. PEN AND INK CHANGES TO THE TECHNICAL CONTENT OF THE TECHNICAL

MANUAL ARE NOT AUTHORIZED. THE FOLLOWING TECHNICAL CONTENT CHANGE

INFORMATION APPLIES TO THE FOLLOWING REFERENCE PAGES AND PARAGRAPHS

OF THE SUBJECT MANUAL UNTIL A FORMAL CHANGE IS RELEASED.

B. SECTION II, PAGE 2‐2, TABLE 2‐1: DELETE NOTE 1.

C. SECTION II, PAGE 2‐2, TABLE 2‐1: ADD NOTE 1: "FOR OXYGEN

PRODUCED SHIPBOARD BY THE PSA OR VSA PROCESS, THE MINIMUM OXYGEN

PURITY IS 94 PERCENT (VOLUME). OXYGEN PRODUCED BY LEGACY

DISTILLATION PLANTS, MINIMUM OXYGEN PURITY IS 98 PERCENT (VOLUME)

(SHIPBOARD ONLY). ALL DON LAND BASED OXYGEN SITES ARE REQUIRED TO

MAINTAIN A MINIMUM OXYGEN PURITY LEVEL OF 99.5 PERCENT (VOLUME).

CHANGES ARE AS REQUESTED BY PMA‐202 LTR SER PMA 202/11 DTD 10 MAR

2004 AND ENDORSED BY BUREAU OF MEDICINE AND SURGERY LTR SER

M3F8/O4UM3F07007 DTD 15 APR 2004."

D. SECTION II, PAGE 2‐4: ADD 2‐4 TO THE BOTTOM LEFT CORNER.

E. SECTION III, PAGE 3‐2, PARAGRAPH 3‐10.2, CHANGE PARAGRAPH 3‐10.2

TO READ: "LOCAL MANUFACTURE OF A SERVICE ADAPTER FOR OXYGEN SAMPLING

IS RECOMMENDED TO UTILIZE THE HOKE SAMPLE CYLINDER SUPPLIED WITH

CRYOGENIC SAMPLER, MODEL FCS 2001, P/N 600646. ALL PARTS SHALL BE

CLEANED FOR OXYGEN USE IN ACCORDANCE WITH NAVAIR 06‐30‐501. THE

MATERIAL REQUIRED TO LOCALLY MANUFACTURE THE SERVICE ADAPTER IS AS

FOLLOWS:

QTY (1) COUPLING, TUBE, P/N 4‐HX6‐SS, CAGE CODE 30780.

QTY (1) REDUCER BODY, TUBE, P/N 8‐4TRTXN‐SS, CAGE CODE 30780.

QTY (1) COUPLING, PIPE, P/N 600388A, CAGE CODE 59672."

F. SECTION III, PAGE 3‐2, PARAGRAPH 3‐10.3, CHANGE PARAGRAPH 3‐10.3

TO READ: "GASEOUS OXYGEN SAMPLES SHALL BE TAKEN AT THE TERMINAL END

OF THE SERVICING HOSE IN ACCORDANCE WITH NAVAIR 19‐5‐37. SAMPLES

SHALL BE SUBMITTED TO AN ABO TEST SITE FOR ANALYSIS.

G. SECTION IV, PAGE 4‐2: ADD 4‐2 TO THE BOTTOM LEFT CORNER.

5. VALIDATED BY: PAUL KLEIN, NAVAIR LAKEHURST NJ, CODE: 4.8.6.10,

TEL: 732‐323‐2963.

6. RELATED INSTRUCTIONS:

A. MAINTAIN THIS IRAC WITH THE APPLICABLE TECHNICAL MANUAL BY

PLACING OR ATTACHING IT DIRECTLY BEHIND THE TITLE PAGE. MARK THE

SPECIFIC CHANGE AREA IN THE MARGIN OF EACH PAGE AFFECTED WITH A

VERTICAL LINE, AND INCLUDE THE IRAC NUMBER AND DATE TIME GROUP (DTG)

OF THE IRAC MESSAGE. THIS IRAC SHALL NOT BE REMOVED UNTIL RECEIPT OF

THE FORMAL UPDATE.

B. FOR IRACS AFFECTING MANUALS ON CD‐ROM: AFFIX AN ADHESIVE LABEL

TO THE CD‐ROM CASE, ANNOTATE WITH THE APPLICABLE PUBLICATION NUMBER,

IRAC NUMBER AND DTG OF THE IRAC MESSAGE. THE LABEL SHOULD BE

POSITIONED TO ALLOW FOR ADDITIONAL UPDATES AS THEY OCCUR. MAINTAIN

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C. SUBJECT IRAC SHALL BE INCORPORATED INTO THE APPLICABLE TECHNICAL

MANUAL NO LATER THAN 12 MONTHS AFTER IRAC ISSUE DATE BY NAVAIR CODE

6.6.4.9.//

TPDR-1 (TPDR-2 Blank)

LIST OF TECHNICAL PUBLICATIONS

DEFICIENCY REPORTS INCORPORATED

ACTIVITY/IDENTIFICATION NO. QA SEQUENCE NO. LOCATION.

CSFWP DET AIMD Lemoore / 44321 2005 0140 Section 4, Page 4-1, Para. 4-3.2.1.1

AIMD NAS Keflavik / 44335 2000 0007 Section 2, Table 2-1

MALS 13 MAG 13 3rd MAW / R5708 2006 0110 Section 2, Page 2-5, Para. 2-15.1.2

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TABLE OF CONTENTS

i

Section Page I GENERAL................................................................................................................... 1-1 1-1. Purpose and Scope..................................................................................................... 1-1 1-2. General........................................................................................................................ 1-1 1-3. General Safety Principles............................................................................................. 1-1 1-4. Description and Properties of Oxygen.......................................................................... 1-1 1-5. Physical Properties of Oxygen..................................................................................... 1-1 1-6. Chemical Properties of Oxygen.................................................................................... 1-1 1-7. Production (Generation) of Oxygen.............................................................................. 1-1 1-8. Liquid Oxygen Generating Plants................................................................................. 1-2 1-9. Supply Sources of Oxygen........................................................................................... 1-2 1-10. Contaminants and Contamination of Liquid Oxygen...................................................... 1-2 1-11. Types and Significance of Contaminants in LOX.......................................................... 1-2 1-12. Sources of Increasing Contamination........................................................................... 1-3 1-13. Increasing Concentration Due to Evaporation of LOX................................................... 1-4 1-14. Handling and Transfer Operations................................................................................ 1-4 1-15. Equipment................................................................................................................... 1-4 1-16. Contaminants and Contamination of Gaseous Aviators Breathing

Oxygen 1-4

1-17. Periodic Sample........................................................................................................... 1-4 1-18. Sampling...................................................................................................................... 1-5

II QUALITY CONTROL OF AVIATORS LIQUID BREATHING OXYGEN........................ 2-1 2-1. Introduction................................................................................................................. 2-1 2-2. Scope.......................................................................................................................... 2-1 2-3. Personnel.................................................................................................................... 2-1 2-4. Control of Contamination.............................................................................................. 2-1 2-5. Vaporization................................................................................................................. 2-1 2-6. Equipment................................................................................................................... 2-1 2-7. Handling and Transfer.................................................................................................. 2-1 2-8. Quality Control Requirements of Aviators Liquid Breathing

Oxygen 2-1

2-9. Emergency Conditions……………………………………………………………………... 2-1 2-10. Supply Sources of Aviators Liquid Breathing Oxygen................................................... 2-3 2-11. Sampling and Testing.................................................................................................. 2-3 2-12. On-Base Testing.......................................................................................................... 2-3 2-13. Periodic or Requested Tests for ABO Purity and Contamination

Levels 2-4

2-14. Tests After Incidents Affecting Flying Personnel........................................................... 2-4 2-15. Sampling Requirements............................................................................................... 2-4 2-16. LOX Wash/Purging...................................................................................................... 2-5

TABLE OF CONTENTS - Continued ii

Section Page

III QUALITY CONTROL OF AVIATORS GASEOUS BREATHING OXYGEN................... 3-1

3-1. Introduction..................................................................................................................... 3-1 3-2. Scope………………........................................................................................................ 3-1 3-3. Personnel....................................................................................................................... 3-1 3-4. Quality Control Requirements of Aviators Gaseous Breathing

Oxygen………………… 3-1

3-5. Supply Sources of Aviators Gaseous Breathing Oxygen……….................................... 3-1 3-6. Receipt of Aviators Gaseous Breathing Oxygen from a Contractor…………………….. 3-1 3-7. Periodic or Requested Tests for Purity and Contamination

Levels………… 3-2

3-8. Navy and Marine Corps Operated Generating and Charging Plants............................. 3-2 3-9. Quality Control of Contents of Filled Cylinders............................................................... 3-2 3-10. Gaseous Oxygen Servicing Trailers............................................................................... 3-2

IV ABO TEST SITES 4-1

4-1. Test Site........................................................................................................................ 4-1 4-2. Personnel...................................................................................................................... 4-1 4-3. Responsibilities............................................................................................................. 4-1 4-4. Site Cleanliness and Safety........................................................................................... 4-3

V INSTRUCTIONS FOR ABO CORRELATION PROGRAM........................................... 5-1 5-1. General......................................................................................................................... 5-1 5-2. Sample Testing............................................................................................................. 5-1 5-3. Reporting Format.......................................................................................................... 5-2

LIST OF TABLES

Numbe r

Title Page

1-1. Oxygen Weight-Volume Equivalents.............................................................................. 1-6 2-1. ABO Contamination Limits Maximum Concentration (PPM (v))..................................... 2-2 2-2. Testing and Sampling Equipment................................................................................... 2-3

1- 1

SECTION I

GENERAL

1-1. PURPOSE AND SCOPE.

1-1.1. The purpose of this laboratory manual and field guide is to provide information, guidance, instructions, and procedures for quality control of liquid and gaseous oxygen used for aviators breathing purposes.

1-2. GENERAL.

1-2.1. Aviators Breathing Oxygen (ABO), MIL-PRF-27210, comes in both gaseous (Type I) and liquid (Type II) states. The liquid oxygen (LOX) is converted to a gaseous state prior to its delivery to the aircrew. LOX requires frequent and continuous monitoring to facilitate adequate detection of contamination. A surveillance / correlation program is the primary methodology of ensuring that each operation in the LOX supply system is carried out in strict compliance with established procedures. The surveillance begins with procurement or generation of LOX by Navy and Marine Corps activities located throughout the world, and continues throughout storage, handling, transfer, and servicing of aircraft.

This surveillance / correlation program is further extended to the world wide facilities through coordination with the U.S. Air Force, Aerospace Fuels Laboratory, Wright-Patterson Air Force Base, Dayton, Ohio.

1-3. GENERAL SAFETY PRINCIPLES.

1-3.1. The best assurance of personnel safety lies in the safety education of the people themselves. The safety of personnel can be assured only when there is thorough understanding of potential hazards, the correct procedures and equipment are used, and the equipment is in good working condition. Knowledge of a job situation and appropriate safety equipment is vital to successful completion of the job. Follow established safety procedures in NAVAIR 06-30-501.

1-4. DESCRIPTION AND PROPERTIES OF

OXYGEN.

1-4.1. Oxygen can exist as a solid, liquid or gas, depending upon the temperature and pressure to which it is subjected. At atmospheric pressure, oxygen exists as a solid at temperatures below its melting point, -361°F (-218 °C) and remains in this state until the temperature rises to its boiling point, -297 °F (-183 °C). At this latter temperature, LOX vaporizes into the gaseous state. Conversely, gaseous oxygen will turn liquid at atmospheric pressure by cooling to a temperature below -297 °F. By increasing the pressure, gaseous oxygen can be liquefied at higher temperatures, up to its critical temperature, -182 °F (-119 °C). Oxygen will not condense to a liquid at temperatures above its critical temperature regardless of the pressure applied. The pressure required to liquefy oxygen at its critical temperature is known as its critical pressure, 736.5 psig. The application of high pressure and ultra-low temperatures to convert gases into their liquid state is known as the science and technology of cryogenics. LOX is a cryogenic fluid.

1-5. PHYSICAL PROPERTIES OF OXYGEN.

1-5.1. Gaseous oxygen is colorless, odorless, tasteless and about 1.1 times as heavy as air. LOX is an extremely cold, pale blue fluid, which flows like water. One gallon of LOX weighs 9.519 pounds which is approximately 1.14 times the weight of one gallon of water (see Table 1-1). LOX is stored and handled at atmospheric pressure in well insulated containers which maintain the liquid at its boiling point. Therefore, LOX is boiling as it slowly turns into gaseous oxygen.

As the expanding gas from the boiling liquid increases in amount, it builds up pressure within the container.

Therefore, the expanding gas must be vented to the atmosphere, because confinement is both dangerous and impractical. When the cold and colorless gas is vented to the atmosphere, it produces a fog as it immediately condenses moisture and carbon dioxide in the air.

1-6. CHEMICAL PROPERTIES OF OXYGEN.

1-6.1. Oxygen is a very reactive material, combining with most of the chemical elements. The union of oxygen with another substance is known as oxidation.

Extremely rapid or spontaneous oxidation can lead to combustion of all flammable materials; some to an explosive degree.

1-7. PRODUCTION (GENERATION) OF OXYGEN.

1-7.1. Air, the raw material for the production of oxygen, is principally a mixture of 78.09 percent nitrogen, 20.95 percent oxygen and 0.93 percent argon by volume. The remaining 0.03 percent consists of various gases, vapors and particulate matter in varying concentrations depending upon locality and

1- 2 climatic conditions. Air is compressed and cooled for liquefaction. The LOX in the liquefied air is separated by fractional distillation, whereupon it is withdrawn as a LOX product or passed to a vaporizer for conversion to gaseous oxygen product. The equipment facilities used in producing oxygen are known as LOX generating plants. For in-depth information pertaining to production of oxygen, refer to the Technical Manual of Oxygen/Nitrogen Systems (NAVAIR 06-30-501).

Oxygen can also be produced by employing a Pressure Swing Absorption (PSA) process. A brief description of the PSA process is provided in paragraph 1-8.2.

1-8. LIQUID OXYGEN GENERATING PLANTS.

1-8.1. Most LOX generating plants are of the Fractional Distillation Type. Plants currently deployed by the Marine Corps use the PSA process.

1-8.2. A brief description of the basic steps in the PSA process is as follows:

a. Air from the atmosphere is first filtered to remove particulates before being compressed to approximately 40 psig. The air is then cooled by a heat exchanger.

b. The cooled compressed air is passed through a coalescent filter where water and oil are removed from the compressed air prior to passing through two beds of 13X molecular sieve. The molecular sieve traps the nitrogen molecules and allows the oxygen molecules to pass through. The air is passed through the two beds alternately; while one bed is being pressurized, the other is being depressurized. Depressurizing the bed of molecular sieve releases the trapped nitrogen molecules accumulated during the pressurizing cycle.

c. The oxygen gas passed through the molecular sieve beds is either fed to a compressor for high pressure gaseous oxygen or to a liquefier for liquid oxygen.

1-9. SUPPLY SOURCES OF OXYGEN.

1-9.1. Commercial Plants. Liquid and gaseous oxygen generated at commercial plants for aviators breathing purposes is procured in accordance with the current issue of MIL-PRF-27210.

1-9.2. Government Owned-Government Operated Plants. Liquid oxygen plants which are government owned and government operated, produce liquid and gaseous oxygen for breathing purposes in support of aircraft. Generated liquid and gaseous oxygen must meet the requirements of the current issue of

MIL-PRF-27210.

1-9.3. Liquid and gaseous oxygen produced using the PSA process contains no less than 94.0 percent pure oxygen by volume and meets all other limits established by the current issue of MIL-PRF-27210.

1-10. CONTAMINANTS AND CONTAMINATION OF

LIQUID OXYGEN.

1-10.1. The following discussion on contaminants and contamination applies to aviators liquid breathing oxygen. LOX as produced by generating plants contains contaminants which are not completely removed by the generating process. Atmospheric air, from which LOX is generated, is the primary source of contamination. Additional sources of contamination are the compressors and other equipment of the generating plants. Airborne contaminants and those added by the generating plants are partially removed by a system of filters, absorbers, dryers, and heat exchangers before the air is finally liquefied. When the LOX separates from the liquefied air it carries with it those contaminants which are not completely removed.

The variety and concentration of contaminants which separate with the LOX depend on how effective their removal has been during the generating process.

Generating plants are designed to remove contamination to the lowest limits possible, both for safety of operation and for quality of product. The contamination limits of LOX produced by any generating plant for the Navy or Marine Corps as breathing oxygen are specified as procurement limits.

Procurement limits and the ultimate use limits of contamination are based on the types and significance of contaminants, and the sources of increasing contamination in liquid oxygen during storage, handling and transfer.

1-11. TYPES AND SIGNIFICANCE OF

CONTAMINANTS IN LOX.

1-11.1. Hydrocarbons. These contaminants are present in atmospheric air and are also added by the compressors and other equipment of the generating plant. They are only partially removed by the low temperature hydrocarbon absorption purifiers of the generating plants. Those which separate with the LOX are called light hydrocarbons because they contain four carbon atoms or less, such as methane, acetylene, ethane, ethylene, propane, and butane.

Heavier hydrocarbons are removed to insignificant

1- 3 concentrations in properly operating plants. However, the use of faulty equipment and handling will increase the presence of heavy hydrocarbon contamination in the form of solvents, oils, greases or fumes. The presence of hydrocarbons in LOX constitutes a potential fire and explosion hazard. The hazard increases during storage and handling because all of the common hydrocarbon contaminants are less volatile than LOX and, therefore increase in concentration. If either the solubility limit or the low flammability limit of the hydrocarbon is exceeded, the condition is especially hazardous.

A source of ignition can initiate a reaction if the hydrocarbon is present in sufficient concentration to sustain combustion. Ignition sources can be static electricity, mechanical and fluid friction, particle impact and shock waves introduced by impact. Whenever a hydrocarbon is present in quantities greater than its solubility in liquid oxygen, it separates out of the liquid as a solid. Even the smallest grain of hydrocarbon solid in LOX has the potential of igniting if sufficient energy is present to initiate a reaction. Although one tiny particle may not be dangerous in itself, a collection of such particles could be serious, since ignition may propagate from particle to particle.

Acetylene is especially hazardous in this respect.

Acetylene is the most hazardous hydrocarbon contaminant because it is very insoluble and it can readily be triggered into ignition. Since it is chemically unstable it can decompose under certain conditions and provide its own source of ignition. Hydrocarbon contaminants in LOX create, in addition to their potential fire and explosion hazards, potential psychological and physiological hazards to aircrews when LOX is used for breathing purposes. Depending upon the type and concentrations of hydrocarbons, psychological effects may be uneasiness, apprehension or possible panic resulting from detecting their presence by odor. Physiological effects may be nausea, illness, intoxication or possible asphyxia.

1-11.2. Inert Solids. These contaminants are classified as inert solids because they normally do not react with oxygen to create a fire or explosion hazard, and to distinguish them from hydrocarbons, which become solids when their solubility limits are exceeded. Inert solid contaminants in LOX are hazardous for a number of reasons. First, they may cause mechanical malfunctions or failures. Second, they may cause plugging of filters, lines, injectors, valves, etc. Third, they may accumulate charges of static electricity.

Fourth, impinging particles on system components may possess sufficient energy to initiate a reaction at the point of impact. Inert solids consist of three distinct forms: particulate matter, moisture or carbon dioxide.

1-11.2.1. Particulate Matter. These solids consist of rust, metal fragments, dust and fibers derived from the equipment or the environment of the LOX supply system. These contaminants are solids at normal temperatures as well as at LOX temperature.

Hazards are the same as discussed in paragraph 1-11.2.

1-11.2.2. Moisture. In its liquid or vaporous form, moisture condenses to ice on contact with LOX or with the cold surfaces of equipment. Atmospheric moisture is an ever present source of contamination. Moisture has been identified as the cause of numerous LOX converter explosions due to pressure devices frozen in place.

1-11.2.3. Carbon Dioxide. This contaminant is slightly soluble in LOX, but separates out of LOX as a solid when its solubility limit is exceeded.

1-11.3. Toxic and Odorous Contaminants. The odorous and toxic characteristics of hydrocarbons have already been discussed in paragraph 1-11.1. In addition to the hydrocarbons, there are other contaminants which, if present in aviators liquid breathing oxygen, may also affect the mental and physical well-being of aircrews. In particular, these contaminants are nitrous oxide and halogenated fluorocarbons.

1-11.3.1. Nitrous oxide may present such hazards as those listed above, as well as the inherent danger of co-precipitating with acetylene when both exceed their solubility limits. The co-precipitate thus formed may concentrate at the bottoms of tanks and can detonate.

1-11.3.2. Halogenated compounds (FREONS) present in the sample may indicate refrigerant leaks in the generation plant, may be a residue of equipment cleaning operations, or may have been introduced into the oxygen system at the intake air stream of the generating plant. All halogenated compounds present in the oxygen are treated as refrigerants, regardless of the use of the compound.

1-12. SOURCES OF INCREASING

CONTAMINATION.

1-12.1. The concentration of LOX contaminants increases continuously after it is produced, because non-volatile contaminants are concentrated by the evaporation of LOX. This gradual process of increasing contamination is accelerated if

1- 4 contaminants are introduced during storage, handling and transfer operations. The contamination of LOX is therefore compounded each time LOX is transferred.

Thus, an acceptable concentration of contaminants in liquid oxygen as generated or procured can increase to a point which may threaten the safety or success of the mission. Therefore, procurement and storage limits require a higher degree of quality to allow for increases of contamination during handling. This margin of safety does not provide a margin for error or for unexpected contamination, and personnel should not relax their vigilance in quality control against the ever present sources of increasing contamination of

LOX.

1-13. INCREASING CONCENTRATION DUE TO

EVAPORATION OF LOX.

1-13.1. LOX in storage systems is always boiling and evaporating. Non-volatile contaminants in LOX are always increasing in concentration as the amount of liquid decreases. This ever-present process of increasing contamination is intensified by cool-down vaporization losses associated with liquid transfer operations. Concentration of contaminants will increase in approximate proportions to the amount of LOX loss by vaporization. For example, if a 10 percent vaporization loss occurs, the concentration of contaminants will automatically increase by factor of

1.11. Obviously, repeated losses will increase

contamination to dangerous levels.

1-14. HANDLING AND TRANSFER OPERATIONS.

1-14.1. These operations are a continuing source of increasing contamination by contaminant addition.

The types of contaminants range from dust and dirt to moisture and other atmospheric constituents.

Whenever transfer operations require the connection or disconnection of a transfer line, the opportunity for introducing additional contamination arises. At the time of connection, atmospheric contaminants or dust and dirt may be trapped in a section of the transfer line, which can be carried into the supply system by the flowing liquid. At the time of disconnection, atmospheric contamination may become deposited inside the cold transfer equipment, ready to enter the rest of the system during the next transfer operation.

Field and laboratory experiments have shown that strong convective currents are formed by the density difference between cold oxygen vapors and warm ambient air. As the cold, denser oxygen vapors flow out of the low points of cold transfer equipment, the warm, less dense air flows in at the high points, depositing moisture and other condensables in the form of frost. Both mechanisms of contamination can be controlled by strict adherence to proper procedures. The trapped portion of the atmosphere may be removed by adequate purging before transferring, and condensables may be prevented from entering cold transfer connections by allowing the connections to warm-up before disconnecting.

The making and breaking of transfer connections should be accomplished as quickly as careful handling will permit.

1-15. EQUIPMENT.

1.15.1. The sources of increasing contamination of

LOX from equipment are variable both as to time and origin. Long-term deterioration of mechanical equipment must be expected. The moving parts of valves and pumps will wear and contribute to particulate contamination. Other sources of potential contamination are the solvents and solids which may remain from repair or cleaning operations.

1-16. CONTAMINANTS AND CONTAMINATION OF

GASEOUS AVIATORS BREATHING OXYGEN.

CAUTION

Great care should be exercised in selecting the portion of the sample of the whole, so that it will represent the composition of the sampled storage container. The best analysis can be completely invalidated by poor sampling.

1-16.1. Prior to acceptance by the Government, gaseous aviators breathing oxygen and cylinders are inspected by Government quality assurance representatives to determine compliance with contractual requirements. Tests which are required prior to shipment are performed at the supplier’s facility by supplier personnel under the surveillance of a government representative. Trace contaminants are analyzed at Government test sites at 45-day intervals.

Once the quality of oxygen within a cylinder has been established, that quality will continue so long as a positive pressure is maintained within the cylinder.

Consequently, retesting of the gaseous oxygen at periodic intervals during storage is not necessary.

1-17. PERIODIC SAMPLE.

1-17.1. The periodic sample is required to determine the exact composition of the oxygen at that instant. Its purpose is to provide data that each government generating facility and contractor delivery equipment is capable of supplying a good product and that subsequent operations have not changed the product radically. Small variations from the procurement or

1- 5 use limit are not physiologically critical, but are indicators that demand a return to the originally good product to the originally good product. The LOX periodic sample from station storage tank provides information that the tanks are clean and capable of maintaining the ABO at an acceptable level of quality.

1-18. SAMPLING.

1-18.1. Sampling is required in order to obtain a small portion which is representative of a large quantity, and it is the most important operation in the analysis of oxygen.

1- 6

Table 1-1. Oxygen Weight-Volume Equivalents

MASS LIQUID VOLUME AT BOILING POINT GAS VOLUME AT ONE

ATMOSPHERE AT 70°F

Grams Pounds Liters Gallons Cubic Feet Liters Cubic Feet

1.000 1.112205 0.00087766 0.0002316 0.00003096 0.7540 0.02663

435.6 1.000 0.3976 0.1050 0.01404 342.0 12.08

1141.0 2.515 1.000 0.2642 0.03532 860.11 30.38

4318.0 9.519 3.785 1.000 0.1337 3256.0 115.0

32300.0 71.21 28.32 7.481 1.000 24355.0 860.1

1.326 0.002924 0.001163 0.0003072 0.00004107 1.000 0.035

37.55 0.08280 0.03292 0.008697 0.001163 28.32 1.000

2-1

SECTION II

QUALITY CONTROL OF AVIATORS LIQUID BREATHING OXYGEN

2-1. INTRODUCTION.

2-1.1. Lack of proper quality control of aviators breathing oxygen, can directly cause loss of aircrews, affect civilian lives and property in the path of flight, and impact mission effectiveness. The quality control of this oxygen requires frequent and continuous surveillance. Surveillance begins with base generation or procurement and continues throughout storage, handling, transfer and servicing of the aircraft.

Adequate and reliable quality control of aviators breathing oxygen demands that each operation in the aircraft oxygen supply system must be carried out in strict compliance to ensure flight safety and mission completion.

2-2. SCOPE.

2-2.1. This section establishes procedures and requirements for the quality control of oxygen that is procured, generated, stored, transferred, and used at Naval and Marine Corps Air Stations or aboard aircraft carriers for breathing purposes by aircrews. This section is applicable to all personnel who are responsible for supervising or performing the operations associated with receipt, generation, storage, transferring of, and servicing aircraft with aviators breathing oxygen.

2-3. PERSONNEL.

2-3.1. Personnel selected to perform operations in the oxygen supply system should be trained and have thorough knowledge of the characteristics of all forms of oxygen, the significance of contamination when used for breathing purposes, and the oxygen system to be quality controlled. Only those personnel who demonstrate understanding of the operations involving reliable performance should be assigned duties and responsibilities in the supply of ABO. See paragraph 4-2.1 for training requirements.

2-4. CONTROL OF CONTAMINATION.

2-4.1. A knowledge and understanding of how contaminants are concentrated in LOX and the sources of increasing contamination are essential to the effective control of contamination. (See paragraph 1-10.)

2-5. VAPORIZATION.

2-5.1. The increase in concentration of contaminants in storage tanks due to LOX vaporization cannot be prevented. However, the rate of increasing contamination from this source shall be controlled by minimizing heat additions due to handling and transfer through proficient performance of operations.

2-6. EQUIPMENT.

2-6.1. Addition of contaminants from equipment shall be reduced or prevented by operating and maintaining generators, storage tanks, servicing carts, and aircraft oxygen systems in accordance with applicable technical manuals.

2-7. HANDLING AND TRANSFER.

2-7.1. The addition of contaminants from the environment shall be prevented by careful and proficient handling and transfer operations. LOX strongly attracts and absorbs atmospheric gases, some of which are odorous and which may be present in the atmosphere, due to an environmental source.

2-8. QUALITY CONTROL REQUIREMENTS OF

AVIATORS LIQUID BREATHING OXYGEN.

2-8.1. Procurement Limits. Aviators liquid and gaseous breathing oxygen, whether it is generated by Navy and Marine activities or procured from commercial sources, must meet the purity and contamination requirements as shown in Table 2-1.

2-8.2. Use limits are applicable to receiving /storage tanks, servicing equipment and converters in service shown in Table 2-1.

2-9. EMERGENCY CONDITIONS

2-9.1. The exceptions listed below are for use by local commands in emergency conditions to continue operations until an ABO analyzer is available, or oxygen conforming to specification is available.

2-9.2. Conditions may arise when shipboard or expeditionary units lose the ability to analyze oxygen product that is being produced due to analyzer malfunction. If operations are mandatory, utilization of the generator’s past run sheets is authorized.

2-2

Table 2-1. ABO Contamination Limits Maximum Concentration (PPM (v))

PURITY 99.5% (VOLUME) 1

TYPE I (GASEOUS OXYGEN) TYPE II (LIQUID OXYGEN) 2

Converter Procurement

Limits Use

Limits 3 Procurement/Gen-erated Limits Use Limits

CONSTITUENT

MIL-PRF-27210 MIL-PRF-27210 Storage Tank

Service Tank

Carbon dioxide CO2 20 10 20 5 10 15 Methane CH4 4 100 50 100 25 50 75 Acetylene C2H2 0.2 0.1 0.2 0.05 0.1 0.15 Ethylene C2H4 0.8 0.4 0.8 0.2 0.4 0.6 Higher Hydrocarbons (Ethane equivalent C2+)

10 6 10 3 6 8

Nitrous Oxide N2O 6 4 6 2 4 6 Halogenated Compounds 5 Total Refrigerants (Freons)

4 2 4 1 2 3

Total Solvents 0.4 0.2 0.4 0.1 0.2 0.3 Moisture H2O

(Dew point °F)

Other

(-58)

0.4

(-82)

0.2

0.4

(-82)

0.1

0.2

0.3

NOTES

1 For oxygen produced by the PSA process, the minimum purity is 94.0% (volume). Use of this product is as authorized by Chief of Naval Operations Ltr 505F190595302 dated 25 July 1989.

Aircrew breathing regulators should be properly adjusted before 94.0% pure oxygen is used.

2 LOX shall contain no particles with any dimension larger than 1,000 microns; no fibers (as described in MIL-PRF-27210) longer than 6,000 microns. Total solids shall not exceed 1.0 mg per liter.

3 When sampled out of gas cylinders.

4 For carrier produced LOX, the Use Limit for Methane when sampled at the receiver/storage tank is 75 PPM vice 50 PPM.

5 All FREONS are treated as refrigerants regardless of use.

grichards Text Box

SEE IRAC # 1

2-3

By evaluating historical records from past operations, the length of operation time required to produce oxygen in compliance with Table 2-1 can be determined. Once in production past the time required to produce suitable oxygen, then the product can be discharged to the storage container.

2-9.3. Emergency Use Limits. Following guidance is provided concerning use of ABO under emergency conditions when liquid ABO contains a greater concentration of contaminants than the use limit or has a low purity. Where immediate decision is essential, local commands may use the following guide for making on-site decisions on the use of such oxygen. The risk in usage is minor if nitrous oxide (in the total absence of acetylene), methane, and ethylene, do not exceed three times their respective use limits. For example, if an analysis of LOX from a storage tank indicates that methane contamination is 150 ppm (3 times normal use limits), only minor risk would be involved in its usage in an emergency situation. However, LOX is not recommended for use when any of the following apply: nitrous oxide (in the presence of acetylene at any concentration) exceeds 4 ppm, carbon dioxide exceeds 20 ppm, acetylene exceeds 0.2 ppm, or high hydrocarbons (ethane equivalent) exceed 8 ppm. In the instance that gaseous aviators breathing oxygen is being tested, the following will also apply: Carbon dioxide and moisture may exceed their use limits by three times. It is imperative that the source of excessive contamination be determined and alleviated. Thus, if the LOX sampled at the aircraft converter outlet is found to contain excessive amounts of a particular constituent, not only should the converter be investigated for problems, but so should the service cart, transfer lines used, and any other possible sources until the fault is uncovered and corrected.

2-10. SUPPLY SOURCES OF AVIATORS LIQUID

BREATHING OXYGEN.

2-10.1. Commercial Oxygen Sources. Aviators Breathing Oxygen procured from commercial sources must meet the requirements of the current issue of

MIL-PRF-27210.

2-10.2. Navy and Marine Corps Operated Generating Plants. Aviators liquid breathing oxygen produced by Navy and Marine Corps generating plants must meet the requirements cited in Table 2-1.

2-11. SAMPLING AND TESTING.

2-11.1. Sampling and testing of LOX at specified intervals and points in the supply system provide the continuous monitoring of contamination that is essential to the quality control of ABO. However, if the sample taken does not truly represent its source, then test results cannot serve the intended purpose.

Careful observation of operating instructions for LOX samplers is important to ensure representative samples.

2-12. ON-BASE TESTING.

2-12.1. Navy and Marine Corps Activities which produce liquid oxygen shall sample and test the contents of the generating plant in accordance with paragraph 2-15.1. Receipt of aviators breathing oxygen from a contractor shall also be tested in accordance with this paragraph, and by the following test for particulate matter, before unloading is permitted. Periodic surveillance of storage tanks, servicing trailers and aircraft converter systems shall be made as specified in paragraph 2-15.2 through 2-

15.4. Table 2-2 lists the testing and sampling

equipment required to perform the particulate test.

Table 2-2. Testing and Sampling Equipment.

ITEM

NO.

TYPE/PART

NUMBER

NOMENCLATURE

1 NNN-B-175,

Type 1, 400 ml

Beaker, Laboratory

2 DD-W-131, Class A, Size 7, 100 mm

Watch-Glass, Laboratory

3 UU-P-236, Class 2, Type 1, 5.5 cm disc

Paper, Filter

NOTE

Test for particulate is only required when contamination is suspected.

2-12.1.1. Particulate Test. Approximately 200 milliliters of the sample shall be poured into a clean 400 ml beaker or similar container, without a filter paper in the bottom. A watch-glass cover or some other means of partially covering the top of the beaker shall be used as the 200 milliliters of liquid evaporate to dryness. When the frost on the outside of the beaker has melted, the outside of the beaker shall be wiped with a clean dry cloth and the beaker placed on clean white paper. The interior of the beaker shall be visually examined, without the aid of magnification for the presence of particles.

2-13. PERIODIC OR REQUESTED TESTS FOR

ABO PURITY AND CONTAMINATION LEVELS.

2-13.1. Analytical tests are performed in the continental United States and overseas locations by Navy and Marine Corps ABO Test Sites. Test sites are generally located at the AIMD oxygen shops ashore and afloat, or at the facility oxygen generation site for shore base so equipped. All test sites performing ABO analysis, will participate in the ABO correlation program sponsored by the Aerospace Fuels Laboratory at Wright-Patterson Air Force Base, Dayton, Ohio as a joint program with the Navy. All analysis of ABO will be performed in accordance with prescribed procedures, unless a waiver is granted by NAVAIR Lakehurst Program Manager to use another procedure.

2-14. TESTS AFTER INCIDENTS AFFECTING

FLYING PERSONNEL.

2-14.1. Samples taken after incidents in which flying personnel are affected, and any additional samples deemed necessary by flight safety officer or flight surgeon, will be submitted to the appropriate supporting ABO Test Site.

2-15. SAMPLING REQUIREMENTS.

2-15.1. GENERATING PLANTS. Navy and Marine Corps operated oxygen/nitrogen generating plants shall sample and test the contents of the generator tanks as follows:

2-15.1.1. Sampling Location. Samples shall be taken at the drain valve.

2-15.1.2. Test and Frequencies. Test for constituent contaminants and purity at generator start-up, or if in continuous production, once every 24…