7488748_B.doc

H-01 (HOLD UP)

ASSOCIATED MARK-UP WORK INSTRUCTIONS

IDENTIFYING FLUSHING PATHS PENDING

RECEIPT FROM NASSCO PRODUCTION DEPT.

H-02 (HOLD UP)

DETAILS OF FLUSHING REQ’TS FOR FM 200 SYSTEM PENDING SYSTEM DESIGN DEVELOPMENT

H-03 (HOLD-UP)

BOW THRUSTER L.O. SYSTEM (DIAGRAM 7128) FLUSHING MEDIA & CLEANLINESS CRITERIA PENDING VENDOR GUIDANCE.

ABS

DISTRIBUTION STATEMENT C - DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; (CRITICAL). OTHER REQUESTS FOR THIS DOCUMENT WILL BE REFERRED TO COMNAVSEASYSCOM (PMS 325).

WARNING - THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SEC. 2751 ET. SEQ.) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED (TITLE 50, U.S.C., APP. 2401, ET. SEQ.). VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATION IN ACCORDANCE WITH PROVISIONS OF OPNAVINST 5510.161.

DESTRUCTION NOTICE - FOR UNCLASSIFIED, LIMITED DOCUMENTS, DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT.

A GENERAL DYNAMICS COMPANY

2798 HARBOR DRIVE

SAN DIEGO, CA 92113

DRAWN:

C. Chen

DRY CARGO / AMMUNITION SHIP

T-AKE 1 CLASS

CHECKED:

M.R. Brooks

FLUSHING CRITERIA AND GUIDELINES

APPROVED:

K.M. Scott

DATE:

12/18/02

APPROVED

SUPSHIP, SAN DIEGO

REVISION SHEET

REVISION SHEET

Aviation F-44 Systems- comments section to include hand wiping of Aviation Fuel Storage Tank. Change incorporated via ECN E-01.

REVISION SHEET

TABLE OF CONTENTS

ITEM NO.

ITEM NO.

APPENDIX A - TURBULENT FLUSH CRITERIA

APPENDIX B – FME-MAN 48/60 ENGINE FLUSH CLEANLINESS CRITERIA

APPENDIX C – CATERPILLAR EDG FLUSH CLEANLINESS CRITERIA

APPENDIX D – YORK MARINE AB FLUSHING PROCEDURE

SYSTEM SPECIFIC NOTES

1. The body of this document follows in the tabular form, sorted on System Diagram Number for those systems requiring flushing.

2. The enclosed document provides suggested general guidance and cleanliness criteria for flushing and flowrates to achieve turbulent flow for hydraulic, fuel, lube and diesel oil systems. An associated system work instruction providing specific flushing loops is provided in the Livelink files, which is co-located in Livelink with this document.

3. Low flow volume or dead spots shall be minimized to the extent practicable during a system flush. Dead ended system lines shall be flushed .

4. Normally flush medium is specified except where safer, compatible or less expensive mediums are permissible. Lubricating/hydraulic system mediums are specified in Drwg. 471-342-4970 “List of Lubricants”.

5. No flush setup shall exceed a systems test pressure.

6. No flush setup shall exceed temperature restrictions shown on the system diagram. Heating shall only occur where internal preservation removal requires it, where reduction in flush medium’s viscosity is needed or where internal fluid friction heat is developed.

7. Components that have been purchased and certified clean shall be bypassed.

8. Components such as heat exchangers, control valves, regulating valves, orifices, solenoids and other equipment having in-line mechanisms capable of trapping or affected by carry-over of foreign matter shall be jumpered or removed to ensure that debris does not damage or become lodged during the flush, unless protected by a suitable strainer.

9. Mechanical vibrators shall be used judiciously as determined by flush supervisor and generally employed only for the lube oil systems.

10. For systems requiring only blow down, clean yard compressed air shall be applied. Prior to application, air hose shall be blown-out to remove any condensation accumulation.

11. Where ship's tanks are included in the flushing circuit, the tanks shall be opened and cleaned before and after flushing.

12. All muslim bags referred to in this document shall be nylon mesh type, 150 micron filtration, for all locations where used unless where otherwise specified.

13. After a flush is completed, system strainers shall be inspected to ensure no debris remains in the flushing loop.

14. The maximum permissible water content for hydraulic oil is 0.05% and for fuel oil is 0.2%.

15. Source of turbulent flow criteria specified in Appendix A charts is derived from SupShip San Diego Reference 224, “Flushing of Repaired, New or Disturbed Piping Sections” Rev. E, dated 28 May, 1992.

ITEM

No.

Temp

water Static head for water

ITEM

No.

Temp

Systems using seawater from the firemain may be flushed during this operation.

ITEM

Temp

distributionpiping

2062 psig actuation piping

Repeat air blowdown for all compartments with FM 200 systems. System nozzles shall not be installed until after all flushing and pressure testing has been completed.

Unobstructed flow until clear discharge is attained.

Install FM 200 nozzles after pressure testing and air blow down is complete. Vendor shall install the nozzles.

ITEM

Temp

Cargo Hold

Sprinkling Systems Diagram

Blow down each segment of the sprinkling grid piping using compressed air.

Repeat air blow down for all compartments with sprinkler systems, removing sprinkler heads during process.

Perform operational flush using system pumps during at sea operational system test.

Unobstructed flow until clear discharge is attained.

Reinstall sprinkler heads after air blow down is complete.

ITEM

Temp

LO Fill, Transfer & Purif.

System

43.5 psig

Purification 185(F

Transfer

226(F

Purification

Use temporary flush rig. Use flushing loop recommendations shown on the corresponding work instruction.

Cleanliness criteria is NAS Class 10.

Upon completion of flush, all piping and components are to be completely drained of all flushing oil including any intermediate low points in the piping, unless system oil is being reused.

Tanks shall be hand wiped with lintless cloth.

ITEM

Temp

con’t

43.5 psig

Purif.

185(F

Transfer

226(F

Purif.

Fill system with oil and circulate the heated oil through the system piping. Piping on the purifier skid should be bypassed.

After completion of inspection and manual cleaning, all inspection and cleanout covers will be reinstalled.

ITEM

Temp

(preheated to 40-50(C) or as an alternative SAE 20 oil may be used for flush

If SAE 20 is used, system must be fully drained after flush.

Use flush rig for main diesel generator engine supply and return piping (flush at minimum flowrate of 162 gpm based on flush with SAE 20 oil at 160(F), turbocharger run down tank and turbocharger outlet piping. Upon completion of flush, remove temporary flush equipment and reconnect piping.

Fairbanks Morse Guidance (Operating Media Systems Flushing and Cleaning) for Lube Oil, are contained in Appendix ‘B’.

NAS Class 10

Lube oil piping should be pickled prior to installation.

Note that the Main Engine L.O. service pumps are built into the engine and therefore can not be used for initial flush due to potential internal damage to the engine.

Final on board main engine lube oil system flush shall be called out w/ Fairbanks Morse present.

ITEM

Temp

water

Flush piping to equipment located in:

· HV Equipment Room

· EOS

· AMR

· Propulsion Motor Room.

ITEM

Temp

water.

Prior to initial operation of the engine, system (including engine) is to be flushed with freshwater. See Appendix B for cleaning procedure.

Main DG engine need not be bypassed if normal system strainer at inlet to each engine is fitted.

Following the flushing operation, flush system with plain freshwater.

ITEM

Temp

Seawater Cooling System Diagram

33.4 psig

(Sea suction/ discharge)

Line up two of the three SW pumps to take suction from the high and low seachests. Verify suction piping from main suction strainers to pumps is visually free of debris.

Unobstructed flow.

ITEM

Temp

Bilge System Diagram (Machinery Space)

water

ITEM

Temp

(Vent piping)

Blow down with compressed air.

Unobstructed flow.

ITEM

Temp

479 psig @ compressor discharge

Use air from the air compressor to blow piping clear prior to running through engine, bypassing the Diesel Engines, Turning gear.

Blow out piping using ships starting air compressors.

Upon completion of blow out- restore system.

ITEM

Temp

fitted with filters. Bypass installed pump, fuel recirculating control valve, fuel service tanks and hose reel assembly.

NAS Class 10

ITEM

Temp

38 psig

Fuel fill & transfer piping upstream of standpipe:

200 psig

Fuel purification discharge:

45 psig

Fill lines (port and starboard double hose receiving stations) can be done when loading fuel with strainers prior to tanks to catch contaminants.

Transfer piping can be done with ship’s pumps with nylon (mesh type 150 micron) filters during operational test.

Muslin bags should be installed in transfer pump suction inlets.

Cleanliness criteria is NAS Class 10 for fuel purification system.

For other parts of the system, strainers are visibly free of harmful contaminants.

Purifier piping is considered most critical loop to flush, using flush rig.

ITEM

Temp

116 psi

Follow FME-Man B&W Standard Procedure (Operating Media Systems Flushing and Cleaning) Fuel Delivery System. See Appendix B.

Load fuel prior to operation of engines.

ITEM

Temp

Ballast System

Seawater

72.5 psig

95(F

Operational flush.

Verify suction piping from seachest to pump is visually free of debris.

Aft Ballast Tanks:

Operationally flush seawater through main header and branch piping to the aft ballast tanks. Dewater tanks using temporary pump when flush is complete and clean tanks.

Forward Ballast Piping:

Flush forward ballast piping utilizing system ballast pumps to flush seawater discharge to the ballast tanks. Dewater tanks using temporary pump after flush is complete and clean tanks.

Unobstructed flow, all strainers are visibly free of harmful contaminants

ITEM

Temp

Ship Service and

Control Air

2. Air blowdown

Compressor/Receiver/ Dehydrator Piping:

Blowout drains in piping and receiver until discharge is visibly free of moisture and foreign matter.

Machinery Rooms, Cargo Holds, RAS/FAS Stations, Lines to all decks:

Blow out system mains and branches using dock air in accordance with the detail work instruction.

Unobstructed flow until clear discharge is attained.

Bypass or remove filters and lubricators.

Air blowdown until clear , dry discharge is attained.

ITEM

Temp

(cont.)

Ship Service and

Control Air

(continued)-

Antenna Dry Air System

1. Clean in accordance with MIL-STD-1622B.

2. Before system cleaning, disconnect components subject to damage from cleaning fluids. Where feasible install temporary jumpers to provide circulation through dead ends.

3. Cleaning of the piping system shall be accomplished by the following methods: circulation of hot cleaning solution, filling and soaking dead end portions where circulation is not feasible, or by separate scrubbing or soaking or both, of components which cannot be cleaned by flushing.

Following installation and cleaning of Antenna Dry Air System, purge in accordance with NAVSEA SE-000-00-EIM-110.

ITEM

Temp

(cont.)

Ship Service and

Control Air

(continued)

ITEM

Temp

(cont.)

Ship Service and

Control Air

(continued)

ITEM

Temp

Sludge Collection and Transfer System

for sludge transfer pump discharge, 38 psig for gravity drain piping.

113(F

Gravity drains shall be operationally tested and proven clear with water.

Transfer piping will be tested in service with the sludge transfer pump protected by the installed suction strainer.

Unobstructed flow.

ITEM

Temp

Vents, Sounds & Overflow Diagram

(aviation tank vents) 35 psig

(tank vents)

50 psig

(sea connection) 95(F 95(F

95(F Remove vent screen from vent lines.

Blow down all vent lines on equipment and tanks with air.

Air blow down to verify no obstructions.

ITEM

Temp

Auxiliary SW

Services:

Stern Tube

BowThruster & Incinerator

87 psig

95(F

122(F

Stern Tube :

Operational flush using the firemain system. For initial flush, bypass filters and verify unobstructed flow at flange before the stern tube seal.

After initial flush, flush through system filters to ensure all piping is clear.

Bow Thruster:

Use firemain system to flush through piping to bow thruster motor and thruster converter. Jumper bow thruster motor and thruster converter tying into the flushing water collection system. Overboard discharge piping will be flushed in the normal course of operational testing.

Unobstructed flow. No visible contaminants at the filter.

Unobstructed flow. No visible contaminants at the filter.

Bypass stern tube cavity.

ITEM

Temp

20 (con’t)

Auxiliary SW

Services:

Solid Waste Processng

Solid Waste Processing Room:

Use firemain to flush through piping jumpering around CMU cooling unit and Pulper Assembly to the flushing water collection system. Overboard discharge piping will be flushed in the normal course of operational testing.

ITEM

Temp

Distilled Water Transfer

Water:

(distilled water transfer piping)

Fresh Water:

(fresh water drain tank piping)

99.5 psig

140 psig 113 (F

113 (F

Use system pumps to perform operational flush or flush directly from shore side water main through system.

If flush uses dockside water, drain system at completion of flush.

Unobstructed flow, no harmful contaminants.

ITEM

Temp

Distilling Plant Services

Feed

78 psig

(Sw feed) 38 psig

(distillate line) 113 (F 95 (F Operational flush for seawater feed piping. Isolate entire distilling plant from sw feed system. Use installed pump and discharge to brine overboard piping.

FW soak distillate piping from evaporator discharge to termination of lines in potable and distillate water tanks including Recirculation Brominator piping. Flush from evaporator distillate outlet valve to potable and distillate water tanks using shore side water main. At conclusion of flush, chlorinate distillate piping and tanks to:

100 ppm min in tanks

50 ppm min. in system. After min. concentration is achieved let stand for minimum of 4 hours. Take coliform sample.

No harmful or visible contaminants detected at discharge.

For the distillate piping, the pressure test period will be concurrent with the chlorination soak period.

Chlorination will be performed on the potable water supply piping only, and will not include the distilled water tank supply piping.

ITEM

Temp

A/C Refrigeration & Purge Pumpout System

Ship Stores Refrig. 1 & 2 & Cargo Refrig. & Purge Pumpout System

Relief Valve Discharge

R134A

R404A

Air High:

203 psig

Low:

150 psig

Low:

123.6 psi

High:

438 psi

< 50 psig 125.3(F

105.1(F

59(F

150(F

113(F Flush required- flush interconnecting yard piping with Castrol E 68 oil prior to being connected to the condensing unit or evaporator coils.

After interconnecting piping is flushed and installed, use nitrogen purge to prevent scale and oxidation of copper. Leak check unit and purge with nitrogen. Evacuate system and charge with applicable refrigerant and reclaim same fluid.

Evacuate system again, and recharge system with clean refrigerant.

Air blow down using compressed air.

Verify unobstructed flow.

Shipyard flushing rigs and filters will be used for this flush. Do not use system compressor for oil flush.

No flush is required for the pumpout systems as this all consists of vendor supplied hoses used for temporary hookup when needed.

ITEM

Temp

Hydraulic Piping

Hydraulic oil

ISO 46 Hydraulic oil

36 psig (handpump discharge line) 10 psig (head tank) 1000 psig

113(F

113(F

Bow Thruster Lube Oil:

Use a temporary flush rig to flush head tank supply line. Flush handpump suction and discharge lines.

Personnel Access Door:

Use a temporary flush rig fitted with a 3 micron filter to flush supply and return lines. Upon flush completion drain entire system Reassemble jumpered areas and refill w/ new medium.

ISO 4406

Grade 16/13

ISO 4406

Grade 17/14

During fab. of piping, pickle and oil steel piping. After flush, use 10 mic. or better filter when using new hyd. oil. Before filling system with oil, allow supplier to check system

ITEM

Temp

Hydraulic Piping (con’t):

MIL-H-22072 Hydraulic oil 450 psig

1800 psig 113(F

140(F Quick Closing Valves

Each pipe length shall be hand cleaned, deburred and blown out with dry compressed air before mounting.

Stabilized Glide Slope Indicator System:

Flush supply and return line by disconnecting lines at shutoff valves and forming loop with flush pump.

NA

ISO 4406

Grade

19/16 Flush at minimum flowrate of 9 gpm @ 130(F temperature

ITEM

Temp

100 ppm min in tanks 50 ppm min. in system Flush system through each outlet.

After minimum concentrations is achieved in all legs of system, let stand for a min. of 4 hours. Flush clear with freshwater from tanks – take coliform samples.

ITEM

Temp

Vacuum Sewage & Plumbing Drains System

ITEM

Temp

ITEM

Temp

Oil

Fresh water Fuel:

38 psi

Jacket water:

54 psig

SCAC:

44 psig 120 (F.

215(F Use temporary flush rig and follow Caterpillar EDG flush guidance provided in Appendix C. Use flushing loop recommendations shown on flush work instruction.

Diesel Oil Piping:

Flush diesel oil supply (using T15 hydraulic oil) and return piping from connections to Emergency Diesel Generator Fuel Service Tank.

Fresh Water Cooling Systems:

Disconnect flanged joints and flush piping (including expansion tank piping) with FW hose using dockside water supply.

Cleanliness criteria is NAS Class 10 for diesel oil piping.

No visible contaminants in water piping.

During fabrication of piping, pickle and oil steel piping. Wash piping with suitable solvent and dry thoroughly. No flush required for EDG exhaust. Bypass control valves.

ITEM

Temp

28 (con’t)

Emergency Diesel Generator Services Diagram

Air

Atm.

435 psig 150(F

120(F.

Lube Oil System:

Flush lube oil piping (utilize 15W40 CG-4 lube oil) bypassing the EDG and the Generator.

Start Air System:

Use air from the air compressor and/or flasks to blow piping clear prior to running through engine.

Cleanliness criteria is NAS Class 10 for lube oil piping.

Unobstructed flow. Continue blow out until discharges are visibly free of harmful contaminants.

ITEM

Temp

150 psig

HT CW

100 psig

LT CW

55(F

HT CW

90(F Use installed pumps. Install temporary strainers on suction side of pumps.

Low temperature loop serves the Accommodation and Cargo Space HVAC.

High temperature loop serves the Machinery Space pre-cooling coils.

ITEM

Temp

Cargo Refrigeration Secondary Coolant Circulation System

99.4 psig

Ambient

Follow York Marine AB Installation, Blowing and Flushing Procedure, Appendix D. Procedure calls for air blowdown, pressure test, vacuum suction and fill and flush with Refrig. Secondary Coolant. Temporary flush strainer can be installed in downstream bypass of Defrost pump (referred to as Main Pump No. 3 in York procedure).

Note:

piping referred to as X, Y and H in York procedure correspond to system diagram as follows:

· X: chill piping

· Y: freeze piping

· H: defrost piping

· Constant pressure overflow valves:

ITEM

Temp

30 (con’t)

Cargo Refrigeration Secondary Coolant Circulation System

RA-V-210, RA-V-211

Pneumatic operated stop valve referred to in section 2/e:

RA-V-209.

ITEM

Temp

With fwd foam proportioner isolated, utilize seawater supply from firemain system to flush each segment of the foam piping to Cargo Pump Room Bilge and the forward hose reel stations.

Use countermeasure washdown system to flush flight deck sprinkling piping (see Item 32,Countermeasure Washdown System).

No visible harmful contaminants are detected.

Remove sprinkler nozzles during flush. Complete flush prior to installation of nozzles and operational test of system piping.

ITEM

Temp

Remove actuating and drain lines and blow down with air.

ITEM

Temp

Cargo Hold and Misc. OWT System

water 58 psig

(Bilge, MD designator) 72 psig

(oily waste transfer, OW designator)

ITEM

Temp

200 psig

Pump discharge:

189 psig 113(F

113(F Operational test; use installed pumps. Clean potable water tanks, fill with FW and chlorinate to:

100 ppm min in tanks 50 ppm min. in system Flush system through each outlet.

After minimum concentrations is achieved in all legs of system, let stand for a min. of 4 hours. Flush clear with freshwater from tanks – take coliform samples.

ITEM

Temp

Aviation

F-44 Transfer and Service Systems

148.4 psig

(transfer /purifier outside of tanks)

7.3 psig (transfer /purifier inside of tanks)

55.9 psig

(stripping outside of tanks

7.3 psig

(stripping inside of tanks) 113 (F 113 (F

Aviation Fuel Service Tank and Aviation Fuel Storage Tank to be hand wiped clean.

ITEM

Temp

Gravity fill each cargo oil tank with seawater.

Perform operational flush of system; utilize F-76/F-44 Main Cargo Transfer pumps, flush fill and transfer lines for each tank and recirculate back to same tank by opening Sta. nos. 3, 4, 5A, 7A during flush and jumpering stations together to complete flush loop that returns seawater back to tank via the 200 mm fill lines at Sta. 5A and 7A.

Use temporary pumps to empty seawater from cargo oil tanks when flush is complete.

ITEM

Temp

36 (con’t)

Fresh water

Air 200 psig

87 psig

140 psig 122 F

122 F

122 F Utilize Aux. Cargo F-44 pumps to perform similar operational flush of smaller 65mm Sta. nos.3, 4 ,5 & 6, jumpering stations together and connecting to 65 mm flushing connections at Sta. 3 & 4 leading back to the slop tank.

Use temporary pumps to empty seawater from slop tanks when flush is complete.

Flush cargo oil monitor piping (bypassing CO monitor and pump).

Blowdown CO air piping.

Strainers visibly free of foreign matter

ITEM

Temp

High Pressure

Low Pressure 3200 psig

110 psig 176(F

120(F

1. Piping hydrostatic test

2. Air blowdown

Compressor/Receiver Piping:

Blowout drains in piping and receiver until discharge is visibly free of moisture and foreign matter.

UNREP Ram Tensioner, Accomodation Ladders, Pilot Ladder Reels:

Blow out each air connection. Start at the Auxiliary Machinery Room and blow out through each air connection and drain to the air bank piping, bypassing the air bank charge station assembly.

ITEM

Temp

241 psig

Distilled Water Tank Ppg:

50 psig

Also flush suction piping from distilled water tanks to pump suction.

Section Valve -

Unit should be bypassed during flush.

APPENDIX A

TURBULENT FLUSHING CHARTS

MINIMUM TURBULENT FLOWRATE FOR WATER (GPM)

MINIMUM TURBULENT FLOWRATE FOR ISO 15 HYDRAULIC OIL (GPM)

MINIMUM TURBULENT FLOWRATE FOR ISO 32 HYDRAULIC OIL (GPM)

MINIMUM TURBULENT FLOWRATE FOR ISO 46 HYDRAULIC OIL (GPM)

MINIMUM TURBULENT FLOWRATE FOR SAE 20 HYDRAULIC OIL (GPM)

MINIMUM TURBULENT FLOWRATE FOR SAE 40 HYDRAULIC OIL (GPM)

APPENDIX B

FME-MAN 48/60

ENGINE FLUSHING CLEANLINESS CRITERIA

APPENDIX C

CATERPILLAR EDG FLUSHING CLEANLINESS CRITERIA

APPENDIX D

YORK MARINE AB

BLOWING AND FLUSHING PROCEDURE

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B

B

PAGE

Dry Cargo / Ammunition Ship

T-AKE 1 Class Flushing Criteria and Guidelines

NAVSEA Dwg. No. 505-7488748

NASSCO Dwg. No. 471-342-7138, Rev. B Sheet 2

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