UIPI 5050-903.pdf

UNIFORM INDUSTRIAL PROCESS INSTRUCTION (UIPI)

FOR OFFICIAL USE ONLY

TITLE: CLEANING MARINE GROWTH FROM A

COMPONENT OR SYSTEM USING

AUTHORIZED DESCALING AGENT (ADA)

NO. 5050-903D CH-1

CANCELS 5050-903D

ISSUE DATE 4/28/17

SECTIONS

TYPE B

SHIP CLASS CODE SURFACE/SUB/MTS

I EQUIPMENT SHIP SYSTEM SEAWATER SYSTEMS

II MATERIAL TSD

III OSH/ENVR KEY SHOP

IV QA ASSIST SHOPS

V TRAINING/SKILL

VI METHOD ORIGINATOR

VII FEEDBACK SHIPYARD PHNSY & IMF

CODE 260.1

STANDARD DISTRIBUTION PREPARED BY K. Siaki SEA 04XE SEA 05S PHONE/DSN 808-473-8000 x2581 SEA 04XB SEA 04M3(SHAPEC) E-MAIL kristinakate.siaki@navy.mil

SEA 04XP SEA 07T

SEA 04XQ SRF Yokosuka, C/240.1 APPROVAL

SEA 04R FKP7(C/240)

SEA 04RP FKP8(C/200) Dawn Yoshida 4/28/17

SEA 08X FKP26 (C/200, C/300) CHIEF ENGINEER

NRRO Portsmouth, Groton, Newport News Shipbuilding Newport News, Norfolk, Eric Garcia for (Email) 6/29/2016 Puget Sound, Pearl General Dynamics EB C/2300 CONCURRENCE N-CNR N/A NSRO Portsmouth, Oceaneering Pearl, Puget, Norfolk International/CLT Traci Hanlon (Email) 5/2/2016 Copy to: BPMI C/900 CONCURRENCE

NAVSEA Concurrence Jerrod Tamashiro (Email) 7/6/2016

C/106 CONCURRENCE

/S/ Chris C. Paquette 3/24/17 NAVSEA 05 CONCURRENCE Daniel Yamane 7/7/2016

C/130 CONCURRENCE

/S/ Todd A. Walters 4/18/17 NAVSEA 04X1 CONCURRENCE Cliff Imamura (Email) 7/6/2016

C/260 CONCURRENCE

DISTRIBUTION STATEMENT D: Distribution authorized to DoD and DoD contractors only; Administrative or Operational use. Other U.S. requests shall be referred to PHNSY & IMF.

THIS TYPE “B” INSTRUCTION IS A STANDING INSTRUCTION FOR A PROCESS THAT QUALIFIED PERSONNEL ARE EXPECTED TO KNOW AND PERFORM. TYPE B INSTRUCTIONS SHALL BE CITED IN THE GENERAL REQUIREMENTS

SECTION OF THE TECHNICAL WORK DOCUMENT (TWD).

PERIODIC REVIEW: THIS INSTRUCTION SHALL BE REVIEWED EVERY 2 Year

Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility 667 Safeguard St. Ste 100

JBPHH, HI 96860-5033

NAVAL SEA SYSTEMS COMMAND

Pearl Harbor Naval Shipyard &

Intermediate Maintenance Facility

C H

-1

UNIFORM INDUSTRIAL PROCESS INSTRUCTION 5050-903D CH 1

UIPI CHANGE NOTICE TRANSMITTAL

Instruction No. 5050-903 Rev. D CH 1

Title: CLEANING MARINE GROWTH FROM A COMPONENT OR SYSTEM USING AUTHORIZED

DESCALING AGENT (ADA)

1. Purpose: NAVSEA 05 has reported that SSN 688 shallow depth gages in the Depth Sensing system have slow tracking while the submarine surfaces. NAVSEA 05 requests to chemically clean the system. This change includes the procedure to chemically acid clean the Depth Sensing System for all U.S. Navy submarines, provides the materials needed, safety gear required, and the equipment. This change also updates the cognizant owner of this UIPI to Pearl Harbor Naval Shipyard C260.1.

2. Description of Changes:

a. Sheet ii: Added Enclosure (9) to the list of Enclosures.

b. Sheet VI-17: Added paragraph 6.14.4 to annotate that the Depth Sensing System may be cleaned per Enclosure (9).

c. Added new Enclosure (9) “Depth Sensing System Chemical Cleaning Procedure.”

3. Note: Significant changes are identified by blue text, margin bars and “CH-1” in the outside margins.

4. Action: This is an integrated change. Replace previous issue of this UIPI (Rev. D) with this new Revision D Change 1.

5. Concurrence: Off-Yard concurrences and dates received (for Revision D Change 1 only):

PHNSY concurrence signatures and dates (for Revision D Change 1 only):

ORIGINATOR CODE DATE

/S/ Kristina Siaki 260.1B(KS) 4/25/17

SUPERVISOR CODE DATE

/S/ A. McNally 260.1B 4/26/17

CONCURRENCE CODE DATE

/S/ B. Kuanoni for 260 4/26/17

CONCURRENCE CODE DATE

/S/ D. Yoshida 240 4/28/17

6. Concurrence: Off-Yard concurrences and dates received (for Revision D Change 1 only):

CORPORATE CONCURRENCES

NNSY /s/ Mark Everett DATE 11/16/16

PNSY /s/ David Cynewski DATE 1/06/17

PSNSY & IMF/s/ Michael S. Barry DATE 3/3/17 i

Table of Contents

SECTION PARAGRAPH TITLE PAGE

Table of Contents ........................................................... i List of Figures ................................................................ ii List of Forms .................................................................. ii List of Tables .................................................................. ii References ..................................................................... iii

PURPOSE/SCOPE

GENERAL NOTES

DEFINITIONS

I 1. EQUIPMENT .................................................................... I-1

II 2. MATERIALS .................................................................... II-1

2.1 ADA ............................................................................... II-1

2.2 Neutralizer ..................................................................... II-1

2.3 pH Sampling ................................................................... II-1

2.4 Filters ............................................................................. II-1

2.5 Zinc Anodes and Replacement Items ............................. II-1

2.6 Collection Equipment ..................................................... II-1

2.7 Temporary Hoses .......................................................... II-1

III 3. OCCUPATIONAL SAFETY & HEALTH (OSH), AND

ENVIRONMENTAL PROTECTION

III-1

IV 4. QUALITY ASSURANCE .................................................. IV-1

V 5. TRAINING/SKILLS .......................................................... V-1

5.1 Required Competencies ................................................ V-1

5.2 Security Clearance Requirements ................................. V-1

VI 6. METHODS ....................................................................... VI-1

6.1 WARNING Notices ......................................................... VI-1

6.2 System Check ................................................................ VI-3

6.3 Air Groom ...................................................................... VI-6

6.4 Water Pressure Check ................................................... VI-6

6.5 Clean Water Check ........................................................ VI-6

6.6 pH .................................................................................. VI-8

6.7 Chemical Soak & Flush Cleaning .................................. VI-8

6.8 Draining and Managing Chemical Solution .................... VI-9

6.9 System & Component Rinsing ....................................... VI-9

6.10 Transferring Chemical and Rinse Solution to Waste

Tank

VI-10

6.11 System & Component Restoration ................................. VI-12

6.12 Passivation of Cleaned Piping & Components ............... VI-14

UNIFORM INDUSTRIAL PROCESS INSTRUCTION 5050-903D CH-1

ii

SECTION PARAGRAPH TITLE PAGE

6.13 Soak Tank Process Cleaning Of Portable Components VI-15

6.14 Special Procedures ........................................................ VI-16

6.15 Flow Charts .................................................................... VI-18

6.15.1 In-Line Flush .................................................................. VI-18

6.15.2 Dip Tank ........................................................................ VI-21

VII 7. FEEDBACK ..................................................................... VII-1

ENCLOSURE

1 Authorization of Chemical Cleaning

2 Procedure For Cleaning Verdigris And Scale From AHP System Valve Body In-Place, When Valve Is Disassembled

3 Procedure For Cleaning Individual Heat Exchanger Tubes On R- 114 Plant, In Assistance Of “Goodway” type Brush Cleaning, When Both Ends Of Tubes Are Accessible

4 Plumbing System Chemical Cleaning Procedure

5 Unplugging Tubes Individually Using Small Pump

6 GOTAR Product Chemical Flush Procedures

7 Clearing Tubes Individually Using Small Pump or No Pump

8 ADA Manufacturer Qualification Process

9 Depth Sensing System Chemical Cleaning Procedure

List of Figures

FIGURE TITLE PAGE

I-1 Basic Authorized Descaling Agent (ADA) Equipment Diagram Applicable to Single Components and Small Systems

I-1

I-2 Pierside ADA System Wide Use ................................................ I-3

VI-1 Schematic of Flush Fluid Removal System. ................................ VI-11

List of Forms

FORM TITLE PAGE

1 UIPI FEEDBACK RECORD ....................................................... VII-2

List of Tables

TABLE TITLE PAGE

II-1 List of Approved ADA ........................................................ II-2

1, 2, 3 Deleted

C iii

REFERENCES

(a) NAVSEA Technical Manual 389-0317, “PROCEDURES FOR MAINTENANCE AND

REPAIR OF NAVAL REACTOR PLANTS”

(b) NAVSEA S9254-AX-MMA-020 R1 Nov 2009 Inspection of Steam Condensers in Nuclear Surface Ships and Submarines and Reboilers in Nuclear Surface Ships.

(c) OPNAVINST 5100.23G Ch-1 of 21 July 2011, Navy Safety and Occupational Health Program

(d) NAVSEA S9531-BH-MMI-01 Rev 2 of 15 May 2009, Heat Exchanger Repair of Heat Exchangers, Coolers, and Distilling Plants

(e) Naval Ships Technical Manual (NSTM) S9086-HY-STM-010/CH-254 R5, of 1 Sep 2012; Condensers, Heat Exchangers, and Air Ejectors

(f) NAVSEA DWG 516-6828103; PSNS Type Misc. Seawater System Chemical Flush Equipment Arrangement & Installation

(g) NAVSEA 0905-485-6010; Manual for the Control of Test and Ship’s Conditions

(h) 33CFR154 of 2012-07-01, Facilities Transferring Oil or Hazardous Material in Bulk.

(i) OPNAVINST 5090.1D 1/10/2014; Environmental Readiness Program Manual

(j) 33CFR156 of 2012-07-01, Oil and Hazardous Material Transfer Operations.

(k) 29CFR1915.1200 of 2012-07-01, Hazard Communication

(l) 29CFR1915.152 of 2012-07-01, Personal Protective Equipment, General Requirements

(m) NAVSEA TL855-AA-STD-010, Revision 3, ACN-1 of Apr 2011; Naval Shipyard Quality Program Manual (QPM)

(n) Uniform Industrial Process Instruction 0505-908B CH-1, “LEVEL II AND III

CLEANLINESS FOR PIPING SYSTEMS/EQUIPMENT.”

(o) Naval Surface Warfare Center, Carderock Division, “PROCEDURE FOR ON SITE

DESCALING OF HEAT EXCHANGERS AND DISTILLING PLANTS ON

SURFACE SHIPS”, of 14 MAY 2001.

(p) NAVSEA S6470-AA-SAF-010 Rev 04; Naval Maritime Confined Space Program

(q) NAVSEA 0924-062-0010 Rev C Ch-5; Submarine Safety (SUBSAFE) Requirements Manual

(r) Uniform Industrial Process Instruction 0900-111D, “Re-entry Control (REC) Process”

(s) NAVSEAINST T9074-AT-GIB-010/2032 R2 of 31 Jan 2012; Eddy Current Inspection of Heat Exchanger Tubing on Ships of the United States Navy.

(t) Naval Ships Technical Manual (NSTM) S9086-HY-STM-010/CH-516 R5 of 30 May 2005; Refrigeration Systems

NOTE. Latest revision of referenced documents shall be used unless otherwise specified in the applicable Technical Work Document (TWD).

PURPOSE/SCOPE

This process is for chemical cleaning of copper-nickel alloy seawater systems and/or titanium components (see restrictions Enclosure (1)) on all Navy vessels. This process is applicable to the removal of shells and low temperature scale (calcium carbonate and magnesium hydroxide). Chemical cleanings are not intended for the removal of mud, sand, or plant growth. This process may be used at foreign shipyards if personnel are properly trained and local environmental regulations followed. This Instruction is dual-use, for both nuclear and non-nuclear applications.

Precaution: Authorized Descaling Agent (ADA) testing has shown that hydrochloric based ADAs have produced crevice corrosion in Inconel 625. Testing did not include several other high strength, high nickel alloys such as Hastalloy 276 and Alloy

20. Hydrochloric based ADAs shall only be used in systems where Inconel 625 components are replaced or approval is obtained via departure. It is the responsibility of the flushing activity to have a thorough knowledge of all fluid system and component parts wetted during flushing, prior to the flush.

Precaution: ADA testing has shown that failure to remove all zinc anodes prior to flushing can initialize stress corrosion cracking of K-monel fasteners. See specific flushing requirements for K-monel fasteners and zinc removal, paragraph 6.2.1.d.

Note: Modification of this procedure is not allowed without specific approval from shipyard design authority. A departure from specification is required to document modification or deviation from this UIPI or ADA usage requirements.

A submarine system/component may be chemically cleaned up to three times without further NAVSEA specific approval; surface ship flushes are limited by NAVSEA letters shown in Enclosure (1) (See exceptions below). See GENERAL NOTES, paragraph C for tracking information. Obtain heat exchanger performance data from the NAVSEA Performance Monitoring Team (PMT) when deciding whether to chemically flush the system or component.

Enclosure (1) provides a list of systems and components on nuclear vessels that are authorized by NAVSEA for chemical cleaning. Systems and components on nuclear vessels that are not in Enclosure (1) must be approved by NAVSEA before chemical cleaning is performed.

Reference (a) takes precedence over this UIPI where any conflicts exist. Chemical flushes that involve nuclear-cognizant heat exchangers require local cognizant nuclear engineering department approval.

This process is warranted for system flushing when significant fouling exists such that the cost of cleaning the system and/or components by other methods is greater than performing this process. This process is warranted for individual components if the cost of other cleaning methods is greater than the cost of performing this procedure, or the effectiveness of this procedure is greater than that of other cleaning methods.

ADAs are used for the chemical removal of marine growth and scale from surfaces of pipes, tubes, and other components. Do not use an ADA unless the post-flush waste streams are registered with the local environmental authority.

Certain materials may not be flushed by ADAs identified in Table II-1, and other materials as shown must be removed or else inspected following the flush.

While most heat exchangers and systems use copper nickel alloys, newer classes of materials are being developed and implemented in the fleet. For these materials, phosphoric acid based chemical was demonstrated by the Naval Research Lab, in Report 6130/8006 dated 22 FEB 2006, to be less corrosive to Inconel 625 than hydrochloric acid based chemical. Therefore the following guidelines apply for selecting the ADA for each application:

1. A facility intending to flush heat exchangers and associated piping systems and valves with hydrochloric acid based chemical shall identify materials in the system that are not compatible as identified in Table II-1, and demonstrate either through lab testing or through other evidence that the flush solution will not damage these materials by pitting or crevice corrosion. Otherwise, a phosphoric acid based chemical shall be used.

2. Individual heat exchangers which are of a material other than copper-nickel may be flushed using hydrochloric acid based chemical providing the facility can show that there is negligible galvanic or crevice corrosion risk.

Otherwise, a phosphoric acid based chemical shall be used.

3. K-monel fasteners are to be removed before flushing or else replaced after the flush. Fasteners that are welded in will be thoroughly rinsed with fresh water following the flush and inspected for cracks.

ADA, mixing and neutralization ratios, and flushing procedures used shall be per references provided by NAVSEA, which shall control specific manufacturer’s instructions.

WARNING. DO NOT COMBINE TWO OR MORE ADAS FOR ANY FLUSH PROCEDURE

UNLESS SPECIFICALLY AUTHORIZED BY NAVSEA.

WARNING. Monel waterboxes, which are on submarine 688, 726, and MTS class main condensers, and R-114 waterboxes on 726 Classes, have a solder coating on the interior wetted surfaces that contains lead. Do not open the condenser or allow personnel to enter inside the waterbox until appropriate lead controls are in place in accordance with reference (b) Chapter B10, or reference

(c) Chapter 21. Be sure to implement local OSHE requirements prior to entering the water boxes to ensure appropriate safety, PPE, ventilation, and environmental controls are addressed.

This instruction provides the equipment selection criteria, use, acceptance criteria, safety, and disposal methods for ADAs.

GENERAL NOTES

A. Use of ADAs is limited to shipyards, contractors, and depot level activities experienced in performing chemical cleaning operations for the removal of scale from fouled heat exchangers, coolers, and other seawater components.

B. Deleted.

C. Pearl Harbor Naval Shipyard and Intermediate Maintenance Facility (PHNSY&IMF) is required to track all carrier and submarine chemical flushes that use this UIPI for authorization. Contact Code 260.1 (808-473-8000 X2581) prior to chemical cleaning seawater systems or components, and to report the results following the flush. See paragraph 6.11.1.4, and Enclosure (4) paragraph #14, and Enclosure (9) paragraph #12 for specific details to report.

D. ADAs can be used for component or system flushes onboard ship, or as a circulating flush or tank dip in shop. See the conditions and limitations in General Note L.

E. ADAs will dissolve the calcium in bio fouling and scale buildup. They will not dissolve certain sea plants or fibrous material. However, since much of the insoluble material is anchored to the pipe with calcium-based cement, these items may be released from the pipe wall surface to drift through the system during the flush and rinses.

F. ADAs will effectively remove marine growth and scale, when the following steps are included in the procedure:

a. A circulation path must be established so the flow of liquid will dissolve and remove adherent scale and exposed particles of marine growth, and will penetrate and soften the scale and particles during soaking.

b. In general, the temperature range of the flush should be between 50 and 120 degrees Fahrenheit (°F). If the temperature approaches 120 °F, cool the solution with cooling coils or other method until the chemical cleaning is complete. For Air Conditioning Plants, consult NSTM Chapter 516, reference

(t) for the maximum flushing fluid temperature.

G. ADAs have advantages over conventional methods such as rotary brush and hydro-blast wand since:

a. The component or system to be cleaned does not need to be disassembled.

In some cases the inlet and discharge zinc inspection ports on heat exchangers may be used for the flush path, thus eliminating the removal of lagging, spool pieces, or other joints. O-rings, gaskets, ball seats, and other non-metallic parts in the chemical flow path should be replaced to the maximum extent practical after contact with the ADA. Per reference (a), for heat exchangers employing zinc anode plugs or manway/hand-hole covers, it

C is a firm requirement that the O-rings associated with that design aspect shall be replaced.

b. The system or component will usually be clean within a few hours. Additional time is required for rinsing and cleanup. When the flow rate of the ADA pump is not enough to provide rapid volume change, the calcium-based scale, shells, and other growth will be dissolved leaving behind a visible amount of sea grass and other soft debris. Depending on the quantity, this debris is typically removed when the ship’s pumps are activated.

H. ADAs may be used in a dip tank or “parts washer” configuration, to clean portable components such as small heat exchangers, valves, or other components. Refer to reference (d) for additional specifications regarding tank and procedure.

I. Material Limitations: ADAs are formulated using phosphoric acid or hydrochloric acid, which react differently with each type of material being flushed. Refer to Table II-1 for material compatibility of each ADA. This process removes the protective oxide layer from copper alloy surfaces, and passivation is required to restore this protective layer.

See reference (e) for additional information on passivation.

J. Each activity shall add locally developed waste management plans. Prior to the commencement of any work, environmental issues shall be addressed and a plan established to ensure compliance.

K. Per 40 CFR Part 1700.32, Uniform National Discharge Standards for Vessels of the Armed Forces - Phase II Batch One, Seawater Piping Biofouling Prevention, for all vessels, except submarines, the discharge of any fouling organisms removed during cleaning is prohibited.

L. Chemical cleaning of non-reactor plant systems or components affecting nuclear plant operations requires cognizant nuclear code concurrence.

M. This process will not remove deposits from tubes or pipes completely blocked with scale and/or sand. A path through the scale and/or sand must be created to allow ADA to flow through the tube/pipe. See Section VI and Enclosures (2), (3), (4), (5) and (9).

N. ADA will not remove high temperature scale (calcium sulfate) formed by improper operation of heat exchangers at temperatures over 200 °F. If the scale does not dissolve in the approved ADA using this procedure, contact NSWCCD Code 615 or PHNSY&IMF Code 260.1 for guidance. A good source of help 24/7/365 is Global Distance Support Center www.anchordesk.navy.mil .

O. Any heat exchanger suspected of having a leak (e.g., tube leak or tube-to-tube sheet leak) shall be hydro tested prior to flushing, to establish whether a leak exists.

P. If this process is used to clean reactor plant components, the date of cleaning and the specific ADA used shall be recorded in each of the affected component’s material history. Additionally, a report of the cleaning results shall be forwarded to the

C

C http://www.anchordesk.navy.mil/ appropriate cognizant technical agency and NAVSEA for information. See reference (a) for the requirements which apply to reactor plant components.

Q. Enclosures (2) through (7), and (9) document special flush procedures which may be used for applications in which the standard method of Section VI is not practical.

R. Large volume heat exchangers, of more than one thousand gallons capacity in head and tube volume, may be less expensive to clean mechanically than with chemicals.

The large volumes in the heads require a greater quantity of chemical than is needed to clean the tubes, requiring expensive post-flush treatment as liquid hazardous waste.

Also, heat exchangers that are scheduled to be open for inspection, or for other purposes, may also be less expensive to mechanically clean, since tubes are readily accessible and inspections can be more thorough.

S. Fixed or portable containment must be provided per 33 CFR 154.530 at hose manifolds and under each temporary hose connection that will be coupled or uncoupled as part of the transfer operation.

T. For facility transfers of hazardous material to or from a vessel, where the vessel has a total capacity, from a combination of all bulk products carried of 10,500 gallons or more (e.g., Naval submarine), the requirements of 33 CFR 154 and 156 apply.

Requirements to transfer include but are not limited to, Person in Charge (PIC) trained personnel, Declaration of Inspection (DOI), pre-transfer brief, certified hoses with proper markings and fittings, discharge containment, communications, and adequate lighting.

DEFINITIONS

Authorized Descaling Agent

(ADA)

Chemical cleaning compounds authorized by NAVSEA for cleaning seawater heat exchangers and other piping and components.

Dead-leg Piping A portion of a system through which the flow of a gas or liquid cannot be accomplished without cutting or removing a pipe or component.

Hazardous Material Any material or substance that because of its quantity, concentration, physical or chemical characteristics, or if improperly handled (or disposed of), can be damaging to human health or the environment.

Hazardous Waste Any waste that exhibits certain hazardous characteristics such as ignitability, corrosivity, reactivity, or toxicity.

Personal Protective Equipment

(PPE)

A device or item worn, used, or put in place for the safety or protection of an individual or the

C public at large, when performing work assignments in or entering hazardous areas or under hazardous conditions. Equipment includes hearing protection, respirators, electrical matting, barricades, traffic cones, lights, safety lines, life jackets, etc.

pH A symbol for the degree of acidity or alkalinity of a solution. It is the logarithm of the reciprocal of the hydrogen-ion concentration in gram equivalents per liter of solution. pH values from 0 to 7 indicate acidity and from 7 to 14 indicate alkalinity.

Soaking A liquid fill with either no forced circulation or a forced flow of insufficient velocity to cause turbulence in liquid being circulated.

Departure A formal document to NAVSEA detailing a condition of flushing that occurred during the flush which was not in agreement with the UIPI or Flush Procedure.

Submarine Material Control List

(SMCL)

Part of the Nuclear Powered Submarine Atmosphere Control Manual S9510-AB-ATM- 010 (U) whose primary purpose is to identify materials and their inherent hazards that may affect the atmosphere of the submarine while in a closed boat condition. Products are off-gas tested to determine what, if any, hazards may be created, and then assigned a usage category basically indicating, when, where, and how much of the product may be used onboard.

Technical Work Document

(TWD)

Documents that provide technical direction to production Shops or Codes to accomplish authorized work.

I-1

SECTION I

1. EQUIPMENT

1.1 The basic equipment for cleaning a single component or small system consists of a pump, mix tank, temporary flush rig valves (preferably ball valves), relief valve, connecting tubing, and adapters, as shown in Figure I-1. Additional equipment may include a filter, vent and drain tubing, shell-side tubing, and bottles for detecting leaks in heat exchangers, cofferdams, etc.

In

Out

Temporary Compartment

Exhaust Ventilation

Condenser Or Other Component

Or System To Be Cleaned

Tank (Open

V-1

V-3

V-2

To Waste Tank

Transfer Pump

Circulating Pump

V-1 Pump Discharge Valve

V-2 Tank Recirculation Valve

V-3 Pump Suction Valve

V-4 Relief Valve

Figure I-1. Basic Authorized Descaling Agent (ADA) Equipment Diagram Applicable to Single Components and Small Systems

FRESH

WATER

SOURCE

Air Gap

Totalizer

V-4

I-2

1.1.1 List of Recommended equipment. Refer to reference (f), or other applicable NAVSEA drawings, for approved equipment and arrangement. Size and capacity of equipment may vary where applicable.

a. Circulation Pump: One or more primary pump(s) and at least one backup pump (installed in system or staged ready for installation) to ensure a means for removing cleaning/flushing fluids should a main pump fail. If there is more than one primary pump, one can serve as the backup pump. Pumps must be acid-resistant. The pump and cleaning system shall be sized such that flow rates through the components to be cleaned shall provide at least one change of component volume during each circulation period and not exceed design flow rate. The number of Circulation and backup Circulation pumps required is determined by flow rates and pressures necessary to achieve desired cleaning.

b. Transfer or Utility Pump: This pump is used to transfer flush fluid from the chemical mix and rinse tanks to the waste tank for fluid processing. It must be sized to overcome water head and friction losses associated with fluid movement from chemical and rinse tanks to the waste tank.

c. Circulation Hoses: clear, acid-resistant, reinforced plastic, size 1”, 1-¼”, 1-½”, or larger. Hoses shall be sized for each flush based on flushing flow rates, pressures, and fluid volume. (Per reference (f) or equal)

d. Valves: Globe, ball, butterfly and relief valves shall be acid-resistant. Relief valves shall be acid-resistant, sufficient to relieve pump capacity, and set below system/component maximum pressure rating. Relief valve hoses shall be connected back to the mix tank, to contain hazardous material or waste.

e. Tank(s): Acid-resistant, vented, no aluminum fittings, and with lifting and/or forklift capability for moving tank(s). Semi-clear poly material is preferred tank material. Tanks shall be either double walled or have a means of secondary containment if the tank is located outside the skin of the ship (i.e., pier side, topside, on a barge)

f. Air hose with air regulator.

g. In-line flow totalizer meter or other component to measure the volume of water needed to fill the system.

h. Tank(s) should be open for addition of the cleaning product, and for inspecting the flush progress. It should contain enough volume to keep the pump from cavitating before adjustments can be made to the system. If possible, tank(s) shall have clear or translucent sides or a tank fluid level indicator.

I-3

1.2 Cleaning entire systems or very large components, shipboard or in shop, may require additional flushing rig valves or manifolds to handle the larger volumes of fresh and spent chemical, and rinse water. See Figures I-1 and I-2 for items in the flushing loop.

1.3 Equipment set-up. The equipment may be staged above or below the component to be cleaned. Precautions must be taken to ensure the ADA will be contained in the event of hose, tubing or piping rupture or disconnection. The pump must also have the capacity to pump to the height required by the set-up. A source of fresh water is required. To prevent an unrestricted flow of fluid to the environment, ensure that tank vent terminates at a safe level above the system high point or that the tank will hold more volume than the volume of the flush fluid in the component. A vacuum breaker fitting or valve assembly installed in the vent hose line will also prevent a vacuum from forming in the component or system.

Figure I-2. Pierside ADA System Wide Use

Pier

Fresh

Water

System Vent Open

Tank

(Vented) Drain Pump

Ship

System

I-4

1.4 Hoses leading from vent and drain fittings of the heat exchanger to collection bottles, collection manifold, or mix tank, will provide additional flow paths and will avoid “dead legs”. Plastic or rubber tubing should also be used in the circulation path. Hoses shall be per General Note 3.01 of reference (f). Hose tubing must be attached to “barbed” type connectors/fittings secured with hydraulically or manually tightened bands or other vendor specified configuration. Hose tubing passing through submarine hatches must be removed in an emergency. Install valves on the section of hose tubing before and after the hatch to allow for a quick disconnect. For submarines, ensure the requirements of reference (g) are followed for hoses going through water tight hatches and doors.

1.5 If required, remove relief valves and/or ships gages from the installed system and blank the tubing ends. Ensure circulation following the flush will dilute and remove any area of concentration from the “dead-end piping” leading to the relief valves, gages, or other components.

1.6 Wherever practical, provide a filter for use in removing insoluble debris from the system. The filter must consist of acid resistant material. Attach the filter to the inlet of the mix tank, or to any convenient location in the flush path. The filter should be easily removable, to clean or replace during the initial cycles of the flush. The size of the filter will be determined by the size of the component to be flushed.

1.7 SOAK TANK or “DIP TANK” method: The basic equipment to clean portable components in shop consists of a tank large enough to soak and cover the component, a tank to rinse and neutralize the component, and equipment to rinse and spray off the component following neutralizing rinse. See reference (d) for additional guidance if needed. The tanks should be made of a translucent material and consist of acid-proof materials, which will not leach out or contaminate the cleaning solution, or cause plating to occur on the components to be cleaned. Additional refinements for a dip tank would include a small circulation pump and hose for convenient flow control.

II-1

SECTION II

2. MATERIAL

NOTE. Refer to reference (f), or other applicable NAVSEA drawing, for approved system materials applicable to component and system flushes.

2.1 ADA. Authorized Descaling Agents shall be approved by NAVSEA prior to listing in Table II-1. See reference (a) for nuclear cognizant components which can be chemically cleaned. Petitions to include other chemical cleaning compounds on the ADA list products shall be directed per Enclosure (8).

2.1.1 Mixing and concentration directions are per ADA manufacturers recommendations, as controlled by NAVSEA instructions or else in this UIPI.

2.1.1.1 For GOTAR ADA mix solution per Enclosure (6).

2.2 Neutralizer. Shall be available for spill cleanup and neutralizing any ADA if warranted.

2.2.1 Baking soda (sodium bicarbonate), laboratory grade or better, NSN 6810- 002411143 (or other). If Baking soda is used, it should be provided in a maximum proportion of one pound per 25 gallons of rinse water. Applicable to all ADAs.

2.2.2 Soda ash (sodium carbonate), laboratory grade or better, NSN 6810-002628567 (or other). If soda ash is used, it should be provided in a maximum proportion of one pound per 50 gallons. Applicable to all ADAs.

2.3 pH Sampling. Litmus paper, calibrated pH meter, or other method capable of measuring 0 to 12 pH should be staged on hand for reading the pH of the ADA or rinse water solution. Note: pH meter reading becomes erratic at a pH near 0. Be sure to have a standard pH strip ready to back up readings taken with meter.

2.4 Filters. Acid resistant filters are important for removing visible debris from the flushing fluid.

2.5 Zinc Anodes and Replaceable Items. Remove zinc anodes before ADA flush, and replace zinc anodes and access cover gaskets/o-rings as directed by TWD or other document. Remove K-monel fasteners per requirements of paragraph 6.1.1.1.

2.6 Collection Equipment. Barrels, tanks, or other collection equipment used to collect ADA solution and rinse water must be provided and comply with the requirements of local safety and environmental reference.

2.7 Temporary Hoses. Temporary hoses used in flushing shall meet the requirements of reference (h), applicable NAVSEA drawings, and local hose instruction, as applicable. Each hose shall have a separate label plate with the words “Chemical Hose UIPI 5050-903”. Do not use these hoses with other fluids or flushing processes.

Each hose shall have marked, or refer to a facility hose record, the maximum working pressure, Date of manufacture, and Date of the latest hydro test required by 33 CFR

II-2

156.170, and on the hose, “HAZMAT SERVICE, SEE FLUSH PROCEDURE”. The hose shall only be used to support a flush procedure.

2.8 Small Discharge Containment. General Note: Fixed or portable containment must be provided per 33 CFR 154.530 at hose manifolds and under each temporary hose connection that will be coupled or uncoupled as part of the transfer operation.

2.9 Sulfide Test Kit. Provide a test kit, such as CHEMetrics Hydrogen Sulfide CHEMets Kit K-9510, to the chemistry laboratory, or provide sufficient lead time for the chemistry laboratory to obtain this test kit or to setup sulfide test method

2.10 General Information for Transfer of Hazardous Material Over Water.

General Note: For facility transfers of hazardous material to or from a vessel, where the vessel has a total capacity, from a combination of all bulk products carried of 10,500 gallons or more (e.g., Naval submarine), the requirements of 33 CFR 154 and 156 apply. Requirements to transfer include but are not limited to, Person in Charge (PIC) trained personnel, Declaration of Inspection (DOI), pre-transfer brief, certified hoses with proper markings and fittings, discharge containment, communications, and adequate lighting.

2.11 General information for testing hose for underwater service. Each transfer system must not leak under static liquid pressure at least 11/2 times the maximum allowable working pressure, per 33 CFR 156.170 (a)(4).

II-3

Table II-1 List of Approved ADA.

See notes at bottom of Table for restrictions regarding specific authorizations.

PRODUCT

(Manufacturer’s Telephone No.)

Compatible Materials for flushing

NSN QUANTITY

SAFE-D-SCALE

(888-337-2253)

Group 6850-01-465-9251 5 gal. Jug 6850-01-465-9246 55 gal. Drum 275-gal. Tote

RYDLYME

(800-451-6291)

Group 6850-01-457-8789 5 gal. Jug 6850-01-457-8790 55 gal. Drum 330-gal. Tote

GOTAR-D/

GOTAR DC*

(877-994-6827)

Group 6850-01-550-6520 5 gal. Jug 6850-01-550-6529 55 gal. Drum 6850-01-550-6524 275 gal. Tote

DYNAMIC DESCALER

(817-447-9898)

Group 6850-01-549-3959 5 gal. Jug 6850-01-549-3960 55 gal. Drum 6850-01-549-3964 275 gal. Tote

* UNITOR Descaling Liquid # (800-424-9300)

Group

* Marine Grade Blow Out #

(757-625-3200 EXT 117)

Group

ScaleBreak (800-333-7467)

Group 5 gal. Jug

55 gal. drum

330 gal. tote

FREE FLO 34 Group 6850-01-509-0819 5 gal. Jug 6850-01-509-0820 55 gal. drum 6850-01-509-0815 275 gal Tote

PIPE RENEW 950 #

(757-606-1840)

Group

5 gal. Jug

55 gal. drum

275 gal Tote

PIPE RENEW HCL #

(757-606-1840)

Group

5 gal. Jug

30 gal. Carboy

55 gal. Drum

SUBLIME #

(866-525-3615)

Group 5 gal. Jug

30 gal. Carboy

55 gal. Drum

Group : Hydrochloric Acid based ADA is compatible with these materials: Cu, CuNi, NiCu, Brz, Ti, Fe, soft goods (gaskets, seals, o-rings, etc.) found in heat exchangers and systems.

Group : Phosphoric Acid based ADA is compatible with these materials: Cu, CuNi, NiCu, Brz, Ti, Inconel 625, Stainless 316, Fe, soft goods (gaskets, seals, o-rings, etc.) found in heat exchangers and systems.

*Authorized Descaling Agent is in concentrated form. Use is limited to experienced chemical cleaning Contractor and Shipyard personnel.

# Not approved for nuclear cognizant component/system, including main/turbine condenser use unless authorized by Ref (a) or NAVSEA 08 letter.

III-1

SECTION III

3. OCCUPATIONAL SAFETY, HEALTH, AND ENVIRONMENTAL PROTECTION

3.1 All local, state, and federal Occupational Safety and Health (OSH) and Environmental Protection rules and regulations shall be complied with per references (c) and (i). OSHE requirements for the local activity apply. Handling and disposal of liquid waste and Water Pollution Prevention Plan shall be per local instruction of “Hazardous Waste Management Plan”, “Water Pollution Prevention and Control Plan”, “Liquid Waste, Shipboard (Non-Radioactive), Sample & Dispose”. Manage all waste (PPE/excess hazardous materials (determined to be waste)/cleaning solutions/rinse water/filters/etc.) generated by this UIPI in accordance with Federal, State and local laws, rules, regulations, and the applicable facilities waste management plans (i.e. Solid Waste, PCB, Hazardous Waste). Hazardous waste generated by this process shall be minimized to the maximum extent possible per local instruction, “Hazardous Material Control and Management Program”.

3.1.1 The Technical Work Document (TWD) shall identify specific OSH requirements applicable to the job, such as location of eyewash stations, deluge shower, Personal Protective Equipment (PPE), etc.

3.1.2 Insure that OSH requirements are known prior to starting the job. These requirements must be complied with throughout the job.

3.1.3 Follow local facility oil and hazardous material handling operations manual per references (h) and (j). Note that flush operations over water require special training and responsibility per references (h) paragraph 154.500, Hose assemblies; and (j), paragraphs 156.120, Requirements for transfer; 156.125, Discharge cleanup; 156.130, Connection; 156.160, Supervision by person in charge; 156.170 Equipment tests and inspections.

3.1.4 Work per this instruction may require entry into a confined space or poorly ventilated space. Prior to entering any confined or poorly ventilated space obtain a “Safe For Entry” certificate from a Navy competent person.

3.2 Hazardous Material and Hazard Communication. Before working with hazardous material, the material must be approved for use at the installation via the Hazardous Material Authorized Use List (AUL) per local instruction “Hazardous Material Control and Management Program”. Workers shall receive hazard communication training. Workers shall be given a hazardous material brief (presented by their supervisor) before using hazardous material, which shall include at a minimum, review and discussion of the Material Safety Data Sheet (MSDS)/Safety Data Sheet (SDS).

MSDSs/SDSs are available from the manufacturer or from the local facility hazardous materials coordinator. Hazardous material briefing must be documented and records

C

III-2

maintained for five years, per reference (c) Chapter 7, Hazardous Material Control and Management (HMC&M), and reference (k).

3.3 All facilities are required to manage their waste and designate it in accordance with reference (i). Each facility shall have an environmental/waste management plan.

3.4 No special medical qualifications are required to perform work per this instruction. However, if employees show unusual sensitivity to cleaners or detergents used, they shall be provided adequate personal protective equipment to protect them from these substances or not be allowed to perform work bringing them in contact with the substances. However, for submarine main seawater system flushing, an industrial hygienist is required to assess, and coordinate if necessary any special worker lead safety requirements or medical surveillance in connection with post-flush work within the MSW system.

3.5 WARNING: Monel water boxes, which are on submarine main condensers of the SSN 688, SSBN/SSGN 726, and MTS classes, have a solder coating on the interior wetted surfaces that contains lead. Do not open the condenser or allow personnel to enter inside the water box until appropriate lead controls are in place in accordance with reference (b) Chapter B10, or reference (c) Chapter 21. To ensure appropriate safety, PPE, ventilation, and environmental requirements are addressed, implement local OSHE requirements prior to opening condensers or allowing personnel to enter the water box.

3.6 Personal Protective Equipment (PPE). PPE is not a desired substitute for administrative or engineering controls. Employer shall provide employees performing the process or those who will be affected by the process with appropriate PPE and ensure that employees are trained on how and when to use it. See 3.1.1. Reference (l) applies.

3.7 Environmental Requirements. Per 40 CFR Part 1700.32, Uniform National Discharge Standards for Vessels of the Armed Forces - Phase II Batch One, Seawater Piping Biofouling Prevention, for all vessels, except submarines, the discharge of any fouling organisms removed during cleaning is prohibited. Contact the Contracting Office’s (or department) Environmental Coordinator prior to performing any work that is expected to generate Hazardous Waste (HW) Hazardous Waste (HW) containing corrosives and heavy metals. This is required to determine the appropriate containers to manage waste, labeling requirements, area the work will be performed in, and proper posting requirements. Store materials and manage all waste per local facility requirements. Label the waste as

“Used cleaning solution , UIPI 5050-903”

Or

“1 st rinse solution pH = ___, UIPI 5050-903”, etc.

C

III-3

Ensure containers are kept closed and secured at all times except when adding waste.

Upon completion of packaging, the Environmental Coordinator must notify Code 106 or environmental department.

NOTE. Environmental disposal and/or processing costs can be reduced by ensuring cleaning flush waste and subsequent rinses are segregated.

3.8 Minimize usage of hazardous material and the generation of hazardous waste through engineering and work process methods in order to accomplish Pollution Prevention (P2) in accordance with reference (i). A 2nd or 3rd rinse volume may be reused when mixing up the next initial ADA flush, and a used chemical flush effluent solution may be reused in combination with additional flush solution, or in place of, if the acid strength is acceptable. This is generally determined by chemical laboratory analysis.

3.9 Equipment installation shall be accomplished to ensure any leakage is contained, per local, state, and federal requirements. This should be accomplished by using containments at piping joints and cofferdams/secondary containment under process tanks, waste collection containers, and pumps. Nothing shall be discharged to storm drains, sewer systems, dry dock drains, or the harbor unless prior approval has been obtained from the local Environmental Department. Fixed or portable containment must be provided per 33 CFR 154.530 at hose manifolds and under each temporary hose connection that will be coupled or uncoupled as part of the transfer operation.

3.10 In the event of a spill the requirements of local oil and hazardous substance, including lead, if present, spill contingency plan shall be followed.

3.11 When a facility performs work on heat exchangers that have water boxes coated with lead-tin solder it will follow local OSHE instructions to manage flushing and post-flushing processes; and to properly dispose of lead-containing residue or debris.

IV-1

SECTION IV

4. QUALITY ASSURANCE

4.1 Per reference (m), the Shipyard Commander or other facility commanding officer is charged with the overall responsibility for quality and is responsible to define and document the quality policy including the quality objectives and the shipyard’s commitment to quality. The quality policy must be understood and implemented at all levels of the shipyard.

4.2 Video (i.e. boroscope) and observe piping and components to be cleaned as much as practicable prior to the chemical cleaning, to determine extent and severity of fouling. Also look for deteriorated pipe wall or valve internals.

4.3 Report inoperative or leaking valves, flanges, plugged drain lines, or other problems to Ship’s Force or facility engineering department for evaluation and resolution.

4.4 Monitor telltale drains in tube sheet voids and secondary (shell side) systems during the cleaning, for high salinity concentrations, which would indicate leakage from the seawater system. Where shipboard systems are secured and salinity cells are off-line (such as for component flushes), an alternate method shall be used for detection of leakage. The alternate leak detection method may include visual inspections. Refer to paragraph 6.7.3 for additional requirements for submarine RPFW or PPFW coolers.

4.5 Surfaces flushed by ADAs shall meet or exceed the cleanliness requirements of reference (n), or applicable system cleanliness requirements as specified by the cognizant technical code. Seawater systems and components are Level III Clean per reference (n). Notify Project Trouble Desk if grease, oil, or other materials are not being removed by flushing.

4.6 Verify cleanliness of the component or system following the cleaning, by visually observing the pipe wall surface, and interior sections of other components, if accessible.

If Eddy Current Testing (ET) will be accomplished after cleaning, dummy ET probes inserted into the straight section length of each tube will indicate satisfactory cleaning and clearance of obstructions. If tasked, use a ball-type air flow meter supplied by low-pressure air, in a “puff test” to reveal blockages or restrictions in both straight and curved tube sections. CAUTION: Do not allow air pressure to exceed component operating pressure. If tubes blocked by sea fouling cannot be cleared by chemical and/or mechanical means, refer to reference (b) for additional information regarding blocked tubes.

4.6.1 Measure (when tasked) heat exchanger tubes for signs of thinning, pitting or other damage by using borescope, eddy-current probe, or other method. See paragraph 6.11.1.3.

C

IV-2

4.6.2 Tightness test the component to prove whether leakage is occurring through the tubes or tube sheets (when tasked). See paragraph 6.4.

4.7 As soon as components or systems cleaned using ADAs are wetted with seawater, they must be rinsed with clean seawater for a minimum of 21 days to restore a passive layer. See section 6.12 for additional information regarding passivation procedures and requirements.

V-1

SECTION V

5. TRAINING/SKILLS

5.1 Required Competencies. Personnel who work to this UIPI will be able to perform the following minimum competencies:

Be familiar with the basic equipment for cleaning a single component or system.

Determine the use and handling of cleaning fluid by reviewing the MSDS/SDS and the Product Specifications provided by the manufacturer.

Discuss procedures to obtain and interpret pH readings using litmus paper, calibrated pH meter, or other method.

Understand and follow a written cleaning test procedure.

Discuss the PPE and precautions to be used when working or coming in contact with cleaning fluid.

Discuss waste management requirements for all waste generated by this process.

5.2 Security Clearance Requirements. ADA cleaning personnel assigned to work in machinery spaces or other restricted areas of nuclear powered ships shall have applicable security clearance for the specific area they are working.

VI-1

SECTION VI

6. METHOD

Legend: CL - Chemical Laboratory; EPD – Engineering & Planning Department; PMT - NAVSEA Performance Monitoring Team PTD – Project Trouble Desk; SF – Ship’s Force; QPP – Qualified Project Personnel

PARAGRAPH

SHOP/CODE

or TSD

PROCEDURE

6.1 All WARNING Notices. Reference (o).

6.1.1 Hydrogen or other gases may be present in the steam side or seawater side of a heat exchanger, particularly if the unit has been idle and secured for a considerable time. No open flame or spark causing equipment should be brought near a newly opened heat exchanger. For large heat exchangers, personnel shall not be allowed to enter until it has been thoroughly ventilated and declared safe by a Navy competent person. The Navy Competent Person should perform tests, using a combustible gas indicator and a hydrogen sulfide detector. These tests and equipment are described in reference (p). Users of these detection devices are cautioned to observe instructions supplied with each device. The improper use of any detection device could be damaging to material and fatal to personnel.

6.1.1.1 The Naval Research Lab Report 6130/8006 dated

09/01/2005 details negligible change in tensile strength following exposure to hydrochloric or phosphoric acid for…