Hot_Oil_FLush_CDRLs.pdf

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DD FORM 1423-1, FEB 2001

CONTRACT DATA REQUIREMENTS LIST

(1 Data Item)

PREVIOUS EDITION MAY BE USED.

Form Approved OMB No. 0704-0188

The public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden, to the Department of Defense, Executive Services Directorate (0704-0188). Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. Please do not return your form to the above organization. Send completed form to the Government Issuing Contracting Officer for the Contract/PR No. listed in Block E.

A. CONTRACT LINE ITEM NO. B. EXHIBIT C. CATEGORY:

TDP ________ TM _______ OTHER

D. SYSTEM/ITEM E. CONTRACT/PR NO. F. CONTRACTOR

1. DATA ITEM NO. 2. TITLE OF DATA ITEM 3. SUBTITLE

4. AUTHORITY (Data Acquisition Document No.) 5. CONTRACT REFERENCE 6. REQUIRING OFFICE

7. DD 250 REQ

8. APP CODE

9. DIST STATEMENT

REQUIRED

10. FREQUENCY

11. AS OF DATE

12. DATE OF FIRST SUBMISSION

13. DATE OF SUBSEQUENT

SUBMISSION

14. DISTRIBUTION

a. ADDRESSEE

b. COPIES

Draft Final

Reg Repro

15. TOTAL

16. REMARKS

17. PRICE GROUP

18. ESTIMATED

TOTAL PRICE

G. PREPARED BY H. DATE I. APPROVED BY J. DATE

Page of Pages

16. REMARKS (Continued)

DD FORM 1423-1, FEB 2001 Page of Pages

INSTRUCTIONS FOR COMPLETING DD FORM 1423

(See DoD 5010.12-M for detailed instructions.)

FOR GOVERNMENT PERSONNEL

Item A. Self-explanatory.

Item B. Self-explanatory.

Item C. Mark (X) appropriate category: TDP - Technical Data Package;

TM - Technical Manual; Other - other category of data, such as "Provisioning,""Configuration Management," etc.

Item D. Enter name of system/item being acquired that data will support.

Item E. Self-explanatory (to be filled in after contract award).

Item F. Self-explanatory (to be filled in after contract award).

Item G. Signature of preparer of CDRL.

Item H. Date CDRL was prepared.

Item I. Signature of CDRL approval authority.

Item J. Date CDRL was approved.

Item 1. See DoD FAR Supplement Subpart 4.71 for proper numbering.

Item 2. Enter title as it appears on data acquisition document cited in Item 4.

Item 3. Enter subtitle of data item for further definition of data item (optional entry).

Item 4. Enter Data Item Description (DID) number, military specification number, or military standard number listed in DoD 5010.12-L (AMSDL), or one-time DID number, that defines data content and format requirements.

Item 5. Enter reference to tasking in contract that generates requirement for the data item (e.g., Statement of Work paragraph number).

Item 6. Enter technical office responsible for ensuring adequacy of the data item.

Item 7. Specify requirement for inspection/acceptance of the data item by the Government.

Item 8. Specify requirement for approval of a draft before preparation of the final data item.

Item 9. For technical data, specify requirement for contractor to mark the appropriate distribution statement on the data (ref. DoDD 5230.24).

Item 10. Specify number of times data items are to be delivered.

Item 11. Specify as-of date of data item, when applicable.

Item 12. Specify when first submittal is required.

Item 13. Specify when subsequent submittals are required, when applicable.

Item 14. Enter addressees and number of draft/final copies to be delivered to each addressee. Explain reproducible copies in Item 16.

Item 15. Enter total number of draft/final copies to be delivered.

Item 16. Use for additional/clarifying information for Items 1 through 15.

Examples are: Tailoring of documents cited in Item 4; Clarification of submittal dates in Items 12 and 13; Explanation of reproducible copies in Item 14.; Desired medium for delivery of the data item.

FOR THE CONTRACTOR

Item 17. Specify appropriate price group from one of the following groups of effort in developing estimated prices for each data item listed on the DD Form 1423.

a. Group I. Definition - Data which is not otherwise essential to the contractor's performance of the primary contracted effort (production, development, testing, and administration) but which is required by DD Form 1423.

Estimated Price - Costs to be included under Group I are those applicable to preparing and assembling the data item in conformance with Government requirements, and the administration and other expenses related to reproducing and delivering such data items to the Government.

b. Group II. Definition - Data which is essential to the performance of the primary contracted effort but the contractor is required to perform additional work to conform to Government requirements with regard to depth of content, format, frequency of submittal, preparation, control, or quality of the data item.

Estimated Price - Costs to be included under Group II are those incurred over and above the cost of the essential data item without conforming to Government requirements, and the administrative and other expenses related to reproducing and delivering such data item to the Government.

c. Group III. Definition - Data which the contractor must develop for his internal use in performance of the primary contracted effort and does not require any substantial change to conform to Government requirements with regard to depth of content, format, frequency of submittal, preparation, control, and quality of the data item.

Estimated Price - Costs to be included under Group III are the administrative and other expenses related to reproducing and

d. Group IV. Definition - Data which is developed by the contractor as part of his normal operating procedures and his effort in supplying these data to the Government is minimal.

Estimated Price - Group IV items should normally be shown on the DD Form 1423 at no cost.

Item 18. For each data item, enter an amount equal to that portion of the total price which is estimated to be attributable to the production or development for the Government of that item of data.

These estimated data prices shall be developed only from those costs which will be incurred as a direct result of the requirement to supply the data, over and above those costs which would otherwise be incurred in performance of the contract if no data were required. The estimated data prices shall not include any amount for rights in data. The Government's right to use the data shall be governed by the pertinent provisions of the contract.

DD FORM 1423-1 (BACK), FEB 2001

data_item: A003 title: CONDITION FOUND REPORT (CFR) sub: UNSATISFACTORY CONDITIONS, PROPOSED REPAIRS, PARTS AND PRICING auth: DI-MGMT-81648 ref: PWS Paragraph 3.8 req_ofc: PSNS and IMF dd250: N/A appcode: N/A dist: D freq: ASREQ asof: See BLK 16 firstsub: ANGEN subsub: See BLK 16 addressee1: PSNS C/400 COR draft1:

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total_draft: 0 total_reg: 1 total_repro: 0 remarks: Block 9: DISTRIBUTION D: Distribution authorized to Department of Defense and US DoD contractors only (administrative or operational use) (As of 7-8-2016) Other requests for this document shall be referred to PSNS and IMF, 1400 Farragut Ave. Bremerton, WA 98314.

Block 11 and 13: Submit CFR within 24 hours of identifying the deficient condition.

Block 12 - Contractor shall deliver an electronic copy of the report to the Contracting Officer's Representative (COR) within one (1) business day of discovery.

group:

total_price:

prep_name: Richard Parker line_item: CLIN 000X exhibit: A xtdp: Off xtm: Off othercat: X system: Diesel Engine Generator Lube Oil Flush ctr_no: N4523A-18-X-XXXX contr: TBD remarksb:

Page2: 2

Reset:

2017-10-12T12:51:38-0700

PARKER.RICHARD.BRETT.1091818619

prep_date: 17OCT12 app_by: Kjiersten McKinney

2017-10-16T06:35:29-0700

MCKINNEY.SUSAN.K.1128778795

app_date: 17OCT16

Page: 1 of_pages: 3 app: Adobe Professional 8.0

DD FORM 1423-1, FEB 2001

PREVIOUS EDITION MAY BE USED.

Form Approved OMB No. 0704-0188

The public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing the burden, to the Department of Defense, Executive Services Directorate (0704-0188). Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently valid OMB control number. Please do not return your form to the above organization. Send completed form to the Government Issuing Contracting Officer for the Contract/PR No. listed in Block E.

1. DATA ITEM NO. 2. TITLE OF DATA ITEM 3. SUBTITLE

4. AUTHORITY (Data Acquisition Document No.) 5. CONTRACT REFERENCE 6. REQUIRING OFFICE

7. DD 250 REQ

8. APP CODE

9. DIST STATEMENT

REQUIRED

10. FREQUENCY

11. AS OF DATE

12. DATE OF FIRST SUBMISSION

13. DATE OF SUBSEQUENT

SUBMISSION

14. DISTRIBUTION

a. ADDRESSEE

b. COPIES

Draft Final

Reg Repro

15. TOTAL

16. REMARKS

17. PRICE GROUP

18. ESTIMATED

TOTAL PRICE

G. PREPARED BY H. DATE I. APPROVED BY J. DATE

Page of Pages

16. REMARKS (Continued)

DD FORM 1423-1, FEB 2001 Page of Pages

INSTRUCTIONS FOR COMPLETING DD FORM 1423

(See DoD 5010.12-M for detailed instructions.)

FOR GOVERNMENT PERSONNEL

Item A. Self-explanatory.

Item B. Self-explanatory.

Item C. Mark (X) appropriate category: TDP - Technical Data Package;

TM - Technical Manual; Other - other category of data, such as "Provisioning,""Configuration Management," etc.

Item D. Enter name of system/item being acquired that data will support.

Item E. Self-explanatory (to be filled in after contract award).

Item F. Self-explanatory (to be filled in after contract award).

Item G. Signature of preparer of CDRL.

Item H. Date CDRL was prepared.

Item I. Signature of CDRL approval authority.

Item J. Date CDRL was approved.

Item 1. See DoD FAR Supplement Subpart 4.71 for proper numbering.

Item 2. Enter title as it appears on data acquisition document cited in Item 4.

Item 3. Enter subtitle of data item for further definition of data item (optional entry).

Item 4. Enter Data Item Description (DID) number, military specification number, or military standard number listed in DoD 5010.12-L (AMSDL), or one-time DID number, that defines data content and format requirements.

Item 5. Enter reference to tasking in contract that generates requirement for the data item (e.g., Statement of Work paragraph number).

Item 6. Enter technical office responsible for ensuring adequacy of the data item.

Item 7. Specify requirement for inspection/acceptance of the data item by the Government.

Item 8. Specify requirement for approval of a draft before preparation of the final data item.

Item 9. For technical data, specify requirement for contractor to mark the appropriate distribution statement on the data (ref. DoDD 5230.24).

Item 10. Specify number of times data items are to be delivered.

Item 11. Specify as-of date of data item, when applicable.

Item 12. Specify when first submittal is required.

Item 13. Specify when subsequent submittals are required, when applicable.

Item 14. Enter addressees and number of draft/final copies to be delivered to each addressee. Explain reproducible copies in Item 16.

Item 15. Enter total number of draft/final copies to be delivered.

Item 16. Use for additional/clarifying information for Items 1 through 15.

Examples are: Tailoring of documents cited in Item 4; Clarification of submittal dates in Items 12 and 13; Explanation of reproducible copies in Item 14.; Desired medium for delivery of the data item.

FOR THE CONTRACTOR

Item 17. Specify appropriate price group from one of the following groups of effort in developing estimated prices for each data item listed on the DD Form 1423.

a. Group I. Definition - Data which is not otherwise essential to the contractor's performance of the primary contracted effort (production, development, testing, and administration) but which is required by DD Form 1423.

Estimated Price - Costs to be included under Group I are those applicable to preparing and assembling the data item in conformance with Government requirements, and the administration and other expenses related to reproducing and delivering such data items to the Government.

b. Group II. Definition - Data which is essential to the performance of the primary contracted effort but the contractor is required to perform additional work to conform to Government requirements with regard to depth of content, format, frequency of submittal, preparation, control, or quality of the data item.

Estimated Price - Costs to be included under Group II are those incurred over and above the cost of the essential data item without conforming to Government requirements, and the administrative and other expenses related to reproducing and

c. Group III. Definition - Data which the contractor must develop for his internal use in performance of the primary contracted effort and does not require any substantial change to conform to Government requirements with regard to depth of content, format, frequency of submittal, preparation, control, and quality of the data item.

Estimated Price - Costs to be included under Group III are the administrative and other expenses related to reproducing and

d. Group IV. Definition - Data which is developed by the contractor as part of his normal operating procedures and his effort in supplying these data to the Government is minimal.

Estimated Price - Group IV items should normally be shown on the DD Form 1423 at no cost.

Item 18. For each data item, enter an amount equal to that portion of the total price which is estimated to be attributable to the production or development for the Government of that item of data.

These estimated data prices shall be developed only from those costs which will be incurred as a direct result of the requirement to supply the data, over and above those costs which would otherwise be incurred in performance of the contract if no data were required. The estimated data prices shall not include any amount for rights in data. The Government's right to use the data shall be governed by the pertinent provisions of the contract.

DD FORM 1423-1 (BACK), FEB 2001

data_item: A002 title: LIST OF ALL DELIVERABLES sub: Drawings, analysis performed, technical manuals developed, procedures, plans, etc.

auth: DI-MISC-81920 ref: PWS Paragraph 3.5.1 req_ofc: PSNS and IMF dd250: LT appcode: NA dist: D freq: ASREQ asof: See BLK 16 firstsub: ASREQ subsub: See BLK 16 addressee1: PSNS C/400 COR draft1:

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total_draft: 0 total_reg: 1 total_repro: 0 remarks: Block 9: DISTRIBUTION D: Distribution authorized to Department of Defense and US DoD contractors only (administrative or operational use) (As of 7-8-2016) Other requests for this document shall be referred to PSNS and IMF, 1400 Farragut Ave. Bremerton, WA 98314.

Block 11 and 13: Provide one legible copy, in electronic media, of a report of documentation of flush to the COR within 24 hours of system oil flush completion .

group:

total_price:

prep_name: Richard Parker line_item: CLIN 000X exhibit: A xtdp: Off xtm: Off othercat: X system: Diesel Engine Generator Lube Oil Flush ctr_no: N4523A-18-X-XXXX contr: TBD remarksb:

Page2: 2

Reset:

2017-10-12T12:50:09-0700

PARKER.RICHARD.BRETT.1091818619

prep_date: 17OCT12 app_by: Kjiersten McKinney

2017-10-16T06:34:06-0700

MCKINNEY.SUSAN.K.1128778795

app_date: 17OCT16

Page: 1 of_pages: 3 app: Adobe Professional 8.0

DATA ITEM DESCRIPTION

Title: CONDITION FOUND REPORT

Number: DI-MGMT-81648 Approval Date: 20040809 AMSC Number: N7531 Limitation: N/A DTIC Applicable: N/A GIDEP Applicable: N/A Office of Primary Responsibility: N PEO SHIPS-FL32 Applicable Forms: N/A

Use/Relationship: The Condition Found Report identifies needed repairs and recommends corrective action for work discovered during the contract performance period which are not covered by the work specifications.

This DID contains the format, content, and intended use information for the data product resulting from the work task described in the contract.

Requirements:

1. Reference documents. N/A.

2. Format. The report shall be in contractor’s format.

3. Content. The report shall be serialized by CFR Number, and shall include the following:

a. Contract number, ship and hull number

b. Work Item Number to which the CFR relates

c. Date work requirement was discovered

d. Clear description of the work requirement

e. Specific location of the work requirement

f. Recommendation for corrective action

3.1 Recommendation for appropriate/best time to accomplish (i.e. during current availability with or without schedule change, future CNO or Continuous Maintenance Availability), and supporting rationale for the recommendation (such as cost efficiencies, availability of work force, availability of material, premium expenditures, etc.).

3.2 Cost and time estimates and the time frame for which it is valid, including:

a. Class “C” cost estimates. For work requirements which could be estimated within five working days, a class “F” estimate (+/-40%) identifying any potential impact which may affect the current schedule shall be included. The Class “F” estimate shall also contain the date on which a class “C” estimate will be provided.

b. Estimated Premium/Acceleration Costs, including premium costs for; material, subcontractors, man-hours, rework and any additional costs to on going work resulting from inclusion of the CFR work requirement.

c. Identification of related changes, if any, to the internal milestones and production and contract completion dates shall be included. When no changes were required a statement to that fact shall also be included

4. Media. The electronic media requirements shall be as specified in the contract on the DD 1423 CDRL.

5. End of DI-MGMT-81648

Source: https://assist.dla.mil -- Downloaded: 2017-09-29T12:43Z

Check the source to verify that this is the current version before use.

DATA ITEM DESCRIPTION

Title: Repair Procedure

Number: DI-MGMT-81910 Approval Date: 20130520 AMSC Number: N9369 Limitation: N/A DTIC Applicable: N/A Office of Primary Responsibility: SH/SEA00C

GIDEP Applicable: N/A

Applicable Forms: N/A

Use/relationship: The Repair Procedure will be used to document plans to perform individual work tasks assigned by the contract.

This Data Item Description (DID) contains the format, content, and preparation instructions for the data product resulting from work tasks specified in the contract.

Requirements:

1. Format. The Repair Procedure shall be in the contractor’s format.

2. Content. The Repair Procedure shall contain a cover page identifying the following:

a. Procedure name, number, revision/change, date of issue.

b. Contractor name and address.

c. Security classification, if classified.

d. Distribution Statement and Destruction Notice.

2.1. The Repair Procedure shall address each of the following:

a. Certification Page

b. Purpose.

c. Applicability

d. General Notes.

e. References.

f. Materials.

g. Tools.

h. Responsibilities.

i. Work Procedure.

j. Reporting Requirements

k. Testing Requirements

l. Appendixes, if required.

Source: https://assist.dla.mil -- Downloaded: 2016-09-21T17:41Z

DI-MGMT-81910

Page 2 of 2 pages

2.2. The Repair Procedure shall contain a list of all revisions and shall also identify the following information:

a. Revision number or letter.

b. Date of each revision.

c. Pages affected by each revision

4. Media Requirements. The Repair Procedure shall be presented in Adobe Acrobat (PDF).

5. End of DI-MGMT-81910.

Source: https://assist.dla.mil -- Downloaded: 2016-09-21T17:41Z

Title: LIST OF ALL DELIVERABLES

Number: DI-MISC-81920 Approval Date: 201300613

AMSC Number: N9383 Limitation: N/A

DTIC Applicable: N/A GIDEP Applicable: N/A

Office of Primary Responsibility: SH/PMS391

Applicable Forms: N/A

Use/Relationship:

The List of All Deliverables will identify all drawings, analysis performed, technical manuals developed, procedures, plans, etc. that will be delivered to the government during the period of performance.

This Data Item Description (DID) contains the format and content preparation instructions for the data product generated by the specific and discrete task requirements as delineated in the contract.

Requirements:

1. Format. The List of All Deliverables shall be in the Contractor’s format.

2. Content. The List of All Deliverables shall contain:

a. Applicable Contract number

b. Associated Contract line Item Number CLIN

c. Name, title, description and quantity of each item.

3. Media Requirement. The media requirement for the List of All Deliverables shall be

Microsoft Excel, version 2007-2010.

4. End of DI-MISC-81920.

Source: https://assist.dla.mil -- Downloaded: 2017-02-01T16:49Z

FOR OFFICIAL USE ONLY

S9233-DM-HBK-010-003 SSBN/SSGN

Revisions / Changes

Rev Description NAVSEA Phila

Approval & Date

Table of Contents

GENERAL INFORMATION AND SAFETY PRECAUTIONS

1 SAFETY PRECAUTIONS

2 MATERIALS

3 TOOLS / EQUIPMENT

4 PERFORMANCE SPECIFICATIONS FOR TOOLS / EQUIPMENT

FLUSHING PROCEDURE

1 PRELIMINARY PROCEDURES TO COMPLETE BEFORE

FLUSHING IS TO BEGIN

2 FLUSHING SEQUENCE

3 IN-PLACE LUBE OIL COOLER FLUSH

4 EXTERNAL PIPING

5 INTERNAL PIPING

6 FINAL FLUSH (COMBINED EXTERNAL AND INTERNAL)

7 LUBE OIL SYSTEM RESTORATION

LIST OF FIGURES

Figure 1, Scavenging Air Blower Lube Oil Line Location Figure 2: Valve Manifold Assembly Identification Figure 3: EDG Lube Oil Cooler Flush Set Up Diagram Figure 4: EDG Lube Oil External and Internal Flush Set Up Diagram

LIST OF ENCLOSURES

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

LIST OF TABLES

Table 1: Valve Alignment

GENERAL INFORMATION AND SAFETY PRECAUTIONS

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

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

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

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

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

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

MAINTENANCE STANDARD

EQUIPMENT / COMPONENT

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

S9233-DM-HBK-010-003

SYSTEM

SSBN / SSGN 726 Class Emergency Diesel Generator Sets

RELATED MAINTENANCE

MS DESCRIPTION: Comprehensive Monitored Hot Lube Oil Flushing procedure for SSBN / SSGN 726 Class Emergency Diesel Engine Generator Set, Fairbanks Morse Diesel Model 8-1/8 12 Cylinder.

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

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

1 SAFETY PRECAUTIONS

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

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

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

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

2 MATERIALS

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

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

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

NOTE 4: Mil-PRF-9000 (9250) oil can be used only with prior approval of NSWCCD-SSES, Philadelphia code 931. If MIL-PRF-9000 oil is utilized, oil temperature shall be 190-196 F.

3 TOOLS / EQUIPMENT

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

3-1.1 Positive displacement pump.

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

3-1.3 Digital Flow Meter.

3-1.4 A 2000-gallon steel storage tank. (optional) 3-1.5 Pump 1-1/2-inch connections.

3-1.6 Pump minimum 1-inch connections.

3-1.7 Portable Pore Blockage Particle Counter.

3-1.8 Quadraplex Bag Filter System.

3-1.9 Cartridge Filtration System.

3-1.10 Magnetic Filter System.

3-1.11 Simplex Process Heating System Unit. (optional) 3-1.12 Triplex Process Heating System Unit.

3-1.13 Oil Spill Containment

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

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

3-4 Valve Manifold Assembly.

3-5 Flow Straightener.

3-6 Assorted hand tools.

3-7 Various Spool Pieces (“SP”).

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

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

3-10 Various Jumper Lines (“JL”).

3-11 Various Temporary Valves (“TV”).

3-12 Pressure Gauges.

3-13 1-inch CPV fitting with Cam-lock style fitting (“CPV”), if required.

3-14 Various sizes of Pancake Blanks (“PB”).

4 PERFORMANCE SPECIFICATIONS FOR TOOLS/EQUIPMENT: The Flushing

Module shall have the following Performance Specifications:

4-1 Positive Displacement Pump shall:

4-1.1 Be capable of 260 gallons per minute @ 120 PSI.

4-1.2 Have a minimum 3-inch threaded suction and discharge ports. Be driven by a (minimum) 20 HP 440V 3-phase motor in order to achieve the 260 GPM flow rate specification at the Quadraplex Bag Filter inlet.

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

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

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

5 Digital Flow Meter shall:

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

5-2 Have current calibration and calibration log 5-3 Be sized to measure 260-300 GPM.

6 The optional 2000-gallon steel storage tank shall have:

6-1 One 4-inch inlet arranged so that the return flow will enter the tank along the side of the internal wall creating a vortex rotation and a 4-inch outlet pipe that draws suction from the center of the tank, 2 inches from the bottom.

6-2 Two threaded 2-inch inlet and outlet couplings placed on opposite sides of the tank to enable cross flow for the pump heater loop.

6-3 Two each, 6-inch threaded nipples on the top of the tank with caps to enable access for filling and inspection.

6-4 One 2-inch vent on the top of the tank.

6-5 One man-way access on the side of the tank for easy access for cleaning and inspection.

6-6 Lifting rings and forklift capable.

6-7 Constructed with a minimum wall thickness of 11-gage steel with a non-corrosive coating on the exterior.

6-8 Constructed with a tank bottom that has a minimum 3/16-inch thick steel.

7 Pump, 1-1/2-inch connections, for use in the storage tank heating loop.

8 Pump, minimum 1-inch connections, for the transfer, filling and draining of flushing fluid.

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

10 Quadraplex Bag Filter System shall consist of the following:

10-1 The Quadraplex Bag Filter Assembly is to be plumbed in parallel with individual isolation valves that allow filter/bag change-out while maintaining fluid flow, to allow for efficient filter change-outs.

10-2 Rated at a flow rate of 260 GPM or greater.

10-3 Fitted to accommodate 4 each, size 2, 25-micron commercial polyester-felt, full flow filter bags.

10-4 The Quadraplex Bag Filter assembly shall be equipped with pressure gages at inlet and outlet.

NOTE 5: Nylon bag filters are not an acceptable substitute and shall not be used.

11 Cartridge Filtration System shall include:

11-1 A minimum of 5 each, 36-inch tall filters in a parallel flow design with individual isolation valves to allow for efficient filter change-outs.

11-2 Rated at a flow rate of 260 GPM or greater.

11-3 Equipped with pressure gages at inlet and outlet.

11-4 A minimum filtration efficiency of the Cartridge filters shall be 3 microns with a beta ratio of 200.

11-5 Sufficient capacity to limit the clean pressure to 5 PSID while operating.

11-6 The Cartridge Filtration System shall be equipped with a check valve on the outlet to prevent filter damage/collapse during an emergency stop.

12 Magnetic Filter System shall consist of:

12-1 Three each (arranged in parallel) full flow magnetic filters.

12-2 A parallel flow design that provides a pressure drop of less than 1 PSID.

12-3 A minimum 2-inch inlet and outlet ports.

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

13-1 Rated at a minimum of 35 KW with a watt density no greater than 28 watts per square inch.

13-2 3-inch inlet and outlet ports.

13-3 Redundant controls to prevent overheating and burning of the flushing medium.

13-4 Flow switches to allow the Process Heating Systems to only turn on when fluid flow is present at the outlet of the heaters.

13-5 Thermocouples attached to the heating elements to monitor the temperature of the elements.

13-6 Thermocouples to be attached to safety shutoff circuit to prevent overheating.

13-7 The Process Heating Systems shall be controlled using Proportional-

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

14 Oil Spill Containment shall have the following:

14-1 Sufficient capacity to contain all modules of the Flushing Module including:

14-1.1 The optional Storage tank 14-1.2 Quadraplex Filter System 14-1.3 Magnetic Filter System 14-1.4 Cartridge Filter System 14-1.5 Process Heating Systems 14-1.6 Miscellaneous pumps 14-1.7 The main pump when located in the engine room and the suction/return hoses are exempt from this line item.

14-2 Sufficient capacity to hold at least 75% of the flushing medium.

15 Hose Assemblies shall have the following:

15-1 Hoses shall at a minimum conform to MIL-H-24135.

15-2 3-inch suction/discharge hose to run as suction and discharge between the engine being flushed and the Flushing Module.

15-3 3-inch hose sections to connect Flushing Module components.

15-4 2-inch hose to connect Flushing Module components.

15-5 All hoses shall be pressure tested and certified to 1.5 times working pressure annually and tagged with date of test and tested pressure.

15-6 All hose fittings shall be aluminum cam-lock style with self-locking mechanisms, equipped with barbed type fittings, and at a minimum shall conform to A-A-59326B (Army Specification) formerly MIL-C-27487.

15-7 All cam-lock fittings shall be attached to the hose with steel or stainless steel crimped ferrules.

15-8 All hose assemblies shall include caps and plugs to prevent any residual spillage of oil.

16 Valve Manifold Assembly shall have the following:

16-1 Each Valve Manifold Assembly shall consist of a minimum 3-inch pipe and minimum 3-inch ball or gate valves with locking cam-lock style fittings attached.

16-2 Each valve of the Manifold Assembly shall be numbered and each valve shall be identified in accordance with Figure 2.

16-3 Each Manifold Assembly shall be equipped with a relief valve set to ensure maximum flushing pressure shall not exceed 110 percent of attached lube oil pump relief valve setting.

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

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

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

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

21 MISCELLANEOUS

21-1 Caution or Danger Barrier tape. (as required) 21-2 Soft mallets.

21-3 Safety signs; 11 x 8-1/2-inch, stating at minimum “Keep Clear. Hot Lube

Oil Flush in Progress.”

21-4 ID tags for blank flanges and any other removed Ships System components.

21-5 Oil Absorbent pads.

21-6 Lint free rags 21-7 Pails; 3-gallon minimum size.

21-8 Temporary Valve (TV) jumpers for the ship’s strainer and filter relief valves.

HAZARDOUS MATERIAL CONTROL STATEMENT

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

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

NOTE 6: Ships Force or repair activity shall drain the lube oil from the engine sump, full flow filter, strainer, generator bearing drain tank, LO cooler and all external lube oil piping. Refill engine and support systems, as necessary, using the applicable oil for this application to the applicable levels upon completion of the lube oil flush.

NOTE 7: Ships Force or repair activity shall remove the lube oil filter elements before flushing. Reinstall new elements, as required, upon completion of the lube oil flush.

NOTE 8: Ships Force or repair activity shall remove and clean lube oil strainer elements. Reinstall strainer elements upon completion of the lube oil flush.

NOTE 9: This Maintenance Standard shall be performed in full and in accordance with the specified sequence and procedures. Partial steps or step modification shall not be performed unless authorized by NSWCCD-SSES, Philadelphia Code 931.

NOTE 10: All daily progress and / or current status reports shall be forwarded to NSWCCD-SSES, Philadelphia Code 931 for review.

NOTE 11: All Enclosures shall be filled out and signed or initialed where required. Enclosure 6 (Flushing Log General Comments) shall be used for recording all events, inspections, shifting of Quadraplex Filters, valve line-ups, filter changes, or any conditions affecting the Lube Oil Flushing procedure.

NOTE 12: Checkpoints are designated as follows:

(V): Contractor Representative.

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

NOTE 13: Flushes shall always include External, Internal and Combined phases except when authorized by NSWCCD-SSES, Philadelphia code 931. Once commenced, each flushing phase shall be continuous until the cleanliness requires have been met for that phase.

NOTE 14: Any existing ship installed component or piping section removed shall be logged, removed and reinstalled, on Enclosure (1) of this procedure. A condition and / or cleanliness report shall be required for any item serviced by an outside activity, otherwise, record findings on Enclosure 6.

NOTE 15: Measuring equipment shall be calibrated in accordance with ISO 10012-1. Enter all calibration data on Enclosure (2) of this procedure.

NOTE 16: Discrepancies and/or deficiencies noted during the accomplishment of required steps shall stop further procedure(s) until the appropriate corrective action has been taken.

NOTE 17: All blank or cam-lock flanges, pipe plugs, spool pieces, or any other temporary component shall be serialized, tagged and painted with highly visible paint and logged on Enclosure (3) of this procedure.

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

NOTE 18: All checkpoints shall be verified, logged on Enclosure (4) of this procedure and signed by performing activity representative and DEI before the next step can be performed. Verify with ship’s force representative only if required.

NOTE 19: The Flushing Log General Comments, Enclosure (6) of this procedure, shall be maintained to document flushing of each component/segment of system.

NOTE 20: All spools shall be the same size or larger than the component it replaces.

NOTE 21: Spools Pieces for the ship’s strainers, filters and relief valves shall have built in valves and shall be installed in place of the relief valves for ship filters and strainers to achieve full flow during flush.

NOTE 22: All piping, pumps and components removed, disconnected or jumpered around, will have the lube oil flow areas hand cleaned completely before being blanked.

NOTE 23: Whenever a tank, inspection cover of engine, pipe or similar part of the lube oil system is opened for any length of time and not attended, the opening(s) shall be hard blanked or covered with ‘Herculite’ or equivalent, to prevent any entry of foreign material.

NOTE 24: Absorbent pads and lint free rags shall be readily available at the flushing job site and within the auxiliary spaces for the duration of the flushing evolution.

NOTE 25: Ships strainer elements shall be removed during flush and the shifting levers shall be placed in the “BOTH” position, if applicable, and logged on the Flushing Log, Enclosure (1). Ships strainers that are not capable of being placed in the “BOTH” position shall be shifted midway during the accomplishment of the flush to insure a through flushing of the strainer assembly and piping. A sign shall be posted to indicate the on-line basket.

NOTE 26: Any removed pressure relief/by-pass or regulating valves not having a test data tag, expiring, or expired test date shall be tested in accordance with current maintenance documentation. The contractor shall notify the DEI, ships supervisor and ships force of any deficiencies regarding pressure relief/by-pass valves test dates.

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

NOTE 27: Ships Force or ship supervisor submit work request to have generator bearing lube oil supply pressure regulating valve disassembled, cleaned, tested, and reassembled in accordance with diesel engine technical manual.

NOTE 28: All system connection hoses (to and from the flushing module) shall have valves at low points to drain fluid.

NOTE 29: All engine and associated piping assembly hookups, from flushing module connection hoses to ship’s piping, shall have cam-lock style fittings with self-locking mechanisms attached to the flanges.

NOTE 30: All flushing module system components shall be fully isolatable.

FLUSHING PROCEDURE

WARNING: All hoses, cables, and lines must have quick disconnect fittings installed within five (5) feet of hatches to permit re-establishment of hull integrity in case of an emergency. If a quick disconnect is not installed, an alternate means must be provided.

1 PRELIMINARY PROCEDURES TO COMPLETE BEFORE FLUSHING IS TO

BEGIN:

NOTE 31: Ships force shall ensure correct lube oil system alignment. Unless otherwise annotated, the existing lube oil system valves should be aligned for normal operation. Valves connected to the fill / transfer / purification / waste / drain systems shall be verified shut / closed.

1-1 Verify all cylinder test cocks are open.

1-2 Verify lube oil has been drained from engine sump, full flow filter, knife-edge strainer, generator bearing drain tank, and all external lube oil piping.

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

1-4 Verify removal and hand cleaning of permanently installed knife-edge strainer element before flushing.

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

1-5.1 Remove lube oil knife-edge strainer pressure relief/by-pass valve and install blank flanges / FME protection on valve. Install temporary valve, see Figure 4 for TV-1 location.

1-5.2 Verify the lube oil filter continuous vent is secured.

1-5.3 Replace generator bearing lube oil supply pressure regulating valve with a spool piece; see Figure 4 for SP-1 location. Install blank flange on engine cover.

1-5.4 Remove the generator bearing scavenging pump and hand clean oil flow areas. Install blank flanges on generator bearing scavenging pump.

Install a spool piece between suction and discharge piping; see Figure 4 for SP-2 location.

NOTE 32: After removal of pump the DEI shall inspect pump for foreign material, debris and excessive wear. If pump requires disassembly for cleaning or additional maintenance, Ship’s Force shall submit a work request for additional work as required. Record condition and disposition on Flushing Log General Comments, Enclosure 6.

1-5.5 Install temporary plugs and caps in the generator pedestal bearing scavenging oil pump priming line and fittings, if required.

1-5.6 Install jumper line around the generator bearing; see Figure 4 for JL-1 location. Connect bearing oil supply line directly to generator bearing oil drain line.

1-5.7 Remove attached lube oil pump pressure relief/by-pass valve and install temporary valve; see Figure 4 for TV-2 location.

1-5.8 Remove the lube oil pump discharge piping connection to the attached lube oil pump and remove the attached lube oil pump, if required. Hand clean inlet and outflow areas and install blank flanges on the attached oil pump and mounting plate as required.

NOTE 33: If removed, the DEI shall inspect pump for foreign material, debris and excessive wear. If pump requires disassembly for cleaning or additional maintenance, Ship’s Force shall submit a work request for additional work as required. Record condition and disposition on Flushing Log General Comments, Enclosure 6.

1-5.9 Install cam-lock flange on attached lube oil pump discharge piping flange;

see Figure 4 for CF-1 location.

1-5.10 Disconnect the scavenging air blower oil supply line piece no. 78, Figure 1 from elbow piece no. 95 and install a plug.

1-5.11 Disconnect the lube oil supply piping to the engine lube oil header. Hand clean oil flow areas and install cam-lock flanges, see Figure 4 for CF-2 and CF-3 location.

NOTE 34: Removal of the lube oil hand priming pump internals and flushing through the pump body / casing is an acceptable alternative to removal of the pump and installation of a spool piece.

1-5.12 Remove the lube oil hand priming pump. Hand clean inlet and outflow areas and install blank flanges / FME protection on the lube oil hand priming pump, if applicable.

NOTE 35: After removal of pump or pump internals the DEI shall inspect pump / internals for foreign material, debris and excessive wear. If pump requires disassembly for cleaning or additional maintenance, Ship’s Force shall submit a work request for additional work as required.

Record condition and disposition on Flushing Log General Comments, Enclosure 6.

1-5.12.1 Install spool piece to flush lube oil hand priming pump inlet and outlet piping, see Figure 4 for SP-3 location, if applicable.

1-5.12.2 Remove lube oil hand priming pump suction flexible hose and install FME protection.

1-5.12.3 Install Cam-lock CPV fitting on inlet piping to lube oil hand priming pump; see Figure 4 for CPV-1 location.

1-5.12.4 Install cap / plug on lube oil hand priming pump suction flexible hose inlet pipe connection; see Figure 4 for pipe cap / plug location.

1-5.13 Remove a diesel engine crankcase cover and install hose assembly; route to the Comprehensive Flushing Module.

1-5.14 Remove lube oil cooler pressure relief/by-pass valve and install blank flanges / FME protection on valve.

1-5.15 Remove lube oil filter pressure relief/by-pass valve and install blank flanges / FME protection on valve.

NOTE 36: If lube oil cooler was not removed for independent cleaning, accomplish paragraph 1-5.15.1 through paragraph 1-5.15.5 and flush lube oil cooler in accordance with paragraph 3.

1-5.15.1 Install a blank flange on the piping inlet to the lube oil cooler pressure relief/by-pass valve; see…