S9555-FE-MMC-010_3_2.pdf

CUI

S9555-FE-MMC-010 REV 03

EQUIPMENT TECHNIC AL MANUAL

FOR

HEF F I R E F I G H T I NG COMPONENTS

MODEL 630

(EPF 1 & FOLLOW)

Manufacturer: Hiller Systems, Inc .

3751 Joy Springs Drive Mobile, AL 36693

Contract No.:

N00024-08-C-2217

T-EPF CL ASS

CUI

01 FEB 22

Distribution Statement D:

Distributio n authoriz ed to the Department of Defense and DoD Contractors only (Critical Technolog y, 1 Aug 03).

Warning:

This document contains technical data whose export is restrict ed by the Arms Export Control Act (Title 22, U.S.C., Sec. 2751, et seq.) or the Export Admi nistration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violatio ns of these laws are subje ct to severe criminal penaltie s.

Destruction Notice: Destroy by any method that will prevent disclosure of contents or reconstructio n of document.

POINT OF CONTACT: MILITARY SEALIFT COMMAND, CODE N037, 757-341-4610

NO _

CONTROLLED BY: UNITED STATES NAVY, COMMANDER MILITARY SEALIFT COMMAND

CUI CATEGORY: CONTROLLED TECHNICAL INFORMATION (CTI)

(If NO, record un-releasa ble data information on the following sheet. Data restriction rules within GD-AIDE must apply.)

Is this technical data RELEASABLE within the AUSTAL JHSV Team under TA 1615-07 YES _X

CHANGE RECORD

Change No Date Title and/or Brief Description Signature of Validating Officer

1. 9-2-21 Added Eaton brand controller for EPF 11 and follow. Revised Joslyn type to 1-10. Added approved LSI information. Added TMDER, NSN Bar code. Revised distribution statement to D.

Change Record 1

2. 1-31-22 Updated cover page by adding 'Controlled by', 'CUI Category' and 'Point of Contact'.

HILLER RECORD OF CHANGES

CHANGE NO. Rev DATE DESCRIPTION

1 - 03/01/2010 Original Submittal File (JG6321-HEF-Technical Manuals.pdf)

2 A 08/30/2010 Revised IAW Austal Comments File (JG6321-HEF-Technical Manuals-RevA.pdf)

3 B 02/21/2011 Revised IAW Austal Comments File (JG6321-HEF-Technical Manuals-RevB.pdf)

4 C 03/07/2011 Updated Joslyn Controller Data, Added Low Level Switch and Level

Indicator Switch.

File (JG6321-HEF-061011-JHSV-B054.pdf)

5 D 06/10/2011 Updated Controller, Added Low Level Switch, Level Indicator File (JG6321-HEF-061011-JHSV-B054.pdf)

6 E 04/15/2014

Revised IAW Austal Comments, Removed Non-Hiller Provide Equipment and Reference Thereto, Added Maintenance and Test Procedure, IBP-2M Dwgs and Reference, Updated Dwg for Skids and ABS Approvals, Added Ansul Bulletin #59, Updated Foam Generator Nozzles, Revised 2.75% Foam Data Sheet and MSDS

Information, Revised Flushing Diagram. File (JG6321-HEF-041514-JHSV-B054.pdf)

7 F 07/01/2014

Revised IAW 6/24/14 Comment, Expanded Record of Change, Added Safety Summary Precautions, Expanded Warnings &

Cautions, Corrected Typo on Page 10 Sect. 1.3.3, Added Components to ‘Functional Descriptions’ Sect. 2.1, Re-wrote Paragraph 2 of ‘Functional Descriptions’ to Reference In-Line

Balance Proportioning Skid Only, Renumbered Flushing Section, Inserted Revised HEF Placard, Appendix U, V & W are Deleted and the Information moved to Section 3.1.

File (JG6321-HEF-070114-JHSV-B054.pdf)

8 G 08/22/2014 Add bookmarks – Internal edit only. File (JG6321-HEF-082214- JHSV-B054.pdf

9 H 08/27/2014 Revised IAW 08/19/14 comments, Expanded Record of Change, inserted revised HEF placard, Renumbered sections & changed page numbering for better flow of information.

File (JG6321-HEF-082714-JHSV-B054.pdf

10 I 09/08/14 Revised IAW 9/8/14 Comments, Insert Revised HEF Placard, Added Notations TM-10, TM-12, TM-16, TM-31, TM-32, TM-70.

File (JG6321-HEF-090814-JHSV-B054.pdf)

11 DRL

B054

REV

B

11/12/14 Revised IAW 10/24/14 Comments against Rev A submittal of TM. Added section 2.2.4 for ref. to Containment Curtain.

Added MOV and POV ref. data to TM. Added warning for static seawater, TM-10. Ref. to FM and IMCS tie in data see TM-13. Added Tank drawing B015-46.90-630-555-04- 601.Ref. Update Flushing procedure revised per section 4.2,

4.3. Removed HEF schematic drawing and added ref to

same. Updated sect. 3.1.2 relief valve setting to read 193.

Corrected various spelling errors. Updated TOC as result of change. For more information see actual responses to comments and TM updates.

12 DRL 02/28/15 Updated manual by adding Section 4.4 Pump Recirculating and 4.5 System Standby Procedures to manual. Sections were previously

4.1.1 and 4.1.5. Added Duplex Pressure Gauge info to manual, Appendix T, was appendix D in previous REV.

B054

REV

C

13 REV

D 03/17/15 Revised section 4.5 by correcting port Stbd designations for valves

HEF-V-075 & 083 to Stbd and HEF-V-076 & 084 to port.

14 J 2/3/2017 First Release-Revise hull effectivity for pressure relief valve as follows: 1” x 1-1/2” for hulls 1-6, 1-1/2” x 2” for hulls 7AF.

TM2

david.holder Typewritten Text

Approved Rev. Item Description By By Date

F I. Technical Manuals SDRL B054: HEF Fire Fighting System AB AB 07-01-14

G I. Technical Manuals SDRL B054: HEF Fire Fighting System DG AB 08-19-14

H I. Technical Manuals SDRL B054: HEF Fire Fighting System DG AB 08-29-14

I

J

I.

I.

Technical Manuals SDRL B054: HEF Fire Fighting System

Technical Manuals SDRL B054: HEF Fire Fighting System

DG

DG

AB

AB

09-08-14

12-06-16

General Notes

Includes Technical Manuals SDRL B054 in pdf format. REVISION G IS INTERNAL ONLY. REVISION H

INCORPORATES COMMENTS RECEIVED 08-19-14. REVISION I INCORPORATED AUSTAL ADDITION

COMMENT RECEIVED 09-08-14.

REVISION J INCORPORATES PRESSURE RELIEF VALVE REVISION TO SKID DRAWING AND PRV

DATA SHEETS.

HILLER SYSTEMS

a division of The Hiller Companies, Inc.

3751 JOY SPRINGS DRIVE

MOBILE, ALABAMA 36693

Client: Austal USA, LLC 100 Dunlap Drive

Mobile, Alabama 36602 Title:

Technical Manuals Joint High Speed Vessel (JHSV) Project

HIGH EXPANSION FOAM FIRE FIGHTING SYSTEM

Austal P.O. No.: D13904-4, Hull 630 - Ship 1

Austal P.S. No.: 630-555-03-607-3_B054 American Bureau of Shipping (ABS) Class: High Speed Naval Craft (Guide for Building and

Classing High Speed Naval Craft) 2007 Rules

“Distribution Statement D: Distribution authorized to the DOD and U.S. DOD Contractors only. Other requests shall be referred to PEO Ships PMS 385.”

3 Hiller System Proposal Revision J dated 3/26/2009 2 Austal PS: 630-555-03-607-3_B054 JHSV Procurement Specification 1 Austal Design System Drawing: “TBD” HEF FIRE FIGHTING SYSTEM DIAGRAM

REF. No. DOCUMENT No. DESCRIPTION (TITLE)

Generated By: A. BOWEN

Checked By: A. BOWEN

Approved By: B. ROBERTS (06-10-11) Document: Bill Roberts, Hiller Systems

Approved

DOCUMENT NO: JG6321-B054-630 REV (J) Austal Data No.: JHSV-SDRL-B054

COVER SHEET 1 of 1

TM-1

HILLER SUBMITTALS

LIST OF AUSTAL DRAWING REFERENCES

CDRL DOC TYPE DRAWING

NUMBER/TM NUMBER

TITLE

B015-47 SYSTEM DRAWING 630-555-01-606 HEF SCHEMATIC

B054 EQUIPMENT MANUAL S9303-AP-DCT-010 DAMAGE CONTROL

BOOK (JHSV 1)

B054 EQUIPMENT MANUAL S9555-FH-MMC-010 HEF CONTAINMENT

CURTAIN

B054 EQUIPMENT MANUAL S9436-BN-MMC-010 IMCS VOL. 1

B054 EQUIPMENT MANUAL S6435-2L-MMC-010 FIREMAIN & HEF Motor

Operated Valves (MOV) B054 EQUIPMENT MANUAL S6435-ZM-MMC-010 Pneumatically Operated

Valves (POV)

B081-03 TEST INSTRUCTION 633-555-09-606 STAGE IV-HEF MISSION

BAY, ALL VESSELS

B081-03 TEST INSTRUCTION 633-555-09-611 STAGE IV-HEF MISSION

BAY, ALL VESSELS

B081-03 TEST INSTRUCTION 633-555-09-612 STAGE IV-ENGINE

ROOM, ALL VESSELS

STAED DC-2 HEF MISSION BAY

DOCKSIDE

STAED DC-2A HEF ENGINE

ROOMS IN PORT DEMO

STAED DC-2B HEF MISSION

BAY AT-SEA

TM5

TM3

Table of Contents

Page No.

Engineering Submittal Cover P age ........................................................................................................... TM-1

Record of Changes .................................................................................................................................... TM-2

Table of Co ntents & Appendix ................................................................................................................. TM-3

Appendix .................................................................................................................................................. TM-4

List of References…………………………………………………………………………………………………………………………… TM-5

Safety Summary ............................................................................................................................. TM-6-TM-9

Safety Precautions ................................................................................................................................... TM-10

1.1 Safety Preca utions ..............................................................................................................................TM-10

1.1.1 Specific Warnings & Cautions ............................................................................... TM-10-TM-11

HEF System & Equipment Description ................................................................................................... TM-12

2.1 HEF System ....................................................................................................................................... TM-12

2.2 Equipment Descri ption ..................................................................................................................... TM-12

2.2.1 Controller & Electrical Components................................................................................ TM-12

2.2.2 HE F Pump Skid ................................................................................................................ TM-12

2.2.3 HE F Concentrate Storage Tank ....................................................................................... TM-12

2.2.4 HEF Containment Current.………………………………………………………………………………………. TM-12

3.1 Functional Description Introduction .................................................................................... TM-13-TM-14

3.1.1 Motor Controller ............................................................................................................. TM-13

3.1.2 HE F Single-Speed Injection Pump & Motor..................................................................... TM-13

3.1.3 Proportioni ng Assembl y .................................................................................................. TM-13

3.1.4 Y-Type Strainer ................................................................................................................ TM-13

3.1.5 1 ½” Spool Valve.............................................................................................................. TM-13

3.1.6 1 ½” Manual Foam Bala ncing Valve ................................................................................ TM-13

3.1.7 Morin Double Acting A ctuator ........................................................................................ TM-14

3.1.8 Jet-X 2 ¾% Foam ............................................................................................................. TM-14

3.1.9 MOV Motor Operated Valves……………………………………………………………………………………. TM-14

3.1.10 POV Pneumatically Operated Valves ………………………………………………………………………. TM-14

Figure 1 ....................................................................................................................................TM-15

HEF System Flushing Pro cedure .....................................................................................................TM-22-TM-25

4.1 Inspection, Maintena nce & Testing ….......................................................................TM-20-TM-21

4.2 HEF Engine Room System FW Flushing Procedure............................................................... TM-22

4.2.1 Port Engine Room ……………............................................................................................. TM-22

4.2.2 Port Engine Room ……………............................................................................................. TM-22

4.3 HEF Mission Bay System F W Flushing …...................................................................TM-23-TM-25

4.4 Pump Recirculation Procedure ………………………………………………………………………………… TM-26

4.5 System Standby Procedure ……………………………………………………………………………………… TM-26

TM4

Ap pendix

Page No.

Appendix A: Skid Drawing 2” & 6” IBP-2M Drawings ............................................................... TM-16-TM-19

Appendix B: Y-Strainer............................................................................................................... TM-27-TM-28

Appendix C: W e k s l e r Pressure Gauge ................................................................................ TM-29

Appendix D: ¼ ” D r a i n C o c k V a l v e D r a w i n g ......................................................... TM-30

Appendix E: Double Acting Actuator ......................................................................................... TM-31-TM -42

Appendix F: Jet-X-2A & Jet-X-20 High Expansion Foam Generator ........................................... TM-43-TM-51

Appendix G: Jet-X High Expansion Foa m ................................................................................... TM-52-TM-59

Appendix H: In-Line Balance P ressure Proportioner ................................................................. TM-60-TM-84

Appendix I: HEF Motor .............................................................................................................. TM-85-TM-110

Appendix J: Single Speed Pump ............................................................................................... TM-111-TM-149

Appendix K: Ball Valves ......................................................................................................... TM-150-TM-153

Appendix L: Spool Valve ........................................................................................................ TM-154-TM-155

Appendix M: Check Valve ....................................................................................................................TM-156

Appendix N: Relief Valve ....................................................................................................... TM-157-TM-158

Appendix O: Hytrol Valve ...................................................................................................... TM-159-TM-172

Appendix P: Pressure Relief C ontrol Valve ............................................................................ TM-173-TM-177

Appendix Q: Globe Valve.....................................................................................................................TM-178

Appendix R: Fire Pump Controller ......................................................................................... TM-179-TM-209

Appendix S: Liquid Level Gauges……...................................................................................... TM-210-TM-216

Appendix T: Duplex-Pressure Gauges With Bourbon Tube ……………………………………………… TM-217

12. SAFETY SUMMARY

The following general safety precautions supplement the specific Warnings and Cautions throughout this manual. These general precautions are related to the JHSV HEF System. They are precautions that must be understood and applied before and during work on the system.

DANGER, WARNING AND CAUTION STATEMENTS

DANGER, WARNING, AND CAUTION statements have been strategically placed throughout this text prior to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING) or equipment and property (CAUTION). A DANGER, WARNING, or CAUTION will apply each time the related text is repeated. Prior to starting any task, the DANGERS, WARNINGS, or CAUTIONS included in the text for that task will be reviewed and understood. Refer to the materials list figure at the beginning of the appropriate manual section for material used during maintenance of this equipment. The detailed warnings for hazardous material only are listed separately in the safety summary as the "Hazardous Materials Warnings" section.

General Safety Precautions The hazards identified with the operation of HEF system include:

- Rotating and moving machinery hazards

- Electrical, hydraulic, or other power source hazards

- Test equipment

- Eye hazardous areas and operations

- Hazardous materials and hazardous waste

- Heat or chemical burn hazards

- Corrosion control

- Do not repair or adjust alone.

- First Aid

Rotating and Moving Machinery Hazards The majority of machinery plant systems have moving parts. Moving parts create the possibility of personnel injury. Personnel must observe the safety precautions and adher e to the standard operating procedures that are applicable to machinery plant systems.

Failure to observe proper safety precautions during machinery plant system alignment, operation, and securing may endanger personnel as well as equipment. Only those personnel who have been properly instructed, qualified, and officially designated should be per mitted to perform the alignment, operation, and s ecuring of machinery plant systems. They must become thoroughly familiar with the safety precautions set forth in this manual, equipment operating procedures, maintenance procedures, and manufacturer’s technical manuals.

Sources of danger most usually encountered during the alignment, operation, and securing of the main propulsion plant, propulsion auxiliaries, and independent auxiliaries include:

- Non-compliance with equipment tag-out procedures

- Operation of machinery and equipment by unauthorized/unqualified personnel

- Personnel not wearing the required protective equipment

- Protective covers, guards, or plates removed from equipment

- Improper use of flammable liquids as cleaning solutions

When aligning, operating, or securing specific systems consult the applicable manufacturer’s technical manuals for complete safety precautions.

Electrical Hazards Electric shock is a v ery real hazard. T he combinations of high humidity, metal structures, high voltage electricity, and perspiration ensure that the potential for an electrical hazard in machinery plant spaces continually exists. Electrical safety is the responsibility of all hands. Personnel must adhere to the vessel’s electrical safety program to prevent mishaps that could cause fatal injuries and extensive damage to shipboard equipment and may compromise the vessel’s mission capabilities. Under no circumstances should any person reach into or enter an electric enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable of rendering aid.

TM6

Compressed Air Precautions Compressed air can be us eful, but it can be danger ous if not used properly. Most shop air is under high pressures often exceeding 100 p.s.i. A blast of air under only 40 p.s.i. from four inches away can rupture an ear drum or cause a br ain hemorrhage. As little as 12 p. s.i. can “pop” an eyeball from its socket. Air can enter the navel, even through a layer of clothing, and inflate and rupture the intestines. And there are reports that compressed air under 80 p.s.i. struck a small hand wound and i nflated the arm, causing shooting pains from the fingers to the shoulder.

Compressed air can cause bubbles of air in the blood stream. One authority estimates that as little as 4 p. s.i. can rupture the bowel. Directed at the mouth, it can rupture the lungs and intestines. It can be dangerous to use compressed air to blow dust or dirt off clothing or body parts. Horseplay is never funny when it causes an accident, and fooling around with compressed air can be lethal.

The following guidelines can help reduce the risk of injury when using compressed air:

- Examine all hoses, connections, and equipment to see that they are in good condition before turning the pressure on.

- Never point an air hose at any part of your body or at any other person. No horseplay with the air hose.

- Never kink the hose to stop the air flow – turn it off at the control valve.

- When using compressed air for cleaning, make sure the pressure is no higher than 30 p.s.i.

- Always wear eye protection when using compressed air.

- Before using compressed air, make sure that dirt will not be blown onto other workers in the area. Only the user should be in the vicinity.

- Turn off the valve on both the tools and the air line when the job is finished.

- Remember, failure to follow safety procedures properly or to pay attention to workplace safety could result in injury to you and your fellow workers.

Hydraulic System Hazards

- Hydraulic systems store fluid under high pressure.

- Three kinds of hazards exist: burns from the hot, high pressure spray of fluid; bruises, cuts or abrasions from flailing hydraulic lines; and injection of fluid into the skin.

- Safe hydraulic system performance requires general maintenance.

- Proper coupling of high and low pressure hydraulic components and pressure relief valves are important safety measures.

Hydraulic systems are popular because they reduce the need f or complex mechanical linkages and allow remote control of numerous operations. Hydraulic systems are used to lift heavy loads;

to change the position of implement components; to operate remote hydraulic motors; and to assist steering and braking. Hydraulic systems store fluid under high pressure, typically 2,000 psi or more. One hazard is removing or adjusting components without releasing the pressure. The fluid, under tremendous pressure, is also hot. To work on the system safely, relieve the pressure first.

Test Equipment Ensure test equipment is operating correctly. Z ero hydraulic pressure before removing any hydraulic lines for testing. Remove fittings slowly and bleed any residual pressure from lines or components if necessary. Ensure hydraulic test equipment connections are secure before pressurizing the system.

Eye-Hazardous Areas and Operations Policy requires that personnel working in eye-hazardous areas or operations wear adequate eye protection. Machinery plant personnel must wear eye protection when performing eye-hazardous operations such as:

- Pouring or handling acids or corrosive liquids and solids

- Blowing down equipment and/or components with compressed air

- Using high pressure washers

- Cutting, drilling, grinding, milling, or chipping operations

- Dust and particle producing operations

Any personnel in the immediate vicinity of such operations, including visitors, shall also wear eye protection.

The Medical Office has a f ixed eyewash station for flushing debris or fluids. P ortable eyewash stations are located in eye hazardous areas.

TM7

Hazardous Materials warnings In order to attain and maintain operational effectiveness, machinery plant systems require specified types and quant ities of hazardous materials and, as a r esult, accumulate hazardous waste. To prevent injury to personnel, damage to equipment, or harm to the environment, Great care must be taken in handling, using, and storing, and disposal of hazardous materials, and in preventing the accumulation of hazardous waste. Risks associated with hazardous materials are greater on board a vessel than on shore because of the limited number, confined nature, and at sea environment of shipboard spaces.

Hazardous Materials Hazardous materials are any material that, because of its quantity, concentration, or physical or chemical characteristics, may pose a s ubstantial hazard to human health or the environment when purposely, accidentally released or spilled. Subcategories of hazardous materials include:

- Flammable/combustible materials

- Toxic materials

- Corrosive materials (including acids and bases)

- Oxidizing materials

- Compressed gases

Hazardous Waste Hazardous waste is any discarded material (liquid, solid, or gas) which meets the above definition of hazardous material and/or is designated as a hazardous waste by the Environmental Protection Agency (EPA). To minimize hazardous conditions, machinery plant personnel must adhere to the following guidelines:

- Hazardous materials removed from storage for use must be r eturned to storage upon completion of use, or at the end of the work day, whichever is earlier.

- Follow the instructions provided for the proper use of hazardous materials.

- Collect and segregate any waste resulting from the use of hazardous material, or any other waste designated as hazardous waste, for proper disposal in accordance with the cutter’s hazardous material and hazardous waste material handling program.

- Report any spills of hazardous materials/hazardous waste to the Officer of the Deck (OOD) and the Engineer Officer.

Burn Hazards Personnel are exposed to burn hazards when working or coming into contact with equipment, components, or systems that generate excessive heat loads during operation, or when fuel-fired systems are used to accomplish a specific purpose. Personnel should refrain from servicing or adjusting the following equipment, systems, and t heir related components when they are in operation:

- Main diesel engines

- Auxiliary / emergency diesel generator

- Electric motors

- Air compressors

- Hydraulic system

Thermal shields must be kept in good condition and secured in place to afford personnel protection from burn hazards. Special caution should be taken to prevent serious burns or injury if equipment has been running and exposed components, internal fluids, or piping is still hot.

Extreme care must be exercised before attempting to service overheated equipment or systems.

Under no circumstances should personnel attempt to remove pressure caps, manually lift relief valves, or disconnect components or fittings of equipment that is overheated. When an overheated condition occurs, all unnecessary personnel must clear the surrounding area.

Personnel assigned to handle the casualty must wear the proper protective equipment before proceeding with casualty control measures.

Prior to performing any preventive or corrective maintenance procedure on a system containing pressurized hot liquid, the system must be tagged “Out of Service,” isolated, vented and allowed to cool. P ersonnel must be al ert for possible pressure when disconnecting any device from a system suspected of being pressurized.

TM8

Corrosion Control Physical and chemical processes that may require the use of chemicals, solvents, paints, or other commercially available material. The user of this publication should obtain the material safety data sheets (Occupational Safety and H ealth Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. The user must become completely familiar with the manufacturer/supplier information and adhere to the procedures, recommendations, warnings and c autions of the manufacturer/supplier for the safe use, handling, storage, and disposal of these materials. The following are general safety precautions and i nstruction that people must understand and apply during many phases of operation and maintenance to ensure personal safety and health and the protection of DOD property. Portions of this may be repeated elsewhere in this publication for emphasis.

Do Not Repair or Adjust Alone Do not repair or adjust energized equipment alone. The presence of a qualified individual capable of rendering 1st aid/CPR is required. Always protect against grounding hazards and make adjustments with one hand free and clear of equipment. Be aware that even after equipment has been de-energized, dangerous electrical hazards can exist due t o capacitors retaining electrical charges. Circuits shall be grounded and capacitors discharged.

First Aid Attend to all injuries, however slight, by obtaining first aid or medical attention immediately.

TM9

1.1 SAFETY PRECAUTIONS

Safety notices are listed throughout this manual. These notices are in the form of warnings and cautions. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. Should situations arise that are not covered in the general or specific safety precautions, the local authority will issue orders as deemed necessary to cover the situation.

W arnings and cautions appear in the text. A warning addresses a situation or procedure that may involve a haz ard to personnel. Cautions address a pr ocedure that may involve a haz ard to equipment.

1.1.1 Specific Warnings and Cautions

The following sections contain warnings and c autions that are specific to the procedures in this manual. Read and understand all applicable warnings and cautions before performing an operational procedure. The definitions of a warning and a caution are:

WARNING

An operating or maintenance procedure, practice, condition, or statement that, if not strictly observed, could result in injury or death of personnel.

CAUTION

An operating or maintenance procedure, practice, condition, or statement that, if not strictly observed, could result in damage to or destruction of equipment, loss of mission effectiveness, or long-term health hazards to personnel.

The following are W ARNING and CAUTIONS are specific to this manual:

WARNING: Static HEF/seawater solution may produce toxic hydrogen sulfide

(H2S) gas in high enough concentrations to cause injury or death.

Therefore, this maintenance or any pipe rupture or leak may release H2S that has generated within the piping system. H2S is colorless and smells strongly of rotten eggs. If detected, or an unexpected HEF/seawater discharge occurs, immediately leave the area and notify proper authority. Ventilate, and monitor the space using a gas analyzer; odor becomes undetectable with continuous exposure or at high concentrations. Appropriate measures should be used to monitor for the presence of hydrogen sulfide gas when disassembling sections of the HEF piping that may contain static HEF/seawater solution.

WARNING: Avoid repeated/prolonged skin contact with hazardous materials.

Wash affected areas with soap and water upon completion of task or prior to eating, drinking, smoking, or applying cosmetics.

WARNING: Consider all electrical leads to be energized until positively proven they are de-energized.

WARNING: Avoid inhalation of, ingestion of, skin contact with, and eye contact with hazardous materials. Avoid use near heat or open flame and provide adequate ventilation. Consult work center supervisor if unsure whether ventilation is adequate and if respiratory protection is necessary.

TM10

WARNING: Consider all electrical leads t be energized until positively proven they are de-energized.

WARNING: Spring loaded valve is heavily spring loaded. Ensure jacking bolts are utilized to maintain pressure on valve cover when releasing spring tension.

WARNING: Venting the diaphragm control chamber is required to remove entrapped air. Air and water will discharge when performing the venting procedure, exercise caution while loosening the vent screw.

Loosen vent screw only enough for trapped air to escape.

WARNING: Prior to entering HEF tank for cleaning, tank should be adequately ventilated and certified that atmosphere is not immediately dangerous to life or health by the Gas Free Engineer.

CAUTION: Using the Reset/Emergency Run pushbutton without clearing the fault can cause serious damage to the motor control, cables, and motor.

CAUTION: HEF should not discharge overboard within 3 nautical miles of shore or in port. Discharge should be in accordance with regulatory requirements. HEF foam should only be discharged only to a tank, barge, or authorize truck.

CAUTION: Wear appropriate chemical resistant clothing. Chemical resistant gloves. Do not get in eyes. Wear approved chemical safety glasses or goggles where eye exposure is reasonably probable.

CAUTION: Components of the HEF may be absorbed into the body through the skin. Blood disorder may occur after ingestion. Liver toxicity.

Contact may irritate or burn eyes.

CAUTION: HEF concentrate will present a slip hazard on solid surfaces. Keep work areas clear of spills.

CAUTION: A protected area filled with discharged HEF foam solution can and will be hazardous to maneuver in. Use extreme caution as vision, navigation and communication will be impaired.

CAUTION: After an HEF/Seawater discharge the compartment reentry can be accomplished by adjusting a hand line nozzle to spray pattern and moving into the compartment to knock the HEF down into the bilge.

Take care to avoid spraying directly on electrical panels as much as possible to minimize drying time. All equipment within the space shall be inspected and verified by OEM before operating and any wet insulation needs to be replaced.

TM11

2.1 HEF SYSTEM

High Expansion Foam (HEF) is one of the most widely used fire-fighting agents. HEF is primarily used aboard ship to fight class BRAVO fires. This manual covers the operation, maintenance, troubleshooting and repair of the Hiller HEF system. Operating and maintenance personnel must have a basic understanding of the operation of the Hiller HEF system and the function of each of the components of the system. It is an In-Line balanced pressure proportioning system for use with HEF foam concentrate. Firemain seawater is mixed with HEF concentrate to create a 2.75% HEF solution used to extinguish Class B fires (flammable liquids and gases). For more information refer to latest revision of HEF schematic 630-555-01-606.

2.2 EQUIPMENT DESCRIPTION

The three major components of the HEF system are:

Controller and Electrical Components HEF Pump Skid HEF Concentrate Storage Tank

Materials used to construct the items listed above are outlined in Ansul Technical Bulletin in Appendix S of this manual.

2.2.1 Controller and Electrical Components

The motor controller is mounted near the skid and is connected to the ship’s normal and emergency power supplies. The controller has indicating lights for monitoring the system, and three controls to operate the system.

2.2.2 HEF Pump Skid

The HEF skid houses several components including:

HEF Single-Speed Injection Pump HEF Pump Motor Back Pressure Regulating Valve Proportioning Assembly Check Valve Assembly Various Gate Type Cutout Valves Various Globe Type Valves Various Indicating Gauges Y-Type Strainers

2.2.3 HEF Concentrate Storage Tank

HEF concentrate is stored near the HEF skid in the HEF concentrate storage tank. The Austal manufactured tank i s rectangular in shape and is fabricated out of SS316L. The tank is fitted with a gooseneck vent, drain connection, manual fill connection w/cradle, liquid level indicator (sight glass), re-circulating line (return) connection, supply line connection, access manhole for tank maintenance. The gooseneck vent prevents excess buildup of pressure within the tank during storage and prevents a vacuum when the system is in operation. For more information pertaining to the tanks see drawing B015-46.90-630- 555-04-601.

2.2.4 HEF Containment Curtain

The HEF Containment Curtain is used in conjunction with the HEF firefighting system as a way to contain and prevent the spread of HEF outside of the Mission Bay area. For more information pertaining to the HEF Containment Curtain manual see S9555-FH-MMC-010.

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3.1 FUNCTIONAL DESCRIPTION

The Hiller HEF Skid System is an In-Line Balanced Pressure Proportioning System for the use with HEF Foam Concentrate. Firemain water is mixed with HEF concentrate to create a pressurized 2.75% HEF solution that is used to extinguish Class B fires (flammable liquid gases).

The HEF system is comprised of a storage tanks, a motor controller, and a pump skid with various control and regulating valves, a motor and direct driven pum p, strainers, gauges, a check valve, an In-Line balanced pressure proportioning assembly and piping.

HEF concentrate is pumped to the proportioner as required to maintain a 2.75% solution to the rem ote service stations when needed. Excess concentrate is returned to the storage tank via a return piping system . A spool valve uses sensing lines from the seawater side and the HEF solution side to control the flow of HEF concentrate to maintain the output at a 2.75% solution. For additional information pertaining to Firemain see Damage Control Book and for IMCS see

S9436-BN-MMC-010.

3.1.1 Motor Controller

The HEF (High Expansion Foam) Motor Controller is part of the ship’s HEF system designed to provide HEF to areas where a Class B fire may be expected. The motor controller is mounted near the skid and is connected to the ship’s service and emergency 460Vac/60Hz/3ph power from the HEF Power Panel.

3.1.2 HEF Single-Speed Injection Pump and Motor

The HEF single-speed injection pump is a permanently mounted, positive displacement, gear type of pump. The pump is direct driven by a high efficiency 15 horse power electric motor via a couplng. The motor is energized with 460Vac/60Hz/3ph power supply from the motor controller. he pump capacity is 65 (±5) gpm at 200 psi discharge pressure.

The pump unit consists of a pump, motor, and direct drive via a coupling, mounted on a steel base. The pump is fitted with an external relief valve set at 193 psi, which opens to prevent damage to the pump. The motor rotates at 3450 rpm. The injection pump and the injection station piping are sized to produce a 3 percent nominal concentrate at peak dem and by injecting HEF concentrate into the seawater distribution system . HEF concentrate is supplied from the HEF storage tank.

3.1.3 Proportioning Assembly

The proportioner houses no internal m oving parts and uses the venturi principle to allow for complete mixing of HEF/seawater solution. An orifice plate controls the volume of HEF concentrate entering the proportioner. The size of the orifice is determined by the maximum demand of the fire-fighting agent placed on the system. The water-sensing line connection for the proportioner is piped directly from the proportioner body to the spool valve.

3.1.4 Y-Type Strainer

The Hiller HEF system has two strainers. One on the HEF concentrate suction line near the inlet to the pump and the other on the seawater supply line. The strainers are used to reduce the chance of the pump becoming clogged and starving the pump or stopping the flow of seawater to the control valve. The strainers must be maintained so that heavy dirt and sludge does not accumulate on the strainers.

3.1.5 1½” Spool Valve

The spool valve senses the pressure in the foam concentrate and water lines and automatically adjusts the concentrate flow to the proportioner.

3.1.6 1½” Manual Foam Balancing Valve

The manual foam balancing valve on the IBP provides a backup means to adjust the concentrate pressure to balance the seawater pressure. Both pressures are indicated by the duplex gauge.

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3.1.7 Morin Double Acting Actuator

Double acting actuator valves control the flow of foam to the spool valve on the IBP. The actuator opens upon detection of water flow in the system distribution pipe after the sea water begins to flow.

3.1.8 Jet-X 2³/4% Foam

Jet-X 2³/4% high expansion foam concentrate is a synthetic-based formulation comprised of hydrocarbon surfactants, solvents, and stabilizers for use with high expansion foam generators. It is transported and stored as a concentrate that can be used to produce 200:1 to 1000:1 expansion ratio.

3.1.9 Motor Operated Valves (MOV) (JHSV 2 ONLY)

The HEF system is provided with MOV’s in support the HEF system. See S6435-2L-MMC- 010 for additional information.

3.1.10 Pneumatically Operated Valves (POV) (JHSV 1, 3 and Follow).

The HEF system is provided with POV’s in support of the HEF system. See S6435-ZM- MMC-010 for additional information.

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FIGURE 1

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4.1 INSPECTION, M AINTENANCE AND TESTING HEF PROPORTIONING SKID & SYSTEM

Inspection Frequency Check Valves Monthly Look for leakage, corrosion, damage Discharge Devices Monthly Look for leakage, wear, corrosion, damage (through screens) Pipe and Fittings Monthly Look for mechanical damage, missing or damaged paint, leaks Regulating and Relief Valves Monthly Look for leakage, broken or missing components Control Valves Monthly Look for leakage, corrosion, damage Foam Tank Monthly Look for leakage, internal and external corrosion

Spool Valve Quarterly Remove sensing lines and validate free movement of spool

Foam Concentrate Monthly Take samples and look for liquid clarity (lack of) or discoloration. Any discoloration Of the HEF concentrate in which it looks diluted or anyway different than its distinctive Green color would be unacceptable.

Foam Concentrate Weekly Check that foam concentrate storage temperature is within acceptable limits (35°F-120°F)

Maintenance Frequency Foam Concentrate Pump Operation Quarterly Run through recirculation procedure Foam Concentrate Strainer Quarterly Remove and clean

Foam Concentrate Samples Annuall y Take samples from tanks and send to factory for testing Control Valves Annuall y Lubricate valve, open & close valve to distribute lubricant & prove operation

Regulating Valve Annuall y Inspect diaphragm and replace if necessary. Remove and clean the regulating valves small strainer located on the sensing line.

Gauges Annuall y Calibrate gauges

H ydraulic Actuators Annuall y Check seals, check internals for corrosion, and re-grease piston cylinder Spool Valve Annuall y Flush, then remove sensing lines & validate free movement of spool.

Lubricate O-rings with #4 silicon grease

Concentrate Pump Service Annually Inspect bearings, impellers, seals, coupling for excessive wear Lubricate pump bearings, timings gears

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Testing Frequency Discharge Devices Annually Block rotation, and check flow & spray pattern with sw, followed by fw rinse Discharge Devices Annually Check rotation by hand and verify smooth operation

Regulating and Relief Valves Annually Test set points and adjust as necessary

Proportioning System Annually Operate & discharge system to collect foam sample to verify concentration

Complete System Annually Verify all discharge devices flowing; control valves operating correctly (full open/full close) and in the prescribed time, control interface signals operating properly and in sequence, shut down functioning

Note: For testing procedures see the following documents:

633-555-09-606 Test Instruction, Stage IV - HEF Mission Bay System, All Vessels 633-555-09-611 Test Instruction, Stage VII - HEF Mission Bay System, All Vessels 633-555-09-612 Test Instruction, Stage IV - HEF Engine Room System, All Vessels DC-2 HEF Mission Bay dockside DC-2A HEF Engine Rooms In port Demo DC-2B Mission Bay At-Sea

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4.2 HEF Engine Room System FW Flushing/Blowdown Procedure

Note: This procedure is to be completed following a system discharge of foam solution and/or salt water via the overboards or the generators. The procedure will ensure all equipment is flushed of foam concentrate and/or salt water. Refer to Operating schematic Fig 1 for identification and location of system valves. For HEF schematic layout see latest revision of drawing 630-555-01-606.

Note: Do not exceed system pressure when performing fresh water flush.

4.2.1 Port Engine Room:

1. Ensure skid is tagged out, and cannot be activated during system flush.

2. Open the following valves:

a. ER Overboard Throttle Valve HEF-V-090

b. ER Overboard Isolation Valve HEF-V-086

c. ER Generator Isolation Valve HEF-V-084

d. ER Main Generator Isolation Valve HEF-V-052

e. ER Bilge Generator Isolation Valve HEF-V-054

3. Ensure the following valves are closed:

a. ER Overboard Sample/Blowdown Valve HEF-V-088

b. ER Overboard Blowdown Valve HEF-V-092

c. ER Generator Blowdown Valve HEF-V-094

4. Attach a fresh water hose to the overboard connection. Open water supply valve and flow water down through overboard line, and down to the generators. Flow water until it appears clean and clear.

5. With water still flowing, close ER Generator Isolation Valve HEF-V-084. Then open/close drain cock valves on ER spool valve to flush sensing lines until clear water flows.

6. Upon finishing the flush of the Port ER Generators and spool valves, prepare to blowdown the system and generators.

7. Open the following valves:

a. ER Overboard Sample/Blowdown Valve HEF-V-088

8. Attach air hose to connection by HEF-V-088. Open air supply valve and blowdown lines until all water has exited out of the Engine Room Generators.

9. Restore all valves to normal operating positions.

4.2.2 Stbd Engine Room:

1. Ensure skid is tagged out, and cannot be activated during system flush.

a. ER Overboard Throttle Valve HEF-V-089

b. ER Overboard Isolation Valve HEF-V-085

c. ER Generator Isolation Valve HEF-V-083

d. ER Main Generator Isolation Valve HEF-V-051

e. ER Bilge Generator Isolation Valve HEF-V-053

3. Ensure the following valves are closed:

a. ER Overboard Sample/Blowdown Valve HEF-V-087

b. ER Overboard Blowdown Valve HEF-V-091

c. ER Generator Blowdown Valve HEF-V-093

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4. Attach a fresh water hose to the overboard connection. Open water supply valve and flow water down through overboard line, and down to the generators. Flow water until it appears clean and clear.

5. With water still flowing, close ER Generator Isolation Valve HEF-V-083. Then open/close drain cock valves on ER spool valve to flush sensing lines until clear water flows.

6. Upon finishing the flush of the Stbd ER Generators and spool valves, prepare to blowdown the system and generators.

7. Open the following valves:

a. ER Overboard Sample/Blowdown Valve HEF-V-087

8. Attach air hose to connection by HEF-V-087. Open air supply valve and blowdown lines until all water has exited out of the Engine Room Generators.

9. Restore all valves to normal operating positions.

4.3 HEF Mission Bay System FW Flushing/Blowdown Procedure

Note: This procedure is to be completed following a system discharge of foam solution and/or salt water via the overboards or the generators. The procedure will ensure all equipment is flushed of foam concentrate and/or salt water.

Note: For ease of completion, this flush procedure will start with port side aft-most generators, working to the forward port side generators, then across the ship to forward stbd generators, and then aft-ward to the final stbd side aft-most generators.

Note: Do not exceed system pressure when performing fresh water flush.

1. Ensure skids are tagged out, and cannot be activated during system flush.

a. Port MB Generator Flush Valve HEF-V-029

3. Close the following valves:

a. Port MB Generator Isolation Valve HEF-V-014

4. Attach fresh water hose to connection by HEF-V-029. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

5. Restore valves to normal operating positions before moving forward to the next generator.

6. Open the following valves:

a. Port MB Generator Flush Valve HEF-V-030

7. Close the following valves:

a. Port MB Generator Isolation Valve HEF-V-015

8. Attach fresh water hose to connection by HEF-V-030. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

9. Restore valves to normal operating positions before moving forward to the next generator.

10. Open the following valves:

a. Port MB Generator Flush Valve HEF-V-032

11. Close the following valves:

a. Port MB Generator Isolation Valve HEF-V-016

12. Attach fresh water hose to connection by HEF-V-032. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

13. Restore valves to normal operating positions before moving forward to the next generator.

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14. Open the following valves:

a. Port MB Generator Flush Valve HEF-V-034

15. Close the following valves:

a. Port MB Generator Isolation Valve HEF-V-017

16. Attach fresh water hose to connection by HEF-V-034. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

17. Restore valves to normal operating positions before moving forward to the next generator.

18. Open the following valves:

a. Port MB Generator Flush Valve HEF-V-035

19. Close the following valves:

a. Port MB Generator Isolation Valve HEF-V-018

20. Attach fresh water hose to connection by HEF-V-035. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

21. Restore valves to normal operating positions before moving across the ship to the next generator.

22. Open the following valves:

a. Stbd MB Generator Flush Valve HEF-V-027

23. Close the following valves:

a. Stbd MB Generator Isolation Valve HEF-V-013

24. Attach fresh water hose to connection by HEF-V-027. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

25. Restore valves to normal operating positions before moving aft to the next generator.

26. Open the following valves:

a. Stbd MB Generator Flush Valve HEF-V-025

27. Close the following valves:

a. Stbd MB Generator Isolation Valve HEF-V-012

28. Attach fresh water hose to connection by HEF-V-025. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

29. Restore valves to normal operating positions before moving aft to the next generator.

30. Open the following valves:

a. Stbd MB Generator Flush Valve HEF-V-003

31. Close the following valves:

a. Stbd MB Generator Isolation Valve HEF-V-011

32. Attach fresh water hose to connection by HEF-V-003. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

33. Restore valves to normal operating positions before moving aft to the next generator.

34. Open the following valves:

a. Stbd MB Generator Flush Valve HEF-V-023

35. Close the following valves:

a. Stbd MB Generator Isolation Valve HEF-V-010

36. Attach fresh water hose to connection by HEF-V-023. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

37. Restore valves to normal operating positions before moving aft to the next generator.

38. Open the following valves:

a. Stbd MB Generator Flush Valve HEF-V-022

39. Close the following valves:

a. Stbd MB Generator Isolation Valve HEF-V-009

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40. Attach fresh water hose to connection by HEF-V-022. Open water supply valve and flow water through the generator. Flow water until it appears clean and clear.

41. Restore valves to normal operating positions.

42. Open the following valves:

a. Port MB Flush/Blowdown Valve HEF-V-028

b. Stbd MB Flush/Blowdown Valve HEF-V-021

43. Ensure the following valves are closed:

a. Port MB Generator Header Drain Valve HEF-V-007

b. Stbd MB Generator Header Drain Valve HEF-V-005

44. Attach fresh water hose to connection by HEF-V-028 & HEF-V-021.