USCGC KATMAI BAY HOT OIL FLUSH

FAIRBANK MORSE MODEL 8 1/8 OPPOSED PISTON HOT OIL FLUSH SPECIFICATION FOR DOCKSIDE MAINTENANCE Developed By: IBCT Product Line (Rev-0, 27 Feb 2025) TABLE OF CONTENTS Revisions Record. iii Consolidated List of References. iv Consolidated List of Government-furnished Property. v Consolidated List of Critical Inspection Items. vi General Requirements. 8 WORK ITEM 1: Main Diesel Engine (MDE, Hot Lube Oil Flush....16 Revisions Record This page is used to record specification revisions, which may have occurred subsequent to a Revision 0 (Rev-0) package. Information listed is intended to provide contractors and field unit personnel a means to ensure all the current specification revision pages are present when reviewing or utilizing this specification package. DATE REV# WORK ITEM# CHANGES MADE NOTE : All work item and paragraph numbers listed above for a given revision correspond to same numbers in the previous revision. This revised specification is self-contained with all of the above listed changes incorporated. Consolidated List of References The below-listed documents form a part of this specification to the extent specified herein. Approval/publication dates or revision dates/numbers are also identified, to ensure that same document versions are used at time of specification writing and during contract execution. All Coast Guard drawings, technical publications, and standard specifications will be provided to contractors by the Coast Guard at an appropriate time, or upon request, free of charge. Other Government documents may be accessed - free of charge - as follows: MIL/DOD/CID Specifications: http://www.assistdocs.com/search/search_basic.cfm Commandant Instruction Manuals: http://www.uscg.mil/directives/default.asp Public Laws, Code of Federal Regulations, U.S Codes, and other Federal Government laws:: www.gpoaccess.gov The Government is aware of the following internet web links where contractors may procure commercial specifications: American Welding Society (AWS): http://www.awspubs.com/index.php ANSI, ASTM, IEEEE, NFPA, ASME, SAE Standards: http://www.techstreet.com/ NFPA: http://www.nfpa.org SSPC Standards and pictorial guides: http://shopping.netsuite.com/sspcmarketplace COAST GUARD DRAWINGS Coast Guard Drawing 140 WTGB 101-001, Rev -, Booklet of General Notes & Details Coast Guard Drawing 140 WTGB 201-001, Rev B, Machinery Arrangement Coast Guard Drawing 140 WTGB 262-001, Rev -, Lube Oil System Diagram Coast Guard Drawing 140 WTGB 262-002, Rev -, Lube Oil System A & D Coast Guard Drawing 140 WTGB 262-003, Rev -, Lube Oil System Mods Incidental to Spinner II Installation Coast Guard Drawing 140 WTGB 262-004, Rev A, Lube Storage Tank System A & D COAST GUARD PUBLICATIONS Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Coast Guard Technical Publication (TP) 3473, SWBS 233, Section A, Mar 2022, Main Diesel Engine - Model 38D8-1/8 Coast Guard Technical Publication (TP) 3474, SWBS 262, Section A, Pump and Motor, Main Lube Oil Coast Guard Technical Publication (TP) 3474, SWBS 262, Section B, Lube Oil System, MDE Support System OTHER REFERENCES None Consolidated List of Government-furnished Property The following is a list of property, which the Government will furnish. This list supersedes any other material obligations indicated or implied by referenced drawings. None Consolidated List of Critical Inspection Items The following is a list of work items, which contain Critical Inspection reports, which the Contractor must complete within the first 25% of the availability contract period (see SFLC Std Spec 0000, paragraph 3.2.6.5 (Inspection report particulars)): None 23300_SSDG #1 and #2Overhl_0819_IBCT General Requirements 1. SCOPE 1.1 Intent. The work item describes the requirements for the contractor to perform a center section overhaul of engines described in Table 1. Table 1. Engine(s) to Fl Engine # Manufacturer Model Serial # #2 MDE Fairbanks Morse 38 1/8 Opposed Piston 38D877037DSMP 1.2 Government-furnished property. None 2. REFERENCES Coast Guard Drawings Coast Guard Drawing 140 WTGB 101-001, Rev -, Booklet of General Notes & Details Coast Guard Drawing 140 WTGB 201-001, Rev B, Machinery Arrangement Coast Guard Drawing 140 WTGB 262-001, Rev -, Lube Oil System Diagram Coast Guard Drawing 140 WTGB 262-002, Rev -, Lube Oil System A & D Coast Guard Drawing 140 WTGB 262-003, Rev -, Lube Oil System Mods Incidental to Spinner II Installation Coast Guard Drawing 140 WTGB 262-004, Rev A, Lube Storage Tank System A & D Coast Guard Publications Coast Guard Commandant Instruction (COMDTINST) M10360.3 (series), Coatings and Color Manual Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Coast Guard Technical Publication (TP) 3473, SWBS 233, Section A, Mar 2022, Main Diesel Engine - Model 38D8-1/8 Coast Guard Technical Publication (TP) 3474, SWBS 262, Section A, Pump and Motor, Main Lube Oil Coast Guard Technical Publication (TP) 3474, SWBS 262, Section B, Lube Oil System, MDE Support System Other References None REQUIREMENTS 3.1 General. 3.1.1 CIR. None. 3.1.2 Tech Rep. The Contractor must provide the services of a qualified mechanic, who is familiar with lube oil hot flushing of the Fairbanks Morse Engine (FME) Model 38D8-1/8 diesel engines and related equipment (lube oil coolers, strainers, etc), to do the following, on site: Advise on manufacturer's proprietary information pertinent to the system. Assist with proper methods of connection(s) and lube oil system bypass methods required for proper diesel engine hot flush procedure in accordance with this specification. Ensure compliance with manufacturer's procedures and standards during system disassembly, inspection, and reassembly as applicable. 3.1.2.1 Ensure the Tech Rep has experience with the system/equipment stated above and demonstrated on their r'sum. 3.1.2.2 Submit the name and r'sum of the Tech Rep to the COR at the Arrival Conference. 3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection). 3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following: Deck plates. Deck framing. Piping. Handrails. Electrical wiring and cables/cableways. Miscellaneous machinery. 3.1.5 Contamination prevention. The Contractor must take all precautions to prevent contamination of personnel and spaces in accordance with all applicable Federal, state, and local regulations. 3.2 Fluid handling. The Contractor must remove and dispose of removed fluids from the affected piping system, in accordance with all applicable Federal, state, and local regulations. WARNING Do not drain ANY fluids, including fresh water, into any space, bilge, or exterior location. 3.3 Work plan. The Contractor shall provide a work plan to the Contracting Officer (KO), at the time of solicitation submission, which lists all procedures, plans, and equipment the Contractor will utilize in support of flushing requirements. At a minimum, the plan shall include the following: Qualifications of Project Manager / Lead Mechanic overseeing flushing operations. List of all equipment used in support of flushing operations, including models and ratings. List of safety equipment, devices, and procedures. Quality assurance controls, including sample checklists, logs, checkpoints, etc. Step-by-step flushing procedure, including system diagrams and valve lineups. System restoration procedure. 3.4 Flushing requirements. 3.4.1 Flushing equipment. The Contractor shall provide all equipment required to support flushing operations, including (but not limited to), the following: note The Contractor should be aware that neither the cutter, nor the cutter support base, is capable of providing the 440 VAC power necessary to operate any flushing support systems and that the Contractor must provide a suitable 450 VAC power source. 3.4.1.1 Flushing pump. A positive displacement pump capable of providing 260 GPM flow rate at 120 psig. 3.4.1.2 Flow meter. A flow meter capable of measuring flow of flushing fluid. 3.4.1.3 Portable Particle Counter. A particle counter capable of continuously measuring fluid contamination with output in NAS code. 3.4.1.4 Filtration system. A bag and cartridge filtration system that allows for continuous operation, rated at the flow rate of the pump (or greater), that is capable of supporting the following: - In-flush bag change-outs. 25-micron commercial polyester, full-flow filter bags. 3-micron cartridge filters. Magnetic filters. 3.4.1.5 Heating system. A heating system capable of accurately maintaining flushing fluid at 160 -190 - F. 3.4.1.6 Oil spill containment. A pier-side oil spill containment system with sufficient capacity to contain all components associated with the filtration, heating, and flushing pump systems. 3.4.1.7 Temporary valves, spools, blanks, and jumper lines. All valves, spools, blanks, flanges, and jumper lines required in support of flushing operations. 3.4.2 Filter bags. The Contractor shall accomplish the following for the flushing media filters/filtration system: 3.4.2.1 Filter the flushing fluid using commercial polyester full flow filter bags (sized to suit strainer basket) rated at 25 microns particle retention rating. 3.4.2.2 Renew filter bags as necessary during flushing operations to maintain a differential pressure increase of no more than 5 psig over the differential pressure of a clean filter bag. 3.4.3 Flushing media. The Contractor shall use commercial grade (non-synthetic) SAE 10W High Detergent oil, with an API rating of SC or better, in support of flushing operations. note Upon completion of lube oil flushing loop, the flushing oil may be returned to clean containers and can be used for the next hot lube oil flush provided cleanliness of lube oil can be maintained. 3.4.4 Component removal/reinstallation tracking. The Contractor shall ensure that all components removed from the engine/lube oil system are match-marked and tracked via a recorded log to ensure proper reinstallation. Submit a CFR as follows: Beginning of each flushing stage to document equipment/components removed. Completion of each flushing stage to document equipment/components reinstalled. 3.4.5 COR notification. The Contractor shall notify the COR at least 24 hours prior to beginning each flushing operation. 3.4.6 Inspector witnessing and approval. The Contractor shall ensure that the Coast Guard Inspector is present during all flushing oil sampling and inspection. The Contractor's final sampling and inspection shall be approved in writing by the COR and Coast Guard Inspector. 3.4.7 Pre-flush cleanliness verification. Prior to starting flushing, the Contractor shall perform the following: 3.4.7.1 Remove and dispose of engine filters. 3.4.7.2 Drain and clean engine sump, screens, filter housing(s), and strainer housing(s). 3.4.7.3 Remove and clean oil strainers. 3.4.7.4 Wipe clean and oil-wet engine interior surfaces and components (e.g., crankcase, crankshaft, connecting rods, bearing caps, gears, etc.) to prevent - flash rusting. 3.4.8 Post-flush report requirements. After each flushing stage, the Contractor shall submit a detailed report to the COR within 24 hours, to include the following at a minimum: Method used to obtain the particulate contamination reading. Method used to determine particle size. Final contamination level readings. List of all particles collected and description (size, nature, etc) 3.5 Flushing procedure. Using the Coast Guard Drawings and Technical Publications listed in Section 2 - References as guidance, the Contractor shall conduct a staged flush of the MDE lube oil system as follows: 3.5.1 Flushing sequence. 3.5.1.1 Conduct the MDE hot lube oil flush in the following sequence: External Internal Combined external and internal 3.5.1.2 The following flushes / cleanings may be accomplished in any sequence (prior to, concurrent, or after) the flushing of Para 3.4.1.1, but prior to system restoration: Outflushes of disconnected instrumentation, drain, and vent lines. Cleaning of all - jumpered components (system pumps, filters, and associated - dead legs) Lube oil cooler. 3.5.2 Pre-flushing preparations. The Contractor shall perform the following prior to commencing the applicable flushing stage procedure: Blank off bearing oil feed lines. Disconnect & blank the pre-lube oil and main oil pumps, installing jumper lines to by-pass. Disconnect the lube oil cooler and install jumper line with valve to by-pass the cooler. Disconnect main bearing jumper lines and end plugs on main internal lube oil header; hand lean accessible ports and plug. Disconnect all lube oil supply lines to internal components including cam bearing, gear train, governor, and cylinders, as applicable. 3.5.3 Flushing acceptance criteria. The Contractor shall flush each loop until the following cleanliness criteria is maintained for a 2-hour period. 3.5.3.1 Differential pressure. Differential pressure increase of less than 2 psig higher than the differential of a clean filter bag can be maintained for a 2-hour period. 3.5.3.2 Visual inspection. Visual inspection of all contaminants (solid, solid-based, and nonsolid) collected from the filter bag and magnets after the end of the 2-hour collection period indicates that the sum total volume of particles shall not exceed the volume of a U.S. dime (10-cent piece). The filter bags and strainer magnets shall contain no more than five solid or solid-based contaminants, no one greater than 1/64 inch in any direction. The filter bags and strainer magnets shall contain no non-solid contaminant larger than 1/16 inch in any dimension except for hairlike particles which can be up to 1/8 inch long. note Solid-based contaminants are defined as particles which cannot be crushed between the thumbnail and finger. 3.5.3.3 Particulate count. Fluid contamination levels do not exceed NAS Code 1638 -Class 9 for the duration of the 2-hour period. note 1) The flushing process duration begins when the oil is within and maintains the specified flushing temperature (170 to 180 F) and flowrate (260 gpm). Temperatures and flow rates shall be maintained for the duration of the flush. 2) During flushing, the system shall be manually shocked or vibrated using soft mallets or mechanical vibrators to dislodge contaminants within the piping. 3) Filter bags and cartridges shall be changed as needed to maintain a differential pressure increase of no more than 5 psig over the differential pressure of a clean filter bag. 4) Rotate the engine crankshaft (for internal flush sequences) through 90 degrees travel at 20 minute intervals. 3.5.4 Sequence flush. 3.5.4.1 Heat a quantity of clean flushing oil, equaling 60 to 70 percent of sump capacity, to a temperature of 170 to 180 F. 3.5.4.2 Circulate the oil throughout the lube oil circuits in the following increments, confirming secure connections prior to each next incremental increase: 20 gpm; 75 gpm; 260 gpm (not to exceed 120 psi). 3.5.4.3 Flush each lube oil system loop for a minimum of 12 hours. 3.5.4.4 Continue flushing each loop until the cleanliness criteria of Para 3.5.3 is maintained for a 2 -hour period for applicable loop. 3.5.5 Ancillary components. 3.5.5.1 Disconnected instrumentation lines. Flush all disconnected gage and pressure switch lines using flushing oil or compressed air. 3.5.5.2 Jumpered components and equipment. Hand clean all components and piping (both removed and blanked) not flushed during the flushing process. Inspect condition of all components and piping. Submit a CFR. 3.5.5.3 Lube oil cooler. 3.5.5.3.1 Disconnect and remove the lube oil cooler assembly and transport it to the shop. 3.5.5.3.2 Soak the cooler in cleaner bath for 4 hours to remove any dirt or sludge build up and then clean the cooler. 3.5.5.3.3 In the shop, hydrostatically test the lube oil cooler to ensure that there are no water leaks. Test pressure will be as specified by the technical representative. If any leaks are detected, repairs will be the subject of a contract modification. 3.5.5.3.4 Reassemble the cooler using new gaskets, O-rings and lantern ring. 3.5.5.3.5 Reinstall the cooler assembly on the engine using new gaskets and O-rings. 3.6 System restoration. Upon completion of engine flushing, accomplish the following: 3.6.1 Drain flushing oil from sump, piping, filter and strainer housings, placing flushing oil in suitable containers. Dispose of all removed oil. note 1) Every effort shall be made to remove flushing oil from the lube oil system, to including removal of oil sump screens and wiping the sump clean with lint free rags. This will ensure a satisfactory test for viscosity, which will eliminate the need to change oil after a few hours of engine operation. 2) Careful use of clean low pressure air (100 psi or less) may be used to blow flushing lube oil back to the engine sump through the filter and strainer housings. 3.6.2 Clean and inspect lube oil sump using lint-free rags. Clean and inspect internal lube oil pump suction piping from the suction bell mouth or strainer to the pump inlet. 3.6.3 Restore lube oil system to original configuration in preparation for engine run. note Ships Force will reinstall all engine filters and replenish oil upon satisfactory completion of all system restoration. 3.7 Engine run after flushing completion. The Contractor shall be present during testing of the MDE (s) to ensure satisfactory flushing was accomplished. NOTE Coast Guard personnel will operate all shipboard machinery and equipment. caution! Monitor the differential pressure across the strainer and filter during engine operation. Ensure the differential pressure does not exceed bypass valves set point. If the strainer or filter requires repeated cleaning to maintain proper differential pressure, the entire flushing procedure shall be repeated. warning Some debris is expected during engine operations for various reasons (i.e. internal engine components that cannot be 100% flushed, potential overhaul/repair work accomplished concurrently with flushing, vibrations created by engine operations, etc). Engine run-in should continue, monitoring pressures and filter contents, to ensure residual debris is filtered by the installed system before making official determination regarding efficiency of the flush. Immediately stop all engine run-in procedures if evidence of substantial debris (i.e. metal shavings, large contaminates, etc) are discovered that could be indicators of potential issues. 4. NOTES 4.1 Equipment operation. Coast Guard personnel will operate all shipboard machinery and equipment during all operational tests. 4.2 System lube oil. Current lube oil in use is Mobilguard 410. ITEM 1: Main Diesel Engine (MDE), Hot Lube Oil Flush 1. SCOPE 1.1 Intent. This work item describes the requirements for the Contractor to perform a staged hot flush to the Lube Oil (LO) systems on each of the Main Diesel Engines (MDEs) listed below: 1.1.1 MDE #2. Fairbanks Morse Opposed Piston (OP) Engine - Model 38D8-1/8, S/N 38D877037DSMP 1.2 Government-furnished property. None. 2. REFERENCE Coast Guard Drawings Coast Guard Drawing 140 WTGB 101-001, Rev -, Booklet of General Notes & Details Coast Guard Drawing 140 WTGB 201-001, Rev B, Machinery Arrangement Coast Guard Drawing 140 WTGB 262-001, Rev -, Lube Oil System Diagram Coast Guard Drawing 140 WTGB 262-002, Rev -, Lube Oil System A & D Coast Guard Drawing 140 WTGB 262-003, Rev -, Lube Oil System Mods Incidental to Spinner II Installation Coast Guard Drawing 140 WTGB 262-004, Rev A, Lube Storage Tank System A & D Coast Guard Publications Coast Guard Technical Publication (TP) 3473, SWBS 233, Section A, Mar 2022, Main Diesel Engine - Model 38D8-1/8 Coast Guard Technical Publication (TP) 3474, SWBS 262, Section A, Pump and Motor, Main Lube Oil Coast Guard Technical Publication (TP) 3474, SWBS 262, Section B, Lube Oil System, MDE Support System Surface Forces Logistics Center Standard Specification 0000 (SFLC Std Spec 0000), 2022, General Requirements Other References None. 3. REQUIREMENTS 3.1 General. 3.1.1 CIR. None. 3.1.2 Tech Rep. The Contractor must provide the services of a qualified mechanic, who is familiar with lube oil hot flushing of the Fairbanks Morse Engine (FME) Model 38D8-1/8 diesel engines and related equipment (lube oil coolers, strainers, etc), to do the following, on site: Advise on manufacturer's proprietary information pertinent to the system. Assist with proper methods of connection(s) and lube oil system bypass methods required for proper diesel engine hot flush procedure in accordance with this specification. Ensure compliance with manufacturer's procedures and standards during system disassembly, inspection, and reassembly as applicable. 3.1.2.1 Ensure the Tech Rep has experience with the system/equipment stated above and demonstrated on their r'sum. 3.1.2.2 Submit the name and r'sum of the Tech Rep to the COR at the Arrival Conference. 3.1.3 Protective measures. The Contractor must furnish and install all protective measures in accordance with SFLC Std Spec 0000, paragraph 3.3.3 (Vessel component, space, and equipment protection). 3.1.4 Interferences. The Contractor must handle all interferences in accordance with SFLC Std Spec 0000, paragraph 3.3.5 (Interferences). Known interferences include, but are not limited to the following: Deck plates. Deck framing. Piping. Handrails. Electrical wiring and cables/cableways. Miscellaneous machinery. 3.1.5 Contamination prevention. The Contractor must take all precautions to prevent contamination of personnel and spaces in accordance with all applicable Federal, state, and local regulations. 3.2 Fluid handling. The Contractor must remove and dispose of removed fluids from the affected piping system, in accordance with all applicable Federal, state, and local regulations. WARNING Do not drain ANY fluids, including fresh water, into any space, bilge, or exterior location. 3.3 Work plan. The Contractor shall provide a work plan to the Contracting Officer (KO), at the time of solicitation submission, which lists all procedures, plans, and equipment the Contractor will utilize in support of flushing requirements. At a minimum, the plan shall include the following: Qualifications of Project Manager / Lead Mechanic overseeing flushing operations. List of all equipment used in support of flushing operations, including models and ratings. List of safety equipment, devices, and procedures. Quality assurance controls, including sample checklists, logs, checkpoints, etc. Step-by-step flushing procedure, including system diagrams and valve lineups. System restoration procedure. 3.4 Flushing requirements. 3.4.1 Flushing equipment. The Contractor shall provide all equipment required to support flushing operations, including (but not limited to), the following: note The Contractor should be aware that neither the cutter, nor the cutter support base, is capable of providing the 440 VAC power necessary to operate any flushing support systems and that the Contractor must provide a suitable 450 VAC power source. 3.4.1.1 Flushing pump. A positive displacement pump capable of providing 260 GPM flow rate at 120 psig. 3.4.1.2 Flow meter. A flow meter capable of measuring flow of flushing fluid. 3.4.1.3 Portable Particle Counter. A particle counter capable of continuously measuring fluid contamination with output in NAS code. 3.4.1.4 Filtration system. A bag and cartridge filtration system that allows for continuous operation, rated at the flow rate of the pump (or greater), that is capable of supporting the following: - In-flush bag change-outs. 25-micron commercial polyester, full-flow filter bags. 3-micron cartridge filters. Magnetic filters. 3.4.1.5 Heating system. A heating system capable of accurately maintaining flushing fluid at 160 -190 - F. 3.4.1.6 Oil spill containment. A pier-side oil spill containment system with sufficient capacity to contain all components associated with the filtration, heating, and flushing pump systems. 3.4.1.7 Temporary valves, spools, blanks, and jumper lines. All valves, spools, blanks, flanges, and jumper lines required in support of flushing operations. 3.4.2 Filter bags. The Contractor shall accomplish the following for the flushing media filters/filtration system: 3.4.2.1 Filter the flushing fluid using commercial polyester full flow filter bags (sized to suit strainer basket) rated at 25 microns particle retention rating. 3.4.2.2 Renew filter bags as necessary during flushing operations to maintain a differential pressure increase of no more than 5 psig over the differential pressure of a clean filter bag. 3.4.3 Flushing media. The Contractor shall use commercial grade (non-synthetic) SAE 10W High Detergent oil, with an API rating of SC or better, in support of flushing operations. note Upon completion of lube oil flushing loop, the flushing oil may be returned to clean containers and can be used for the next hot lube oil flush provided cleanliness of lube oil can be maintained. 3.4.4 Component removal/reinstallation tracking. The Contractor shall ensure that all components removed from the engine/lube oil system are match-marked and tracked via a recorded log to ensure proper reinstallation. Submit a CFR as follows: Beginning of each flushing stage to document equipment/components removed. Completion of each flushing stage to document equipment/components reinstalled. 3.4.5 COR notification. The Contractor shall notify the COR at least 24 hours prior to beginning each flushing operation. 3.4.6 Inspector witnessing and approval. The Contractor shall ensure that the Coast Guard Inspector is present during all flushing oil sampling and inspection. The Contractor's final sampling and inspection shall be approved in writing by the COR and Coast Guard Inspector. 3.4.7 Pre-flush cleanliness verification. Prior to starting flushing, the Contractor shall perform the following: 3.4.7.1 Remove and dispose of engine filters. 3.4.7.2 Drain and clean engine sump, screens, filter housing(s), and strainer housing(s). 3.4.7.3 Remove and clean oil strainers. 3.4.7.4 Wipe clean and oil-wet engine interior surfaces and components (e.g., crankcase, crankshaft, connecting rods, bearing caps, gears, etc.) to prevent - flash rusting. 3.4.8 Post-flush report requirements. After each flushing stage, the Contractor shall submit a detailed report to the COR within 24 hours, to include the following at a minimum: Method used to obtain the particulate contamination reading. Method used to determine particle size. Final contamination level readings. List of all particles collected and description (size, nature, etc) 3.5 Flushing procedure. Using the Coast Guard Drawings and Technical Publications listed in Section 2 - References as guidance, the Contractor shall conduct a staged flush of the MDE lube oil system as follows: 3.5.1 Flushing sequence. 3.5.1.1 Conduct the MDE hot lube oil flush in the following sequence: External Internal Combined external and internal 3.5.1.2 The following flushes / cleanings may be accomplished in any sequence (prior to, concurrent, or after) the flushing of Para 3.4.1.1, but prior to system restoration: Outflushes of disconnected instrumentation, drain, and vent lines. Cleaning of all - jumpered components (system pumps, filters, and associated - dead legs) Lube oil cooler. 3.5.2 Pre-flushing preparations. The Contractor shall perform the following prior to commencing the applicable flushing stage procedure: Blank off bearing oil feed lines. Disconnect & blank the pre-lube oil and main oil pumps, installing jumper lines to by-pass. Disconnect the lube oil cooler and install jumper line with valve to by-pass the cooler. Disconnect main bearing jumper lines and end plugs on main internal lube oil header; hand lean accessible ports and plug. Disconnect all lube oil supply lines to internal components including cam bearing, gear train, governor, and cylinders, as applicable. 3.5.3 Flushing acceptance criteria. The Contractor shall flush each loop until the following cleanliness criteria is maintained for a 2-hour period. 3.5.3.1 Differential pressure. Differential pressure increase of less than 2 psig higher than the differential of a clean filter bag can be maintained for a 2-hour period. 3.5.3.2 Visual inspection. Visual inspection of all contaminants (solid, solid-based, and nonsolid) collected from the filter bag and magnets after the end of the 2-hour collection period indicates that the sum total volume of particles shall not exceed the volume of a U.S. dime (10-cent piece). The filter bags and strainer magnets shall contain no more than five solid or solid-based contaminants, no one greater than 1/64 inch in any direction. The filter bags and strainer magnets shall contain no non-solid contaminant larger than 1/16 inch in any dimension except for hairlike particles which can be up to 1/8 inch long. note Solid-based contaminants are defined as particles which cannot be crushed between the thumbnail and finger. 3.5.3.3 Particulate count. Fluid contamination levels do not exceed NAS Code 1638 -Class 9 for the duration of the 2-hour period. note 1) The flushing process duration begins when the oil is within and maintains the specified flushing temperature (170 to 180 F) and flowrate (260 gpm). Temperatures and flow rates shall be maintained for the duration of the flush. 2) During flushing, the system shall be manually shocked or vibrated using soft mallets or mechanical vibrators to dislodge contaminants within the piping. 3) Filter bags and cartridges shall be changed as needed to maintain a differential pressure increase of no more than 5 psig over the differential pressure of a clean filter bag. 4) Rotate the engine crankshaft (for internal flush sequences) through 90 degrees travel at 20 minute intervals. 3.5.4 Sequence flush. 3.5.4.1 Heat a quantity of clean flushing oil, equaling 60 to 70 percent of sump capacity, to a temperature of 170 to 180 F. 3.5.4.2 Circulate the oil throughout the lube oil circuits in the following increments, confirming secure connections prior to each next incremental increase: 20 gpm; 75 gpm; 260 gpm (not to exceed 120 psi). 3.5.4.3 Flush each lube oil system loop for a minimum of 12 hours. 3.5.4.4 Continue flushing each loop until the cleanliness criteria of Para 3.5.3 is maintained for a 2 -hour period for applicable loop. 3.5.5 Ancillary components. 3.5.5.1 Disconnected instrumentation lines. Flush all disconnected gage and pressure switch lines using flushing oil or compressed air. 3.5.5.2 Jumpered components and equipment. Hand clean all components and piping (both removed and blanked) not flushed during the flushing process. Inspect condition of all components and piping. Submit a CFR. 3.5.5.3 Lube oil cooler. 3.5.5.3.1 Disconnect and remove the lube oil cooler assembly and transport it to the shop. 3.5.5.3.2 Soak the cooler in cleaner bath for 4 hours to remove any dirt or sludge build up and then clean the cooler. 3.5.5.3.3 In the shop, hydrostatically test the lube oil cooler to ensure that there are no water leaks. Test pressure will be as specified by the technical representative. If any leaks are detected, repairs will be the subject of a contract modification. 3.5.5.3.4 Reassemble the cooler using new gaskets, O-rings and lantern ring. 3.5.5.3.5 Reinstall the cooler assembly on the engine using new gaskets and O-rings. 3.6 System restoration. Upon completion of engine flushing, accomplish the following: 3.6.1 Drain flushing oil from sump, pi...