FM 38-700 Packaging of Materiel - Preservation

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FM 38-700

DEPARTMENT OF THE ARMY FIELD MANUAL FM 38-700MARINE CORPS ORDER MCO P4030.31DDEPARTMENT OF THE NAVY PUBLICATION NAVSUP PUB 502DEPARTMENT OF THE AIR FORC E PAMPHLET AFPAM(I) 24-237DEFENSE LOGISTICS AGENCY INSTRUCTION DLAI4145.14

PACKAGING OF MATERIEL

PRESERVATION

DEPARTMENTS OF THE ARMY, THE NAVY, THE AIR FORCE,AND THE DEFENSE LOGISTICS AGENCY

700DISTRIBUTION RESTRICTION: Approv ed f or public release; distribution is unlimited.


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*FM 38-700

MCO P4030.31D

NAVSUP PUB 502AFPAM(I) 24-237

DLAI 4145.14

DEP ARTMENTS OF THE ARMY,

NAVY, AND AIR F ORC E, AND TH E

DEFE NSE LOGI STI CS AGENCY

P ACKAGING OF MATERIE L

PRESERVATI ON

CH AP TE R P AGE

CHAPTE R 1 - INTRODUCTION PACKAGING P OLICYGENE RAL ..................................................................................................................... 1-1

UN IT PACK................................................................................................................... 1-1

INTERMEDIATE PACK .............................................................................................. 1-1

EF FICI EN T AND ECON OMICAL HANDLIN G ........................................................ 1-2

LEVELS OF PROTEC TION ........................................................................................ 1-3

ELE CTROSTATIC SE NSITI VE DISC HARGE (ESDS) ITE MS................................ 1-3

PROTECTING RETROGRADE CARGO OR RETURNE D MATERIEL .................. 1-3

OTH ER POLI CY REQUI REMEN TS........................................................................... 1-4

CHAP TER 2 CLE ANING AND DR YINGBASIC CLE ANING PRINCIP LES .............................................................................. 2-1

CLE ANING REQUI RE MEN TS ................................................................................... 2-2

PROCE SS SEL ECTION REQU IRMEN TS ................................................................. 2-2

CLE ANING P ROCE SSE S............................................................................................ 2-4

ULTRASONIC CLEANING (FI GURE 2-36)............................................................... 2-45

DRYING P ROCE DUR ES ............................................................................................. 2-53

J ET SP RAY WASHIN G................................................................................................ 2-54

NAVY'S HAZARDOUS MATERIALS REDU CTION PROGRAMS ........................... 2-58

CHAPTE R 3 P RE SERVATIVES AND THEIR APP LICATION

BASIC PRIN ICP LES OF P RES ERVATIVES PROTE CTION ................................... 3-1CLASSIF ICATION OF PR ES ERVATIVES ................................................................ 3-4

PE RMANE NT PR ES ER VATIVES FOR MET ALS..................................................... 3-4

CHEMI CAL CONVERSI ON COATINGS ................................................................... 3-5

*This field ma nu al s uper sedes D LAM 4145.2, Vol I/TM 38-230-1/ AFP 71-15, Vol 1/NAVSUPPUB 502, Rev. Vol 1/MCO P4030.31C, Packaging of Materiel Preservation (Volume I),

August 1982

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CHAPTER 3 PRESERVATIVES AND THEIR APPLICATION

(CONTINUED)PRES ERVATIVES FOR NONME TALS...................................................................... 3-8

CONTACT PRES ER VATIVES FO R METALS ........................................................... 3-10

LUBRICANTS AND TEMPORARY PRESERVATIVES OTHE R TH AN

CONTACT PRESE RVATIVES ................................................................................ 3-12

METH ODS OF APP LYING P RES ERVATIVES TO ME TAL ITEMS....................... 3-16VOLATILE CORROS ION INH IBI TORS (VCI) .......................................................... 3-25

CHAPTE R 4 METHODS OF P RE SERVATION (UNIT P ACK)GEN ERAL PRIN CIPLE S AND RE UQIRE MEN TS ................................................... 4-1

SOURCE S OF PACKAGING REQU IREME NTS ....................................................... 4-2

PACKAGIN G MATERI ALS ......................................................................................... 4-4

CUSH IONIN G MATERIALS AND THE IR APP LICATIONS ................................... 4-16

HE AT SE ALING ........................................................................................................... 4-36

CONSTRU CTION OF METH ODS OF PRE SE RVATION ......................................... 4-41

METHOD 20 PRESERVATIVE COATING ONLY (WITH

GRE ASEP ROOF WRAP, AS REQUI RED) ............................................................. 4-54

METHOD 30 WATERPROOF OR WATERPROOF-GREASEPROOF

PRO TECTION WITH P RES ERVATIVE AS RE QUIRE D .................................... 4-58

METHOD 40 WATERVAPORPROOF PROTECTION WITH

PRESE RVATIVE AS REQUI RED .......................................................................... 4-65

METHOD 50 WATERVAPORPROOF PROTECTION WITH

DE SICCANT ............................................................................................................ 4-76

QUANTITY PE R UNIT PACK (QUP) ......................................................................... 4-90

QUALIT Y ASSURANCE PROVISIONS ..................................................................... 4-90

LEAKAGE TES TS ........................................................................................................ 4-92

HE AT-SEALED SEAM TE ST ...................................................................................... 4-94

CONTAINE R PE RFORMANCE TESTIN G ................................................................ 4-97

DETE RMINATION OF PRE SE RVATION RE TEN TION ......................................... 4-99

DISP OSI TION OF SAMPLES ..................................................................................... 4-101

MARKING UN IT AND INTE RMEDIATE PACKS .................................................... 4-101

CHAPTE R 5 SPR AYABLE, STRIP P ABLE F ILMS AND CONTROLLED

HUMIDITY SP RAYABLE, STRIP P ABLE FILMSGENE RAL ..................................................................................................................... 5-1

CONTROLLE D H UM IDITY ........................................................................................ 5-3

CHAPTE R 6 FIBE RBOARD AND P AP ER BOARD CONTAINER SINTRODU CTION ......................................................................................................... 6-1

FI BERBOARD BOXES ................................................................................................. 6-1

PAP ERBOARD CON TAINE RS ................................................................................... 6-14

FOLDIN G PAPE RBOARD BOXES ............................................................................. 6-15

SE TUP BOXES (PP P-B-676) ....................................................................................... 6-17METAL-EDGE D PAP ERBOARD BOXES (PP P-B-665)............................................. 6-22

TRIPLE -WALL CORRUGATED FIBE RBOARD BOXES (ASTM D 5168)............... 6-24

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CHAP TER 7 CANS AND DR UMSDESCRI PTIO N, CLASSIFI CATION AND SE LECTION F ACTORS ....................... 7-1

FI BER DRUMS (PP P-D-723) ....................................................................................... 7-2

CANS, CO MPOSI TE, FOR DRY P RODUCTS (PPP -C-55)........................................ 7-6

METAL CANS, 28 GAGE AND LIGHTER (PP P-B-96) ............................................. 7-6

SHIP PING AND STORAGE, REU SABLE ME TAL DRUMS

(CAPACITY 88 TO 510 CUBIC INCH ES) (MIL-D-6055) ..................................... 7-7

CHAPTE R 8 REUSABLE CUSHIONED C ONTAINERSINTRODU CTION ......................................................................................................... 8-1

BOXES, SHIP PIN G, REU SABLE, WITH CUSHIO NIN G (PP P-B-1672)................. 8-1

CONTAINE RS, PLASTIC REU SABLE SHI PP ING AND STORAGE ...................... 8-12

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Chapter 1

Introduction - Packaging Policy

GENERALAR700-15/NAVSUP INST 4030.28D/AFJ MAN 24-206/MCO 4030.33D/DLAD 4145.7

Packaging of Materiel, is a joint regulation for all Department of Defense (DOD)

component s which esta blishes p olicies on t he development of un iform r equiremen ts

for th e packa ging of ma ter iel acquired , stored , or shipped. The joint regu lation

implements DOD 4140.1-R, DOD Materiel Management Regulation, and covers

policy requ iremen ts concernin g the following:

Packaging Specifications an d Sta nda rds Levels of Protection Project Informa tion Exchange

It pr ovides uniform criteria for th e selection an d pr escription of packaging at th etime of acquisition, storage, or shipment.

While the Pa ckaging of Mater iel publicat ion r elates to both preser vation of th e un itpacks and packing of the shipping containers, this document will only addresspreservat ion requirement s, including the levels of protection. Unit packs an dinterm ediate packs will also be discussed in t his chapter .

UNIT P ACKUnit pa cks are often r eferred to as interior packs. Figure 1-1 is a diagra m whichconceptualizes a shipping container with four unit packs and two intermediatepacks. Listings of inter mediate an d shipping container s are foun d in the MIL-STD-

2073-1C, Sta ndar d Pra ctice for Militar y Pa ckaging. This docum ent will be discussedlater in the chapters on preservation and preservation methods.

A unit pa ck is defined a s th e first t ie, wrap, or contain er a pplied to a single item, ora qu ant ity ther eof, or to a group of items of a single stock num ber, preserved orun preserved, th at constitutes a single complete or identifiable package.

Unit pa cks are, for the most pa rt, int erior pa cks; however, th ere ar e preservat ionmethods requiring the unit pack to also be the shipping container. Those situationswill be presented in cha pter four .

INTERMEDIATE P ACKAn intermediat e pack is a wrap, box, or bundle th at cont ains t wo or more u nit pa cksof identical items. Inter mediate cont ainers or packs ar e used when th ey facilitate

han dling, stora ge and resh ipment; when th e exterior sur face of the un it pack is abag or wrap; when the u nit pack volume is less tha n 64 cubic inches and t he exteriorcontainer is a rigid type; and when specified by the procuring activity.


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Figure 1-1. A packaging diagra m.

The development a nd ordering of quan tities to be placed in th e un it, intermediate,an d exterior pack require coordina tion with th e man aging activity. These quant itieswill be established after evaluating all known factors, including the following:

maint enan ce concept for t he item being sup ported basis for issue such as allowance and load list life expectancy such as shelf-life and mortality rate chemical an d p hysical cha racteristics constr uction a nd functiona l requirement s fragility or u nit cost ease of accounta bility an d invent ory commercial practice quantity for like items militar y stan dard s or applicable regulations

EF FICIE NT AND ECONOMICAL HANDLINGThe m ilitary concept of economy in preservat ion is to obtain maximum output ofadequa tely protected items at a m inimum cost. Economy measur es, consistent withthe degree of protection required by an item, should be of prime concern toindividua ls establishing preserva tion and packaging requirem ents. They mu st alsobe a concern to personnel in charge of or performing packing operations.

Significant savings can be accomplished by reducing the weight and cube; by theemployment of options concerning pa ckaging m ater ials, i.e., barriers, wr aps andcushioning; an d aut omat ion. The concepts of minimu m weight and cube packs an din addition, a packaging design to fit the item", may not always be possible norpra ctical. The un it and interm ediate packs, shall, however, be of uniform size.


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LEVELS OF P ROTECTIONLevels of protection is defined as a means of specifying the level of militarypreservation a nd the levels of packing th at a given item requires to assure t hat it isnot degraded du ring shipment an d storage.

Military level of preservation is the packaging protection given an item duringshipment, handling, indeterminate storage, and distribution to consigneesworldwide.

The militar y levels of pa cking consist of th e following:

Level A. Pr otection required to meet th e most severe worldwide shipmen t,ha ndling, and storage conditions. Exam ples of situa tions which indicate aneed for u se of a Level A pack ar e as follows:

war reserve material mobilization strategic and theater deployment open storage deck loadin g

Exam ples of cont ainer s used for Level A packing requ iremen ts include, but ar e notlimited t o, overseas type wood boxes, and plastic and m etal r eusable cont ainers.

Level B. Protection required to meet moderat e worldwide shipment ,ha ndling, and storage conditions. Exam ples of situa tions which indicate aneed for u se of a Level B pa ck ar e as follows:

security assistance, e.g., Foreign Military Sales (FMS) conta inerized overseas sh ipments

Exam ples of cont ainer s used for Level B packing requ iremen ts include, but ar e notlimited t o, the following:

domestic wood crat es weath er-resistan t fiberboar d containers fast-pack conta iners weather-resistant fiber drums weath er-resistant pa per an d multi-wall shipping sacks

ELE CTROSTATIC DISCHARGE SENSITIVE (ESDS) ITEMSPackaging required to protect ESDS items against damage and deteriorationfrom t he t ime of acquisition to an ticipated u se will be pr ovided at th e time ofacquisition. MIL-STD-1686, Electrosta tic Dischar ge Contr ol Pr ogram forPr otection of Electrical and Electronic Par ts, Assemblies, and E quipment , an dMIL-HDBK-773, Electrostatic Discharge Protective Packaging, will be used asguidelines in th e identification, pa ckaging, ha ndling, and storing of ESDS items.

P ROTECTING RETROGR ADE CARGO OR RE TURNED MATERIELRetrograde materiel will be protected consistent with provisions of thecommodity grouping, in the original packaging.

C ONSUMABLE , SERVICEABLE (E XCESS ) R ETURNS

To prevent deterioration and damage, consumable, serviceable (excess) returnsfor credit will be retur ned in t he origina l vendor or depot un it pack or in a unitpack which is th e equivalent of th e origina l unit pa ck. Consider th e followingbefore return ing these items:


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En sure item serviceability and/or if condition warra nt s retur n. If notwar ra nte d, dispose of locally, as app ropriate, t hr ough th e servicing DefenseReut ilizat ion a nd Ma rk etin g Office (DRMO).

Fa ilure to follow th e above procedur es for ser viceable ret ur ns will result inth e loss of credit. To minimize the p ossibility of credit loss, it is impera tiveth at t he item not be removed from th e original unit pa ck until ready for use.

H AZARDOUS MATERIALS R E T U R N

When hazardous materials are being returned, packaging must conform to theapp licable modal regu lations. Modal regu lat ions ar e found in th e following:

International Civil Aviation Organization (ICAO) technical instructions, International Air Transport Associations (IATA) regulations, Int erna tional Maritime Dan gerous Goods (IMDG) Code of th e Inter na tiona l

Maritime Or ganizations (IMO) Title 49 Code of Feder al Regulat ions (49 CFR), and AFJMAN 24-204/TM 38-250/NAVSUP PUB 505/MCO P4030.19/DLAI

4145.3, Prepar ing Hazar dous Materials for Militar y Air Shipmen ts.

OT H E R R ETROGRADE C ARGO

Serviceable and unserviceable reparable materiel will be retained in the originalpackaging to maint ain t he int egrity of the degree of serviceability of th e ma terielbeing r eturned.

Depot level reparables (DLR), serviceable and unserviceable, whose packagingprescription dictat es th e use of reu sable cont ainers, sh all be afforded th at protectionthroughout their life cycle.

All items will be identified with t he nat iona l stock n um ber (NSN), nomenclatu re,and qu an tity. Materiel condition ta gs or labels an d mar kings will be applied asrequired by MIL-STD-129 and MIL-HDBK-129 and t he DOD component . Theshipper will be responsible for adequa te pa ckaging of materiel retu rn s.

OTHER P OLICY REQUIRE MENTSOther packaging or pa ckaging r elated policies addressed in t he u niform requ irementcovered by DOD 4140.1-R, previously mentioned, include the areas of commercialpackaging, options, military ma rkings, unit pa ck qua ntities, safety and health, a ndecology.

C OMMERCIAL P ACKAGING

Commercial packaging shall be used by DOD components when it is cost effectivean d when commer cial packaging will with sta nd a nticipat ed logistics conditions. Allpacka ging, includ ing comm ercial packa ging sha ll be based u pon th e following:

natu re of the item, known logistics requ irements, a nd economic or norma l consu mer order qua ntities.

As previously stated, MIL-STD-2073-1C provides a military packagingdevelopmen t-decisions cha rt which leads t o the det ermina tion of wheth er militarypackaging or comm ercial packaging is war ra nt ed in accorda nce with (IAW) ASTMD3951, Practice for Commercial Packaging.

Item s not going int o stock shall be packaged IAW ASTM D3951. This includes itemssuch as:


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items intended for immediat e use items for not mission-capable supply items int ended for depot operational consu mption small parcel shipments (CONUS) not-for-stock direct vendor deliveries (CONUS)

Items intended for deliver-at-sea, delivered during wartime, or items requiringreusa ble containers ar e exceptions to th e above list of items.

OP T I O N S

When standards, specifications, purchase descriptions, packaging data sheets orcards, special packaging instruction, drawings, or other authorized instructionscontain options for selecting packaging methods, materials, or procedures, the optionthat provides protection at the lowest overall cost will be selected.

MARKING

DOD policy directs componen ts t o develop and apply un iform m ark ing requiremen tsto facilita te sa fe han dling a nd efficient r eceipt, storage, an d sh ipment of mat eriel.DOD 4500.32-R, Military Standard Transportation and Movement Procedures(MILSTAMP), provides policies an d pr ocedur es requ ired to ma na ge an d cont rol themovement of mat eriel through t he Defense Tran sportation System (DTS).

MIL-STD-129, DOD Standard Practice for Military Marking, is to be used only formar king of military supplies which ar e intended for storage an d shipment within th emilitar y distribution system, i.e., for mar king of materiel not inten ded for imm ediateuse, th at is stored an d/or moved with in or between DOD facilities. This docum entcomplies with the wording and requirements of MIL-STD-2073-1C.

MIL-HDBK-129, DOD Handbook Military Marking, is also available to DODdepart ment s and a gencies but is used for guidance only. This han dbook, althoughbased upon marking procedures from MIL-STD-129, cannot be cited as arequiremen t. If it is, the contr actor does not have to comply.

Ha zardous ma terials sha ll be packaged and ma rked in a ccorda nce with a pplicableFedera l and int erna tional regulations su ch a s th e following:

Code of Federal Regulations Title 49, Transporta tion International Civil Aviation Organization (ICAO) Technical Instructions International Air Transport Association (IATA) Dangerous Goods

Regulations Int erna tional Maritime Dangerous goods (IMDG) Code United N ations Ora nge Source Book Acceptance of Hazardous, Restricted or Perishable Matter, USPS

Publication, 52 AFJMAN 24-204, Preparing Hazardous Materials for Military Air Shipments

For th e pur pose of packaging pr oject informat ion exchan ge, a project is any plan nedwork load involving 160 or m ore man -hours (including all supp ort functions). This

entitles research, development, testing, or evaluation that may result in new orimproved packaging concepts, methods, or procedures.


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CHAPTER 2

Cleaning and Drying

BASIC CLEANING P RINCIP LES

I MPORTANCE OF CLEANINGThe success of preservation and packing operations depends upon the cleaning of itemsby suggested processes. A preservative film will not protect an item if the surfaces aredirty or are covered with corrosion-producing particles. Inadequate cleaning makes allsucceeding operations ineffective.

C ONTAMINATIONWhen surfaces of items are dirty or are covered with substances that are notpar t of th e items, th ey are contam inated. Every manu factur ed item issubjected to ma ny kinds of conta mina tion from th e time it is pr oduced un til itis received by the user. Examp les of contam inan ts ar e drawing, milling, orcooling compounds, metal shavings, chips, abrasives, shop dirt, or corrosionproducts that form during various steps in manufacture.

TYPE S OF CONTAMINANTS (FIGURE 2-1)Contaminants are classified into the following four categories:

Water soluble contaminants, such as heat treated salts, welding fluxes, solderingcleansers, chalk, fingerprints, and perspiration, which must be removed withwater.

Oil (solvent type) soluble contaminants such as oils, greases, soaps, and cuttingand drawing compounds which must be removed with solvents other than water.

Loosely adhering insoluble contaminants such as solid dirt particles, abrasivegrains, metal chips, and filings which can be rinsed off with water or solvent.

Solidly (tightly) adhering insoluble contaminants such as mill and heat scale,carbon deposits, rust, and other corrosion products which cannot be removed

except by mechanical means.

Figure 2-1. Types of contaminants.


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E F F E C T S O F CONTAMINANTSContaminants affect the surfaces of items in varying ways. Manycontaminants are corrosive; others are hygroscopic (they absorb moisture)and pr omote corrosion. Some cont amina nt s prevent adequa te adh esion of anapplied coating. Solid cont amina nt s int erfere with a n applied protective filman d provide points of ent ry for wat er or oth er corr osive agent s. All of th eseproperties of contaminants tend to cause items to corrode, since corrosion

may occur on certain metals whenever any of the following conditions exist:

A metal (the item) plus oxygen and water. A metal (the item) plus acids or alkalies and water. A metal (the item) plus salts and water. A metal (the item) plus corrosive gases or vapors and water.

Note tha t wa ter in a ny form is the common factor in a ll four situa tions.

R EMOVAL OF CONTAMINANTSRemoval of contaminants depends upon the composition, degree ofcriticalness, and complexity of the item, and upon the type of contaminantpresent. Contaminants are not all affected in the same way by a givensolvent . For insta nce, a clean er tha t is suit able for rem oving oil-soluble

contam inan ts ma y not be capa ble of removing rust and scale. Likewise, acleaner that is suitable for removing rust and scale may not removefingerprint s and other water-soluble contamina nt s. Oil-soluble or easilyemulsified contaminants can be removed either by solvents or water-emulsion solut ions. Highly finished items cont amina ted with perspirat ion,fingerprint s, an d oil-soluble cont amin an ts require a combinat ion of cleanersto insur e the removal of the fingerpr ints and perspira tion. A cleaningprocess or combination of processes should be chosen that will remove allcontaminants.

CLEANING REQU IRE MENTS (figur e 2-2)Basic cleaning r equirement s ar e listed in MIL-STD-2073-1C. Items sh all becleaned and dried by any suitable process or processes which are notinjurious t o the items. Critical sur faces (close machined toleran ces) must be

cleaned to ensure total removal of corrosion, soil, grease, fingerprints,perspirat ion and all other acid and alkali residues. Disassembly mu st bediscour aged. Complex items will not be disa ssembled with out pr ioraut horization a nd/or t echn ical instr uctions.

P ROCESS SELECTION CRITERIAThe selection of a cleaning process depends upon the characteristics of theitem, the nature of the contaminants, availability of cleaning materials andequipment, an d th e safety ha zards involved.

C OMPOSITION OF THE I TE MThe composition of the item limits the choice of the cleaning process.Aluminum or zinc items should not be cleaned in highly alkaline cleanersbecause of detr imen ta l effect of th e clean er. Nonm eta llic item s of ru bber,

fabric, cork, or other organic composition should not be cleaned haphazardlyin orga nic or wat er-soluble alka line clean ers. If solvent clean ing is app lied tosuch items, the solvent exposure must be brief and scrubbing action limitedwhen dimensions and use conditions of th e item ar e critical. Petr oleumsolvents are detriment al to most rubber and synthet ic rubber ma terials. Ifmetallic and nonmetallic materials are combined in an assembly, theclean ing pr ocess mu st be car efully consider ed and t he choice of th e processgoverned by the n atu re of th e mat erials combined in t he assem bly.

SURFACE F INISH OF THE I TE MSome cleaning processes are safe to use on highly finished and precisionsurfaces while other processes are likely to mar t he finish. For instan ce,alkaline cleaning should not be used on polished aluminu m. Acid cleaners


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are u sed on iron and st eel with extreme care. For most critical sur faces ofmetal items, the petroleum solvent or vapor degreasing processes usua llyar e recommen ded. Sur faces of rough forgings or castin g, rough groun d orrough machined items, or surfaces having no finishing after stamping ordra wings ar e cleaned by alkaline cleaning processes. Items with poroussurfaces, small crevices, or with capillary h oles ar e n ot cleaned with alkalinecleaning processes because the complete removal of all residues is not

possible an d corrosion will resu lt. This is also tru e of item s which haveextended lap joints, riveted areas, spot-welded additions, and similarconstr uctions. Porous, oil-impregnat ed, or graph ite lubricated items shouldbe cleaned by wiping with a dry cloth . Items with porcelain or paintedsurfaces are not cleaned in strong a lkaline solut ion. Solvent cleaning cannotbe applied indiscriminately to painted surfaces; however, zinc-chromatedprimers, exterior paints, lacquers, and enamels are usually handled safely inpetroleum solvent cleaner s.

Figure 2-2. Cleaning requirements.


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C OMPLE XITY OF TH E ITE MItems having irregular surfaces, crevices, undercuts, and pockets that could trap thecleaning fluids may only be cleaned by brushing or wiping when solvent cleaning isemployed. Clean complex assemblies prior to assembly. Such assemblies as electricgenerators, motors, starters, gauges, meters, timing devices, and other complex unitsshould be cleaned before assembly and kept clean thereafter.

AVAILABILIT Y OF F ACILITIESApproved mater ials and equipment sh ould be used wherever possible. If thedesired cleaning materials and equipment are not available, considercarefully th e selection of an a lter na te process. Solvent cleanin g can be donein pails, buckets, dru ms, or barr els in an emergency. The hot vapordegreasing process requires specially designed equipment, but the solventsused for vapor degreasing can be used cold if due caution is taken to avoidoverexposur e to th e vapors. Most clean ing processes ar e not too complex, andopera tions can be modified to meet t he n eeds of the situa tion.

H EALTH AND SAFETY H AZARDSAll cleaning materials must be selected and used in accordance withapplicable Environmental Protection Agency (EPA) regulations, OccupationalSafety and H ealth Stan dar ds (OSHA), Code of Federa l Regulations (CFR) 29,

Section 1910, General Industry and Air Pollution Control statutes, andregulations in force in the geogra phic and indust rial ar ea wh ere th e cleaningis per form ed. Man y of th e clean ing processes (for example, vapor degreas ing,solvent cleaning, and finger pr int rem oving) involve th e use of chemicals tha tcould present a safety hazard. CFR 29, Section 1910.1200, (the "workers-right-to-know" sta nda rd) was writt en t o reduce injuries or illnesses caused bypersonnel working with or exposed to chemicals. Worker s need to know thechemical hazard s th ey are exposed to and th e safe practices linked with t hosechemicals used in the work place. CFR 29, Section 1910, requires that aMaterial Safety Data Sh eet (MSDS) be available to workers at a ll times. AMSDS contains applicable information regarding product identification,hazardous ingredients, physical data, fire and explosion hazard data,reactivity data, health hazard data, spill or leak procedures, and precautionsto be taken in han dling and st oring.

CLEANING PR OCESSES

ANY GENERAL CLEANING P ROCESS (F ORMERLY C-1)Any process not required by an order or contra ct may be used. Any processor combination of processes which will accomplish thorough cleaning withoutdam age to the item will be appr opriat e. If a specific process can not be cited,then an y genera l cleaning process is in order. All cleaning processes mustresult in noninjury to items and the satisfactory passing of the qualityconformance test as specified in the Preservation Inspection Provisions, ofMIL-STD-2073-1C. Clean ing processes are eith er mecha nical or chemical.

M e ch a n i c a l P r o c e s se sThe mechanical processes are used to remove solidly or tightly adhering

conta minan ts. These processes use abra sive ma terials, pressure tools andpower tools and often su bject the items to severe treat ment . Some of themechanical processes are air-vacuu m cleaning, barr el tumbling, impact toolcleaning, and wire brush ing.

A i r -v a c u u m Cl e a n i n gThis process is used to remove dust an d lint from items d uring final assem blyoperat ions. The clean ing of electr onic componen ts is an exa mple in whichair-vacuum cleaning is u sed.


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Ba r r e l Tu m b l i n g ( f i g u r e 2 -3 )This process consists of the cleaning mass, composed of the items to becleaned, an abra sive or rolling medium , a fluid lubricant (usually water), anda chem ical corrosion inhibitor mixed togeth er in a cylinder or barr el. Thiscleaning ma ss rolls an d tu mbles upon itself in th e barr el by being carr ied upthe side un til it reaches a point where it slides down becau se of gravity, thusscrubbing and polishing all surfaces to be cleaned.

I m p a c t To o l Cl e a n i n gThese processes are used on noncritical surfaces to remove mill scale, rust, orold paint coatings. They are done by poun ding, hamm ering, or chiseling thesurface of the item with manual or pneumatic hammers, chisels, scalers,scra pers, rotary wheels, or vibrators. Wherever these tools are employed,they mu st be suitably sharp. Dull tools tend t o drive scale and corr osionproducts into the surface of the metal, creating a nucleus for corrosion.Because they prevent effective cleaning, oily and greasy contaminants mustbe rem oved before imp act t ool clean ing.

Wi r e B r u s h i n gWire brushing removes loose scale, corrosion products, old paint, and similarencrusta tions from meta llic surfaces. It will not r emove tightly-adh ering mill

scale, tight oxides, or em bedded corrosion pr oducts.

C h e m i c a l P r o c e s s esThe chemical processes ar e acid, alkaline, and detergent cleaning.

Ac i d C l ea n i n g ( p i c k l i n g )Acid cleaning or pickling consists of removing surface oxides, scale, and rust from metalby immersion in an acid solution. Oil-soluble contaminants must be removed before acidcleaning. After immersion in the acid solution, the item is rinsed thoroughly to removeany remaining acid from its surface. In some operations, the acid residues are removedby scrubbing, while rinsing or neutralizing the items. In other operations, an alkalinerinse, used to remove the acid residues, is followed by a chromate or phosphoric-chromicacid rinse to neutralize the alkali and retard corrosion. In all cases, the surfaces of theitem must be neutral before applying a protective coating. The most common types of

pickling solutions are sulfuric and hydrochloric acids. Nitric, phosphoric, andhydrofluoric acids are used for some applications. One of the most serious problems inconnection with the acid cleaning is what is known as "acid brittleness" or "hydrogenembrittlement" (Penetration of generated hydrogen on metal surfaces). This may beeliminated by soaking the items in boiling water immediately after pickling, or may beminimized by the use of the proper inhibitor. Water rinsing is a very important operationafter pickling to remove all traces of acid and iron salts. If complete removal of suchresidues by the water rinse alone is doubtful or if the parts must remain unprotected for aperiod of time, an alkaline rinse is recommended to neutralize any remaining acidresidues.

A l k a l i n e D er u s t i n g C om p o u n d sAlkaline derusting, using an immersion process with either electrolytic ornonelectrolytic equipment, removes rust from steel objects better than acid

cleaning, and without affecting the dimensions of the base metal in theprocess. Much less hydrogen embrittlement (entr apped hydrogen bubbleswithin the porous structure of the metal and rerusting of the base metal)occur when alka line derust ing is used. MIL-C-14460 iden tifies two types ofderu stin g compoun ds. Type I is a mixtur e of sodium hydr oxide, sodiumgluconate, a complexing agent , and a foaming agen t. Type II is a m ixture ofsodium hydroxide, sodium cyanide, a complexing agent, and a foamingagent.


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Figure 2-3. Barr el tu mbling.


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Type I compound is used for rust removal by simple immersion of items inthe hea ted deru sting solution. The usu al concentr ation of th is compoun d is 5pounds per gallon of solution. If type I mat erial is used, the solut ion isheat ed to boiling. A "rolling" boil gives effective agit at ion.

Type II compound is used for the most severe conditions of rusting onexterior or interior surfaces where equipment for electro-cleaning isavailable. Usu ally, it is mixed at t he ra te of 2 or 3 pounds per gallon of

solution. This mat erial should not be used at tempera tu res above 130F. Itshould not be used for cleaning portable water tanks, food containers, andsimilar item s.

Both type I an d type II compounds are used for r emoving rust an d scale fromiron an d steel. The compounds m ay be used for cleaning nonferrous metals.

However, their effect on the metal to be cleaned should be checked beforethey are used for cleaning items. These compoun ds have been found toatt ack aluminum , copper, brass, and zinc. Articles should be thoroughlyrinsed in clean hot water and dried immediately after removal from thecorr osion r emoving compoun d.

De tergent CleaningDetergent mat erial (MIL-D-16791) is used for removing cont amina nt s from avast range of items such as rubber, plastics, canvas, and metallic materials.For m ost clean ing operat ions, 1/4 to 1/2 ounce of deter gent in a gallon of freshwat er or sea wat er, prefera bly hot, is sufficient . The det ergen t will efficientlyremove grease, oil, and dirt from a wide variety of surfaces.

SOLVENT CLEANING P ROCESSES

Solvent cleaning makes use of several solvents, utilizing processes known assolvent cleanin g an d fingerp rin t removal. A combin at ion of solvent cleanin gfollowed by fingerprint removal will be discussed extensively in a laterparagraph entitled Perspiration and Fingerprint Removal.

App l icab i l it y o f t he P r oces s e sThe solvent cleaning processes are u sed to remove oils an d greases rema iningafter machining, milling, polishing, and similar operations or any time theitem is contam inat ed with oil-soluble contam inan ts. Solvent cleanin g withpressure spray equipment removes loose chips and other loosely adheringpar ticles produ ced dur ing fabrication of th e item. Solvent cleaning is usedwhen t he only cont amina nt is a light grease or oil. The spra ying process is

DANGER

Type I compoun d causes severe bur ns t oskin a nd eyes. Wear goggles or face shieldwhen ha ndling. Avoid dust and fumes.Keep awa y from food pr oducts. In caseof eye or skin contact, flush immediatelywith plentiful amount s of water for a tleast 15 minutes a nd get immediate medicalattention.

DANGER

Type II compound contains sodium cyanide!Do not mix with or allow to come in cont actwith acids or acid solutions. Conta ct withacid liberat es poisonous cyan ide gas. Keepcont ainer closed an d in a dry place.


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used on items of simple const ru ction with su rfaces th at can be rea ched by thesolvent spray. Solvent cleaning will not remove rust or corrosion products.

M at e r i a l s fo r So l ven t C l ean i n gSolvent cleaning ma terials ar e dry-cleaning solvent, p aint th inner, corrosionpreventive fingerprint remover compound, a nd t etra chloroethylene.

Dry-cleaning Solvent (P-D-680)This is a clear, solvent-based liquid which is neutral to metals and onlyslightly irritating to the skin. It ma y be mildly na useat ing when excessivevapors are breath ed. It evaporates quickly without leaving a corrosionindu cing film on met al sur faces. It is used especially for rem oving oils andgreases from metal surfaces by brushing, wiping, spraying, or immersion.Dry-cleaning solvent has a flash-point (the point a t wh ich ther e ar e sufficientvapors from the solvent to ignite in the presence of a flame or spark) of100F., or higher. The mater ial mus t be used only at room tempera tur e,since heating significan tly increases the fire hazar d. See the para graph inthis cha pter entitled En vironmen tally Safe Solvents.

Vo l a t i l e Mi n e r a l S p i r i t s , Pa i n t Th i n n e r ( A -A-2 90 4)Paint thinner is supplied as two grades of petroleum distillate. Only grade I (lightthinner) is used for petroleum solvent cleaning. It is an excellent solvent for oils andgreases. It is similar to dry cleaning solvent (P-D-680), having the same flashpoint anddegree of toxicity, but is more highly refined and is usually higher priced.

Fingerp r in t R em over Corrosion Prevent i ve Comp oun d (MIL-C-15074)This is a homogeneous stable mixtur e of solvent, soap, an d water . It iscapable of removing water soluble contaminants such as fingerprints,suppr essing perspirat ion corrosion, and tempora rily protecting steel sur faces.It is n ontoxic an d free from disa greea ble or offensive odors.

Tech ni ca l Te t ra chloroe thy len e (perch loroe thy lene) (AST M D 4081, AS TM D 4376)Tetr achloroethylen e is similar to tr ichloroethylen e. Its differences ma ke itthe pr eferred solvent in some situa tions. It is completely insoluble in water .Any water that condenses in the degreaser at night is soon evaporated tostea m before th e solvent rea ches its boiling point (250F). This high boilingpoint also permits a longer cleaning cycle than possible withtrichloroethylene because of the longer time required to reach temperatureequilibrium. The vapor of tetr achloroethylene is six times heavier th an a ir,thu s restr icting th e loss of vapor. This permits const ruction of portable, air-cooled degrea sers. Tetr achloroethylen e is less toxic th an tr ichloroeth ylene,but it must be ha ndled with r easonable car e. Str ong vapor concentr ationswill result in sympt oms similar t o those cau sed by tr ichloroethylene, which isprohibited for DOD use. Tetrachloroethylene is more sta ble and requires n o

stabilizers. It is nonflamm able and will only decompose at extrem ely hightemper atu res. It does not remove fingerprint s, ru st, or scale.

Eq u i p m e n t Us ed i n S o l v e n t C l ea n i n gThe equipment required for solvent cleaning includes petroleum solventtan ks, porta ble solvent degreasers, an d solvent spr ay washer s.

S o l v e n t T a n k s ( f i g u r e 2-4 )Solvent tanks are simply constructed but must be capable of holding thesolvent. Where cleaning is conducted at an established installation, specialsafety featu res are required in the tan k design. Tank s are constru cted oflow-carbon steel and ar e welded at th e seams. A typical solvent ta nk withsafety features consists of a rectangular compartment, with a tight fitting

WARNING

Keep solvent away from any open flame or source of sparks.


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cover h eld open du ring cleaning operat ions by m eans of a cha in conta ining afusible link. This is held togeth er by a low-melting solder. Sh ould th esolvent catch fire, the heat evolved melts the solder and allows the lid to closean d smother th e fire. For this reason, it is importan t tha t the fusible linkshould always be in an opera ble condition. The lid sh ould never be wired orfasten ed so th at it cann ot close automa tically in case of fire. Tan ks mu st beprovided with a ground connection to carry off any static charges of

electricity.

I m p r o v i se d S o l v e n t Ta n k sIn the absence of approved cleaning equipment, solvent cleaning can be done indru ms, pails, cans, or other conta iners. Fifty-five-gallon dr um s split in ha lf ma kesuit able tan ks for field expedience. Regar dless of th e conta iner u sed, provisionmust be made to keep it closed when not in use.

Other types of solvent spr ay cleaner s ar e shown in figure 2-5.

S a f e t y Pr ec a u t i o n s o f S o l v e n t C l e a n i n g ( f i g u r e 2 -6 )When not in use, covers mu st be kept in place on all solvent t an ks. To preventthe a ccum ulat ion of flamm able vapor an d th e build up of an explosive mixtur e,adequa te ventilation mu st be provided, especially if paint thin ner is used. Carbon

dioxide fire extinguishers m ust be located in t he vicinity, and p ersonnel mu st betra ined in their use. A fire blanket should be locat ed nearby. Solvents removena tur al oils an d may cau se skin irr itations. Some people are susceptible to thesolvent and are afflicted with blisters and chapped skin upon exposure.Operators should wear oil-resistant rubber or plastic gloves and work apronsdur ing cleaning operations to protect t hemselves and to keep th e items free fromfingerprint s. High vapor concentr at ions of these solvents m ay cause dizziness,fainting, an d nau sea, if inhaled.

Figure 2-4. Solvent safety tan k.


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Figure 2-5. Solvent spra y cleaners.

SOLVENT CLEANING METHODS

Imm er s ion ( f igur es 2-7 an d 2-8). The solvent cleaning immersion operations are as follows:

Wear safety goggles, rubber gloves, and apron. Immer se items in solvent. Agita te items th oroughly. Position item s to receive th e most effective

washing a ction. Use a bru sh wher e necessary to remove dirt.

Remove items from tan k wh en visually clean. Drain completely, allowing excess solvent t o retur n to th e ta nk . Immer se items in a second tan k of clean solvent. Agitate a s necessary. Place items on tr ay to drain. Apply appr opriate cleanliness te sts.


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Figur e 2-6. Solvent safety cloth ing.

Figur e 2-7. Solvent cleaning by immer sion.


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Figure 2-8. Solvent immers ion operations.

Scrubbing and Wiping (figure 2-9).When cleaning items that are too large for available cleaning tanks, orbecau se it is impra ctical to clean by immersion or spr aying, the sequence ofopera tions is -

Wear safety goggles, rubber gloves, and apron. Soak cleaning cloth or brush in clean solvent. Apply cleaning cloth or brush in clean solvent. Use a combinat ion of soaking, scrubbing, an d wiping a s n ecessary. Rinse off ar ea with a clean cloth soaked in clean solvent. Flu sh over

cleaned a rea a nd r inse. Dra in, sh ak e, or wipe off excess solvent. Apply appr opriate cleaning t ests.

Spraying (figure 2-10)If items are of simple constru ction an d free of cavities an d inden tat ions, a ndif the equipm ent is available, the solvent spr aying steps ar e -

Wear rubber gloves, goggles, and apron. Load items int o solvent sp ray a rea. Turn on spray pump an d direct nozzle at items. Shift items in ba sket so spray reaches all areas. Remove items from spray zone and permit t o drain . Apply appr opriate cleaning t ests.


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Figure 2-9. Solvent scrubbing and wiping.

P ERSP IRATION AND F I N G E R P R I N T R EMOVALPerspiration and fingerprint removal equipment and processes are depictedin figures 2-11 and 2-12. All item s with critical fun ctionin g sur faces or withclose tolerances must be cleaned in perspiration and fingerprint removeruntil they will pass the cleaning tests as specified in MIL-STD-2073-1C.Items are treated for fingerprint removal (figure 2-12) by the following steps:

Wear safety goggles, rubber gloves, and apron. Immerse items in perspiration and fingerprint removal compound. Agitate items for a minimum of 2 minutes. If item is too large for complete immersion, clean critical surfaces with a lint

free clean cloth saturated in fingerprint remover. After the petroleum base fingerprint remover (MIL-C-15074) is used, rinse

items in a second tank containing clean solvent conforming to A-A-2904,ASTM D 4081, ASTM D 4376 (grade 1), P-D-680 or MIL-T-81533, to removethe fingerprint residue.

Agitate items in rinse solvent for at least 2 minutes. After rinsing, drain items thoroughly. Apply appropriate cleanliness tests.

Solvent clean ing followed by fingerp rint rem oval is shown in figur e 2-13. Thesteps given previously for solvent cleaning followed by the steps forfingerprint r emoval are t he sam e as th e steps in vapor degreasing cleaning.

VAPOR DEGREASING

The basic pr inciples of vapor degrea sing are sh own in figure 2-14. Vapordegreasing is used for the rapid and thorough removal of heavy oils andgreases from most met al products. It u tilizes the vapor of special grades ofnon-flam ma ble, chlorin at ed solvents . When an oily, grea sy item is loweredinto the vapor, the vapor condenses on the item and the resulting hot liquidrapidly dissolves and rinses away th e contam inan ts. As the item reaches thesame temper atu re of th e vapor, condensation ceases and clean ing stops. Thedegreasing process is quite simple, but must be performed only in speciallydesigned equipment becau se of the hea lth haza rd involved. Operat ing rulesas out lined in manu factur ers' man ua ls mu st be str ictly followed. Thisprocedure is being replaced by a less environmentally hazardous procedurewhich will be discussed later in this cha pter. See paragra ph entitledRestr ictions in t he U se of Solvent s.


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Figur e 2-10. Solvent spr ay clean ing.


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Figure 2-11. Persp irat ion and fingerpr int removal.

Figure 2-12. Fingerpr int removal operations.


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Figur e 2-13. Solvent clean ing followed by finger prin t rem oval.

Figur e 2-14. Vapor degrea sing prin ciple.


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VAPOR DEGREASING F OLLOWED BY F INGERPRINT R EMOVALItems will be cleaned in accordance with the vapor degreasing processfollowed by the fingerpr int r emoval process as deta iled in t his chapt er.

Appl icabi l i tyThis process is used whenever the temperatures involved will not result indama ge, injury, or malfunction of th e item. Vapor degrea sing is extensively

used because of the ease and rapidity of removal of oils and greases frommeta l items of simple constru ction. The items ar e clean, dry, and rea dy forpreservation and packing as soon as they are removed from the degreaseran d allowed to cool. The pr ocess is economical, once the equ ipmen t isinstalled, and u se is made of solvents th at ar e free from fire h azar ds.

Vap or Degr e a s i ng M a t e r i a l s ( so l ven t s )One of the materials used for vapor degreasing is a product of the chemicalindustr y kn own a s t echn ical tetr achloroethylene (perchloroethylene) (ASTMD 4081, ASTM D 4376) and k nown a s chlorina ted solvent.

Res t r i c t ions i n t he Us e o f So lven t sCare shall be taken to assure th at when th ese solvents a re used, aluminumsur faces are n ot adver sely affected by depletion of inh ibitors or decompositionof th e solvent .

Any cleaning material used in the process must be selected to comply withSection 236 of Public Law 102-484 which prohibits the Government fromawarding any contract which includes a specification or standard thatrequires the use of a Class I ozone-depleting substance identified in theClean Air Act Amen dmen t of 1990. The Feder al and milita ry specificationsO-T-620, MIL-T-81533, and MIL-C-81302, are Class I ozone-depletingsubsta nces an d should not be used. Substitu te mater ials such as ASTM D4081, ASTM D 4376, A-A-2904, or th ose which conform to ASTM D 4081 an dASTM D 4376 are free of ozone depleting materials and should be used.Preservatives, as well as cleaning materials, must be in compliance with thepreviously men tioned law.

Some of the solvents may not have ozone-depleting characteristics, but theymay have some other environmentally unsafe attributes which render themun desira ble for contin uin g use. P-D-680 is one of th ose solvents a nd will bementioned later under the paragraph Environmentally Safer CleaningMeth ods. The pra ctice of vapor degrea sing by ut ilizing tr adit iona lchlorinated solvents is decreasing a nd will eventu ally be supplanted by a lessenvironm enta lly hazardous procedure. The use of chlorina ted solvent s invapor degreasing has been bann ed entirely in the Sta te of California. Thereare various aqueous-based solvents available through the GSA sources, butther e are n one (for vapor degreasing) to this dat e, that ha ve reached the levelof efficiency comparable to the old chlorinated solvents for vapor degreasing.Testing of new solvents continu es, of cour se. See the par agra ph lat er in th ischapter entitled En vironm enta lly Safe Solvents.

Equ i pm en t Us ed i n Vapor Degr ea s i ng (fi gu r e 2 -15)

Vapor degreasing should be performed only in properly designed and controlledequipment. The manufacturer's guide to operations must be carefully followed.Degreasers vary greatly in size and complexity, but they all have basic components thatare included in all units. A vapor degreaser in its simplest form consists of the followingcomponents:

Heating elements (A). A source of heat designed to raise the temperature of thesolvent to the boiling point.

Boiling chamber (B). A tank or vat capable of holding the solvent. Vapor area (C). A work space between the surface of the boiling solvent and

the top of the condenser, large enough to hold the vapor and accommodate thework.


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Figure 2-15. Basic vapor degreaser.

Condenser (D). The water jacket and coils used to balance th e heatinput and condense the vapor. (Degreasers designed fortetr achloroethylene only may be without a conden ser. The walls ofthe tank are correspondingly higher to provide for air cooling.)

Work clear an ce spa ce (E). Additional wall height above th econdenser prevents normal air currents from pulling vapor from the

degreaser. Safety ther mostat (F). This shuts off th e heating element s if th e

vapor should rise a bove the condenser. Dra ina ge tr ough (G). This collects th e cond ensed solvent s from the

walls and delivers them through the water separator to the storagetan k or boiling chamber.

Water separa tor (H). This collects moistu re, conden ses it andsepara tes it from th e solvent.

Clean solvent storage tan k (J ). Where the retu rn ing solvent can beheld or retur ned t o the boiling cha mber.

O p e r a t i n g Ch a r a c t e r i s t i csThe solvent in the boiling cha mber is hea ted by th e heating elements unt ilboiling begins and vapor rises into the vapor area. As th e vapor reaches

about midpoint of the condenser, it begins condensing along the walls of thedegreaser. The condensed solvent then flows into the draining trough andback to the wat er separat or where a ny moisture in t he solvent is trapped an dremoved as necessar y. From the separa tor, th e solvent ret urn s to th e cleanstorage tan k or back into the boiling chamber. If the conden ser cooling watersupply should fail during operations, the rise of vapor above the tank isprevented by a safety thermostat which automatically turns off the heatingcoils. Another ther mostat is often located just a bove the h eating coils to turnthe h eat on a gain when the va por level drops too low.

Type s of Vapor Degr ea ser s (f igu re 2-16)Vapor degreasers are manufactured in many sizes and shapes, ranging fromsmall, batch-type, manually operated models, to huge, continuous, fully


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aut omatic, conveyorized insta llations. Vapor degreasers m ay be heated bygas, stea m, or electr icity. They may be designed for use withtrichloroethylene or tetrachloroethylene only, or they may be capable of usingeither solvent.

There are manually operated, water and air-cooled degreasers; manually

operated, flush vapor degreasers; manually operated, two- and three-dip

vapor degreasers; and several designs of conveyorized vapor degreasers,which incorporat e various special featur es. Several types of vapor degreasers

are illustra ted in figure 2-16.

I n s t a l l a t i onVapor degreasers m ust be insta lled to keep solvent vapor loss to a minimum .The degreaser sh ould, th erefore, be located away from abnorma l air curr entssuch as hea ting and ventilating equipment , open windows and doors, and outof direct line of an y air flow or down dra fts. Air exha ust system s should beprovided only when necessary, such as required for a pit-installed vapordegreaser. A degreaser should not be located near open flames, an y hightemperature surfaces (above 750F), or where direct sunlight will reach thevapor zone. Flames, sunlight , high temper at ur e, an d wat er will causedecomposition of th e degreasin g solvent . Decomposition products ar e toxic

and corr osive gases. They are extremely dan gerous to personnel and causerap id rust ing of equipment within a considerable area of the degrea ser.

M is c e ll a n e o u s E q u i p m e n t

Other equipment tha t is n ecessary for efficient degrea sing operations include

storage tanks for retention of contaminated solvent, metal safety containers

for the storage of cleaning rags, mops or absorbent materials, a solvent

recovery still, an d, where required, an a ir exhau st system.

Figur e 2-16. Types of vapor degreas ers.


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SAFETY P RECAUTIONS OF VAPOR DEGREASING

S o lv e n t H a z a r d sDegreasing solvents are narcotic and produce a feeling of exhilaration andintoxicat ion similar to the more pleasa nt ph ases of alcoholic int oxication. Donot overexpose anyone to the vapor. Overexposure t o the vapor may producenau sea, dizziness, heada ches, an d general ill feeling. Skin cont act with th e

solvent removes natural skin oils resulting in excessive dryness andsubsequent cracking and cha pping of th e skin. Solvent absorption th roughthe pores ma y produce effects similar t o breat hing th e vapor. These solventsdecompose at high temperatures, producing gases that are very dangerousand corrosive. Attempts t o neutra lize an acid condition by using alkalies isalso par ticular ly dan gerous. This will result in an explosive mixture.

Hand l i ng So l ven t sKeep all solvent containers, drums, and storage tanks closed to avoidevaporation and vapor contamination of the area, except when using.Provide a pu mp for solvent tra nsfer from stora ge containers to the degrea ser.Never use buckets or pails for the tra nsfer. This invar iably leads tosplashing and spillage. Clean up any spilled solvent immediately afteradequa tely protecting your self with sa fety equipment . Do not u se forced airto dry up spills as th is increases air conta mina tion. Use mops, ra gs, or oth erabsorbing mater ials to soak up t he solvent, place them immediately in closedmeta l cont ainers an d remove for drying. Tran sport and store sludge an dused solvent in closed dr um s.

P r o t e c t i v e E q u i p m e n tPersonnel who use the degreaser should obtain protective equipment,maintain it in good condition, and replace it as soon as it becomes worn orun safe. The following item s of pers onal protective equipm ent sh ould befur nished, consistent with th e hazar ds involved:

Solvent-resistant gloves and aprons (fabricated from, or impregnated withpolyvinyl chloride or neoprene plastics).

Chemical safety goggles, and acid-type goggles, where there is any possibilityof splashing.

Hose masks, with hose inlet in a vapor free atmosphere; or air line masks withproper reducing valve and filter for use where conditions will permit safe escapeif the compressed air supply should fail.

Self-contained breathing equipment with stored oxygen or air. Rescue harness and lifelines.

Saf e t y Ru l e sIf solvent is properly handled, and equipment well designed, maint ained, an dopera ted, health h azard s will be at a minimu m. The following rules must beposted and observed by all opera tors.

Know your equipment and its operation. Do not smoke near a degreaser. Inhaled vapor breaks down into acidic

components by the heat of cigarettes.

Handle all solvents in closed containers. Use pumps and pipelines to maketransfers of liquid.

Maintain the vapor within the degreaser by careful operation. Never spray solvent above the vapor level, thus driving vapor into surrounding

area. Do not lower work too rapidly into the vapor area, thus driving out vapor. Do not bring open flames, hot surfaces, or open electric heaters near the vapor. Do not permit the cleaning of clothing in the vapor degreaser. The vapor

remains entrapped in the fabric and may result in serious blisters. If a unit must be entered for cleaning, do so only after all solvent liquid and

vapors have been removed or dissipated, and then only if at least one otherworkman is in attendance on the outside. A workman entering a machine forany purpose should wear a mask which provides a source of outside air.


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Se l ect i on o f I t em s f o r Degr ea s i ngNonporous items of simple construction should be selected for vapordegreasing. Porous organic materials such as leather, rubber, and fabricsmay be damaged by th e heat an d the solvent action. Items joined with low-melting solders m ay be injured by tetra chloroethylene degreasing.

S t a r t i n g t h e D e g r e a s e r

Before start ing the degreaser, th e operator mu st per form th e following:

Check the degreaser an d a ll pipelines for a ny evidence of leaks. Check the solvent level. It mu st be above the heating elements, the

depth (2 to 4 inches) as specified by the m an ufacturer. Check the condition of th e solvent. Determine its acid and sludge

content. See that water, heat, and power sources are available for full

operation. After making certain that the degreaser and equipment are in

readiness, open the shutoff valve to the condenser and waterseparator precooler water line, if the degreaser is equipped with aprecooler.

Turn on the power for au xiliary equipment .

Start t he heating unit . For steam heated degreasers, open the stemvalve slowly and p ermit a gradu al buildup of steam . On electricallyheat ed degreasers, turn th e heat switch to th e ON position. Withgas-fired degreasers, follow manufacturer's manual for lighting theburners.

After starting the degreaser, but before commencing operations,check and ad just the cooling water temper atu re. Allow the vapor toreach the midcenter of the condenser coils and then adjust the watersupply so that t he tempera tur e at the dischar ge end is slightly warmto th e ha nd (90 to 120F).

Raise the cover slowly to minim ize vapor distu rba nce. Check forvapor buildup by observing the presence of a wet line along thedegreaser wa lls at th e conden ser level.

Degr ea s ing Wi th Vapor Alone ( figur e 2-17)Items to be cleaned by vapor alone should be of simple construction andlightly contam inat ed. Perform th e following degreasing steps:

Lower items slowly into the vapor area at a rate of not more than 12feet per minu te.

Suspend items from hooks, racks, or in baskets so that the liquid, asit condenses, can drain off without collecting in pockets or crevices.When the vapor stops condensing on items, the cleaning has stoppedan d items ar e ready for removal.

Remove items slowly from th e vapor area. If items a re of small ma ssan d heavily coated, some soil may still rema in. This requires asecond pass th rough th e vapor. Hold items br iefly above the vaporlevel for cooling. When item s have cooled slightly, retu rn t o th e

vapor area to complete th e cleaning. Keep items a bove the vapor line long en ough for t he liquid solvent todrain back into the degreaser.

Remove from degreaser. Apply appr opriate cleanliness test s.


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Figure 2-17. Degreasing with vapor alone.

Degr ea s i ng Wit h Vapor an d Sp r a y Cyc le ( fi gu r e 2 -18)When contaminants on items include solid particles such as chips, dust, or

tur nings, and equipment is available, th e use of a spray n ozzle is advisable.

Degr eas in g Wi th War m Liqu id-Vapor Cycle (f igu re 2-19)Items which heat up too rapidly and slow down the rate of condensation areeffectively cleaned using an extra wa rm or hot solvent t ank . The warm tan kis suitable for small items closely packed together. The liquid penetra tes int oblind h oles and recesses dissolving and loosening the dirt . The meth od issuitable for the removal of flammable solvents and low boiling point oils fromitems, before subjecting them to the high vapor tempera tur es.

Degr eas in g Wi th Boi l ing Liqu id-War m Liqu id-Vapor Cycle (f igur e 2-20)This cycle of clean ing is us ed wh ere complex oils, grea ses, waxes, a nd similardifficult cont am ina nt s are to be rem oved. The sur ging action of th e boilingsolvent loosens caked-on contaminants and penetrates hard-to-reach

crevices.

ALKALINE C LEANING P ROCESSESAlkaline cleaning will remove shop dirt, soil, oily and water-solublecontam inan ts, and heavy waxes an d buffing compoun ds. Highly alkalinesolutions ar e used for hea vy-dut y cleanin g of steel, and the more moderat elybuffered solutions are employed for aluminum and for aluminum and zincbase castings. Almost all man ufacturing contam inan ts, except tight lyadhering, insoluble compounds such as chalk, etching inks, heavy rust, andmill scale ar e removed. Some alkaline deru stin g processes will even removelight ru st.


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Figure 2-18. Vapor-spray-vapor cycle.

Figure 2-19. Warm liquid-vapor cycle.


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Figur e 2-20. Boiling liquid-war m liquid-vapor cycle.

Appl icabi l i tyIf items are of simple construction, have noncritical surfaces, and arecomposed of iron and steel, they can be effectively cleaned by the alkalinecleaning processes with an assurance that they will be thoroughly cleaned,uninjured, free from cleaner residues and fingerprints, and capable of

passing the requ ired test. Metals cleaned in alkaline cleaning solutions mu stafterwar ds be th oroughly rinsed in hot water at 180F. A rinsing proceduretha t fails to remove residual alka li will give un satisfactory resu lts.

M at e r i a l sAlkaline cleaners have become highly specialized and a great variety ofcompoun ds for specific clean ing jobs are ava ilable. Follow the su pplier'srecomm endat ions when using these compoun ds. Alkaline cleaners arecomposed of mixtu res of alkaline sa lts wh ich loosen t he soil for easy wa shin g,plus small amounts of soap increasing cleaner penetration and bufferingcompounds for maintaining the alkalinity in the presence of acid-typeconta minan ts that ten d to neut ra lize th e cleaner . The amount of soappresent depends upon the type of equipment used and the hardness of thewater . For exam ple, alka line cleaning by immer sion requires more soap th an

pressur e spra y cleanin g. This is becau se th e pressur e spra y cleanin gproduces excessive foaming unless the soap concentration is reduced, so lesssoap is required.

Co mp o u n d , A l k a l i , Bo i l i n g Va t ( S o a k ) o r Hy d r o st e a m ( A-A-5 91 46 )Alkaline cleaning compound A-A-59146 comes in one grade for use in the hotsoak ta nk cleaning of ferr ous and nonferrous par ts. It is also used inhydrosteam u nits operating on existing steam su pply for steam cleaning.

Cl ea n i n g Co mp o u n d , H i g h Pr e s su r e ( S t e a m ) C l e a n e r ( A -A-5 91 33 )This cleaning compound is for use in steam cleaning machines for cleaningferrous and nonferrous sur faces. Type I compoun d contains phosphat eswhile type II compound does not.


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A l k a l i n e c l ea n i n g c o m p o u n d f o r s t e el ( S AE A MS 1 5 47 )

Alka line clean ing compoun d is requ ired for steel. AMS 1547 is used wh en a

heavy-duty anodic electro-cleaner is required.

E q u i p m e n t

The equipment necessary for alkaline cleaning may vary with the process,

but it must be capable of providing sufficient heat to maintain a boiling

solution. There a re several designs of cleaning ma chines equipped to fur nish

heat by gas, steam, or electricity. Steam is usu ally considered th e most

efficient source of heat .

I m m er s i on t an ks ( fi gu r e 2 -21)

Hot alkaline cleaning tanks are commercially available in many sizes with

capa cities ranging from 10 gallons to several hun dred gallons. They are

fur nished with sta nda rd equipment consisting of sludge drains, scum gutt ers,

drain valves, hinged covers, dial thermometers, removable grilles, and

automatic temperatu re contr ols. Tanks ar e furn ished for use with nat ura l,

manufactured, and liquid petroleum gas, kerosene, electricity, and steam

heat. Under field conditions, tanks may be devised from steel drums, or

fabricated ta nks which will meet th e minimu m n eeds of field operations.

Al ka l i ne s p r ay wa s he r s ( fi gu r e 2 -22)

These machines are well ada pted to large volume operat ions. The most

widely used are the belt conveyor washers, built with cycles from single stage

washing to multi-stage processing. These machines are a dapt ed for cleaning

man y types of items of all sizes an d sha pes, placed singly or in basket s on a

belt. Monorail spra y washer s car ry items thr ough washing, rinsing, an d

other stages. Some of th ese washer s are arr an ged for straight line

production. Other s have a continuous retur n conveyor for loading and

un loading at one sta tion. Batch rotary-drum washer s ha ve a cylindrical

dru m with an inter ior spiral conveyor to car ry work th rough the dru m. The

items are loaded in batches, cleaned while the drum rotates in one direction,

an d finally discha rged by reversing the direction of th e drum rotation. Therotation platform washers have a circular table that rotates slowly to carry

work pa st wash ing and r insing spray nozzles and th rough a dr ying section.

Al ka l i ne e l ec t r oc lean i ng t an ks ( fi gu r e 2 -23)

These tanks, designed similar to immersion tanks, are equipped with heating

coils and overflow dams. Sheet steel electrodes hang from electrode rods in

front of th e coils and da ms. The electrodes should have th e top edges about 3

inches below th e norma l solution level and porcelain in sulat ors at th e bottom

edges to prevent conta ct with t he ta nk sides.

S a fe t y P r e c a u t i o n s

The health hazards involved in alkaline cleaning are mainly skin irritations

produced by the alkaline compoun ds. A high relative hum idity in alka lineclean ing area s will aggra vat e irr ita tions. Use protective goggles, gloves, an d

apr ons to prevent eye or skin conta ct with t he alka line compounds. Avoid

splashing hot solvents, which ma y result in bur ns a nd blisters.


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Figure 2-21. Alkaline immersion tan k.


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Figure 2-22. Types of alkaline spray wash ers.

Figur e 2-23. Alka line electr oclean ing ta nk .


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I m m er s i on Techn i que ( fi gu r e 2 -24)

This process consists of immer sing an d soaking items in a n alkaline cleaner

(A-A-59146) and rin sing in clean wat er above 180F. To accomplish a lkaline

immersion cleaning, perform the following steps:

Wear goggles, rubber gloves, and apron.

Mix 7 oz. of compound per gallon of water at a rolling boil for soak

cleaning. There must be no un dissolved mater ial in the tan k.

Lower items t o be clean ed int o the h ot (205 - 212F) alka line solution

and allow to soak from 2 to 10 minutes, depending on the degree of

contamination.

Agitate a nd bru sh items t o speed up an d improve cleaning.

Transfer items to the rinse tank, allowing sufficient time for the

solution to dr ain.

Rinse item s for 30 t o 60 seconds in h ot wat er 180F or above.

Drain a nd dry immediately.

Apply appr opriate cleanliness te sts.

P r es s u r e Sp r ay Techn i que ( fi gu r e 2 -25)

This process consists of subjecting items to a pressure spray of alkalinecleaning solution (A-A-59146) followed by a rinse of hot water above 180F.

Alkaline spray cleaning is performed in mechanical washing machines as

shown in figure 2-25. Spra y cleaning is preferred t o immer sion clean ing

when conta minat ion on items is heavy enough t o require the spr ay impact for

removal. The force of the spr ay against t he items rem oves both solid

part icles an d soluble contam inan ts. The steps are-

Place items on the washer conveyor so that the sprayed solution can reach all ofthe surfaces of the item.

Adjust sprayer nozzles and conveyor feed for effective cleaning.

Pass items through the cleaning, rinsing, and drying stages. If the machine has

no separate drying stage, dry items immediately after rinsing by an approved

procedure. Apply appropriate cleanliness tests.

Figur e 2-24. Alka line immer sion clean ing.


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Figure 2-25. Alkaline cleaning by pressur e spray.

Elec t r oc lean ing ( figur e 2-26)This process consists of immersing items in an alkaline cleaning solution with the item

serving as an element of an electrochemical cell. Plater's electrocleaning compound for

steel, SAE AMS-1547 (formerly P-C-535), is used for alkaline electrocleaning. A hot

water rinse (above 180F) must follow the electrocleaning process. Decomposition of

water with the evolution of the gases results when a low voltage current is passed through

the electrocleaning solution to the item. Gas bubbles develop on the surface of the item

and as they expand and escape to the surface, they exert both a "throwing off" and a

"scrubbing" action, which is very effective. This process should be used only on unititems or simple assemblies. Items having internal cavities should not be electrocleaned,

since only small amounts of gas are liberated on these internal surfaces. Items of

magnesium, zinc, or their alloys should not be electrocleaned unless special approval is

obtained and special cleaners and special care are employed in their cleaning. Highly

finished or critical surfaced items should not be cleaned by this process. The steps in

performing this process are -

Wear protective goggles, gloves and aprons.

Attach items to cleaning fixtures and lower into cleaning tank with solution of8 to 12 ounces of compound per gallon at 205 to 212F.

Clean items by making them cathodic (charged negatively) for 1 to 5 minutes.

Relieve hydrogen embrittlement by reversing the current and making items

anodic (charged positively) for 15 to 30 seconds. (If the tank does not have areversing switch, two separate tanks are necessary.)

Transfer items to the rinse tank. Allow time for excess cleaner to drain, without

drying on the item.

Rinse items for 30 to 60 seconds in overflowing hot rinse water (above 180F).

Inspect item for cleanliness by watching for an even flow of water from surfaceswithout any breaking of the water film.


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Figur e 2-26. Electr oclean ing.

Em u ls ion Clea nin g (f igur e 2-27)

Emulsion cleaning is accomplished by blending an emulsifying concentrate

with ker osene. The clean ing oper at ion rem oves oil-soluble an d water -solubleconta minan ts. Em ulsion cleaning removes cont amina nt s not readily

removed by vapor degreasing alone or a lkaline cleaning alone. It combines

desira ble featu res of both of th ese processes. Kerosen e is mixed with the

emulsifying agents an d applied to items by immer sion or spr aying. Additions

of small amounts of alkali to these emulsions are sometimes recommended

where h eavy oils and greases ar e to be removed.


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Figure 2-27. Emulsion cleaning.


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Appl icabi l i ty

Emulsion cleaners are effective for removing stubborn pigmented, drawing,

buffing, and polishing compound s and slush ing oils. Since tra ces of a soapy

film are left on an items surface after emulsion cleaning, this type of

cleaning is used only when the permitted degree of cleanliness is somewhat

less than that obtained by the petroleum solvent or alkaline cleaning

processes. Em ulsion cleaning should not be used on an y assembliescontaining fabrics, rubber, and other organic materials, unless it has been

reliably determin ed tha t no ha rmful effects will result. Also, it should not be

used on any item or assembly which will tend to trap and hold rinse water

tha t would eventu ally cau se corr osion.

M a t e r i a l

An approved emulsion cleaning material is grease emulsifying, solvent

clean ing compoun d (P-C-444). It is a liquid concent ra te capa ble of mixing

readily with ker osene or other solvents.

Equ i pm en t (fi gu r e 2 -28)

The equipment required for emulsion cleaning is essentially the same as

described for petroleum solvent cleaning. Representa tive types of spra y

equipment ar e shown in figur e 2-28.

Figure 2-28. Emu lsion spray wash ers.


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P r e s su r e S p r a y T e ch n i q u eThis process subjects items t o a pressur e spray of emulsion cleaner. It sh ouldbe limited to cleaning unit metal items or very simple assemblies, on whichall surfaces can be reached by the spra y, and on wh ich n o surface will tend t otra p the solut ion. The steps for this cleaning are -

Wear protective goggles, rubber gloves, and apron.

Adjust all spra y nozzles for proper spr aying.

Check filter screens in t he circulating system t o permit a free flow of

cleaner through th e unit .

Adjust temperature controls to keep heaters operating within the

ran ge recommended by the man ufacturer of the equipmen t.

Load items so that sprayed emulsion will reach all surfaces to be

cleaned.

Adjust nozzle spray pressure so all surfaces will be reached with

enough impa ct to remove the soil.

Pa ss items thr ough or suspen d them in th e emulsion spra y zone.

Check results of cleaning and readjust spray nozzles as necessary to

insu re effective clean ing.

Follow the pressu re spr aying by thorough immersion rinsing in cleanhot water (180F).

If machine is equipped with a drier, allow items to remain in the

drying zone u ntil dry.

If equipment does not have an automatic blowoff, dry items with

clean compr essed air or other appr oved drying pr ocedure. Inspect for clean liness an d test as n ecessary.

I m m e r s io n T e ch n i q u eThis process consists of soaking item s in a tan k of emulsion cleaner at roomtemperature, followed by an immersion rinse in clean water above 180F.The emulsion solvent cleaner must not be heated above room temperaturesbecau se of th e fire hazar d. The hot rinse helps remove emu lsion cleanerresidues and aids in th e drying procedure. Accomplish the cleaning asfollows:

Take necessary safety precau tions a nd wear safety equipment .

Place item s int o basket s, on h ooks, or on ra cks to provide for complet e

drainage from pockets and crevices.

Lower items to be cleaned into emulsion ta nk an d allow th em to soak

for 1 t o 10 minutes, as determ ined by amoun t of dirt to be removed.

If the tank is not equipped with agitation devices, agitate and scrub

items to speed up the operation.

Take items from solvent tank after they have soaked enough to be

clean.

Exam ine for cleanliness while items a re dr aining.

Transfer, if clean, to a hot (above 180F) water rinse for 30 to 60seconds.

Remove, drain, an d dry. Test for cleanliness as a ppropriate.

Stea m Clean ing ( figur e 2-29)

G e n e r a l

Steam cleaning subjects items to a stream of steam alone or to a stream of

steam with a n ad ded cleaning compoun d followed by steam alone. Steam

cleaning is a common cleaning process because of the relatively low cost of

material, the simplicity of steam generating units, and the adaptability to

various items to be cleaned. Steam cleaning combines th ree powerful


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cleaning actions: the chemical action of th e detergent, in penetrat ing,

wetting, and emulsifying surface deposits; the physical action of the high

pressure steam and solution working their way through successive layers of

dirt and grease; and the dissolving action of the heat on oils, greases, and

other deposits.

App l icab i l it y o f S t eam Cl ean i ngSteam clean ing has wide applications. It is used on vehicles and other field

equipment too large to be soaked in tanks or conveyed through spraying

machines. By using steam with detergent , all types of cont amina nt s except

solid rust an d scale are r eadily removed.

M at e r i a l s

Materials required for steam cleaning are water for steam and steam

cleaning compound.

Wa t e r f o r S t e a m

Water sh ould be as free from scale forming contam inan t as possible. Ha rd

water will cause rapid formation of coil-clogging scale and increase the

corrosion of the steam m ater ial. Use of water softening equipment is

essential in har d water area s. Periodic descaling of steam coils is also animportant preventive maintenance operation.

Figure 2-29. Steam cleaning.


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WARNING

Remember that steam causes very serious

burns! Be careful at all times!

S t e a m Cl ea n i n g Co mp o u n d ( A-A-5 91 33 )

This is a uniformly granular mixture of alkaline compounds and soaps

developed for use in high pressure steam clean ing machines. It is a

noncaking, nonclogging blend of powders which should not cause skin burn or

sneezing to users.

E q u i p m e n t

The equipment required for steam cleaning may be either stationary orportable.

Clean er , S t eam , Pressure J e t , Sk id-Mou nt ed (MIL-C-9911 (USA F))

This specification covers one type of electrically operated, skid-mounted, kerosene or

diesel fuel-fired, pressure jet, steam cleaner. The cleaner covered by this specification is

intended for use in the washing and cleaning of aircraft engines and components,

vehicles, and miscellaneous ground equipment by the application of vapor pressure and

cleaning compound solution.

Clean er , S team , Pressure J e t , Tr a i l er Mou n ted (MIL-C-23023 (MC))

This specification covers one type of trailer mounted, gasoline engine driven,

steam cleaner designed to remove surface deposits of foreign material by

means of a forced stream of steam and water or steam, water, and detergent.This cleaner is intended for use in the cleaning of vehicles, vehicle parts,

aircraft engines, machinery, an d oth er surfaces. The unit ma y also be used

for sterilizing, disinfecting, and paint r emoval. This cleaner ma y be

connected to a cold water supply tank, pressure tap, a well, lake, stream,

river, or a ny other available out side source of water .

Clean er , S tea m, Pr essu re J e t , Wh eel -Moun ted (MIL-C-22894).

This specification covers two sizes of electric-motor-driven, wheel-mounted,

oil-fired, pressure jet, steam cleaners with a minimum discharge capacity of

100 gallons per h our (gph) or 180 gph. The cleaner is inten ded for the

washing a nd cleaning of vehicles and miscellan eous groun d equipmen t by th e

applicat ion of steam , pressu re, an d cleaning compound solution.

S a fe t y P r e c a u t i o n s

Boots, rubber a prons, gloves, and goggles must be worn t o protect a gainst th e

hot steam an d avoid burn s from han dling the hose and nozzle. When steam

cleaning compound is used, avoid excessive contact of the material with the

eyes and skin. The closing off and shu tting down of a porta ble steam cleaner

requires car eful safety procedur es. The supplier's

Documents

FM 38-700 Packaging of Materiel - Preservation