Process Specification

PCS-2620
Issue: 3
Date: 23th January 2009

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HOT DEGREASING

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DEGRAISSAGE A CHAUD

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Issue N° Date Changes

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1 01/04/2001 Creation of PCS-2620.

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2 01/04/2002 Addition of a third method for checking acid acceptor, a change in Compatibility
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Table 1 and inclusion of definitions.

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3 23/01/2009 Addition of CFRP composite to Appendix A Table 2, introduction of n-propyl-bromide

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Compiled by F. PESTEL: Materials and Processes Laboratory Engineer (F) Approved on file
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Approved on file
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P. GREGORY: Materials and Processes Laboratory Engineer (UK)

Agreed by Approved on file

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R. RAININGER: Materials and Processes Laboratory Engineer (C)

Approved on file
C. NADEAU: Group Leader of Operations (C)

Specification prime P. TAYLOR: Materials and Processes Laboratory Manager (F)

Approved on file
owner

Page1/14E
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 Process Specification
PCS-2620
Issue: 3
Date: 23th January 2009
INDEX

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Page

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1. INTRODUCTION ........................................................................................................................... 3

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2. SCOPE .......................................................................................................................................... 3

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3. ASSOCIATED SPECIFICATIONS ................................................................................................ 3

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4. HEALTH AND SAFETY ................................................................................................................. 3

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5. DEFINITIONS ................................................................................................................................ 4

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6. PLANT CONDITIONS.................................................................................................................... 5
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7. SOLVENT ...................................................................................................................................... 5
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8. CLEANING PROCEDURE ............................................................................................................ 6

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9. SOLVENT CONTROL ................................................................................................................... 7

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10. FACILITY QUALIFICATION .......................................................................................................... 8

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APPENDICES
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A. COMPATIBILITY OF SOLVENTS AND MATERIALS ................................................................... 9

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B. HALOGENATED SOLVENTS - CHARACTERISTICS IN USE................................................... 14

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C. BOILING POINTS OF MINERAL OIL AND CHLORINATED SOLVENT MIXTURES................. 15

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D. DENSITY OF MINERAL OIL AND CHLORINATED SOLVENT MIXTURES .............................. 16

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page 2/14E
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 Process Specification
PCS-2620
Issue: 3
Date: 23th January 2009

PCS-2620

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Hot Degreasing

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1. Introduction

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A. This specification covers the degreasing of components using hot solvents in vapour form or in liquid
form.

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B. At present the process is carried out using chlorinated solvents, however, non-chlorinated solvents can
be qualified if needed.

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C. The present specification takes into account requirements from European Directive 1999/13/CE dated

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11th March 1999, especially about setting and following of Solvent Management Plan (SMP).

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D. The implementaion date of this new issue is 12 months after the issuing date.
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2. Scope
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A. Vapour phase degreasing is a degreasing operation of a very high quality, but is not compatible with all
materials. Special attention is drawn to Table 1 in Appendix A.
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B. In order to avoid the build-up of contaminants and the degradation of the solvent, care shall be taken to
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adhere to the procedure laid down in this specification for the regular cleaning of the plant, the control of
the degreasant and the technique of handling the parts to be treated.
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C. The efficiency of the plant decreases with the increase in oil contamination of the solvent. The effect on
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the boiling point and density of the solvent is illustrated in Appendix C and Appendix D.
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D. When called up on a drawing, the application of this Standard is mandatory for all manufacturing work
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carried out at Messier-Dowty, its Partners or its Sub-Contractors. Alternative procedures may be
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adopted by sub-contractors, provided full approval has been obtained from Messier-Dowty.
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E. This specification supersedes PS203 and the section in IFC40-711-01and DCMP-176 covering vapour
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degreasing.
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F. Attention is drawn to the Safety Precautions in Section 4.

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3. Associated Specifications

A. European Directive 1999/13/CE dated March 11th 1999.

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B. Messier-Dowty

(1) PCS-2800 Temporary Corrosion Protection of Parts

4. Health and Safety

A. The fluids called up in this specification may be dangerous to health and shall, therefore, be handled in a
safe manner.

page 3/14E
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 Process Specification
PCS-2620
Issue: 3
Date: 23th January 2009
B. It is the Departmental Managers responsibility to develop safe working practices for the use of these
materials and to take notice of the hazards detailed on the materials Health and Safety Data Sheet.

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C. The following procedures should be considered when establishing a safe working practice.

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(1) Smoking is prohibited in the neighbourhood of the plant.

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(2) The plant shall be situated in a well-ventilated, but not draughty, location.

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(3) The solvent manufacturer’s instruction notices and first-aid instructions shall be displayed
prominently near to the degreaser and kept in good condition.

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(4) On degreasing tanks equipped with a lid, it shall be kept closed as often as possible.

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(5) Under no circumstances may anybody enter a degreasing plant for cleaning purposes without
permission being granted by a departmental manager.

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(6) When such permission has been granted, the plant shall be completely drained of all solvent. A
supply of fresh air shall be made to the sump to expel fumes. If the plant is entered, a lifeline shall
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be worn and a second person shall be standing outside to render assistance. Breathing and
reviving apparatus shall be provided and be easily accessible, if required under the local Health and
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Safety Legislation
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D. If leakage, or spillage’s, occurs, then the liquid should be cleaned up with a non-combustible absorbent
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material. The contaminated cleaning material shall be removed as soon as possible from the work
place to a safe storage awaiting disposal.
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E. Contaminated cleaning material and other unwanted materials shall be disposed of in accordance with
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the requirements of the local legislation.

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5. Definitions
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A. Competent Authority: person (or group of people) belonging to Messier-Dowty who are qualified to allow
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dispensation from the standard. This (These) person(s) is (are) defined as follows: “When there is a
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request for any deviation from the requirements of this specification, the request shall be processed via
the Quality Department responsible for the surveillance of the area/site of manufacture. All queries
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relating to any technical aspect of the component must subsequently be addressed to the Technical
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Design Office, within Messier-Dowty, responsible for the design of the part. Along with any Materials
Laboratory input that may be required, for decisions on parts where the base material, its processing or
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treatments are concerned, the responsible Technical Design Office will provide the decision. When the
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query addresses issues, which will not affect the life or function of the part, eg “cosmetic” variations; the
decision will be given by the responsible Quality Department. (Please note that surface finish, protective
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treatment variances and profile variations must not be interpreted as “cosmetic”).”

page 4/14E
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 Process Specification
PCS-2620
Issue: 3
Date: 23th January 2009

6. Plant Conditions

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A. The tank shall be operated in accordance with the manufacturers instructions, with special
attention being paid to the following:

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(1) Level of solvent

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(2) The condenser shall be working effectively

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(3) The water separator (Florentin vessel), shall be working effectively

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(4) Thermostatic control of the heat input such that the supply of solvent vapour is always

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sufficient to ensure condensation on all surfaces of the parts even for the largest of

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components

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B. The tank shall carry a sign stating which particular degreasing solvent it contains.

7. Solvent
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A. The solvent shall conform to the physical and chemical characteristics listed in Appendix B,
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Table 1.
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B. The solvent shall be a highly stable neutral grade containing a stabiliser package to confer
resistance to decomposition by heat, light, air and reactive metals.
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C. The solvent shall be one of the following:

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(1) Methylene Chloride

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(a) This is the most powerful of the solvents listed in this specification. It is one of the more
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stable chlorinated solvents and can be used satisfactorily for cleaning all the common
metals. Commercially available grades, containing appropriate inhibitors, are
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recommended for use in vapour degreasing plants made of the normal metals of
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construction. They are stable in the presence of the usual metal working lubricants,
processing aids and light metals. If not adequately stabilised or if denuded of stabiliser by
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conditions of use, methylene chloride can attack aluminium. It can slowly degrade in strong
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sunlight, or in the presence of moisture, producing acidity and hence corrosion of metals
left in contact with the solvent.
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(2) Trichloroethylene

(a) This solvent is available commercially in stabilised grades suitable for cleaning all
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common metals. The correct grade shall be selected when dealing with aluminium and
other light metal grades, particularly when swarf and finely divided particles are
encountered, because it can react autocatalytically with these metals in a vigorous,
exothermic reaction. Trichloroethylene is stable in the presence of the usual metal
working lubricants and processing aids. If inadequately stabilised or denuded of
stabiliser by conditions of use, trichloroethylene will hydrolyse slowly in the presence
of water, resulting in the formation of hydrochloric acid.

page 5/14E
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 Process Specification
PCS-2620
Issue: 3
Date: 23th January 2009
(3) Perchloroethylene

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(a) Although not as powerful as trichloroethylene, this solvent is a very good solvent for

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oils, fats waxes, greases, etc. In vapour degreasing, the combination of solvent effect

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and temperature (boiling point 121 ºC [250 ºF]) is particularly useful for removing high
melting point waxes and greases. The solvent is inherently stable to light metals and

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commercially available grades, containing only small amounts of stabiliser, can be
used repeatedly without attack on the common metals, or on equipment made from the

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normal metals of construction. Perchloroethylene is stable in the presence of the usual
lubricants and processing aids.

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(4) N-propyl Bromide

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(a) This solvent is the direct replacement for trichloroethylene and other hazardous

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cleaning solvents. It has no flash point and classified as non-hazardous. N-propyl
bromide boiling temperature is 70 °C (158 °F). This solvent possesses excellent

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cleaning properties, solvency, and soil-loading characteristics for a wide range of
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organic, polar and non-polar soils.
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D. Different types of solvent shall not be mixed.
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8. Cleaning Procedure
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A. Heavily contaminated parts shall first be pre-cleaned by cold solvent degreasing, for example
by using a high-pressure paraffin wash. This is to ensure that the cleanliness of the degreasing
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bath is maintained as long as possible, and to remove fine swarf. This is particularly important
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with light alloy parts, which if dry, may be blown clean with compressed air.
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B. On non-automatically loaded degreasing plants all work shall either be loaded in suitable
containers, such as baskets, or hung on convenient slings in such a position that air-locks and
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the trapping of solvent in pockets or on horizontal surfaces is avoided as far as possible.

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Where possible the surfaces of individual components should not come in contact with one
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another.
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C. On automatically loaded plants, place the part on the staging provided in such a position that
air-locks and the trapping of solvent in pockets or on horizontal surfaces is avoided as far as
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possible. Start the automatic sequence.

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D. On non-automatic plant the work should be lowered gently into the vapour zone of the
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degreasing tank, where vapour will condense on the cold surfaces. If the load is large, relative
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to the heat input of the plant, the vapour level will drop, but will rise again as the work surfaces
become warmed.
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E. The majority of components will reach a temperature at which no more condensation of vapour
can occur. This is normally the end of the vapour treatment. Large components, however,
which have a large heat capacity, will continue to condense vapour for some time while heat is
being conducted to the interior of the metal.

F. The degreasing of titanium alloy parts with hot chlorinated solvents (vapour form or liquid form)
is not allowed if parts are heated to more than 200 °C (392 ºF) during later processing. This
means that processes such as stress relieving, welding and heat treatment, shall be done
before degreasing.

page 6/14E
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 Process Specification
PCS-2620
Issue: 3
Date: 23th January 2009
NOTE: Pay particular attention to the deburring operation when ‘spattering’ can
cause cracking.

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G. After degreasing, the load should be raised slowly to the area above the liquid surface, or

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vapour level, where it should be held until completely dry. Drying by blowing compressed air
inside the degreasing machine is forbidden.

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H. Degreased parts are particularly susceptible to corrosion, so a particular attention should be
taken to prevent oxidation and corrosion. A temporary protective treatment, in accordance with

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PCS-2800 may be necessary unless proceeding to another operation without undue delay.

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I. If necessary, the effectiveness of the degreasing process shall be checked by the following

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water droplet test.

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(1) Degreasing is satisfactory if the water wets the surface completely, producing an unbroken

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film, with no separation into individual droplets.

9. Solvent Control
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A. At a frequency determined by the Competent Authority, the following determinations shall be

carried out:
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(1) Oil content:

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(a) Check the oil content of the solvent by measuring the density of a sample of the
solvent. If the machine works in vapour form, the sample of solvent will be taken from
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the reservoir at the bottom of the tank. If the machine works in liquid form with distilled
solvent, oil content will be checked only if necessary. The maximum permitted oil
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content is 30% by volume. The density of the solvent shall be greater than the
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minimum density given in Appendix B, Table 1.

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NOTE: If the degreasing facility is an enclosed automatic degreaser, the machine

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will not operate when the oil content exceeds approximately 30%. For this
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type of machine the test is not mandatory.

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(b) If the result is unsatisfactory the solvent shall be replaced.

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(2) Acid Acceptor:

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(a) Check the Acid Acceptor Value with a frequency determined by the Competent
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Authority. The acid acceptor value shall be determined by one of the following
methods:
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1 Using a test kit available from the solvent supplier

2 Chemical analysis, using a proven method covered in any relevant literature

3 Using an acidified 1% Bromo Cresol Green indicator solution in accordance with

Appendix B, Table 4

page 7/14E
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 Process Specification
PCS-2620
Issue: 3
Date: 23th January 2009
(b) When the method of test produces a numerical value, acceptable limits are listed in
Appendix B, Table 2, if the pH is checked, and in Appendix B, Table 3, if pH is not

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checked.

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(c) If the result is unsatisfactory, the solvent shall be either partly or completely replaced, or
corrected by addition of acid acceptor.

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(3) pH:

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(a) At a frequency determined by the Competent Authority, the pH shall be checked. The

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pH value, which shall fall within the limits listed in, Appendix B Table 2 shall be

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determined using the following method: Rinse out a container with distilled water with

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a pH of 7. Pour 50 ml of solvent and 50 ml of distilled water, with a pH of 7, into the
container. Stir for at least 2 minutes, and then leave to settle. The water will rise to the

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top rapidly. Measure the pH of the aqueous layer using a pH meter, or an indicator
paper sensitive between at least pH 6 and 10.

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(b) If the result is unsatisfactory the solvent shall be replaced. Correction with sodium
hydroxide or lime is forbidden.
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B. For each degreasing tank, the following records shall be kept:

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(1) The dates on which the baths were made up and topped up
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(2) The quantities of solvents introduced and drained

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(3) The results of the tests listed in para. 8.A.(1) to (3)

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(4) The machine running time (hours per day), when usage monitoring is to be carried out
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10. Facility Qualification

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A. Every degreasing facility shall to be qualified, using samples made of 2024 aluminium alloy, by
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the following method:

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(1) Coat each aluminium alloy sample, by immersion or spraying, with a product typically
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removed by degreasing, such as a temporary protection wax or a cutting fluid.

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(2) Degrease the samples in the degreaser for 15 to 20 minutes.

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(3) Check the test panels, after return to ambient temperature, for:
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(a) Degreasing effectiveness by doing the water droplet test

(b) Absence of metal attack: colouring, pits, corrosion marks

page 8/14E
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 Process Specification
PCS-2620
Issue: 3
th
Date: 23 January 2009
APPENDIX A
Table 1

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Compatibility of Solvents and Materials

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APPLICATION SOLVENT REMARKS

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METHYLENE PERCHLOROETHYLENE TRICHLO N-PROPAL-
CHLORIDE ROETHYL BROMIDE

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ENE

1 BARE METALS

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STEELS - IRON BASED

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ALLOYS 9 9 9 9

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ALUMINIUM ALLOYS
9 9 9 X

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COPPER ALLOYS
9 9 9 X

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MAGNESIUM ALLOYS Degrease with a
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! ! ! X stabilised solvent in
vapour form. Re-
protect in accordance
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with PCS-2800
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TITANIUM ALLOYS Permissible if part is

! ! ! X
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not heated after

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degreasing to more
than 200 °C (welding,
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heat treatment, stress

relieving and
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deburring).
SUPER-ALLOYS
9 9 9 X
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(INCONEL)
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2 PROTECTED METALS
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Steels and iron based

alloys with chemical 9 9 9 X
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treatments or
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thermochemical
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treatments (phosphating,
black oxide coating,
sulfinuz, nitriding,
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carburizing)
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Steels and aluminium

and copper alloys with 9 9 9 X
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electrolytic coatings
Aluminium alloys with
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chemical treatments 9 9 9 X
Anodised aluminium
9 9 9 X
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alloys
Magnesium alloy with Contact restricted to
chemical treatment ! ! ! X 30 minutes max
Anodised titanium alloys Permissible if part is
! ! ! X not heated after
degreasing to more
than 200 °C (welding,
heat treatment, stress
relieving and
deburring).

9 = Fully authorised ! = Permitted – See Remarks X = Prohibited

page 9/14E
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 Process Specification
PCS-2620
Issue: 3
th
Date: 23 January 2009
Table 2
Compatibility of Solvents and Materials

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SOLVENT

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APPLICATION METHYLENE PERCHLOROETHYLENE TRICHLOR N-PROPAL- REMARKS

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CHLORIDE OETHYLE BROMIDE
NE
3 NON-METALLICS

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Elastomers X X X X

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Polyethylene X X X X
Polypropylene ! ! ! X Contact restricted to 15

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minutes max

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PVC X X X X
Rilsan and nylon X X X X

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Teflon 9 9 9 X
Polyacetate X X X X

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Carbon fibre composite X X X X Prohibited for all
material

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solvents

Bituminous coatings
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X
4 SURFACE FILLERS
X X X
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Self adhesive X X X X
identification plates
Loctite ! ! ! X Contact restricted to 30
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minutes max
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Rubberised sealing ! ! ! X Contact restricted to 15

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compound - minutes max

polysulphide
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Chromate jointing X X X X
compound. Silicone
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jointing compound.
Conductive jointing
compound
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Parts with lubricating ! ! ! X Contact restricted to 5

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coatings (Airflon,...) minutes max

Microflon X X X X
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9 = Fully Authorised ! = Permitted – see remarks x = Prohibited

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page 10/14E
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 Process Specification
PCS-2620
Issue: 3
th
Date: 23 January 2009
Table 3
Compatibility of Solvents and Materials (cont)

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SOLVENT

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APPLICATION METHYLENE PERCHLOROETHYLENE TRICHLOR N-PROPAL- REMARKS
CHLORIDE OETHYLE BROMIDE

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NE
4 SURFACE FILLERS (continued)

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Paint oven cured at Contact restricted to 1
>200 °C ! ! ! X hour max

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Nitro-vinyl paint
X X X X

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Identification plates
X X X X

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Coating - Polysulphide
PR 1432 X X X X

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Teflon coating
9 9 9 X

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Rilsan

Protective varnish itio td arm

X X X X
X X X X
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Thermosetting varnish
X X X X
Thermoplastic varnish
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X X X X
Stanal 400
s

X 9 9 X
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Sermetel 962
X 9 9 X
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Sermetel W
X 9 9 X
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Flexible polyurethane Contact restricted to 30

paint X ! ! X minutes max
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Rigid polyurethane Contact restricted to 30

paint X ! ! X minutes max
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9 = Fully Authorised ! = Permitted – see remarks x = Prohibited

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page 11/14E
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 Process Specification
PCS-2620
Issue: 3
th
Date: 23 January 2009
APPENDIX B
Table 1

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Halogenated Solvents - Characteristics in Use

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PROPERTIES SOLVENT
TRICHLOROETHYLENE PERCHLOROETHYLENE METHYLENE

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CHLORIDE

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Boiling Point (°C) 86 to 90 120 to 124 38 to 42

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Liquid Density 1.29 to 1. 47 1.37 to 1.63 1.21 to 1.33

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at 20 °C

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Maximum % Oil 30 30 30

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(by volume)
Table 2

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If pH is checked
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PROPERTIES SOLVENT
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TRICHLOROETHYLENE PERCHLOROETHYLENE METHYLENE

CHLORIDE
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pH 7.0 to 9.5 6.0 to 9.5 6.5 to 8.5

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Acid Acceptance >0.01 >0.01 >0.04

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% of NaOH by weight
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Table 3
If pH is not checked
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PROPERTIES SOLVENT
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TRICHLOROETHYLENE PERCHLOROETHYLENE METHYLENE

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CHLORIDE
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Acid Acceptance >0.05 >0.01 >0.04

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% of NaOH by weight
Table 4
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Acidified Indicator
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RESULTANT COLOUR
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TEST SOLUTION
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BLUE BLUE-GREEN GREEN-YELLOW

Shake
5 mls Trichloroethylene Satisfactory Re-distillation/ Re-distillation + Partial or
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+ New Fluid Required Complete Change of Fluid

5 mls Acidified Indicator Soon
(5 mls N/10 HCl +
5 mls of 1% Bromo
Cresol Green Solution +
water to 1000 mls

page 12/14E
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 Process Specification
PCS-2620
Issue: 3
th
Date: 23 January 2009
APPENDIX C

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BOILING POINTS OF MINERAL OIL AND CHLORINATED SOLVENT
MIXTURES

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200

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190

de ct
180

un -O
170

o) 20
160

dig on
150 PERCHLOROETHYLENE

ns (In a
140
itio td arm
130
nd n L Sh

120
TEMPERATURE ( C)

Co atio hit

110
s

TRICHLOROETHYLENE
Av ak

100
e :R

90
lob by

80
rg ed

70
In ad

60
of nlo
te

50 METHYLENE CHLORIDE
w
us Do

40

30
-

-
e
siv tial

20
clu en
e

10
ex nfid

0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Co

MINERAL OIL CONTENT (c.c./litre of m ixture)

page 13/14E
For reference only when printed. Check revision level prior to use for possible updates.

This document is the property of Messier-Dowty and cannot be reproduced or communicated without its prior authorization.
 Process Specification
PCS-2620
Issue: 3
th
Date: 23 January 2009
APPENDIX D

s& e
rm th
DENSITY OF MINERAL OIL AND CHLORINATED SOLVENT MIXTURES

Te for
APPENDIX 4

LS 21
1.7

r S -20
de ct
un -O
1.6

o) 20
PERCHLOROETHYLENE

dig on
1.5

ns (In a
itio td arm
nd n L Sh

1.4
Co atio hit
DENSITY AT 20 C (kg/dm3)

s
Av ak

TRICHLOROETHYLENE
1.3
e :R
lob by

i
rg ed

1.2
In ad
of nlo
te
w

1.1
METHYLENE CHLORIDE
us Do
-

-
e
siv tial

1
clu en
e
ex nfid

0.9
Co

0.8
0 100 200 300 400 500 600 700 800 900 1000
MINERAL OIL CONTENT (c.c/litre of m ixture)

page 14/14E
For reference only when printed. Check revision level prior to use for possible updates.

This document is the property of Messier-Dowty and cannot be reproduced or communicated without its prior authorization.