1.03.042 GM 8.1 (496) Intake Manifold torque procedure

This Policy is completed and is waiting on Field Service, Engineering, and Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for torquing the engine Intake Manifold on General Motors 8.1 (496) Vortec style engines as laid out in this procedure.

Procedure

This procedure applies to all General Motors 8.1 (496) Vortec style engines on Flogistix skids equipped with the General Motors 8.1 Vortec engine drive units that are currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the torque procedure as outlined in this procedure. This procedure will be performed after Intake Manifold has been replaced, or removed from the engine and reinstalled.

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

GM 8.1 (496) Intake Manifold Torque

When replacing or reinstalling the Intake Manifold after removing the intake or after replacing the cylinder heads on the GM 8.1 (496) Vortec style engine the proper torque and bolt torque sequence must be done to assure the proper sealing of the intake gasket according to GM guidelines.

Below is how the GM 8.1 intake bolts are numbered when torquing.

1. With the Intake Manifold setting on the cylinder heads and block install all the intake bolts.

2. With a socket run all the intake bolts into cylinder head until the head of the bolt touches the Intake Manifold.

3. First Pass torque all bolts to 44 lb in (Inch Pounds)

4. Second Pass torque all bolts to 77 lb in (Inch Pounds)

5. Third Pass torque all bolts to 106 lb in (Inch Pounds)

6. Fourth and Final Pass torque all bolts to 12 lb ft (Foot Pounds)

After the previous steps have been completed the Intake Manifold will be torqued to GM guidelines.

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all General Motors 8.1 Vortec style Natural Gas Engines and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of extremely hot exhaust pipe surfaces, potential exposure and the inhalation of engine exhaust. Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes.

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure.

Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3

This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• Emission set up knowlege for Natural Gas Engines

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing this procedure shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

• Basic Hand Tools to include metric sockets

• Torque Wrench capable of torquing up to 106 (Inch Pounds)

• Torque Wrench capable of torquing 12 ft lbs (Foot Pounds)

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: