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This Policy is completed and is waiting on Field Service, Engineering, and Safety approval.
Purpose
Purpose
The purpose of this procedure is to establish the minimum requirements for torquing the engine cylinder heads on Cummins G855 style engines as laid out in this procedure.
Procedure
Procedure
This procedure applies to all Cummins G855 style engines on Flogistix skids equipped with the Cummins G855 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 cylinder heads have been replaced, or removed from the engine and reinstalled or anytime the engine cylinder heads torque needs to be checked.
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.
Cummins G855 Cylinder Head Torque
When replacing cylinder heads or after replacing the cylinder head gasket on the Cummins G855 style engine the proper torque and head bolt torque sequence must be done to assure the proper head gasket crush and head bolt stretch according to Cummins guidelines. Head bolts can be reused after an inspection has been done on them. You need to look for any physical and corrosion damage. After cleaning and inspecting apply a film of clean engine oil to bolts.
Below is how the Cummins G855 head bolts are oiled and numbered when torquing.
With the cylinder head on engine install head bolts. Head bolts need to be lightly lubricated with clean engine oil.
With a socket run all the head bolts into cylinder block until the head of the bolt touches cylinder head.
First Pass torque all bolts to 100 ft lbs starting with the bolt labeled #1 and continue using the bolt sequence from the example above.
Second Pass torque all bolts 220 ft lbs starting with the bolt labeled #1 and continue using the bolt sequence from the example above.
Third Pass rotate all bolts 90 degrees at least one flat, but no more than two flats
After the previous steps have been completed the engine cylinder head will be torqued to Cummins guidelines.
Responsibilities
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
Scope
This procedure applies to all Cummins G855 style Natural Gas Engines and is applicable to all Flogistix employees, contractors, and temporary employees.
Hazards
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
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
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
Torque Wrench capable of torquing 225 ft lbs
Approvals
Field Service approved by:
Date:
Engineering approved by:
Date:
EHSS approved by:
Date:
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