1.03.072 Cummins G855 Flywheel removal and installation 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 removing and installing the engine flywheel on Cummins G855 style engines as laid out in this 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.

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 Flywheel removal procedure

Remove the flywheel bolts.

Remove the flywheel from the engine.

After removing the engine flywheel inspect the engine flywheel for any of the following:

• Abnormal pitting on the flywheel surface

• Rust or other surface damage

• Flywheel bolt holes for any signs of wear or fretting from improperly installed flywheel bolts

• Damaged ring gear teeth

• Loose or improperly positioned ring gear **The ring gear has an interference fit onto the engine flywheel and the ring gear should be positioned completely flat against the flange of the flywheel.

Cummins G855 Flywheel installation procedure

Install the Flywheel using two 5/8 -18x6 guide studs

Loctite threads with blue loctite on all capscrews

Install all capscrews and remove the guide studs and install capscrews

Tighten the flywheel capscrews in a star pattern hand tight making sure the flywheel is fully mated to the crankshaft surface.

Torque the flywheel bolts to

First 35 ft lb

Second 70 ft lb

Final plus 90 degrees

Torque the flywheel bolts following the torque sequence below

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 Cummins G855 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

• 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 75 ft lbs (Foot Pounds)

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: