1.03.073 Cummins G855 Sparkplug Installing/removing 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 changing the engine sparkplugs on Cummins G855 style engines as laid out in this procedure.

Procedure

This procedure applies to Flogistix skids equipped with a Cummins G855 engine that is currently in service either in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the engine sparkplug removal and installation procedure as outlined in this procedure. This procedure will be performed for preventative maintenance, after an engine has been removed and been replaced, after cylinder heads have been installed, or anytime the engine sparkplugs have been determined to need to be checked or replaced.

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.

Removing engine sparkplugs.

With the engine stopped and not running:

The engine sparkplugs are only to be removed when the engine is not running and the engine has stopped rotating. Read through all the steps before attempting to remove or install the sparkplugs

Impact wrenches are not to be used to remove sparkplugs.

1. Before attempting to remove the sparkplug wires from the sparkplugs make note of the sparkplug wire arrangements.

2. With the engine not running, remove the sparkplug wire boot from the sparkplug or sparkplugs being removed. Sometimes the sparkplug wire boot becomes stuck to the porcelain of the sparkplug. To remove the boot, a slight twisting motion of the sparkplug boot will help to break the seal of the boot on the sparkplug. It is best to try to use sparkplug boot pliers to remove the boot. Simply pulling on the sparkplug wire to remove the sparkplug boot could cause damage to the sparkplug boot, sparkplug wire or sparkplug wire terminal

3. Once the sparkplug boot has been removed the sparkplug can now be removed from the engine

4. Using a 13/16" sparkplug socket, place the socket over the sparkplug making sure that the socket is all the way on the sparkplug.

5. Caution must be taken when attempting to remove a sparkplug. Sparkplugs on G855 have a tapered seat, the sparkplug can sometimes break loose or free from the cylinder head all at once. When attempting to remove the sparkplugs make sure that you have good footing and your hands, arms, or other body are clear of any objects when attempting to remove the sparkplugs.

6. With the sparkplug socket all the way on the sparkplug, turn the socket counterclockwise using a long-handle ratchet making sure the pressure applied is straight and not at an angle.

7. Once the sparkplug has been unseated from the engine cylinder head the sparkplug should be relatively easy to turn to continue spinning it out to remove.

8. If removing all sparkplugs, repeat this process for all the sparkplugs.

9. Inspect each sparkplug after it has been removed. If a sparkplug has an abnormal amount of ash on the electrode or looks to be fouled the cause needs to be determined

Installing Engine Sparkplugs

Impact wrenches are not to be used to install sparkplugs.

1. Remove all the sparkplugs that are going to be installed from their original box.

2. Inspect each sparkplug for any damage or abnormalities to the electrode, porcelain, or threads.

3. Check the gap of the sparkplug electrode. Proper gap should be .013" to .016" gap. The maximum gap should only be .020" gap.

4. Install the sparkplug(s) into each cylinder by threading them in by hand until the sparkplug is seated. Anti-seize compound is NOT to be used on sparks plugs per Cummins spec Manuel 013-015

5. Install the sparkplugs by turning them in a clockwise rotation until the sparkplug is full seated by turning tight. With the sparkplug is fully seated in the cylinder head use a 13/16" sparkplug socket to tighten sparkplugs. On a hot engine allow the spark plugs to warm to cylinder head temperature prior to torquing.

   1. Proper torque for the sparkplug installed in cylinder head is 28 lb ft

6. Before installing the sparkplug wires inspect each sparkplug wire, sparkplug wire boot, and sparkplug wire boot on the coil for wear or damage. Replace worn or damaged sparkplug wires as needed.

7. Apply a small amount of Dielectric grease to each sparkplug boot and the coil boot if it was removed.

• 1. With the sparkplugs properly installed, next install the correct sparkplug wire on each sparkplug according to the correct engine firing order.

After Engine has been restarted:

1. Make sure engine is running smoothly after being restarted

2. Listen for any abnormal noise from engine.

3. Listen for any misfiring of an engine cylinder

4. Carefully inspect around engine to make sure sparkplug wires are not arcing around sparkplugs to the engine cylinder

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, and rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and the 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

• 13/16" Sparkplug socket

• Long handle ratchet

• Torque wrench that can properly torque to 30 lb ft

• Sparkplug boot pliers (recommended)

• Dielectric grease.

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: