1.03.081 Cummins G8.3 Cylinder Head Torque Procedure

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

Purpose

The purpose of this procedure is to establish the minimum requirements for torquing the engine cylinder heads on Cummins G8.3 style engines as laid out in this procedure.

Procedure

This procedure applies to all Cummins G8.3 style engines on Flogistix skids equipped with the Cummins G8.3 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 G8.3 Cylinder Head Torque

When replacing cylinder heads or after replacing the cylinder head gasket on the Cummins G8.3 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 and bolt stretch. After cleaning and inspecting apply a film of clean engine oil to bolts.

Note: Short bolt max length is 3.2 in

Long bolt max length is 6.4 in

1. With the cylinder head on engine install head bolts.

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

3. First Pass torque all bolts to 30 ft lbs starting with the bolt labeled #1 and continue using the bolt sequence from the example above.

4. Second Pass torque all bolts 60 ft lbs starting with the bolt labeled #1 and continue using the bolt sequence from the example above.

5. Third Pass torque all bolts 90 ft lbs starting with the bolt labeled #1 and continue using the bolt sequence from the example above.

   1. Final 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

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 G8.3 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

• Torque Wrench capable of torquing 100 ft lbs

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: