Purpose

This procedure provides a proper way to evacuate Hazardous Fluids like production fluid condensate from gas engines cylinders, and the oil crankcase.  This procedure will also aid in helping to remove some of the potential hazardous such as exposure to flammable fluids and the inhalation of vapors when removing them from the engine cylinders and the engine oil crankcase.  

This procedure follows a lot of the same guidelines as Flogistix policy 1.05.002 for the removal of Flammable and Production fluids from Flogistix compressors

Procedure

This procedure applies to all Flogistix Gas Engine Driven compressor packages that are setting on an Oil or Gas Production Location, or at a Flogistix Service location when the engine cylinders and/or crankcase have become full of production fluids.  The following steps must be followed

If a Flogistix Technician finds an engine full of production fluid, they are to immediately notify the Area Manager before preceding with removing the fluids.

At no time is it acceptable to drain any production fluids onto the skid or into the environmental rails of the skid.    Policy link listed below:

   1.05.006  No Draining of Fluids on Compressor Skid 

All Flogistix employees have Brake for Safety Authority per the Flogistix EHS Manual Section 8 - 8.2  

Always position yourself upwind of any work being performed or of any potential gas being released.  

With any production fluids there can be the possibility of exposure to H2S and other substances.

Removal of production fluids from Engine Cylinders and Crankcase​. 

Before any work is performed a JSA must be completed according to Flogistix EHS Manual Section 6 - 6.1, along with any customer requirements before any work is started.

When it is determined that the engine cylinders have become full of production fluids, the production fluids will need to be removed.  The only way to remove the fluids is by rotating the engine after all sparkplugs have been removed.

Before removing sparkplugs for removal of fluids, all battery voltage power needs to be isolated and engine ignition system disabled, per the Flogistix Lock Out Tag Out Procedure listed in the Flogistix EHS Manual Section 9 - 9.11

Follow the correct procedure for removing the engine sparkplugs.   

1.03.083 Cummins G8.3 Sparkplug Installing/removing procedure 

1.03.073 Cummins G855 Sparkplug Installing/removing procedure 

1.03.011 GM 5.7 (350) Sparkplugs Installing/removing 

After removal of each sparkplug from all engine cylinders.  The engine will need to be rotated, then as the engine is rotated the piston of each cylinder will push the fluids out of the sparkplug hole as the piston reaches top dead center. 

At no time is it permitted to use the engine starter to rotate the engine to remove the production fluids.  

Use the following recommendations for rotating the engine by the engine type listed below. 

Cummins G8.3 - Engines The 8.3 engine can be rotated by using the Cummins turning tool and using a ratcheting wrench as illustrated below to correctly rotate the engine.

Cummins G855 - Engines Can be rotated by using a socket and ratcheting wrench on the accessory drive as illustrated below to correctly rotate the engine.

GM - 8.1, 8.0, 5.7, 4.3, & 3.0  -  Engines  To manually rotate the GM engine it is best to use a strap wrench for this when wrapped around the front Harmonic Balancer.  In the illustration pictured below the Strap Wrench used was a RIDGID brand Strap Wrench.  RIDGID part # 31365

Any Strap Wrench will work, but the length of the strap will need to be a Minimum of 31" long to be able to wrap around the Harmonic Balancer.

When wrapped around the Harmonic Balancer the engine can be manually rotated as shown in the illustration photo below.

This is the recommended way to manually rotate the GM style engine to remove production fluids from the engine cylinders.

Continue to rotate the engine to try to remove any fluid that can be evacuated by rotating the engine by hand.

When rotating the engine, any production fluids that run out of the engine cylinders must be contained and cleaned from the skid.  

On the Inline Cummins G8.3 and the G855 engine all of the production fluids will not run be able to run out of the engine sparkplug holes because of the design of the engine with the sparkplug tubes facing upward.  This creates an area not allowing all the fluid the drain out by gravity.  On the Cummins style engine, the Sage Vac System will need to be used to evacuate the production fluid out of each individual cylinder as that cylinders piston is at the Top Dead Center position.

No production fluid is permitted to be left on the skid or to be allowed to be drained into the Environmental Rails.  

Once all production fluid has been removed from the engine cylinders by manually rotating the engine by hand, the sparkplugs can then be reinstalled. 

Follow the Sparkplug installation procedures listed below for the type engine.

1.03.083 Cummins G8.3 Sparkplug Installing/removing procedure 

1.03.073 Cummins G855 Sparkplug Installing/removing procedure 

1.03.011 GM 5.7 (350) Sparkplugs Installing/removing 

Once sparkplugs have been installed, continue to rotate the engine manually by using the approved methods for the engine type.  

Continue rotating until several turns have been achieved.  This will insure that no production fluids are impeding the rotation of the engine.

Engine should be able to be rotated without any tightspots when rotating manually.   

Engine Crankcase

Check the engine oil level in the oil pan or crankcase.  If the oil is above the normal level, check to make sure no production fluid has gotten into the crankcase or oil pan.

If the engine oil needs to be drained, this shall be done by using the Sage Vac System.

It is not permitted to intentionally drain any engine oil onto the skid or into the environmental rails of the skid.

All production fluids, hazardous fluid, or flammable fluids must be cleaned from skid.  The Environmental Rails will also need to be cleaned of any production fluid before engaging the engine starter or attempting to restart the engine

Fuel Supply Line

The Fuel Supply Line should be checked to make sure no production fluids are remaining in the fuel system. 

After all production fluids have be evacuated from the engine cylinders, engine oil pan or crankcase, and fuel system the engine can be attempted to be started.

Process Piping on Compressor Skid

If any production fluids are present in any of the process piping on the skid, this will need to be evacuated before attempting to restart the compressor package.

Follow the procedures listed below for removing fluids from Vessels and piping.

1.05.002  Field Service Procedure for removal of Flammable or Production Fluids from Flogistix Compressors 

1.05.004  Purging and Removal of fluids from units known to have been in H2S service 

Special Note:

Equipment design changes and special tools are currently under development.  Upon release of these new design features and tools, this procedure will be revised and redistributed.  Included in this scope are piping and vessel changes to new compressors going forward which will facilitate connection of auxiliary fuel and scrubber dump supply gas and will improve the mechanical ability of the system to stop liquid ingress to the engine.  Further, engineering is developing specialized adapters for use with the Sage Oil-Vac system that is integral to all service trucks.  This adapter is intended to connect the Oil-Vac to the engine cylinders at the spark plug port, allowing full containment and capture of any liquids that may be present while rolling the engine over.  Details of these features and tools are pending.  

Responsibilities

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

EHS - 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 FLOGISTIX –Field Service, Rebuild locations and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

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.  

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.  

Environmental spill of compressor oil and production fluids 

Safety

All Personal Protective Equipment (PPE) for Field Mechanical duties apply for this procedure. Flogistix EHS Manual, Section 8, Procedure 8.3 Personal Protective Equipment (PPE)   

Four Gas Monitor, which is outlined in the Flogistix EHS Manual, Section 8, Procedure 8.3 Personal Protective Equipment (PPE) and Procedure 8.9 Hazardous Gases

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 any Customers safety practices.

Proper use of required tools 

Disposal of Production fluids 

Flogistix Service Technicians performing Procedure will dispose of any production fluids according to Flogistix policy.  Disposal of any fluids will be done at an approved or designed waste location.  

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Emergency and First Aid procedures

• 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 Procedure of removing production fluids from compressor units shall be required to have the listed tools to perform job tasks:

• Flogistix Service truck with an oil evacuation (Sage) system.

• 1/2" Ratcheting Wrench with long handle capable of rotating the Cummins G8.3 using the Cummins rotating tool

• 1  5/16" Socket to fit on Hex Nut on the G855 Accessory Drive used for manually rotating the engine

• Ratcheting Wrench that will fit the 1 5/16" Socket used to rotate nut on G855 Accessory Drive

• Strap Wrench (RIDGID part #31365) or comparable Strap Wrench with at least 31" strap to be able to wrap around the GM Harmonic Balancer.  

• Sparkplug Socket and Ratcheting Wrench to remove the sparkplugs per the Sparkplug Removal/Installation Procedure for the engine being worked on.

Approvals:

Field Service approved by:  Charles Crenshaw, VP Field Service Date: 12/20/2023

Engineering approved by:  Aaron Baker, VP Compressor Engineering Date: 12/18/2023

EHS approved by:  Michael Southard, VP-EHS Date: 12/13/2023