1.09.004 Reich ARCUSAFLEX type coupling on Cummins G855

This Policy is completed waiting on Field Service, & Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for the installation of the Reich ARCUSAFLEX coupling sometimes referred to as the Ringfeder type soft coupling on Cummins G885 series engines driving LeRoi 175 model compressors as laid out in this procedure.

Procedure

This procedure applies to all skids equipped with the Cummins 855 series engine and LeRoi 175 compressor 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 installation as required according instruction 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.

When installing the ARCUSAFLEX style soft coupling it needs to be installed correctly so that the coupling has full engagement with the outer coupling flywheel adapter on the engine.

To adapt the LeRoi 175 model compressor to the Cummins 855 series engine a SAE adapter needs to be used to be able to mount the SAE #2 on the LeRoi compressor to the SAE #1 Flywheel housing. This is referenced on the illustration reference below as #10 and described as Part # 022-023-079.

1. The SAE #1 to SAE #2 adapter ring #022-023-079 uses two sizes of bolts, the adapter ring to the engine flywheel housing requires 7/16" bolts torqued @ 70 ft-lbs, the LeRoi compressor housing to the adapter ring requires 3/8" bolts torqued @ 44 ft-lbs.

2. The ARCUSAFLEX adapter that mounts on the flywheel requires 7/16" bolts that need to be installed without lockwashers or flat washers. Use Red Loctite #272 Threadlocker to maintain torque. The ARCUSAFLEX flywheel adapter to flywheel 7/16" bolts torque to 70 ft-lbs of torque. If the 7/16" bolts are installed with lockwashers, there is not enough clearance inside the LeRoi housing and the the 7/16" bolts will come into contact with the compressor housing, resulting in a seized or locked-up assembly.

3. The correct spacing of the coupling on the compressor must to be set to insure the coupling element is fully engaged in the outer coupling adapter (drive ring) that is mounted on the flywheel. To achieve proper coupling engagement, measure from the end of the compressor shaft and make a mark at 2 3/16" inches. Reference drawing Section A-A. The mark on the shaft can be done with a sharpie marker.

4. When installing the ARCUSAFLEX coupling element part # 021-002-535 referenced in the drawing below as # 6 needs to be installed with the coupling element going over the compressor shaft first with the small diameter of the taper closest to the compressor.

5. Then install the taper lock bushing part # 016-034-535 referenced in the drawing below as #3 on the compressor shaft. Install the taper lock bushing so that the end of the bushing is at the mark indicating the 2 3/16" from the end of the compressor shaft.

6. Once the taper lock bushing is in the proper position on the compressor shaft slide the ARCUSAFLEX element on the taper lock bushing and start the taper lock bushing capscrews. Continue tightening the three taper lock bushing capscrews in a crossing pattern until the coupling element is firmly set on the taper lock bushing.

7. Torque the taper lock bushing capscrews to 83 ft-lbs

Once the ARCUSAFLEX coupling element is installed on the compressor shaft rotate the compressor shaft by hand and check that the compressor turns freely. Also when rotating the coupling, look to see that the element seems to be running true with the compressor shaft and the element does not have any front to back movement of the coupling element when rotated.

When installing the compressor to the engine lift the compressor to match the coupling height of the flywheel. Align the coupling teeth of the ARCUSAFLEX coupling to the flywheel coupling adapter so the coupling will start to engage into the outer coupling adapter (drive ring) mounted on the flywheel. The coupling should slide together when aligned and the SAE housing of the compressor should match up to the SAE adapter ring on the engine very little or no gap. Once the compressor and engine are mated together install the 3/8" bolts to mount the compressor to the SAE flywheel adapter and torque bolts to 44 ft-lbs.

** Compressor housing to SAE flywheel housing adapter should not have a gap or space in between when first mated up. DO NOT USE housing bolts to pull compressor housing into SAE adapter housing if there is a gap.

Once bolts on compressor housing have been torqued, check to see if engine can be rotated easily. If engine rotates freely with compressor coupled to engine then the engine crankshaft end-play should be checked. The engine crankshaft should be able to be moved in both directions with out springing back in either direction.

If the crankshaft end-play is correct the coupling installation process is complete.

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 855 series engines driving the LeRoi 175 model compressor equipped with the Reich ACUSAFLEX (Ringfeder) style soft coupling and are applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of lifting heavy loads and the potential for injury due to pinch points, lifting or falling heavy loads. Proper lifting Technics need to be followed. 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. Environmental spill of compressor oil and production fluids during disassembly or lifting of compressor to access compressor coupling.

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

• 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

• Proper lifting technics for heavy lifting

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

• Correct lifting equipment to lift compressor. (Estimated compressor weight 1250 lbs)

• Torque wrench capable of torquing bolts to 83 ft-lbs

Approvals

Field Service approved by:

Date:

Engineering approved by: Aaron Baker

Date: April 26, 2017

EHSS approved by:

Date: