SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solar’s best judgment regarding the Service
Bulletin. All questions should be directed to your Solar Field Service Representative. Solar, Saturn, Centaur, Taurus, Mercury,
Mars, Titan, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated. Cat and Caterpillar are trademarks of
Caterpillar Inc. Specifications subject to change without notice.

NUMBER: 3.0/105G
ISSUED: December 1983
REVISED: July 2012
PRODUCT: All
MODEL(S): All
Specifics:

SUBJECT: EXHAUST SYSTEM PURGE CRANK TIMES TO PREVENT POTENTIAL

SAFETY HAZARDS DUE TO UNBURNED FUEL OR OTHER
COMBUSTIBLE MATERIALS IN GAS TURBINE EXHAUST SYSTEMS

PRODUCT SAFETY

—REVISION NOTICE—
Updated Titan™ 130 maximum purge crank speed. Added
Titan 250 purge information. Revised Taurus™ 70 purge crank
speed limit.

Type of Change: Product Safety

Recommended
Compliance: Immediate

Purpose:
This Bulletin provides important actions required by turbine operators to avoid the risk of hazardous
combustion in the engine exhaust system.

GENERAL INFORMATION:
Hazardous combustion can occur if the exhaust system is inadequately purged or if the fuel or
exhaust system controls malfunction.

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 NOTE
Within this document, the term, “exhaust system” is meant to include all
ducting and/or devices such as heat exchangers, boilers, heat recovery
units, recuperators or silencers attached to a gas turbine engine.

If unburned fuel or other combustible material enters a gas turbine exhaust system, this fuel or other
material may ignite if the fuel/air ratio reaches combustible limits and ignition sources are present.
The fuel or other combustible material can enter the exhaust system by various means, but Solar is
primarily concerned with situations after flameout or after failure to light. In addition, fuel or other
combustible material may accumulate in the exhaust system prior to any start.

The severity of combustion and subsequent overpressure can be substantially greater if the exhaust
system contains a large volume or if there is significant pressure loss in the exhaust system.
Overpressure can cause rupture of ducting or the exhaust system. This rupture can result in the
discharge of hot gas and be potentially hazardous to personnel and surrounding property.

To prevent the accumulation of unburned fuel or other combustible material in the turbine or the
exhaust system, the engine and exhaust system are purged during each start sequence. In most
applications, the starter motor is used to crank the turbine before light-off to ventilate the engine,
the air inlet and exhaust system. A crank speed of 20 to 25% NGP is generally recommended to
generate sufficient mass flow for effective purging (exceptions are described in the Action Required
section). In this speed range, the air mass flow is below 10% of full speed flow.

NOTE
• Modern gas turbine compressors with adjustable "inlet guide vanes" and
multiple adjustable stator stages generate relatively small airflows at
crank speed. These turbines will produce purge airflows as low as 3%
of full mass flow.
• The purge air flow at crank speed is limited by the size of the air passages
in the last compressor stages and cannot be increased by opening the
variable inlet guide vanes (last compressor stages are in choke).
• The starter motor power increases rapidly when the crank speed is
elevated. Most electric starter motors reach their nameplate rating at
about 20% NGP and will overheat at higher speeds. They can operate
at speeds above 20% NGP for short periods of time only. The use of
external purge fans should be considered if purge times exceed 15
minutes.
• External purge fans must be installed if the turbine air flow at or above
a crank speed of 20% NGP is deemed insufficient to purge a waste heat
recovery unit.

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 • If the purge time and/or flow rate as defined in this bulletin cannot be
maintained for any reason, the "Lower Explosive Level" (also called
"Lower Flammability Limit" or "LFL") in the exhaust system must
be measured before any light-off attempt to ensure that the value is
not greater than 25%. Measurements should be made in all pockets
of the exhaust system where significant concentrations of fuel could
accumulate.

The potential for ignition of unburned hydrocarbons in exhaust systems exists for all gas turbine
installations. The risk of this occurrence will vary depending on the fuel used and the configuration
of the exhaust system. In addition to the Solar-recommended operating and maintenance
procedures, the following action should be taken.

ACTION REQUIRED:
Complete all of the following steps to ensure proper purging of your exhaust system.

1. Normal purge crank speed:

Obtain the normal gas producer speed (NGP) reached during purge crank. The speed in
most cases must be above 15% NGP. The generally recommended purge crank speed is
between 20 and 25% NGP. Exceptions to these limits are noted below.

NOTE
• Taurus 70 turbines should not be purge cranked at speeds above 27%
NGP.
• Mars® gas producer rotors have resonant frequencies above 25% NGP.
Though the excitation forces are low at these speeds, Mars turbines
should not be purge cranked above 25% NGP.
• The Mercury™ engine has a rotor critical frequency around 15% NGP.
Minimum crank speed is 20% NGP.
• Titan 130 gas producer rotors have resonant frequencies above 22% NGP.
Therefore, Titan 130’s should not be purge cranked above 22% NGP.
• Titan 250 gas producer rotors have a resonant frequency above 20%
NGP. The recommended purge crank speed is 15% NGP. Light-offs
become more difficult above 15% NGP, and speeds above 20% should
be avoided due to vibration issues.

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NUMBER: 3.0/105G
 2. Calculate the free exhaust volume.
2.1. Determine the internal free volume of the exhaust path(s) to be purged. This
is the total volume of the exhaust system, downstream of the gas turbine exhaust
collector flange, through which exhaust gas will pass. This volume includes
possible heat exchangers, after boilers, other waste heat recovery systems, and
catalysts. For exhaust systems supplied by Solar, basic dimensions can be found
in the Mechanical Installation Drawings supplied with the package.

NOTE
To calculate the total exhaust volume on Mercury 50 turbines, begin with
the exhaust volume downstream of the recuperator flange rather than the
exhaust flange.

2.2. If your exhaust system includes multiple paths with the flow direction
established by diverter valves, each of the paths must be analyzed and purged
separately (Step 4).
2.3. If you used the metric system to calculate the exhaust volume, be sure to
convert the calculated final exhaust volume into English units (cubic feet). The
nominal engine purge air flows provided in this document are rough, rounded
numbers and are, therefore, only listed in English units (1m3 = 35.3 ft3).
3. Identify your exhaust system type:
3.1. Solar distinguishes between two types of exhaust systems.
3.2. Use the following definitions to determine the type of your specific exhaust
system.

Table 1 Exhaust System Type Definitions

Exhaust systems that consist of a single turbine equipped with its own
silencer and a short duct. The internal volume of the complete exhaust
Type A: system must be less than the values listed in Table 2.
Most packages equipped with simple exhaust systems supplied by Solar
fulfill these requirements.
Any exhaust system which is more complex (e.g., includes a heat recovery
Type B:
system) or has a volume above the threshold for a Type A system.

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Page 4 of 12 NUMBER: 3.0/105G
 Table 2 Maximum Exhaust Volumes for Type "A" Exhaust Systems
Type A Maximum Exhaust Volume
Turbine Type
FT3 M3
Saturn® 110 3.1
Centaur® 40, 50 350 9.9
Mercury 50 350 9.9
Taurus 60 660 18.7
Taurus 65 660 18.7
Taurus 70 800 22.7
Mars 90, 100 1300 36.8
Titan 130 1550 43.9
Titan 250 2800 79.3

4. Calculate the minimum purge time based on exhaust volume.

4.1. The recommended number of exhaust volume changes is based on Solar’s
experience with different exhaust systems.
4.1.1. Type A exhaust system:
Three complete volume changes are deemed sufficient for simple exhaust
systems to achieve a complete engine and exhaust stack purge before
light-off.
4.1.2. Type B exhaust system:
Type B exhaust systems should be purged to achieve at least five volume
changes of the exhaust system and/or heat recovery system before light-off
and for a duration of not less than 5 minutes.
4.2. Procedure:
(Use consistent units for volume and flow in the calculation)
4.2.1. Multiply the internal exhaust volume (Step 2) by 3 or 5, as dictated by
exhaust type. Obtain “total purge volume”.
4.2.2. Select turbine model. Use actual crank speed (Step 1) and flows
from Table 3 (interpolate between values listed or use formula given) and
determine the “actual purge air flow” at your particular crank speed.

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NUMBER: 3.0/105G
 Table 3 Nominal Purge Air Flows in SCFM (standard
cubic feet / minute)
Flow Rate in SCFM at Various Cranks Formula
Speeds in % NGP (use up to
Product
35% NGP
15% 20% 22% 25% 27% 30% only)
Saturn 750 1000 1100 1250 1350 1500 SCFM =
10, 20 50 x % NGP
Centaur
40, 50, SCFM =
1800 2400 2640 3000 3240 3600
Taurus 120 x % NGP
60, 65
Mercury Note 2400 2640 3000 3240 3600 SCFM =
50 5 120 x % NGP
Taurus 1800 2400 2640 3000 3240 Note SCFM =
70 8 120 x % NGP
Mars 90, 3000 4000 4400 5000 Note Note SCFM =
100 4 4 200 x % NGP
Titan 130 3300 4400 4840 Note Note Note SCFM =
6 6 6 220 x % NGP
Titan 250 4200 5600 Note Note Note Note SCFM =
7 7 7 7 280 x % NGP

NOTE
1. Flows are corrected to 59°F, 14.7 PSIA (15°C, 101.3 kPa ).
2. Conversion factor: 35.3 SCFM = 1m3/min @ 15°C.
3. Centaur 40, Centaur 50, Mercury 50 and Taurus 60 turbines have different
air mass flows at full power. However, they all share common final stages
of the air compressor. At crank speed, these stages are in “choke” and
limit the turbine compressor airflow. The listed turbine models have
roughly identical purge airflows.
4. Mars turbines should not be purge cranked at speeds above 25% NGP.
5. Minimum crank speed for Mercury 50 is 20% NGP.
6. Titan 130 turbines should not be purge cranked at speeds above
22% NGP.
7. Titan 250 turbines should not be purge cranked at speeds above
20% NGP. The recommended purge crank speed is 15% NGP. Light-offs
become more difficult above 15% NGP, and speeds above 20% should
be avoided due to vibration issues.
8. Taurus 70 turbines should not be purge cranked at speeds above
27% NGP.

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Page 6 of 12 NUMBER: 3.0/105G
 4.2.3. Divide “total purge volume” by “actual purge air flow” and obtain the
minimum purge time in minutes.
4.2.4. If you have a Type B exhaust system, use at least 5 minutes as
minimum.
4.2.5. Repeat procedure if your exhaust system includes multiple paths with
the flow direction established by diverter valves. Each of the paths must be
purged separately in this case.
4.2.6. For multiple pathways, add purge times required for each and confirm
that the control logic provides for the purging of all exhaust paths and
correctly operates the diverter valves.

NOTE
• The minimum exhaust volume changes and the purge airflow
calculations used in this service bulletin are based on Solar’s experience
and are recommendations, only. The formulas used are deliberately kept
simple and do not consider the exhaust duct temperature. It remains
the customer’s responsibility to select and adjust the desired exhaust
purge time. All turbine exhaust systems (especially when including heat
recovery units) must be evaluated individually and must meet local
regulations and insurance requirements.
• Within the limitations of the turbine and the start system, the purge time
can be freely chosen to suit local preferences and/or requirements. Other
requirements might demand longer purge times.

5. Minimum gas turbine purge / crank time.

5.1. Consult Table 4. Obtain the minimum starter crank time for Solar’s turbine
engines. See noted exceptions below the table.
5.2. Divide values in Table 4 by 60 to obtain minutes.

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NUMBER: 3.0/105G
 Table 4 Minimum Starter Crank Times for Solar Product Lines to
Fulfill Purging and/or Rotor Dynamic Requirements
Turbine Type Minimum Time (Seconds)
Saturn 30
Centaur 40, 50 30
Mercury 50 240
Taurus 60 30
Taurus 65 240
Taurus 70 240
Mars 90, 100 240
480**
Titan 130 240
480**
Titan 250 240
480**

** within 24 hours of a fast stop shutdown and an incomplete slow roll cycle

NOTE
• The minimum times listed in Table 4 for the various product lines are
not only related to purging the turbine; they also take dynamic engine
requirements into account (i.e. avoidance of thermal rotor bow). The
minimum time requirements obtained from Table 4 must be fulfilled by
physically cranking the turbine on the starter. This turbine purge/crank
time must not be shortened and cannot be substituted by using external
purge fans.
• Exceptions - Certain Saturn, Centaur and Taurus 60 turbines,
BURNING LIQUID FUEL ONLY, allow shorter minimum purge
times than listed in Table 4. Usually, these turbines drive emergency
generators, and their application depends on a rapid start up. If engine
and exhaust drain systems are properly maintained in these packages,
the risk of exhaust explosions is low and no changes are required in the
existing procedures for a cold start or for a restart after a normal shut
down. (Refer to Table 5 for purge recommendations after a failed start
attempt.)

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 Table 5 Start Procedures and Exhaust Purge Volumes for Solar Turbines
Exhaust Cold Start or Restart Following
System Restart After Flameout or Failure
Type Fuel Used Normal Shutdown to Light-Off
Diesel #1 No change from normal Minimum of 3 exhaust
Diesel #2 start procedures volume changes
Kerosene
A JP5
Natural Gas Minimum of 3 exhaust Minimum of 3 exhaust
Dual Fuel volume changes volume changes
Diesel #1 No change from normal Minimum of 5 exhaust
Diesel #2 start procedures volume changes
Kerosene
B JP5
Natural Gas Minimum of 5 exhaust Minimum of 5 exhaust
Dual Fuel volume changes / no volume changes / no
less than 5 minutes less than 5 minutes

6. Purging of a waste heat recovery unit

6.1. Obtain the minimum purge time of any existing waste heat recovery unit
as mandated by the manufacturer or by an applicable certification agency.
Manufacturers of waste heat recovery units (boilers, recuperators) and/or
certification agencies often dictate different minimum purge times from those
suggested by Solar.

NOTE
• Certain manufacturers of heat recovery systems and/or certification
agencies dictate more stringent purge requirements than recommended
by Solar. Typically, they not only require a minimum number of air
changes before light-off, but also specify minimum purge air flows.
Minimum flows specified can be as high as 25% of full mass flow.
Gas turbine packages cannot reach flow rates of this magnitude while
cranking on the starter.
• Table 3 (Step 4.2.2) lists the purge air flows of Solar’s engines at various
crank speeds. THE INSTALLATION OF EXTERNAL PURGE FANS
IS RECOMMENDED IF THE PURGE REQUIREMENTS EXCEED
15 MINUTES AND/OR THE LISTED FLOWS DO NOT FULFILL
LOCAL CODE REQUIREMENTS.

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NUMBER: 3.0/105G
 • Additional control logic is required if external purge fans are being used.
This logic is not included in Solar’s standard control logic.
• Often, the manufacturers of diverter valves and heat recovery systems
supply their own control systems. It is the customer’s responsibility to
safely integrate these systems into the turbine start logic and to confirm
that Solar’s minimum purge requirements are adhered to.

7. Select the applicable purge time.

7.1. Review Steps 4, 5, and 6 and pick the longest of the calculated purge times.
Enter this value as the recommended purge time into the control logic (Step 8).

NOTE
• Certain electric starter motors may not be able to support continuous
cranking of 15 minutes or longer. Install external purge fans in this case.
• Observe the minimum turbine purge / crank time obtained in Step 5. This
minimum engine purge must be done by CRANKING THE TURBINE
STARTER, even if external purge fans are used to purge the remaining
exhaust duct(s) and a possible waste heat recovery unit.

8. Set your purge timer.

8.1. If the calculated purge time is different from the present setting, set the package
purge timer to the new value calculated.
8.2. In control systems provided by Solar, the purge timer may be an adjustable
time delay relay or a software timer.
8.3. If the unit has a relay control system, set the timer by rotating the timer
adjustment to the proper setting and verifying the selected interval during a test
start.

NOTE
Some mechanical timers do not have enough range to cover extended
purge times. In this case, the timer must be upgraded. Timers with increased
adjustment ranges are available for most models. Please contact your near-
est Solar office with the part number of your present timer for assistance with
a replacement.

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 8.4. For Mars and Titan engines, the minimum turbine purge / crank time varies
depending upon the previous shutdown condition. For relay control systems, the
time selected during Step 5 must be the greater value.
8.5. If the unit has a programmable logic controller-based control system (PLC),
it will be necessary to revise the set points within the software to adjust the timer.
Contact your local Solar District Service office for assistance.

NOTE
• If the recommended minimum purge time and/or flow rate cannot be
maintained for any reason, the volumetric concentration of fuel in the
exhaust system must be determined before any light-off attempt to ensure
that this value is not greater than 25% of the Lower Explosive Limit
(LEL), also called the Lower Flammability Limit (LFL). Measurements
should be made in all pockets of the exhaust system where significant
concentrations of fuel could accumulate.
• When identifying pocket locations, be sure to consider the fuel being
used and its density in the gaseous form.
• At times, the minimum crank time indicated in Table 4 (which changes
with elapsed time following shutdown) for Mars and Titan turbines can
rise above the calculated minimum purge time derived from Steps 4 or
6. Therefore, it may be desirable for units with PLC’s to add additional
control logic to select the appropriate purge time for the situation rather
than selecting the greater time value.

9. Maintenance
9.1. If engine flameout or failure to light occurs at any time, take corrective
maintenance action prior to initiating a restart.
9.2. In addition, the following is recommended on a continuing basis:
9.2.1. Properly maintain and adjust all gas turbine controls and exhaust
systems as recommended by the manufacturer.
9.2.2. Make certain that any exhaust gas valves or dampers are correctly
installed and operating properly. It is particularly important that a free
passage of exhaust gas to atmosphere is maintained during engine start up
and operation.
9.2.3. Heat recovery exhaust systems are frequently equipped with diverter
valves to control the amount of gas that passes through the system. If a
diverter valve is installed, ensure that it is functioning correctly to bypass
the heat recovery device during gas turbine startup.

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NUMBER: 3.0/105G
 9.2.4. Make certain that gas turbine, exhaust collector, and exhaust system
liquid drains are functioning properly.
9.2.5. Maintain fuel quality within the limits specified by Solar. Deviation
from Solar fuel specifications can result in malfunction of the fuel control
system.

SUMMARY:

Uncontrolled combustion in the exhaust system as described in this

Service Bulletin can rupture the exhaust system and result in personal
injury or property damage.

It is important that the essential actions described above are followed, particularly if your
installation includes complex ducting and/or devices such as heat exchangers, recuperators or
silencers. This must be accomplished at commissioning, whenever changes to the exhaust system
are made, and at intervals specified in the Operation and Maintenance manual.

Please contact your local Solar District Service Office for further information or assistance.

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