SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solar's best j udgment regarding the Service
Bulletin. All questions should be directed to your Solar Field Serv ice 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 w ithout notice .

NUMBER: 3.0/105K
ISSUED: December 1983
REVISED: 2018
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 SYSTEM S

—REVISION NOTICE—
Revised to address complex configurations.

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 exhaus t
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 mos t
applications, the starter motor is used to accelerate 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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 • Pneumatic start is not recommended for units with waste heat
recovery because of the large supply of air or natural gas required.
When selected it should be sized for a minimum of three start
attempts. Please contact the local Solar District Service Office for
additional guidance.

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 configuratio n
of the exhaust system. In addition to the Solar-recommended operating and mainten anc e
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 turbines must not be purge cranked at speeds above 15% NGP.

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 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 exhaus t
collector flange, through which exhaust gas will pass. This volume includes
possible heat exchangers, after boilers, other waste heat recovery systems ,
bypas s s tac ks 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 of the turbine.

2.2. If your exhaust system includes multiple paths with the flow direc tion
established by diverter valves, each of the paths must be analyzed and purged
separately (Step 4). Complex installations with multiple turbines and/or gas
engines require additional engineering analys is that is outside the scope of this
bulletin. Please contact the local Solar District Office for additional support.
2.3. Packages utilizing the purge credit methods defined in NFPA 85 should contact
the local Solar District Office for further information.

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 exhaus t
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.
Often 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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 Table 2 Maximum Exhaust Volumes for Type "A" Exhaust Systems
Type A Maximum Exhaust Volume
Product
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 130-2050X and lower ratings 1550 43.9
Titan 130-22401 1780 50.4
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 exhaus t
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 flow s
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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 Table 3 Nominal Purge Air Flows in SCFM (standard cubic feet/minute)

Flow Rate in SCFM at Various Cranks Formula (use

Speeds in % NGP up to 25% NGP
Product
only)
15% 20% 22% 25%
Saturn 10, 20 750 1000 1100 1250 SCFM = 50 x % NGP
Centaur 40, 50,
Taurus 60, 65 1800 2400 2640 3000 SCFM = 120 x % NGP
Mercury 50 Note 5 2400 2640 3000 SCFM = 120 x % NGP
Taurus 70 1800 2400 2640 3000 SCFM = 120 x % NGP
Mars 90, 100 3000 4000 4400 5000 SCFM = 200 x % NGP
Titan 130-2050X and SCFM = 220 x % NGP
lower ratings 3300 4400 4840 Note 6

Titan 130-22401 and SCFM = 245 x % NGP

3630 4900 5320 Note 6
23X00
Titan 250 4200 Note 7 Note 7 Note 7 SCFM = 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 must not be purge cranked at speeds above
15% NGP.
8. Taurus 70 turbines should not be purge cranked at speeds above
27% NGP.
9. Package start motors and VFDs may not be capable of reaching
higher speeds or may be limited in duration.

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 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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 Table 4 Minimum Starter Crank Times for Solar Product Lines
to Fulfill Purging and/or Rotor Dynamic Requirements
Product 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

Liquid Fuel
Minimum of 3 exhaust
Natural Gas
A volume changes Minimum of 3 exhaust
Dual Fuel
volume changes
Liquid Fuel Minimum of 5 exhaust Minimum of 5 exhaust
B Natural Gas volume changes / no volume changes / no
Dual Fuel 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 thos e
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. S o l a r g as 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 EXTERN AL
PURGE FANS IS RECOMMENDED IF THE PURGE
REQUIREMENTS EXCEED 15 MINUTES AND/OR THE LISTED
FLOWS DO NOT FULFILL LOCAL CODE REQUIREMENTS.
• Hot purging is an operation where hot combustion gas is used as the
purge medium for a multiple unit system. It is potentially dangerous
because it cannot be guaranteed that the exhaust gas temperature will
always remain below the auto-ignition temperature of the fuel that may
be present. Hot purging is not recommended by Solar Turbines.

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 • 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. Modern control systems provided by Solar require a programming terminal
to set purge timers in the software.
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.
8.4. For Mars and Titan engines, the minimum turbine purge / crank time varies
depending upon the previous shutdown condition.
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
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 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 Step 4
6.

9. Maintenanc e
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 exhaus t
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 bypas s
the heat recovery device during gas turbine startup.
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. Deviat io n
from Solar’s fuel specification ES9-98 can result in malfunction of the fuel
control system.

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 or whenever changes to the exhaust system
are made.

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