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Service Bulletin

This service bulletin alerts users to a safety issue involving the potential failure of recuperator air outlet ducts in Mercury 50 generator sets. A failure has occurred where the duct ruptured and deformed exterior ducting. To prevent injury, personnel should remain outside enclosed packages and stay at least 9 feet away from unenclosed recuperators during operation. The manufacturer is redesigning the recuperator with a more durable nickel alloy to prevent catastrophic duct bursts from occurring.

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77 views4 pages

Service Bulletin

This service bulletin alerts users to a safety issue involving the potential failure of recuperator air outlet ducts in Mercury 50 generator sets. A failure has occurred where the duct ruptured and deformed exterior ducting. To prevent injury, personnel should remain outside enclosed packages and stay at least 9 feet away from unenclosed recuperators during operation. The manufacturer is redesigning the recuperator with a more durable nickel alloy to prevent catastrophic duct bursts from occurring.

Uploaded by

jussmeee
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© © All Rights Reserved
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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: 23.2/100
ISSUED: May 2002
REVISED:
PRODUCT: Mercury 50, Centaur 40 Package S/N DCG0185
MODEL(S): Generator Set
Specifics:

SUBJECT: SAFETY NOTICE - RECUPERATOR


AIR OUTLET DUCT FAILURE
THIS SERVICE BULLETIN REPLACES
PRODUCT ADVISORY 23.2/100A.

PRODUCT SAFETY

Type of Change: Product Safety


Recommended
Compliance: Immediate

Purpose:
This service bulletin alerts users to the possibility of a failure in the recuperator air outlet duct. This
duct is almost entirely enclosed by the exhaust gas inlet duct, and is not visible from the outside.
It is possible for an air outlet duct failure to rupture the exhaust gas duct and cause a discharge of
very hot air into the enclosure.

SERVICE BULLETIN Page 1 of 4


NUMBER: 23.2/100
During loaded operation, personnel should remain outside of any en-
closed package, and at least 9 ft. (3 m) away from any unenclosed re-
cuperator.

GENERAL INFORMATION:
A Mercury 50 Generator Set operating at Solar Turbine’s Harbor Drive facility experienced a failure
of the recuperator air outlet duct while operating at approximately 3 MW. The internal duct rupture
deformed the exterior ducting of the recuperator causing a small rip. This type of failure has the
potential to release 1200 F (600 C) gases into the package enclosure or the area surrounding the
recuperator. Although there has only been one incidence of a sudden duct failure, this represents a
serious personnel safety issue.

A detailed structural analysis of the Mercury 50-style all stainless steel recuperator has been com-
pleted for various exhaust temperature operating conditions. Calculated stress levels and associated
life indicate the stainless steel air duct will not be acceptable for long term service with the pos-
sibility of air duct cracks leading to a catastrophic burst of the pressurized duct. To achieve long
term (>30,000 hours) service without incident, the recuperator is currently being re-designed using
a superior nickel-based alloy. Solar will advise users once this new design is available for retrofit.

ACTION REQUIRED:
• During operation above 0 kW, personnel should remain outside of any enclosed package,
and the package enclosure doors should remain shut.
• Personnel should stay well away, at least 9-ft (3 m), from any unenclosed recuperator during
operation.
• Operational inspections should be done only when the unit is at idle speed, 0 kW load, when
the internal air pressure and temperature is greatly reduced.
• Operational set point T7.1 should be adjusted so as not to exceed 1165F to minimize the
possibility of high temperature air outlet duct failure.

Page 2 of 4 SERVICE BULLETIN


NUMBER: 23.2/100
Figure 1 Typical Engine, Recuperator, and Package Configuration

SERVICE BULLETIN Page 3 of 4


NUMBER: 23.2/100
Figure 2 Recuperator Air Outlet Duct/ Exhaust Gas Inlet Duct

Page 4 of 4 SERVICE BULLETIN


NUMBER: 23.2/100

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