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: 2.0/112C
ISSUED: October 2011
REVISED: October 2015
PRODUCT: All
MODEL(S): All
SPECIFICS:

SUBJECT: IMPROPER BARRING OF A TURBINE SHAFT TO

RESOLVE ROTOR LOCKUP CAN CAUSE EQUIPMENT
DAMAGE AND PERSONAL INJURY

PRODUCT SAFETY

-REVISION NOTICE-

1. Removed Caution note for the 24 hour hold time on

Taurus 70 engines.
2. Edited general information section

Type of Change: Product Safety

Recommended
Compliance: Immediate

Purpose
To mitigate the risk for personal injury and significant damage to the start motor or
turbine engine due to unsafe practices when barring the engine shaft.

GENERAL INFORMATION
Recently, two incidents were reported in which personnel were injured while attempting
to bar a turbine engine shaft (Figure 1).

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NUMBER: 2.0/112C Page 1 of 7
 Figure 1 Example of an Access Point on a Starter to Rotate an Engine Rotor

In both cases, torque was applied by way of a socket wrench to the starter motor in an
attempt to breakaway a locked-up turbine engine rotor. In one incident, during use of a
socket wrench, the ratcheting gear fractured, resulting in bruising of the worker’s elbow.
In another incident, a breaker bar fractured, striking the user in the face. In either case,
the amount of force used and the suitability of the tools employed remain in question.

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Rotor Lockup Discussion
There have been occasional reports in which the start system was unable to turn the gas
producer rotor following an attempt to restart a hot engine. When an engine start
command is initiated and the rotor does not reach a minimal, detectable speed within a
given time, the package control system annunciates “rotor lockup” with the indication of
fail-to-crank or fail-to-start. Significant temperature gradients, between rotating and
stationary engine components, can reduce seal and tip clearances such that the available
starter rotational force is insufficient to overcome resulting frictional forces. After
several hours, temperature gradients will eventually reduce and clearances will adjust
sufficiently to allow engine shaft rotation. To avoid restart-inhibiting frictional forces,
engines equipped with a Variable Frequency Drive (VFD) controlled electric starter or
with a turning gear can be rotated at a low speed following shutdown. The slow rotation
provides more uniform and effective cooling of engine components, avoiding the
temperature gradients leading to rotor lockup. This process is called slow rolling. Slow
rolling or allowing several hours for the engine to cool and normalize, are the two
preferred ways to avoid rotor lockup. Baring an engine shaft however is another method
sometimes used to free a rotor, when a restart in imperative and time constraints or lack
of slow roll capability are factors.

Conclusion
In both personal injury incidents discussed above, the inability of the workers to monitor
the amount of torque applied and the lack of knowledge of the tool’s torque rating most
likely contributed to overloading of the tools being used. In addition, there was risk of
damage to turbine equipment, given that the equipment torque limits were not known and
the amount of torque applied was not monitored.

In the near-miss situation, workers neglected to follow fundamental safety protocol

during a period of non-operation of the turbine. Various devices on a turbine package
remain operational, even when the turbine isn’t running.

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NUMBER: 2.0/112C Page 3 of 7
Resolution
For Titan 250, Titan 130, Mars and Taurus 70, slow roll is found to be the best method
for prevention of rotor lockup. For engines with electric starter motor it is easy to slow
roll the engine, as required by Solar’s Controls Specifications, for up to four hours. For
Titan 130, Mars and Taurus 70 engines with pneumatic starter motors there is a kit
available, which includes a small electric motor, to slow roll the engine (Reference SB
8.7/127). Allowing an engine to cool with either slow roll or time prior to attempting a
restart is highly recommended to avoid rotor lockup. Avoid barring the engine if possible.
If the rotor is locked up, it is best to wait 24 hours before attempting to restart a turbine
engine to allow the engine to cool and clearances to be re-established.

If it is absolutely necessary to start the turbine without waiting, specific practices are
required to bar an engine shaft to avoid personal injury and damage to the start motor and
the engine:
• The correct tools must be used.
• The torque applied to an engine must be kept below the limits of the tools and the
limits of the turbine equipment.
• Fundamental safety practices must be followed, regardless of whether a turbine
appears to be running or not.
o Energy to equipment being serviced must be isolated.
o Tools and equipment must not be overloaded.

Please see the Action required section for specific information.

ACTION REQUIRED:

Follow all locally- and employer-required risk mitigation

practices before starting any work.

Prior to barring an engine, verify that the turbine is not rotating and
review the turbine control display screen to determine if the turbine
is in Slow Roll mode. Barring an engine during Slow Roll mode can
result in serious injury and/or death.

Lockout and tag out power to the start motor and/or turning gear.

Isolate motive force gas to pneumatic starters.

Lockout and tag out power and isolate sources of fuel and motive
force to electro-hydraulic, diesel-hydraulic, and turbo-hydraulic
starters.

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 Do not over-torque an engine rotor. Equipment damage will
result.

Do not attempt to bar a Titan 250 engine rotor prior to

expiration of the 12-hour lockout period. Equipment damage
will result.

If it becomes necessary to bar a turbine engine shaft

• Select a wrench or combination of tools that
o Limit and/or monitor torque. A CLICK-TYPE ADJUSTABLE TORQUE
WRENCH is recommended.
o Are rated to withstand torque values above what is to be applied.
Consider using a torque multiplier when necessary to achieve the higher
torque values required for larger engines.

NOTE
When using a torque multiplier, ensure that the reaction
bar or plate is firmly stabilized and that the supporting
structure is adequate to withstand the high forces imparted
by the geared output of the multiplier. The reaction force
can be determined by dividing the maximum torque value
to be applied to the engine (at the multiplier output) by the
distance from the multiplier output shaft center to the
anchor point of the reaction bar or plate. When barring the
engine, be sure to remain clear of the reaction bar or plate.
IF IN DOUBT, PLEASE CALL SOLAR FOR ASSISTANCE.

o Ratchet to prevent injuries or equipment damage due to engine rotor

momentum when the rotor breaks free.
o Have six-point IMPACT sockets. DO NOT USE EIGHT- OR TWELVE-
POINT SOCKETS.
• Remove any paint and burrs from the hex starter fitting to ensure ease of socket
removal.
• Ensure the socket is fully engaged on the hex shaft.
• Remain within the recommended torque ranges provided in Table 1.

Exceeding the maximum torque values specified below can

result in personal injury and damage to the starter and the
turbine engine.

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 Table 1 Maximum Allowable Breakaway Torque at Each Start Motor
Engine Number of Max Breakaway Torque in ft-
Engine Shafts Combustion System Starters lb (N-m)
Saturn® 10 1 Standard 1 305 (414)
Saturn 10 2 Standard 1 305 (414)
Saturn 20 1 Standard 1 305 (414)
Saturn 20 2 Standard 1 305 (414)
®
Centaur 40 1 SoLoNOx™ 1 600 (813)
Centaur 40 1 Standard 1 600 (813)
Centaur 40 2 SoLoNOx 1 288 (390)
Centaur 40 2 Standard 1 288 (390)
Centaur 50 1 SoLoNOx 1 600 (813)
Centaur 50 1 Standard 1 600 (813)
Centaur 50 2 SoLoNOx 1 288 (390)
Centaur 50 2 Standard 1 288 (390)
Mercury™ 50 1 Standard 1 455 (617)
Taurus™ 60 1 SoLoNOx 1 600 (813)
Taurus 60 1 Standard 1 600 (813)
Taurus 60 2 SoLoNOx 1 600 (813)
Taurus 60 2 Standard 1 600 (813)
Taurus 65 1 SoLoNOx 1 720 (976)
Taurus 70 1 SoLoNOx 1 782 (1060)
Taurus 70 1 Standard 1 782 (1060)
Taurus 70 2 SoLoNOx 1 500 (678)
Taurus 70 2 Standard 1 500 (678)
Mars® 90 2 SoLoNOx 1 480 (651)
Mars 90 2 Standard 1 480 (651)
Mars 100 2 SoLoNOx 1 480 (651)
Mars 100 2 Standard 1 480 (651)
Titan™ 130 1 SoLoNOx 2* 675 (915)***
Titan 130 1 Standard 2* 675 (915)***
Titan 130 2 SoLoNOx 1 480 (651)
Titan 130 2 Standard 1 480 (651)
Titan 250 2 SoLoNOx 1 53 (72) **
Titan 250 2 Standard 1 53 (72) **

* For engines with two start motors, two wrenches are required, and the same torque value is to be
simultaneously applied to each motor (Figure 2).
** Applied at the turning gear (recommended). Alternately, apply a maximum of 919 ft-lbs (1245 N-m) to
the start motor.
***When the generator being driven is equipped with an oil jacking system, the maximum torque that can
be applied by the start system through each starter pad is 300 ft-lb for a total of 600 ft-lb for 50 Hz gearbox
and 250 ft-lb for a total of 500 ft-lb for 60 Hz gearbox.

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 Figure 2 Example of a Titan 130 with Two Start Motors. Arrows Indicate Dual
Barring Locations.

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