Service Bulletin 8-12-109h

7/24/2019 Service Bulletin 8-12-109h

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SERVICE BULLETINNOTICE: The Type of Change and Recommended Compliance speci fied reflects Solars best judgment r egarding 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: 8.12/109H

ISSUED: Ap ri l 2007

REVISED: April 2015

PRODUCT: Centaur40, Centaur50, Taurus 60

MODEL(S): CompressorSet,MechanicalDrive,Hot-End-DriveGeneratorSet

Specifics: Equipment with a 30- or 36-inch-Diameter Marman-Style

Exhaust-Collector Discharge Flange

SUBJECT: INTRODUCTION OF BOLTED FLANGES AND DISCONTINUATION

OF MARMAN FLANGES FOR RIGHT-ANGLE-DISCHARGE

EXHAUST COLLECTORS AND BELLOWS

REVISION NOTICE

Added Centaur 40 bellows blanket kit and updated Table 4

Type of Change: Product Improvement

RecommendedCo mp lian ce: In fo rmat io n

Purpose:

To announce a repair/replacement procedure for worn exhaust collector outletflanges and

bellows inlet flanges that improves durability and necessitates the use of bolted-flange

components.

To announce the discontinued availability of Marmanflanged exhaust collectors, expansion

bellows and repairflanges for affected product lines.

GENERAL INFORMATION:

In 1998, Solar issued Service Bulletin 11.6/101 addressing exhaust bellows durability concerns.

The bulletin focused on wear of the Marman flanges interfacing between the bellows and exhaust

collector. In some cases, wear resulted in exhaust gas leakage and flange failure. The service

bulletin introduced a more uniform bellows flange, designed to reduce fretting problems. However,

wear issues still persist on some Centaur40, Centaur50, andTaurus60 two-shaft engines.

SERVICE BULLETIN Caterpillar Confidential: Green Page 1 of 16NUMBER: 8.12/109H


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Centaur 40, Centaur 50 and Taurus 60 two-shaft engines have right-angle discharge exhaust

collectors. To improve reliability where Marman flange wear occurs, Solar introduced a

bolted-style flange (Figure ) on exhaust collectors and mating bellows forCentaur50 andTaurus

60 units in 2007.

Figure 1 The New Bolted Flange Interface Mitigates Wear and Fretting (Centaur 50 show n)

Used on larger engine models for many years, the bolted joint with gasket has proven to be a more

durable interface design. Following release of theCentaur

50 /Taurus

60 design improvement, itbecame evident that Centaur40 two-shaft engines can also benefit from the bolted-flange design.

Therefore, the bolted-flange design has been adopted forCentaur40 two-shaft engines.

Discontinued Availability of Marman-Flanged Components and Repair Parts

Effective immediately forCentaur40s and beginning January 2012 forCentaur50s andTaurus

60s, right-angle exhaust collectors, mating expansion bellows, and repair flanges will only

be available with bolted flanges. Marman-flanged components for these products are being

discontinued.

Existing equipment need not be upgraded until component condition necessitates repair orreplacement.

Page 2 of 16 Caterpillar Confidential: Green SERVICE BULLETIN

NUMBER: 8.12/109H


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Exhaust System Description

For the purposes of this document, the exhaust system for two-shaft engines will be discussed as

having three major sections:

1. Exhaust Collector (connecting to the turbine engine)

2. Exhaust Bellows (thermal expansion joint)

3. Exhaust Duct (point of interface with the rest of the exhaust system further downstream)

NOTE

Inlet refers to the flow inlet side of each piece; Exit is the flow exit (outlet

or discharge) side of the piece. This terminology will be used throughout

this Service Bulletin.

Centaur 40 Improvements

Converting the Centaur 40 exhaust collector exit flange from Marman to bolted style requires

accommodating 3 different configurations.

The Marman flange configuration (Existing Design, Figure 2) and the new bolted-flange

configuration (New Design, Figure2) are depicted below.

Figure 2 Centaur 40 Design Improvement



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The new configuration has three exhaust bellows options to accommodate the exhaust duct inlets

which have:

Differentflange sizes

Different bolt hole diameters

Different bolt hole patterns

Hardware part numbers and details can be found in the Hardware Replacement section of this

service bulletin.

1. Exhaust Collector The new production exhaust collector design eliminates the Marman

flange (legacy flange, Figure3) and introduces the bolted exit-flange (new production

flange, Figure3).

Figure 3 Centaur 40 Marman Flange vs. the Improved Flange Design


NUMBER: 8.12/109H


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2. Exhaust Bellows Three new bellows designs have been created. Each of the three

designs has the same inlet flange as the exhaust collector exit flange shown above.

However, there are three different exit flange options as shown in Figure 4. The exit

flanges possess a slip system that permits rotation of the flange for easier alignment

of bolt holes during installation.

Figure 4 Centaur 40 Bellows Exit Flange Options

3. Exhaust Duct Inlet The bellows exit flange options (Figure4, above) are intended

to provide a means of matching bolt patterns andflange diameters with the adjoining

exhaust duct inlet flange located immediately downstream of the bellows.



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Centaur50 and Taurus 60 Improvements Introduced in 2007

The legacy configuration (pre-2007 design, Figure 5) and the improved configuration (current

design, Figure5) are depicted below.

Figure 5 Centaur 50 and Taurus 60 Design Improvement

The new confi

guration has two options to accommodate bolt diameters of either 0.75 or 1.50 asdictated by the exhaust duct inlet flange:

Initially, exhaust duct inletflanges were designed for 1.50 diameter bolts.

In 1992, the bolt size was changed to 0.75. The current standard production is still the

0.75 bolt pattern.

Hardware part numbers and details can be found in the Hardware Replacement section of this

service bulletin.

1. Exhaust Collector - The new production exhaust collector design introduced in 2007

eliminated the Marman flange (legacy flange, Figure 6) and introduced the boltedexit-flange (new productionflange, Figure6).


NUMBER: 8.12/109H


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Figure 6 Centaur 50 and Taurus 60 Marman Flange vs. theImproved Flange Design

2. Exhaust Bellows Each of the two new-production exhaust bellows designs have the

same inletflange as the new-production exhaust collector exit flange shown above. The

exhaust bellows designs have two exit flange options as shown below in Figure7. The

exit flanges possess a slip system that permits rotation of the flange for easier alignment

of bolt holes during installation.

Figure 7 Centaur 50 and Taurus 60 Bellows Exit Flange Options

3. Exhaust Duct Inlet The bellows exitflange options (Figure7, above) are intended to

provide a means of matching bolt diameters with the adjoining exhaust duct inlet flange

located immediately downstream of the bellows.



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ACTION REQUIRED:

Risk mitigation practices must be in place before starting any work;

comply with all local and employer risk mitigation requirements.

Equipment and systems should complete normal shutdown cycles,

coast down to a complete stop, and complete post-lubrication cycles

before commencing work.

Hazardous energy isolation lock-out and tag-out (LOTO) is required.

Isolations and procedures for the turbomachinery package, ancillar-

ies, and associated equipment/systems must be appropriate to the

work being completed.

Hot surfaces may be present, exposing personnel to burn injury haz-

ards. Allow surfaces in the proximity of the work area to adequatelycool, removing the hazard. Combustible gases or vapors may be

present. Test for combustible gases and vapors; if present, stop

work until safe levels are achieved. Fuel and ignition sources must

be isolated and controlled via LOTO.

Please review the two approaches presented below if exhaust collector Marman flange wear issues

necessitate repair.

NOTE

1. Please be aware that, for enclosed units, the additional bulk of the boltedflange may

require some modification to any interfering enclosure components in some cases.

Also, future engine removal might require temporary removal of additional panels and

supports.

2. Marman replacement/repair flanges are no longer supported for Centaur40, Centaur

50, and Taurus 60 two-shaft exhaust systems. The information contained herein is

presented with the intention of providing a durable exhaust collector exit flange repair

scheme, should repair become necessary. Conversion to a bolted-flange system is only

required if Marman flange replacement becomes necessary. However, when requesting

a replacement or spare exhaust collector or bellows of the Marman-flange-type throughSolars Service Parts depot, you will be presented with options for converting to a

bolted-flange arrangement.

Again, these are only repair procedures, not upgrade requirements. Units operating in the field

with no issues need not be modified. Please contact your local Solar Service Parts provider if

you are repairing a Marman flange connection at the exhaust collector and wish to purchase items

mentioned in this bulletin. All costs are to be covered by the owner/operator.


NUMBER: 8.12/109H


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Exhaust Collector Flange Repair - Welded Retrofi t Approach

Retrofit kits have been developed to convert existing exhaust collector Marmanflanges to the bolted

style. Kits include:

A separate bolt-style flange to be welded to the existing exhaust collector exit opening.

A new bellows with boltedflanges on both ends.

All necessary gaskets, bolts, washers, etc., to complete installation of the bellows to both

the exhaust collector side and the exhaust duct side.

It should be noted that all flange bolt patterns (Figures 3 and 6) are oriented to straddle the

centerlines as is standard practice in pipe work.

Please beprepared to handle cutting and welding issues on your own if you select this option.

Weldingservices will not be provided by Solar. Welding instructions are provided in the retrofit

kit installation instructions. The base material to be welded is composed of 0.090-inch-thick

type-409 corrosion-resistant (stainless) steel sheet per ASTM A176 or A240. The weld filler

material recommended can be either ER 308 or ER 409 stainless steel, both per AWS A5.9. The

filler material should be in wire form, 0.035 inches in diameter for metal-inert-gas arc welding

(MIG or GMAW) or 0.035 to 0.062 inches in diameter for tungsten-inert-gas arc welding (TIG

or GTAW). This material is not available from Solar. There are several good global sources in

existence for welding supplies.

To proceed with the welded upgrade approach, select the appropriate kit for your installation from

Tables or2 below, depending on the engine.



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Table 1 Centaur 40 Weld-On Retrofi t (Includes New Bolted-Collector

Flange, Bellows And Hardware)

ENGINE TO BE

UPGRADED ORDER ONE ALL INCLUSIVE KIT

Engine

Retrofi t Kit Part

Number for Units

Installing to

Current 32 Bol t

Hole Pattern on the

Exhaust Duct Inlet

Retrofi t Kit Part

Number for Units

Installing to

Legacy 28-Bolt

Hole Pattern on the

Exhaust Duct Inlet

Retrofi t Kit Part

Number for Units

Installing to

Legacy 20 Bolt

Hole Pattern on the

Exhaust Duct Inlet

Centaur40 1090336-10X

1090336-20X

1090336-40X (for

Inconel bellows only)

1090336-30X

NOTE:The above information is current as of this writing, however, should this change, the most

current part number will be supplied when ordering.


NUMBER: 8.12/109H


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Table 2 Centaur 50 and Taurus 60 Weld-On Retrofi t (Includes New

Bolted-Collector Flange, Bellows And Hardware)

ENGINE TO BE

UPGRADED ORDER ONE ALL INCLUSIVE KIT

Engine

Retrofi t Kit Part Number for

Units Using 0.75 Diameter

Bolts on the Exhaust Duct

Inlet Flange

Retrofi t Kit Part Number for

Units Using 1.50 Diameter

Bolts on the Exhaust Duct

Inlet Flange

Centaur 50

(conventional

combustion)

1044517-50X 1044517-40X

Centaur50S 1044517-30X 1044517-20X

Taurus 60

(conventional

combustion)

1044517-50X 1044517-40X

Taurus 60S 1044517-30X 1044517-20X





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1. Centaur40s use a 30-inch pipe diameter exhaust collector exit flange. Selection of the

proper kit is based upon the number of bolt holes used to connect the bellows exit

flange to the exhaust duct inlet flange.

2. Centaur50s andTaurus 60s both use 36-inch pipe diameter exhaust collector exit

flanges. Selection of the proper kit is based upon the bolt diameter used where the

bellows exit flange connects to the exhaust duct inlet flange.

3. The retrofitkit includes a flange and ring assembly. The purpose of the ring is to slip

inside theexhaust collector and be welded in place. Feedback received from the field,

and subsequent dimensional inspection of inventory on hand indicates some of these

rings may be too large and have an interference fit. This was not the design intent.

ACTION: Prior to cutting the marman flange off the exhaust collector at site, measure

the OD ofthe flange (P/N 1102982-100) ring from kit P/N 1044517-XXX. if the ring OD

is larger than 36.15 + 0.03 inches, do not proceed with the flange retrofit. The supplier

has corrected the problem. Retrofit kits shipped after Octboer 13, 2014 are manufactured

per thedrawing.

Figure 8

Complete Exhaust Collector Replacement Approach

Alternately, you may wish to purchase an entirely new exhaust collector to avoid welding. It should

be noted that all flange bolt patterns (Figures4and7) are oriented to straddle the centerlines as is

standard practice in pipe work.

1. Determine the engine model to be upgraded and consider the following:

a. Centaur 40s use a 30-inch pipe-diameter exhaust-collector exit

flange. From Table 3, select the exhaust collector and the appropriate

bellows kit based on the number of bolt holes in the existingbellows-exit-flange-to-exhaust-duct-inlet-flange connection.

b. Centaur 50s and Taurus 60s use 36-inch pipe diameter exhaust

collector exit flanges. From Table 4, select the exhaust collector and

appropriate bellows kit based on the bolt diameter required on the existing

bellows-exit-flange-to-exhaust-duct-inlet-flange connection.


NUMBER: 8.12/109H


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Table 3 Centaur40 Exhaust Collector Replacement - Select the Bellows That

Matches Number of Bolt Holes on the Exhaust Duct Inlet Flange

ENGINE TO BE

UPGRADED

ORDER ONE

EXHAUST

COLLECTOR

ORDER ONE BELLOWS KIT

(INCLUDES HARDWARE) **

Engine*

New Exhaust

Collector Part

Number

Bellows Kit

PN for 32

Bolt Holes

and 0.75

Diameter

Bolts on the

Exit Flange

Bellows Kit

PN for 28

Bolt Holes

and 1.25

Diameter

Bolts on the

Exit Flange

Bellows Kit

PN for 20

Bolt Holes

and 0.75

Diameter

Bolts on the

Exit Flange

1090345-10X - - - - - - - - - -

- - - - -

1090346-10X

1090346-20X

(for Inconel

bellows only)

- - - - -Centaur40

195095-50X

(with blankets)

or

111841-70X

(without

blankets)

- - - - - - - - - - 1091707-10X

1090345-10X - - - - - - - - - -

- - - - -

1090346-10X

1090346-20X(for Inconel

bellows only)

- - - - -Centaur40S

195095-60X

(with blankets)

or195112-30X

(without

blankets)

- - - - - - - - - - 1091707-10X

* For exhaust retrofit hardware for the Centaur40L-5302 low speed turbine engine, contact your

local Solar District Service Office. This model typically utilizes a Taurus60-7302 2-stage power

turbine but will require consultation to provide correct hardware for each specific site.

** For Centaur 40, order bellows blanket kit, P/N 1112954-10X. Kit includes bellows blanket, P/N

1112291-10X andflange blanket, P/N 1112292-10X.





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Table 4 Centaur50 and Taurus 60 Exhaust Collector Replacement

ENGINE

TO BE

UPGRADED

ORDER

ONE

EXHAUST

COLLECTOR

ORDER ONE BELLOWS

PLUS BLA NKETS ***

ORDER

ONE INLET

FLANGE

HARDWARE

KIT

ORDER

ONE EXIT

FLANGE

HARDWARE

KIT

Engine

New

Exhaust

Collector

Part Number

Bellows

PN using

0.75 Bolt

Diameter

on Exit

Flange

Bellows

PN using

1.50 Bolt

Diameter

on Exit

Flange

Hardware

K i t

Bellows

Inlet

Flange

Hardware

Kit Bellows

Exit Flange

1100961-10X - - - - - 1073591-10X 1073591-10X

Centaur50

-6102 and

-5702

136994-40X*

(with

blankets)

or

136500-100X*(without

blankets)

- - - - - 1100961-30X 1073591-10X AX-3608

1100961-10X - - - - - 1073591-10X 1073591-10X

Centaur50

-6202 and

-5902

180146-40X*

(with

blankets)

or

180145-30X*

(without

blankets)

- - - - - 1100961-30X 1073591-10X AX-3608

1097061-10X - - - - - 1073591-10X 1073591-10X

Centaur50S

-6102 and

-5702

136994-50X**

(withblankets)

or

136500-110X

**

(without

blankets)

- - - - - 1138267-100 1073591-10X AX-3608


NUMBER: 8.12/109H


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Table 4 Centaur50 and Taurus 60 Exhaust Collector Replacement (Contd)

ENGINE

TO BE

UPGRADED

ORDER

ONE

EXHAUST

COLLECTOR

ORDER ONE BELLOWS

PLUS BLA NKETS ***

ORDER

ONE INLET

FLANGE

HARDWARE

KIT

ORDER

ONE EXIT

FLANGE

HARDWARE

KIT

Engine

New

Exhaust

Collector

Part Number

Bellows

PN using

0.75 Bolt

Diameter

on Exit

Flange

Bellows

PN using

1.50 Bolt

Diameter

on Exit

Flange

Hardware

K i t

Bellows

Inlet

Flange

Hardware

Kit Bellows

Exit Flange

1097061-10X - - - - - 1073591-10X 1073591-10X

Centaur50S

-6202 and

-5902

180146-60X**

(with

blankets)

or180145-40X**

(without

blankets)

or

180146-40X*

(with

blankets)

or

180145-30X*

(without

blankets)

- - - - - 1138267-100 1073591-10X AX-3608

1100961-10X - - - - - 1073591-10X 1073591-10X

Taurus 60

-7302 and

-7802

180146-40X*

(with

blankets)

or

180145-30X*

(without

blankets)

- - - - - 1100961-30X 1073591-10X AX-3608

1100961-10X - - - - - 1073591-10X 1073591-10X

Taurus60M

-7002 and

-7302

180146-50X*

(with

blankets)

or

180145-30X*(without

blankets)

- - - - - 1100961-30X 1073591-10X AX-3608



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Table 4 Centaur50 and Taurus 60 Exhaust Collector Replacement (Contd)

ENGINE

TO BE

UPGRADED

ORDER

ONE

EXHAUST

COLLECTOR

ORDER ONE BELLOWS

PLUS BLA NKETS ***

ORDER

ONE INLET

FLANGE

HARDWARE

KIT

ORDER

ONE EXIT

FLANGE

HARDWARE

KIT

Engine

New

Exhaust

Collector

Part Number

Bellows

PN using

0.75 Bolt

Diameter

on Exit

Flange

Bellows

PN using

1.50 Bolt

Diameter

on Exit

Flange

Hardware

K i t

Bellows

Inlet

Flange

Hardware

Kit Bellows

Exit Flange

1097061-10X - - - - - 1073591-10X 1073591-10X

Taurus 60S

-7302 and-7802

180146-60X**

(with

blankets)

or180145-40X**

(without

blankets)

- - - - - 1138267-100 1073591-10X AX-3608

*For engines with three-inch bleed ducts

**For engines with four-inch bleed ducts

***ForCentaur50 andTaurus60, order bellows blanket, P/N 1091567-10X, andflange blanket,

P/N 1044587-10X.

NOTE:Ensure that the existing bleed duct size (3 or 4) on site matches that of the replacement

collector part being ordered. Contact your local Solar District Service Office for assistance. Theabove information is current as of this writing, however, should this change, the most current part

number will be supplied when ordering.


Documents

Service Bulletin 8-12-109h