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: 3.1/103A
ISSUED: October 1979
REVISED: May 1981
PRODUCT: Centaur, Saturn
MODEL(S): All
Specifics: Units with natural gas or dual fuel systems

SUBJECT: POSSIBLE HAZARDOUS ACCUMULATION OF NATURAL

GAS IN THE ENGINE AND EXHAUST DUCT SYSTEM

PRODUCT SAFETY

—REVISION NOTICE—
Revision A provides additional information for cleaning the fuel
control valve filter on Centaur engines and to avoid the clogging
of the restrictor orifice.

Type of Change: Product Safety

Recommended
Compliance: Information

Purpose:
This safety bulletin advises customers of a potential hazard and provides recommendations for
elimination of the hazard.

GENERAL INFORMATION:
The gas fuel control valve assembly furnished on Solar turbine packages will not provide the proper
fuel amount if dirt, metal chips, or other debris accumulate within the poppet valve. When foreign
material is entrapped under the poppet valve, excess fuel could be supplied to the engine during

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NUMBER: 3.1/103A
the start cycle, which would cause improper ignition, resulting in a hazardous accumulation of gas
within the engine and exhaust duct system.

Dirt and debris may enter the fuel system downstream of the inlet strainer during initial equipment
installation or maintenance that involves disconnection of fuel lines.

Difficulty in light-off occurs as a result of improper positioning of the poppet valve. Figure 1 and
Figure 2 depict typical Centaur and Saturn gas fuel systems.

ACTION REQUIRED:

GAS FUEL IS HIGHLY FLAMMABLE AND EXPLOSIVE. USE EXTREME

CAUTION WHEN PERFORMING MAINTENANCE PROCEDURES ON
FUEL SYSTEM COMPONENTS. CHECK THAT GAS FUEL SUPPLY
SHUTOFF VALVES ARE TIGHTLY CLOSED AND ENGINE IS SHUT
DOWN, UNLESS OTHERWISE SPECIFIED IN THE TEST. PERMIT NO
SMOKING OR OTHER FIRE OR SPARK SOURCE IN THE WORK AREA.

CHECK POSSIBLE GAS ACCUMULATION BY USING A GAS DETEC-

TION DEVICE (SNIFFER).

LINE BLOWDOWN
Prior to attempting the initial start of the engine following installation, all inlet fuel lines must be
blown down to remove any foreign matter. This should be accomplished utilizing the fuel supply
(vented to a safe area) or compressed air, taking care to protect the eyes from flying debris.

VALVE CHECK
The following procedures must be followed prior to initiating start sequence, and after blowdown
of lines to ensure a properly functioning gas fuel control valve assembly.

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NUMBER: 3.1/103A
 Figure 1 Centaur Package Gas Fuel System Schematic

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NUMBER: 3.1/103A
 Figure 2 Saturn Natural Gas Fuel System Schematic

SATURN ENGINES
1. Ensure that gas fuel supply to the skid is between 140 and 160 psi and that gas pressure
is 0 psi after the primary and secondary fuel valves.

DISCONNECT AND INSULATE IGNITION CABLE CONNECTION AT

SPARK PLUG TO PREVENT ELECTRICAL CURRENT ENERGIZING
ENGINE IGNITION CIRCUITRY. CAREFULLY PERFORM THE FOLLOW-
ING PROCEDURES. FAILURE TO COMPLY WITH THIS WARNING CAN
RESULT IN FIRE OR EXPLOSION. TREAT INJURED PERSONNEL.
SUMMON PHYSICIAN.

2. Tag Master switch and Start button with "DO NOT OPERATE" tags for protection.
3. Remove 1/8-inch NPT plug from side of gas fuel control valve near serrated shaft and
connect 200 psi pressure gage.
4. Apply 24-volt dc power to terminals of primary gas fuel valve solenoid and to terminals
of secondary valve pilot vent valve solenoid to open valves and admit gas to the

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NUMBER: 3.1/103A
 fuel control valve. Admit only enough gas to obtain a pressure gage reading; then
immediately disconnect power to close shutoff valves.
5. If a low reading is observed, replace the 200 psi gage with a 30 psi or lower gage. Repeat
step 4.
6. Observe pressure gage; outlet pressure indications should normally be 0.5 to 1.5 psi.

NOTE
If gage registers in excess of 2.0 psi, remove the fuel control valve and ei-
ther clean or replace it. Refer to instructions in Operation and Maintenance
Instruction manual or instructions given below.

7. Disconnect electrical power from terminals of primary gas fuel valve solenoid and
terminals of secondary valve pilot vent valve solenoid.
8. Remove gage from gas fuel control valve and replace 1/8-inch plug.
9. Connect electrical input lead to ignition exciter.
10. This completes the checkout. Cleaning instructions should be performed, if necessary.

CLEANING SATURN GAS FUEL CONTROL VALVE FILTER - (See Figure 3)

PRIOR TO PERFORMING THE FOLLOWING STEPS ENSURE THAT

PACKAGE IS SHUT DOWN AND ALL GAS IS TURNED OFF.

INSTALL TAGS FOR PROTECTION ON MANUAL VALVES (OFF SKID

CUSTOMER FURNISHED).

USE A GAS DETECTION DEVICE (SNIFFER) TO CHECK FOR GAS

LEAKS.

OPEN ELECTRICAL CIRCUIT BREAKERS TURN MASTER SWITCH TO

OFF POSITION AND INSTALL TAGS FOR PROTECTION.

1. Remove hexagon-head plug located directly below No. 1 loader.

2. Remove filter element and discard O-Ring seal.

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NUMBER: 3.1/103A
 Figure 3 Installation of Saturn Gas Fuel Control Valve Filter Element

DO NOT OPERATE ENGINE WITH FILTER REMOVED. A RESTRICTOR

ORIFICE, AN INTEGRAL PART OF FILTER, AIDS IN CONTROLLING
GAS FLOW TO MAIN POPPET VALVE.

3. Clean filter element with Stoddard solvent or equivalent, then blow dry with clean,
compressed air.

NOTE
If element is excessively contaminated, replace with a new element.

4. Remove any foreign matter remaining in filter housing.

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NUMBER: 3.1/103A
 WHEN PERFORMING FOLLOWING STEP, ENSURE THAT O-RING
SEAL IS SEATED IN GROOVE PROPERLY TO PREVENT GAS LEAK-
AGE DURING OPERATION. A FIRE OR EXPLOSION COULD RESULT
IF GAS LEAKS. TREAT INJURED PERSONNEL. SUMMON PHYSICIAN.

5. Place new O-Ring seal in groove on filter element; apply light film of petroleum jelly or
light turbine oil to O-Ring seal.
6. Install filter as shown in Figure 3; tighten hexagon-head plug securely.

NOTE
If, at any time, engine light-off difficulties are experienced, and fuel flow is
to be checked, the above procedure must be followed.

INSPECTING SATURN FUEL CONTROL MAIN POPPET VALVE

Perform the following steps to check that the gas fuel control valve main poppet valve is clean and
free of corrosion. Replace parts if necessary.

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NUMBER: 3.1/103A
Step 1

Remove plug on top of fuel control valve.

Figure 4

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NUMBER: 3.1/103A
Step 2

Remove spring.

Figure 5

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NUMBER: 3.1/103A
Step 3

Extract poppet valve using pliers or similar tool.

Figure 6

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NUMBER: 3.1/103A
Step 4

Clean poppet valve with lint free cloth and Stoddard solvent. Check valve surface for damage and
corrosion.

Figure 7

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NUMBER: 3.1/103A
Step 5

Check valve stem for corrosion or other damage. ( Figure E)

Figure 8

Step 6

Reinstall the main poppet valve by reversing the disassembly procedures. ( Figure E)

Step 7

Restore all systems to NORMAL.

CENTAUR ENGINES
1. Ensure that gas fuel supply to the skid is between 165 and 200 psi and that gas pressure
is 0 psi after the primary and secondary fuel valves.

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NUMBER: 3.1/103A
 DO NOT ALLOW THE ENGINE IGNITION CIRCUITS TO BECOME EN-
ERGIZED. PERFORM THE FOLLOWING PROCEDURES CAREFULLY,
EQUIPMENT DAMAGE OR PERSONNEL INJURY COULD OCCUR.

2. Disconnect input lead from ignition exciter. Tag Master switch, Reset and Start button
for protection.
3. Disconnect and remove torch gas line from.torch gas outlet nipple located near outlet
port on the fuel control valve . Connect a 200 psi. gage to the fuel control valve using a
suitable adapter fitting.
4. Apply 24-volt dc power to the terminals of fuel valve solenoids L341-1, L341-2, and
L342 to open primary and secondary shutoff valves and admit gas to the fuel control
valve. Admit only enough gas to obtain a pressure gage reading; then immediately
disconnect power to close shutoff valves.
5. If a low reading is observed, replace the 200 psi gage with a 30 psi or lower gage. Repeat
step 4.
6. Observe pressure gage; outlet pressure reading should be 1 to 3 psi.

NOTE
If gage registers in excess of 4 psi, remove the fuel control valve and either
clean or replace it. Refer to instructions in Operation and Maintenance In-
struction manual or instructions on next page.

7. Disconnect electrical power from terminals of primary and secondary fuel valves.
8. Remove gage from gas fuel control valve and reinstall torch gas line.
9. Connect electrical input lead to ignition exciter.
10. This completes the checkout. Cleaning instructions should be performed, if necessary.

CLEANING GAS FUEL CONTROL VALVE FILTER (See Figure 4)

PRIOR TO PERFORMING THE FOLLOWING STEPS ENSURE THAT

PACKAGE IS SHUT DOWN AND ALL GAS IS TURNED OFF.

INSTALL TAGS FOR PROTECTION ON MANUAL VALVES (OFF SKID

CUSTOMER FURNISHED).

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NUMBER: 3.1/103A
 USE A GAS DETECTION,DEVICE (SNIFFER) TO CHECK FOR GAS
LEAKS.

OPEN ELECTRICAL CIRCUIT BREAKERS, TURN MASTER SWITCH TO

OFF POSITION AND INSTALL TAGS FOR PROTECTION.

1. Remove filter hexagon head plug and O-Ring located in a boss on the side of valve body
assembly. Discard O-Ring.

Figure 9 Installation of Centaur Fuel Control Valve Filter

PRIOR TO REMOVING THE FILTER ELEMENT AND O-RING, USE SHOP

AIR (80 TO 100 PSI) TO CLEAN THE CAVITY AROUND THE FILTER.
AFTER ELEMENT HAS BEEN REMOVED CHECK TO SEE IF BROKEN
O-RING PIECES DID NOT FALL TO THE BOTTOM. INSPECT BOTTOM
RESTRICTOR ORIFICE WITH A FLASHLIGHT FOR POSSIBLE CLOG-
GING. CLOGGING OF THE RESTRICTOR ORIFICE WILL ALTER THE
FUNCTION OF THE FUEL CONTROL VALVE AND MAY CAUSE ENGINE
DAMAGE.

2. Using a screwdriver, remove filter element and O-Ring.

3. Discard O-Ring and clean element with Stoddard solvent and dry with compressed air.

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NUMBER: 3.1/103A
 NOTE
If element appears contaminated, replace it with a new part.

4. Remove any foreign matter remaining in filter housing.

WHEN PERFORMING THE FOLLOWING STEP, ENSURE THAT O-RING

SEAL IS SEATED IN GROOVE PROPERLY TO PREVENT GAS LEAK-
AGE DURING OPERATION. A FIRE OR EXPLOSION COULD RESULT
IF GAS LEAKS.

5. Place a new O-Ring in groove on filter element, and coat O-Ring lightly with
high-temperature silicone grease.
6. Install filter element as shown in Figure 4; place a new O-Ring on plug and tighten plug
securely.

NOTE
If, at any time, engine light-off difficulties are experienced, and fuel flow is
to be checked, the above procedure must be followed.

INSPECTING CENTAUR FUEL CONTROL MAIN POPPET VALVE

Perform the following steps to check that the gas fuel control valve main poppet valve is clean and
free of corrosion.

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NUMBER: 3.1/103A
Step 1

Loosen bolts and remove main poppet valve cover.

THE POPPET VALVE COVER IS SPRING LOADED. LOOSEN COVER

BOLTS EVENLY, IN SMALL INCREMENTS, TO RELIEVE SPRING TENS
ION.

Figure 10

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NUMBER: 3.1/103A
Step 2

Remove spring from fuel control housing.

Figure 11

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NUMBER: 3.1/103A
Step 3

Extract poppet valve assembly from fuel control housing.

Figure 12

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NUMBER: 3.1/103A
Step 4

Clean poppet valve with lint free cloth and Stoddard solvent. Check bellows,, valve surface,, and
stem for corrosion and damage. ( Figure I)

Figure 13

Step 5

Reinstall the main poppet valve assembly by reversing the disassembly procedures. ( Figure I)

Step 6

Restore all systems to NORMAL.

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NUMBER: 3.1/103A