The following report was received via facsimile:
PART 21 involving Wartsila type SACM UD45 Emergency Diesel Generating [EDG] set big end bearings installed in the US nuclear power stations of Constellation Energy at Calvert Cliffs and Xcel Energy at Prairie Island.
COMPONENT: Big end bearing DLT141885 all batches & DLT123351 batches A2, F2, J2 on Wartsila type SACM UD45 [EDG] sets.
DISCUSSION: Three of four incidents which have been reported to Wartsila France are related to UD45 diesel engines operating at 1500 rpm in nuclear installations. Big end bearing damage can result in non-availability of the diesel engine. Wartsila France has been working on the root cause analysis after the first reported failure and has given an overall recommendation in October 2009 regarding the risks of using the above mentioned big end bearings on diesel engines running at 1500 rpm (50 Hz applications). An additional technical evaluation has been issued in November 2009 after testing a new big end bearing. The evaluation has determined that this is potentially a reportable defect as defined by 10CFR21.
AFFECTED USERS: UD45 engines
CORRECTIVE ACTION: Being unable to predict the occurrence of such a random event, Wartsila France has advised its customers to: identify the [EDG] sets equipped with big end bearings above referenced in COMPONENT, stop the utilization of big end bearings above referenced in COMPONENT, replace all above referenced in COMPONENT big end bearings by a new reference PAAG129161 which has been qualified after extensive running tests on a 1500 rpm engine. Wartsila has not recorded such a situation on other UD45 diesel engines running at a lower speed of 1200 rpm (60 Hz applications) which are installed as Emergency Generating sets in nuclear power plants. Nevertheless Wartsila France recommendation if components have also been identified in 1200 rpm units installed in US nuclear power plants or if such components are held in stock, is to replace them with the new reference big end bearing PAAG129161.