ML26033A212
| ML26033A212 | |
| Person / Time | |
|---|---|
| Site: | Dresden, Davis Besse, Nine Mile Point, Perry, Watts Bar, Grand Gulf, Sequoyah, Brunswick, Turkey Point, Quad Cities, FitzPatrick  |
| Issue date: | 01/30/2026 |
| From: | Darrell Roberts Engine Systems |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| 10CFR21-0140, Rev. 0 | |
| Download: ML26033A212 (0) | |
Text
2026/01/30 15:01:17 1 /11 Engine Systems Inc 175 Freight Road Rocky Mount NC 27804 FROM ~ TO Name Susan Woolard Phone Fax 7134351000 301-816-5151 E-mail Susan Woolard@kirbycorp com NRC Operations Center Sent 1 /30/26 at 3 01 17 PM 11 page(s) (including cover)
Subject Report No 10CFR21-0140, Rev 0 Comments See attached report
2026/01/30 15:01:17 2 /11
~ ENGINE -Y-TEMS. INC.---
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TELEFAX Date:
January 30,2026 Company:
NRC Operations Center Fax Number:
301/816-5151 Verification No.:
301/816-5100
Reference:
Report No. 10CFR21-0140, Rev. 0 From:
Dan Roberts
Dear Sir / Madam:
F-- ~-- this cover isa copy of our report 10CFR21-0140, Rev. 0, for a 1 FR21 reportable notification for EMD Cylinder Head, P/N 40121485, with ar--'; date from May 2023 to;
+ 2025.
A copy ofthe r..will be mailed tothe NRC Document Control Desk and to our - 0 1 nuclear customers.
-:- -' you have o' n.3.51-17, -'- - - let us know.
ENGINE SYSTEMS, INC A /23-Dan Roberts r*../...
/sjw Performance With Pride
2026/01/30 15:01:17 3 /11 ENGINE SYSTEMS INC.
3-175 Freight Road, Rocky Mount, NC 27804 Telephone 252/977-2720 Fax 252/446-1134 Report No. 10CFR21-0140 Rev. 0:
01/30/26 10CFR21 REPORTING OF DEFECTS AND NON-COMPLIANCE COMPONENT: EMD Cylinder Head with a casting date from May 2023 to August 2025 Part Number 40121485 SYSTEM:
Emergency Diesel Generator CONCLUSION: Reportable in Accordance With 10CFR21
- C
--.By ~>>47 - 1703=77-Date: ~03626 17-
/07-u_ UJ Reviewed By:
Date*
1,30-,16 Quality Performance With Pride liliF./.4
2026/01/30 15:01:17 4 /11 Report No 10CFR21-0140 Record of Revisions Page 1 ofl REV DATE PAGE DESCRIPTION 0 01/30/26 Original Issue.
2026/01/30 15:01:17 5 /11 Report No 10CFR21-0140 Revision 0
Date 01/30/26 Page 1 of 2 Pursuant to 10 CFR 21.21(d)(4), ESI is presenting the required information as follows:
(i) Name and address of the individual or individuals informing the Commission.
Dan Roberts John Kriesel Quality Manager Engineering Manager Engine Systems Inc Engine Systems Inc 175 Freight Rd 175 Freight Rd Rocky Mount, NC 27804 Rocky Mount, NC 27804 (ii) Identification of the basic component supplied within the United States which fails to comply or contains a defect.
EMD cylinder head, P/N 40121485, with a casting date from May 2023 to August 2025 (iii) Identification of the firm supplying the basic component which fails to comply or contains a defect.
Engine Systems Inc (ESI)
(iv) Nature of the defect or failure to comply and the safety hazard which is created or could be created by such defect of failure to comply.
Commercial, high duty cycle applications have experienced cracks between the core plugs and in~ector well on EMD cylinder heads cast from May 2023 to August 2025 The effect is a minor Jacket water leak at the top of cylinder head If the leakage goes undetected, there is the long term possibility of lube oil dilution that could prevent the engine from fulfilling its safety-related function (v) The date on which the information of such defect or failure to comply was obtained.
December 10, 2025 (vi) In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured, or being manufactured for one or more facilities or activities subject to the regulations in this part.
See Appendix A for a list of affected users Note the cylinder head is typically supplied within a power pack assembly The power pack assembly part number ordered by the customer is shown in the table (vii) The corrective action which has been, is being, or will be taken; the name of the individual or organization responsible forthe action; and the length of time that has been or will be taken to complete the action.
For affected customers ESI recommends no near term action Data obtained from commercial applications indicates these top deck head cracks developed in only the heaviest loaded engines and at an average of 3000 hours0.0347 days <br />0.833 hours <br />0.00496 weeks <br />0.00114 months <br /> Considering a typical EMD nuclear engine operating time of 50 hours5.787037e-4 days <br />0.0139 hours <br />8.267196e-5 weeks <br />1.9025e-5 months <br /> per year, a cylinder head is expected to last 60 years in an emergency standby application before a crack may develop For the few commercial applications impacted by this issue (<0 5%), cracks were detected during top deck inspections, but the leakage did not negatively affect engine operation Crack propagation has not been a concern and the issue is localized to the top deck area ad~acent to the core plugs Effect of the crack was nuisance leakage If left undetected, one symptom of the leak is oil dilution It is recommended to perform periodic top deck visual inspections of the head and continue performing lube oil analysis ForESI Corrective actions have been implemented by the casting manufacturer effective August 2025 For future shipments, ESI will ensure all cylinder heads have a cast date after August 2025
2026/01/30 15:01:17 6 /11 Report No 10CFR21-0140 Revision 0
Date 01/30/26 Page 2 of 2 (viii) Any advice related to the potential defect or failure to comply about the facility, activity, or basic component that has been, is being, or will be given to purchasers or licensees.
Photos 1 and 2 below show a typical cylinder head top view and location of cracks when they have occurred Cracks have been detected on 51 out of 10,534 heads (<0 5%) supplied for commercial applications No maJor engine damage has occurred and there have been no cracks reported in emergency applications Engine hours required to potentially develop cracks exceed the expected service time of nuclear standby units 7...4, it ;14 1/'
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Photo 1 : Typical Cylinder Head Photo 2: Location of Crack Formation (top view)
2026/01/30 15:01:17 7 /11 Report No 10CFR21-0140 Revision 0
Appendix A List of Affected Customers Page 1 of 5 Customer ESI Sales Cyl Head Casting Part Number Customer PO Order Serial Number ESI C-of-C Date Date Code Ordered 23J0297 2023-0704 23J0319 2023-0717 23J0386 2023-0717 23J0405 2023-0630 CONSTELLATION-23J0416 2023-0511 40124898 01448871 3025358 5/29/2024 DRESDEN 23J0424 2023-0605 (Blade Power Pack) 23J0429 2023-0717 23J0532 2023-0607 23J0540 2023-0612 23J6071 2023-0711 23J0324 2023-0717 23J0330 2023-0629 40124897 23J0423 2023-0630 5/30/2024 (Fork Power Pack) 23J0432 2023-0717 CONSTELLATION-23J0436 2023-0717 01448876 3025380 DRESDEN 23J0322 2023-0717 23J0323 2023-0717 40124897 23J0328 2023-0717 6/27/2024 (Fork Power Pack) 23J0331 2023-0705 23J6065 2023-0717 CONSTELLATION-24E0320 2024-0321 40124897 01478888 3026099 10/23/2025 DRESDEN 24E0324 2024-0321 (Fork Power Pack) 23G0476 2023-0608 23G0481 2023-0608 23G0485 2023-0607 CONSTELLATION-23G0489 2023-0607 40124898 01372298 3023905 9/6/2023 FITZPATRICK 23G0492 2023-0608 (Blade Power Pack) 23G0502 2023-0608 23G0504 2023-0608 23G0509 2023-0602 CONSTELLATION-40124898 01449105 8004093 23J0544 2023-0612 7/22/2024 FITZPATRICK (Blade Power Pack) 23G0149 2023-0524 23G0191 2023-0515 23G0195 2023-0515 CONSTELLATION-0000703-23G0212 2023-0512 40124897 3023906 9/6/2023 FITZPATRICK 13854 23G0247 2023-0512 (Fork Power Pack) 23G0471 2023-0613 23G0479 2023-0608 23G0482 2023-0608
2026/01/30 15:01:17 8 /11 Report No 10CFR21-0140 Revision 0
Appendix A List of Affected Customers Page 2 of 5 ESI Sales Cyl Head Casting Part Number Customer Customer PO Order Serial Number ESI C-of-C Date Date Code Ordered CONSTELLATION-23H1240 2023-0612 40124897 01448184 3025346 6/26/2024 NINE MILE POINT 23H1320 2023-0705 (Fork Power Pack) 23J0538 2023-0608 23J0602 2023-0711 23J0623 2023-0329 23J6073 2023-0717 24E0313 2024-0321 40124897 7/21/2025 24E0311 2024-0314 (Fork Power Pack) 24E0323 2024-0321 24D1377 2024-0314 24E0275 2024-0322 CONSTELLATION-24E0315 2024-0321 01466186 3025808 QUADCITIES 23J0246 2023-0718 23J0256 2023-0705 23J0273 2023-0704 23J0275 2023-0704 23J0278 2023-0704 40124898 7/21/2025 23J0607 2023-0711 (Blade Power Pack) 23J0612 2023-0718 23J0614 2023-0718 23J0619 2023-0511 23J0628 2023-0425 DUKE-40121469 03186370 4011179 24E0304 2024-0321 11/6/2024 BRUNS\A/ICK (Cylinder Head Assy) 23J0984 2023-0718 23J 1016 2023-0811 23J 1042 2023-0810 23J 1044 2023-0810 23J 1045 2023-0810 40124897 23J 1052 2023-0718 (Fork Power Pack) 3/28/2024 23J 1053 2023-0718 23J 1058 2023-0718 23J 1059 2023-0710 23J 1086 2023-0811 ENERGY HARBOR 23J6095 2023-0710 CORP - DAVIS 45680875 3023968 BESSE 23J0987 2023-0810 23J 1001 2023-0810 23J 1020 2023-0810 23J 1043 2023-0810 23J 1047 2023-0810 40124898 23J 1048 2023-0810 (Blade Power Pack) 3/28/2024 23J 1080 2023-0811 23J 1085 2023-0811 23J 1089 2023-0811 23J 1090 2023-0811 23J 1091 2023-0811
2026/01/30 15:01:17 9 /11 Report No 10CFR21-0140 Revision 0
Appendix A List of Affected Customers Page 3 of 5 ESI Sales Cyl Head Casting Part Number Customer Customer PO Order Serial Number ESI C-of-C Date Date Code Ordered ENERGY HARBOR 40124897 CORP-PERRY 45688545 3024827 23J0410 2023-0530 (Fork Power Pack) 3/5/2024 NUCLEAR PO\AER 23H0538 2023-0706 23H0547 2023-0620 23H0567 2023-0620 23H0570 2023-0620 23H0575 2023-0705 23H1268 2023-0616 40124897 1/29/2024 23H1324 2023-0704 (Fork Power Pack) 23J0992 2023-0810 23J 1014 2023-0811 23J 1018 2023-0810 23J 1046 2023-0810 ENTERGY OPERATIONS INC-23J 1050 2023-0810 10683340 3022678 GRAND GULF 23H0479 2023-0629 NUCLEAR 23H0483 2023-0623 23H0498 2023-0613 23H0563 2023-0626 23H0572 2023-0620 23H0579 2023-0705 40124898 12/18/2023 23H1218 2023-0615 (Blade Power Pack) 23H1265 2023-0615 23H1305 2023-0717 23H1312 2023-0717 23H1325 2023-0704 23H6026 2023-0626 23J0537 2023-0607 ENTERGY OPERATIONS INC-23J0547 2023-0612 40124897 62323413 3026888 6/6/2025 GRAND GULF 23J0613 2023-0718 (Fork Power Pack)
NUCLEAR 23J0617 2023-0718 FLORIDA PO\AER &
40111744-ESI LIGHT - TURKEY 02458184 3024528 23H1308 2023-0717 (Fork Power Pack) 6/24/2024 POINT 24E0284 2024-0321 24E0274 2024-0321 40124897 10/6/2025 24E0267 2024-0322 (Fork Power Pack) 0081320029 /
TAIWAN PO\AER 008132002901 23J0624 2023-0425 3025425 COMPANY 24E0293 2024-0321 420001461 24E0246 2024-0321 40124898 10/6/2025 24E0276 2024-0321 (Blade Power Pack) 24E0273 2024-0321
2026/01/30 15:01:17 10 /11 Report No 10CFR21-0140 Revision 0
Appendix A List of Affected Customers Page 4 of 5 ESI Sales Cyl Head Casting Part Number Customer Customer PO Order Serial Number ESI C-of-C Date Date Code Ordered 23G0188 2023-0515 23H0453 2023-0629 23H0475 2023-0629 23H0495 2023-0612 23H0497 2023-0613 23H0701 2023-0619 40124897 9/14/2023 23H0718 2023-0515 (Fork Power Pack) 23H0730 2023-0602 23H0767 2023-0615 23H0773 2023-0615 23H0779 2023-0616 23H0784 2023-0602 23H0474 2023-0629 23H0502 2023-0612 23H0507 2023-0612 23H0726 2023-0602 23H0729 2023-0530 23H0735 2023-0605 40124897 9/29/2023 23H0738 2023-0602 (Fork Power Pack) 23H0761 2023-0602 23H0778 2023-0616 23H1279 2023-0602 23H1282 2023-0602 TENNESSEE VALLEY 23H1286 2023-0711 7332773 3023002 AUTHORITY -
23H0489 2023-0623 SEQUOYAH 23H0501 2023-0612 23H0504 2023-0612 23H0512 2023-0628 23H0514 2023-0629 23H0515 2023-0629 40124897 10/4/2023 23H1259 2023-0619 (Fork Power Pack) 23H1270 2023-0602 23H1275 2023-0602 23H1296 2023-0710 23H1306 2023-0717 23J0413 2023-0530 23G0161 2023-0511 23H0503 2023-0612 23H0505 2023-0612 23H0509 2023-0613 23H0516 2023-0629 23H0525 2023-0623 40124898 9/14/2023 23H0752 2023-0602 (Blade Power Pack) 23H0756 2023-0602 23H0764 2023-0602 23H0765 2023-0602 23H0772 2023-0615 23H0774 2023-0615
2026/01/30 15:01:17 11 /11 Report No 10CFR21-0140 Revision 0
Appendix A List of Affected Customers Page 5 of 5 ESI Sales Cyl Head Casting Part Number Customer Customer PO Order Serial Number ESI C-of-C Date Date Code Ordered 23H0520 2023-0629 23H0749 2023-0602 23H0757 2023-0602 23H0768 2023-0749 23H0769 2023-0615 23H0777 2023-0615 40124898 9/29/2023 23H0781 2023-0616 (Blade Power Pack) 23H0782 2023-0615 23H0783 2023-0607 23H0786 2023-0607 23H0787 2023-0607 TENNESSEE VALLEY 23H0789 2023-0607 7332773 3023002 AUTHORITY -
23H0492 2023-0629 SEQUOYAH 23H0510 2023-0613 23H0518 2023-0623 23H0522 2023-0630 23H0523 2023-0629 23H0527 2023-0704 40124898 10/4/2023 23H0529 2023-0705 (Blade Power Pack) 23H0553 2023-0612 23H0555 2023-0613 23H0557 2023-0619 23H1285 2023-0711 23H1293 2023-0710 TENNESSEE VALLEY 40124897 7570605 3025178 23J 1055 2023-0717 2/28/2024 AUTHORITY -
(Fork Power Pack)
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