TECHNICAL

BULLETIN

Wärtsilä low-speed engines RT-108

Services 2-stroke Issue 1, 18.05.2011

Rail unit support cracks Next opportunity

Current situation
Cracks have been reported in the rail unit
supports of some engines, caused by
Information to all Owners and Operators of excessive vibrations.
Wärtsilä RT-flex96C-B engines
Problem
Depending on the kind of crack, it might
weaken the support and reduce the
stiffness in the longitudinal direction.

Preventive action
Check the rail unit supports for possible
cracks at the next opportunity.

Solution
Apply an arresting hole at the end of the
crack and mount a new fixing block.

Wärtsilä Switzerland Ltd. Tel (24h): +41 52 262 80 10

PO Box 414 Fax: +41 52 262 07 31
CH-8401 Winterthur technicalsupport.chts@wartsila.com
 TECHNICAL BULLETIN RT-108
Issue 1, Page 2 / 6

Contents
Page
 
Introduction 2 
Kind of cracks 3 
Required actions 4 
Contact 6 

Introduction
Wärtsilä has received reports of cracks on the rail unit supports (1) on Wärtsilä
RT-flex96C-B engines. The cracks start from the weld seam corner (3) at the
connection of the H-beam (2) to the mounting flange (4).
Even when cracked, the rail unit support is strong enough to carry the rail unit
and engine parts placed on the platform during maintenance.

Attention:
It is not allowed to place and store engine parts, spare parts and/or tools on
engine platforms during engine operation.
According to the National Authorities 1 it has to be ensured that escape and
emergency routes must be kept free from any restrictions.

Location of cracks

4
1

1. Rail unit support, 2. H-beam, 3. Starting point of crack, 4. Mounting flange

Fig. 1

1
The International Sailing Federation (ISAF) consists of over 130 Member National Authorities (MNAs). The MNAs are the
principle members of ISAF and are responsible for the decision making process that governs the sailing world.
 TECHNICAL BULLETIN RT-108
Issue 1, Page 3 / 6

Kind of cracks
Investigations showed two different kinds of crack. The starting point of the crack
is always at about the same point. Depending on how they propagate and stop,
they are referred to as harmless or harmful cracks.

Harmless cracks
The harmless crack is self-arresting in an adjacent screw hole or plate-end of the
support. A harmless crack needs no further action such as an additional stiffener
or mechanical and/or welding processing of the affected part.

Example of harmless cracks

1 2
1. Cracks end in screw hole, 2. Crack ends in plate end
Fig. 2

Harmful cracks
The harmful crack is one that is growing into the H-beam girder, along the
longitudinal direction of the beam.
In order to avoid uncontrolled damage to the rail unit supports to the point where
the safety of the structure becomes affected, the harmful cracks must be
stopped.

Example of harmful crack

1. Crack in vertical H-beam plate, action required

Fig. 3
 TECHNICAL BULLETIN RT-108
Issue 1, Page 4 / 6

Required actions
In order to stop further growth of started cracks in the rail unit supports a number
of countermeasures and actions shall be performed.

Arresting hole at the end of the crack

After the discovery of a harmful crack, apply immediately an arresting hole. The
arresting hole must be drilled at the very end of the crack.

Drilling of arresting hole

ø20

2
R2

3
R2
1 2
(Dimensions in mm)

1. End of crack, 2. Arresting hole, 3. Cracked part

Fig. 4

Fixing block
Since cracked supports reduce the stiffness of the structure in the longitudinal
direction, fixing blocks must be mounted. As already described, first priority is to
stop the crack using an arresting hole. Mounting of a fixing block must be done at
the next opportunity.

Note:
Fixing blocks are only required if harmful cracks are discovered. One fixing block
is required for each cracked rail unit support.

The fixing block re-establishes the longitudinal stiffness and thus reduces the
longitudinal movement of the rail unit.
 TECHNICAL BULLETIN RT-108
Issue 1, Page 5 / 6

Location and mounting of fixing block

Place and mount the fixing block at the starboard side of the rail unit, i.e. between
the rail unit and the cylinder block.
The exact location is defined by the starting air pipe holder (3), which is now also
used as the holding point for the retrofit fixing block (1) or (2), see Figure 5.
Wärtsilä will deliver the fitting procedure together with the ordered parts, which
include the fixing block and necessary bolts and nuts.

Note:
The fixing block execution can be selected according to the type of the starting
air pipe holder (3), see Figure 5.

Location and execution of fixing block

4 4

1 3 2 3

1. Fixing block – Execution A – Order # DF 55200, 2. Fixing block – Execution B

– Order # DF 55201, 3. Starting air pipe holder with clamp, 4. Starting air pipe
Fig. 5
 TECHNICAL BULLETIN RT-108
Issue 1, Page 6 / 6

Contact
If you have discovered cracks on the rail unit supports, please contact Wärtsilä
Services.
A retrofit package including repair instructions is available through the Wärtsilä
Worldwide Services & Support organisation. This package includes the fixing
block, bolts and nuts. Depending on the fixing block execution, the retrofit
package can be ordered using the part number:

• Fixing block – Execution A: Part No. DF 55200

• Fixing block – Execution B: Part No. DF 55201

For questions about the content of this Technical Bulletin or if you need Wärtsilä
assistance, services, spare parts and/or tools, please contact your nearest
Wärtsilä representative or send your enquiry to:
technicalsupport.chts@wartsila.com
or phone 24hrs Support: +41 52 262 80 10.

© 2011 Wärtsilä Switzerland Ltd. – All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical,
graphic, photocopying, recording, taping or other information retrieval systems) without the prior written
permission of the copyright holder. Wärtsilä Corporation makes no representation, warranty (express or implied)
in this publication and assumes no responsibility for the correctness, errors or omissions for information
contained herein. Information in this publication is subject to change without notice.
Unless otherwise expressly set forth, no recommendation contained in this document is to be construed as
provided due to a defect in the engine, but merely as an improvement of the engine and/or the maintenance
procedures relating thereto. Any actions by the owner/operator as a result of the recommendations are not
covered under any warranty provided by Wärtsilä and such actions will thus be at the owners/operators own
cost and expense.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS
ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS
CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.