Bulletin 90-01: Loss of Fill-oil in Transmitters Manufactured by Rosemount
OMB No.: 3150-0011
NRCB 90-01
UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, D.C. 20555
March 9, 1990
NRC BULLETIN NO. 90-01: LOSS OF FILL-OIL IN TRANSMITTERS MANUFACTURED
BY ROSEMOUNT
Addressees:
All holders of operating licenses or construction permits for nuclear power
reactors.
Purpose:
This bulletin requests that addressees promptly identify and take
appropriate corrective actions for Model 1153 Series B, Model 1153 Series D,
and Model 1154 transmitters manufactured by Rosemount that may be leaking
fill-oil.
Description of Circumstances:
NRC Information Notice No. 89-42, "Failure of Rosemount Models 1153 and 1154
Transmitters," dated April 21, 1989, was issued to alert industry to a
series of reported failures of Rosemount Models 1153 and 1154 pressure and
differential pressure transmitters. The reported failures occurred at
Northeast Utilities' Millstone Unit 3 between March and October 1987.
Subsequent investigation into the cause of the failures by Rosemount
confirmed that the failure mode was a gradual loss of fill-oil from the
transmitter's sealed sensing module.
Discussion of Safety Significance:
The performance of a transmitter that is leaking fill-oil gradually
deteriorates and may eventually lead to failure. Although some failed
transmitters have shown symptoms of loss of fill-oil prior to failure, it
has been reported that in some cases the failure of a transmitter that is
leaking fill-oil may be difficult to detect during operation. An undetected
transmitter failure has a greater adverse effect on safety system
reliability than a failure that would be readily detectable during normal
operation. For example, electronic circuit malfunctions are routinely
detected either by observing instrument channel readout or during periodic
surveillance tests. Transmitter failures that are not readily detectable
increase the potential for common mode failure and may result in the
affected safety system not performing its intended safety function. This
common mode failure potential is of increased concern when transmitter
designs are particularly susceptible to loss of fill-oil.
9003050148
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Discussion:
Model 1151, 1152, 1153, and 1154 Rosemount transmitters are utilized
extensively in nuclear power plants. Model 1153 and 1154 transmitters are
supplied by Rosemount as both seismically and environmentally qualified
equipment. Model 1152 transmitters are supplied by Rosemount only as
seismically qualified equipment. Model 1151 transmitters are supplied by
Rosemount as commercial-grade equipment.
Rosemount has indicated, to date, that failure of approximately 91 Model
1153 Series B, Model 1153 Series D, and Model 1154 transmitters due to loss
of fill-oil from a glass to metal seal failure have been confirmed. Since
the sensing module is sealed, loss of fill-oil cannot be visually confirmed
without destructive analysis of the sensing module. NRC staff review of
this issue has identified additional Model 1153 and 1154 transmitters with
symptoms indicative of loss of fill-oil that may not have been brought to
Rosemount's attention. Thus, the number of Model 1153 and 1154 transmitters
that have experienced a loss of fill-oil may be even greater than that
confirmed by Rosemount.
Model 1153 Series B, Model 1153 Series D, and Model 1154 transmitters,
because their construction incorporates the use of a metal o-ring, appear to
be particularly susceptible to loss of fill-oil due to a glass to metal seal
failure. Accordingly, the NRC staff believes that the degree of
susceptibility of these transmitters to loss of fill-oil warrants their
being subjected to an enhanced surveillance program. In addition, certain
manufacturing lots of Model 1153 Series B, Model 1153 Series D, and Model
1154 transmitters have been identified by Rosemount as having had a high
failure fraction due to loss of fill-oil. Specific information needed to
identify transmitters that are from these suspect lots has been provided to
industry by Rosemount concurrent with Reference 4. Accordingly, the NRC
staff believes that this additional degree of susceptibility warrants not
utilizing these suspect lot transmitters in the reactor protection or
engineered safety features actuation systems.
Rosemount has indicated that failures of Model 1151 and 1152 transmitters
due to loss of fill-oil have also been confirmed. The construction of Model
1151, 1152, and 1153 Series A transmitters is similar to that of Model 1153
Series B, Model 1153 Series D, and Model 1154 transmitters (i.e., the
utilization of a glass to metal seal) except the construction of Model 1151,
1152, and 1153 Series A transmitters incorporates an elastomeric o-ring
instead of a metal o-ring. The NRC staff does not, at present, have
sufficient information to effectively address the susceptibility of Model
1151, 1152, and 1153 Series A transmitters to loss of fill-oil. Therefore,
in order to obtain relevant operational experience data, addressees are
encouraged to report Model 1151, 1152, and 1153 Series A, as well as Model
1153 Series B, Model 1153 Series D and Model 1154 transmitters that may have
exhibited symptoms indicative of loss of fill-oil or have been confirmed to
have experienced a loss of fill-oil to the Nuclear Plant Reliability Data
System (NPRDS). In addition, while enhanced surveillance of Model 1151,
1152, and 1153 Series A transmitters is not specifically requested by this
bulletin, addressees are encouraged to undertake such efforts on Model 1151,
1152, and 1153 Series A transmitters utilized in either safety-related
systems or systems installed in accordance with 10 CFR 50.62 (the ATWS
rule).
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Rosemount has indicated that they have instituted additional quality control
and quality assurance steps in the manufacturing process and modified
specifications on bolt torque to reduce stress levels. These changes should
minimize the potential for Model 1153 Series B, Model 1153 Series D, and
Model 1154 transmitter failures due to loss of fill-oil. As a result,
Rosemount has indicated that transmitters of these types manufactured after
July 11, 1989 are not subject to their May, 1989 10 CFR Part 21
notification. The NRC staff has not, to date, received operational
experience data that indicates that Model 1153 Series B, Model 1153 Series D
and Model 1154 transmitters manufactured after July 11, 1989 are as
susceptible to loss of fill-oil as those manufactured prior to July 11,
1989. Accordingly, while enhanced surveillance of transmitters of these
types manufactured after July 11, 1989 is not specifically requested by this
bulletin, addressees are encouraged to undertake such efforts on these
transmitters if they are utilized in either safety-related systems or
systems installed in accordance with 10 CFR 50.62 (the ATWS rule). In
addition, Model 1153 Series B, Model 1153 Series D and Model 1154
transmitters manufactured after July 11, 1989 that exhibit symptoms
indicative of loss of fill-oil or are confirmed to have experienced a loss
of fill-oil should be reported in accordance with the report requirements of
this bulletin.
The NRC staff encourages utilities to work collectively under the guidance
of a technical industry organization to develop and analyze an operational
experience database concerning all models of Rosemount transmitters. The
NRC staff will continue to obtain and analyze operational experience data
pertaining to Model 1151, 1152, 1153, and 1154 transmitters. Further
regulatory action, such as requesting expansion of enhanced surveillance
activities to include Model 1151, Model 1152, and Model 1153 Series A
transmitters and Model 1153 Series B, Model 1153 Series D and Model 1154
transmitters manufactured by Rosemount after July 11, 1989 or requesting
replacement of additional suspect lot transmitters, may be taken if
warranted.
Addressees may have obtained transmitters that were manufactured by
Rosemount or that contain Rosemount manufactured sensing modules from a
number of different sources. The following information is provided to
facilitate addressee's identification of transmitters that were manufactured
by Rosemount or that contain Rosemount manufactured sensing modules:
- Rosemount has indicated that unauthorized remanufacturers and
refurbishers exist for Model 1151 transmitters. Unauthorized
remanufacturers and refurbishers may also exist for Model 1152, 1153,
and 1154 transmitters.
- All Model 1153 and 1154 transmitters, whether obtained directly from
Rosemount, obtained through intermediary suppliers, or provided as an
integral part of another component (such as an emergency diesel
generator), should a) indicate manufacture by Rosemount, b) have a
distinctive Rosemount model and serial number, c) have the physical
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profile characteristics of a Rosemount transmitter, and d) have a blue
or stainless steel housing. Rosemount has indicated that Model 1153
and 1154 transmitters are not provided to other manufacturers for
resale under a different brandname. In addition, a simplified diagram
that describes the typical physical characteristics of a Rosemount
transmitter is provided by Attachment 1.
- Model 1152 transmitters, except as noted below, should a) indicate
manufacture by Rosemount, b) have a distinctive Rosemount model and
serial number, c) have the physical profile characteristics of a
Rosemount transmitter, and d) have a blue or stainless steel housing.
Rosemount has indicated that they have supplied Model 1152 transmitter
sensing modules to Bailey Controls (formerly Bailey Meter). Bailey
manufactured transmitters that contain Rosemount manufactured Model
1152 sensing modules have gray housings that appear slightly different
than Rosemount housings.
- Model 1151 transmitters, except as noted below, should a) indicate
manufacture by Rosemount, b) have a distinctive Rosemount model and
serial number, c) have the physical profile characteristics of a
Rosemount transmitter, and d) have a blue housing. Model 1151
transmitters manufactured by Rosemount may have been supplied for use
in nuclear power plants by other original equipment manufacturers.
These transmitters should have the physical profile characteristics of
a Rosemount transmitter and have a blue housing. Fisher Controls may
also offer for resale under their own brandname Model 1151 transmitters
purchased from Rosemount. These transmitters should have the physical
profile characteristics of a Rosemount transmitter, but have a green
housing.
The earliest symptom a Model 1153 Series B, Model 1153 Series D, or Model
1154 transmitter may exhibit during normal operation prior to failure if it
is leaking fill-oil is:
- a sustained drift
The symptoms a Model 1153 Series B, Model 1153 Series D, or Model 1154
transmitter may exhibit during normal operation subsequent or immediately
prior to failure if it is leaking fill-oil include:
- a sustained drift
- an abrupt decreasing drift (for high range gauge or absolute
transmitters)
- a change in process noise including amplitude variations,
"one-sided-noise," or asymmetric noise distributions
- slow response to or inability to follow planned or unplanned plant
transients
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The symptoms a Model 1153 Series B, Model 1153 Series D, or Model 1154
transmitter may exhibit during calibration activities if it is leaking
fill-oil include:
- inability to respond over the entire design range
- slow response to either an increasing or decreasing test pressure
- a sustained zero or span shift
The NRC staff believes these symptoms can also be utilized to detect Model
1151, 1152, and 1153 Series A transmitters that may be experiencing a loss
of fill-oil.
The NRC staff has reviewed the information which has been provided by
Rosemount, including References 1, 2, 3, and 4, to assist industry in
detecting transmitters that may be leaking fill-oil. The NRC staff has
concluded that Rosemount has provided sufficient bases to support their
proposed diagnostic procedures (trending calibration data, trending
operational data, sluggish transient response, and process noise analysis)
for detecting whether a transmitter may be leaking fill-oil. Accordingly,
the actions requested in this bulletin are intended to reflect these
diagnostic procedures. However, the NRC staff has concluded that Rosemount
has not provided sufficient bases to support their proposed methodology
(pressure versus time-in-service) for identifying which transmitters should
be subject to an enhanced surveillance program. Specifically, the NRC staff
believes that the methodology utilized by Rosemount to support their
proposed pressure versus time-in-service criteria for identifying which
transmitters should be subject to an enhanced surveillance program does not
provide the necessary high degree of confidence that this failure mode will
not occur.
Rosemount had initially indicated that Model 1153 Series B, Model 1153
Series D, and Model 1154 transmitters that were experiencing a loss of
fill-oil should fail within approximately 36 months of in-service time.
Recent information indicates that the rate of loss of fill-oil is
application and pressure dependent. Although transmitters subject to
continuous high-pressure (e.g. reactor operating pressures) may fail within
this timeframe, transmitters utilized in low-pressure systems or not subject
to continuous high-pressure may take longer to fail.
General Design Criterion (GDC) 21 "Protection System Reliability and
Testability" of 10 CFR 50, Appendix A requires the protection system to be
designed for high functional reliability and with sufficient capability to
allow periodic testing of its functioning when the reactor is in operation
in order to readily detect failures of subcomponents and subsystems within
the protection system as well as loss of the required protection system
redundancy as they occur. 10 CFR 50.55a(h) requires that protection systems
meet the Institute of Electrical and Electronics Engineers Standard:
"Criteria for Protection Systems for Nuclear Power Generating
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Stations" (IEEE-279). IEEE-279 states that means shall be provided for
checking, with a high degree of confidence, the operational availability of
each system input sensor during reactor operation. Thus, the NRC staff
concludes that facilities that utilize transmitters that may be particularly
susceptible to loss of fill-oil may not be in full compliance with these
regulations because undetected transmitter failure could occur.
Accordingly, the NRC staff requests that addressees take the actions
requested below.
Requested Actions:
Operating Reactors
All holders of operating licenses for nuclear power reactors are, within 120
days after receipt of this bulletin, requested to:
1. Identify Model 1153 Series B, 1153 Series D, and Model 1154 pressure or
differential pressure transmitters, excluding Model 1153 Series B, 1153
Series D, and Model 1154 transmitters manufactured by Rosemount
subsequent to July 11, 1989, that are currently utilized in either
safety-related systems or systems installed in accordance with 10 CFR
50.62 (the ATWS rule).
2. Determine whether any transmitters identified in Item 1 are from the
manufacturing lots that have been identified by Rosemount as having a
high failure fraction due to loss of fill-oil. Addressees are
requested not to utilize transmitters from these suspect lots in the
reactor protection or engineered safety features actuation systems;
therefore, addressees are requested to develop and implement a program
to replace, at the earliest appropriate opportunity, transmitters from
these suspect lots in use in the reactor protection or engineered
safety features actuation systems.
3. Review plant records (for example, the three most recent calibration
records) associated with the transmitters identified in Item 1 above to
determine whether any of these transmitters may have already exhibited
symptoms indicative of loss of fill-oil. Appropriate operability
acceptance criteria should be developed and applied to transmitters
identified as having exhibited symptoms indicative of loss of fill-oil
from this plant record review. Transmitters identified as having
exhibited symptoms indicative of loss of fill-oil that do not conform
to the operability acceptance criteria should be addressed in
accordance with the applicable technical specification. Transmitters
identified as having exhibited symptoms indicative of loss of fill-oil
that do not conform to the operability acceptance criteria and are not
addressed in the technical specifications should be replaced at the
earliest appropriate opportunity.
4. Develop and implement an enhanced surveillance program to monitor
transmitters identified in Item 1 for symptoms of loss of fill-oil.
This enhanced surveillance program should consider the following or
equally effective actions:
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a) Ensuring appropriate licensee personnel are aware of the symptoms
that a transmitter, both during operation and during calibration
activities, may exhibit if it is experiencing a loss of fill-oil
and the need for prompt identification of transmitters that may
exhibit these symptoms;
b) Enhanced transmitter monitoring to identify sustained transmitter
drift;
c) Review of transmitter performance following planned or unplanned
plant transients or tests to identify sluggish transmitter
response;
d) Enhanced awareness of sluggish transmitter response to either
increasing or decreasing test pressures during calibration
activities;
e) Development and implementation of a program to detect changes in
process noise; and
f) Development and application to transmitters identified as having
exhibited symptoms indicative of loss of fill-oil of an
appropriate operability acceptance criteria. Transmitters
identified as having exhibited symptoms indicative of loss of
fill-oil that do not conform to the operability acceptance
criteria should be addressed in accordance with the applicable
technical specification. Transmitters identified as having
exhibited symptoms indicative of loss of fill-oil that do not
conform to the operability acceptance criteria and are not
addressed in the technical specifications should be replaced at
the earliest appropriate opportunity.
5. Document and maintain in accordance with existing plant procedures a
basis for continued plant operation covering the time period from the
present until such time that the Model 1153 Series B, 1153 Series D,
and Model 1154 transmitters from the manufacturing lots that have been
identified by Rosemount as having a high failure fraction due to loss
of fill-oil in use in the reactor protection or engineered safety
features actuation systems can be replaced. In addition, while
performing the actions requested above, addressees may identify
transmitters exhibiting symptoms indicative of loss of fill-oil that do
not conform to the established operability acceptance criteria and are
not addressed in the technical specifications. As these transmitters
are identified, this basis for continued plant operation should be
updated to address these transmitters covering the time period from the
time these transmitters are identified until such time that these
transmitters can be replaced. When developing and updating this basis
for continued plant operation, addressees may wish to consider
transmitter diversity and redundancy, diverse trip functions (a
separate trip function that may also provide a corresponding trip
signal), special system and/or component tests, or (if necessary)
immediate replacement of certain suspect transmitters.
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Construction Permit Holders
1. All construction permit holders that anticipate receiving an operating
license within 120 days after receipt of this bulletin are requested to
perform Items 1, 2, 4, and 5 of Requested Actions for Operating
Reactors within 120 days after receipt of this bulletin.
2. All construction permit holders that do not anticipate receiving an
operating license within 120 days after receipt of this bulletin are
requested to, prior to the date scheduled for fuel loading, complete
Items 1 and 4 of Requested Actions for Operating Reactors and to
address the intent of Items 2 and 5 of Requested Actions for Operating
Reactors by:
a) Identifying and replacing Model 1153 Series B, 1153 Series D, and
Model 1154 transmitters from the manufacturing lots that have been
identified by Rosemount as having a high failure fraction due to
loss of fill-oil that are installed in the reactor protection or
engineered safety features actuation systems; and
b) Documenting and maintaining in accordance with existing plant
procedures a basis for continued plant operation that addresses
transmitters that, subsequent to fuel loading, are identified as
exhibiting symptoms indicative of loss of fill-oil that do not
conform to the established operability acceptance criteria and are
not addressed in the technical specifications covering the time
period from the time these transmitters are identified until such
time that these transmitters can be replaced.
Reporting Requirements:
Operating Reactors
1. Provide, within 120 days after receipt of this bulletin, a response
that:
a) Confirms that Items 1, 2, 3, 4, and 5 of Requested Actions for
Operating Reactors have been completed.
b) Identifies the indicated manufacturer; the model number; the
system the transmitter was utilized in; the approximate amount of
time at pressure; the corrective actions taken; and the
disposition (e.g., returned to vendor for analysis) of Rosemount
Model 1153 Series B, Model 1153 Series D, and Model 1154
transmitters that are believed to have exhibited symptoms
indicative of loss of fill-oil or have been confirmed to have
experienced a loss of fill-oil. This should include Model 1153
Series B, Model 1153 Series D and Model 1154 transmitters
manufactured after July 11, 1989.
c) Identifies the system in which the Model 1153 Series B, 1153
Series D, and Model 1154 transmitters from the manufacturing
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Page 9 of 11
lots that have been identified by Rosemount as having a high
failure fraction due to loss of fill-oil are utilized and provides
a schedule for replacement of these transmitters which are in use
in the reactor protection or engineered safety features actuation
systems.
2. Model 1153 Series B, Model 1153 Series D and Model 1154 transmitters
that, subsequent to providing the response required by Item 1 above,
exhibit symptoms of loss of fill-oil or are confirmed to have
experienced a loss of fill-oil should be reviewed for reportability
under existing NRC regulations. If determined not to be reportable,
addressees are requested to document and maintain, in accordance with
existing plant procedures, information consistent with that requested
in Item 1 b) above for each transmitter identified.
Although not required by this bulletin, addressees are encouraged to report
information consistent with that requested in Item 1 b) above through the
Nuclear Plant Reliability Data System (NPRDS) for all Rosemount Model 1151,
1152, 1153 and 1154 transmitters that exhibit symptoms indicative of a loss
of fill-oil or are confirmed to have experienced a loss of fill-oil.
Construction Permit Holders
1. All holders of construction permits that anticipate receiving an
operating license within 120 days after receipt of this bulletin are
required to, within 120 days after receipt of this bulletin, provide a
response that:
a) Confirms that Items 1, 2, 4, and 5 of Requested Actions for
Operating Reactors have been completed; and
b) Identifies the system in which the Model 1153 Series B, 1153
Series D, and Model 1154 transmitters from the manufacturing lots
that have been identified by Rosemount as having a high failure
fraction due to loss of fill-oil are utilized and provides a
schedule for replacement of these transmitters which are in use in
the reactor protection or engineered safety features actuation
systems.
2. All holders of construction permits that do not anticipate receiving an
operating license within 120 days after receipt of this bulletin are
required to, prior to the date scheduled for fuel loading, provide a
response that confirms that Item 2 of Requested Actions for
Construction Permit Holders has been completed.
3. Model 1153 Series B, Model 1153 Series D and Model 1154 transmitters
that, subsequent to providing the response required by Item 1 or 2
above, exhibit symptoms of loss of fill-oil or are confirmed to have
experienced a loss of fill-oil should be reviewed for reportability
under existing NRC regulations. If determined not to be reportable,
addressees are requested to document
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and maintain, in accordance with existing plant procedures, information
consistent with that requested in Item 1 b) of the Reporting
Requirements for Operating Reactors above for each transmitter
identified.
Although not required by this bulletin, addressees are encouraged to report
information consistent with that requested in Item 1 b) of the Reporting
Requirement for Operating Reactors through the NPRDS for all Rosemount Model
1151, 1152, 1153 and 1154 transmitters that exhibit symptoms indicative of
loss of fill-oil or are confirmed to have experienced a loss of fill-oil.
As has been previously indicated, the NRC staff believes that the
methodology utilized by Rosemount to support their proposed pressure versus
time-in-service criteria for identifying which transmitters should be
subject to an enhanced surveillance program does not provide the necessary
high degree of confidence that this failure mode will not occur. Additional
operational experience data, such as that to be generated in response to
this bulletin, could be utilized by industry either to provide additional
insight as to the appropriateness of Rosemount's pressure versus
time-in-service criteria or to develop bases for staff con-sideration of an
amendment to or termination of the actions requested by this bulletin.
Accordingly, the NRC staff encourages utilities to work collectively under
the guidance of a technical industry organization to develop an operational
experience database concerning all models of Rosemount transmitters.
The written reports required above shall be addressed to the U.S. Nuclear
Regulatory Commission, ATTN: Document Control Desk, Washington, D.C.
20555, and shall be submitted under oath or affirmation pursuant to the
provisions of Section 182a, Atomic Energy Act of 1954, as amended and
10 CFR 50.54(f). In addition, a copy shall be submitted to the appropriate
Regional Administrator.
Backfit Discussion
The objective of the actions requested in this bulletin is to ensure that
transmitter failures due to loss of fill-oil are promptly detected. Loss of
fill-oil may result in a transmitter not performing its intended safety
function.
The actions requested in this bulletin represent new staff positions and
thus, this request is considered a backfit in accordance with NRC
procedures. Because established regulatory requirements exist but were not
satisfied, this backfit is to bring facilities into compliance with existing
requirements. Therefore, a full backfit analysis was not performed. An
evaluation of the type discussed in 10 CFR 50.109(a)(6) was performed,
including a statement of the objectives of and reasons for the actions
requested and the basis for invoking the compliance exception. It will be
made available in the Public Document Room with the minutes of the 179th
meeting of the Committee to Review Generic Requirements.
This request is covered by Office of Management and Budget Clearance Number
3150-0011 which expires January 31, 1991. The estimated average burden
hours are 6 person-hours per transmitter per licensee. This includes
assessing the requested actions, gathering and reviewing plant records,
analyzing the data
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obtained from the plant records, and preparing the required response. This
does not include developing and implementing the requested enhanced
surveillance program or replacing transmitters from the manufacturing lots
that have been identified by Rosemount as having a high failure fraction due
to loss of fill-oil that are utilized in the reactor protection or
engineered safety features actuation systems. Send comments regarding this
burden estimate or any other aspect of this collection of information,
including suggestions for reducing this burden, to the Information and
Records Management Branch, Division of Information Support Services, Office
of Information Resources Management, U.S. Nuclear Regulatory Commission,
Washington, D.C. 20555; and to the Paperwork Reduction Project (3150-0011),
Office of Management and Budget, Washington, D.C. 20503.
If you have any questions about this matter, please contact one of the
technical contacts listed below or the appropriate NRR project manager.
Charles E. Rossi, Director
Division of Operational Events Assessment
Office of Nuclear Reactor Regulation
Technical Contacts: Jack Ramsey, NRR
(301) 492-1167
Vince Thomas, NRR
(301) 492-0786
References:
1. Rosemount Technical Bulletin No. 1 dated May 10, 1989
2. Rosemount Technical Bulletin No. 2 dated July 12, 1989
3. Rosemount Technical Bulletin No. 3 dated October 23, 1989
4. Rosemount Technical Bulletin No. 4 dated December 22, 1989
Attachments:
1. Typical Physical Characteristics of a Rosemount Transmitter
2. List of Recently Issued NRC Bulletins
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Attachment 1
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March 9, 1990
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TYPICAL PHYSICAL CHARACTERISTICS OF A ROSEMOUNT TRANSMITTER
(Figure can not be transmitted electronically)
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