ML20244D586
| ML20244D586 | |
| Person / Time | |
|---|---|
| Issue date: | 06/01/1989 |
| From: | Ramsey J Office of Nuclear Reactor Regulation |
| To: | Berlinger C Office of Nuclear Reactor Regulation |
| References | |
| REF-QA-99900271 NUDOCS 8906190153 | |
| Download: ML20244D586 (10) | |
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UNITED STAT Es 1.
NUCLEAR REGULATORY COMMISSION j,I 'A y
WASWNGTON, D. C. 20555 e
June 1,
1989 MEMORANDUM FOR:
Carl H. Berlinger, Chief Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation FROM:
Jaime Guillen Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation l
John Ramsey l
Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation
SUBJECT:
TRIP REPORT - ROSEMOUNT, INCORPORATED On May 18, 1989, we accompanied Mr. Kamalakar Naidu of NRR's Vendor Inspection
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Branch to Rosemount, Incorporated in Eden Prairie, Minnesota. The purpose of i
the trip was to observe the manufacture of sensing modules used in Rosemount j
pressure measurement instruments, including models 1153 and 1154 pressure transmitters, and to discuss the status of the Rosemount testing program to address the loss of fill oil issue affecting some of these sensing modules. A l
synopsis of events that led to the visit and some of the items discussed with i
Rosemount personnel during our meeting are provided below.
l Rosemount initially advised the nuclear industry in December 1988 that a small l
number of 1153 and 1154 pressure transmitters had malfunctioned over the past j
few years due to a loss of oil from the sensing module.
In February 1989, Rosemount informed specific customers that transmitters from certain lots had been identified by Rosemount as being susceptible to a loss of oil from the j
sensing module and were potentially defective. On April 13, 1989, the NRC staff met and discussed this matter with Rosemount and several industry groups.
At that meeting, Rosemount stated that they had launched a program to identify the root cause of the loss of oil and to determine recommendations for its customers to address potentially defective transmitters.
In addition, Rosemount stated that changes had been made in the manufacturing process and l
that these changes had minimized variations in the nianufacture. of sensing CONTACTS: Jaime Guillen, NRR 492-1170
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John Ramsey, NRR 492-1167 go
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June 1,
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, Carl H. Berlinger module lots. On May 10, 1989, Rosemount issued a technical bulletin to the nuclear industry to provide additional technical information and to inform the industry of the status of the test program.
]
During our visit to Rosemount, we met with Steve Wanek, V.P. Operations, Michael Hoffman, Specialty Operations Manager, Gerald Andersen, Quality Assur-I ance Supervisor, and Jane Sandstrom, Marketing Manager. Mr. Wanek informed us
']
that his group had been reorganized and that a Speciality Operations Group had I
been formed to handle all orders for the nuclear industry.
The Specialty j
Operations Manager reports directly to Mr. Wanek and his group receives additional support from other groups as needed.
Mr. Wanek escorted us through the Rosemount Eden Prairie facilities where we observed the manufacture of sensing modules for Rosemount pressure measurement instruments. The manufacture of sensing modules begins with the cutting of stainless steel bar stock into segments that are machined into sensing cups.
The sensing cups are then polished and ultrasonically cleaned to remove impuri-l ties.
Next, a ceramic tube is added to create a small passage way from'one side of the cup to the other. The sensing cups are then filled with lead glass pellets and run through a furnace where the glass melts around the ceramic tube and bonds-to the sensing cup. A sensing cell is created by placing a sensing diaphragm between two sensing cups that are arranged with the glass sides facing each other.
Next, an isolating diaphragm is placed on each outer side of the sensing cell and the assembly is welded together.
This arrangement allows small cavities to form on either side of the center sensing diaphragm as j
well as on the inside of each isolating diaphragm with the ceramic tube acting as a path between the center and isolating diaphragms (see Figure 1). After the modules are welded together, the cavities are filled with silicone oil through two fill tubes that are inserted before the sensing cups are run through the furnace. After the oil is added, the fill tubes are crimped and l
used as lead wires.
These sensing modules are the basic component in various pressure measurement devices manufactured by Rosemount.
For the models 1153 and 1154 pressure transmitters, process flanges are placed around the sensing modules to form a sensing module assembly. Next, an electronics housing is mounted on the l
sensing module assembly and the sensing module lead wires are connected to the l
circuit boards (see Figure 2).
During the tour of the manufacturing facilities, Mr. Wanek pointed out some of the manufacturing changes Rosemount had made in the last several years.
Most of the changes involved automating some tasks previously performed manually and replacing existing machinery with state of the art equipment.
Specific changes included automating the grinding process, upgrading some welding techniques, dnd improving the furnace Controls and indications.
Rosemount indicated that these changes have eliminated significant variations in the manufacture of sensing cell lots and decreased the total number of cells that are rejected because they do not meet Rosemount quality standards.
Mr. Wanek and other Rosemount personnel demonstrated some of the test equipment developed.by Rosemount to evaluate the loss of oil issue.
In addition, we observed some of the testing and analyses being performed to provide more
y June'i, 1989 1
c 1
1 Carl H. Berlinger.
d comprehensive diagnostic and monitoring methods for potentially defective transmitters. The Rosemount testing program includes frequency response analysis, long term pressure. testing to determine leak rates,_and continued I
characterf ration of the failure mode to determine simple monitoring techniques (including testing' for different pressure ranges).
We also observed the Rosemount procedures for processing transmitters that are returned by customers and for determining whether a transmitter has malfunc-j tioned due to a loss.of oil.
Before destructively examining the transmitter, I
I the procedures require reviewing the performance information provided by the' i
customer, performing complete calibration checks, checking the electronics, I.
measuring the transmitter's response time, and measuring oil level.. Next, the sensing module assembly weld rings are removed and the internals are. visually examined for oil and the welds and fill tubes are microscopically inspected.
The cell halves are then separated and machined in order to determine the exact leak path. Once the leak path is identified and the examination is completed, the results are documented and forwarded to engineering and other. groups.
During our final discussions with Rosemount, we emphasized the importance of' maintaining their customers informed of the Rosemount efforts and test program results. Mr. Wanek indicated that Rosemount will' continue to provide technical bulletins to their customers as soon as additional information is available.
I Rosemount expects to issue the next technical bulletin within the next several weeks. Mr. Wanek also indicated that their technical analysis and product improvement efforts will continue to ensure thet the loss of oil issue'is fully addressed and resolved.
/sl Jaime Guillen l
Generic Communications Branch l
Division of Operational Events Assessment Office of Nuclear Reactor Regulation 1
kl l
John Ramsey Generic Communications Branch Division of Operational Events Assessment
Enclosures:
Office of Nuclear Reactor Regulation As stated DISTRIBUTION e/ enclosures JHSniezek, NRR CERossi, NRR JGuillen, NRR JRamsey, NRR WDLanning, NRR
-JACalvo, NRR BBrach, NRR SNewberry, NRR JTaylor, EDO 6CefitFar Files %
PDR DCS DOEA R/F'~""""9 OGCB R/F JGuillen R/F 0'-
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June 1, 1989 MEMORANDUM FOR:
Carl H. Berlinger, Chief Generic Communications Branch bivision of Operational Events Assessment Office of Nuclear Reactor Regulation FROM:
Jaime Guillen Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation John Ramsey Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation
SUBJECT:
TRIP REPORT - ROSEMOUNT, INCORPORATED On May 18, 1989, we accompanied Mr. Kamalakar Naidu of NRR's Vendor Inspection Branch to Rosemount, -Incorporated in Eden Prairie, Minnesota.
The purpose of the trip was to observe the manufacture of sensing modules used in Rosemount pressure measurement instruments, including models 1153 and 1154 pressure transmitters, and to discuss the status of the Rosemount testing program to address the loss of fill oil issue affecting some of these sensing modules. A synopsis of events that led to the visit and 5 se of the items discussed with Rosemount personnel during our meeting are pm'.ded below.
Rosemount initially advised the nuclear industry in December 1988 that a small number of 1153 and 1154 pressure trar:smitters had malfunctioned over the past few years due to a loss of oil from the sensing module.
In February 1989, Rosemount informed specific customers that transmitters from certain lots had been identified by Rosemount as being susceptible to a loss of oil from the sensing module and were potentially defective. On April 13, 1989, the NRC staff met and discussed this matter with Rosemount and several industry groups. At that meeting, Rosemount stated that they had launched a program to identify the root cause of the loss of oil and to determine recommendations for its customers to address potentially defective transmitters.
In addition, Rosemount stated that changes had been made in the manufacturing process and that these changes had minimned variations in the manufacture of sensing l
CONTACTS:
Jaime Guillen, NRR l
492-1170 John Ramsey, NRR 492-1167
r-1 June 1,
1989 q
Carl H. Berlinger I 1
l J
l module lots. On May 10, 1989, Rosemount issued a technical bulletin to the nuclear industry to provide additional technical information and to inform the l
industry of the status of the test program, i
During our visit to Rosemount, we met with Steve Wanek, V.P. Operations, I
Michael Hoffman, Specialty Operations Manager, Gerald Andersen, Quality Assur-ance Supervisor, and Jane Sandstrom, Marketing Manager. Mr. Wanek informed us that his group had been reorganized and that a Speciality Operations Group had been formed to handle all c.- %rs for the nuclear industry. The Specialty Operations Manager reports dL ectly to Mr. Wanek and his group receives 1
additional support from other groups as needed.
l Mr. Wanek escorted us through the Rosemount Eden Prairie facilities where we observed the manufacture of sensing modules for Rosemount pressure measurement instruments. The manufacture of sensing modules begins with the cutting of stainless steel bar stock into segments that are machined irto sensing cups.
The sensing cups are then polished and ultrasonically cleaned to remove impuri-t ties.
Next, a ceramic tube is added to create a small passage way from one side of the cup to the other.
The sensing cups are then filled with lead glass pellets and run through a furnace where the glass melts around the ceramic tube and bonds to the sensing cup.
A sensing cell is created by placing a sensing diaphragm between two sensing cups that are arranged with the glass sides i
facing each other. Next, an isolating diaphragm is placed on each outer side i
of the sensing cell and the assembly is welded toosther. This arrangement allows small cavities to form on either side of the center sensing diaphragm as well.as on the inside.of each isolating diaphragm with the ceramic tube acting as a path between the center and isolating diaphragms (see Figure 1).
After the modules are weldad together, the cavities are filled with silicone oil through two fill tubes that are inserted before the sensing cups are run through the furnace. After the oil is added, the fill tubes are crimped and used as lead wires.
These sensing modules are the basic component in various pressure measurement devices manufactured by Rosemount.
For the models 1153 and 1154 pressure transmitters, process flanges are placed around the sensing modules to form a sensing module assembly.
Next, an electronics housing is mounted on the sensing module assembly and the sensing module lead wires are connected to the circuit boards (see Figure 2).
l l
During the tour of the manufacturing facilities, Mr. Wanek pointed out some of the manufacturing changes Rosemount had made in the last several years. Most of the changes involved automating some tasks previously performed manually and replacing existing machinery with state of the art equipment.
Specific changes included automating the grinding process, upgrading some welding techniques, and improving the furnace controls and indications.
Rosemount indicated that these changes have eliminated significant variations in the manufacture of sensing cell lots and decreased the total number of cells that are rejected because they do not meet Rosemount quality standards.
Mr. Wanek and other Rosemount personnel demonstrated some of the test equipment developed by Rosemount to evaluate the loss of oil issue.
In addition, we observed some of the testing and analyses being performe) to provide more 1
f June 1, 1989 Carl H. Berlingcr comprehensive diagnostic and monitoring methods for potentially defective transmitters. The Rosemount testing program includes frequency response analysis, long term pressure testing to determine leak rates, and continued characterization of the failure mode to determine simple monitoring techniques (including testing for different pressure ranges).
We also observed the Rosemount procedures for processing transmitters that ar; returned by customers and for determining whether a transmitter has malfunc-tioned due to a loss of oil.
Before destructively examining the transmitter, the procedures require reviewing the performance information provided by the customer, performing complete calibration checks, checking the electronics, measuring the transmitter's response time, and measuring oil level. Next, the sensing module assembly weld rings are removed and the internals are visually examined for oil anc the welds and fill tubes are microscopically inspected.
The cell halves are then separated and machined in order to determine the exact leak path.
Once the leak path is identified and the examination is completed, the results are documented and forwarded to engineering and other groups.
During our final discussions with Rosemount, we emphasized the importance of maintaining their customers informed of the Rosemount efforts and test program results.
Mr. Warek indicated that Rosemount will continue to provide technical g
bulletins to their customers as soon as additional information is available.
Rosemount expects to issue the next technical bulletin within the next several weeks. Mr. Wanek also indicated that their technical analysis and product improvement efforts will continue to ensure that the loss of oil issue is fully addressed and resolved.
/s/
Jaime Guillen Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation kl John Ramsey Generic Communications Branch Division of Operational Events Assessment
Enclosures:
Office of Nuclear Reactor Regulation As stated DISTRIBUTION w/ enclosures JHSniezek, NkH CERossi, NRR JGuillen, NRR JRamsey, NRR WDLanning, NRR JACalvo, NRR BBrach, NRR SNewberry, NRR JTaylor, ED0 Central Files PDR
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