ML20246P960
| ML20246P960 | |
| Person / Time | |
|---|---|
| Site: | Millstone, Haddam Neck, 05000000 |
| Issue date: | 05/10/1989 |
| From: | Berlinger C Office of Nuclear Reactor Regulation |
| To: | Rossi C Office of Nuclear Reactor Regulation |
| Shared Package | |
| ML20246P965 | List: |
| References | |
| REF-PT21-89 IEIN-89-042, IEIN-89-42, NUDOCS 8905220319 | |
| Download: ML20246P960 (23) | |
Text
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pa ucg*1 UNITED STATES 43
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NUCLEAR REGULATORY COMMISSION j
WASHINGTON, D. C. 20S55 5
s May 10, 1989 i
MEMORANDUM FOR:
Charles E. Rossi, Director Division of Operational Events Assessment Office of Nuclear Reactor Regulation FROM:
Carl H. Berlinger, Chief Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation
SUBJECT:
MEETING WITH ROSEM0UNT AND INDUSTRY REGARDING MALFUNCTIONS OF ROSEMOUNT TRANSMITTERS The Generic Communications Branch (0GCB), with the support of the Vendor Inspection Branch (VIB) and the Instrumentation and Control Systems Branch (SICB), sponsored a meeting on April 13, 1989, between NRC, Rosemount, Incorpo-rated, and several industry groups to discuss the recent malfunctions of Rosemount models 1153 and 1154 transmitters and industry actions to address the issue. A listing of meeting attendees and the meeting agenda are provided in Enclosures 1 and 2 respectively.
NRC Information Notice 89-42, " Failure of Rosemount Model 1153 and 1154 Transmitters," dated April 21,1989, which incorporates some of the information provided at the meeting, is provided as.
Summarized herein are the minutes of the April 13, 1989, meeting.
At the meeting, I presented the NRC's perspective on the issue and I stated that the main purpose of the meeting was to provide the NRC staff with the available information regarding the transmitter failures and allow the NRC to better assess the safety significance and generic implications of these mal-functions at nuclear power plants.
The Rosemount representatives, Mr. Steve Wanek, Vice President, Operations, Ms.
Jane Sandstrom, Marketing Manager, and Mr. Terry Krouth, consultant, presented a brief history of the transmitter malfunctions and a summary of the ongoing Rosemount program to address the issue. provides the slides presented by Rosemount during their presentation. Rcsemount stated that 78 transmitters have been confirmed as having failed due to a loss of fluid from the transmitter sensing module; an additional 11 failures have been reported but they have not yet been confirmed. Rosemount added that according to the failure data, most of the transmitters have failed within the first 30 months of service; therefore, they believe that transmitters that have been in service
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Charles E.-Rossi ' for over 36 montos are not likely to malfunction due to this phenomena.
However, it was pointed out that this conclusion was inexact because it was based on failure data derived from calibration and refueling outage dates and not'from the actual time in service.
Rosemount believes that the defective transmitters are currently limited to approximately 20 suspect manufacturing lots (referred to as weld lots by Rosemount), or a total of 1,004 transmitters, out of a total of 14,145 model 1153 and 1154 transmitters that were shipped.
Rosemount stated that it hd notified its customers of the potential for transmitter failure and had gecif-ically recommended to all customers who purchased transmitters from the suspect lots to identify the location of the suspect transmitters and determine the effects of reduced performance.
Specific manufacturing lots were identified by Rosemount as suspect if a transmitter from that lot failed because of the loss of fill fluid; therefore, Rosemount stated that if additional failures from other lots are ccnfirmed, the number of suspect lots will be expanded and the respective customers will be informed.
Mr. Terry Krouth,'a Rosemount consultant, discussed the design of the model 1153 and 1154 transmitters and the manufacturing processes used to produce the sensing module. Mr. Krcuth explained that the fill fluid has been found to be leaking at the glass to metal seal located around the sensing cavity where the fill fluid is located. Mr. Krouth stated that leakage occurs within the transmitter internals and is not externally visible.
In addition, oil has not
. been observed to have leaked into the process fluid.
Variations in the manu-facturing processes and the use of a metal 0-ring are possible contributors to a weak glass to metal seal that allows a transmitter to leak oil.
Rosemount added that the metal 0-ring was used in model 1153 and 1154 transmitters in j
order to meet environmental qualification standards for nuclear power plants.
.. The Rosemount representatives stated that they had launched a full scale analysis program to address these failures. This program includes analysis of the failure mechanism, glassing controls, manufacturing methods, and various methods to improve the process controls.
Rosemount has designed and is l
presently testing special apparatuses to determine transmitter performance as a function.of variable oil volumes and process fluid pressures.
Rosemount stated that the test program is expected to be completed within the next three to six months at which time they will provide their customers specific recommendations for addressing potentially defective transmitters.
Mr. Fred Sear's, Vice President, Northeast Utilities (NU), presented a brief summary of the Rosemount transmitter failures at Millstone, Unit 3, and some of the actions taken by NU to address the problem. provides informa-tion.that was submitted to the NRC by NU, some of which was presented by Mr.
Sears during the meeting.
Mr. Sears stated that in 1986 and 1987 Millstone experienced a total of five failures of model 1153 transmitters in safety-related applications and one failure in a non-safety-related application.
Millstone personnel attempted to calibrate the failed transmitters but were unsuccessful; consequently, the transmitters were replaced. The failed transmitters were returned to Rosemount l
and destructive testing revealed that the failures were attributed to the loss
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May 10, 1989 4
o Charles E. Rossi l' of fill oil. As a corrective action, Millstone personnel replaced all failed transmitters and increased the response time testing requirements for all model l
1153 transmitters to preclude operation with any failed transmitters. Although the 1986 and 1987 transmitter failures were considered random at the time, NU made a 10 CFR Part 21 notification to the NRC in March 1988.
According to Mr. Sears, the Electric Power Research Institute (EPRI) initiated a program in mid-1988 to reduce response time testing requirements for pressure transmitters.
EPRI became aware of the Millstone transmitter failures and requested to review the NU information regarding the failures.
The information reviewed included data gathered by NU using their Off-Site Information System (0FIS), a computer system that continuously records discrete plant data at intervals of approximately 30 seconds. This data revealed that the failed transmitters exhibited certain symptoms prior to being detected.
These symp-toms included "one sided" or " clipped" responses to random noise, slow drift in one direction of 1/4 percent or more per month, reduced noise sensitivity level, slow transient response, inability to respond over its entire range, and deviation of one channel from redundant channels.
It was during the review of this information that NU fully realized the significance of the failures.
Mr. Sears stated that as a result of the Millstone experience, NU has had numerous interactions with EPRI, Rosemount, NRC, Nuclear Management Resources Council (NUMARC), and various other industry representative in order to provide a better understanding of the issue and to develop a possible resolution.
Mr. Paul Blanch, Supervisor, I&C Special Programs and Studie';, NU, presented additional information regarding the Millstone experience with Rosemount transmitters and also presented some personal views en the matter.
provides the slides presented by Mr. Blanch during the meeting. Mr. Blanch reiterated some of the historical information provided by Mr. Sears, including the real time symptoms and calibration symptoms observed by Millstone person-nel. Mr. Blanch also explained NU's approach to identify and address poten-tially defective transmitters that included an indepth investigation of all Rosemount 1153 and 1154 transmitters in safety-related applications, full range exercising of all safety-related transmitters, and waekly observations of 0FIS time history data to look for symptoms of possible transmitter failures.
Mr. Blanch stated that during his investigation of the failures he had made the following observations:
the onset of a transmitter failure is difficult to detect, the probability of failure decreases with time in service, the rate of degradation is less than 2 percent of capsule range per month, the probability of two or more simultaneous failures in redundant channels is small, the pressure transmitters appear to fail in one direction, and the time from failure to detection can be 1 to 12 months and is influenced by the oil leak rate, the capsule range and calibrated span, functional setpoint, and static operating pressure.
Mr. Blanch emphasized the need for the industry to evaluate the potential safety significance of the failures and to develop short and long term guide-lines for the use of existing installed Rosemount transmitters. According to Mr. Blanch, this evaluation should consider time history data and current calibration procedures.
In addition, Mr. Blanch stated that the industry
% _ Charles E. Rossi
-4Y should consider addressing the following items: confirming the infant mortali-ty postulation, quantifying failure rates and probabilities, reviewing risk assessment associated with failure modes, quantifying the degradation rate, and developing incipient failure detection methods.
Mr. Bill Raisin, Director, Technical Division, NUMARC, stated that his organ-ization had facilitated the initial information exchange between NU, Rosemount, and various industry groups.
In addition, NUMARC made sure that the industry was informed of the issue and that Rosemount was providing applicable recommen-dations to its customers. Mr. Raisin added that NUMARC had met with the various owners groups representatives on April 12, 1989, and that the owners group had stated that they were not currently considering any specific actions since. they felt the industry had been properly apprised of the issue and that the individual utilities needed to address the significance of the issue at their respective plants.
The NRC and Rosemount will continue to address the issue and keep the industry informed as additional information becomes available.
Rosemount plans to provide an interim report to the industry in early May 1989 delineating the status of their test program. Rosemount anticipates completing its test program and providing final recommendations to the industry within six months from the date of the meeting.
Original SW e Carl H.hrW Carl H. Berlinger, Chief Generic Communications Branch Division of Operational Events Assessment Office of Nuclear Reactor Regulation
Enclosures:
1.
Meeting Attendees 2.
Meeting Agenda 3.
NRC Information Notice No. 89-42 4.
Slides Presented by Rosemount 5.
Information Submitted by NU 6.
Slides Presented by P. Blanch cc:
Steve Wanek, Rosemount Fred Sears, Northeast Utilities Paul Blanch, Norhteast Utilities Bill Raisin, NUMARC Joe Weiss, EPRI Kent Petersen, Analysis and Measurement Services Corporation DISTRIBUTION w/ enclosures CERossi, NRR CHBerlinger., NRR JGuillen, NRR WDLanning, NRR BKGrimes, NRR SNewberry, NRR VThomas, NRR BBrach, NRR KNa..idu, NRR BRaymond, RI PDR
. Central Filesi DCS DOEA R/F
' OGCB R/F JGuillen R/F
- Comme s were provided by V. Th S'CB, and R. Wilson, VIB, to J. Guillen OGC C/0GCB:00EA:NRR JGu CHBerlinger 05/f/89 05/
Enclos'ure i f
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MEETING PARTICIPANTS Charles E..Rossi, NRC/NRR Carl H. Berlinger, NRC/NRR Scott Newberry, NRC/NRR Bill Brach, NRC/NRR.
Jaime Guillen, NRC/NRR Vincent Thomas, NRC/NRR Fred Paulitz, NRC/MRR Kamal Naidu, NRC/NRR George Hubbard..HRC/NRR.
Prasad Kadambi, NRC/NRR Roby.Bevan, NRC/NRR Edwin Lea, NRC/NRR Jay McGurren, NRC/0GC Richard Wilson, NRC/NRR
' Bill Farmer,' NRC/RES Subinoy Mazumdar NRC/AEOD Steve Wanek, Rosemount Jane Sandstrom, Rosemount Jeffrey W. Schmitt, Rosemount Bob Kodiman, Rosemount Terry Krouth, Consultant-Rosemount Fred Sears, NU Paul Blanch, NU 1
Robert McGuinness,-NU Arnold Roby, NU Jay Ely, NU G. Leonard Johnson, NU Bill Raisin, NUMARC.
Alex Marion, NUMARC' Russell Bell, NUMARC-Joe Weiss, EPRI ~
Ted Marstim, EPRI Richard'Szoch, BG&E Jim Pfeifer, CE Adam Geesey, INPO Bill Horin, Bishop Cook J. H. Taylor, B&W Danialle Weaver, McGraw Hill Roger L. Johnson, PG&E' R. B. Borsum, B&W Jack Carey, PSE&G Dick Beckwith, PSE&G John Thompson, PSE&G Bob Mitchell, GE Ronald Rogers, TVA Richard Brehm, TVA Stephanie Sharron, Bechtel Kent Petersen, A&M Services
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Enclosure I a - _ - _ ___ - _ _-_ -_ __-_ _ __--- ___- _ ___. _ _ _ - _ _ _ _ - _ _ _ _ - _ _ _ _ _ - _ _ _ _ _ - -
May 10, 1989 e i-MEETING ON ROSEMOUNT TRANSMITTERS APRIL 13, 1989 9:00 A.M.
INTRODUCTION:
CARL H. BERLINGER, NRC 9:IS A.M.
OVERVIEW 0F TRANSMITTER MALFUNCTIONS, SYMPTOMS, AND CAUSES; DETAILS OF TEST PROGRAM BEING CONDUCTED BY ROSEMOUNT; PROPOSED RECOMMENDATIONS FOR MONITORING AND IDENTIFYING POTENTIALLY DEFECTIVE TRANSMITTERS:
STEVE WANEK, ROSEMOUNT
'10:15 A.M.
INFORMATION REGARDING TRANSMITTER MALFUNCTIONS AT MILLSTONE:
FRED SEARS, NORTHEAST UTILITIES 11:15 A.M.
OVERVIEW 0F EPRI PROGRAM ON ROSEM0UNT TRANSMITTERS:
JOE WEISS, EPRI 11:30 A.M.
NUMARC PERSPECTIVE ON ISSUE AND GENERAL INDUSTRY ACTIONS:
(TFitTATIVE)
ALEX MARION, NUMARC 11:45 A.M.
0WNERS GROUPS PERSVfTIVE ON ISSUE; ACTIONS BEING TAKEN TO (TENTATIVE)
ADDRESS ISSUE; PROPOSED RECOMMENDATIONS FOR MONITORING AND IDENTIFYING POTENTIALLY DEFECTIVE TRANSMITTERS:
GE OWNERS GROUP WESTINGHOUSE OWNERS GROUP B&W OWNERS GROUP CE OWNERS GROUP 12:45 P.M.
DISCUSSION OF SHORT-TERM AND LONG-TERM ACTIONS TO ADDRESS ISSUE; APPROPRIATE ACTIONS AND SCHEDULE:
MEETING PARTICIPANTS 1:45 P.M.
CLOSING COMMENTS CARL H. BERLINGER, NRC
osme.3 f,3 May 10, 1989 w
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UNITED STATES NUCLEAR REGULATORY COMMISSION OFFICE OF NUCLEAR REACTOR REGULATION L
WASHINGTON, D.C.
20555 April 21,1989 E
NRC INFORMATION NOTICE NO. 89-42: FAILURE OF ROSEMOUNT MODELS 1153 AND 1154 TRANSMITTERS 1
Addressees:
All holders of operating' licenses or' construction pemits for nuclear power reactcrs.
Purpose:
This information notice is being provided to alert addressees about recent
-failures of.Rosemount models 1153 and 1154 pressure and differential pressure transmitters.
It is expected that recipients will review the information for applicability to their. facilities and consider actions, as a)propriate, to avoid similar problems. However, suggestions contained in t11s infomation notice do not constitute NRC requirements; therefore, no specific action or written response is required.
Description of Circumstances:
During 1986 and 1987, five Rosemount model 1153 HD5PC differential pressure transmitters malfunctioned at Northeast Utilities' (NU) Millstone Nuclear Power Station, Unit 3.
During power operation, the Killstone operators noted that the signals from the Rosemount 1153 transmitters were deviating from redundant channel signals and that the transmitters were indicating reduced levels of process noise. The transmitters were declared out of service by NU personnel, and the affected channels were placed in the tripped condition.
After attempts to calibrate the transmitters failed, NU returned the trans-mitters to Rosemount and informed them that the malfunctions had occurred with transmitters of the same model and related serial numbers. Destructive testing' performed by Rosemount determined that the failures were caused by the loss of oil from the transmitter's sealed sensing module.
However, Rosemount indicated that the failures appeared to be random and.not related.to any generic problem with Rosemount 1153 pressure transmitters. NU submitted a 10 CFR Part 21 notification to the NRC on this issue on March 25, 1988, and provided additional information on the failures via a letter dated April 13, 1989.
Discussion:
After additional evaluations by NU and Rosemount, Rosemount issued a letter to its customers on December 12, 1968, regarding the potential malfunction of models 1153 and 1154 pressure and differential pressure transmitters. The I
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IN 89-42 April 21, 1989-Page 2 of 3 1
Rosemcunt letter was supplemented with a letter dated February.7,1989, to i
customers who had purchased transmitters from specific lots that were identi-fied by Rosemount as being potentially defective. Rosemount issued a separate letter dated February 16, 1989, to customers who had purchased model 1153 and 1154 transmitters from lots that were not considered suspect. Rosemount indi-cated that transmitters from the suspect lots were susceptible to a loss of silicone oil from the transmitter sealed sensing module and to possible fail-ure. -According to Rosemount, as the oil leaks out of the sensing module the transmitter's performance gradually deteriorates and may eventually lead to a detectable failure..
Some of the symptoms that have been observed during operation and before failure include. slow drift in either direction of about 1/4 percent or more per month, lack of response over the transmitter's full range, increase in the transmitter's time response, deviation from the nomal signal fluctuations, decrease in the detectable noise level, deviation of signals from one channel compared with redundant channels, "one sided" signal noise, and slow response to a transient or inability to follow a transient.
Some of the symptoms observed by NU personnel during calibration include the inability to respond
,over the transmitter's entire range, slow response to either increasing or decreasing hydraulic test pressure, and drift of greater than 1% from the p'revious calibration.
Although some of the defective transmitters have shown certain symptoms before their failure, it has been reported that in some cases the failure of a trans-I mitter may not be detectable during operation.
In addition, Rosemount now indicates that the potential for malfunction may not be limited to the spect-fied manufacturing lots previously identiftmi in the February 1989 letter.
It is-important for addressees to determine whether any Rosemount models 1153 and 1154 pressure and differential pressure transmitters, regardless of their
-. manufacturing date, are installed in their facilities and to take whatever actions are deemed necessary to ensure that any potential failures of these transmitters are identified. Although it may not be possible to detect the onset of failure in all instances, some transmitters have exhibited sone of the aforementioned symptoms before failure.
It is important for potential failure modes to be identified and that operators be prepared for handling potential malfunctions.
In addition, careful examination of plant data, l
calibration records, and operating experience may yield clues that identify potentially defective transmitters. Addressees may wish to contact Rosemount for assistance in determining appropriate corrective actions whenever any of the aforementioned symptoms are observed or if failures are identified.
On April 13, 1989, the NRC staff met and discussed this matter with Rosemount and several industry groups.
Rosemount has launched a program to identify the root cause of the loss of oil from the sensing module and to determine recom-mendations for its customers to address potentially defective transmitters.
h-_m____._______.____.___.______
g-IN 89-42 April 21, 1989
+
Page 3 of 3 No specific action or written response is required by this information notice.
If you have any questions regarding this matter, please contact one of the technical contacts listed below or the' Regional Administrator of the appro-priate regional office.
arle Division of Operational Events Assessment Office of Nuclear Reactor Regulation Technical Contacts:
Kamal Naidu, NRR (301)492-0980 0
-1 b
reattachment: List of Recently Issued NRC Information Notices
6 Attachment IN 89-42 April 21, 1989 Page 1 of 1 LIS'i 0F RECENTLY ISSUED NRC INFORMATION NOTICES Information Date of Notice No.
Subject Issuance Issued to 89-41 Operator Response to 4/20/89 All holders of OLs Pressurization of Low-or cps for nuclear Pressure Interfacing power reactors.
Systems 88-75, Disabling of Diesel 4/17/89 All holders of OLs Supplement 1 Generator Output Circuit or cps for nuclear Breakers by Anti-Pump power reactors.
Circuitry 89-40 Unsatisfactory Operator Test 4/14/S9 All holders of OLs Results and Their Effect on or cps for nuclear the Requalification Program power reactors.
89-39 List of Parties Excluded 4/5/89 All holders of OLs from Federal Procurement or cps for nuclear or Non-Procurement Programs power reactors.
89-38 Atmospheric Dump Valve 4/5/89 All holders of OLs Failures at Palo Verde or cps for nuclear Units 1, 2 and 3 power reactors.
89-37 Proposed Amendments to 4/4/89 All U.S. NRC licensces.
40 CFR Part 61, Air Emission Standards for Radionuclides j
'89-36 Excessive Temperatures 4/4/89 All holders of OLs in Emergency Core Cooling or cps for nuclear System Piping Located power reactors.
Outside Containment 88-86, Operating with Multiple 3/31/89 All holders of OLs Supp. 1 Grounds in Direct Current or cps for nuclear Distribution Systems power reactors.
89-35 Loss and Theft of Un-3/30/89 All U.S. NRC byproduct, secured Licensed Material source and special nuclear material licensees, j
OL = Operating License CP = Construction Pernit i
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ROSEMOUNT INCORPORATED i
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.4-Rosemount Inc Presentation April 13, 1989 NRC Meeting
-Rockville, MD Attached are copies of the 10 overheads used as visual aids by Rosemount during our presentation at the April 13, 1989 NRC meeting.
'Rosemount wants you to understand that while these visual aids are factual and accurate to the best of our current knowledge, they are not complete without the accompanying verbal discussion provided during the presentation.
The overheads, by themselves and without the associated verbal information, may result in inappropriate conclusions.
Please direct any questions regarding this information to Steve Wanek, Rosemount Inc.,
(612) 828-3674.
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APRIL 13,1989 HISTORICAL-VIEW OF THE 1153/54 FAILURES NUMBER OF UNITS SHIPPED REPORTED FIELD FAILURES ESTIMATE OF TIME ~lN SERVICE MECHANICS OF THE LOSS OF FILL FLUl3 IN TRANSMITTERS INTRODUCTION TO THE STRUCTURE GEOMETRY.
STRUCTURAL ANALYSIS AND STRAIN MEASUREMENTS DEFLECTION ANALYSIS UNDER LOAD COMPRESS!ON LOADING OF GLASS AND GLASS / METAL BOND CONTINUING PROJECT WORK FAILURE MECHANISM ANALYSIS IMPROVED PROCESS CONTROL BEHAVIOR & DIAGNOSTICS OF IN-SERVICE TRANSMITTERS i
VARIABLE OIL VOLUME FREQUENCY RESPONSE EXPERIMENTS TIME CONSTANT DECAY FIELD DETECTABLE TRANSMITTER PERFORMANCE This visual aid is one of ten used to support a verbal presentation.
interpretations of one or more of the overheads without the accompanying verbal discussion may lead to inappropriate conclusions.
Please direct any questions regarding this information to Rosemount Inc;
- Stevo Wanek (612)'828-3674.
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,"!F1T2PATRICC..1153085 410050 1053036 NINE MILE 1153DB5' 416253 1493131 Y
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4 DIABLO CAN 11540P4 419006 1792289
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,.This; visual aid'is one of ten used to support a verbal presentation.
Interpretations of one or more of the overheads without the accompanying verbal discussion may. lead to inappropriate conclusions.
o iPlease..' direct any; questions regarding this information to Rosemount Inc; h
iSteve Wanek (612) 828-3674.
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i OIL LEAKAGE FIELD FAILURE RETURNS TOTAL 78 FAILURES NO CONFIRMED FAILURES OF MODEL 1152 TOTAL MODEL 1153'S AND 1154'S SHIPPED,14,145 1
ONLY TWO FAILURES ON UNITS MANUFACTURED AFTER AUGUST 1986.
This visual aid is one of ten used to support a verbal presentation.
Interpretations of one or more of the overheads without the accompanying verbal discussion may lead to inappropriate conclusions.
Plcase direct any questions regarding this information to Rosemount Inc; StGve Wanek-(612) 828-3674.
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