ML20094B910
| ML20094B910 | |
| Person / Time | |
|---|---|
| Site: | Oyster Creek |
| Issue date: | 07/30/1984 |
| From: | GENERAL PUBLIC UTILITIES CORP. |
| To: | |
| Shared Package | |
| ML20094B892 | List: |
| References | |
| TASK-03-10.A, TASK-3-10.A, TASK-RR TDR-519, TDR-519-R, TDR-519-R00, NUDOCS 8408070306 | |
| Download: ML20094B910 (33) | |
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- SEP Topic No. III-10A, Thermal-Overload Protection for }iotors -of Motor-0;P,erated Valves -
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.. TDR No. 519 Rev. 0 l
Themal Overload Set Points for Safety Related ! Hotor Operated Valves i Table of Contents
- Se ction Title Page 1.0 Introduction 2 c;
-2.0 References 2 3'. 0 Methods 3 l
4.0 Results - 23 5.0 Conclusions 25 6.0 Reconnendations 25 7.0 Appendices 26 0256M Le J
TDR No. 519
- Rev. O Page 2 of 27
1.0 INTRODUCTION
This study was initiated as a result of the SEP TOPIC III-10-A on themal overicad (TOL) protection of the motor o)erated valves (!!O/) on soiety related systems. A generic met 1od for establishing the TOL set points was developed to satisfy the requirements of Regulatory Guide (RG) 1.106 position C2, i.e., the trip setpoint of the themal overload protection devices should be established with all uncertainties resolved in favor of completing the safety-related action. . This method was based on the factors that influence the sizing and performance of thermal overload relays at the Oyster Creek fbclear Generating Station (OCllGS). A sample calculation was performed for a safety related (SR) motor operated valve at the OCNGS. The results were reviewed and demonstrate compliance with RG 1.106 position C2. 2.0 REFERE NCES: 2.1 Telecon w/Denny Custodio - Plant Engr. OCNGS. - dt: 11/02/83 2.2 Limitorque Valve Actuator Test Reports: - 01 BilR Containment Qualification Report No. 600376A 02 QJtside Containment Qualification Repo:t #B0003 03 DC Actuator Qualification Report No. B0009 04 Limitorque Test Report #F-C3271 " Qualification T9st of Limitorque Valve Actuator in a Steam Environment"
- February 1972. .n 2.3 EDS Report No. 02-0990-1085, July 1981 " Post Accident f Environmental 11apping of the Reactor Bldg".
2.4 Oyster Creek Qualified Equipment Locations and Environments - TDR No. 297 2.5 " Voltage Drop Analysis Study for OCNGS" - Burns & Roe. Inc., DCC File No. #20.3003-4370-ET310 2.6 GE Heaters Selection Guide - GET2G81H 2.7 Limitorque Bulletin Lil-77, Limitorque liotors. 2.8 Limitorque Bulletin FC-77, Fast Closing Valve Operators 2.9 "The Dangers of Bypassing Thermal Overload Relays in fbclear Power. Plant !!otor uperated Valve Circuits." A paper by Farouk Baxter presented at IEEE PES liinter fleeting in New York, Feb. 3-8,.1980. 0256f1
I i TDR No. 519 l
- Rev. O Page 3 of 27 i
2.10 OCNGS - Plant Procedures #610.4.003. 2.11 Field Verification of Operator Motor data for Core S pray Val ve s V-2 0-15, V-20 40. V-2 0-20. V-20-41.TR
#002993 Response - ATMCGARRIGUE to A. Baig dated 3/2/83.
2.12 " Hema Code Letters" - Nema Standards 1101-10.36. 2.13 :0CNGS - thintenance Procedure #700.2.010. ,
3.0 PETHODS
Thermal overload (TOL) relays are current sensitive devices'which, (when properly sized, protect motors against overheating due to
-overloads. The relays operate on a thermal principal in which the heat that causes relay operation is obtained from a TOL " heater" which is in series with the motor winding. When a motor is '
L overloaded, due to locked rotor or running overload condition, it draws more than the rated full load current (FLC) and the " heater"
. develops sufficient thermal enenjy to move the bi-metal strip of the relay and cause its operation. The relay trips and
;de-energizes the holding coil of the motor starter causing the
- opening of the starter main contacts and disconnection of the motor from its power source.
flotor operated valves (MOV) are powered from motor control centers (tCC) which may be located in a different environment than the opera tor. In order to effectively protect the motor winding, TOL
. relays should simulate the operator environment and its heating effect on the motor winding. Section 3.1 lists the Reg. Guide 1.106 requirements for the TOL set points and the uncertainties whid influence their performance. These factors are discussed under Section 3.2 'on a generic basis for OCNGS, and corresponding
. multi) liers are applied.to arrive at the modified values of motor full "oad current (Ig) and the motor locked rotor current
-(ILRC) whis are then used to calculate the proper TOL heater sizes. Section 3.3 establishes the acceptance criteria for the TOL set points. Section 3.4 describes a step ny step generic approach for sizing the TOL heaters at the OCNGS. In Section 3.5 sample calculations are performed for a safety related MOV by applying the generic method of 3.4 and the ' acceptance criteria of Section 3.3.
Requirements of Section 3.1 are then applied to these setpoints to
-see if they meet the Reg. Guide 1.106 position C2 with all
' uncertainties resolved. This is discussed under Section 3.5.
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TDR No. 519
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.3.1 REQUIREMENTS OF REG GUIDE 1.106:
l Position #C2 of Reg Guide 1.106 is applied to arrive at the acceptable setpoints for the TOL relays. Its requirement s i are: 3.l.1 The TOL setpoints shall allow the MOVs to go to the f ully closed or fully ope n position and vice-versa to c omplete their safety function for a saf e shutdown.
-3.1.2 The following uncertainties should be resolved for a cceptance of the TOL set points:
3 .1. 2 .1 Variations in the ambient temperature at the installed location of the overload protection devices and the valve motors. 3 .1. 2 . 2 Inaccuracies in motor heating data and the overload protection device trip
- characteristics and matching of these two items.
3 .1. 2 . 3 Set point drift. 3.2 CRITERIA FOR SIZING THE TOL's: This - sect ion discusses the effect of various factors that influence the sizing and performance of TOL's. Multiplie rs to the nameplate rated motor full load currents are applied to compensate for the affect of these factors. 1
~3.2.1- MOTOR FULL LOAb AMPERES ( MFLA):
Motor nameplate current, rather than the current from NEC tables or any calculated value should be used in 17 sizing the TOL heaters. NEC tables represent only an average value of the motor full load current. 3.2.2' MOTOR SERVICE FACTOR (MSF): A higher than unity (1.0) service factor offers
- . f ollowing inherent' motor design advantages. -
( a) Longer insulation life expectancy when the motor is operated at the nameplate rated standard horsepower (HP), and ambient temperature. .s
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0256M L lll _ -
y TDR No. 519 Rev. O Page 5 of 27 (b) Operation of the motor at higher ambient temperature at the base rated HP with the assurance of full normal insulation life expectancy. (c) Continuous overload capability (e.g.15% more for a 1.15 SF motor) within the motor rated ambient and with normal service factor L insulation life expectancy. (d) A motor with a hi@er than unit service factor can deliver higher than the nameplate rated HP and motor current. The multiplier for adjusting the IFLA is the mtor Service Factor (MSF). At OCNGS, Limitorque operators are used on It0V's. The motors on these operators have a service factor (SF) of 1.0. This means the motor shall be able to provide all the above described design advantages for the duration of the motor duty rated time. If the MOV stroke time is less than the motor duty time, the additional design advantages are due to the inherent motor service factor for which no additional credit is taken. This service factor is given by the following: Duty Rating = inherent service facter Operating Time For a conservative approach the MSF is taken to b e = 1.0 3.2.3 Af1BIENT TEltPERATURE: (AT) The !!0V operator may experience a higher or lower ambient _than its design. To compensate for the affect of this temperature differential the IFLA and motor locked rotor current (ftLRC) to be used in sizing the TOL heaters should be adjusted as follows: (i) Decrease the WLA and itLRC by 5% for every 50C the operator motor ambient exceeds its qualification ambient. (ii) Increase the WLA & IfLRC by 5% for every 5 0C the operator qualification ambient exceeds its accident operating ambient. 0256ft i
e TDR No. 519 Rev. O Page 6 of 2 7 The multiplying f actor ATo in this case = (1+0.01To , where T o is the temperature dif ferential in steps of 500. Similarly when TOL relays and operator motor are located in a different ambient, the MFLA and motor locked rotor current (MLRC) should be adjusted by using a multiplying factor of ATd
= (1+0.01Td )-
When the TOL are located in a varying ambient and non-ambient compensating TOL relays are used, a similar multiplying factor ATc = (11 0.01Tc ) should be applied to compensate for its affect on the performance of TOL relays. At OCNGS the MOV ope rators are by Limitorque Corporation. The TOL relays and TOL heaters are G.E. type CR-124A and CR-123 respectively (Ref.
#1). The GE reversing starter for the operators has coil type CR-109 These TOL-relays are rated for -200 thru 600C ambient.
At OCNGS the affect of ambient temperature is reviewed as follows: 3.2.3.1 LIMITORQUE OPERATOR AMBIENT (ATo ) Equipment qualification reports of Ref. 2.2 from Limitorque corporation list the thermal aging performances for the valve actuators of various types and sizes of MOVs on a generic basis. Motor winding thermal withstand ratings from these reports can be used to ascertain if they will be able to withstand the accident condition ambient temperatures listed in Ref. #2.3 & 2.4 These references list the aging temperatures representing the conservative plant operating temperatures and the maximum temperatures expected during a postulated accident. If the qualification temperature of the operators is higher than their postulated accident condition maximum temperature, no multipliers are used to take credit for the extra temperature withstand capability of the operators. This action is in a 0256M YL ]
TDR No. 519 t .- Rev. O V, Page 7 of 27 conservative direction and in compliance of i RG 1.106. If the qualification temperature 1 is less than the accident anbient, the ! multiplier " ATo" for IFLA and MLRC is as follows: ATo = (1-0.0lTo) At OCNGS, all the Operators for the safety related systems are qualified for Class lE application, the operators qualification ambient, therefore, will be at least equal to or better than the accident ambient temperaturas, they could be called upon to experience. In either case, the multiplier ATo is taken to be = 1. 3.2.3.2 OPERATOR VS. IEC #1BIENT (ATd ) Ref. #2.3 & 2.4 document the ambient tem 3erature s during normal power and the acc< dent conditions in different plant location s. If the 11CC and the operator are located in the same area, they will experience the same ambient during normal power and s accident conditions. No correction factor is needed to be applied to the IFLA. If the operator is located in a higher anbient than the llCC which is located in a non-varying ambient, no correction factor is applied. By ignoring any correction factor, which would have resulted in lowering the size of TOL heaters, the approach is in a conservative direction, to allow the valve to perform its safety function and satisfy the Reg. Guide requ irement . 3.2.3.3 Varying ICC Anbient (ATc) ibitiplier "ATc" is applicable when the ICC is located in a varying and different anbient than the operator. The multiplier "ATc" is taken to be unity, if ambient compensating type of TOL relays are used 0256M J
E TDR No. 519
.' - Rav. O Page 8 of 27
-and the highest expected temperature is within the TOL relay design limit. For the non-ambient temperature compensating type of relays, if the operating ambient at all times is less than their design basis, the TOLs will trip at a higher motor operating current. No credit is taken for this extra capacity. If t he operating temperature at any time is higher than the design basi s, the multiplier f or MFLA and MLRC is taken to be as "ATc " = (1-0.0lT c) .
At OCNGS, the operating temperatures as documented in Ref. 2.4 are well within the operating range of the TOL-relays (-200C to 600C or 00F to 1280F) the multiplier "AT"c, therefore, is taken a s
= 1.
3.2.4 DEGRADED PLANT VOLTAGE (V) The effect of lower than the equipment's rated nominal voltage is to inc rease the running motor current and decrease the motor starting current. This change in current at running load is inversely proportional to the percentage change in the motor t erminal voltage from the motor rated nominal v oltage. -The valve opera tor motors at OCNGS are p rated at 440 VAC and 460 VAC. The voltage drop study of Ref #2.5 revealed that the
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most critical low voltage at a 460V bus is 403V. This means approximately 14% increase in the MFLA for the' 460V rated motors and about 9% increase in MFLA f or the '440V rated motors. .The multiplying f actors
' f or the MFLA will be as f ollows VOC1 - for 460 VAC motors = 1.14 VOC2 - for 440 VAC motors = 1.09 3.2.5 MOTOR DUTY: (MD)
As discussed earlier the TOLs are basically current sensitive devices which respond to a thermal effect
. by the flow of current irrespective of the motor duty. The. TOL heater selection tables by the supplier are prepared for continuous duty motors.
By using a multiplier for the MFLA as suggested by the supplier, the same tables can be used to select a TOL-heater size to protec t an intermittent duty motor. 0256M-1
. TDR No. 519 Rev. O Page 9 of 27 The frame size and motor duty rating of the Limitorque operator motors is based upon the short stroke time of the operators and an optimum combination of motor frame size for 3-phases and a single phase AC or DC motors Limitorque valve operator motors are rated at 15- minutes and 5-ainutes respectively. The multiplier f1D for various duty motors as per Ref. # 2.6 is as follows:
thitiplier ibtor Duty 1.0 For Continuous Duty Ibtors 0.8 For 60 minutes rated AC/DC motors 0.75 For 30 minutes rated AC/DC motors 0.70 For 15 minutes rated AC/DC motors 0.60 For 5 minutes rated AC/DC motors 3.2.6 TYPE OF EtCLOSllP.E(N): - The Nema type of enclosure, housing the TOLs have an effect on the TOL ambient and their heat dissipation. Heater Selection tables by some vendors use a multiplying factor (N) to be applied to IFLA to compensate for this effect. The PCCs housing these TOLs at the OCNGS have a Nema 1 enclosure the multiplying factor according to
- Ref. # 2.6 Page 3, i s = 0.9.
3.2.7 CALOJLATIONS OF IB & IIRC: - The modified values of IFLA (IB) and the motor locked rotor current (ILP,C) can be calculated as follows: IB = IFLA x (ibitiplying Factors)
=lF LA x AT x flSF x (VOC 1 or VOC 2 ) x ItD x 1 xN CT PATIO ILRC = !!LRC x (ibitiplying Factors)
= ALRC x AT y 117 x (Voc 1 or VOC 2 ) x MD x 1 xN CNT10 The resolution on these multiplying factors is based on the discussions of Sections 3.2.7.1 and 3.2.7.2.
0256H
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TDR No. 519
- Rav. O Page 10 of 27 3 . 2. 7.1 At OCNGS these factors can be applied as follows:
As per discussions of 3.2.2 and 3.2.3, "MSF" and "AT" each f actor is = 1.0. There are no C.Ts used on the MOV motor feede r circuits. The factor "N" according to Section 3.2.6 i s = 0.9. 3.2.7.2 As discussed under Section 3.2.4 the ef fect of degraded voltage conditions is to Y increase the running MFLA and decrease the LRC. Similarly , the ef fects of applying the "MD" f actor s of Section 3.2.5 is to decrease the 'DDL-h' eater size. The maximum multiplying fac tor for this from Section 3.I.4 will result in 14% increase in IB and proportionate d ecrease in the ILRC. This means the ef fec t of the degraded voltage condition is to lower the TOL-heater size for normal running. conditions. In order to protect the motor under all. conditions and compensate for the effect of degraded voltage on MLRC only the higher value of MLRC will be used.
, Application of' a "MD" factor of Sec. 3.2.5 will result in a decrease in the TOL-heater size by 40% for 5 minutes rated AC/DC motors and 30% for the 15-minutes rated AC motors. A wors t case cumulative af fect due
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to the factors AT and MD will be an overall
. decrease in the TOL-heater size by up to a s
maximum of 26%. According to Re f. #2.7, 5 or 15 minute rated operator motors can deliver the rated running torque (20% of starting torque) for at least- the 5 or 15 minutes respectively
-L without exceeding . its allowable Nema temperature rise for the insulation system
^.
used. The same motor, therefore, can be -
' used for much higher running loads for shorter periods of time, provided the Nema UE insulation rating for the corresponding running duty or the starting duty is not increased. Again according to Ref. #2. 7,
, Limitorque motors have ample
'0256M
1 l TDR No. 519 1* Rev. O Page 11 of 27 thermal capacity to operate at twice the standard 20% rated running torque which is the name five (5) plate listed(15) or fifteen torque, for periods of minutes. Based on the above, the following conclusions can be applied: 3.2.7.2.1 Do not include the cumulative affect of plant degraded voltage and motor duty. This will . result in a higher TOL heater size and the effect will be in a conservative direction in allowing the !!0V to perform its safety function, and thereby satisfy the Reg. Guide requ irement . 3.2.7.2.2 The motor shall be able to supply 200% of the running torque (40% of the name plate rated or the starting torque) for a time period required for stroking the valve from fully open to fully close position or vice-vers a. This conclusion is further modified under Section 3.3.2 by applying a safety factor, to contain the running overloads to be within the notor windings sa+e thermal limits. 3.2.7.3- Based on the above discussions the modified values of motor starting current (ILRC) and the motor full load running current (IB) to be used in the heater sizing can be calculated as follows: IB = IFLA x AT x tiSF x (VOC 1 or VOC2 ) x flD x 1 x fl CT RAT IO IFL A x 1 x 1 x 1 x 1 x 1 x 0.9
=lFL A x 0.9 Similarly ILRC = 11LRC x 0.9 0256t1
c.1 TDR No. 519 , R2v. O Page 12 of 27 3.3 ACCEPTANCE CRITERIA: - The TOL-heaters selected according to the procedures of , Section 3.4.2 shall be subject to the following acceptance :' criteria. This acceptance. criteria applies to only a single full stroking application of an MOV. 3.3.1 WHEN CARRYING LRC THE TOL RELAY SHOULD ACTUATE IN LESS TRAN OR EQUAL TO 80% OF MOTOR'S LIMITING TIME FOR CARRYING THE LRC. This will establish an upper limit on the TOL setpoints and protect the motor from LRC under all conditions - including frozen bearing, tight packing or any other mechanical obstruction during starting. The 80% .of motor's limiting time gives a 20% safety margin for the inaccuracies of the motor windings thermal curves. As discu ssed under Section 3.2.7.2, the LRC calculated under 3.2.7.3 shall be used for this analysis. For a given Nema class of insulation,- motor torque rating and motor ambient rating this time can be easily calculated from the locked rotor thermal limit curve of a motor similar to the typical c urve of attachment #1. 3.3.2 FOR RUNNING OVERLOADS OF UP TO 200% OF RUNNING TORQUE, THE MINIMUM TRIP TIME OF TOL RELAYS SHOULD BE MORE THAN THE VALVES STROKE TIME AND THE TORQUE SWITCH TRIP TIME, PROVIDED IT'S WITHIN 80% OF
- OPERATOR MOTOR'S LIMITING TIME CORRESPONDING TO 200%
FULL LOAD TORQUE. According to the discussions of Section 3.2.7.2 Limitorque motors have ample thermal capacity to supply running overloads of up to 200% for periods corresponding to the operator motor duty rating. Again, for a given Nema class of insulation, motor torque rating and motor ambient rating, this time to carry 200% running load c an be easily established f rom the motor's 40% thermal limit curve for that motor, similar to the typical curve of attachment
# 1. This time should be greater than the operator s troke time to perform it s safety function. Also the MOV operator circuit trip time due to the torque switch setting should be less than the TOL-relay trip time, which in turn should be less than 80% of the operator motor's limiting time for running overload corresponding to 200% torque. Again, the 80% of the 0256M k _ _ _ _ _
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** TDR No. 519 , R3v. O Page 13 of 27 motor's limiting time gives a 20% safety margin f or the inaccuracies of the motor winding's thermal c urves. This can be demonstrated by plotting all three on the time current (T-C) axis.
3.4 PROCEDURE FOR TOL-HEATER SIZINC: - This proc edure is based on the me thods of Ref. #2.9 and i s divided into following sections. 3.4.1 OPERA , DATA:
'3.4.1.T , Operator Motors Name Plate Data:
e MFLA, HP, MSF, Volts - AC or DC, Nema code letter or MLRC, rated ambient at rated Nema class of insula tion, starting torque, running full load and 200% of full load torques. 3 . 4.1. 2 Operator Type and size. 3.4.1.3 MOV Stroke Time. 3 . 4 .1. 4 _ TOL Relay Information: TOL relay type, TOL heater type, TOL heater selection table s, TOL-relay time-current characteristic curves. 3.4.1.5 Torque Switch S etting. 3.4.1.6 MOTOR CHARACTERISTIC CURVES Motor winding thermal limit curves at locked rotor, f ull load running torque and at 200% of full load torque. 3.4.1.7 Ambient Tempera tures MOV operator motor's design basis accident ambient. MOV operator motor's qualification ambient. Maximum ambient of the MCC housing the TOL relays. 3.4.1.8 MCC's Nema enclosure type. 0256M
o TDR Ho. 519 Rev. O Page 14 of 27 3.4.1.9 tetor Themal Limit For Locked Rotor From the liOV data find the operator motor's temperature rise over and above the motor's rated ambient for its Nema class of _ insulation. From the motor's thernal limit curve for locked rotor conditions (similar to the curve of attachmentt #1 marked LKD - Temp.) find the time corresponding to the temperature rise. 80% of this time is the safe stall time for a locked rotor condition. This time will be used for calculating the high setpoint for the TOL relay. 3.4.1.10 Motor Current For Calculating The Lower Setpoints Of TOL: Find the amps (Is) corresponding to the 40% of the 110V's rated torque and the amps (ITS) corresponding to TS setting. Use the lower of the two values for calculating the lower setpoints. The 'IS ' and 'ITS ' can be calculated as follows: 3.4.1.10.1 -IS: The notor naneplate rated torque for a MOV represents the rated starting torque and 20% of this torque represents the rated full load running torque (TFL) (Ref. 2.7) . The amps 'IS' can be calculated from the following relationship: lbtor Torque (Tl) is proportional to the square of the motor Current (11)2 If we know the amps at 20% torque, the anps at 40% torque can be calculated from: (Is - at 40% torgue)2 = (I at 20% torque) x 2 = (tFL A)2 x 2. 0256ft
F' TDR lio. 519 Rev. O PaSe 15 of 27 ' 3.4.1.10.2 ITS: Find the TS setting in f t-lbs. from the vendor supplied data or plant procedure s. Find the anps 'ITS' from the torque-amps curve of Attachment #1 for the torque setting of the TS. 3.4.1.11' Motor Themal Limit Corresponding to IS/ITS:
-For a five (5) or fifteen (15) minute rated motor, the stroking time of a valve is generally very sna11 in comparison to its rating. The inherent service factor from Ref . # 2.7. i s give n by ibtor Duty Stroke Time A 110V motor can easily sustain temporary overloads of up to 200% of the normal running full load for the duration of its stroking period. Therefore, the motor themal limit for either IS or ITS can be based on the 40% curve (Attachment #1) instead of the themal curve corresponding to a lower value of torque for the TS setting. This themal limit can be calculated from the 40% torque curve in a similar way to that of Section 3.4.1.8.
3.4.1.12 Torque Switch Trip Time: This is the time in seconds it will take for the torque switch to actuate at its predetemined setting plus the motor starter drop-out time. From Ref. #2.8 the TS contact parting time including the mechanical play in the fixed and moving contacts of the TS, is approximately 50 milli seconds (ms) . Depending upon the
!!ema size of starter, the starter drop-out time after. a torque switch is actuated, varies from 25-50 ms. Total time fron TS '
actuation to the starter drop-out could be a maximum of 100 ms. 0256!1
3 TDR No. 519
..- Rav. 0 Page 16 of 27 3.4.2 STEP BY STEP METHOD:
3.4.2.1 On the T-C curve of TOL relay (Attachment
#2) draw a horizontal line at thermal time limit for carrying locked rotor current from Section 3.4.1.8.
'3.4.2.2 This line intersects the curve at multiples of relay trip currents X1 and X2. Due to relay tolerance the multiples XI and X2 will have minimum and maximum trip time s of tl-t2 and t3-t4 respectively. Select the multiple which gives the maximum trip time within the acceptance criteria #1. Let this multiple be X2 3.4.2.3 The Locked Rotor Current = X2 x Relay Trip
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Current or the Relay Trip Current = I g_ = X3 3.4.2.4 Select the applicable heater from heater selection table s of Attachment #3 Select
, the appropriate heaters and find the minimum trip current for this heater. Let this current be = X4
;_ 3.4.2.5 LRC corresponding to the selected heater = I g_= X5 4
x (times) the minimum relay trip current. From Attachment- #2 find the maximum trip time for X5. If this time meets the acceptance criteria #1, this will represent the acceptable upper limit of the TOL set point. If not, go back to step 3.4.2.4 and select a heater one size lower. 3.4.2.6 For evaluating the lower set point of the TOL relay, select the motor current IS or
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ITS. The corre sponding relay trip current will be IS or ITS = X7 x the minimum X4 relay trip current.
- If 80% of the minimum trip ' time (t7)
"+ - corresponding t o X7 is greater than the MOV stroke. time to perform the design basis safety function, then X7 meets part of the
. criteria #2 for the lower setpoints.
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- TDR No. 519 <
Rev. 0 1 Fage 17 of 27 j 3.5 SAfPLE CALCULATION - CORE SPRAY ISOLATION VALVE V-20-41: 3.5.1 OPERATOR DATA'(Ref. attadment #1) WLA=5.2, HP=3.2 0 460 VAC, 60!!z, S.F.1.0 , llotor Loded Rotor Current (MLRC) = 404 (from Section ; 3.5.2) ' RPit-1700, ibtor Rated Amb.0C/INSUL = 40/B Motor Torque =25 f t.-lb. (Ref. 2.11) , Operator - Limitorque type SitB-001 (Ref. 2.ll) Motor Stroke Time 22s (Ref. 2.10) tbtor Winding themal Limit for locked rotor current
=10.5 6s-( Sec . 3.5 3)
IB . (from Se c. 3.5.5) = 4.68A ILRC (from Sec. 3.5.5) = 3 6.0A Is (from Sec. 3.5.4) liotor running current corresponding to 200% of the motor's full load running torque = 6.62 amps (Sec. 3.5.4) Operator Motor FL running torque = 5 f t.-lbs.
' Operator tbtor 200% FL running torque = 10 f t .-lb s.
flotor winding thermal limit for 200% FL running torque (Sec. 3.5.4) =4.0 minutes TOL-Relays - GE type CR-124A2 ) TOL Heaters - GE type CR-123 ) Combination Starter Coil - Nema Size #1, GE type CR-109CO)Ref. 2.1 T-C Characteristic Curve for Type CR124 TOL Relays ) FCC's enclosure - Nema Size il 3.5.2 Motor LRC:'- Only name plate value should be used. However, for the purpose of this cales, for a given Nema Code letter the Av. value of motor LRC can be calculated from MLRC i 1000XHPXKVA/ilP 1.732XV For code letter 'L' use (9-10KVA/HP) (Ref. 2.12) MLRC=. 1000X3.2X10 = 40 Amps 1.732X460 3.5.3 - MOTOR THERIML LI!!IT (LRC CONDITION):- Nema Class B insulation has a temperature rating of 1300C. The operator motor has Class B insulation
- and rated for operation in a 400C ambient. The net rate of temperature rise the motor winding will be able to withstand is 900C. From the LKD temp.
rise - sec. curve of Attachment No.1, the safe stall time is 13.2 seconds. Allowing a 20% margin of error in the motor heating curve accuracy due to sustained temperature condition, deyaded motor ventilation and 0256ft
r TDR No. 519 Rev. O Page 18 of 27 the inaccuracy in duplicating the exact motor winding heating affects due to temperature rise, etc., the net safe stall time to be used in the calculations = 0.8 X 13.2 = 10.56s. 3.5.4 110 TOR CURRENT AND THERtRL LIltIT - CORRESPONDING TO T.S SETTING: - For this study the approach is to limit the running overloads to a maximum of 200% of the full load torque. The motor current IS will be used for these calculations. From 3.4.1.10.1 I2 = (WLA)2 X2
= (5.2)2 X2 IS = 7.35 amps
. IS = 0.9 X 7.3 5 = 6.6 2 The net current IS to be used in sizing.the TOL heaters will be = 0.9 x 7.35 = 6.62 0 460 VAC. The motor thermal limit for the 200% of full Ivad torque of 10 ft.-lbs. is about five minutes. Again using a 205 ' safety factor, the _ net safe overload running time is = 5 X 0.8 = four minutes. 3.5.5 NET MOTOR LRC AND RUNNING CURRENT: From Ref. 3.2.7.3 IB =- tFL A x 0.9 ILRC = MLRC x 0.9 Atta6 ment #5 shows the temperature profile of the operator during an environmental test qualification. The maximum temperature sustained was 2100F for approximately six (6) hours. The maximum temperature sustained during an emergency condenser line break, the worst case accident condition, as seen from attachment #6 is approximately 1900F for about three (3) minutes. This means the equipment qualification temperature is higher and therefore the multiplier " AT0" is taken to be = 1 Ref. 2.4, the maximum ambient for itC -1AB2 under all conditions is 950F. According to Attachment #2, the performance of the TOL relay is not affected by the temperature variations, the maximum working range being 1280F. The multiplier "ATc" is, therefore taken to be = 1. IB = 0.9 x if LA = 0.9 x 5.2 = 4.68 amps
~
0256M ILRC = 0.9 x UC = 0.9 x 40 = 36 amps a
TDR ib. 519 .* - Rev. O Page 19 of 27 3.5.6 STEP BY STEP ETM)D
- 1. On the T-C characteristic curve for TOL-relay.
CR-124A draw a horizontal line at 10.56 seconds (motor's safe stall time) . This line intersects the daracteristics band at 5.6 times and 9.8 1 times the-relay pick up (PU) current.
- 2. At 5.6 times the PU the I-tinimum & Maximum trip times from the characteristics band are 10.56s (seconds) and 16s. At 9.8 times the pu the minimum.and maximum trip times from the daracteristics band are 7.2 & 10.56 :;econds. .
Select the 9.8 times the pu current to size the TOL-heaters, because this gives the trip times within the safe motor-thermal limit for LRC.
- 3. . LRC = 9.8 x Relay Trip Current The Relay Trip Currentj=ILRC = 36 = 3.67 amps TiB~ B For .TOL heaters type CR-123, TOL relays type CR-124 mounted directly on the starter and in a Nena #1 !!CC enclosure, TQ.-heaters selected from Table 46, Col. B of Ref. 2.6 = C-419A Minimum trip current for this heater = 3.35 amps.
- 6. LP,C corresponding to the selected heater = 36 = ILRC = 10.75 DT T.3F times the relay trip current.
flin. & max. trip times for this current = 7.0s
& 9.8s The max. trip time of 9.8s is within the motor stall time of 10.56s. This meets the acceptance criteria #1 for the high setpoint of the TOL relays.
- 7. In order to find the lower trip point, find the Relay current corresponding to ITS. This trip current =
g = 1.98 times the relay current. The min. & max. trip times for 'this current, from attachment #2 are 34s & 68s, again applying a 20% factor of safety, the 0256!!
1 TDR No. 519 , Rev. 0 ' Page 20 of 27 minimum time is = 0.8 X 34 = 27.2s.
.Because the minimun trip time is hi@er than the valve stroke time of 22s, it meets one of the requirements of acceptance criteria #2.
3.6 TOL SET POINTS r.EVID! AGAlf:ST REQUIREltEilTS OF REG. GUIDE 1.106 The TOL setpoints as arrived at in Section 3.5 were reviewed for RG 1.106, position #C2 compliance. These requirements
- are ' stated in substance under Section 3.1. The uncertainties associated with this position are discussed below to see if they have been adequately resolved through the use of the methods of Section 3.4 and 3.5 for sizing the TOLs. -
3.6.1 Ref. #2.4 lists the normal power aging temperatures and the maximum operating tenperatures for a worst case postulated accident. The accident conditions temperature profiles for these areas are documented under Ref. 2.3. The affect of differer.t ambient temperature factors of Sec. 3.2.3 as applied to the sample example is discussed as follows: 3.6.1.1 Operator kibient Factor (ATO) Attadiment #5 (from Ref. #2.2.4) shows temperature test profile for the valve V-20-21 of the sample calculations in Section 3.5. As observed, the valve was subject to a test temperature of 2100F for almost six (6) hours. Attachment #4 (from Raf. 2.3) shows the ambient ten)erature profile inside the reactor bui" ding following an emergency condenser line break. The maximum sustained temperature here is about 1900F for a duration of 3 minutes. In this case the operator qualification tenperature for the valve V-20-21 operator is 200F higher than the maximum operator ambient. According to the discussion of Section 3.2.3.1, no credit is taken for a higher temperature withstand capacity of the operator motor in adjusting the IB & ILRC used in sizing the TOL heaters. 0256ft
TDR No. 519 Rev. O Page 21 of 27 3.6.1.2 Operator Vs. FCC Ambient Factor (ATd) The maximum post accident temperature for the V-20-21 operator fnom attachment #4 is 1900F (990C) while the maximum operatig temperature for MCC-1AB2 is 950F (4PC) Ref. 2.3. The maximum temp differential could be 950F (400C) . Accordirs to discussions of Section 3.2.3 (ii) the IFLA & MLRC would have required a multiplying factor of ---- ATd = 1 - 0.01 X (40 C) = 1 - 0.01 x 8 5
= 0.9 2 This could have resulted in a smaller heater size. By ignoring the factor Atd the resultant TOL heater size is .8%
hi gher. This results in an action which is in line with the R.G.1.106 requirement of completing the safety function. 3.6.1.3 Variations in MCC Ambient (ATc): (Ref. Sec. 3.2.3.3) By ignoring the multiplier " Atd" above, the TOL heaters are sized on the basis of 950F operating temperatures. The TOL relays are (see Attachment #2) rated for
-200C (o0F) to 600C (1280F)
L operation. Therefore, no multiplying factor is applied. This resolves the issue of the effects of ambient temperature variations, and the resolution is to size the TOL to complete the safety action, a prime requirement of th e R .G. 1.106. As will be seen later, this is also accomplished within the operator motor winding's thermal limit at all times. 3.6.2 INACCURACIES IN MOTOR THERIAL CURVES & TOL-RELAY CURVES: Inaccuracies in the motor thermal curves of attachment #1 under the LRC conditions and running 0256ti
TDR No. 519 Rev. O Page 22 of 27 overload conditions are resolved in Sections 3.5.3 _ and 3.5.4 respectively. By using a 0.8 multiplier for the motors limiting time, there is a safety margin of 25% for the safe LRC and running overload operations of the motor. This more than adequately
. covers the motor thermal curve inaccuracies.
The daracteristics of a TOL relay, Attachment #2 are represented by wide band, which has a low and a high TOL relay trip setpoints. This implies that the TOL relay could trip anywhere between these two setpoints. The acceptance criteria of Section 3.3 is based on selection of these two points. Since the inaccuracy of the TOL relay 6aracteristics, like that of arty thermally actuated device, are represented by the wide band, no additional safety factor need be applied. The resolution of Sec. 3.5 on these setpoints assures the completion of the MOV safety function within the motor windings thermal limit. Hence, the issue is adequately resolved. 3.6.3 SET POINTS DRIFT: This issue can be resolved by testing the adequately sized TOL-heaters prior to installation. The acceptance criteria shall be for the T-C test point for the heater to fall within its TOL-relay characteristic band. This test point can be reviewed under two adverse scenarios:- First, if the test point is just within the lower limit of the TOL-relay setpoint, in actual use the heater could trip in less or more time than its
. tested set point. The downward drif t could mean that at a running overload of 200% of full load, the heater may trip earlier than the testpoint.
According to acceptance criteria #2, the application of a multiplier of 0.8 to the trip time fron the
-curve provides a 25% safety factor for this downward
- drift. This ensures that even after accounting for a setpoint drift of 2SE in the adverse direction, the TG.-trip time would be more than the HOV stroke time. This test point will allow the completion of safety' function without tripping prematurely, and is, therefore, acceptable.
In the second case, the test point could lie within the TOL relay T-C curve band but close to the upper setpoint limit. A setpoint drift in an adverse
' 0256ft -
_ _ _ _ _ _ . . _ . . _ _ _ . . _ . _ _ . _ . . x , . . . _
TDR No. 519
. Rev. O Page 23 of 27 direction could mean that the heater trip time is more than the test time. Here the effect is to allow even more time to perform its safety function by applying the starting torque for a longer period of time to ensure the valve operation. At the same time it should be within the motor's safe thermal time limit. Again. 0.8 multiplier to the safe stall time for LRC condition (Section 3.3.1) provides a safety margin of 25% to ensure the safe themal time limit for the motor winding. This test point will, therefore, be acceptable.
4.0 RESULTS
'4.1 A generic fomula was developed for the modified value of motor running current (IB) and motor locked rotor currents (ILRC) for sizing the TOL setpoints to meet the RG 1.106 position C2. The fomulae are:
IB = IFLC x AT x !!SF x (V0Cl or VOC2) x 11D x 1 xN CT Ratio ILRC = MLRC x AT x MSF x (VOCl or VOC 2) x f1D x 1 xN CT Ratio 4.2 The generic expression for calculating the adjusted motor running currents IB and motor locked rotor current ILRC for sizing the TOL setpoints for the safety related fl0Vs at OCNGS are as follows: IB = IFLA x 0.9 ILRC = !!LRC x 0.9 4.3 A generic step by step method was established to size the TOL's for safety related valves. This method was applied in sizing the TOL's for a safety related valve as a specific exampl e. The results were found to be in compliance with the requirements of RG 1.106 position C2, demonstrating the validity of the approach. 4.4 The safety margins employed for the various factors that influence the sizing and perfomance of T0Ls at the OCNGS are as follows: 4.4.1 At1BIENT T9tPERATURE: (AT) In sizing the TOLs, no credit is taken for the extra safety margins provided by following conditions for various multipliers: TT::: ~ 10256ti
. . - - - - - - - _ . _ _ = .
TDR ND. 519 l3:. V
;e R2v. 0 Page 20 'I 4.4.1.1 MULTIPLIER ATo:
Where the operator qualification is for higher temperatures than the postulated accident condition ambient and sustained for longer durations than the design basis
.m action required of an MOV.
4.4.1.2 MULTIPLIER ATd: By ignoring the compensating multiplier
> (1-0.01Td) for the motor currents where the operator is located in a higher ambient than the MCC housing the TOLs.
4.4.1.3 MULTIPLIER-ATc: By . ignoring the compensating multiplier (1+0.01Tc) for the motor currents where the
' MCC ambient is less than its design basis.
4.4.2 DEGRADED PLANT VOLTAGES (VOC 1 OR VOC 2) LIgnoring the maximum multiplier of 1.14 for this condition provides a safety margin of 14%. 4.4.3 MOTOR DUTY (MD1
# ~ 4.4.3.1- The maximum saf ety margin provided by ignoring the motor duty multiplier is 40%
for five minutes rated AC/DC motors and 30% for the 15 minutes rated AC motors. 4.4.3.2 The safety margin provided by ignoring the D.. ,. inherent service f actor of a five minute and 15 minute motor duty motor for a 60 second stroke time MOV will be 500% and
- 1500% respectively.
+
For MOVs with different stroke lengths, it will be different, but will always have more than sufficient safety margin. 4.4.4: MOTOR THERMAL LIMITS - By considering only 80% of the operator motor's thermal limit time for the locked rotor condition
- during -starting and for a running overload condition corresponding to 200% of the full load torque, a 20%
safety margin is provided. 0256M 7
+_
y TDR Na. 519 4 Rav. O Page 25 of 27
- ~
5.0 CONCLUSION
S: 5.1 The traditional method of TOL sizing providing 125% of full load current protection does not taka into account the intermittent motor duty rating, the application nature of the safety related MOV's and the special characteristics of the operator motors. 5.2 This study has established a generic method of developing the
-TOL setpoints that meet the RG 1.106 position C2.
Safety factors are employed in establishing these setpoints to help ensure completion of the valve operation (safety related function) without undesired tripping. These setpoints though still provide full time motor protection, particularly during surveillance testing without temporarily altering the circuitry (lif ting bypass leads) and without complicating the circuitry with automatic bypass features.
'5.3 This method is based upon the characteristics and application specifics of the operator motors for the safety related valves and could also be applied to non-safety related loads.
5.4 The sample example of sizing the TOL proves that the generic approach of section 3.4.2 assures the completion of the MOV's safety function within the operator motors safe thermal limit for the starting as well as the running overloads. 6.0 RECOMMENDATIONS 6.1 The generic approach of section 3.4.2 for sizing the TOL's should be formalized into Engineering Standards. These standards should include the acceptance criteria for the high and low TOL setpoints and the testing of the TOL's. 6.2 The TOLs on all safety related MOVs should be reviewed according to the new standards of Section 6.1. The TOL heater sizes should be documented as a part of the plant procedures. 6.3 TOL's should be tested before installation to meet the acceptance criteria of new standards. Also, the existing TOL
- relays should be tested for their operability.
Li~i _. _.JD2 5 6M
.h a TDR No. 519
. t. R.v. 0
/,, Page 26 of 27 s 6.4 'Ref. Sec. 3.3, the sizing of the TOL's is based on a. single full stroke application of en MOV. For jogging duty appliclations, the adequacy of this method of TOL sizing should be analysed separately on a case by case basis. For continuous full stroking of the valve more than once, equal periods o f "run" and " rest" betwe en successive starts sho uld be observed In any case, manuf acturers limitations on the maximum number of starts in a given period shall always apply.
These limitations should be incorporated in the existing plant. pro cedure s. 7.0 . APPENDICES 7.1 Attachmen t No. 1 "AC Motor Perf or: nance Curves" s 7.2 Attachment No. 2 "TOL Relays Type CR-124, Time-Current Curves" g. i' 7.3 Attachmen t No. '3 " Selection Tables Fer G.E. TOL-heaters" te i 7.4 . Attachren t No. 4 - Temperature Te st Profile for Valve V-2 0-41 (from Ref. #2.3) ,p 7.5 Attachment No. 5 - Temperature Profile For The V-20-41 Operator in the Accident Environment Ambient. -i T 4
\ e t
-4 ,4 ,
w g , ( A 6, s a 0256M- /[ < , A e j
~D <
g .
~
~
TDR No. 519
- Rsv. O Page 27 of 27 8.0I ' List of the Abbreviated terms frequently used in this report:
AT - Ambient Temperature Multipliers ATO - For Limitorque Operator Ambient
,ATd - For Operator VS MCC Ambient ATc -
For Varying MCC Ambient FLC - Full Load Current IB - ' Modified Values of MFLA, after applying the applicable multiplying f actors of Section 3.2. This is the value which will be used in arriving at the TOL set points. ILRC - Locked value of MLRC to be used in sizing the TOL heaters and modified in a similar manner to tha t of IB. LRC - Locked Rotor Current MCC - Motor Control Center MD - Multiplier for Intermittent Duty Motor rating MFLA - Motor Full Load Amps (frbe the motor name plate) MLRC - Motor Locked Rotor Current (f rom the motor name plate) MOV . Motor Operated Valve MS - Milli Seconds MSF - Motor Service Factor Multiplier N - Multiplier for Nema Type of enclosure f 'RG-1.106 - Regulator Guide 1.106 SF - Motor Service Factor (from motor name plate) TOL - Thernal Over Load - Wherever used the term is intended to be implied to include both, the relays and heaters. TS - Torque Switch VOC1 - Multiplier for degraded vcitage condition at 460 VAC MCC buses, at OCNGS VOC2 - Multiplier for degraded voltage condition at 440VAC MCC buses at OCNGS TFL - Operator motor full load running torque. TO - Temperature differential in OC between the Operator motor ambient and its qualification temperature. Tc = Temperature differential in C between the MCC design basis temperature and its highest ambient. Td = Temperature dif ferentici in OC between the MCC and operator motors ambient. 0256M J
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/ eh M MULTIPLES OF CURRENT RATING THERMAL OVERLOAD RELAYS GE5 7201 A GENER AL $ ELECTRIC EWH ''''
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.o Table 0, um sue. 00,0, a i Table 48 mm sue 2 Table 50, um ame 4 -
. n - Use Cetwai A For: Use Column A Foc Use Column A For:
( CR108, CR100@, Open, Typee 4,7,9 CR108. CR109@, Open, Typee 4,7,9 CR108 CR100@, Open, Types 4,7,9 V) ' CR110, CR11J@, M Encinouhe CR110, CR111'D, M EnCiosures CR110, CR111@, M Enclosures CR124Al@@, Open or Type 1 CR12481@@, M CR131F@, M CR133C@ CR1310, CR1330, CR134C@, Ah CR133F@, M EnCicouros
. Use Column a For: Use Column 8 For: Ues Column 3 For:
CR108. CR100@, Types 1,12 - CR100, CR100@, Types 1, I'2 CM108, CR100@, Types 1,12
. CR107, CR100@, M Enclosures CR107. CR100@, M Enclosures CR107 CR100@, M Enclosures CR1e0C1@ CRie0C2@ ,,,,,,,
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0 33 0 31 C030A 0 83 Cet&A es 8 46 3 Faa4
+ c 37 0 34 C03BA 7N . . . . . . . .O at C77tA S42 de 0 FleM 0 41 0.3 C043A 8N 7.7e CW 7A N.0 St a mi43 0 44 0 43 'C040A 9 30 8 83 Ce86A .
O S2 0 47 Cos4A g 33 g.33 C1044 et 5 57 4 Fe6te 0 52 C000A 10 7 Cit 3B 70 8 01 8 F7tte O ST 0 98 C005A 11.2 It s 11.7 C1305 O st M4 73 0 Flee 8 O 87 0 02 C07tA 14 1 it 8 C1379 "' 83 8 "' *8 0 75 0 et C07aA IS S to 3 C1518 0 to 0 77 C007A 17 4 to 1 Cle38 100 94 7 FiesC H0 --- FH4C 0 to 0 87 COS7A 19 8 17.9 C100s m tos FueC 1 03 0 04 CiODA ti t 10.3 C1000 W US Ft33C 1 to 1 04 C118A at 7 21 e C2148 ~""" m F14ec 1 30 1.10 C131A 94 9 32 e Caste 1 42 1.30 C1 dea 27.3 94 0 C3808 10 i 33 t Ts 8:= CiseA 40 r 34 e S:;". C330s Table 51, muA sa. s Use Column A Foc
!3! N3 $#'e r3 as O C440s CR108, CR100@, Open, Types 4, 7,9 CR110, CR111@, M Enclosures sa 40 CaesA
_ j fe, ag C#;^ C CR131G, CR1330@, M 3 32 3 02 C3mA Table 49, NEMA Size 3 Uec Column 8 Foc 8" Use Column A Foc CR108, CR10@, Types 1,12 4 si 4 s0 CaseA CR106, CR109@, Open, Types 4,7,9 CR107. CR10@, M Enclosures A s 2; a 73 CsteA
" CR110. CR111@, M Enclosurea e ii ' -sN C 3N CR131E@, M *"*'W""**'** Mester Cet ha Col A Cet e EAIII e e3 e2 Cessa CR1:3E@, M Enclosures 7 10 e e2 C77eA e de 7 e4 .Cas7A Use Column 8 For: 7e r ...... C37s4 lA! lU C= CR108 CR109@, Ty;3ee 1,12 $l E! CaU Cae nf
. 12 2
, e, 10 9 CuSe C1258 CR107. CR100@, M Enclosures
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'35 92 0 C1378 teen. Motor Fus-leed Amperos 122 194 CSEA Meeter Cet too- 137 127 C0954 to 6 13 0 CIStB CRtt3 te : 14 3 C1838 Cat. A Cat. p 15 C hh hgg 23 1 20 9 F2438 185 159 C95$4 20 e 18 t C2148 M3 23 6 F2700 301 $70 C10aB 22 6 19 9 C2268 NS PS S F3008 2t3 teS Cit 38 30 9 27 7 F3275 pas 302 C1258 24 8 21 8 C2508 F3578 33 8 30.3 goe 218 C1378
. 27 0 2 270 231 C1118 38 5 32 8 F3060 41 1 37 1 F4308 gg0 Ct438 370 C3308 42 9 F4478 y70 47 6 Cte06 s2 s 47 0 Foers Table 47,' CR106K, Site 19@ 56 e s01 !Peise j
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Type tacteaure oevtse 0] ,1 rl- _m o,, ( ,e, ,, t.12 CRt06 7e e7 3 77.5 F F9148 ~,e e e0 0 33 2 F104C tees. theter Moseer Cat. tse. . 90 0 Fi14C Fus.4eed Amperse CR183 15 t - - . . . CittB @ Heaters for cuneat cecces e*, now nosected trr type et 98 7 15 C Ctt38 oncioeuro See ietse NEn4A fyee Encewures. page to
', @ Three hee'ert recured. Singse+hese-One heeler, fee.
$0 'P**8 #* N'* a heatem j 2f a f90 C2149 1
g: gl g;= @- Do not use.,e,rAo.40,e,
@ One K required e to tetse for ete,ter -te , for CR124 re:4rs moun'ed dkoctty on i
2e 7 25 4 C2738 l 31 2 27 e C3Das @ Three he4 ers ressered so 0 30 7 C330s l
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