Tài liệu Qualification Standard Reference Guide SEPTEMBER 2008 ppt

Mechanical Systems Qualification Standard Reference Guide SEPTEMBER 2008 This page is intentionally blank. Table of Contents i LIST OF FIGURES iii LIST OF TABLES iv ACRONYMS v PURPOSE 1 SCOPE 1 PREFACE 1 ACKNOWLEDGEMENTS 2 TECHNICAL COMPETENCIES 3 General Technical 3 1. Mechanical systems personnel shall demonstrate a working level knowledge of steady- state heat transfer. 3 2. Mechanical systems personnel shall demonstrate a working level knowledge of thermodynamics 6 3. Mechanical systems personnel shall demonstrate a working level knowledge of fluid mechanics 12 4. Mechanical systems personnel shall demonstrate a working level knowledge of the concepts, theories, and principles of basic material science 19 5. Mechanical systems personnel shall demonstrate a working level knowledge concerning the selection of appropriate components and materials in support of a mechanical system design or modification. 32 6. Mechanical systems personnel shall demonstrate a working level knowledge of mechanical diagrams, including: 41 7. Mechanical systems personnel shall demonstrate a working level knowledge of installed mechanical equipment. 45 8. Mechanical systems personnel shall demonstrate a working level knowledge of a typical diesel generator, including support systems. 46 9. Mechanical systems personnel shall demonstrate a working level knowledge of the construction and operation of heat exchangers 54 10. Mechanical systems personnel shall demonstrate a working level knowledge of the theory and operation of heating, ventilation, and air conditioning (HVAC) systems. 57 11. Mechanical systems personnel shall demonstrate working level knowledge of general piping systems 76 12. Mechanical systems personnel shall demonstrate a working level knowledge of the general construction, operation, and theory of valves. 87 13. Mechanical systems personnel shall demonstrate a working level knowledge of safety and relief devices. 97 14. Mechanical systems personnel shall demonstrate a working level knowledge of pump theory and operation. 100 15. Mechanical systems personnel shall demonstrate a working level knowledge of strainers and filters. 112 16. Mechanical systems personnel shall demonstrate a working level knowledge of the basic components, operations, and theory of hydraulic systems. 120 Table of Contents ii 17. Mechanical systems personnel shall demonstrate a working level knowledge of the components, operation, and theory of pneumatic systems. 123 18. Mechanical systems personnel shall demonstrate a working level knowledge of the basic design, construction, and operation of glovebox systems 129 19. Mechanical systems personnel shall demonstrate a working level knowledge of the principles of lubrication. 146 20. Mechanical systems personnel shall demonstrate a familiarity level knowledge of reading and interpreting electrical diagrams and schematics. 152 21. Mechanical systems personnel shall demonstrate a familiarity level knowledge of reading and interpreting electrical logic diagrams 158 Regulatory 161 22. Mechanical systems personnel shall demonstrate a working level knowledge of the requirements of DOE O 420.1B, Facility Safety, and the associated guidance of DOE G 420.1-1, Nonreactor Nuclear Safety Design Criteria and Explosives Safety Criteria Guide for Use with DOE O 420.1, Facility Safety; and DOE G 420.1-2, Guide for the Mitigation of Natural Phenomena Hazards for DOE Nuclear Facilities and Nonnuclear Facilities 161 23. Mechanical systems personnel shall demonstrate a working level knowledge of safety in design as described and required in DOE O 413.3A, Program and Project Management for the Acquisition of Capital Assets, and DOE M 413.3-1, Project Management for the Acquisition of Capital Assets, and DOE-STD-1189-2008, Integration of Safety into the Design Process 169 24. Mechanical systems personnel shall demonstrate a working level knowledge of the following standards related to natural phenomena hazards: 173 25. Mechanical systems personnel shall demonstrate a working level knowledge of DOE maintenance management requirements as defined in DOE O 433.1A, Maintenance Management Program for DOE Nuclear Facilities 175 26. Mechanical systems personnel shall demonstrate a working level knowledge of DOE standard DOE-STD-1073-2003, Configuration Management 178 27. Mechanical systems personnel shall demonstrate a familiarity level knowledge of the codes and standards of the American Society for Testing and Materials (ASTM)*. 180 28. Mechanical systems personnel shall demonstrate a working level knowledge of the codes and standards of the American Society of Mechanical Engineers 182 29. Mechanical systems personnel shall demonstrate a familiarity level knowledge of the following organizations’ non-mechanical systems-specific codes and standards: 189 30. Mechanical systems personnel shall demonstrate a familiarity level knowledge of the codes and standards of the American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 191 31. Mechanical system personnel shall demonstrate a working level knowledge of the quality control inspection techniques described in sections V and XI of the ASME Boiler and Pressure Vessel code and the verification of mechanical system integrity, including: . 192 Management, Assessment, and Oversight 202 Table of Contents iii 32. Mechanical systems personnel shall demonstrate a working level knowledge of problem analysis principles and the ability to apply techniques necessary to identify problems, determine potential causes of problems, and identify corrective action(s) 202 33. Mechanical systems personnel shall demonstrate a working level knowledge of assessment techniques (such as the planning and use of observations, interviews, and document reviews) to assess facility performance and contractor design and construction activities, report results, and follow up on actions taken as the result of assessments. 215 Other 220 34. Mechanical systems personnel shall demonstrate a working level knowledge of the safety and health fundamentals of mechanical systems and/or components. 220 35. Mechanical systems personnel shall demonstrate a working level knowledge of the following engineering design principles: 236 36. Mechanical systems personnel shall demonstrate a working level knowledge of maintenance management practices related to mechanical systems 243 Selected Bibliography and Suggested Reading 247 Figures Figure 1. Mollier diagram 8 Figure 2. Carnot cycle representation 9 Figure 3. Typical steam plant cycle 10 Figure 4. Ideal Otto cycle 11 Figure 5. Pascal’s law 15 Figure 6. Pressure-volume diagram 18 Figure 7. Effects of gamma radiation on different types of hydrocarbons 28 Figure 8. Idealization of unloaded region near crack flanks 30 Figure 9. The fracture energy balance 31 Figure 10. Charpy test equipm ent 36 Figure 11. Material toughness test 37 Figure 12. Successive stages of creep with increasing time 39 Figure 13. Valve conditions 41 Figure 14. Title block 42 Figure 15. Notes and legend 44 Figure 16. Natural convection cooling tower 56 Figure 17. Vapor-pressure curve 58 Figure 18. Simplified centrifugal pump 62 Figure 19. Balanced heat recovery ventilation schematic 71 Figure 20. Orif ice plate 83 Figure 21. Gate valve 91 Figure 22. Globe valve 92 Figure 23. Ball valve 94 Figure 24. Swing check valve 95 Figure 25. Butterfly check valve 96 Figure 26. Variable reducing valve 97 Table of Contents iv Figure 27. Centrifugal pump 103 Figure 28. Single and double volutes 103 Figure 29. Reciprocating positive displacement pump operation 104 Figure 30. Single-acting and double-acting pumps 108 Figure 31. Two screw, low-pitch screw pump 109 Figure 32. Three screw, high-pitch screw pump 110 Figure 33. Rotary m oving vane pump 111 Figure 34. Typical m ulti-cartridge filter 113 Figure 35. Pneumatic actuator 124 Figure 36. Arrangement of indicating devices in glovebox ventilation system 134 Figure 37. Typical local mounting for differential pressure gauge 135 Figure 38. Indicating a pressure drop through a filter 135 Figure 39. Velocity measurements 136 Figure 40. Orifice meter method of measuring volume flow rate in small ducts 137 Figure 41. Arrangement of sharp-edge concentric orifice in small duct 138 Figure 42. Typical glovebox with major features 141 Figure 43. Characteristics of gloveboxes 142 Figure 44. Glovebox with multiple gloveports to facilitate access 143 Figure 45. Methods of injecting test aerosol and extracting samples (Methods A and B) 145 Figure 46. Methods of injecting aerosols and extracting samples (Methods C and D) 145 Figure 47. Basic transformer symbols 153 Figure 48. Transformer polarity 154 Figure 49. Switches and switch symbols 154 Figure 50. Switch and switch status symbology 155 Figure 51. Three-phase and removable breaker symbols 155 Figure 52. Common electrical component symbols 156 Figure 53. Large common electrical components 157 Figure 54. Basic log ic symbols 159 Figure 55. Conventions for depicting multiple inputs 159 Figure 56. Truth tables 160 Figure 57. ISM functions and the B-level cau sal analysis tree branches 205 Figure 58. C-level causal analysis tree codes 206 Figure 59. CAT branch A3 matrix (continued on next page) 207 Figure 60. Six steps of change analysis 210 Figure 61. Mini-MORT analysis chart 211 Figure 62. MORT-based root cause analysis form 212 Figure 63. Cause and effect chart process 213 Figure 64. Exam ple of cause and effect charting 214 Tables Table 1. Radiolytic decomposition of polyphenyls at 350 °C 28 Table 2. Loss of head for various d/D ratios 138 Table 3. Nondestructive testing personnel training requirements 201 v ACRONYMS °C degree Celsius °F degree Fahrenheit °R degree Rankine ABS acrylonitrile butadiene styrene AC alternating current AGS American Glovebox Society AISC American Institute of Steel Construction ALARA as low as reasonably achievable ANS American Nuclear Society ANSI American National Standards Institute API American Petroleum Institute ASCE American Society of Civil Engineers ASHRAE American Society of Heating, Refrigeration, and Air-Conditioning Engineers ASME American Society of Mechanical Engineers ASTM ASTM International (formerly American Society for Testing and Materials) B&PV ASME Boiler and Pressure (B&PV) Vessel Code BCC body-centered cubic BMEP brake mean effective pressure BNA baseline need assessment Btu British thermal unit CAT causal analysis tree CD critical decision CFC commercial chlorofluorocarbon cfm cubic feet per minute CFR Code of Federal Regulations cfs cubic feet per second CIPT contractor integrated project team COR code of record CPVC chlorinated polyvinyl chloride CRD contractor requirements document CSE cognizant system engineer dB decibel DC direct current DDESB DoD Explosives Safety Board DMG directives management group DoD U.S. Department of Defense DOE U.S. Department of Energy vi ACRONYMS DP differential pressure DSA documented safety analysis E.O. Executive Order EGSA Electrical Generating Systems Association EPA U.S. Environmental Protection Agency ESF engineered safety feature eV electron volt FAQS functional area qualification standard FCC face-centered cubic FEMA Federal Emergency Management Agency FHA fire hazard analysis fpm feet per minute fps feet per second ft foot or feet FTF filter test facility h hour HCFC hydrochlorofluorocarbon HEPA high efficiency particulate air HFC hydrofluorocarbons hp horsepower hp horsepower HT hydrostatic test HVAC heating, ventilation, and air conditioning IBC International Building Code IMEP indicated mean effective pressure in. inch IPT integrated project team ISM integrated safety management kg kilogram kH kilohertz KSA knowledge, skill, and ability kV kilovolt LANL Los Alamos National Laboratory lbf pound-force lbm pound-mass LC50 median lethal concentration LMTD log mean temperature difference vii ACRONYMS LT load test LTA less than adequate M&TE measuring and test equipment MeV million electron volts MIT Massachusetts Institute of Technology MJ megajoule mm millimeter MORT management oversight risk tree MSDS material safety data sheet MT magnetic particle test NASA National Aeronautics and Space Administration NCG non-condensable gas NDT nil-ductility transition NEHRP National Earthquake Hazards Reduction Program NFPA National Fire Protection Association NIST National Institute of Standards and Technology NLGI National Lubricating Grease Institute NNSA National Nuclear Security Administration NPH natural phenomena hazard NPSH net positive suction head NQA National Quality Assurance NRC Nuclear Regulatory Commission OMB Office of Management and Budget OPMO Organizational Property Management Office ORPS Occurrence Reporting and Processing System OSH Act Occupational Safety and Health Act OSHA Occupational Safety and Health Administration P&ID piping and instrumentation diagram PAFT Programme for Alternative Fluorocarbon Toxicity Testing PD project director PEP project execution plan PF packing factor PM program manager ppm parts per million psi pounds per square inch psia pounds per square inch absolute psig pounds per square inch gage viii ACRONYMS PT dye-penetrant test PTFE polytetrafluorethylene PVC polyvinyl chloride rad radiation absorbed dose RAMI reliability, availability, maintainability, and inspectability rem roentgen equivalent man rpm revolutions per minute RT radiographic test RTD resistance temperature detector RTP rapid transfer port sec second SEI Structural Engineering Institute SO Secretarial Officer SSCs structures, systems, and components TSR technical safety requirements TWA time-weighted average USDA U.S. Department of Agriculture UT ultrasonic test V volt VE value engineering VI visual inspection W watt wg water gage [...]... for those statements in this document is not practical In those instances, references are included to guide the candidate to additional resources SCOPE This reference guide addresses the competency statements in the June 2008 edition of DOE-STD-1161 -2008, Mechanical Systems Functional Area Qualification Standard The qualification standard contains 36 competency statements Please direct your questions... plain text, also mostly without remark Capitalized terms are found as such in the qualification standard and remain so in this reference guide When they are needed for clarification, explanations are enclosed in brackets Every effort has been made to provide the most current information and references available as of September 2008 However, the candidate is advised to verify the applicability of the information... identified In those cases, such documents should be included in local qualification standards via the Technical Qualification Program 1 In the cases where information about an FAQS topic in a competency or KSA statement is not available in the newest edition of a standard (consensus or industry), an older version is referenced These references are noted in the text and in the bibliography Only significant...PURPOSE The purpose of this reference guide is to provide a document that contains the information required for a Department of Energy (DOE)/National Nuclear Security Administration (NNSA) technical employee to successfully complete the Mechanical Systems Functional Area Qualification Standard (FAQS) Information essential to meeting the qualification requirements is provided; however,... second) is equal to the power produced by the engine Gas Standard Cycle The following is taken from McGraw-Hill Dictionary of Scientific and Technical Terms A gas standard cycle is a sequence in which a gaseous fluid undergoes a series of thermodynamic phases, ultimately returning to its original state The Brayton cycle is an example of a gas standard cycle This cycle, also called the Joule or complete... Gravity Specific gravity is a measure of the relative density of a substance as compared to the density of water at a standard temperature Physicists use 39.2 °F as the standard, but engineers ordinarily use 60 °F In the International System of Units, the density of water is 1.00 g/cm3 at the standard temperature Therefore, the specific gravity (which is dimensionless) for a liquid has the same numerical... during the process (Btu/lbm) Like enthalpy, entropy cannot be measured directly Also, like enthalpy, the entropy of a substance is given with respect to some reference value For example, the specific entropy of water or steam is given using the reference that the specific entropy of water is zero at 32 °F The fact that the absolute value of specific entropy is unknown is not a problem, because it is... a substance, like pressure, temperature, and volume, but it cannot be measured directly Normally, the enthalpy of a substance is given with respect to some reference value For example, the specific enthalpy of water or steam is given using the reference that the specific enthalpy of water is zero at 01 °C and normal atmospheric pressure The fact that the absolute value of specific enthalpy is unknown... your questions or comments related to this document to the NNSA Learning and Career Development Department PREFACE Competency statements and supporting knowledge and/or skill statements from the qualification standard are shown in contrasting bold type, while the corresponding information associated with each statement is provided below it A comprehensive list of acronyms and abbreviations is found at... grammatical or spelling corrections, and changes to style) appear without remark ACKNOWLEDGEMENTS Thanks to Del Kellogg (Pantex Site Office) for participating in the development and/or review of this reference guide, including providing some of the content for the responses to the knowledge, skill, and ability statements 2 TECHNICAL COMPETENCIES General Technical 1 Mechanical systems personnel shall demonstrate . Mechanical Systems Qualification Standard Reference Guide SEPTEMBER 2008 This page is intentionally blank. Table. references are included to guide the candidate to additional resources. SCOPE This reference guide addresses the competency statements in the June 2008