Mechanical Systems Qualification Standard DOE-STD-1161-2008 August 2012 Reference Guide The Functional Area Qualification Standard References Guides are developed to assist operators, maintenance personnel, and the technical staff in the acquisition of technical competence and qualification within the Technical Qualification Program (TQP). Please direct your questions or comments related to this document to Patrick C. Romero, Deputy TQP Manager, Office of Leadership and Career Management, NNSA Albuquerque Complex, 505.845.6371. This page is intentionally blank. Table of Contents FIGURES ....................................................................................................................................... v TABLES ....................................................................................................................................... vii VIDEOS ......................................................................................................................................... vii ACRONYMS ................................................................................................................................ ix PURPOSE ...................................................................................................................................... 1 SCOPE ........................................................................................................................................... 1 PREFACE ...................................................................................................................................... 1 TECHNICAL COMPETENCIES ............................................................................................... 2 1. Mechanical systems personnel shall demonstrate a working level knowledge of steady-state heat transfer. ............................................................................................................................ 2 2. Mechanical systems personnel shall demonstrate a working level knowledge of thermodynamics. ...................................................................................................................... 5 3. Mechanical systems personnel shall demonstrate a working level knowledge of fluid mechanics. ............................................................................................................................. 14 4. Mechanical systems personnel shall demonstrate a working level knowledge of the concepts, theories, and principles of basic material science. ................................................................. 21 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. ...................................................................................................................... 46 6. Mechanical systems personnel shall demonstrate a working level knowledge of mechanical diagrams, including: .............................................................................................................. 56 7. Mechanical systems personnel shall demonstrate a working level knowledge of installed mechanical equipment. .......................................................................................................... 60 8. Mechanical systems personnel shall demonstrate a working level knowledge of a typical diesel generator, including support systems. ......................................................................... 61 9. Mechanical systems personnel shall demonstrate a working level knowledge of the construction and operation of heat exchangers. ..................................................................... 69 10. Mechanical systems personnel shall demonstrate a working level knowledge of the theory and operation of heating, ventilation, and air conditioning (HVAC) systems. ..................... 77 11. Mechanical systems personnel shall demonstrate working level knowledge of general piping systems. ................................................................................................................................ 100 12. Mechanical systems personnel shall demonstrate a working level knowledge of the general construction, operation, and theory of valves. ..................................................................... 116 13. Mechanical systems personnel shall demonstrate a working level knowledge of safety and relief devices. ....................................................................................................................... 127 ii 14. Mechanical systems personnel shall demonstrate a working level knowledge of pump theory and operation. ...................................................................................................................... 131 15. Mechanical systems personnel shall demonstrate a working level knowledge of strainers and filters. ................................................................................................................................... 144 16. Mechanical systems personnel shall demonstrate a working level knowledge of the basic components, operations, and theory of hydraulic systems. ................................................. 151 17. Mechanical systems personnel shall demonstrate a working level knowledge of the components, operation, and theory of pneumatic systems. ................................................. 163 18. Mechanical systems personnel shall demonstrate a working level knowledge of the basic design, construction, and operation of glovebox systems. .................................................. 168 19. Mechanical systems personnel shall demonstrate a working level knowledge of the principles of lubrication. ...................................................................................................... 182 20. Mechanical systems personnel shall demonstrate a familiarity level knowledge of reading and interpreting electrical diagrams and schematics. .......................................................... 191 21. Mechanical systems personnel shall demonstrate a familiarity level knowledge of reading and interpreting electrical logic diagrams. ........................................................................... 196 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. ........ 199 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. .................................................................................................................... 206 24. Mechanical systems personnel shall demonstrate a working level knowledge of the following standards related to natural phenomena hazards: ................................................ 211 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. ............................................................ 213 26. Mechanical systems personnel shall demonstrate a working level knowledge of DOE standard DOE-STD-1073-2003, Configuration Management. ............................................ 217 27. Mechanical systems personnel shall demonstrate a familiarity level knowledge of the codes and standards of the American Society for Testing and Materials (ASTM)*. .................... 219 28. Mechanical systems personnel shall demonstrate a working level knowledge of the codes and standards of the American Society of Mechanical Engineers. ..................................... 221 29. Mechanical systems personnel shall demonstrate a familiarity level knowledge of the following organizations’ non-mechanical systems-specific codes and standards: .............. 227 iii 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). ......................................................................................................... 228 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: ....... 229 MANAGEMENT, ASSESSMENT, AND OVERSIGHT ...................................................... 238 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). ........................ 238 33. Mechanical systems personnel shall demonstrate a working level knowledge of assessment techniques (such as the