PALO VERDE NUCLEAR GENERATING STATION HVAC Training Classroom Lesson HVAC Training Date: 2/9/2011 9:41:06 AM LP Number: NMH30C000105 Rev Author: Ron Newell Title: Chiller Maintenance Technical Review: Williams, Donnell L(Z08141) Digitally signed by Williams, Donnell L(Z08141) DN: cn=Williams, Donnell L(Z08141) Reason: I have reviewed this document Date: 2011.02.
HVAC Training Title: Chiller Maintenance Page: 2 of 42 Lesson Plan #: NMH30C000105 INITIATING DOCUMENTS 15DP-OTR69 Training and Qualification Administration Training Program Description for HVAC Maintenance ACAD 02-001 The Objectives and Criteria for Accreditation of Training in the Nuclear Power Industry REQUIRED TOPICS TCSAI# 2874669 CRDR# 2850439 THREAD SEALER ON CHILLER 1MECBE01 GUIDE VANE SHAFT TCSAI# 2947906 CRDR# 2934843 (U-2) ON 10/23/06 AT APPROXIMATELY 0624, ESSENTIAL CHILLER "B" TRIPPED ON LO
HVAC Training Title: Chiller Maintenance Page: 3 of 42 Lesson Plan #: NMH30C000105 VTD-J010-0005 JAMESBURY INSTALLATION, MAINTENANCE & OPERATING INSTRUCTIONS EJS0, EJX50, EJ90t AND EJX90 ELECTRIC VALVE ACTUATORS [PUB. # IMO-48]. VTD-J010-0023 JAMESBURY INSTALLATION, MAINTENANCE AND OPERATING INSTRUCTIONS FOR EJ/EJX (MODEL G) ELECTRIC ACTUATORS [PUB. # IMO-49]. WO Task# 069215 Perform maintenance on essential chiller. WO Task# 092726 Perform inspection/rework of chiller internals and replace PVS.
HVAC Training Title: Chiller Maintenance Page: 4 of 42 Lesson Plan #: NMH30C000105 CRDR 2689093 Low oil level caused low oil temperature on 2MECBE01. CRDR 2553858 Several of the normal chillers have tripped due to low lube oil pressure. CRDR 2421005 Oil leak caused by a loose clamp on an oil line support.
HVAC Training Title: Feb 09, 2011 Chiller Maintenance Ron Newell Page: 5 of 42 Lesson Plan #: NMH30C000105 Added operating experience from CRDR 3409841
HVAC Training Title: Page: 6 of 42 Chiller Maintenance Lesson Plan #: NMH30C000105 Tasks and Topics Covered The following tasks are covered in Chiller Maintenance : Task or Topic Number* Task Statement Lesson: Chiller Maintenance CHL111 Change oil filter CHL112 Change filter/dryer CHL118 Inspect refrigerant safety relief valve CHL119 Install refrigerant safety relief valve CHL121 Remove refrigerant safety relief valve Total task or topics: 5
HVAC Training Title: Chiller Maintenance Page: 7 of 42 Lesson Plan #: NMH30C000105 TERMINAL OBJECTIVE: 1 Given the applicable work instructions, reference documents, and M&TE the trainee will, perform various maintenance activities on the Carrier 19FA Centrifugal Chiller. Mastery will be demonstrated by class participation, and successfully completing a written examination with a minimum score of 80%. 1.
HVAC Training Title: Page: 8 of 42 Chiller Maintenance Lesson Plan #: NMH30C000105 Course Introduction In this course the HVAC Trainee will learn how to perform chiller maintenance on the Normal and Essential chillers. It is everyone’s responsibility to perform their work safely. Ask yourself before starting the job these Prevent Event questions…………………….. I. Pre-Job Brief A. Focus On Five (Task Preview) Familiarize worker with the scope of work, task sequence, and critical steps. 1.
HVAC Training Title: Chiller Maintenance Page: 9 of 42 Lesson Plan #: NMH30C000105 4. Identify specific error prevention defenses to be used. 5. Identify actions to assure proper configuration control. B. Schedule 1. Length of class 2. Break policy a. Two Minute Drill – After lunch at a minimum 3. Evaluation 4. Post training critique C. Qualification 1. Identify what they will be qualified to do upon completion of the course 2.
HVAC Training Title: Chiller Maintenance Page: 10 of 42 Lesson Plan #: NMH30C000105 Calibrate Flow transmitter and ratemeters Evaluations: Written Evaluation Laboratory Practical – Calibrate Controls Laboratory Practical – Calibrate Agastat Relays Laboratory Practical – Motor Terminal Qualification Requirements NMH30 - Chiller Maintenance and Calibration (Initial Training) JQC - NMH0100051 Chiller Maintenance and Calibration JQC - Calibration of the Cooler water low temperature switch (recycle) on a Pow
HVAC Training Title: TO: 1 Chiller Maintenance Page: 11 of 42 Lesson Plan #: NMH30C000105 Given the applicable work instructions, reference documents, and M&TE the trainee will, perform various maintenance activities on the Carrier 19FA Centrifugal Chiller. Mastery will be demonstrated by class participation, and successfully completing a written examination with a minimum score of 80%.
HVAC Training Title: EO: 1.1 Chiller Maintenance Page: 12 of 42 Lesson Plan #: NMH30C000105 Discuss lessons learned from selected Operating Experience and CRDRs associated with performing chiller maintenance activities. Introduction The weekly PM is a valuable tool to monitor chiller overall condition and performance. Many of the corrective maintenance activities are first identified when performing the weekly PM.
HVAC Training Title: Chiller Maintenance Page: 13 of 42 Lesson Plan #: NMH30C000105 A total volume of 8 gallons of oil in the chiller seems a little low for a chiller with the oil level in the upper portions of the upper site glass. It may be possible that the oil volume accounting for this chiller may not be correct. A contributing factor may have been the condition of the chiller bull’s eye type site glasses to prevent identifying a problem before it caused a problem.
HVAC Training Title: Chiller Maintenance Page: 14 of 42 Lesson Plan #: NMH30C000105 Details of the event: We have experienced problems with the lube oil heater temp controllers in the past. 200 °F has been used as a "cut-off" temperature to evaluate whether lube oil lubrication ability could be subject to premature breakdown. The temperature controller (1JECATC0518) for the EC chiller oil sump heater has some history of the set point drift.
HVAC Training Title: Chiller Maintenance Page: 15 of 42 Lesson Plan #: NMH30C000105 Due to the reactor being shutdown for maintenance the “B” essential chiller had been operated at a low load condition for several days. Oil had been added to the oil sump several times during this time. When the chiller was secured following reactor startup, it was not noticed that the oil level was below the bottom of the lower site glass.
HVAC Training Title: Chiller Maintenance Page: 16 of 42 Lesson Plan #: NMH30C000105 This event was discussed with System Engineering and the HVAC Maintenance personnel. No new issues were raised during the review of this event. Being mindful of plant conditions and the effect on the running chiller is important. No other actions have been identified during this adverse CRDR evaluation. CRDR 2553858 Documents that several of the normal chillers have tripped due to low lube oil pressure.
HVAC Training Title: Chiller Maintenance Page: 17 of 42 Lesson Plan #: NMH30C000105 This modification will require two adjustments. Change the oil sump temperature setpoint: The setpoint change requires the chiller to be shutdown while the controller is being adjusted. Remove the cover from the oil sump temperature controller. Adjust the oil sump temperature setpoint to 155°F ± 5°F. Verify that the oil sump temperature controller is cycling the heater on and off to maintain temperature.
HVAC Training Title: Chiller Maintenance Page: 18 of 42 Lesson Plan #: NMH30C000105 On October 23, 2006, the Essential Chiller 2MECBE01 tripped on low oil pressure. Operations generated work order 2934841 to troubleshoot and rework. On October 23, HVAC performed troubleshooting. Initial problem indication was possibly a loose connector but after tightening the connection and running the pump; the amp draw was too high. The decision was made to replace the oil pump.
HVAC Training Title: Chiller Maintenance Page: 19 of 42 Lesson Plan #: NMH30C000105 Operations was notified by HVAC that during the performance of PM Task # 2615486 that the refrigerant level was less than the minimum OPERABILITY level (3 3/8 inches). This notification resulted in the control room conservatively declaring (U-3) Essential Chiller B INOPERABLE( due to the words MINIMUM OPERABILITY LEVEL).
HVAC Training Title: Chiller Maintenance Page: 20 of 42 Lesson Plan #: NMH30C000105 3. If the refrigerant level remains out of range notify Operations, Engineering and HVAC for additional direction. The intent is to insure an accurate level is obtained prior to making an operability or corrective action decision. However, operations is required to be notified and requested to run the chiller.
HVAC Training Title: Chiller Maintenance Page: 21 of 42 Lesson Plan #: NMH30C000105 STA made a conservative decision to declare the Chiller inoperable prior to performing these steps and has every right to do so. The discrepancy between the Operability level listed in the task and the 40OP are due to the stand-by vs. operating conditions when the readings are required to be taken.
HVAC Training Title: Chiller Maintenance Page: 22 of 42 Lesson Plan #: NMH30C000105 On 10/28/99, the elbow on the inlet line to the oil cooler on essential chiller 1MECBE01 was removed and reinstalled (under Corrective Maintenance Work Order 00889903) in an attempt to eliminate an oil leak in the line. During the performance of this work, the technician had difficulty removing the elbow from the oil cooler. After repeated attempts, the technician was finally able to remove the elbow.
HVAC Training Title: Chiller Maintenance Page: 23 of 42 Lesson Plan #: NMH30C000105 Additional lessons learned: OE11587 documents the failure of the Control room ventilation syste m chiller at Oconee Nuclear Site caused by refrigerant leaks. On March 9, 2000, with all three Oconee Units at 100 percent power, both control room chillers were declared inoperable after both had tripped. The station started to shutdown the units as required by the plant technical specifications.
HVAC Training Title: Chiller Maintenance Page: 24 of 42 Lesson Plan #: NMH30C000105 CRDR 2850439 Thread sealer on Chiller 1MECBE01 Guide Vane Shaft Failure Description HVAC Maintenance found one of the set screws loose on the guide vane shaft crank arm during the performance of normal chiller maintenance on essential chiller 1MECBE01 during U1R11. The crank arm was loose, but was not slipping on the shaft. One of three (3) set screws was found loose.
HVAC Training Title: Chiller Maintenance Page: 25 of 42 Lesson Plan #: NMH30C000105 pulleys or cable. The guide vane actuator seemed to respond to manual control when disconnected from the crank arm linkage. HVAC Technicians removed the guide vane actuator linkage arm in preparation for pulling the suction pipe spool that contains the guide vane mechanism. The technicians noticed a streak of thread sealer from the crank arm to the bearing housing yoke for the guide vane shaft.
HVAC Training Title: Chiller Maintenance Page: 26 of 42 Lesson Plan #: NMH30C000105
HVAC Training Title: Chiller Maintenance EO: 1.2 Page: 27 of 42 Lesson Plan #: NMH30C000105 Discuss the sequence of work to coordinate chiller maintenance activities. Introduction In this lesson the trainee will discuss various maintenance activities on the Carrier 19FA Chiller.These tasks are performed during the outage where coordination of the work activities is critical. Lessons learned form OE15289 - Freon Sprayed out of Chiller Valve due to Delay in Executing Work will also be discussed.
HVAC Training Title: Chiller Maintenance Page: 28 of 42 Lesson Plan #: NMH30C000105 iii) does the machine need to be evacuated iv) what other work is planned during the outage. (CM work may have been added to the scope) i) If we are doing minor work then we only need to go to four inches mercury. Sometimes it’s required to pull down to 4 inches several times on the R – 114 machines. j) A word of caution, care should be taken to not accidentally open the transfer valve.
HVAC Training Title: Chiller Maintenance Page: 29 of 42 Lesson Plan #: NMH30C000105 elapsed from the time of notification by the HVAC group to the actual start of disassembly. Based on the information received from the HVAC mechanic, the I&C technician did not check the freon pressure gage. The technician was loosening the bonnet bolts for the jet pump solenoid valve on "C" Chiller when freon started spraying from the opening.
HVAC Training Title: Chiller Maintenance EO: 1.3 Page: 30 of 42 Lesson Plan #: NMH30C000105 Discuss the process of control panel and field wiring inspection. Introduction In this objective the trainee will learn what to look for when inspecting the chiller control panel and field wiring. Main Idea Perform a Two Minute Drill: What are the task conditions? 1) Assess and address work place hazards. 2) Verify that the chiller control panel is de-energized.
HVAC Training Title: Chiller Maintenance Page: 31 of 42 Lesson Plan #: NMH30C000105 4) Rework per 13-EN-306 and VTM-C150-0001. 5) Due to the connections physical location, ensure the spade lug connections are tight. 6) Also check the box cover gasket condition Good work practices: DMWO# 854746 was written due to the frequent failures (resulting from the high heat conditions) and equipment obsolescence. Extra care should be taken when checking the wiring and connections.
HVAC Training Title: Page: 32 of 42 Chiller Maintenance EO: 1.4 Lesson Plan #: NMH30C000105 Discuss the process of measuring oil heater wattage. Introduction In the previous course NMH29 Chiller Fundamentals the trainee learned how to adjust the thermostat for the oil sump heater. In this objective the trainee will learn how to check the amperage of the oil immersion heater, design heater wattage is 1000 watts.
HVAC Training Title: Chiller Maintenance Page: 33 of 42 Lesson Plan #: NMH30C000105 3) If the heater wattage is not per design notify HVAC for further information. Demo Perform a hazard assessment. Ask the trainee to identify the PPE requirements for this task.
HVAC Training Title: Chiller Maintenance EO: 1.5 Page: 34 of 42 Lesson Plan #: NMH30C000105 Discuss the process for changing the oil filters. Introduction In this objective the trainee review the criteria for changing the oil filters. Main Idea Assess and address workplace hazards. Verify the oil sump heater is de-energized prior to removing oil from the sump. Oil filter change out. Once the chiller pump down is complete, tag out the oil immersion heater and drain the oil sump.
HVAC Training Title: Chiller Maintenance Page: 35 of 42 Lesson Plan #: NMH30C000105 3) A micron is defined as the thousandth part of one-millimeter (.001 millimeter). a) The screen is 18 x 16 mesh aluminum with a wire diameter of .011”. b) The support tube is 3/16” expanded aluminum with both ends molded into epoxy and the cap. c) The felt washers are made of 100% white wool or dacron felt.
HVAC Training Title: Chiller Maintenance Page: 36 of 42 Lesson Plan #: NMH30C000105 Demonstrate how the filters are disassembled and reassembled. Be sure to point out the correct items including the o-rings. Refer to the Carrier training handout Chapter 2 for oil filters Review the required documentation and disposal process for used chiller oil .
HVAC Training Title: Chiller Maintenance EO: 1.6 Page: 37 of 42 Lesson Plan #: NMH30C000105 Discuss the process for changing the refrigerant filters. Introduction In this objective the trainee discuss replacing the refrigerant filter. Main Idea Assess and address workplace hazards. Verify the refrigerant has been transferred and the shell pumped down completely prior to proceeding. Refrigerant filter change out.
HVAC Training Title: Chiller Maintenance Page: 38 of 42 Lesson Plan #: NMH30C000105 On 9/20/04, Operations personnel at Hope Creek identified a refrigerant leak after noticing the formation of ice on a skid mounted CUNO filter. Immediate actions performed included securing the chiller, evacuating the area for personal safety issues due to the presence of R-114 refrigerant, and pumping down the chiller refrigerant charge to the storage vessel.
HVAC Training Title: Chiller Maintenance Page: 39 of 42 Lesson Plan #: NMH30C000105 OE 11587 - Failure of Control Room Ventilation Syste m Chillers 1) What happened? On 9/20/04, Operations personnel at Hope Creek identified a refrigerant leak after noticing the formation of ice on a skid mounted CUNO filter.
HVAC Training Title: Chiller Maintenance EO: 1.7 Page: 40 of 42 Lesson Plan #: NMH30C000105 Discuss the process of inspecting and replacing the refrigerant PSV's Introduction In this objective the trainee will learn what to look for when inspecting the refrigerant pressure safety relief valve and how to replace them. Main Idea Assess and address workplace hazards. Verify the refrigerant has been transferred and the shell pumped down completely prior to proceeding. Use a back-up wrench for removal.
HVAC Training Title: Chiller Maintenance iii) 2 on the Normal chiller E02 at 285 psig c) Pressure rating of the pumpout condenser.
HVAC Training Title: Chiller Maintenance Page: 42 of 42 Lesson Plan #: NMH30C000105 SUMMARY OF MAIN PRINCIPLES The following ite ms are things to consider in your lesson summary. They are not mandatory. You should develop your own summary., Objectives Review Review the Lesson Objectives Topic Review Restate the main principles or ideas covered in the lesson. Relate key points to the objectives. Use a question and answer session with the objectives.
