RCNET Maintenance Toolkit: Mechanical

Toolkit Description: 
This Mechanical course is from RCNET Comprehensive Teaching Toolkit: Maintenance and is drawn from curriculum taught in the Palo Verde Nuclear Generating Station Training Program. The program is designed to train nuclear maintenance technicians to work in nuclear power plants and covers Electrical Maintenance, Instrumentation and Control Maintenance, and Mechanical Maintenance. 

Toolkit Course Contents:
RCNET Maintenance Toolkit: Mechanical covers the topics of diesel engines, heat exchangers, lathe and milling machines, site welding, turbines, fire protection, HVAC, reactor head and components repair and troubleshooting, surveillance testing, and valves.

Materials available as part of the Teaching Toolkit include 65 multi-part lesson plans, 17 PowerPoints, and three course overviews, and other related course materials.

Lesson plans include duration time, objectives, lesson introduction, classroom guidelines, motivation, a lesson outline, as well as a summary of main principles with an objectives review, question and answer section, and problem areas.

The PowerPoints include lesson presentations and collections of drawings and images.

Course overviews include purpose and objectives of the course, who the course is designed for, prerequisites, course methods, course length, retrain interval, class size, passing score, and active lesson plans. 

For orientation purposes Air Start System.pdf is included as a separate attachment and offers a sample of the type of material included in this course. 

Below is a list of the files contained within the .zip attachment. The size of each file is included in parenthesis. 

Mechanical  (118 files 298.7MB)

• Diesel Engines
  • Air Start System Lesson (Air Start System.pdf 183 KB)
  • Auxiliary Drive and Camshaft Lesson (Auxiliary Drive and Camshaft.pdf 173 KB)
  • Bearings Lesson (Bearings.pdf 196 KB)
  • Combustion Air System Lesson (Combustion Air System.pdf 203 KB)
  • Control System Lesson (Control System.pdf 216 KB)
  • Cooling Water System Lesson (Cooling Water System.pdf 163 KB)
  • Emergency Diesel Generator (Emergency Diesel Generator.ppt 43.5 MB)
  • Emergency Diesel Description Lesson (Emergency Diesel_Description.pdf 192 KB)
  • Filter Housing (Filter Housing.ppt 194 KB)
  • Fuel System Lesson (Fuel System.pdf 226 KB)
  • Head Removal (Head Removal.ppt 1.3 MB)
  • Heads, Liners, Pistons and Connecting Rods Lesson (Heads, Liners, Pistons and Connecting Rods.pdf 271 KB)
  • Intercooler (Intercooler.ppt 3 MB)
  • Lubrication System Lesson (Lubrication System.pdf 191 KB)
  • Over speed Trip Issue in unit 3 (Over speed Trip Issue in unit 3.ppt 275 MB)
  • Test Question Bank Diesels (Question Bank_ Diesels.doc 226 MB)
  • Turning Gear Lesson (Turning Gear.pdf 222 KB)
• Fire Protection
  • Components of Fire Protection Systems Lesson (Components of Fire Protection Systems.pdf 223 KB)
  • Fire Protection (Fire Protection.ppt 9.6 MB)
  • Valves of the Fire Protection System Lesson (Valves of the Fire Protection System.pdf 212 KB)
• Heat Exchangers
  • Construction and Operation Heat Exchangers Lesson (Construction and Operation_ Heat Exchangers.pdf 171 KB)
  • Heat Exchangers Lessons (Heat Exchangers.pdf 4.9 MB)
  • Heat Exchangers (Heat Exchangers.ppt 14 MB)
  • Inspection and Cleaning Heat Exchangers Lesson (Inspection and Cleaning_Heat Exchangers.pdf
  • Test Bank Heat Exchangers (Test Bank_Heat Exchangers.doc 51 KB)
  • Tube Maintenance Heat Exchangers Lesson (Tube Maintenance_Heat Exchangers.pdf 243 KB)
• HVAC
  • AC Units Job Qualification Card (AC Units Job Qualification Card.pdf 162 KB)
  • Calibrate Chiller Controls and Indicators Lesson (Calibrate Chiller Controls and Indicators.pdf 393 KB)
  • Calibrate Chiller Water Flow Transmitters and Rate Meters Lesson (Calibrate Chiller Water Flow Transmitters and Rate Meters.pdf 373 KB)
  • Chiller High Voltage Motor Terminations Lesson (Chiller High Voltage Motor Terminations.pdf 200 KB)
  • Chiller Maintenance Lesson (Chiller Maintenance.pdf 416 KB)
  • CO2 Units Lesson (CO2 Units.pdf 121 KB)
  • HVAC A/C Units Course overview (course overview.pdf 63 KB)
  • Diesel Air Dryers Lesson (Diesel Air Dryers.pdf 121 KB)
  • Freeze Seals Laboratory Practical Evaluation (Freeze Seals Laboratory Practical Evaluation.DOC 230 KB)
  • Generrex AC Unit Lesson (Generrex AC Unit.pdf 98 KB)
  • INPO-Freeze Sealing Events (INPO-Freeze Sealing Events.doc 227 KB)
  • Movie notes (do not have the movie) (Movie notes (do not have the movie).DOC 50 KB)
  • Multiplexer and Gas Turbine AC Units Lesson (Multiplexer and Gas Turbine AC Units.pdf 105 KB)
  • Nitrogen Freeze Seal Lesson (Nitrogen Freeze Seal.pdf 203 KB)
  • NMH06 (NMH06.DOC 21 KB)
  • PAMU AC Units Lesson (PAMU AC Units.pdf 116 KB)
• Lathe and Milling Machines
  • Common Milling Machine Operations Lesson (Common Milling Machine Operations.pdf 234 KB)
  • Lathe Operations Course Overview (Course Overview.pdf 101 KB)
  • General Snubbers Drawings (General Snubbers Drawings.ppt 528 KB)
  • Test Bank Lathe Operations (Lathe Operations (1).doc 35 KB)
  • Lathe Operations Lessons (Lathe Operations.doc 904 KB)
  • Lathe Operations (Lathe Operations.ppt 17.3 MB)
  • Machining Between Centers Lesson (Machining Between Centers.pdf 252 KB)
  • Machining In A Chuck Lesson (Machining In A Chuck.pdf 290 KB)
  • Mechanical and Hydraulic Snubbers Lessons (Mechanical and Hydraulic Snubbers.pdf 197 KB)
  • Milling Machine Components Lessons (Milling Machine Components.pdf 269 KB)
  • Test Bank Milling Machine Operations (Milling Machine Operations (1).doc 34 KB)
  • Milling Machine Operations Lessons (Milling Machine Operations.doc 6.3 MB)
  • Milling Machine Operations (Milling Machine Operations.ppt 16.1 MB)
  • RCP Snubber Images (RCP Snubber Images.ppt 326 KB)
  • Safety and Introduction to Lathe Operations Lesson (Safety and Introduction to Lathe Operations.pdf 234 KB)
  • Snubber Identification and Inspection Lesson (Snubber Identification and Inspection.pdf 255 KB)
  • Snubber Prerequisites Lesson (Snubber Prerequisites.pdf 526 KB)
• Reactor Head Components Repair and Troubleshooting
  • Basic MST Construction Lesson (Basic MST Construction.pdf 351 KB)
  • DSTT SETPOINT INFORMATION (DSTT SETPOINT INFORMATION.doc 44 KB)
  • DSTT Setup and Adjustment Lesson (DSTT Setup and Adjustment (2).doc 462 KB)
  • DSTT Setup and Adjustment Lesson (DSTT Setup and Adjustment.doc 529 KB)
  • Maintenance of MST Lesson (Maintenance of MST.pdf 272 KB)
  • Mechanical Seal Assemblies Lesson (Mechanical Seal Assemblies.pdf 260 KB)
  • MST Operation and Troubleshooting Lesson (MST Operation and Troubleshooting.pdf 303 KB)
  • Multi Stud Tensioner Lab Practical (Multi Stud Tensioner Lab Practical.pdf 283 KB)
  • Operate Reactor Head Troubleshoot and Repair MST Lab Practical Evaluation (Operate Reactor Head_troubleshoot and repair MST Lab Practical Evaluation.doc 229 KB)
  • Pump Disassembly and Reassembly Lesson (Pump Disassembly and Reassembly.pdf 349 KB)
  • Reactor Coolant Pump Bearings and Seals Lessons (Reactor Coolant Pump Bearings and Seals.pdf 4.8 MB)
  • Reactor De-Stack Lesson (Reactor De-Stack.doc 597 KB)
  • Reactor Head Assembly Lesson (Reactor Head Assembly.doc 397 KB)
  • Reactor Head Reactor De-Stack Lesson (Reactor Head Reactor De-Stack.doc 516 KB)
  • Reactor Head Lessons (Reactor Head.doc 11.6 KB)
  • Reactor Restack Lesson (Reactor Restack.doc 480 KB)
  • Reactor Support Components Lesson (Reactor Support Components.doc 362 KB)
  • Reactor Vessel Head Multi-Stud Tensioner-partial Lessons (Reactor Vessel Head Multi-Stud Tensioner-partial.doc 422 KB)
  • Remove and Reinstall Reactor Head for Refueling Lessons (Remove and Reinstall Reactor Head for Refueling.doc 288 KB)
  • Seal Replacement Lesson (Seal Replacement.pdf 330KB)
  • Thrust Bearing Maintenance Lesson (Thrust Bearing Maintenance.pdf 390 KB)
  • Troubleshoot and Repair MST Lab Practical Evaluation (Troubleshoot and Repair MST Lab Practical Evaluation.doc 226 KB)
• Site Welding
  • Hanger drawing samples (hanger drawing samples.ppt 614 KB)
  • Pipe Supports and Hangers (Pipe Supports and Hangers.pdf 267 KB)
  • Pipe Supports and Hangers (Pipe Supports and Hangers.ppt 829 KB)
  • Site Welding Safety (Site Welding Safety.pdf 473 KB)
  • Site Welding Safety (Site Welding Safety.ppt 31.3 MB)
  • Weld Safety Test Bank (Weld Safety.doc 34 KB)
• Surveillance Testing
  • Surveillance Testing Test bank (Surveillance Testing Testbank.doc 31 KB) 
  • Surveillance Testing Lesson (Surveillance Testing.pdf 10.7 MB)
• Turbines
  • Hood Gib key 1 (Hood Gib key 1.jpg 889 KB)
  • Hood Gib key 2 (Hood Gib key 2.jpg 895 KB)
  • Hood Gib key 3 (Hood Gib key 3.jpg 885 KB)
  • Large Steam Turbine Generator Lessons (Large Steam Turbine Generator.doc 42.5 MB)
  • Large Steam Turbine Generator (Large Steam Turbine Generator.ppt 37.5 MB)
  • Mechanical Maintenance Training Lesson (Mechanical Maintenance Training.pdf 215 KB)
  • Turb Brg bluing (Turb Brg bluing.jpg 875 KB)
  • Turb brg oil hole blue (Turb brg oil hole blue.jpg 842 KB)
  • Turbine Inspections Lessons (Turbine Inspections.pdf 176 KB)
  • Turbine Operation and Component Identification Lesson (Turbine Operation and Component Identification.pdf 186 KB)
  • Turbine Rework Lesson (Turbine Rework.pdf 178 KB)
  • Turbine Rotor Removal Lesson (Turbine Rotor Removal.pdf 222 KB)
• Valves
  • Air Operated Valve Calibration (Air Operated Valve Calibration.ppt 15.2 MB)
  • Course Overview (Overview.pdf 96 KB)
  • PM Inspection of Limitorque Actuators Lesson (PM Inspection of Limitorque Actuators.pdf 467 KB)
  • Rotork Actuator PM Inspection Lesson (Rotork Actuator PM Inspection.pdf 258 KB)
  • Rotork PM Inspection (continuing) (Rotork PM Inspection (continuing).ppt 1.5 MB)
  •  Valve Services Lesson (Valve Services.pdf 265 KB)