Left: Lubricants and cutting oils are a critical component in many of the manufacturing processes needed in a nuclear plant
technologies, application techniques, and monitoring methods, thereby enhancing the reliability and safety of nuclear systems.
Best practices for large forgings Best practices for large forgings include the selection of lubricants, application techniques, and monitoring and maintenance. Selecting the right type of lubricant for nuclear manufacturing is essential because it must be able to withstand high temperatures without breaking down. They also must have a high load-bearing capacity in order to endure the immense stress placed on large forgings. Application techniques for precision lubrication include manual or automated lubrication systems. Manual application using brushes or spray systems are better suited for hard-to-reach areas, ensuring that the lubricant is applied precisely where needed. Automated systems can be programmed to deliver the right amount of lubricant at the correct intervals, providing a more uniform application and consistent lubrication. Finally, monitoring and maintenance are necessary to ensure that any issues are detected and resolved early and quickly. Regular inspections and lubricant analysis should be conducted to check for signs of inadequate lubrication, contamination, degradation, and other issues. These monitoring techniques help in planning maintenance and avoiding unexpected equipment failures.
Best practices for exotic metals Nuclear manufacturing utilises a variety of exotic metals, including zirconium, titanium, nickel, and stainless steel alloys. Their superior strength and corrosion resistance make them ideal for nuclear applications, but it is important to assess both thermal and chemical compatibility with lubricants used in manufacturing, as well as the surface treatments and applications utilised. Ensure that lubricants are chemically compatible with the specific metal to avoid compromising integrity and ensuring that the lubricants selected can perform consistently across extreme temperature ranges without thermal degradation. Polishing or coating surfaces before applying lubrication can increase bonding, which allows for more effective and longer-lasting lubrication. The correct film thickness in
precision lubrication of exotic metals is also crucial – too much can attract contaminants and too little can result in inadequate protection. The criticality of the additives in the lubricant depends on the specific application and operating environment. The concentration of the most critical additives is monitored directly or indirectly during oil analysis. In mission critical or safety related applications, the lubricant is changed frequently to ensure it performs its design function during under all circumstances, even those unforeseen. Due to close monitoring, additive levels are rarely depleted. In nuclear power plants, the steam turbine oils, which
may remain in the system for over 20 years, are regularly made up with fresh oil (usually up to 5% annually). This maintains satisfactory conditions, assuming continuous filtration system operation. Additionally, although steam turbine oil may remain in place for far longer, best practice is typically to drain the turbine oil from the reservoir every 10 years, while the reservoir is also cleaned during this maintenance interval.
Integrating lubrication with predictive maintenance Integrating precision lubrication with predictive maintenance strategies is a significant advancement for the nuclear sector. Advanced monitoring systems and data analytics can predict lubrication needs, identify potential issues before they cause failures, and optimise maintenance schedules. This proactive approach enhances equipment reliability and reduces unexpected downtime. By adhering to these best practices and leveraging
continuous training, advanced technologies, and predictive maintenance strategies, the nuclear industry can ensure the reliability and safety of its operations, particularly when dealing with the demanding conditions faced by large forgings and exotic metals. Due to the specific requirements that nuclear
manufacturing entails, it’s a good idea to work closely with industry experts to determine the correct lubricants and appropriate applications. They can help determine the best products and practices to use with large forgings and exotic metals to ensure the safety, reliability, and longevity of nuclear manufacturing operations and equipment. ■
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