Reactor Manufacturing and Welding

Reactor fabrication and welding are crucial processes involved in the construction of various types of reactors, including nuclear reactors, chemical reactors, and other industrial-scale reactors. These processes ensure the integrity, safety and efficiency of the reactors.
The following steps are followed in the Reactor Manufacturing and Welding Application.

Reactor Manufacturing:

• Design and Engineering: Reactor production begins with the design and engineering phase, where detailed plans are created taking into account factors such as operating conditions, materials, and safety requirements.
• Material Selection: Material selection for reactor fabrication depends on the reactor type and the process in which it will be used. Common materials include stainless steel, carbon steel, alloy steel, and special alloys that can withstand high temperatures and corrosive environments.
• Cutting and Shaping: Once materials are selected, they are cut and shaped into required components using a variety of techniques such as machining, shearing, bending, and forming.
• Welding and Joining: Welding is an important process in reactor fabrication as it is used to join components and create a structurally sound vessel. Different welding techniques such as shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW) and submerged arc welding (SAW) are used according to material and design features.
• Quality Assurance: Throughout the manufacturing process, quality assurance measures are implemented to ensure that reactor components meet required standards and specifications. Non-destructive testing methods such as radiographic testing, ultrasonic testing, and liquid penetrant testing are commonly used to detect defects or defects.
• Surface Treatment and Coating: Reactor components can be subjected to surface treatment processes such as sandblasting or chemical cleaning to remove impurities and improve corrosion resistance. Additionally, protective coatings or primers can be applied to protect against corrosive substances or extreme temperatures.

Reactor Welding Process;

• Welding Techniques: As mentioned earlier, various welding techniques can be used in reactor fabrication. The choice of technique depends on factors such as material type, thickness and desired weld quality. Common welding processes include Tungsten Inert Gas (TIG) welding, Metal Inert Gas (MIG) welding, and Submerged Arc Welding (SAW).
• Welding Procedure Qualification: Welding procedures undergo qualification to ensure their suitability for the particular reactor structure. This includes testing and evaluating welds for mechanical properties such as strength and ductility and performing non-destructive examinations to detect any defects.
• Welding Codes and Standards: Reactor welding is carried out according to valid codes and standards that vary according to the type of reactor and its intended use. For example, nuclear reactors have strict source codes for nuclear applications, such as ASME Boiler and Pressure Vessel Code Part III.
• Welding Inspection: Qualified inspectors monitor the welding process to ensure compliance with established procedures and standards. They visually inspect welds, perform non-destructive tests and perform dimensional checks to verify the quality and accuracy of welds.
• Post Weld Heat Treatment (PWHT): In some cases, post weld heat treatment may be required to reduce residual stresses and improve the mechanical properties of welded joints. This process involves heating the welded area to a certain temperature and then gradually cooling it according to defined procedures.