Reactor Building Integration_ Final Presentation_ Spring 2014 pfp

UCB Nuclear Engineering Thermal Hydraulics Lab

DESIGN INTEGRATION FOR MK-1 PB-FHR REACTOR BUILDING Jaben Root, Huu Nguyen, Daisuke Kazama, Sea Hong

2 UCB Nuclear Engineering Thermal Hydraulics Lab

Overview of Current Status of the UCB Commercial Prototype Design Effort

Overview

• Objective: design shield building and air duct vault for Mk.1 Pebble Bed Fluoride Salt Cooled Reactor (Mk1 PB-FHR)

– Overview of major systems developed in collaboration with various subject matter experts (SMEs)

– Spacing allocated for major components

– Modular design implemented

– Parameters for estimating structural cost and assessing future economics and life-cycle analysis, such as building and material volumes, quantified through solid modeling

– Storyboard describing detailed construction procedure developed

– Animation developed to illustrate construction storyboard



Starting Design



Final Integrated Plant Design

Underground common utilities tunnel

Shield building

DRACS chimney

Personnel airlock

Equipment hatch

Fuel canister well

Grade level

Intake filter

Main stack

Simple cycle bypass stack

HRSG

Gas turbine

Below-grade air duct vault

Ventilation exhaust system



Final Integrated Design



Proposed 12-unit Mk1 station

• 1200 MWe base load, 2900 MWe peak station output

St.Turbine

Bldg. A

Cooling Tower A

Switch

Yard A

Parking Lot

and Storage

(1200 Spaces)

Security

CheckpointHot/cold

Machine

Shop and

Warehouse

Plant

Entry

BldgControl

Building

Fuel

Handling

and

Storage

St.Turbine

Bldg. B

Cooling Tower B

Switch

Yard B

Common

Underground

Tunnel

Construction

Area

Water Storage

Protected Area Fence

600 m x 200 m

Outage

Support

Building

Administration

Building

Training

Building

Shipping

and

Receiving

Warehouse

Back-

up

Gen

St.Turbine

Bldg C.

Cooling Tower C

Switch

Yard C

Mk1 PB-FHR Modules 75 m O/C

Hydrogen

Storage

Salt

Storage

Water Treatment

Owner Controlled Area Fence

950 m x 750 m

Rad

Waste

Bldg

#9#10#11#12

#8 #7 #6 #5 #4 #3 #2 #1

Admin

Expansion

Training

Expansion



Existing AP1000 module fabrication factories used to build Mk.1 modules



We use the same steel-plate composite wall construction as

AP1000

• Steel plate used as:

– Form

– Reinforcement

• Modular, prefabricated components

• Rapid construction

– Eliminates set up and tear down of plywood framing

AP-1000 Structural Submodule



Modular construction method for Mk.1 demonstrated in Sanmen, China, and US

770-ton AP-1000 auxiliary building module, assembled from factory prefabricated plate components, being set in place onto foundation, Sanmen,

China, July 2009

~ 20 m



Mk1 PB-FHR design uses 9 structural modules

• Like the AP1000, each structural module is assembled from factory sub-modules, in the Mk1 site construction area

• Assembled modules are moved by transporters to the pick-up area for the lift towers

– Use of common utility tunnels simplifies transport of modules

– Modules are smaller and lighter (~200 t) than AP-1000, but due its smaller size the Mk1 PB-FHR needs fewer modules

Example Sanmen module assembly area

• Rate of construction of a 12-unit Mk1 site can be optimized

– Learning is enhanced because work crews can specialize in specific construction activities



Shield Building and Air Duct Vault (1)

Functional Requirements:

- Protection:

Gas leakage explosion

(Blowout panel, Wall Thickness CTAH beryllium control (Ventilation )



Shield Building and Air Duct Vault (2)

Functional Requirements considered: - Maintenance of Equipment - Storage - Utilities access ( Common Tunnel )



Air Flow



Primary modules (9 total) SB1 Module (Lowest level of

shield building)

• SB1 module is first to be set onto the base mat

– We developed a storyboard for the assembly process, but did not have time/information to create a detailed construction schedule

• SB2 is installed next, on top of SB1

SB2 Module (Installed on top of SB1)



Primary modules (continued)

SB3 Module (installed later)

AD1 Module

• AD1 module has warm air ducts already installed

– Other equipment can also be installed, but we did not have time or design information



Primary Modules (continued) AD2 Module

AD3 Module



Primary Modules (continued)

• Three other modules include the reactor cavity structural module, shield building upper ring module and roof module.



Upper Shield Building

• Installed after back-filling the excavation around below-grade structures

• Consists of multiple modules

– See storyboard

• Houses:

– Airlock Entrance

– Emergency Exit

– Equipment Hatch

– Penthouse

– DRAC Chimneys



Expected Material Calculation (1)

• Purpose:

– cost estimation and life-cycle assessment.

• Assumptions:

- 1.27 cm thick double Steel plates for SB1,2,3 and AD1,2,3

- exception of 2.54 cm thick for outer steel between CTAH and

reactor cavity ( protection for potential explosion)

and SB5,6 (Air plane impact)

- Including the use of reinforcing bar of #18 gage rebar for

basemat and floor in square pattern with a spacing of 0.3 m

- 2.54 cm thickness of air ducts made of steel

- Increased by 10 % to account for additional parts



Expected Material Calculation Result (2)

Mass of Steel (Ton) Mass of Concrete (Ton)

Basemat 336.8 3601

Vault Level 1 (AD1) 258.2 1713



Shield Building Level 1 (SB1) 163.8 1638



Shield Building Upper Ring (SB5) 598.8 3499

Shield building roof (SB6) 166.0 680.2

Total: 2540 20398.2



Direct Reactor Auxiliary Cooling System (DRACS)

• Remove 2.36MW from reactor

• Use nature circulation of FLIBE to transfer heat

Fill Tank

Thermosyphon-Cooled Heat Exchanger (TCHX)

DRACS Heat Exchanger (DHX)

Hot Salt Tube

Cold Salt Tube



DRACS (2)



DRAC –TCHX (1)

• Transfer heat by thermal radiation

• Heat transfer from salt to water

Hot salt inlet Cold salt

outlet Bottom water plena

Top water plena



DRAC –TCHX (2)



DRAC –TCHX (3)



DRAC –TCHX (4)

• The total heat transfer coefficient for each bundle is 565W/K

• For 9 bundles, the total heat transfer coefficient is 5089 W/K

• The preliminary total heat transfer coefficient is 5067W/K



Mk1 Construction Story-Board (1)

Construction occurs adjacent to an existing Mk1 unit, outside a temporary protected area fence




Excavation for the new Mk1 module




Construction of the common tunnel section, for plant utilities




Construction of pick-up pad and installation of rails for lift tower Pour basemat




Install first-level module of Mk1 shield building




Install second-level module of Mk1 shield building




Install first-level module of Mk1 air-duct vault




Install second-level module of Mk1 air-duct vault




Install third-level module of Mk1 air-duct vault




Install Mk1 reactor cavity module




Install CTAH.




Install third-level module of Mk1 shield building.




Back fill below-grade structures to grade level




Install main shield building cylinder.




Install polar crane.




Install shield building roof.




Install DRACS chimneys and ventilation filter and exhaust enclosures.




Install gas turbine, intake filter housing, generator and main transformer).




Install heat recover steam generator and stacks.




Install new protected area fence, and remove temporary protected area fence.




Initiate construction on next module (can start before first module is complete)



Construction Animation !

http://youtu.be/G_KKyJGlAJU

http://youtu.be/G_KKyJGlAJU



Future work (1)

• Estimate the Construction Timeline Consulting with advisory panels

• Detail design continued for DRAC system to complete the structure of TCHX.

• The animation can be modified with updated version of the design

• Identify the specific spacing and functional requirements for other major systems in the power plant

• Develop the structural design inside the upper shield building above the reactor deck

• Determine the spacing for auxiliary systems inside the air duct vaults



Questions?

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Reactor Building Integration_ Final Presentation_ Spring 2014 pfp

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