reactor building integration_ final presentation_ spring 2014 pfp
TRANSCRIPT
UCB Nuclear Engineering Thermal Hydraulics Lab
DESIGN INTEGRATION FOR MK-1 PB-FHR REACTOR BUILDING Jaben Root, Huu Nguyen, Daisuke Kazama, Sea Hong
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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
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Overview of Current Status of the UCB Commercial Prototype Design Effort
Starting Design
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Overview of Current Status of the UCB Commercial Prototype Design Effort
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
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Overview of Current Status of the UCB Commercial Prototype Design Effort
Final Integrated Design
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Overview of Current Status of the UCB Commercial Prototype Design Effort
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
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Overview of Current Status of the UCB Commercial Prototype Design Effort
Existing AP1000 module fabrication factories used to build Mk.1 modules
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Overview of Current Status of the UCB Commercial Prototype Design Effort
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
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Overview of Current Status of the UCB Commercial Prototype Design Effort
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
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Overview of Current Status of the UCB Commercial Prototype Design Effort
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
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Shield Building and Air Duct Vault (1)
Functional Requirements:
- Protection:
Gas leakage explosion
(Blowout panel, Wall Thickness CTAH beryllium control (Ventilation )
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Shield Building and Air Duct Vault (2)
Functional Requirements considered: - Maintenance of Equipment - Storage - Utilities access ( Common Tunnel )
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Air Flow
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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)
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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
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Primary Modules (continued) AD2 Module
AD3 Module
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Primary Modules (continued)
• Three other modules include the reactor cavity structural module, shield building upper ring module and roof module.
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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
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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
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Expected Material Calculation Result (2)
Mass of Steel (Ton) Mass of Concrete (Ton)
Basemat 336.8 3601
Vault Level 1 (AD1) 258.2 1713
Vault Level 2 (AD2) 180.6 1713
Vault Level 3 (AD3) 335.4 2267
Shield Building Level 1 (SB1) 163.8 1638
Shield Building Level 2 (SB2) 163.8 2293
Shield Building Level 3 (SB3) 202.6 2994
Shield Building Upper Ring (SB5) 598.8 3499
Shield building roof (SB6) 166.0 680.2
Total: 2540 20398.2
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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
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DRACS (2)
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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
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DRAC –TCHX (2)
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DRAC –TCHX (3)
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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
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Mk1 Construction Story-Board (1)
Construction occurs adjacent to an existing Mk1 unit, outside a temporary protected area fence
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Mk1 Construction Story-Board (2)
Excavation for the new Mk1 module
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Mk1 Construction Story-Board (3)
Construction of the common tunnel section, for plant utilities
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Mk1 Construction Story-Board (4)
Construction of pick-up pad and installation of rails for lift tower Pour basemat
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Mk1 Construction Story-Board (5)
Install first-level module of Mk1 shield building
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Mk1 Construction Story-Board (6)
Install second-level module of Mk1 shield building
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Mk1 Construction Story-Board (7)
Install first-level module of Mk1 air-duct vault
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Mk1 Construction Story-Board (8)
Install second-level module of Mk1 air-duct vault
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Mk1 Construction Story-Board (9)
Install third-level module of Mk1 air-duct vault
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Mk1 Construction Story-Board (10)
Install Mk1 reactor cavity module
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Mk1 Construction Story-Board (11)
Install CTAH.
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Mk1 Construction Story-Board (12)
Install third-level module of Mk1 shield building.
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Mk1 Construction Story-Board (13)
Back fill below-grade structures to grade level
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Mk1 Construction Story-Board (14)
Install main shield building cylinder.
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Mk1 Construction Story-Board (15)
Install polar crane.
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Mk1 Construction Story-Board (16)
Install shield building roof.
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Mk1 Construction Story-Board (17)
Install DRACS chimneys and ventilation filter and exhaust enclosures.
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Mk1 Construction Story-Board (18)
Install gas turbine, intake filter housing, generator and main transformer).
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Mk1 Construction Story-Board (19)
Install heat recover steam generator and stacks.
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Mk1 Construction Story-Board (20)
Install new protected area fence, and remove temporary protected area fence.
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Mk1 Construction Story-Board (21)
Initiate construction on next module (can start before first module is complete)
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Construction Animation !
http://youtu.be/G_KKyJGlAJU
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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