Modularity Approach of the Modular Pebble Bed Reactor (MPBR) Marc - - PowerPoint PPT Presentation

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Modularity Approach of the Modular Pebble Bed Reactor (MPBR) Marc - - PowerPoint PPT Presentation

Jun 04, 2023 131 likes •477 views

MIT NED MPBR Modularity Approach of the Modular Pebble Bed Reactor (MPBR) Marc Berte Professor Andrew Kadak Massachusetts Institute of Technology Nuclear Engineering Department Nuclear Energy Research Initiative Grant Number

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SLIDE 1

4/23/03

MIT NED MPBR

Modularity Approach

  • f the

Modular Pebble Bed Reactor (MPBR)

Marc Berte Professor Andrew Kadak Massachusetts Institute of Technology Nuclear Engineering Department

Nuclear Energy Research Initiative Grant Number DE-FG03-00SF22168

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MIT NED MPBR

Project Objectives

  • To apply modularity principles to the design,

construction and operation of advanced nuclear energy plants

  • To employ manufacturing and factory assembly

principles to nuclear plants.

  • To minimize on site work by assembling plants on

site rather than construct them as in the past.

  • To allow for conventional truck and rail shipments of

most components allowing for siting flexibility.

  • To reduce overall construction time and cost.
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MIT NED MPBRModular High Temperature Pebble Bed Reactor

  • Modules added to meet

demand.

  • No Reprocessing
  • High Burnup >90,000

Mwd/MT

  • Direct Disposal of HLW
  • Process Heat

Applications - Hydrogen, water

  • 120 MWe
  • Helium Cooled
  • 8 % Enriched Fuel
  • Built in 2 Years
  • Factory Built
  • Site Assembled
  • On--line Refueling
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MIT NED MPBR

Reference Plant

Modular Pebble Bed Reactor

Thermal Power 250 MW Core Height 10.0 m Core Diameter 3.5 m Fuel UO2 Number of Fuel Pebbles 360,000 Microspheres/Fuel Pebble 11,000 Fuel Pebble Diameter 60 mm Microsphere Diameter ~ 1mm Coolant Helium

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MIT NED MPBR

Indirect Cycle with Intermediate Helium to Helium Heat Exchanger

Current Design Schematic

Generator

522.5°C 7.89MPa 125.4kg/s 509.2°C 7.59MPa 350°C 7.90MPa

Reactor core

900°C 7.73MPa 800°C 7.75MPa 511.0°C 2.75MPa 96.1°C 2.73MPa 69.7°C 8.0MPa 326°C 105.7kg/s 115 °C 1.3kg/s 69.7°C 1.3kg/s 280 °C 520°C 126.7kg/s

Circulator HPT

52.8MW

Precooler Inventory control Bypass Valve Intercooler IHX Recuperator Cooling RPV

LPT 52.8MW PT 136.9MW 799.2 C 6.44 MPa 719.°C 5.21MPa MPC2 26.1 MW MPC1 26.1MW LPC 26.1 MW HPC 26.1MW 30 C 2.71MPa 69.7 C 4.67MPa

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MIT NED MPBR

Features of Current Design

Three-shaft Arrangement Power conversion unit 2.96 Cycle pressure ratio 900°C/520°C Core Outlet/Inlet T 126.7 kg/s Helium Mass flowrate 48.1% (Not take into account cooling IHX and HPT. if considering, it is believed > 45%) Plant Net Efficiency 120.3 MW Net Electrical Power 132.5 MW Gross Electrical Power 250 MW Thermal Power

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4/23/03

MIT NED MPBR 1150 MW Combined Heat and Power Station

Turbine Hall Boundary

Admin Training Control Bldg. Maintenance Parts / Tools

10 9 8 7 6 4 2 5 3 1

0 20 40 60 80 100 120 140 160 20 40 60 80 100

Primary island with reactor and IHX Turbomachinery

Ten-Unit VHTR Plant Layout (Top View)

(distances in meters)

Equip Access Hatch Equip Access Hatch Equip Access Hatch

Oil Refinery Hydrogen Production

Desalinization Plant VHTR Characteristics

  • Temperatures > 900 C
  • Indirect Cycle
  • Core Options Available
  • Waste Minimization
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MIT NED MPBR

Modularity Progression

  • Conventional Nuclear Power Systems
  • Assembled on site
  • Component-level transportation
  • Extensive Site Preparation
  • Advanced Systems
  • Mass Produced / “Off the Shelf” Designs
  • Construction / Assembly Still Primarily on Site
  • MPBR
  • Mass Produced Components
  • Remote Assembly / Simple Transportation & Construction

This is different than other Generation IV approaches in that modularity is the objective which means smaller units.

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MIT NED MPBR

MPBR Modularity Plan

  • Road- Truck / Standard-Rail Transportable

– 8 x 10 x 60 ft. 100,000 kg Limits

  • Bolt-together Assembly

– Minimum labor / time on site required – Minimum assembly tools – Goal: Zero Welding

  • Minimum Site Preparation

– BOP Facilities designed as “Plug-and-Play” Modules – Single Level Foundation – System Enclosure integrated into modules

  • ASME Code compliant

– Thermal expansion limitations – Code material limitations

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MIT NED MPBR

Design Elements

  • Assembly
  • Self-locating Space-frame Contained Modules and

Piping.

  • Bolt-together Flanges Join Module to Module
  • Space-frame Bears Facility Loads, No Additional

Structure

  • Transportation / Delivery
  • Road-mobile Transportation Option

– Reduces Site Requirements (Rail Spur Not Required)

  • Module Placement on Site Requires Simple Equipment
  • Footprint
  • Two Layer Module Layout Minimizes Plant Footprint
  • High Maintenance Modules Placed on Upper Layer
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MIT NED MPBR

Top Down View of Pebble Bed Reactor Plant

IHX Module Reactor Vessel Recuperator Module Turbogenerator HP Turbine MP Turbine LP Turbine Power Turbine HP Compressor MP Compressor LP Compressor Intercooler #1 Intercooler #2 Precooler ~77 ft. ~70 ft. Plant Footprint

TOP VIEW WHOLE PLANT

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MIT NED MPBR

Total Modules Needed For Plant Assembly (21): Nine 8x30 Modules, Five 8x40 Modules, Seven 8x20 Modules Six 8x30 IHX Modules Six 8x20 Recuperator Modules 8x30 Lower Manifold Module 8x30 Upper Manifold Module 8x30 Power Turbine Module 8x40 Piping & Intercooler #1 Module 8x40 HP Turbine, LP Compressor Module 8x40 MP Turbine, MP Compressor Module 8x40 LP Turbine, HP Compressor Module 8x40 Piping and Precooler Module 8x20 Intercooler #2 Module

PLANT MODULE SHIPPING BREAKDOWN

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MIT NED MPBR

Concept

  • Modular Construction

– Space-frame modules

  • Stackable
  • Self-aligning
  • Pre-constructed off-site

– Minimal Assembly On-Site

  • Connect Flanges / Fluid Lines /

Utilities

  • Pre-Assembled Control Facilities
  • Distributed Production

– Common, Simple Module Design – Minimizes Transportation Req. – Eliminates Manufacturing Capital Expense – Module Replacement Instead of Repair—Modules Returned to Fabricator

  • Road-mobile Transportation

– Reduces Cost—Construction of Rail Spur / Canal Not Required – Reduces Location Requirements

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MIT NED MPBR

  • Plant “Farm”: ~10 MPBR Systems per “Power Plant”
  • Containerized Fueling / Waste Disposal Minimizes

Handling Costs – Fuel module (ISO container) is “plugged in” – Spent fuel module is packaged in ISO container and “unplugged” when full

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MIT NED MPBR

Example Plant Layout

Secondary (BOP) Side Hall Primary Side Hall Reactor Vessel IHX Modules Recuperator Modules Turbomachinery NOTE: Space-frames and ancillary components not shown for clarity

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MIT NED MPBR Space Frame Technology for Shipment and Assembly

Everything is installed in the volume occupied by the space frame - controls, wiring, instrumentation, pumps, etc. Each space frame will be “plugged” into the adjacent space frame.

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MIT NED MPBR

Balance of Plant Components

Compressor Set (Black) With Axial Intercooler (Tan) High pressure turbine Precooler Recuperator Module Power Turbine Generator

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MIT NED MPBR

Space-Frame Concept

  • Standardized Frame Size
  • 2.4 x 2.6 x 3(n) Meter
  • Standard Dry Cargo Container
  • Attempt to Limit Module Mass to

~30t / 6m – ISO Limit for 6m Container – Stacking Load Limit ~190t – ISO Container Mass ~2200kg – Modified Design for Higher Capacity—~60t / 12m module

  • Overweight Modules

– Generator (150-200t) – Turbo-Compressor (45t) – Avoid Separating Shafts! – Heavy Lift Handling Required – Dual Module (12m / 60t)

  • Stacking Load Limit Acceptable

– Dual Module = ~380T

  • Turbo-generator Module <300t
  • Design Frame for Cantilever Loads

– Enables Modules to be Bridged

  • Space Frames are the structural

supports for the components.

  • Only need to build open vault areas

for space frame installation - RC & BOP vault

  • Alignment Pins on Module Corners

– High Accuracy Alignment – Enables Flanges to be Simply Bolted Together

  • Standardized Umbilical Locations

– Bus-Layout of Generic Utilities (data/control)

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MIT NED MPBR

Thermal and Mechanical Stress Analysis

  • CAESAR II Pipe Stress Analysis Code
  • ASME B31.3 Piping Code
  • Pipe Material: A335 P2
  • Spaceframe Material: ASTM A-36
  • Preliminary Thermal Analysis Performed to

Create Code Compliant Geometry

  • Hangers not shown for clarity
  • Preliminary Spaceframe structure

– secondary elements not shown

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MIT NED MPBR

Present Layout

Reactor Vessel IHX Vessel High Pressure Turbine Low Pressure Turbine Compressor (4) Power Turbine Recuperator Vessel

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MIT NED MPBR

Detail of Connecting Piping

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MIT NED MPBR

Piping Sizes

0.25 8 Compressor 4 to Recuperator 0.25 8 Intercooler 3 to Compressor 4 0.25 8 Compressor 3 to Intercooler 3 0.25 10 Intercooler 2 to Compressor 3 0.25 10 Compressor 2 to Intercooler 2 0.125 10 Intercooler 1 to Compressor 2 0.125 12 Compressor 1 to Intercooler 1 0.125 13 Precooler to Compressor 1 0.125 14 Recuperator to Precooler 0.25 20 Power Turbine to Recuperator 0.5 18 Turbine 2 to Power Turbine 0.5 16 Turbine 1 to Turbine 2 0.5 16 IHX to Turbine 1 0.5 16 IHX to Reactor Vessel 0.5 16 Reactor Vessel to IHX Wall Thickness (in) OD (in) Pipe

Based on 400m/s internal helium flow velocity with metallic liner and internal insulation

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MIT NED MPBR

17.5 m 32 m

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MIT NED MPBR

Overall Structure

25 m

40 m

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MIT NED MPBR

10 Module Plant - 1200 MWe

165 m 110 m

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MIT NED MPBR

Views Of Plant Layout

TOP VIEW SIDE VIEW FRONT VIEW (FROM REACTOR VESSEL)

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MIT NED MPBR

Plant With Space Frames

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MIT NED MPBR

2.5 m 10 m

Upper IHX Manifold in Spaceframe

3 m

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MIT NED MPBR

Distributed Production Concept

“MPBR Inc.”

Space-Frame Specification

Component Fabricator #1

e.g. Turbine Manufacturer

Component Fabricator #N

e.g. Turbine Manufacturer

Component Design

MPBR Construction Site

Site Preparation Contractor Assembly Contractor

S i t e a n d A s s e m b l y S p e c i f i c a t i

  • n

s Management and Operation

Labor Component Transportation Design Information

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MIT NED MPBR

Distributed Production Concept - Virtual Factory !

  • Evolution of the “Reactor Factory” Concept
  • There Is NO Factory

– Off-load Manufacturing Capital Expense to Component Suppliers

  • Decrease follow-through capital expense by designing to

minimize new tooling—near COTS

  • Major component fabricators become mid-level integrators—

following design delivered from HQ – Reduces Transportation Costs

  • Component weight ≈ Module weight: Why Transport It Twice?

– Enables Flexible Capitalization

  • Initial systems use components purchased on a one-off / low

quantity basis

  • Once MPBR demand established, constant production +

fabrication learning curve lower costs

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MIT NED MPBR

  • Site / Building Design Does Not Require Specialized Expertise

– Enables Selection of Construction Contractors By Location / Cost – Simplified Fabrication Minimizes “MPBR Inc.” Workforce Required

  • Simple Common Space-Frame Design

– Can be Easily Manufactured By Each Individual Component Supplier – Or if necessary sub-contracted to generic structural fabricator

  • Modern CAD/CAE Techniques Enable High First-Fit

Probability—Virtual “Test-Fit”

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MIT NED MPBR

Current Design Issues

  • Thermal Expansion

– Piping Must Be Designed for Substantial Thermal Expansion—requiring Bulky Layout – Flexible Joints Not Possible Due to Code Constraints

  • Space-Frame Loads

– External (Seismic, etc) – Flexibility Limits – Self-Generated – Internal Supports for Component Dead Weight – Structural – Module to Module Loads

  • Alignment Requirements

– Module Construction Accuracy and Installation Alignment Drive Assembly Complexity and Component Design

  • Poor accuracy / alignment requires adjustment of

component position within frame

  • Plant Layout

– Accommodate Remove/Replace Strategy – Accommodate Structural / Thermal Issues

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MIT NED MPBR

Accomplishments

  • Developed a modularity scheme that can be used to

ship most of the components of the plant in truck capable space frames. (ex. RV)

  • Established a fabrication strategy using space frame

technology in a virtual factory environment.

  • Minimized on site construction to large area rooms

into which space frames are installed.

  • Developed an design strategy that focuses on

replacement rather than repair of components to minimize outage losses.

  • If successful, this approach could revolutionize

nuclear plant design and construction.

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MIT NED MPBR

Future Work

  • 1. Tolerance requirements for space frame fit-up and

critical dimensions.

  • 2. Development of “virtual factory” concept with

industrial partners.

  • 3. Establishment of infrastructure development plan for

space frame concept with vendors.

  • 4. Economic assessment of modularity under this

concept with economy of scale for multi-unit plant