1. UCB Nuclear Engineering
Thermal Hydraulics Lab
DESIGN INTEGRATION FOR MK-1
PB-FHR REACTOR BUILDING
Jaben Root, Huu Nguyen, Daisuke Kazama, Sea Hong

2. 2UCB 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

3. 3UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Starting Design

4. 4UCB Nuclear Engineering
Thermal Hydraulics Lab
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

5. 5UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Final Integrated Design

6. 6UCB Nuclear Engineering
Thermal Hydraulics Lab
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

7. 7UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Existing AP1000 module fabrication
factories used to build Mk.1 modules

8. 8UCB Nuclear Engineering
Thermal Hydraulics Lab
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

9. 9UCB Nuclear Engineering
Thermal Hydraulics Lab
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

10. 10UCB Nuclear Engineering
Thermal Hydraulics Lab
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

11. 11UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Shield Building and Air Duct Vault (1)
Functional Requirements:
- Protection:
Gas leakage explosion
(Blowout panel, Wall Thickness
CTAH beryllium control
(Ventilation )

12. 12UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Shield Building and Air Duct Vault (2)
Functional Requirements considered:
- Maintenance of Equipment
- Storage
- Utilities access
( Common Tunnel )

13. 13UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Air Flow

14. 14UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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)

15. 15UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

16. 16UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Primary Modules (continued)
AD2 Module
AD3 Module

17. 17UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Primary Modules (continued)
• Three other modules include the reactor cavity structural
module, shield building upper ring module and roof
module.

18. 18UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

19. 19UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

20. 20UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

21. 21UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

22. 22UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
DRACS (2)

23. 23UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

24. 24UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
DRAC –TCHX (2)

25. 25UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
DRAC –TCHX (3)

26. 26UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

27. 27UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (1)
Construction occurs adjacent to an existing Mk1 unit,
outside a temporary protected area fence

28. 28UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (2)
Excavation for the new Mk1 module

29. 29UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (3)
Construction of the common tunnel section, for plant
utilities

30. 30UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (4)
Construction of pick-up pad and installation of rails for lift tower
Pour basemat

31. 31UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (5)
Install first-level module of Mk1 shield building

32. 32UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (6)
Install second-level module of Mk1 shield building

33. 33UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (7)
Install first-level module of Mk1 air-duct vault

34. 34UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (8)
Install second-level module of Mk1 air-duct vault

35. 35UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (9)
Install third-level module of Mk1 air-duct vault

36. 36UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (10)
Install Mk1 reactor cavity module

37. 37UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (11)
Install CTAH.

38. 38UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (12)
Install third-level module of Mk1 shield building.

39. 39UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (13)
Back fill below-grade structures to grade level

40. 40UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (14)
Install main shield building cylinder.

41. 41UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (15)
Install polar crane.

42. 42UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (16)
Install shield building roof.

43. 43UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (17)
Install DRACS chimneys and ventilation filter and
exhaust enclosures.

44. 44UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (18)
Install gas turbine, intake filter housing, generator and
main transformer).

45. 45UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (19)
Install heat recover steam generator and stacks.

46. 46UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (20)
Install new protected area fence, and remove
temporary protected area fence.

47. 47UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Mk1 Construction Story-Board (21)
Initiate construction on next module (can start before
first module is complete)

48. 48UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Construction Animation !
http://youtu.be/G_KKyJGlAJU

49. 49UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
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

50. 50UCB Nuclear Engineering
Thermal Hydraulics Lab
Overview of Current Status of the UCB Commercial Prototype
Design Effort
Questions?