introduction to b&w mpower™ program iaea … projects = cost/schedule certainty broad industry...

.1© 2011 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved© 2011 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved

Introduction to B&W mPower™ Program

IAEA Interregional Workshop

Vienna, Austria

July 7, 2011

Doug LeeBabcock & Wilcox Company

.2© 2011 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved 2

Outline

• Introduction

• Plant layout

• Integral reactor design

• Safety concept

• Systems

• Development testing

• Implications from Fukushima

• Lead plant deployment

• Conclusion


Alliance between B&W and Bechtel

Risk sharing with 90/10 current ownership

300+ FTE development team

Technology and project execution

Turnkey projects = cost/schedule certainty

Broad industry engagement

Investment from 15 member Consortium

26 member Industry Advisory Council

Goal is to deploy lead plant by 2020

Industry side of public-private partnership

Platform for industry cost/risk sharing

Nebraska Electric G&T Cooperative

Hoosier Energy Rural Electric Cooperative, Inc.

Generation mPower Industry Consortium

Industry Partners

Industry Advisory CouncilIncludes Consortium members above plus:

AEPDayton Power & LightDuke EnergyExelonNPPDVattenfall

Bruce PowerDominionEntergyMidAmericanProgress Energy

www.generationmpower.com

http://www.generationmpower.com/


The Babcock & Wilcox Companyis a leader in clean energy technology and services

for the nuclear and fossil power markets

.4

2010: $2.7B revenue and $5.2B backlog


Bechtel Power

• Over 70 years in the power business

• Over 60 years in nuclear power

• Over 200,000 MW of completed projects

Nuclear: 74,000 MW

Fossil: 118,000 MW/445 units

Hydro: 26,000 MW/155 units

2001–2006: 30,200 MW online in 14 countries

20 years of gasification/IGCC experience

28 CT cogen plants, 5,200 MW; 12 solid fuel cogens

Integrated power/desalination; waste-to-energy

• Over 15,000 MW of active, new generation power projects

• 25,000 employees with nuclear experience

©2011 Bechtel Power Corporation. All rights reserved.


Integrated Supply Chain

• Multiple sources for forgings and plate

• Component fabrication

Mt. Vernon, Indiana

Barberton, Ohio

Cambridge, Ontario, Canada

• Fuel fabrication

Lynchburg, Virginia

• Control rod drive fabrication

Euclid, Ohio

Critical NSSS Components… manufactured in existing B&W facilities


Goal and Value Proposition

Develop and deploy, by 2020, an SMR that offers:

Lower Capital Cost

Schedule & Cost Certainty

Competitive LCOE Pricing

Within the constraints of:

Proven: GEN III+, established NRC regulation

Safe: Robust margins, passive safety

Practical: Standard fuel, construction and O&M

Benign: Underground, small footprint


High-Level Requirements• 125 MWe Nominal Output per Module and 60-Year Plant Life

• NSSS Forging Diameter Allows Readily Available Forgings and Unrestricted

Rail Shipment

• Passive Safety Requirements – Emergency (Diesel) Power Not Required

Minimize Primary Coolant Penetrations, Maximize Elevation of Penetrations

Large Reactor Coolant Inventory

Low Core Power Density

• Standard Fuel (less than 5% U235)

• Long Fuel Cycle, 4+ Year Core Life

• Spent Fuel Storage on Site for Life of Plant

• No Soluble Boron in Primary System for Normal Reactivity Control

• Conventional/Off-the-Shelf Balance of Plant Systems and Components

• Accommodate Air-Cooled Condensers as well as Water-Cooled Condensers

• Flexible Grid Interface (50 Hz or 60 Hz)

• Digital Instrumentation and Controls Compliant with NRC Regulations

.9© 2011 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved 9.9

• “Twin-pack” mPower plant configuration

• 40 acre site footprint

• Low profile architecture

• Water or air cooled condenser

• Enhanced security posture

• Underground containment

• Underground spent fuel pool

• Lower overnight construction cost

• Competitive levelized cost of electricity© 2010 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved. Patent Pending

The B&W mPower™ Nuclear Plant

Security-informed plant design contains O&M costs


Integral Reactor

• Simplified – Integrated, Pressurized Water Reactor

• Internal Components to Minimize Penetrations

Control Rod Drives – No rod ejection

Coolant Pumps – Not safety related

• Control Rods versus Boron Shim

• Load Following Capability – Up to 10%/Min

• Passive Safety

No safety-related emergency diesel generators

No core uncovery during design basis accident (small break

LOCA)

• Performance of Critical Functions by Multiple Systems for Improved

Reliability and Plant Safety

• Multiple Module Plants – BOP Equipment Not Shared


Pressurizer

Steam Generator Tubes

Reactor Coolant

Pumps

Control Rod Drive

Mechanisms

Core

Steam Outlet

Feedwater Inlet

Integral Reactor Arrangement

Primary Loop Secondary Loop

Central Riser

Steam

Feedwater


Key Features of the Integral RCS

Feature B&W 177 Typical Gen 3 PWR

B&W mPower


B&W mPower

Rated Core power (MWth) 2568 3415 425

Core average linear heat rate (kWth/m) 18.7 18.7 11.5

Average flow velocity through the core

(m/s)

4.8 4.8 2.5

RCS volume (m3) 325 272 91

RCS volume to power ratio (m3/MWth) 0.14 0.08 0.21

Maximum LOCA area (m2) * 1.3 1.0 0.009

* Assumes double ended break

RCS volume and small break sizes allow simplification of RCS safety systems


B&W mPower

Rated Core power (MWth) 2568 3415 425

Core average linear heat rate (KWth/m) 18.7 18.7 11.5

Average flow velocity through the core

(m/s)

4.8 4.8 2.5

RCS volume (m3) 325 272 91

RCS volume to power ratio (m3/MWth) 0.14 0.08 0.21

Maximum LOCA area (m2) * 1.3 1.0 0.009

RCS volume/LOCA area ratio (m3 /m2) 250 270 310,000


• Ensure that assemblies are mechanically designed to remain leak tight and maintain structural integrity under all possible conditions

• Load enough fuel inventory to accommodate a 4 year operating cycle at a capacity factor of > 95%

• Optimize fuel assembly design to maximize fuel utilization

• Maintain conservative peaking factors and linear heat rate throughout the operating cycle

• Ensure a shutdown margin of > 1% keff/keff under the most reactive conditions and highest worth CRA cluster stuck out

• Meet a MDNBR > 1.3 for limiting thermal-hydraulic conditions and confirm via unique CHF correlation

Design Objectives – Core and Fuel Assembly


• 69 fuel assemblies

• < 5 wt% 235U enrichments

• No soluble boron for control

• Axially graded BPRs

• Gd2O3 spiked rods

• Control rod sequence exchanges

• AIC and B4C control rods

• 3% shutdown margin

Core Design Features


Fuel Mechanical Design Features

15

Shortened and Simplified Conventional Fuel Assembly Design

Conventional 17x17 design

Fixed grid structural cage

Design optimized for mPower

Upper End

Fitting

End Grid

Mid Grid

17 x 17 Square Array

Control Rod Guide Tube

End Grid

Lower End Fitting


Auxiliary Fluid Systems

Reactor Coolant Inventory and Purification (RCIPS)• Controls the reactor coolant volume by compensating for coolant contraction or

expansion

• Provides hydraulic pressure to CRDM

• Maintains reactor coolant activity at the desired level by removing corrosion and fission products

• Injects chemicals into the RCS to control coolant chemistry and minimize corrosion

• Removes decay heat during normal shutdown and plant cooldown

• Provides for reactor cavity fill

• Provides a means for transferring fluids and gases to the radioactive waste processing system

• Provides RCS pressure control by supplying spray flow to the pressurizer

Component Cooling Water• Supporting system for RCIPS by transferring heat to the chilled water system


• Low Core Linear Heat Rate Low Power Density Reduces Fuel and Clad Temperatures During

Accidents

Low Power Density Allows Lower Flow Velocities that Minimize

Flow Induced Vibration Effects

• Large Reactor Coolant System Volume Large RCS Volume Allows More Time for Safety System Response

in the Event of an Accident

More Coolant Is Available During a Small Break LOCA Providing

Continuous Cooling to Protect the Core

• Small Penetrations at High Elevation High Penetration Locations Increase the Amount of Coolant Left in

the Vessel after a Small Break LOCA

Small Penetrations Reduce Rate of Energy Release to

Containment Resulting in Lower Containment Pressures

Inherent Safety Features

CONFIDENTIAL AND PROPRIETARY TO B&W


ECCS Safety Functions

• Passively removes core heat following certain anticipated

operational occurrences and analyzed accidents

• Passively reduces containment pressure and temperature

following certain analyzed accidents

• Provides an alternate means of reactivity control for beyond

design basis accidents (i.e. ATWS)

• Provides a barrier to the release of fission products to the

environment


B&W mPower Containment

• Underground containment and

fuel storage buildings

• Metal containment vessel

• Environment suitable for human

occupancy during normal

operation

• Simultaneous refueling and

NSSS equipment inspections

• Leakage free

• Volume sufficient to limit internal

pressure for all design basis

accidents

© 2010 Babcock & Wilcox Nuclear Energy, Inc., All rights reserved.


Balance of Plant Design

• Plant designed to produce a nominal

125 MWe

• Conventional steam cycle equipment

(small, easy to maintain and replace)

• BOP operation not credited for design

basis accidents

Conventional

Air-Cooled Condenser

Steam Cycle

© 2011 Babcock & Wilcox Nuclear Energy, Inc. All rights reserved.


• State of the art digital system

• Provides monitoring, control and

protection functions

• Separate safety and non-safety

systems

• Implement lessons learned from

current licensing activities

• Currently developing digital

control system architecture

Instrumentation and Controls

http://www.power-technology.com/contractors/training/corys/


I&C Philosophy

• Highly-Reliable, Integrated and Scalable Digital I&C System

• I&C System Must Have Highest Degree of Licensing Certainty

Complies with All Regulatory, URD Requirements

Minimizes Regulatory Challenges with Digital I&C…Cyber-security, Diversity,

Independence

• Integrated, Modernized Human-Factored Design

• High Level of Plant Automation

Control of Startup, Shutdown, Load Following…support staffing plan

• Deliver Comprehensive O&M Strategy

Use of commercially-available components

Managed obsolescence


• Component Tests

Reactor Coolant Pump

CRDM

Fuel Mechanical Testing

CRDM/Fuel Integrated Test

Fuel Critical Heat Flux

Emergency High Pressure Condenser

• Integrated Systems Test (IST)

Heat Transfer Phenomena

Steam Generator Performance

LOCA Response

Pressurizer Performance

Reactor Control

Development Testing Programs

Center for Advanced Engineering

Research (CAER)

Bedford, VA


Testing Program

Objective Method Location Duration/ Timing

Rx coolant pump performance High temp test loop Curtiss Wright 2011-2016

CRDM performance Bench & autoclave Euclid 2010-2016

Fuel mechanical design Mechanical and cold

flow

Lynchburg 2010-2012

Fuel bundle performance Autoclave Euclid 2012-2013

Integrated CRDM/fuel assembly Autoclave Euclid 2012-2014

DNB correlation CHF testing Stern Lab 2010-2012

Emergency condenser IST & contract TBE 2011-2014

Integral reactor performance IST Lynchburg 2011-2014


IST Objectives

• Integrated system performance

• Steam generator and component performance

• Computer code validation

• Licensing support

• Control and protection systems verification

• Design enhancements

• Simulator development and verification

• Operating procedures and training development

• Demonstration to potential customers

February 2011A broad spectrum of objectives identified


IST Features

Scaling

• Full height

• Full pressure and

temperature

• Power, area and volume

scaled

• Real time operation

• Trace heating

Systems Simulated

• Integral reactor coolant

• Steam and feedwater

• Reactor coolant inventory

and purification

• Emergency core cooling

• Component cooling water

• Protection and control

Integral reactor and important systems carefully designed


Status

• Building complete

• Equipment procurement complete

• Integral loop assembly in process

• Equipment installation in process

• Operating and test teams hired

• Procedures in preparation

• Start-up August-September

Testing will begin this year


Design Considerations for “Fukushima-Type” Events

Events and Threats B&W mPower Reactor Design Features

Earthquakes

And Floods

• Seismic attenuation: Deeply embedded reactor building dissipates energy, limits motion

• “Water-tight” : Separated, waterproof reactor compartments address unexpected events

Loss of Offsite Power • Passively safe: AC power, offsite or onsite, not required for design basis safety functions

• Defense-in-depth: 2 back-up 2.75MWe diesel generators for grid-independent AC power

Station Blackout • 3-day batteries: Safety-related DC power supports all accident mitigation for 72 hours

• APU back-up: Auxiliary Power Units inside reactor building recharge battery system

• Long-duration “station keeping”: 7+ day battery supply for plant monitoring/control

Emergency

Core Cooling

• Gravity, not pumps: Natural circulation decay heat removal; water source in containment

• Robust margins: Core power density (11.5kW/m) and small core (425MWth) limit energy

• Slow accidents: Maximum break small compared to reactor inventory (4.7x10-5m2/m3)

Containment Integrity

and Ultimate Heat Sink

• Passive hydrogen recombiners: Prevention of explosions without need for power supply

• Internal cooling source: Ultimate heat sink inside underground shielded reactor building

• Extended performance window: Up to 14 days without need for external intervention

Spent Fuel Pool

Integrity and Cooling

• Protected structure: Underground, inside auxiliary containment

• Large heat sink: 30+ days before boiling and uncovering of fuel with 40 years of spent fuel

Multi-layer defense … mitigates extreme beyond-design basis challenges


Lead Plant

• Generation mPower and TVA Letter of Intent

• Joint development and pursuit of construction permit and

operation license

• Up to six B&W mPower reactors at the Clinch River site

in Roane County, Tennessee

• Deploy first unit by 2020


Integrated Part 50/52 Lead Plant Deployment ScheduleCY CY CY CY CY CY CY CY CY CY CY

2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021

Clinch River Project – 10 CFR 50 Process

Submit CPA

NRC CPA Review

CP DSER

CP Issuance

Submit OL Application

NRC Review OL Application

FSER Issued

Fuel Load

COL Issuance

Submit DCA

NRC DCA Review

NRC COLA Review

DC RulemakingFSER IssuedCOLA Submittal

COD

mPower DCD & COLA – 10 CFR 52 Process

Pre-op TestingStart-up Testing

Site Prep/Construction/ITAAC/Fuel Load/Startup Testing

Hearing

COD

Site Prep/Construction

OL Issuance


Conclusion

• B&W and Bechtel have formed an alliance to design and

construct turn-key mPower SMR plant

• The mPower modular reactor plant has a unique integral

reactor design with passive safety system design

• Design and licensing activities are well underway

• A comprehensive test program is in process

• A letter of intent has been signed with TVA for up to six units

for deployment of the first unit by 2020

introduction to b&w mpower™ program iaea … projects = cost/schedule certainty broad industry...

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