From field to factory—Taking advantage of shop manufacturing for the pebble bed modular reactor

Abstract

The move of nuclear plant construction from the field to the factory for small, advanced pebble bed modular reactor (PBMR) designs has significant benefits compared to traditional light water reactor (LWR) field oriented designs. The use of modular factory construction techniques has a growing economic benefit over time through well-established process learning applications. This paper addresses the basic PBMR design objectives and commercialization model that drive this approach; provides a brief technical description of the PBMR design and layout with representative CAD views and discusses derived figures of merit highlighting the relative simplicity of PBMR compared to a modern LWR. The discussion emphasizes that more of PBMR can be built in the factory due to the simple design of a direct helium Brayton cycle compared to an indirect LWR steam cycle with its associated equipment. For the PBMR design there are fewer and less cumbersome auxiliary and safety systems with their attendant support requirements. Additionally, the labor force economic efficiency for nuclear projects is better in the factory than in the field, including consideration of labor costs and nuclear quality programs. Industrial learning is better in the factory because of the more controlled environment, mechanization optimization opportunities and because of the more stable labor force compared to the field. Supply chain benefits are more readily achievable with strategic contracts for module suppliers. Although building a nuclear power plant is not a typical high volume manufacturing process, for the PBMR-type of plant, with its high degree of standardization and relatively small, simplified design, the shift to factory work has a significant impact on overall project cost due to earlier identification and better coordination of parallel construction paths. This is in stark contrast to the construction of a large LWR in the past. Finally, the PBMR modular plant concept continues at the overall plant level where up to eight units can be integrated into one site on a plot plan smaller than an equivalent large LWR with similar electric output. The bottom line is that schedules are shorter, the absolute cost is lower, and both are more predictable. These advantages will yield a higher return to clients and investors.