The level of site preparation can be greater with the commoditised module delivery. This can have the effect of moving the nuclear island off the critical path for site construction activities. This potential impact of this is typified by looking at the key dimensions of the typical steam turbine generators, as in Table 12.3.

It can be seen that the larger turbine generators quickly become significant units and sit outside of conventional road transportation envelopes. There are regional variations on transportation sizes. Packages around 5 m wide and tall can usually be accommodated as oversize loads. Moving beyond 5 m moves away from a turbine generator set that can be road transported as a single module. A turbine generator that is not modular can put the rotating machine on the critical path for the site build programme. This is substantiated with information from combined-cycle gas turbine construction programmes. From the time the last generator casings are delivered to site it is a further year until the turbine is running on its turning gear, and a further three months before the set is ready to be synchronised for the first time. It is easily conceivable in a small reactor power plant with larger turbine generators, which are not capable of road transportation as a single unit, that the turbine can sit close to the on-site programme critical path.

12.5.1 Deployment model: in service

The opportunity to deploy a small reactor to compete against in any energy portfolio is challenged by its relatively high $/kW overnight capital cost. Some benefit is derived from a factory build approach of plant modules, but this alone does not achieve the desired cost target. Similarly a position on volume production with an overhead amortised over a larger number of modules will make further inroads into the $/kW. The final element in reduction of the competitive position for a small reactor lies in the in-service deployment.

In March 2012 Jack Bailey — VP Nuclear Generation Development for TVA — offered a view on the FOAK plant in-service model. He commented that initial goals for centralised regional services could not be realised for early deployed small reactor plants. The authors would challenge that view, asserting that it is this operating model that needs to be incorporated from the outset. In the same way as a production line needs to be designed at the outset for a level of product delivery, the in-service support package needs to be designed from the outset. For example, if the small reactor is to secure a level of plant sales comparable to current closed cycle gas turbine plants then the training burden alone needs a level of innovative thinking to support the volume of operating staff that need to be qualified on the plant. Early statements about centralised engineering support need to be developed to maintain support for the plants coming on-line. Part of the market appeal for a small reactor plant is the lower capital outlay. The reduced capital outlay opens up the small reactor to a new population of nuclear owners and operators. These ‘new to nuclear’ owners will not have mature engineering upkeep organisations to support their small reactor plants. As a consequence the third aspect to achieve a competitive cost base for a small reactor is the deployment of a fleet model that provides a centralised support service over a number of sites.

12.3 Conclusion

It can be seen that the supply and deployment of the small reactor offers an opportunity for the nuclear industry to adopt a revolutionary supply chain model, and maybe a new group of suppliers. There are opportunities to build an alternative supply chain established around manufacturing techniques that have been validated in other sectors.

With greater volumes of units flowing through the factories the incorporation of advanced manufacturing techniques can be substantiated. These techniques in turn offer efficiencies in manufacture that are reflected in lower manufacturing costs. The factory assembly of modules can be supported in a manner that offers incremental capacity increases reflecting market certainty.

The incorporation of contemporary automation for factory build techniques delivers a greater level of automatic part tracking from standardised product assembly. This in turn opens up options for fleet management across multiple sites managed to a common template. The deployment model for a small reactor is a revolutionary step for the nuclear industry.

Reference

Ford H and Crowther S, 1922, My Life and Work, Kessinger Publishing.