Written by Hasan Charkas, Senior Principal Team Leader - Advanced Reactor Engineering
Construction has been one of the most difficult hurdles for nuclear power plant project success historically. Most nuclear reactors operating today use traditional gigawatt-scale designs which typically require 6-7 years to construct, not including siting and licensing, and construction delays are a major risk that can cause projects to run over-time and over-budget.
Construction times and costs for gigawatt-scale reactors are driving interest in advanced technologies to expedite the construction process. Advanced reactors (ARs), including small modular reactors (SMRs), non-light water cooled reactors, and microreactors, are usually smaller than traditional reactors and are expected to especially benefit from advanced construction and engineering technologies and techniques, such as modular construction.
EPRI’s construction and engineering innovation research informs those responsible for the engineering, procurement, and construction of new nuclear power plants, including both traditional and advanced designs. In every case, our goal is to lower costs, increase quality, and shorten build times.
Construction & Engineering Tool Development
Since the early decades of nuclear power, new construction and engineering techniques and tools have become available from within and outside the industry that have the potential to increase efficiency, shorten timelines, and reduce costs. EPRI’s research helps nuclear construction projects implement these advancements, and we provide guidelines and best practices on their use.
Advanced Construction Tools
Our research helps establish the technical basis and engineering guidance for advanced construction tools in the nuclear industry, supporting consensus on their use and confidence in their application.
Technical Basis
We’re developing and demonstrating new techniques and tools for use in the industry, including:
High-Energy X-Ray Technology
High-energy X-ray technology can be used for 3D imaging of underground transmission steel casings and inspection of steel-concrete-steel (SC) structures, contributing to safer and more efficient construction.
Thick Section Welding Technologies
New welding technologies could significantly reduce costs for both conventional and advanced reactors. We analyze technologies by comparing the residual stresses of different narrow groove welds, both as-welded and post-heat treatment, to improve quality and strength.
Nondestructive Evaluation on Mockups for Steel-Concrete Structures
We’re working to develop the first nondestructive techniques to inspect steel plate concrete composite structures for use in new plant construction.
Real-Time Nondestructive Evaluation for Weld Inspections
The development of real-time inspection techniques for weld quality can help prevent issues like stress corrosion cracking, improving long-term safety and the case for relicensing.
Engineering Guidance
We offer best-practice guidance on various aspects of construction and engineering to improve project outcomes, including:
Optimization of Concrete Placements for Nuclear Power Plant Construction
Our guide provides best practices for placing concrete, including the many forms used in nuclear power plant projects.
Guide to Designing Structures for Constructibility
Our design constructibility guide addresses the challenges of executing design construction and emphasizes the importance of evaluating designs for constructability, especially with regard to reinforced concrete structures.
Guidance for Cybersecurity During New Nuclear Plant Construction
In an era of increasing cybersecurity concerns and requirements, our cybersecurity guide offers insights to ensure cybersecurity during the construction phase of nuclear plants.
New Nuclear Power Plant Information Turnover Guide
Our information turnover guide focuses on transferring information from engineering, procurement, and construction (EPC) contractors to owner-operators during the plant construction process, which has historically faced efficiency and thoroughness challenges.
Best Practices for Construction Acceptance Tests
Our construction acceptance test guide outlines best practices for conducting tests that ensure the quality and safety of the construction process.
Components & Procurement
Our research provides guidance for the technical analysis and seismic qualification of various components, including pressure vessels, component anchorages, and piping.
Technical Analyses
We characterize materials and components and provide guidelines for their use and procurement, including:
Equipment Reliability for New Nuclear Plants: Industry Recommendations for Design
Our report shares insights and lessons learned about equipment reliability for owner-operators to apply during the design phase. It offers best practices to ensure the long-term reliability of critical plant equipment.
Alloy 690 Steam Generator Tubing Specification Sourcebook: 2023 Revision
Alloy 690 is a corrosion-resistant material frequently used in piping for steam generators and heat exchangers for pressurized water reactors. This document aims to establish consistent codes and standards for manufacturing alloy 690 steam generator tubing.
Alloy 690 Procurement Specification
Our report provides procurement guidelines for alloy 690 for owner-operators to ensure quality and inspectability.
Performance of Hot Isostatic Pressed (HIP) Type 316L Stainless Steel Powders and HIP Processing Available from Today’s International Supply Chain
Powder metallurgy-hot isostatic pressing (PM-HIP) is an advanced manufacturing technique expected to significantly facilitate fabrication of ARs. This study focuses on ensuring consistent quality in 316L hot isostatic pressed stainless steel powders to accelerate commercial deployment of ARs.
Seismic Qualifications
EPRI develops guidelines and standards for reactor components to withstand seismic forces.
Seismic Cost Reduction through Base Isolation
Seismic loads contribute significantly to construction expenses, and base isolation can substantially reduce the seismic impact on nuclear plant structures while reducing equipment costs and construction time. Our report compiles data to evaluate seismic load cost contributions and base isolation viability.
Enhancing Vertical Seismic Design for Embedded Nuclear Structures
Our report introduces an approach to formulate vertical motion in soil-structure interaction analysis, resulting in more accurate seismic designs for embedded structures with global applicability.
Seismic Isolation for Safer Nuclear Facilities
Our report highlights the advantages, past applications, and potential cost savings associated with seismic isolation. We also provide recommendations for developing guidelines to implement seismic isolation in nuclear facilities.
Enhanced Seismic Source Characterization for Nuclear Facilities
Our report introduces a new seismic source characterization (SSC) model for the Central and Eastern United States (CEUS), replacing outdated ones with a comprehensive, traceable process following industry guidelines.
Cost Reduction in Construction Practices
EPRI evaluates and supports development of practical solutions for construction cost reductions. We are exploring advanced technologies such as digital twins and modular construction techniques to evaluate their applicability for nuclear plant application.
Advanced Construction Techniques
New construction and fabrication techniques can be used for cost and time savings in nuclear projects.
Overview of Advanced Construction Techniques for Optimizing New Nuclear Projects
We provide an overview of the advanced techniques expected to optimize AR construction and reduce construction timelines and costs, including modular fabrication, digital tools, advanced welding, and new excavation methods.
Assessment of Moisture-Tolerant Coatings for Decreasing Open Top Construction Time
Open-top construction has successfully facilitated nuclear power plant construction in the past. Before components can be lowered into the containment building, the concrete base must cure, which can take up to 28 days. Our research explores moisture-tolerant coatings that could potentially expedite the curing process to as little as seven days and reduce open-top construction time.
Korea Hydro & Nuclear Power Co., Ltd. Nuclear Power Plants: Construction and Technology Experience
We examine the construction tools and techniques used in the Republic of Korea that helped it become the second fastest nuclear reactor-building country in the 21st century, gaining valuable insights into project delivery efficiency.
Digital Tools
Digital technologies are increasingly being integrated into the construction process, offering new opportunities to improve efficiency and quality. EPRI’s research includes:
Lessons Learned and Best Practices from the Development of a Digital Twin for Construction Quality
Digital twins are computerized replicas of nuclear reactors that are becoming integral in construction projects. During the design and construction stages, digital twins can centralize plans to coordinate contractors working in parallel. Our report shares lessons learned and best practices from the development of digital twins for construction quality.
Augmented Reality Technologies for New Nuclear Plant Applications
We conduct a broad analysis of augmented reality technologies and their potential implementation in new nuclear power plant projects.
Modular Fabrication
Modular construction – or constructing reactor units and assemblies that can be shipped to site from a factory – is expected to significantly lower overnight construction costs for SMRs. Modular construction of ARs will likely involve advanced fabrication techniques, such as PM-HIP and electron beam welding (EBW).
Identifying Gaps for Development to Improve Modular Construction in Future Nuclear Power Plants
Our study identifies gaps for improvement to help modular construction methods succeed.
Quick Insight Brief: Manufacture of Nuclear Components Using Powder Metallurgy and Hot Isostatic Pressing
This brief provides a high-level overview of PM-HIP, a promising fabrication method to decrease costs and improve component quality, particularly of interest for ARs.
Prefabricated Structural Modules for Nuclear Construction—Survey of Experience and Roadmap for Future Development
The use of prefabricated structural modules is examined, providing insights into how this approach can expedite construction in nuclear power plants.
Modular Construction Roadmap
We outline the lessons learned from past projects and remaining research and demonstration needs that will help ARs benefit from modular construction.
Small Modular Reactor Vessel Manufacture and Fabrication
EPRI is working with industry actors to demonstrate several of the advanced fabrication techniques that will facilitate AR deployment, using these methods to construct a ⅔ scale NuScale Power Module™ reactor pressure vessel.
Advancement in Construction Materials
We assess the readiness of innovative construction technologies such as self-consolidating concrete, high-strength rebars, and concrete under elevated temperatures for deployment in nuclear plant projects.
Concrete
Self-Consolidating Concrete
Self-consolidating concrete (SCC) is becoming increasingly popular because it improves concrete workability, reduces the need for mechanical consolidation, improves surface finish, reduces labor, and mitigates difficulties associated with heavy congestion of reinforcing steel and the potential for costly repairs and schedule delays resulting from poor concrete consolidation in congested areas.
Self-Consolidating Concrete for Massive Concrete Applications
SCC quality varies with additives, and mixtures can improve thermal and tensile properties. We examine different SCC types for nuclear applications.
Demonstration and Evaluation of Self-Consolidating Concrete Mixtures
We compare SCC mixtures to conventional concrete, offering data on workability, plastic and hardness properties, and demonstrating the benefits of SCC in nuclear power plant construction.
Mass Concrete Modeling and Thermal Control
Our report examines testing methods to predict concrete cracking in massive concrete structures, a critical concern in nuclear plant construction.
Reinforcing Steel and Sensors
Investigating Mechanical Splicing of Reinforcing Steel
We explore different methods of splicing long rebar formations, providing insights into the best practices for enhancing the integrity of concrete structures.
Embedded Sensors in Concrete
Embedded sensors in concrete provide valuable data for quality and inspection purposes. They are especially useful for long-term maintenance and license extension.
Materials for Advanced Reactors
Many AR reactor designs present greater materials challenges than conventional reactors, including higher temperatures, corrosive environments, and larger neutron fluxes. Developing innovative materials will thus play a vital role in deploying advanced reactors.
New Materials Scoping Assessment for Nuclear Applications
This assessment explores the use of new materials for nuclear applications, enhancing safety and performance.
Composites for Nuclear Applications
Carbon-carbon (C-C) composites are examined for their potential in nuclear applications in 3002026567, and silicon carbide (SiC) composites are investigated.
High-Temperature Concrete
Our report delves into temperature-resistant concrete, which will be vital for AR construction.
Precast Concrete for New Reactor Construction
Especially for smaller reactors sites such as at SMRs, precast concrete could be shipped to site and installed on arrival if storage is limited. Our report examines precast concrete applications in future nuclear reactor construction.
EPRI’s Research Supports Advanced Construction & Engineering
Efforts to reduce construction times, enhance safety, and lower costs are crucial for the continued growth and success of nuclear power. The nuclear industry will continue to play a vital role as the world seeks sustainable energy solutions, and innovations in construction are instrumental in its future.
We encourage all current and prospective owner-operators of nuclear plants to become EPRI members. This grants you access to our entire research library, helping your plant succeed.
To help navigate the different resources available to members and how you can make best use of your membership, we provide a guide to EPRI resources in 3002025692.
In addition to consulting our research, members may find even greater benefit by getting in contact with EPRI for coordinated solutions and strategies for specific projects. You can get in touch with us at ant@epri.com.