COMPOSITE INTEGRATED MODULE

Abstract

A composite integrated module, comprising a formwork; a plurality of frame members mounted on one surface of the formwork; and at least one embedded plate, to which a support member for supporting a first plant structure member is attached, mounted directly to at least one the frame member, wherein one surface, which does not mounted on the frame member, of the embedded plate faces to a direction in which another surface, which does not mounted on the frame member, of the formwork faces.

Description

CLAIM OF PRIORITY

The present application claims priority from Japanese patent application serial no. 2007-199162, filed on Jul. 31, 2007 and Japanese patent application serial no. 2008-191693, filed on Jul. 25, 2008, the content of which is hereby incorporated by reference into this application.

BACKGROUND OF THE INVENTION

The present invention relates to a composite integrated module and, more particularly, to a composite integrated module favorably applicable to construct a building of a nuclear power plant, for example, a reactor building.

In construction of a power plant, for example, a nuclear power plant, plant structures have been modularized in order to shorten the construction period of the plant. Examples of using modularized structures to construct nuclear power plants will be described below.

Japanese Patent Laid-open No. Hei 4 (1992)-293864 discloses a method for constructing a nuclear power plant building using building modules. This building module forms frameworks of a floor section, a plurality of pillars, and a ceiling section with many steel frames. Steel plates for the floor, pillars, and ceiling are attached to the inside of the frameworks. The building module is internally equipped with machine elements such as equipments, pipes, trays, ducts, supports, and the like in advance. A plurality of building modules are set out and concrete is poured between the modules and on their ceilings. The steel plates of the walls and the ceilings are used as formworks when concrete is poured.

A composite integrated module disclosed in Japanese Patent Laid-open No. Hei 10 (1998)-266602 has two sidewall sections and a ceiling section placed on the sidewall sections and forms a room for a nuclear power plant by using these sections. Each sidewall is formed by attaching steel plates, which are used as formworks, to both sides of a steel frame pillar. The ceiling section comprises a deck plate (or a ceiling steel plate formwork) placed on a plurality of ceiling beams, reinforcing steel bars placed on the deck plate (or the ceiling steel plate formwork), and pipes and ducts attached to the ceiling beams. Concrete is poured between sidewall sections of adjacent composite integrated modules, on the deck plate (or the ceiling steel plate formwork), and between the steel plates of each sidewall section.

Japanese Patent Laid-open No. 2003-66177 discloses a hydraulic control unit (HCU) room module for a control rod drive system in a nuclear power plant. The HCU module is formed with a plurality of steel frame structures disposed lengthwise and breadthwise. A plurality of module skids disposed lengthwise and breadthwise is mounted on each steel frame structure. Steel plate reinforcements included in a sidewall are mounted on the steel frame structures and the module skids. The HCU module has an HCU, cable ducts, and pipes. The HCU module is placed on many rotary extendable module receiving pillars that are placed on a floor and can finely control the level of the HCU module. The steel plate reinforcements are used as formworks.

Japanese Patent Laid-open No. 2003-13621 discloses a composite integrated module used for a power plant. In this composite integrated module, a frame is formed by a plurality of steel pillars and a plurality of steel beams, a deck plate (or a ceiling steel plate formwork) is placed on the upper end portion of the frame, and pipes and cable ducts are placed in the module. Reinforcing steel bars are installed around the steel beams and concrete is poured thereto to form concrete walls.

Japanese Patent Laid-open No. Hei 7 (1995)-198885 describes a steel plate block for a wall (see FIG. 12 in it). In the steel plate block, support members for support pipes are attached to H-shaped steels. This patent document also shows a structure of a ceiling in FIG. 6, in which a steel plate disposed between two H-shaped steels is attached to the H-shaped steels, one side plate forming part of an air-conditioning duct is attached to one of the H-shaped steels, and another side plate is attached to the steel plate.

SUMMARY OF THE INVENTION

Units placed on a floor in a building of a power plant are installed on support structures buried in the floor. These support structures must be buried in the floor concrete when concrete is poured. Therefore, to adopt a modular construction method for carrying integrated structure elements to be installed in a room of the plant building, it is difficult to assemble the support structures to a module because joints to the building must be considered.

Described below are problems pertaining to joints of plant facilities, such as equipment, pipes, and the like that need to be disassembled for maintenance and inspection after they have been installed, to a plant building.

When an equipment or plant structure element of a power plant is installed on at least one of a floor and a wall of a building, it is considered that fixing members such as anchor bolts are first buried in the building and then used to fix the equipment or plant structure element. In this installation method, however, it is very hard to align the bolt holes of the equipment or the plant structure element with the anchor bolts buried in the building since their production accuracies are different. If the equipment or the plant structure element is placed on the floor only, a conventional adjustment method is available, in which after the facility or plant structure element has been installed, the periphery of each anchor bolt on the building is enclosed with a sleeve or like and then concrete or mortar is poured in the space between the anchor bolt and the sleeve. However, when the equipment or plant structure element may need to be joined to a wall of the building and thereby concrete (or mortar) may be poured horizontally, the equipment or plant structure element itself becomes an obstacle to the pouring of concrete (or mortar). Therefore, it is difficult to pour the concrete (or mortar). In order to solve this problem, it is necessary to pour concrete, which becomes the building, after the anchor bolts are installed in the wall at the same time when the equipment or plant structure element is installed. However, when an ordinary formwork that is removed later is used, the equipment or the plant structure element itself will interfere with the formwork to be installed and removed. This prevents the equipment from being joined to the formwork and walls. Some equipments and plant structure elements may need to be removed from the skeleton when they are inspected or exchanged. However, when such an equipment or plant structure element is installed on a floor and one or more walls, joints to anchor bolts are necessary in two or more directions, so the equipment or plant structure elements cannot be removed and remounted.

When a equipment or plant structure element that is installed on a concrete groundwork and support structures provided on a floor are assembled into a composite integrated module, it is necessary to place, below the equipment or plant structure element, a steel module frame for supporting the facility or plant structure element. In this case, the concrete groundwork and module frame interfere with each other and consequently the composite integrated module cannot be installed. When a steel groundwork is placed on the steel module frame instead of the concrete groundwork and assembled to the composite integrated module, the module frame is exposed from the building. This aggravates the accessibility. Furthermore, the module frame forms partitioned spaces on the floor, making drainage of the floor worse. Particularly, decontamination cannot be assured in a facility that handles radioactive substances such as a nuclear power plant in which radioactive drainage is generated.

It can be considered that the equipment or the plant structure element is fastened to two surfaces, that is, the floor section and a wall section of a composite integrated module by using anchor bolts installed on the floor section and the wall section of the composite integrated module and nuts, as described above. In this method, however, anchor bolts that are provided on the floor section and wall section cannot be inserted into corresponding bolt holes formed in the equipment or plant structure element.

Composite integrated modules disclosed in Japanese Patent Laid-open No. Hei 10 (1998)-266602 and Japanese Patent Laid-open No. 2003-13621 are respectively equipped with sidewalls and a ceiling and also have pipes and ducts (or trays) therein. However, installation of equipments is not described in these patent documents. Composite integrated modules disclosed in Japanese Patent Laid-open No. Hei 4 (1992)-293864 and Japanese Patent Laid-open No. 2003-66177 are respectively equipped with equipment in addition to structure elements described in Japanese Patent Laid-open No. Hei 10 (1998)-266602 and Japanese Patent Laid-open No. 2003-13621. However, Japanese Patent Laid-open No. Hei 4 (1992)-293864 and Japanese Patent Laid-open No. 2003-66177 do not refer to specific installation structures of the equipment.

A first object of the present invention is to provide a composite integrated module that can support load applied to a plant structure member during a plant operation.

A second object of the present invention is to provide a composite integrated module that facilitates installation of a plant structure member placed in the internal space and can support load applied to another plant structure member during a plant operation.

The present invention to accomplish the above first object is characterized in that a composite integrated module comprises a formwork, a plurality of frame members mounted on one surface of the formwork, and at least one embedded plate, to which a support member for supporting a first plant structure member is attached, mounted directly to at least one the frame member, wherein one surface, which does not mounted on the frame member, of the embedded plate faces to a direction in which another surface, which does not mounted on the frame member, of the formwork faces.

Since the embedded plate, to which the support member for supporting the first plant structure member is attached, is mounted directly to at least one the frame member, the embedded plate can support a load that operate to the first plant structure member during a plant operation. This load is a load caused by, for example, an earthquake.

To accomplish of the above second object, it is preferable to mount at least one anchor member not projected from a second surface, which faces to a diametrically opposed location to a first surface mounted on a frame member, of a formwork, on the first surface of the formwork and to connected removable tightening apparatuses, by which a second plant structure member is mounted on the second surface of the formwork, with anchor members.

Since at least one the anchor member is not projected from the second surface, which faces to a diametrically opposed location to the first surface mounted on the frame member, of the formwork, when the second plant structure member is moved along the second surface of the formwork during the installation of the second plant structure member, the second plant structure member does not collide with anchor members that are to be connected to tightening apparatuses used to install the second plant structure member, preventing the movement of the second plant structure member from being impeded. Therefore, the second plant structure member can be installed on the composite integrated module easily by using the anchor members and the removable tightening apparatuses.

The above first object is also accomplished by a composite integrated module comprises a floor member, a plurality of sidewall members mounted on the floor member, and a ceiling member installed the sidewall members,

wherein the floor member, the wall members, and the ceiling member form an internal space of the module,

the sidewall members respectively has a first formwork facing the internal space,

the floor member has a second formwork facing the internal space,

the ceiling member has a third formwork facing the internal space,

the sidewall members have a first frame member arranged outside the first formwork and attached to the first formwork,

the floor member has a second frame member arranged outside the second formwork and attached to the second formwork,

the ceiling member has a third frame member arranged outside the third formwork and attached to the third formwork, and

at least one embedded plate, to which a support member for supporting a first plant structure member placed in the internal space is attached, is directly mounted to at least one of the first, the second and third frame members.

Since the embedded plate, to which the support member for supporting the first plant structure member is attached, is mounted directly to at least one of the first, second and third frame members, the embedded plate can support a load that operate to the second plant structure member during a plant operation. This load is a load caused by, for example, an earthquake.

To accomplish of the above second object, it is preferable to dispose anchor members outside at least one of the first, second, and third formworks and mounted on at least one of the first, second, and third formworks, and to connected removable tightening apparatuses, by which a second plant structure member disposed in the internal space is mounted on the second surface of the formwork, with anchor members from the internal space.

Since the anchor members are disposed on an outer surface of the formwork, when the second plant structure member is moved along an internal surface of the formwork during the installation of the second plant structure member, the second plant structure member does not collide with anchor members that are to be connected to tightening devices used to install the second plant structure member, preventing the movement of the second plant structure member from being impeded. Therefore, the second plant structure member can be installed on the composite integrated module easily by using the anchor members and the removable tightening apparatuses.

According to the present invention, a load applied to a first plant structure member during a plant operation can be supported by an embedded plate directly attached to a frame member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a structural diagram showing a composite integrated module for a plant of a first embodiment, which is a preferred embodiment of the present invention, showing section I-I in FIG. 2.

FIG. 2 is an oblique perspective view showing the composite integrated module shown in FIG. 1.

FIG. 3 is a detailed structural diagram showing the anchor member shown in FIG. 1.

FIG. 4 is an explanatory drawing showing a method of attaching anchor members by using a positioning tool.

FIG. 5 is a cross sectional view showing section V-V near the embedded plate shown in FIG. 1.

FIG. 6 is a cross sectional view taken along a line VI-VI shown in FIG. 5.

FIG. 7 is an enlarged view of section VII shown in FIG. 6.

FIG. 8 is a longitudinal sectional view showing another example of a ceiling member shown in FIG. 1.

FIG. 9 is a longitudinal sectional view showing a composite integrated module for a plant of a second embodiment, which is another embodiment of the present invention.

FIG. 10 is a longitudinal sectional view showing a composite integrated module for a plant of a third embodiment, which is further another embodiment of the present invention.

FIG. 11 is a longitudinal sectional view showing a composite integrated module for a plant of a fourth embodiment, which is further another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An embodiment of the present invention will be described with reference to the drawings.

First Embodiment

A composite integrated module of a first embodiment, which is one preferable embodiment of the present invention and is used in a plant, will be described with reference to FIGS. 1 to 6. The composite integrated module 1 for a plant (simply referred to below as the composite integrated module 1) in the present embodiment is intended for a single room in a reactor building of a nuclear power plant. As shown in FIG. 2, the composite integrated module 1 includes a plurality of pillar steel frames 2 extending vertically, a plurality of first ceiling steel frames 3, each of which is attached to each side of the plurality of pillar steel frames 2 and extends in a horizontal direction, and a plurality of second ceiling steel frames 4, each of which is attached to each side of each two pillar steel frames 2, their corresponding sides facing each other, and extends in a horizontal direction so that the second ceiling steel frame 4 is orthogonal to the first ceiling steel frame 3. The composite integrated module 1 further includes a plurality of first floor steel frames 5 and a plurality of second floor steel frames 6 that are used to transport the composite integrated module 1. The first floor steel frames 5 are disposed parallel to the first ceiling steel frames 3. The second floor steel frames 6 are disposed orthogonally to the first floor steel frames 5 and parallel to the second ceiling steel frames 4. Another end portion of the first ceiling steel frame 3 is supported by a module skid (frame pillar) 11, which is an H-shaped steel frame, described later. Each pillar steel frame 2 is disposed on a top surface of one first floor steel frame 5. Each second floor steel frame 6 is disposed between two first floor steel frames 5 that are oppositely disposed, both ends of the second floor steel frame 6 being connected to its adjacent first floor steel frames 5. The pillar steel frame 2, first ceiling steel frame 3, and second ceiling steel frame 4 are reinforcing members of the building of the nuclear power plant.

The composite integrated module 1 further includes a plurality of sidewall members 10, a floor member 16, and a ceiling member 21. The four sidewall members 10, which are mutually connected, are disposed in four directions. The floor member 16 is attached to the bottoms of these sidewall members 10. The ceiling member 21 is attached on each end portion of the sidewall members 10. A room 26, which is an internal space of the composite integrated module 1, is formed by being enclosed by the sidewall members 10, floor member 16, and ceiling member 21. At least one sidewall member 10 is provided with a door (not shown) that communicates with the internal space of the room 26. In the composite integrated module 1, equipment 27 such as, for example, a tank, is disposed in a room (internal space) 26. The equipment 27 disposed in the room 26 is a plant structure element (second plant structure member). The composite integrated module 1 is a room module that includes the second plant structure member and a first plant structure member described later. The equipment 27 includes an installation frame 28 facing a sidewall member 10 and installation frame 29 facing the floor member 16. The installation frame 28 is attached to the sidewall member 10 with installation bolts 24, and the installation frame 29 is attached to the floor member 16 with installation bolts 25. Constituent elements of the sidewall member 10, floor member 16, and ceiling member 21, such as frame beams and frame pillars, are made of steel.

The floor member 16 includes a plurality of frame beams (frame members) 17, a plurality of frame beams 18, a plurality of floor steel plates 19, and a plurality of anchor members 20. Each frame beam 17 is disposed parallel to the first floor steel frame 5, and each frame beam 18 is disposed in a direction orthogonal to the frame beam 17, that is, parallel to the second floor steel frame 6. The frame beams 17 and frame beams 18 are mutually welded and form a grating. The frame beams 17 are disposed on the first floor steel frame 5. The floor steel plate 19 is attached to top surfaces of the frame beams 17 and frame beams 18 by being welded. The plurality of anchor members 20 is attached at predetermined positions on the back surface of the floor steel plate 19. These anchor members 20 are perpendicular to the floor steel plate 19 and are not projected from the floor steel plate 19 into the room 26. The central part of the floor member 16 lacks the floor steel plate 19. The frame beam 17 and frame beam 18 are H-shaped steels.

The sidewall member 10 includes a plurality of module skids (frame members) 11, which are frame pillars, a wall steel plate 12, and a plurality of anchor members 13. The module skids 11 are horizontally disposed at predetermined intervals, and welded to a top surface of the frame beam 17. The upper end of each module skid 11 is welded to each undersurface of the first ceiling steel frames 3. The wall steel plate 12 is attached to the module skids 11, the wall steel plate 12 being inside the module skids 11. The wall steel plate 12 faces the room 26 formed in the composite integrated module 1. The plurality of anchor members 13 is attached to the back surface of the wall steel plate 12 at predetermined positions. These anchor members 13 are perpendicular to the wall steel plate 12 and do not extend into the room 26.

The ceiling member 21 includes a plurality of frame beams 22 and a deck plate 23. The frame beams 22 are disposed in parallel and attached to their adjacent first ceiling steel frames 3. The deck plate 23 is disposed on top surface of the frame beams 22. A ceiling steel plate formwork may be used instead of the deck plate 23. The top of the wall steel plate 12 is welded to the frame beam 22. The frame beam 22 is H-shaped steel.

Detailed structures of the anchor members 13 and 20 will be described with reference to FIG. 3. The anchor members 13 and 20 have the same structure, so the anchor member 13 will be mainly described below. The anchor member 13 includes a connection member 15, which is cylindrical, and an anchor bolt 14. The connection member 15 is internally threaded. The anchor bolt 14 has a threaded part that engages with the threads of the connection member 15. The anchor bolt 14 is inserted from an end of the connection member 15 into the interior of the connection member 15, the threads outside the anchor bolt 14 and the threads inside the connection member 15 being mutually engaged. The anchor bolt 14 is inserted to about half the length of the connection member 15. The anchor bolt 14 is then secured to the connection member 15. The anchor member 13, which is integrally formed with the connection member 15 and anchor bolt 14, is secured at a predetermined position on the back surface of the wall steel plate 12. That is, the connection member 15 is attached to the back surface of the wall steel plate 12 with another end of the connection member 15 (an end opposite to an end from which the anchor bolt 14 is inserted) facing the back surface of the wall steel plate 12. An opening 35 is formed in the wall steel plate 12 at a point that is on the extension of a central line of the connection member 15. The opening 35 is formed for each anchor member 13 so that it faces the screw hole of the connection member 15. The anchor member 13 does not extend beyond the wall steel plate 12 toward the room 26.

As with the anchor member 13, the anchor member 20 is also structured by engaging the anchor bolt 14 into the connection member 15. One end, which faces the back surface of the wall steel plate 19, of the connection member 15 of the anchor member 20 is fixed at a predetermined position on the back surface of the wall steel plate 19. Another opening 35 is also formed in the floor steel plate 19 at a point that is on the extension of a central line of the connection member 15. The opening 35 in the floor steel plate 19 is formed for each anchor member 20 so that it faces the screw hole of the connection member 15.

Although the anchor members 13 and 20 are structured by combining the connection member 15 and anchor bolt 14, the structure can also be achieved by using a single member.

The method of fixing the anchor member 13 to the wall steel plate 12 will be described with reference to FIG. 4. The anchor member 20 can be fixed to the floor steel plate 19 in the same way. The position and number of the anchor members 20 to be fixed are determined by the position and number of through holes, in which installation bolts 24 are inserted, formed in the installation frame 28 on which the equipment 27 is placed. A positioning tool 42 shown in FIG. 4 is used to fix the anchor member 13 to the wall steel plate 12. In the positioning tool 42, positions for disposing a predetermined number of anchor members 13 are determined depending on the number of through-holes formed in the installation frame 28 as well as on their positions. As many openings 35 as the numbers of through-holes are formed in the wall steel plate 12 in advance. The positioning tool 42, on which the predetermined numbers of anchor members 13 are held at predetermined positions, is placed at a predetermined position on the back surface of the wall steel plate 12. The connection members 15 of the anchor members 13 held by the positioning tool 42 are fixed sequentially to the back surface of the wall steel plate 12. The use of the positioning tool 42 improves precision of the positioning of the anchor members 13 to the wall steel plate 12 and the positioning of the anchor members 20 to the floor steel plate 19, improving precision of the attachment of the anchor members 13 and 20. Each anchor member 20 is fixed to a position at which no interference occurs with the frame beam 17 and frame beam 18.

The number of anchor members 13 to be attached and the their fixing positions are determined depending on the position and number of through-holes, in which the installation volts 24 are inserted, formed in the installation frame 28 of the equipment 27 is placed. The predetermined anchor members 13 are fixed sequentially on the back surface of the wall steel plate 12 by using the positioning tool 42. Each anchor member 13 is fixed to a position at which no interference occurs with other members.

The equipment 27 is installed to two surfaces of the composite integrated module 1. In the present embodiment, the equipment 27 is installed to the floor member 16 and one sidewall member 10 by using supports 30, as described above. This installation is performed as described below. The installation frame 29 of the equipment 27 is placed on the floor member 16 so that the above through-holes formed in the installation frame 29 are aligned to the openings 35 formed in the floor steel plate 19. The above through-holes formed in the installation frame 28 of the equipment 27 are also aligned to the openings 35 in the wall steel plate 12. A predetermined number of installation bolts (tightening apparatuses) 24 are then inserted through the through-holes formed in the installation frame 29 and the corresponding openings 35 into the screw holes in the connection members 15 of the anchor members 20. When the installation bolt 25 is turned, the threads of the installation bolt 25 engage into the threads of the connection member 15, enabling the installation frame 29 to be removably attached to the floor member 16. A predetermined number of installation bolts (tightening apparatuses) 24 are also inserted through the through-holes formed in the installation frame 28 and the corresponding opening 35 into the screw holes in the connection members 15 of the anchor members 13. When the threads of the installation bolt 24 are engaged into the threads formed on the connection member 15 of the anchor member 13, the installation frame 28 is removably attached to the sidewall member 10.

The composite integrated module 1 further includes a pipe (or a duct) 34 arranged in the room 26. The pipe 34, which is installed in the nuclear power plant, is attached to a support member 33. Water (for example, driving water of a control rod driving mechanism) flows in the pipe 34. A structure for attaching the support member 33 will be described in detail with reference to FIGS. 1, 5, and 6. The pipe (or tray) 34 installed in the room 26 is a tubular member. An embedded plate 31A is welded to one surface of the module skid 11. A plurality of anchor bolts 32A is installed on the back surface of the embedded plate 31A. The support member 33 is welded to the front surface of the embedded plate 31A. The wall steel plate 12 has a notch at a place where the embedded plate 31A is attached to the module skid 11, as shown in FIG. 5, so the embedded plate 31A can be directly welded to the module skid 11. Two wall steel plates 12 adjacent to the sidewall member 10 are welded to one surface of the module skid 11 so that a clearance G (see FIG. 7) is formed between the two wall steel plates. This type of clearance G is also formed at places where the floor steel plate 19 adjacent to the floor member 16 is welded to the frame beam 17 and frame beam 18. It is also possible to install a cable storage tray (not shown) to another support member 33 attached to another embedded plate 31A welded to one surface of the module skid 11. A pipe, a duct (an exhaust duct, for example), and a tray attached to the composite integrated module 1 are also plant structure elements. These elements are collectively called first plant structure members.

A plurality of intermediate floor support members 43 is disposed in the room 26 at an intermediate position in its height direction. Embedded plates 31B, to which both ends of the intermediate floor support member 43 are welded, are each welded to one surface of the module skid 11, as is done for the embedded plate 31A. A plurality of anchor bolts 32B is also attached to the back surface of the embedded plate 31B. A grating 38, which is an operation floor, is disposed on the top surface of the intermediate floor support member 43. Lower end portions of support members 37A and 37B are joined to the intermediate floor support member 43, and upper end portions of the support members 37A and 37B are welded to different frame beams 22. A plurality of support members 39 extending horizontally is attached to each of the support members 37A and 37B. A plurality of pipes 40 is attached to each of the plurality of support members 39. A support member 41 attached to the frame beam 22 also supports the pipes 40.

A method of constructing a building will be described below by using an example in which a nuclear reactor building is employed, which uses the composite integrated module 1 provided with the equipment 27 and pipe 34. The composite integrated module 1 is assembled in a factory and transferred to a building construction field. The composite integrated module 1 may be too large to transfer from the factory to the construction field. When this happens, required parts can be manufactured in the factory and the parts can be assembled to the composite integrated module 1 near the construction field of the nuclear power plant or another place in the field of the nuclear power plant.

Concrete is poured up to predetermined level in an area where a nuclear reactor building is constructed, the composite integrated module 1 being placed in the nuclear reactor building. A crane is used to place the composite integrated module 1 at a predetermined level in an area where the nuclear reactor building is constructed, with the floor member 16 being the lower side. The first floor steel frames 5 and second floor steel frames 6, which have been used to transport the composite integrated module 1, are removed from the composite integrated module 1 before the composite integrated module 1 is placed at the predetermined level. The lower end of the pillar steel frame 2 of the composite integrated module 1 placed at the predetermined level is joined to the upper end of another pillar steel frame that is positioned below the pillar steel frame 2 of the above composite integrated module 1 and buried in concrete, except the upper end of the other pillar steel frame.

Reinforcing steel bars (not shown) are disposed above the ceiling member 21, that is, above the deck plate 23. Four wooden formworks 36 are disposed in the direction facing the corresponding wall steel plates 12 outside the sidewall members 10 positioned as four sides. FIG. 1 shows only one of the four wooden formworks 36. The wooden formwork 36 is not disposed as part of the composite integrated module 1. The wooden formwork 36 is disposed after the composite integrated module 1 is placed at the predetermined position in an area where the nuclear reactor building is constructed but before concrete is poured. A clearance of a predetermined distance is formed between the wall steel plate 12 and wooden formwork 36. Concrete is poured atop the ceiling member 21 and outside the sidewall members 10. When concrete is poured outside the sidewall member 10, it is supplied between the wall steel plate 12 and wooden formwork 36. When concrete is poured in the floor member 16, the frame beams 17, frame beams 18, and anchor members 20 are buried in the concrete. The module skid 11, the anchor members 13 attached to the wall steel plate 12 and the pillar steel frame 2 are also buried in the concrete between the wall steel plate 12 and wooden formwork 36. On the deck plate 23, concrete is poured only up to a predetermined thickness. The first floor steel frames 5 and second floor steel frames 6 are also buried in the concrete. The wall steel plate 12, deck plate 23, and floor steel plate 19 are used as a formwork when concrete is poured. When a ceiling steel formwork is used instead of the deck plate 23, the ceiling steel formwork is used as a formwork for the ceiling.

After the poured concrete is hardened, the anchor member 20 functions as an anchor for the floor steel plate 19 and works together with the installation bolt 25 to support the equipment 27. The anchor member 13 also functions as an anchor for the wall steel plate 12 and works together with the installation bolt 24 to support the equipment 27.

Since, in the present embodiment, the first plant structure members such as the pipe 34 are supported by the embedded plates 31A, which are directly attached to the module skids 11, through the support member 33, the loads of the first plant structure members can be held by the module skids 11 during transportation of the composite integrated module 1. After the nuclear reactor building, which uses the composite integrated module 1, has been constructed, the anchor bolts 32A of the embedded plate 31A directly attached to the module skid 11 and the module skid 11 are buried in the hardened concrete. In addition, since an embedded plate to which support members for supporting the first plant structure members are attached is attached directly to at least one of the first frame member and third frame member, the load applied to the first plant structure members can be supported during a plant operation.

Since the anchor members are attached to the outer surfaces of the formwork, when the second plant structure members are moved along an inner surface of the formwork to install the second plant structure members, the second plant structure members do not collide with the anchor members including the removable tightening apparatuses used to install the second plant structure members and thereby the movement of the second plant structure members is not impeded. This enables the second plant structure members to be easily disposed in the composite integrated module 1 by using the anchor members including tightening apparatuses.

In the present embodiment, the anchor member 13 is disposed on the back surface of the wall steel plate 12 and the anchor member 20 is disposed on the back surface of the floor steel plate 19 and these anchor members do not protrude from the fronts of steel plates. Accordingly, an internal structure member that needs to be attached to at least two of the sidewall member 10, floor member 16, and ceiling member 21, specifically the equipment 27, can be easily disposed in the composite integrated module 1. Concretely, when the underside of the installation frame 29 of the equipment 27 is moved horizontally, for example, near the top surface of the floor steel plate 19, the through-holes formed in the installation frame 29, into which the installation bolts 25 are inserted, can be easily aligned to the openings 35 formed in the floor steel plate 19. When the underside of the installation frame 29 is placed in contact with the top surface of the floor steel plate 19, it is assumed that there may be offsets between the through-holes and the openings 35. In this case, when the equipment 27 is moved with the installation frame 29 in contact with the floor steel plate 19, the through-holes can be easily aligned to the openings 35. While this state is maintained, a side of the installation frame 28 can be directly placed in contact the wall steel plate 12. Then, the through-holes formed in the installation frame 28, into which the installation bolts 24 are inserted, can be easily aligned to the openings 35 formed in the wall steel plate 12. Since the installation bolt 25 and installation bolt 24 can be easily engaged with the connection member 15 of the anchor member 20 and the connection member 15 of the anchor member 13, respectively, as described above, the equipment 27 can be easily attached to two surfaces of the composite integrated module 1. In the present embodiment, when the equipment 27 is placed at the installation position, the anchor member 13 does not protrude into the inside of the wall steel plate 12, and anchor member 20 does not protrude into the inside of the floor steel plate 19. In the present embodiment, it never happens that the equipment 27 collides with the anchor member 13 or 20 and thereby movement of the equipment 27 is impeded. Accordingly, the equipment 27 can be easily attached to the two surfaces of the composite integrated module 1, as described above.

The present embodiment can solve the problem with conventional installation of a plant facility in which foundation bolts are installed to a floor member and a wall member of a composite integrated module and these foundation bolts are used together with nuts to install the plant facility.

When maintenance and inspection of the equipment 27 is carried out during annual inspection of the nuclear power plant after the installation of the composite integrated module 1, the installation bolts 24 and 25 are removed. The equipment 27 can then be moved, enabling the maintenance and the inspection of the equipment 27 to be easily carried out. After the maintenance and the inspection of the equipment 27 have been carried out, it can be easily installed in the composite integrated module 1 as descried above. Force that is generated by tightening the installation bolts 24 and 25 can be transmitted to the concrete through the anchor members 13 and 20.

The pillar steel frames 2 and first ceil steel frames 3 and module skids 11 support the ceiling member 21, so these members can support the load of concrete poured on the deck plate 23. Accordingly, concrete can be poured on the Q-deck 23 and outside the sidewall members 10 simultaneously, shortening a building period of the nuclear power plant. In particular, it becomes unnecessary to establish a period that has been required to wait until concrete poured outside the sidewall members 10 is hardened before concrete is poured into the ceiling section.

In the present embodiment, the embedded plate 31A to which a plurality of anchor bolts 32A (anchor members) 32A is attached is directly fixed to the front surface of the module skid 11, and the support member 33 attached to the embedded plate 31A supports first plant structure members such as the pipe 34 or duct. Accordingly, when the composite integrated module 1 is transported, the loads based on the first plant structure members can be held by the module skids 11. The pipe 34 undergoes thermal expansion during an operation of the nuclear power plant. Due to this thermal expansion and the weight of the fluid flowing in the pipe 34, the load applied to the pipe 34 is extremely larger than the load applied to the pipe 34 during transportation of the composite integrated module 1. If an earthquake occurs during an operation of the nuclear power plant, extremely large loads are applied to the pipe (or duct) 34 and the tray. In the present embodiment, however, after the nuclear reactor building using the composite integrated module 1 has been constructed, the anchor bolt 32A attached to the embedded plate 31A and the module skid 11 are buried in the hardened concrete, the embedded plate 31A being directly attached to the module skid 11. Accordingly, in the present embodiment, since a support structure member, which includes the embedded plate 31A, for supporting the pipe (or duct) 34, and the tray is used, the first plant structure members, to which large loads are applied during a plant operation, such as the pipe (or duct) 34 and the tray can be easily supported. A load applied to the first plant structure members (the pipe 34 and the like, for example) during a plant operation is transmitted through the support member 33 to the embedded plate 31A and further transmitted to the module skid 11 and anchor bolts 32A, which are buried in the concrete. Since the load is transmitted to the module skid 11 and anchor bolts 32A in this way, the pipe 34, to which a large load is applied during a plant operation, can be supported. Materials installed to reinforce the wall steel plate 12 can be substantially lessened.

In a pipe or the like, to which small load is applied during the plant operation, a support structure member for this pipe may be attached directly to the front surface of the module skid 11 without using the embedded plate.

In the present embodiment, the positions of the wall steel plates 12 can be easily adjusted during the manufacturing of the composite integrated module 1 because adjacent two wall steel plates 12 are attached to the front surface of the module skid 11 so that the clearance G is formed between them. The clearance G is also formed when the floor steel plate 19 is attached to the frame beams 17 and 18, facilitating positional adjustment of the floor steel plate 19. Time taken to weld the wall steel plate 12 to the module skid 11 and to weld the floor steel plate 19 to the frame beams 17 and 18 can be substantially shortened, contributing reduction in time taken to manufacture the composite integrated module 1.

In the present embodiment, the module skid 11 can be disposed outside the wall steel plates 12 and buried in the concrete of the nuclear reactor building, so the room 26, which is internally formed, can be enlarged.

Each pillar steel frame 2 is attached to the floor member 16, specifically to the frame beam 17 and the like by using the first floor steel frame 5. Therefore, the lower end portion of the pillar steel frame 2 can be fixed directly to the floor member 16, enabling the composite integrated module 1 to be easily transported. In the present embodiment, the first floor steel frame 5 and second floor steel frame 6 are removed from the composite integrated module 1 when the composite integrated module 1 is placed at a predetermined position in an area in which a nuclear reactor building is constructed before concrete is poured outside the sidewall members 10. However, it is also possible to bury the first floor steel frame 5 and second floor steel frame 6 together with the floor member 16 in the concrete rather than removing the first floor steel frame 5 and second floor steel frame 6. When the first floor steel frame 5 and second floor steel frame 6 are not removed, a point in time at which to start the pouring of concrete can be moved ahead, shortening a building period of the nuclear power plant.

The first plant structure member may be attached to the ceiling member (see FIG. 8), as described below. This ceiling member 21A has a plurality of frame member 46, ceiling steel plate formworks 45 and an embedded plate 31C. The ceiling steel plate formworks 45 are used instead of the deck plate. A plurality of frame members 46 extending in a direction orthogonal to the frame beam 22 is disposed on the frame beam 22. A plurality of ceiling steel plate formworks 45 disposed between the frame member 46 and frame beam 22 are welded to the frame member 46 in the same way as when the sidewall member 10 is attached to the wall steel plate 12. The embedded plate 31C, to which the anchor bolts 32C extending upward are attached, is welded directly to an undersurface of the frame member 46. The support member 48 is disposed on the underside of the embedded plate 31C, and at least one of the pipe, duct, and tray is attached to the support member 48. FIG. 8 shows a state that pipes (first plant structure members) 49 are attached to the support member 48. The adjacent two ceiling steel plate formworks 45 are fixed to the undersurface of the frame member 46 so that a clearance G is formed between the two ceiling steel plate formworks 45 as with wall steel plate 12 shown in FIG. 7. This type of support structure member can support the first plant structure member, which is supported by the ceiling member 21A, to which a large load is applied during a plant operation. The concrete is poured atop the ceiling steel plate formworks 45. The embedded plate 31C can be attached to at least one of the frame members disposed on the sidewall member 10, the floor member 16 and ceiling member 21 based on the arrangement of the first plant structure member in the composite integrated module. In the composite integrated module shown in FIG. 8, it is possible to change the ceiling steel plate formworks 45 to the deck plate 23. When the deck plate 23 is used, the embedded plate 31C is welded directly to an undersurface of the frame member 46.

Second Embodiment

A composite integrated module of a second embodiment, which is another embodiment of the present invention and is used in a plant, will be described with reference to FIG. 9. The composite integrated module 1A of the present embodiment has a structure in which embedded plate 31D and 31E are included in the composite integrated module 1 of the first embodiment.

The embedded plate 31D and 31E are directly fixed on top surfaces of the frame beams 17 of the floor member 16. A support member 50 is mounted on the embedded plate 31D and 31E. Pipes 51 being a first plant structure member are attached to the support member 50. The pipes 51 are disposed toward the front of the equipment 27. The composite integrated module 1A is the same as the composite integrated module 1 exclusive of the embedded plate 31D and 31E, the support member 5b and the pipes 51.

The present embodiment can obtain each effect obtained by the first embodiment.

When the ceiling member 21 having the deck plate 23, it is possible to fix directly the embedded plate 31A, 31B, 31C, 31D or 31E to the frame beam provided in the sidewall member 10 or the floor member 16 based on the arrangement of the first plant structure member. The anchor member 13 can install on at least one of the sidewall member 10, the floor member 16 and the ceiling member 21 based on the arrangement of the second plant structure member.

When the second plant structure member is not disposed in the room 26 and the first plant structure member is disposed in the room 26, the anchor members 13 and 20 are not mounted on the sidewall member 10, the floor member 16 and the ceiling member 21 of the composite integrated module 1A (see, for example, FIGS. 10 and 11). However, the embedded plate is directly fixed on at least one of the module skids 11 of the sidewall member 10 and the frame members of the floor member 16 and the ceiling member 21 based on the position disposing the first plant structure member in the room 26.

Third Embodiment

Each composite integrated module of the first and second embodiments is a room composite integrated module of a target room in the reactor building. However, in the reactor building, a composite integrated module of any one of a sidewall member 10, a floor member 16 and a ceiling member 21 is used in some cases.

A composite integrated module of a third embodiment, which is further another embodiment of the present invention and is used in a plant, will be described with reference to FIG. 10. The composite integrated module 1B of the present embodiment is a composite integrated module of single sidewall member 10 in the composite integrated module 1 of the first embodiment. The composite integrated module 1B can use by disposing at a sidewall in a room not installing the second plant structure member. Therefore, the composite integrated module 1B does not have the anchor members 13 attached to the sidewall member 10 of the composite integrated module 1.

The construction, in which the composite integrated module 1B is used, of a room 26A in the reactor building will be described below. The composite integrated module 1B is disposed at one sidewall of the applicable room 26A by using a crane. The concrete is already poured to a position of a floor of the room 26A. The composite integrated module 1B is disposed on the floor of the concrete. A wooden formwork is arranged oppositely to a steel wall plate 12 of the composite integrated module 1B outside the steel wall plate 12. An interval between the steel wall plate 12 and the wooden formwork is set at a predetermined thickness of a wall of the room 26A. Each of a pair of the wooden formworks is disposed at the remaining three sidewalls 53 of the room 26A. Reinforcing iron bars are disposed between the wooden formworks and between the steel wall plate 12 and the wooden formwork. The wooden formwork is also disposed at the ceiling 54 with reinforcing iron bars. The concrete is poured between the steel wall plate 12 and the wooden formwork disposed at one sidewall 53, and between a pair of the wooden formworks disposed at the remaining three sidewalls 53, and onto the wooden formwork of the ceiling 54 respectively.

After the poured concrete hardened, all the wooden formworks are removed exclusive of the steel wall plate 12. In this way, the room 26A surrounded by the floor 52, four sidewalls 53 and the ceiling 54 is formed. The pipe (or duct) 34 is mounted on the support member 33, which is attached to the embedded plate 31A, of the composite integrated module 1B. It is possible to attach the pipe (or duct) 34 as a component of the composite integrated module 1B to the support member 33 in advance. The steel plate formwork may use instead of the wooden formwork. Especially, in the ceiling, it is preferable to use the deck plate as the formwork.

According to the composite integrated module 1B of the present embodiment, the effect obtained by the first embodiment can be obtained. That is, the large load applied to the first plant structure members as the pipe (or duct) 34 and tray and the like during a plant operation can be supported.

It is possible to dispose the composite integrated module 1B on a surface, which faces the room 26A, of at least one of four sidewalls 53 surrounding the room 26A. A number of the composite integrated module 1B is decided based on the arrangement of the first plant structure member in the room 26A.

When the pipe (or duct) 34 is attached to the support member 33 of the composite integrated module 1B in advance, it is possible to support directly the first plant structure member as the pipe (or duct) 34 and the like to the module skids 11 during transporting the composite integrated module 1B without transmitting directly the load to the steel wall plate 12 being the formwork. Accordingly, the composite integrated module 1B can be easily transported.

When the second plant structure member is disposed in the room 26A, it is preferable to attach the anchor member 13 to a backside of the wall steel plate 12 of the composite integrated module 1B as with the first embodiment.

Fourth Embodiment

A composite integrated module of a fourth embodiment, which is further another embodiment of the present invention and is used in a plant, will be described with reference to FIG. 11. The composite integrated module 1C of the present embodiment is a composite integrated module of the only floor member 16 in the composite integrated module 1A of the second embodiment. The composite integrated module 1C is disposed at a floor of a room 26B not disposing the second plant structure member. Therefore, the composite integrated module 1C does not have the anchor member 20 attached to the floor member 16 of the composite integrated module 1A.

The construction, in which the composite integrated module 1C is used, of a room 26B in the reactor building will be described below. The composite integrated module 1C is disposed on a floor portion of the applicable room 26B by using a crane. The concrete is poured below floor steel plates 19 of the composite integrated module 1C. The anchor bolts 32D and 32E attached to the embedded plates 31D and 31E are buried in the concrete. A After the concrete of the floor portion is poured, each of a pair of the wooden formworks facing each other is disposed on each portion of four sidewall 53 surrounding the room 26B and the reinforcing iron bars are arranged between these wooden formworks. The concrete is poured between the wooden formworks facing each other. After the concrete was poured, the wooden formwork is disposed on a position of the ceiling 54 and the reinforcing iron bars are arranged on this wooden formwork. The concrete is poured onto this wooden formwork.

In this way, the room 26b surrounded by the floor 52, four sidewalls 53 and the ceiling 54 is formed. The pipe (or duct) 51 is mounted on the support member 50, which is attached to the embedded plates 31d and 31E, of the composite integrated module 1C. It is possible to attach the pipe (or duct) 51 as a component of the composite integrated module 1C to the support member 50 in advance. The steel plate formwork may use instead of the wooden formwork. Especially, in the ceiling, it is preferable to use the deck plate as the formwork.

According to the composite integrated module 1C of the present embodiment, the effect obtained by the second embodiment can be obtained. That is, the large load applied to the first plant structure members as the pipe (or duct) 51 and tray and the like during a plant operation can be supported.

It is possible to dispose the composite integrated module 1B of the third embodiment on a surface, which faces the room 26B, of at least one of four sidewalls 53 surrounding the room 26B. A number of the composite integrated module 1B is decided based on the arrangement of the first plant structure member in the room 26B.

When the second plant structure member is disposed in the room 26B, it is preferable to attach the anchor member 13 to a backside of the floor steel plate 19 of the composite integrated module 1C as with the first embodiment.

It is possible to make a composite integrated module of the only ceiling member 21A shown in FIG. 8. This composite integrated module of the ceiling member 21A is disposed on a position of the ceiling 54 of the room 26A or 26B disclosed in the third and fourth embodiments and it is possible to pour the concrete onto the composite integrated module of the ceiling member 21A. This composite integrated module can use by combining with at least one of the composite integrated module 1B and 1C. It is possible to use singly the composite integrated module of the only ceiling member 21A. When the second plant structure member is disposed in a room facing toward the composite integrated module of the ceiling member 21A and the second plant structure member has to attach to this composite integrated module, it is preferable to attach the anchor member 13 to a backside of the ceiling steel plate formwork 45 of this composite integrated module as with the sidewall member 10 of the first embodiment.

The composite integrated module 1 in the present embodiment described above has been applied to a reactor building. However, it will be appreciated that the composite integrated module 1 can also be used in a turbine building or radioactive waste building in a nuclear power plant as well as in a building in a thermal power plant.

Claims

1. A composite integrated module, comprising: a formwork; a plurality of frame members mounted on one surface of the formwork; andat least one embedded plate, to which a support member for supporting a first plant structure member is attached, mounted directly to at least one the frame member,wherein one surface, which does not mounted on the frame member, of the embedded plate faces to a direction in which another surface, which does not mounted on the frame member, of the formwork faces.

2. A composite integrated module according to claim 1, wherein the embedded plate is directly mounted on a surface, on which the formwork is attached, of the frame member.

3. A composite integrated module according to claim 1, wherein at least one anchor member not projected from a second surface, which faces to a diametrically opposed location to a first surface mounted on the frame member, of the formwork, is mounted on the first surface of the formwork; and the anchor member is connected to a removable tightening apparatus by which a second plant structure member is mounted on the second surface of the formwork.

4. A composite integrated module according to claim 1, wherein the composite integrated module is a composite integrated module of any one of a floor member, a sidewall member and a ceiling member.

5. A composite integrated module, comprising: a floor member;a plurality of sidewall members attached to the floor member; anda ceiling member attached to the plurality of sidewall members,wherein an internal space being formed by being enclosed by the floor member, the plurality of sidewall members, and the ceiling member;each of the plurality of sidewall members has a first formwork facing the internal space, the floor member has a second formwork facing the internal space, and the ceiling member has a third formwork facing the internal space;each of the sidewall members has a first frame member to which the first formwork is attached, disposed outside the first formwork;the floor member has a second frame member arranged outside the second formwork and attached to the second formwork,the ceiling member has a third frame member arranged outside the third formwork and attached to the third formwork; andat least one an embedded plate to which a support member for supporting a first plant structure member placed in the internal space is attached is directly mounted to at least one of the first, second and third frame members.

6. A composite integrated module according to claim 5, wherein at least one anchor member is disposed outside at least one of the first, second, and third formworks and mounted on at least one of the first, second, and third formworks; and the anchor member is connected to a removable tightening apparatus by which a second plant structural member disposed in the internal space.

7. A composite integrated module according to claim 5, wherein the first formwork is attached to the second formwork.

8. A composite integrated module according to claim 5, wherein the first formwork comprises a plurality of metal plates; and the adjacent metal plates are attached to one surface of the first frame member so that a clearance is formed between the adjacent metal plates.

9. The composite integrated module according to claim 5, wherein the second formwork comprises a plurality of metal plates; and the adjacent metal plates are attached to one surface of the second frame member so that a clearance is formed between the adjacent metal plates.

10. The composite integrated module according to claim 5, wherein the third formwork comprises a plurality of metal plates; and the adjacent metal plates are attached to one surface of the third frame member so that a clearance is formed between the adjacent metal plates.

11. The composite integrated module according to claim 1, wherein the second plant structure member is one of a tubular member in which a fluid flow and a tray.

12. The composite integrated module according to claim 5, further comprising a plurality of reinforcing members being buried in concrete that is poured.

13. The composite integrated module according to claim 12, wherein the plurality of reinforcing members includes a first reinforcing member extending in the vertical direction, and a second reinforcing member to which the first frame member and the third frame member are attached, extending in a horizontal direction.