Composite integrated module

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.

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.

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.