Dome manufacturing method and dome manufactured using this method

Abstract

A method of manufacturing a dome (2) is described. The method includes the steps of providing a plurality of beams (6, 106, 206, 306), each beam of the plurality of beams (6, 106, 206, 306) having one or more slots (16, 22), and forming at least a portion of the dome (2) by engaging at least one of the slots (16, 22) of each beam of the plurality of beams (6, 106, 206, 306) with one of the one or more slots (16, 22) of another beam of the plurality of beams (6, 106, 206, 306). Also described is a dome (2) manufactured by this method.

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a dome and a dome manufactured using this method. [Background technology]

[0002] Power plants typically include a nuclear reactor housed within a dome-shaped containment vessel, which is designed to contain toxic materials released by the reactor in the event of a reactor malfunction. The dome-shaped vessel is typically forged or fabricated off-site from forged petals and then placed into position by a crane. Such a process is generally time-consuming and expensive, requires a significant amount of space on-site, and requires favorable weather conditions for assembly. Summary of the Invention [Problem to be solved by the invention]

[0003] It would therefore be desirable to provide an improved method for manufacturing domes and domes manufactured utilizing this method. [Means for solving the problem]

[0004] According to a first aspect, there is provided a method of manufacturing a dome, the method comprising the steps of providing a plurality of beams, each beam of the plurality of beams comprising one or more slots, and forming at least a portion of a dome by engaging at least one of the slots of each beam of the plurality of beams with one of the one or more slots of another beam of the plurality of beams.

[0005] At least a portion of each beam of the plurality of beams may be a T-beam which may include a web and a flange.

[0006] The one or more slots may be formed by the web.

[0007] One or more slots may be angled in a non-perpendicular direction from the edge of the web.

[0008] The flange may be curved about its longitudinal axis toward the web.

[0009] The flange may be curved along its longitudinal axis toward the web.

[0010] The edge of the web opposite the flange may be curved along the longitudinal axis of the edge toward or away from the flange.

[0011] Curvature of the web edges can be achieved by weld buildup, compression molding, or rolling.

[0012] Each beam may be fabricated by welding a web to a flange. Cooling of the weld may induce curvature of the web and / or flange.

[0013] At least one of the webs may include a plurality of web sections, each of which may be separated from an adjacent web section by a gap.

[0014] At least one of the flanges may include a plurality of flange sections spaced apart by gaps. Each beam of the plurality of beams may include an additional flange disposed on the web opposite the flange. The additional flange may include a plurality of additional flange sections spaced apart by gaps.

[0015] One or more slots may be formed on either side of the web.

[0016] One or more of the webs and / or flanges may include one or more through holes.

[0017] One or more plates may be welded to the webs of the beams to form the outer skin of the dome.

[0018] One or more plates may be welded to the webs of the beams to form the interior skin of the dome.

[0019] One or more voids may be formed between the outer and inner skins, and one or more of these voids may be filled with a solid mass.

[0020] The lower portion of the dome may consist of a hollow cylindrical structure formed by a number of blocks or plates.

[0021] At least some of the plurality of beams may be arranged in a triangular lattice to form at least a portion of a geodesic dome.

[0022] At least some of the plurality of beams may be arranged in a rectangular grid.

[0023] At least some of the plurality of beams may be arranged in a hexagonal lattice.

[0024] According to a second aspect, there is provided a dome manufactured according to any of the foregoing methods.

[0025] Some configurations will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0026] [Figure 1] FIG. [Figure 2] FIG. 2 is a perspective view of a first beam and a second beam. [Figure 3] 1 is a flow chart of a method for manufacturing a dome. [Figure 4] FIG. 2 is an enlarged perspective view of a portion of the first beam and the second beam. [Figure 5]FIG. 10 is an enlarged perspective view of a portion of a first beam and a second beam connected together. [Figure 6] FIG. 1 is a plan view of a hexagonal lattice structure. [Figure 7] FIG. 10 is a first cross-sectional view of an alternative first beam. [Figure 8] FIG. 10 is a second cross-sectional view of an alternative first beam. [Figure 9] FIG. 10 is a side view of an alternative first beam. [Figure 10] FIG. 10 is a cross-sectional view of an alternative first beam after a first process. [Figure 11] FIG. 10 is a cross-sectional view of an alternative first beam after an alternative process. [Figure 12] FIG. 10 is a side view of an alternative second beam. [Figure 13] FIG. 10 is a perspective view of an alternative third beam. [Figure 14] FIG. 1 is a plan view of a triangular lattice structure. [Figure 15] FIG. 10 is a perspective view of a dome formed by a plurality of alternative fourth beams. [Figure 16] FIG. 1 is a cross-sectional view of a tube of a dome. [Figure 17] FIG. 2 is a cross-sectional view of the dome tube and dome. [Figure 18] FIG. 10 is a cross-sectional view of the tube and dome after forming the outer and inner skins of the dome. [Figure 19] FIG. 1 is a plan view of a rectangular grid structure as configured within a dome. [Figure 20] FIG. 1 is a plan view of a rectangular grid structure as configured for storage or transportation. DETAILED DESCRIPTION OF THE INVENTION

[0027] Figure 1 shows a dome 2 of a nuclear power plant reactor. The lower portion of the dome 2 is formed by a number of blocks or plates arranged into the shape of a hollow cylindrical structure 4, which may taper inwardly towards the top. The upper portion of the dome 2 is formed by a number of beams 6, which are joined together to form a hemispherical frame.

[0028] FIG. 2 shows a first beam 8 and a second beam 10 of the plurality of beams 6. The first beam 8 is a T-shaped beam and includes a web 12 and a flange 14. A series of slots 16 are formed in the web 12 and extend perpendicularly from the outer edge of the web 12. The second beam 10 is also a T-shaped beam and includes a web 18 and a flange 20. A series of slots 22 are formed in the web 18 and extend perpendicularly from the outer edge of the web 18. The slots 16 of the first beam 8 and the slots of the second beam 10 have the same length and extend approximately half the distance from the edges of the webs 12, 18 to the flanges 14, 20. In an alternative configuration, the slots 16, 22 may be angled non-perpendicularly from the outer edges of the webs 12, 18.

[0029] 3 is a flow chart of a method for manufacturing the dome 2. In step A1 of the method, a plurality of beams 6 are provided. In step A2 of the method, at least one of the slots 16, 22 of each beam of the plurality of beams 6 is engaged with one of the slots 16, 22 of one or more slots 16, 22 of another beam of the plurality of beams 6 to form an upper portion of the dome 2.

[0030] FIG. 4 shows a portion of one of the first beams 8 and a portion of one of the second beams 10 after performing step A1 and before performing step A2. For clarity, only a portion of the first beam 8 and the second beam 10 is shown. The first beam 8 and the second beam 10 are positioned orthogonally relative to one another so that their slots 16, 22 are aligned. In step A2, the second beam 10 is moved relative to the first beam 8 in the direction indicated by arrow 24. Alternatively, the first beam 8 may be moved in the opposite direction toward the second beam 10. The beams 6 (e.g., the first beam 8 and the second beam 10) may be positioned using a winch and a crane.

[0031] FIG. 5 shows a portion of a first beam 8 and portions of two second beams 10 after performing steps A1 and A2. A larger portion of the first beam 8 is shown in FIG. 5 than that shown in FIG. 4. In the configuration shown in FIG. 5, the first slot 16 of the first beam 8 engages with the slot 22 of the second beam 10 on the left, and the second slot 16 of the first beam 8 engages with the slot 22 of the second beam 10 on the right. Although not shown, the beams 6 can be pinned together at their respective joints. Alternatively, the beams 6 can be bolted or welded together. Alternatively, the beams 6 can be precision cut to have a tight fit so that an additional joining process is not necessary.

[0032] Web 12 includes a plurality of through-holes 26. These through-holes 26 may serve as passageways to pass utilities such as wires, electrical cables, optical cables, sensors, or pipes, or to allow inspections to be performed. Additionally or alternatively, through-holes 26 may be used as connection or anchoring points to aid in the assembly process.

[0033] The connections between the beams 6 may be achieved by engaging slots 16, 22, thereby producing an upper portion of a dome 2, such as that shown in Figure 1. Figure 6 shows a top view of such a structure. The beams 6 are arranged to form a hexagonal lattice structure 100.

[0034] 7 shows a first cross-sectional view of an alternative first beam 106 in the process of manufacture. This alternative first beam 106 generally corresponds to the previously described beams 6 (i.e., first beam 8 and second beam 10), and features of the alternative first beam 106 are designated using the same reference numerals increased by 100. However, prior to attaching the web 112 to the flange 114, a stub 128 is added to the flange 114 by weld metal buildup. This stub 128 extends along the longitudinal length of the flange 114.

[0035] 8 illustrates, in cross section, a further process in the manufacturing method of the alternative first beam 106. The alternative first beam 106 is shown prior to cooling. As shown, additional welding material 130 is used to bond the flange 114 and stub 128 to the web 112. The provision of the stub 128 improves access for the finish welding process between the web 112 and flange 114. This also creates welding distortion that can be used to create the desired curvature in the web 112 and flange 114.

[0036] FIG. 9 shows an alternative first beam 106 resulting from such a distortion process. A beam not subjected to welding distortion is shown in phantom for comparison. As the stub 128 cools during and after welding, it contracts due to thermal expansion effects. This causes the flange 114 to curve along its longitudinal axis (i.e., resulting in a generally U-shaped configuration in the view shown in FIG. 9). Furthermore, cooling of the additional weld material 130 and its contraction can cause the flange 114 to curve about its longitudinal axis (i.e., resulting in a generally U-shaped configuration in the view shown in FIG. 8).

[0037] FIG. 10 shows a further stage in the manufacture of the dome 2 in cross section. This further stage involves welding multiple plates 32 to the outward web 112. These plates 32 form the exterior skin of the cylindrical structure 4 and close the gaps formed between the beams 106, thereby forming a sealed structure. A flange 114 forms a rigid web that supports the exterior skin. No plates are welded to the inward web or to the flange 114, so the flange 114 and exterior skin form open cells that open to the interior of the cylindrical structure 4. The web 112 and flange 114 can be used to support one or more inspection devices, such as an automated mobile inspection unit that inspects the interior of the dome 2. The connections (i.e., nodes) between the flanges 114 can serve as anchors for local automation of manufacturing, inspection, heat treatment, and assembly, and can also serve as specific frames of reference.

[0038] 11 illustrates an alternative further stage in the manufacture of dome 2. This alternative further stage involves profiling the edges of web 212 so that web 212 is curved along the longitudinal axis of web 212. This profile may be achieved by forming a layer of weld material 34 of varying height along the length of web 212. Alternatively, this profile may be achieved by compression molding or rolling.

[0039] 12 illustrates an alternative second beam 206. This alternative second beam 206 generally corresponds to the previously described beam 6 (i.e., first beam 8 and second beam 10), and features of the alternative second beam 206 are designated using the same reference numerals, increased by 200. However, the web 212 is formed by multiple web sections 36, 38, each spaced apart by a gap 40. The gap 40 allows the web 212 and flange 214 to be more easily bent into their desired shape. Also, notches 42 or keyholes in the web sections 36, 38 allow the web 212 and flange 214 to be more easily bent into their desired shape and simplify welding of the web sections 36, 38 to the flange 214.

[0040] 13 illustrates an alternative third beam 306. This alternative third beam 306 generally corresponds to the previously described beam 6 (i.e., first beam 8 and second beam 10), and features of the alternative third beam 306 are designated using the same reference numerals, increased by 300. However, slots 16 are formed alternately on opposite sides of web 312. An additional flange 250 is provided on the web 312 opposite flange 214. Flange 214 is formed by a plurality of flange sections 44, 46, 48, and additional flange 250 is formed by a plurality of additional flange sections 52, 54, 56. These flange sections 44, 46, 48, 52, 54, 56 are spaced apart by gaps. Slot 16 is positioned within the gaps.

[0041] FIG. 14 illustrates a triangular lattice structure 102 formed by alternative third beams 306. This triangular lattice structure 102 may be used in place of the hexagonal lattice structure 100 described with reference to FIG. 6. In FIG. 14, for clarity, only the webs 312 of the alternative third beams 306 are illustrated. As illustrated, each of the alternative third beams 306 alternately passes above and below another alternative third beam 306, allowing alternating slots 16 located on either side of the webs 312 to engage with slots 16 of another alternative third beam 306.

[0042] 15 illustrates a plurality of alternative fourth beams 406 that are interlocked as previously described to form the dome 58. The alternative fourth beams 406 generally correspond to the previously described beams 6 (i.e., first beam 8 and second beam 10), and features of the alternative fourth beams 406 are indicated using the same reference numerals, increased by 400. For clarity, the flanges of the alternative fourth beams 406 are not shown. As illustrated, the web 312 of the alternative fourth beams 406 is crescent-shaped.

[0043] 16 is a cross-sectional view showing the cylindrical structure 4 alone. As shown, the cylindrical structure 4 extends about a vertical axis 58. The cylindrical structure 4 can be manufactured in a step prior to step A1.

[0044] 17 is a cross-sectional view of the dome 58 after it has been fabricated on top of the cylindrical structure 4 in steps A1 and A2. As shown, the center of the dome 58 is aligned with the vertical axis 58.

[0045] FIG. 18 is a cross-sectional view of the cylindrical structure 4 and the dome 58 after forming the exterior skin 32 and the interior skin 60 on the dome 58. The method of forming the exterior skin 32 on the dome 58 may correspond to the method described above. The method of forming the interior skin 60 on the dome 58 may substantially correspond to the method of forming the exterior skin 32 on the dome 58, except that instead of welding the plates 32 to the outward web 112, the plates 32 are welded to the inward web 112. The exterior skin 32, the interior skin 60, and the flange 114 form closed cells. One or more of the closed cells may be partially or completely filled with a solid mass, such as concrete, to strengthen the dome 58. Additionally or alternatively, one or more of the closed cells may be partially or completely filled with an insulating material to insulate the dome 58. The concrete or insulating material may be supplied to the closed cells through the through holes 26 or injected into the closed cells. These through holes 26 allow gas displaced by the concrete or insulating material to escape.

[0046] 19 shows a plan view of a rectangular grid structure 202 formed by beam 6. Alternatively, this rectangular grid structure 202 may be formed by an alternative first beam 106, an alternative second beam 206, or an alternative third beam 306. The rectangular grid structure 202 may form a dome 2.

[0047] Figure 20 shows the rectangular lattice structure 202 of Figure 19 prior to forming the dome 2. The beams 6 can be collapsed into the rectangular lattice structure 202 shown in Figure 20 for ease of storage and transportation, and then expanded on-site into the rectangular lattice structure 202 shown in Figure 19.

[0048] The components described herein may be designed and manufactured using CAD and CAM. The components may be made from steel. The components may be manufactured using a water jet cutting process.

[0049] Although the dome beams have been described as being arranged in either a hexagonal, triangular, or rectangular grid, they may be arranged in any regular grid configuration. The dome beams may be arranged in a number of different types of grid configurations. By way of example, a first subset of the dome beams may be arranged in a hexagonal grid, a second subset of the dome beams may be arranged in a triangular grid, and a third subset of the dome beams may be arranged in a rectangular grid.

[0050] Although dome 2 has been described as a dome for a power plant reactor, it may be any suitable dome, such as a dome for storing compressed gases, a heat reservoir, a bridge, a ship, or a building assembly. The dome may be used for storing gases such as hydrogen. Gas storage may occur under normal operating conditions. Alternatively, the dome may be for storing (i.e., containing) gases that leak from a structure housed within the dome. [Explanation of symbols]

[0051] 2 Dome 4. Hollow cylindrical structure 6 beams 8 First Beam 10 Second Beam 12. Web 14 flange 16 slots 18 Web 20 flange 22 slots 24 Arrow, flange 26 through holes 32 plates, outer skin 34 Welding material layer 36 Web Sections 38 Web Sections 40 gap 42 Notch 44 flange section 46 flange section 48 flange section 52 flange section 54 flange section 56 flange section 58 Dome, vertical axis 60 Internal Skin 100 hexagonal lattice construct 102 Triangular lattice construct 106 First Beam 112 Web, Inner Web, Outer Web 114 flange 128 Stub 130 Additional welding materials 202 Rectangular grid structure 206 Second Beam 212 Web 214 flange 250 flange 306 Third Beam 312 Web 406 Fourth Beam

Claims

1. A method for manufacturing a dome (2), comprising the steps of: providing a plurality of beams (6, 106, 206, 306), at least a portion of each beam of the plurality of beams (6, 106, 206, 306) being a T-beam, the T-beam comprising a web (12, 18, 112, 212, 312, 412) and a flange (14, 20, 114, 214, 314), each beam of the plurality of beams (6, 106, 206, 306) comprising one or more slots (16, 22) formed in the web (12, 18, 112, 212, 312, 412); forming at least a portion of the dome (2) by engaging at least one of the slots (16, 22) of each beam of the plurality of beams (6, 106, 206, 306) with one slot (16, 22) of the one or more slots (16, 22) of another beam of the plurality of beams (6, 106, 206, 306); Including, at least one of the flanges (314) comprises a plurality of flange sections (44, 46, 48) each spaced apart by a gap, and each beam of the plurality of beams (306) comprises a further flange (350) disposed on the web (312) opposite the flange (314), the further flange (350) comprising a plurality of further flange sections (52, 54, 56) each spaced apart by a gap; The method wherein the one or more slots (16) are formed on both sides of the web (312).

2. 2. The method according to claim 1, wherein the lower part of the dome (2) consists of a hollow cylindrical structure formed by a plurality of blocks or plates.

3. 3. The method of claim 1 or 2, wherein at least some of the plurality of beams (6, 106, 206, 306) are arranged in a triangular lattice to form at least a portion of a geodesic dome.

4. 4. The method of claim 1, wherein at least some of the plurality of beams (6, 106, 206, 306) are arranged in a rectangular grid.

5. 5. The method of claim 1, wherein at least some of the plurality of beams (6, 106, 206, 306) are arranged in a hexagonal lattice.

6. A dome (2) manufactured by the method according to any one of claims 1 to 5, A plurality of beams (6, 106, 206, 306), at least a portion of each beam of said plurality of beams (6, 106, 206, 306) being a T-beam, said T-beam comprising a web (12, 18, 112, 212, 312, 412) and a flange (14, 20, 114, 214, 314), each beam comprising one or more slots (16, 22) formed in said web (12, 18, 112, 212, 312, 412). Equipped with a dome (2) in which at least one of the slots (16, 22) of each beam of the plurality of beams (6, 106, 206, 306) is engaged with one slot (16, 22) of the one or more slots (16, 22) of another beam of the plurality of beams (6, 106, 206, 306) to form at least a portion of the dome (2).

7. 7. The dome of claim 6, wherein at least one of the flanges comprises a plurality of flange sections each spaced apart by a gap, and each beam of the plurality of beams comprises a further flange disposed on the web opposite the flange, the further flange comprising a plurality of further flange sections each spaced apart by a gap.

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