Method of constructing foundation, method of installing module, foundation for plant module, and protective member

Abstract

[Problem] Provided is a method by which it is possible to construct a foundation of a plant module even on narrow sites and transport routes. [Solution] Provided is a method of constructing a foundation of a plant module of a frame structure having a plurality of columns. A plurality of foundations respectively supporting the plurality of columns are provided spaced apart from one another on a site where the plant module is to be installed; a cart onto which the plant module has been loaded travels through the site along a preset travel path; and some of the plurality of foundations are to be arranged at locations that will interfere with the cart. For such a case, the method comprises: a step for constructing a foundation of a non-interference area in which the foundation that will not interfere with the cart traveling through the site is to be provided; next, a step for causing the cart to enter the site along the travel path and placing same on standby at a preset standby location including the site; and thereafter, a step for constructing a foundation of an interference area in which the foundation that will interfere with the cart is to be provided.

Description

Foundation construction method, module installation method, plant module foundation and protective materials

[0001] The present invention relates to a technology for constructing a plant.

[0002] Plants that process fluids include natural gas plants that liquefy natural gas and separate and recover natural gas liquids, oil refineries that distill and desulfurize crude oil and various intermediate products, and chemical plants that produce petrochemical products, intermediate chemicals, polymers, etc.

[0003] These plants are structured with numerous pieces of equipment, including static equipment such as towers and vessels and heat exchangers, and dynamic equipment such as pumps. These pieces of equipment are connected by numerous pipes that transfer fluids between them. When constructing such plants, modularization is often employed, in which the numerous pieces of equipment that make up the plant are divided into blocks, and the equipment in each block is incorporated into a common framework. By dividing a plant into multiple modules and modularizing it, it becomes possible to build each module in parallel in a factory separate from the construction site, thereby reducing the labor required for on-site plant construction. Furthermore, building each module in parallel can also shorten the construction period of the plant. Each module constructed in the factory is transported to the construction site, installed on the designated site, and then the pipes and other components are connected to each other.

[0004] For example, Patent Document 1 discloses that an LNG (Liquefied Natural Gas) plant that performs a process to produce LNG is equipped with a pipe rack for supporting a large number of pipes. The document also describes that the pipe rack is constructed and transported in a divided state into, for example, four modules, and is installed on a plurality of foundations that have been constructed in advance.

[0005] When transporting the divided modules into multiple pieces toward the area where the foundations are being installed, it is necessary to provide a path for moving the modules while avoiding interference with other modules that have already been installed. Meanwhile, from the perspective of reducing construction costs, it may be necessary to further reduce the size of the plant construction site. In this regard, if a modular construction method is adopted, securing a path for moving the modules may become a constraint in establishing a more compact construction site. In this regard, Patent Document 1 does not mention at all the problems associated with securing a path for transporting the modules.

[0006] International Publication No. 2021 / 029051

[0007] The present invention has been made under such circumstances, and provides a technique that enables construction of a foundation for a plant module even on a small site or on a small transport route.

[0008] The present invention is a method for constructing a foundation for a plant module having a frame structure with multiple pillars, wherein a plurality of foundations supporting each of the multiple pillars are provided at a distance from one another on a site on which the plant module is to be installed, and when some of the plurality of foundations are positioned in a position that will interfere with a cart carrying the plant module when the cart moves along a predetermined moving path on the site, the method comprises the steps of: constructing the foundations in a non-interference area where the foundations will be provided so as not to interfere with the cart moving on the site; then, entering the cart along the moving path and having it wait at a predetermined waiting position that includes the site; and then constructing the foundations in an interference area where the foundations will be provided so as to interfere with the cart.

[0009] The method for constructing a foundation for a plant module may have the following features: (a) the non-interference area is located further forward on the movement path than the interference area when viewed along the traveling direction of the carriage when entering the site, and when the carriage is caused to enter the site, the carriage passes through at least a portion of the interference area and waits at the waiting position; (b) in (a), the carriage passes through the entire interference area and waits at the waiting position set in an area that does not include the interference area; (c) in (a), the carriage passes through a portion of the interference area and waits at the waiting position set in an area that includes the interference area other than the portion, and the step of constructing a foundation to be provided in the interference area includes the steps of constructing a foundation in the portion of the interference area, and then moving the carriage toward the portion of the interference area and constructing the foundation in the interference area at the waiting position.

[0010] (d) comprising a step of constructing an underground foundation, which is the underground portion of the foundation in the interference area, before the cart enters the site, wherein in the step of constructing the foundation, an upper foundation, which is the upper portion of the foundation, is attached on top of the underground foundation. (e) In (d), the upper foundation is carried in together with the module by the cart. At this time, the cart passes through part of the interference area and waits at the waiting position set so that the upper foundation carried in by the cart is positioned above the underground foundation, and in the step of constructing the foundation, the upper foundation is lowered from the cart and attached to the underground foundation. (f) In (d), comprising a step of placing a protective member on the underground foundation to protect the underground foundation when the cart passes above the underground foundation after constructing the underground foundation.

[0011] (g) In (f), the protective member is made of wood and includes a frame-shaped body arranged to surround a connecting portion provided on the underground foundation side to connect the underground foundation and the upper foundation, and a beam connecting the inner wall surfaces of the frame-shaped body. In this case, the connecting portion is a plurality of bolts that constitute the underground foundation and are arranged to surround a support member that supports the upper foundation and are arranged to protrude above the support member, and the beam is arranged to pass between adjacent bolts. (h) In (f), the protective member includes a protective cap installed to cover the connecting portion and a concrete lid poured on the protective cap. (i) In (f), the method includes a step of removing the protective member by a lifting mechanism provided on the bogie side as the bogie passes, and transporting it by the bogie before attaching the upper foundation to the underground foundation.

[0012] According to this method, when a plant module having a frame structure is loaded onto a cart and moved along a predetermined movement path, the site on which a plurality of foundations for supporting the plant module are provided is divided into an interference area where the cart interferes with the foundations and a non-interference area where no interference occurs. Then, after the foundations in the non-interference areas are constructed, the cart carrying the plant module is driven into the site and waits at a standby position, after which the foundations in the interference areas are constructed. This improves the degree of freedom in setting the movement path even on a small site.

[0013] 7A and 7B are schematic diagrams illustrating a corner of a plant in which a foundation construction method of a comparative embodiment is used; FIG. 7B is a plan view illustrating a module delivery method in a comparative embodiment; FIG. 7C is a first plan view illustrating a module delivery method of the present embodiment; FIG. 7D is a second plan view illustrating a module delivery method of the present embodiment; FIG. 7E is a third plan view illustrating a module delivery method of the present embodiment; FIG. 7F is a fourth plan view illustrating a module delivery method of the present embodiment; FIG. 7G is a fifth plan view illustrating a module delivery method of the present embodiment; FIG. 7H is a sixth plan view illustrating a module delivery method of the present embodiment; FIG. 7I is a longitudinal side view illustrating the foundation of a non-interference area and an underground foundation before construction of an upper foundation; FIG. 7J is a plan view illustrating the underground foundation in FIG. 9; FIG. 7J is a longitudinal side view illustrating the foundation of a non-interference area and an interference area in FIG. 7; FIG. 7I is a longitudinal side view illustrating the foundation of a non-interference area and an interference area in FIG. 8; FIG. 7I is a first plan view illustrating a module delivery method according to another embodiment; FIG. 7J is a second plan view illustrating a module delivery method according to another embodiment; FIG. 7I is a longitudinal side view illustrating an example of a foundation in an interference area according to another embodiment; FIG. 7I is a first longitudinal side view illustrating a procedure for forming a protective member to protect the underground foundation in the interference area according to another embodiment; FIG. 2 is a second longitudinal side view showing the procedure for forming a protective member. FIG. 3 is a third longitudinal side view showing the procedure for forming a protective member. FIG. 1 is a first to third longitudinal side view showing the construction procedure for an upper foundation according to another embodiment. FIG. 4 is a fourth to sixth longitudinal side view showing the construction procedure for the upper foundation. FIG. 5 is a longitudinal side view showing a foundation in an interference area provided on a sloping site.

[0014] An overview of a plant 100 and a plant module (hereinafter also simply referred to as a "module") 10 for which the foundation construction method of this embodiment is used will be described with reference to Fig. 1. Fig. 1 is a schematic diagram illustrating a corner of the plant 100 for which a foundation construction method of a comparative embodiment, which will be described later, is used. However, the overview of the transport method for the plant 100 and the module 10, that is, matters other than the foundation construction method, which will be described later, are common between this embodiment and the comparative embodiment, and therefore the description will be made with reference to Fig. 1.

[0015] The plant 100 to which this embodiment is applied is not particularly limited as long as it has a function of treating a fluid. Examples include natural gas plants that liquefy natural gas and separate and recover natural gas liquids, oil refineries that distill and desulfurize crude oil and various intermediate petroleum products, chemical plants that produce petrochemical products, intermediate chemicals, polymers, etc., pharmaceutical plants that produce drugs and their intermediate products, and waste treatment plants for low-level radioactive waste.

[0016] The plant 100 may be installed alongside any of the above-mentioned plants that treat various fluids, or may be installed independently, and may be a utility plant such as a boiler plant or power plant that handles fuel fluids, steam, or hot oil used for energy supply or power generation, or a seawater supply plant that supplies refrigerants. The term "fluid" in this example includes not only gases and liquids, but also particulate matter (powders, granules, pellets, etc.) that has fluidity.

[0017] The module 10 constituting such a plant 100 is equipped with a plurality of pieces of equipment for performing various types of fluid processing, as well as portions of a large piece of equipment that is divided into multiple pieces. The module 10 houses these pieces of equipment within a frame structure formed, for example, by a plurality of supports and beams. For the sake of simplicity, individual illustrations and descriptions of these pieces of equipment are omitted for the module 10 shown in the drawings of this application.

[0018] As shown simply in Figure 1, a plurality of beams (hereinafter also referred to as "bottom beams 11"; see also Figure 9) that make up the lower end of the module 10 each have a plurality of pedestals 12 that extend downward. These multiple pedestals 12 are arranged in a grid pattern on the bottom surface of the module 10, for example, at positions where the bottom beams 11 intersect. The pedestals 12 are then respectively placed on a plurality of foundations 2 that have been pre-installed so as to protrude from the site S1, which is the installation area for the module 10, and then connected to each other. Therefore, when viewed from above, the foundations 2 and the pedestals 12 are arranged in the same array.

[0019] In the examples shown in the comparative example and the embodiment, six foundations 2 are provided on the site S1 at intervals along the X direction shown in the figures, and these six foundations 2 are arranged in four rows at intervals along the Y direction shown in the figures. As described above, pedestals 12 are provided on the bottom surface of the module 10 in correspondence with the positions of the foundations 2. Note that the arrangement of the foundations 2 and pedestals 12 in each figure is for the convenience of explaining the comparative example and the embodiment, and may differ from the arrangement in the actual module 10. There are no particular limitations on the number or spacing of the pedestals 12 and foundations 2, as long as they are configured to continue to stably support the module 10 on the site S1 when connected to each other.

[0020] The modules 10 are transported to the site S1 by a plurality of SPMTs (Self-Propelled Modular Transporters) 3, which are carts, via a transport path S2 within the plant 100, and are then installed on the foundation 2. In the example shown in FIG. 1 , other modules and equipment are arranged on both sides of the transport path S2, making it difficult to transport the plant 100 to the site S1 via other routes. The modules 10 are loaded across the loading platforms 31 of the SPMTs 3, which are arranged in multiple rows (three rows in the example shown) with a gap between them, and are transported while still loaded on these multiple SPMTs 3.

[0021] In this case, each pedestal 12 protruding downward from the lower end of the module 10 is positioned in the gap between adjacent rows of SPMTs 3 or on the outer side of the row of SPMTs 3 to avoid interference with the SPMTs 3. The number of rows of SPMTs 3 and the number of SPMTs 3 per row are set appropriately depending on the weight of the module 10 and the bearing capacity of the site S1 and transport route S2.

[0022] To briefly describe the SPMT 3, the SPMT 3 comprises a plate-shaped loading platform 31 that can be raised and lowered, and a plurality of wheels that are disposed below the loading platform 31 and support the loading platform 31 via support shafts. The plurality of pairs of wheels are disposed in the width direction of the loading platform 31 and are arranged along the longitudinal direction of the loading platform. By changing the direction of the rotation shafts of the plurality of wheel pairs by, for example, approximately 90 degrees, the SPMT 3 can move in the longitudinal direction or width direction of the loading platform 31. Furthermore, by appropriately changing the direction of the rotation shafts, the SPMT 3 can also travel diagonally and turn.

[0023] When an operator operates these SPMTs using a controller, each SPMT 3 synchronizes its movements, such as traveling and lifting / lowering the platform, so that each SPMT 3 can transport the module 10 stably without any variations in its movements.

[0024] 2, the aspect ratios of the bottom and top surfaces of the rectangular parallelepiped module 10 transported by the SPMT 3 are significantly different. In this case, if the width of the transport path S2 and the surrounding area of ​​the site S1 are sufficiently wide, the module 10 can be transported to the site S1 without having to worry about the longitudinal direction of the bottom surface, etc.

[0025] However, when all of the foundations 2 are arranged in advance as shown in Figure 2, it is necessary to adjust the approach angle of the rows of SPMTs 3 so that the wheels of each SPMT 3 can enter between the rows of foundations 2 when entering the site S1. By adjusting the approach angle, the wheels can move each SPMT 3 without interfering with the foundations 2 provided on the site S1, and the module 10 can be transported within the site S1.

[0026] However, as mentioned in the background art, in recent years, there has been a demand for a more compact construction site for the plant 100. On the other hand, within the construction site, other modules 10 and equipment are being installed in parallel, making it impossible to provide a transport path S2 of sufficient width, which may limit the angle at which the row of SPMTs 3 can approach the site S1. The above-mentioned problems that arise in the delivery of the modules 10 will be specifically described using a comparative example.

[0027] 1 and 2 are perspective and plan views illustrating the transport of a module 10 to a site S1 in a comparative embodiment. The bold arrows in FIG. 1 indicate part of the travel path of the illustrated module 10, and this is the same in the subsequent figures. As shown in FIG. 2, the module 10 has a significantly different aspect ratio when viewed from above. However, since the width of the transport path S2 is limited, in this comparative embodiment, the travel direction is set so that the short side of the module 10 passes within the path width of the transport path S2 when viewed from above.

[0028] Here, the transport path S2 is not limited to the ground through which the SPMT 3 passes, but also includes the space above the ground, which is free of other structures that may come into contact with the module 10. For this reason, the width of the transport path S2 may differ between the ground and the space above; for example, it may be relatively narrow on the ground and relatively wide in the space above, or vice versa. Even in these cases, as long as a path width is ensured at each height position of the transport path S2 such that the SPMT 3 and module 10 do not interfere with other modules and devices on either side, the module 10 can pass through the transport path S2.

[0029] 1 and 2, the site S1 is positioned so that its long side extends along a direction that passes through the transport path S2 and bends to the left (the X direction in the figure). In this case, in order to have the SPMT3 enter the site S1 and align its angle of entry with the direction of the site S1, the SPMT3 must be turned left from the transport path S2 toward the site S1 while entering.

[0030] However, because the foundation 2 is installed at a position on the site S1 that interferes with the movement path of the SPMT 3, for example, the wheels of the SPMT 3 may come into contact with the foundation 2. In this case, the SPMT 3 cannot enter the site S1 while turning, and therefore the entry angle of the SPMT 3 cannot be adjusted.

[0031] As a result, in order for the SPMT 3 to enter the gaps between the rows of foundations 2, it becomes necessary to secure a turning area for the SPMT 3 by locating the site S1 in an area farther away in the X direction from the transport path S2. However, securing a turning area for the SPMT 3 goes against the demand for further compactness of the construction site of the plant 100. In the following explanation, one end of the row of SPMT 3 will be referred to as the "front" and the other end as the "rear" based on the order of entry into the site S1 after passing through the transport path S2. In this case, the terms "front" and "rear" will not be used interchangeably to reflect the change in direction of travel described below.

[0032] The construction of the foundation 2 and delivery of the SPMT 3 in this embodiment, which can solve the above problems, will be explained using the plan views of Figures 3 to 8. In these figures, the foundation 2 with diagonal lines in Figure 7 indicates a state in which the pedestal 12 is placed above, and the foundation 2 with crossed lines in Figure 8 indicates a state in which the pedestal 12 is connected.

[0033] As shown in FIG. 3 , an adjacent area S3, which serves as a standby position (described later) and is located at the rear of the site S1 when viewed along the direction of travel of the SPMT 3, is provided. The adjacent area S3 is smaller in area than the previously described rotation area required for rotating the SPMT 3. In this embodiment, the site S1 is divided into an interference area, in which foundations 2 are installed in positions that will interfere with the SPMT 3 when each SPMT 3 travels along a predetermined travel path, and a non-interference area, in which foundations 2 are installed in positions that will not interfere with the SPMT 3. By installing foundations 2 at different times in the interference area and the non-interference area, the SPMT 3 can be rotated while minimizing the expansion of the construction site of the plant 100. Hereinafter, foundations 2 installed in the non-interference area may be referred to as "non-interference foundations 21," and foundations 2 installed in the interference area may be referred to as "interference foundations 22."

[0034] The interference area refers to an area within the site S1 where foundations 2 are located that are predicted to come into contact with any part of the SPMT 3, such as the wheels or body, when the SPMT 3 travels along a predetermined travel path. The travel path is set to include the trajectory of the SPMT 3 within a normally acceptable error range. Therefore, not all of the interference foundations 22 installed in the interference area will necessarily be positioned to actually interfere with the SPMT 3 as it travels. Referring to the comparative example in Figure 2, the interference area can be said to be set as an area where the SPMT 3 will turn immediately after entering the site S1.

[0035] The non-interference area refers to an area other than the interference area within the site S1. Referring to Figure 2, the non-interference area can also be said to be set in the area ahead in the direction of travel after passing through the area where the SPMT 3 needs to turn.

[0036] The specific configurations of the non-interference foundation 21 and the interference foundation 22 will be described later, but in general, the interference foundation 22 is separated into an underground foundation 23, which is the underground portion that does not protrude from the ground of the site S1 within the interference area, and an upper foundation 24, which is the portion above the underground foundation 23 (Figure 11). The underground foundation 23 and the upper foundation 24 are constructed at different times.

[0037] As shown in Figure 3, in this embodiment, before the module 10 is delivered, construction of the foundation 2 is carried out differently in the interference area and the non-interference area. That is, in the interference area, only the underground foundation 23 of the interference foundation 22 is constructed, and the upper foundation 24 that protrudes above the ground is not constructed. On the other hand, in the non-interference area, the non-interference foundation 21 is constructed, and the foundation 2 is completed (the process of constructing the foundation in the non-interference area).

[0038] A protective member is provided above the underground foundation 23 of the interference footing 22 to protect the underground foundation 23 when the SPMT 3 passes through. In this embodiment, as shown in Figure 9, a wooden protective member 42, for example, is placed underground, and a steel plate 41 is provided to cover the upper surface of this protective member 42 (Figure 9).

[0039] The protective member 42 is carried, for example, by a worker, and placed above the underground foundation 23. The steel plate 41 is placed above the protective member 42, for example, using heavy machinery. The steel plate 41 is placed so that its upper surface is, for example, roughly flush with the ground. With this configuration, each SPMT 3 that has entered the site S1 can turn without coming into contact with the underground foundation 23 in the interference area, and the approach angle is adjusted so that the wheels of each SPMT 3 can enter the gaps between the rows of non-interference foundations 21.

[0040] Next, as shown in FIG. 4, each SPMT 3 is advanced straight toward the non-interference area, and each SPMT 3 is advanced along the gaps between the rows of non-interference foundations 21. Furthermore, as shown in FIG. 5, as each SPMT 3 is advanced straight, the leading end of each SPMT 3 passes through the non-interference area and moves to a position where it reaches the adjacent area S3 (a process of waiting at a waiting position). In this way, by overrunning the site S1, so to speak, and allowing the leading end of the SPMT 3 to reach the adjacent area S3, the trailing end of the SPMT 3 passes through the interference area and reaches the non-interference area. In this way, by setting the waiting position of the SPMT 3 in an area that does not include the interference area, construction of the upper foundation 24 can be carried out without interfering with the modules 10 placed on the SPMT 3.

[0041] Next, as shown in Figure 6, the upper foundations 24 of the interference foundations 22 are constructed in the interference area after the SPMT 3 has passed (process of constructing foundations in interference areas). To construct the upper foundations 24, first the steel plates 41 are removed with heavy machinery, and then the protective members 42 are removed by workers. The upper foundations 24 are then connected to the exposed underground foundations 23. As a result, the upper foundations 24 are positioned in a state where they protrude from the ground, similar to the non-interference foundations 21, and the interference foundations 22 are completed. The non-interference foundations 21 and interference foundations 22 are installed on the site S1 at the same pitch and height as the foundation 2 shown in the comparative example.

[0042] Next, as shown in Figure 7, each SPMT 3 is moved back toward the interference area, and the module 10 is placed on the site S1. At this time, the rear side of each SPMT 3 travels through the gaps between the rows of non-interference foundations 21 and interference foundations 22 and is placed in the interference area. The front side of each SPMT 3 travels from the adjacent area S3 where no non-interference foundations 21 are provided through the gaps between the rows of non-interference foundations 21 and is placed in the non-interference area. As a result of this movement, each pedestal 12 of the module 10 is placed above the corresponding foundation 2.

[0043] 8, the loading platform 31 of each SPMT 3 is lowered to a preset height, each pedestal 12 is placed on the corresponding foundation 2 (non-interfering foundation 21, interfering foundation 22), and each foundation 2 is connected to each pedestal 12. Thereafter, each SPMT 3 is moved outward from the area directly below the module 10 and withdrawn from the site S1.

[0044] As described above, according to the construction method for the foundation 2 in this embodiment, construction of the interference foundation 22 (connection of the upper foundation 24 to the underground foundation 23) is carried out in the interference area after the SPMT 3 has passed. This makes it possible to utilize the interference area as an area for carrying out the rotation operation of the SPMT 3, so that even if the area surrounding the transport path S2 or site S1 is narrowed, the foundation 2 can be constructed and the module 10 can be transported in.

[0045] Specific configuration examples of the non-interference foundation 21 and interference foundation 22 and the installation of the module 10 are described below with reference to Figures 9 to 12. Figure 9 is a longitudinal side view showing the non-interference foundation 21 and underground foundation 23 when the SPMT 3 passes through the interference area before construction of the upper foundation 24, and corresponds to the state in the plan view of Figure 4. In Figure 9, to clearly show the interference foundation 22, only the underground, steel plate 41, and protective member 42 are shown in cross section, and the SPMT 3 is indicated by a dot-dash line. Figure 10 is an enlarged plan view of the underground foundation 23 in Figure 9, with the steel plate 41 indicated by a dashed line.

[0046] As shown in Fig. 9, the non-interference foundation 21 is made of, for example, steel and is composed of a pile 21a and a head 21b connected to the upper end of the pile 21a by welding or the like. The pile 21a is buried in the ground at the position where the non-interference foundation 21 is to be formed, for example, so as to extend vertically downward. The head 21b is connected to the upper end of the pile 21a. The lower end of the head 21b is connected to the pile 21a underground.

[0047] The upper end of the head 21b is positioned to protrude above the ground. The upper surface of the upper end is larger than the bottom surface of the stud 12 to be supported and is flat so that the bottom surface can rest on and contact the underside of the stud 12. A plurality of rib plates 21d whose diameter increases from bottom to top are provided between the upper and lower ends of the head 21b.

[0048] Next, the interference foundation 22 will be described. As described above, the interference foundation 22 is composed of an underground foundation 23 and an upper foundation 24. As with the non-interference foundation 21, the underground foundation 23 and the upper foundation 24 are made of, for example, steel. The underground foundation 23 is composed of, for example, a pile 22a and a head 22b, for example, welded to the upper end of the pile 22a. The pile 22a is buried in the ground at the position where the interference foundation 22 is to be formed, extending, for example, vertically, to approximately the same depth as the pile 21a on the non-interference foundation 21 side. Meanwhile, the upper end of the pile 22a of the interference foundation 22 is located deeper underground than the pile 21a on the non-interference foundation 21 side.

[0049] The head 22b connected to the upper end of the pile 22a of the interference foundation 22 has a shape similar to the head 21b of the non-interference foundation 21. However, the head 22b of the interference foundation 22 does not protrude above ground level but is entirely underground. The upper end of the head 22b is provided with a head plate (support) 22c on which the upper foundation 24 is placed, multiple through-holes (not shown) formed in the head plate 22c, and set bolts 22d attached to the through-holes as connecting members for connecting the head 22b to the upper foundation 24. The attached set bolts 22d are spaced apart from one another along the periphery of the head plate 22c, which is circular in plan view. Each set bolt 22d protrudes upward from the top surface of the head plate 22c, which forms a horizontal plane when viewed from the side.

[0050] The protective member 42 includes a frame-shaped body 44 and beams 45 arranged to connect the inner wall surfaces of the frame-shaped body 44. The frame-shaped body 44 and beams 45 are made of wooden members strong enough to withstand the load exerted when the SPMT 3 carrying the modules 10 passes above them. The upper surfaces of the frame-shaped body 44 and beams 45 are located at the same height, above the upper ends of the set bolts 22d.

[0051] The frame-shaped body 44 is configured, for example, in a polygonal shape (octagonal in the example shown in FIG. 10 ) in a plan view. The frame-shaped body 44 is disposed, for example, on the upper surface of the head 22b on the interference footing 22 disposed underground so as to surround the periphery of the head plate 22c, with the outside of the frame-shaped body 44 buried underground. In the example shown in FIG. 10 , the beams 45 are disposed so as to intersect in a cross shape in a plan view. The beams 45 are disposed on the head plate 22c, for example, passing through the gaps between adjacent set bolts 22d.

[0052] The protective member 42 configured as described above is made of wood that is strong and lightweight enough to withstand the passage of the SPMT 3 carrying the modules 10 above. A steel plate 41 having a thickness sufficient to withstand the load of the SPMT 3 carrying the modules 10 when it passes over the protective member 42 is placed on the ground, including on the upper surface of the protective member 42.

[0053] In this way, the head 22b of the underground foundation 23 is protected using the protective member 42, and after the SPMT 3 transporting the module 10 has passed, the shape of the upper foundation 24 that is constructed and its construction details will be described using Figures 11 and 12. Figure 11 is a vertical cross-sectional side view showing the non-interfering foundation 21 and the interfering foundation 22, and corresponds to the state of the plan view in Figure 7. Figure 12 is a vertical cross-sectional side view showing the non-interfering foundation 21 and the interfering foundation 22, and corresponds to the state of the plan view in Figure 8.

[0054] 11 , the steel plate 41 and the protective member 42 are removed, and the upper foundation 24 is placed on the exposed head portion 22b using, for example, a crane. For example, the upper foundation 24 is configured as a pedestal (stool) attached to the head portion 22c. A base plate 24a is provided at the lower end of the upper foundation 24, and the lower surface of the base plate 24a has a horizontal surface that is circular in plan view and can be connected to, for example, the upper surface of the head portion 22c.

[0055] The base plate 24a has a plurality of through holes (not shown) formed at intervals along its periphery for passing the set bolts 22d. With the base plate 24a placed on the head plate 22c, the set bolts 22d passing through the through holes are fastened with nuts, thereby connecting the upper foundation 24 to the underground foundation 23.

[0056] The upper end of the upper foundation 24 has a shape similar to the head 21b on the non-interfering foundation 21 side, and is designed to place the pedestal 12 to be supported on and come into contact with the underside of the pedestal 12. After being connected to the underground foundation 23, the upper end of the upper foundation 24 is positioned so as to protrude above the ground. In this case, the height position of the upper end of the upper foundation 24 is positioned at approximately the same height as the head 21b on the non-interfering foundation 21 side.

[0057] After connecting the upper foundation 24 to the underground foundation 23, the corresponding pedestals 12 are positioned above each non-interfering foundation 21 and each interfering foundation 22, as shown in Figures 11 and 12, and then the loading platform 31 of the SPMT 3 is lowered. This places each pedestal 12 on the corresponding foundation 2 (non-interfering foundation 21, interfering foundation 22), and then the pedestals 12 are connected to the foundation 2. According to the method for constructing the foundation 2 of this embodiment, the foundation 2 can be constructed and the module 10 can be installed on the site S1 even in the narrow transport path S2 and in the surrounding area of ​​the site S1.

[0058] The structures of the non-interference foundation 21 and the interference foundation 22 described with reference to Figures 9, 11, and 12 are merely examples. Therefore, various configurations may be used in addition to the illustrated pile foundations, such as spread foundations, and even precast concrete foundations other than steel foundations. A structure like the interference foundation 22M described below may also be used. Furthermore, the interference foundation 22 in this embodiment employs a separate structure consisting of the basement foundation 23 and the upper foundation 24. The non-interference foundation 21 and the basement foundation 23 are constructed first before the SPMT 3 passes, thereby streamlining the construction of the foundation 2. However, this configuration is not the only option. For example, the interference foundation 22 may have a single structure similar to the non-interference foundation 21. In this case, construction from pile driving to head connection may be performed after the SPMT 3 passes. Alternatively, pile driving may be performed together with the non-interference foundation 21, with the upper portion protected by a steel plate 41, and the head portion 21b may be connected to the pile after the SPMT 3 passes.

[0059] Furthermore, the structure of the wooden protective member 42 described with reference to Figure 9 is merely an example, and other configurations may be adopted. For example, the beam 45 does not have to be cross-shaped, and at least one plate-shaped member may be disposed, and it does not have to be disposed at the center of the frame-shaped member 44 in a plan view. Also, as long as strength can be ensured, as with the concrete protective member 43 described below, it is not essential to place the steel plate 41 on its upper surface.

[0060] The standby position of the SPMT 3 is illustrated as an adjacent area S3 (including another adjacent area S4 described later using Figures 13A and 13B) along the approach direction to the site S1, but is not limited to this example. For example, it may be located to the side, shifted toward the width direction of the site S1 (Y direction in the figure). In this case, movement to the standby position on the side is performed by rotating the rotation axis of the wheels of the SPMT 3 located next to the standby position by, for example, 90 degrees.

[0061] In the above example, the module 10 is transported so that its short side passes within the width of the transport path S2 when viewed from above, but this is not a necessary requirement. For example, if the width of the transport path S2 is sufficient for the SPMT 3 and the module 10 to pass through, the module 10 may be transported so that its long side, the bottom side, passes within the transport path S2. In this manner, the transport direction of the module 10 can be appropriately selected according to the width of the transport path S2 and the shape of the site S1. Furthermore, the shape of the bottom of the module 10 is not limited to having short and long sides with different aspect ratios, and may also have the same aspect ratio. Even in these cases, by applying the foundation 2 construction method disclosed herein, the module 10 can be easily transported to the site S1 and the foundation can be constructed.

[0062] However, if it is difficult to transport the modules 10 to the site S1 due to constraints such as the width of the transport path S2, it may be necessary to further subdivide the modules 10 from the original design to make them smaller before transporting them to the site S1. In this regard, according to the construction method for the foundation 2 disclosed herein, it may be possible to transport the modules 10 without further downsizing them, thereby suppressing an increase in the work of connecting the modules 10 on site and saving labor in constructing the plant on site.

[0063] The construction method for foundations 2 disclosed herein is not limited to cases where the orientation of modules 10 passing through transport path S2 differs from the orientation of site S1, as in the example described with reference to Figure 2, and an area for rotating SPMT 3 needs to be secured. For example, even when SPMT 3 is simply moved in a straight line, if the foundations 2 are arranged irregularly rather than in a grid pattern in the area where SPMT 3 enters, and interference occurs between SPMT 3 and the irregularly arranged foundations 2, the area where the irregularly arranged foundations 2 are arranged can be set as the interference area, and the construction method for foundations 2 disclosed herein can be applied.

[0064] The travel of the SPMT 3 and the construction procedure for the upper foundation 24 in this embodiment as described above are merely examples, and various travel patterns for the SPMT 3 and construction procedures for the foundation 2 can be considered using the foundation construction method disclosed herein. A modified example as one example will be described below.

[0065] 13A and 13B are plan views showing other procedures for constructing the foundation 2 and running the SPMT 3. In this example, the site S1 is located closer to the transport path S2 than in FIG. 2, so the interference area (the area where the interference foundations 22 are located) is wider. Specifically, of all the foundations 2, when viewed from the front side in the direction of entry of the SPMT 3, the non-interference area is the area where the four non-interference foundations 21 are located at the farthest rear along the Y direction with a gap between them. Within the remaining interference area, four rows of five interference foundations 22 are arranged along the X direction with a gap between them.

[0066] An example of a method for installing an interference foundation 22 within such a wide interference area will now be described. As shown in FIG. 13A , each SPMT 3 transporting a module 10 passes through the interference area while rotating, then moves straight through the gap between the non-interference foundations 21 and waits at a standby position including the adjacent area S3. At this time, as shown in FIG. 13A , the SPMT 3 passes through only a portion of the interference area. Therefore, the standby position of the SPMT 3 includes the portion of the interference area that the SPMT 3 did not pass through, the non-interference area, and the adjacent area S3. While the SPMT 3 is waiting at the standby position, an upper foundation 24 is constructed in each of the interference areas that the SPMT 3 passed through (see the installation position of the upper foundation 24 in FIG. 13B ).

[0067] Next, each SPMT 3 retreats in the direction from which it began entering site S1 (the base end of the X-axis arrow shown in Figure 13B) and waits in a state where it is retracted from the interference area where no upper foundation 24 is installed. As shown in Figures 13A and 13B, an adjacent area S4 is also set in front of the start position of entry into site S1, allowing part of the SPMT 3 to wait. Therefore, the waiting position of the SPMT 3 includes the interference area where the upper foundation 24 is installed and the adjacent area S4.

[0068] 13B, upper foundations 24 are constructed in the interference areas after the SPMTs 3 are evacuated. Once all foundations 2 are completed, each SPMT 3 moves to the module 10 placement position within the site S1 and then installs the modules 10 on the foundations 2.

[0069] The embodiments described above using Figures 3 to 13B merely illustrate the structure and construction procedures of the non-interference foundations 21 and interference foundations 22 as examples. Therefore, the non-interference foundations 21 and interference foundations 22 may be provided with structures and construction procedures different from those described in these embodiments. Figure 14 is a longitudinal side view showing the configuration of another example of an interference foundation 22M. Unlike the example shown in Figure 11, the underground foundation 23M constituting the interference foundation 22M in the example shown in Figure 14 includes two piles 22a and a footing 22h. The number of piles 22a is not limited to two; one or more piles may be provided. If the ground allows stable installation of the module 10, the piles 22a may be omitted.

[0070] The footing 22h is made of reinforced concrete and has a substantially rectangular parallelepiped shape, and the upper ends of the two piles 22a are inserted into it. A pedestal 22f is formed on the footing 22h, extending upward from the center of its upper end. The pedestal 22f is provided with a plurality of anchor bolts 22e extending vertically inside, and a head plate 22c is provided on its upper surface. The upper ends of each anchor bolt 22e protrude upward from the top surface of the head plate 22c. In this example, an independent footing 22h is provided for each interference footing 22, but this is not limiting; for example, a continuous footing 22h may be used, in which a common footing 22h is provided for all interference footings 22.

[0071] Next, we will explain the case where a concrete protective member 43 is provided to protect the anchor bolts 22e of the footing 22h, instead of the wooden protective member 42 described using Figures 9 and 10. Figures 15 and 16 are longitudinal side views showing the procedure for forming the protective member 43. As shown in Figure 15, the soil around the upper surface of the footing 22h is removed to expose the upper surface. Positioning protrusions 22i are provided on the upper surface of the footing 22h to position the anchor bolts 22e and the upper foundation 24.

[0072] First, protective caps 47 are placed on the anchor bolts 22e and the positioning protrusions 22i, and a wooden frame 48 is placed around them. Next, as shown in Figure 16, concrete is poured inside the wooden frame 48, and handles 49 are placed in the concrete to allow for lifting during removal. Once the concrete hardens, the protective member 43 is formed. Because the protective member 43 is heavier than the wooden protective member 42, heavy machinery is used to remove it.

[0073] Another procedure for forming the protective member 43M will be described with reference to Figure 17. The protective member 43M is formed by covering the upper surface of the footing 22h, specifically the area from above the protective cap 47 to the ground around the footing 22h, with, for example, a blue tarp 48M, without using a wooden frame 48. The protective member 43M may then be formed by pouring concrete on top of the covering blue tarp 48M.

[0074] Here, when removing the protective member 43 or transporting the upper foundation 24, it is possible to use, for example, an SPMT 3 for transporting the module 10 without using heavy machinery. Figures 18(a) to 18(c) and Figures 19(a) to 19(c) are longitudinal side views showing other construction procedures for the upper foundation 24. In Figure 18(a), the steel plate 41 is not shown.

[0075] 18(a), a plurality of lifting mechanisms are attached to, for example, the loading platform 31 of the SPMT 3. The plurality of lifting mechanisms are arranged, for example, at the rear end of the row of SPMTs 3, and include hooks 32 for transporting the protective members 43 and a jack-type lifting mechanism (hereinafter referred to as a jack) (not shown) for suspending and transporting the upper foundation 24. The hooks 32 are arranged further rearward of the row of SPMTs 3 than the upper foundation 24.

[0076] 18(a) and 18(b), a train of SPMTs 3 traveling toward the standby position stops, for example, with its tail end resting on the underground foundation 23 where the upper foundation 24 is to be constructed. Then, after the steel plate 41 is removed using a jack, the hook 32 is positioned above the protective member 42. Next, as shown in FIG. 18(c), the end of the rope hooked onto the hook 32 is tied to the handle 49 (see FIG. 16, etc.) of the protective member 43, and the protective member 43 is lifted and removed from the underground foundation 23.

[0077] 19(a) and 19(b), the SPMT 3 suspending the protective member 43 and upper foundation 24 is moved slightly in the opposite direction from the standby position, and the upper foundation 24 is placed above the underground foundation 23. The SPMT 3 is then lowered and connected to the underground foundation 23. Thereafter, as shown in FIG. 19(c), once all of the interference foundations 22 have been completed, each SPMT 3 is moved so that the pedestal 12 is positioned above the corresponding foundation 2, and the module 10 is installed. The SPMT 3 is then withdrawn from site S1 with the protective member 43 still suspended therefrom, and the protective member 43 is also removed.

[0078] In the embodiments described above using Figures 9, 11, etc., examples have been shown in which the foundation 2 is provided on a flat site S1. However, this is not limiting, and the module 10 can also be installed on a site S1 with a slope, for example. Figure 20 is a vertical side view showing an example in which an interference footing 22M is provided on a site S1 with a slope. The interference footing 22 supports the lower ends of the pedestals 12 at approximately the same height position in order to support the module 10 horizontally on the site S1.

[0079] For this reason, the upper foundations 24 connected to the underground foundations 23M are prepared to have different lengths depending on the height position of the upper end of the underground foundation 23M. That is, a long upper foundation 24 is connected to the underground foundation 23M located on the lower side of the radial slope, and a short upper foundation 24 is connected to the underground foundation 23M located on the upper side of the radial slope.

[0080] According to this example, the upper end of the upper foundation 24 is positioned at a preset height, so that the module 10 can be installed horizontally even on a site S1 with a radially inclined surface.

[0081] DESCRIPTION OF SYMBOLS 2 Foundation 3 SPMT 10 Module 11 Bottom beam 12 Column 21 Non-interference foundation 21a, 22a Pile 21b, 22b Head 21d Rib plate 22, 22M Interference foundation 22c Head plate 22d Set bolt 22e Anchor bolt 22f Pedestal 22h Footing 22i Convex portion 23, 23M Underground foundation 24 Upper foundation 24a Base plate 31 Loading platform 32 Hook 41 Steel plate 42, 43, 43M Protective member 44 Frame-shaped body 45 Beam 47 Protective cap 48 Wooden frame 48M Blue sheet 49 Handle 100 Plant S1 Site S2 Transport route S3, S4 Adjacent area

Claims

1. A method for constructing a foundation for a plant module having a frame structure with a plurality of pillars, wherein a plurality of foundations supporting each of the plurality of pillars are provided at a distance from one another on a site on which the plant module is to be installed, and when some of the plurality of foundations are positioned in positions that will interfere with a cart carrying the plant module when the cart moves along a predetermined moving path on the site, the method comprises the steps of: constructing the foundations in a non-interference area where the foundations will be provided so as not to interfere with the cart moving on the site; then, entering the cart along the moving path and having it wait at a predetermined waiting position that includes the site; and then constructing the foundations in an interference area where the foundations will be provided so as to interfere with the cart.

2. A foundation construction method as described in claim 1, wherein the non-interference area is located further forward on the travel path than the interference area when viewed along the direction of travel of the trolley when entering the site, and when the trolley enters the site, the trolley passes through at least a portion of the interference area and waits at the waiting position.

3. A foundation construction method according to claim 2, wherein the carriage passes through the entire interference area and waits at the waiting position set in an area that does not include the interference area.

4. A foundation construction method as described in claim 2, wherein the carriage passes through a portion of the interference area and waits at the waiting position set in an area including the interference area other than the portion, and the step of constructing a foundation to be provided in the interference area includes a step of constructing a foundation in the portion of the interference area, and then a step of moving the carriage toward the portion of the interference area and constructing the foundation in the interference area at the waiting position.

5. A foundation construction method as described in claim 1, comprising a step of constructing an underground foundation, which is the underground portion of the foundation in the interference area, before the cart enters the site, and in the step of constructing the foundation, an upper foundation, which is the upper portion of the foundation, is attached on top of the underground foundation.

6. The foundation construction method according to claim 5, wherein the upper foundation is carried in together with the module by the cart.

7. A foundation construction method as described in claim 6, wherein the cart passes through a portion of the interference area and waits at the waiting position set so that the upper foundation brought in by the cart is positioned above the underground foundation, and in the step of constructing the foundation, the upper foundation is lowered from the cart and attached to the underground foundation.

8. A foundation construction method as described in claim 5, comprising a step of placing a protective member on the underground foundation to protect the underground foundation when the bogie passes above the underground foundation after the underground foundation has been constructed.

9. A foundation construction method as described in claim 8, wherein the protective member is made of wood and includes a frame-shaped body arranged to surround a connecting portion provided on the underground foundation side to connect the underground foundation and the upper foundation, and a beam connecting the inner wall surfaces of the frame-shaped body.

10. A foundation construction method as described in claim 9, wherein the connecting portion is a plurality of bolts that constitute the underground foundation, are arranged to surround the support member that supports the upper foundation, and are arranged to protrude above the support member, and the beam is arranged to pass between adjacent bolts.

11. A foundation construction method as described in claim 8, wherein the protective member includes a protective cap installed to cover the connecting portion and a concrete lid poured on the protective cap.

12. A foundation construction method as described in claim 8, which includes a step of removing the protective member using a lifting mechanism provided on the cart as the cart passes and transporting it by the cart before attaching the upper foundation to the underground foundation.

13. A module installation method comprising the steps of: after constructing the foundations in the interference area as described in claim 1, moving the carriage to position the module above the multiple foundations; and then lowering the module using a platform lifting mechanism provided on the carriage, and installing the module on the multiple foundations.

14. A foundation for a plant module having a structural frame structure with multiple supports, comprising: an underground foundation that is provided on the site where the plant module is to be installed, that is positioned to interfere with a cart carrying the plant module as the cart moves along a predetermined travel path on the site, and that is constructed underground before the cart enters the site; and an upper foundation, which is the upper part of the foundation, that is attached to the underground foundation after the cart has entered the site.

15. A protective member for protecting an underground foundation according to claim 14, the protective member being arranged to surround the periphery of a connecting portion connecting the upper foundation and the underground foundation.

16. The protective element according to claim 15, wherein the protective element is made of wood.

17. The protective member according to claim 17, comprising a frame-shaped body and a beam connecting the inner wall surfaces of the frame-shaped body.

Images