Installation method for plant module, construction method for foundation, and module foundation

Abstract

[Problem] To provide a method capable of facilitating construction of a foundation of a plant module and installation of the plant module. [Solution] An installation method for a plant module having a frame structure supported by a plurality of support columns, the installation method including: a step for fixing a plurality of lower foundations at positions corresponding to the plurality of support columns so as to be separated from each other, on a site where the plant module is to be installed; a step for fixing upper foundations for respectively supporting the support columns, on the plurality of lower foundations; a step for placing the support columns on the upper foundations; and a step for restraining and supporting the support columns on the upper foundations so as to restrain movement of the support columns with respect to the upper foundations.

Description

Plant module installation method, foundation construction method, and module foundation

[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] The foundations, which are pre-installed at the construction site, are installed at a distance from each other within the plant construction site and are respectively connected to the lower ends of the columns (hereinafter, the lower end regions of the columns are also referred to as "pedestals") installed on the framework that constitutes the module. For example, when installing the modules after the construction of each foundation, the modules are positioned above the foundations and each pedestal of the module is placed, and then the modules are lowered to place each pedestal on the foundation, and then the modules are joined. Therefore, high precision is required for the construction position of each foundation. Furthermore, in order to collectively join the multiple pedestals installed on the modules to each foundation, the position of the large module must be accurately adjusted, which makes on-site work very difficult. Patent Document 1 does not mention any of the above points.

[0006] Furthermore, when transporting the divided modules into multiple pieces toward an area where a foundation is being installed, it is necessary to provide a path for moving the modules while avoiding interference with other modules that have already been installed. On the other hand, 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 setting up a more compact construction site. In this regard, Patent Document 1 does not mention at all the problems of securing a transport path when transporting modules.

[0007] International Publication No. 2021 / 029051

[0008] The present invention has been made in light of the above background, and provides a technique for facilitating the construction of the foundation of a plant module and the installation of the plant module.

[0009] The present invention is a method for installing a plant module having a frame structure supported by a plurality of pillars, comprising the steps of: fixing a plurality of lower foundations spaced apart from one another on a site on which the plant module is to be installed at positions corresponding to the plurality of pillars; fixing upper foundations for supporting the pillars on each of the plurality of lower foundations; placing the pillars on the upper foundations; and restraining and supporting the pillars on the upper foundations so as to restrain movement of the pillars relative to the upper foundations.

[0010] The plant module installation method may have the following features: (a) the lower foundation and the upper foundation, and the upper foundation and the support column are fastened to each other using fastening members; (b) in (a), the fastening members fastening the upper foundation and the support column are arranged inside a rectangle circumscribing a cross section of the support column; and (c) in (b), the fastening members fastening the lower foundation and the upper foundation are arranged outside a rectangle circumscribing a cross section of the support column.

[0011] The present invention also provides a method for constructing a foundation for a plant module installed by the plant module installation method, comprising the steps of: when, on a site where a plurality of foundations are to be installed, a cart loaded with the plant modules moves along a predetermined moving path on the site and some of the plurality of foundations are positioned in a position that will interfere with the cart; constructing the foundations in a non-interference area where the foundations will be installed that will not 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 installed that will interfere with the cart.

[0012] The foundation construction method may have the following features: (d) 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 made to enter the site, the carriage passes through at least a portion of the interference area and waits at the waiting position. (e) In (d), 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. (f) In (d), 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 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.

[0013] (g) constructing the lower foundation underground at the site in the interference area before the cart enters the site, wherein the step of constructing the foundation comprises attaching the upper foundation on top of the lower foundation. (h) In (g), the upper foundation is carried in by the cart together with the plant module. (i) In (h), the cart passes through a 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 lower foundation, and the step of constructing the foundation comprises lowering the upper foundation from the cart and attaching it to the lower foundation.

[0014] (j) In (g), the method includes a step of, after constructing the lower foundation, placing a protective member on the lower foundation to protect the lower foundation when the bogie passes above the lower foundation. (k) In (j), the protective member is made of wood and includes a frame-shaped body arranged to surround a connecting portion provided on the lower foundation to connect the lower foundation and the upper foundation, and a beam connecting the inner wall surfaces of the frame-shaped body. (l) In (k), the lower foundation has a support member for supporting the upper foundation, the connecting portion being a plurality of bolts provided to protrude upward on the support member, and the beam is arranged between adjacent bolts. (m) In (j), the protective member includes a protective cap installed to cover the connecting portion and a concrete lid poured on the protective cap. (n) In (j), before attaching the upper foundation to the lower foundation, a process is included in which the protective member is removed by a lifting mechanism provided on the carriage side as the carriage passes, and the protective member is transported by the carriage.

[0015] According to this method, a foundation for connecting multiple columns supporting a plant module having a frame structure is constructed separately into a lower foundation and an upper foundation. The lower foundations are then fixed at positions corresponding to the columns on the site where the module is to be installed, with a gap between them, and the upper foundation is placed and fixed on the lower foundation, and the columns are restrained and supported on the upper foundation. This allows the foundation to be constructed in a predetermined position with high precision and reduces the difficulty of foundation construction and module installation.

[0016] Furthermore, 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 constructing the foundations in the non-interference areas, 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.

[0017] 12A is a plan view showing the installation of a module in the first embodiment. FIG. 12B is a longitudinal side view showing the installation of a module in a comparative embodiment. FIG. 12C is an enlarged longitudinal side view showing the installation of a module in a comparative embodiment. FIG. 12D is a longitudinal side view showing the joint state between the foundation 2 and the pedestal 12 according to the first embodiment. FIG. 12D is a longitudinal side view showing the A-A' cross section of FIG. 4. FIG. 12E is a longitudinal side view showing the installation work of the module according to the first embodiment. FIG. 12F is a longitudinal side view showing the installation work of the module according to the first embodiment. FIG. 12G is a longitudinal side view showing the joint state between the foundation and the pedestal according to a first modified example of the first embodiment. FIG. 12H is a longitudinal side view showing the joint state between the foundation and the pedestal according to a second modified example of the first embodiment. FIG. 12H is an enlarged longitudinal side view showing the upper fastening member in FIG. 12A. 20. A schematic diagram illustrating a corner of a plant in which a foundation construction method of a comparative embodiment to the second embodiment is used. FIG. 21 is a plan view illustrating a module delivery method in the comparative embodiment. FIG. 22 is a first plan view illustrating a module delivery method of the second embodiment. FIG. 23 is a second plan view illustrating a module delivery method of the second embodiment. FIG. 24 is a third plan view illustrating a module delivery method of the second embodiment. FIG. 25 is a fourth plan view illustrating a module delivery method of the second embodiment. FIG. 26 is a sixth plan view illustrating a module delivery method of the second embodiment. FIG. 27 is a longitudinal side view showing the foundation of a non-interference area and the lower foundation before construction of the upper foundation. FIG. 28 is a plan view showing the lower foundation in FIG. 21. FIG. 29 is a longitudinal side view showing the foundation of a non-interference area and the foundation of the interference area in FIG. 19. FIG. 20 is a longitudinal side view showing the foundation of a non-interference area and the foundation of the interference area in FIG. 21. FIG. 21 is a first plan view illustrating module delivery by another procedure. FIG. 22 is a second plan view illustrating module delivery by another procedure. FIG. 23 is a longitudinal side view showing another example of the foundation of the interference area. 1A to 1C are longitudinal sectional side views showing a procedure for forming a protective member that protects a lower foundation of an interference area, a second longitudinal sectional side view showing a procedure for forming a protective member, and another longitudinal sectional side view showing a procedure for forming a protective member.It is to be noted that the present invention is not limited to the above embodiment, and may be modified in various ways without departing from the spirit and scope of the present invention.

[0018] First Embodiment An installation method for a module 10 constituting a plant 100 will be described with reference to Figures 1 and 2. Figure 1 is a plan view showing installation of a module 10 on a site S1 of a plant 100 common to the first embodiment and a comparative embodiment described later, and Figure 2 is a longitudinal side view showing installation of a module 10 in the comparative embodiment. In detail, Figure 1 is a view showing delivery of the module 10 into the site S1, and Figure 2 shows installation of the module 10 arranged on the site S1 of the comparative embodiment on a foundation 2 m deep, but apart from the foundation 2 m, the installation is common to the first embodiment.

[0019] Before describing the installation method of the module 10 of the first embodiment, the plant 100 to which the installation method of the first embodiment is applied is not particularly limited as long as it has a function of treating fluids. Examples of plants 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.

[0020] 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.

[0021] 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.

[0022] As shown simply in FIG. 13 , which will be used to explain the second embodiment described later, the lower end of the module 10 of the frame structure is composed of multiple beams (hereinafter also referred to as "bottom beams 11"; see also FIG. 21 ). As shown in FIGS. 1 and 2 , multiple pedestals (supports) 12 are formed at the lower end of the module 10, each extending downward. These multiple pedestals 12 are spaced apart from one another in a lattice 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 multiple foundations 2 that are pre-installed to protrude from the site S1, which is the installation area for the module 10, and then connected to one another ( FIGS. 1 and 2 ). Therefore, when viewed in plan, the foundations 2 and the pedestals 12 are arranged in the same arrangement.

[0023] Here, when the modules 10 are placed in the appropriate installation positions, the pedestals 12 and the foundation 2 must be appropriately positioned so that they face each other. Therefore, before constructing each foundation 2, the position of the base plate 13 ( FIG. 2 ), which is the joint between each pedestal 12 and the foundation 2, is measured in advance in a module yard or a backyard where the modules 10 are stored before installation. Based on the measurement results, each foundation 2 is constructed under strict positional control so that the joint portion of the foundation 2 (the upper plate 52 in the first embodiment) is positioned in accordance with the position of the corresponding base plate 13. Thereafter, the modules 10 placed on a self-propelled modular transporter (SPMT) 3 (described later) above each foundation 2 are appropriately positioned at the installation positions, and then the modules 10 are lowered so that the base plates 13 contact the upper surfaces of the footings 25b of all foundations 2. At this time, the pedestal 12 is attached to the foundation 2 so that multiple anchor bolts 25a, which are arranged to protrude upward from the upper surface of the footing 25b, pass through the mounting holes 13a formed on the base plate 13 side.

[0024] As described above, each foundation 2 must be constructed with strict positional control. In addition, in FIG. 1 , a large number of foundations 2 are provided at intervals from one another in a grid pattern along the X and Y directions shown in the figure on the site S1. The arrangement of the foundations 2 and pedestals 12 in each figure is for the convenience of explaining the comparative example and each 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 stably support the module 10 on the site S1 when connected to one another.

[0025] The modules 10 are carried into the site S1 by a plurality of SPMTs 3, which are carts, via a transport path within the plant 100, and are installed on the foundations 2. The loading platforms 31 (see also FIG. 2) of the SPMTs 3 are arranged in a plurality of rows (three rows in the example shown in FIG. 1) with spaces between them. The modules 10 are loaded straddling the loading platforms 31 (see also FIG. 2), and are transported while still loaded on the plurality of SPMTs 3.

[0026] 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.

[0027] 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.

[0028] When a worker operates these SPMTs using a controller, each SPMT 3 synchronizes its movements, such as traveling and lifting / lowering of the loading platform. This allows each SPMT 3 to transport the module 10 stably without any variations in its operation. As shown in Figures 1 and 2, when all the foundations 2 have been constructed and placed in advance, each SPMT 3 moves forward by entering the gaps between the "rows of foundations 2" extending along the X direction. The module 10 is then transported to the position where the corresponding pedestal 12 is placed directly above each foundation 2.

[0029] Thereafter, the modules 10 are lowered vertically to place the pedestals 12 on each foundation 2. When placing the modules 10 in this manner, each foundation 2 must be positioned so that all sets of pedestals 12 and foundation 2 can be joined together.

[0030] Here, a specific example of the structure of a foundation 2m in a comparative example will be described with reference to Figure 3. The foundation 2m is configured as an integrated structure including piles (not shown) driven into the ground and a footing 25b, which constitutes part of the pile and is a joint formed with multiple anchor bolts 25a protruding upward. When installing the module 10, the anchor bolts 25a and the footing 25b are exposed above ground. When joining the module 10, the anchor bolts 25a are inserted through mounting holes 13a formed in a base plate 13 provided at the lower end of the pedestal 12. Thereafter, nuts are fastened to the anchor bolts 25a to secure the pedestal 12 and the foundation 2m.

[0031] In the comparative example described above, when adjusting the position of the module 10 using the SPMT 3, the module 10 needs to be transported at a height sufficiently distant from the anchor bolts 25a so that the pedestals 12 do not come into contact with and damage the anchor bolts 25a (FIG. 2). When adjusting the position of the module 10 at such a high position, the anchor bolts 25a and the base plate 13 are far apart, making it more difficult to adjust the placement of the module 10.

[0032] When the studs 12 are positioned at a height farther away from the anchor bolts 25a in this manner, the higher the position of the studs 12 during transportation, the higher the position of the platform 31 of the SPMT 3 carrying the module 10. As a result, when placing the studs 12 on the 2-m foundation, the amount of descent of the platform 31 from the transport height of the module 10 to the placement height of the studs 12 relative to the 2-m foundation also increases. The placement of the studs 12 on the 2-m foundation includes the accurate insertion of the anchor bolts 25a into the mounting holes 13a formed in the base plates 13 at the lower ends of the studs 12. Since a large module 10 is provided with numerous studs 12, each of these studs 12 must be placed on the 2-m foundation. In this regard, the higher the position of the lower end (base plate 13) of the pedestal 12 before it starts to descend and the further it is from the upper end of the anchor bolt 25a, the more difficult it becomes to simultaneously pass the anchor bolt 25a through multiple mounting holes 13a.

[0033] Furthermore, immediately before installing the module 10, the pedestal 12 must be leveled at a height sufficiently distant from the anchor bolts 25a, which may affect the configuration of the module 10 (in the example described below, the overall length of the module 10). For example, assume that the module 10 is installed on a sloped site S1 (FIG. 32). Considering a state in which the module 10 is horizontally positioned on such a sloped site S1, the height distance from the ground to the bottom of the module 10 is relatively large on the lower side of the slope and relatively small on the upper side of the slope. Therefore, the SPMT 3 temporarily holds the module 10 in a state in which the lower side of the loading platform 31 is raised and the upper side of the loading platform 31 is lowered. In this case, the greater the difference in height between the lower end of the loading platform 31 and the upper end of the slope (i.e., the amount of lift of the loading platform 31), the longer the overall length of the module 10.

[0034] However, in actual SPMTs 3, the lifting range (lifting distance) of the platform 31 is limited. When the lifting distance of the platform 31 is limited, if the module 10 needs to be transported at a height sufficiently distant from the anchor bolts 25a, part of the lifting distance of the platform 31 is used to maintain the pedestal 12 spaced apart from the anchor bolts 25a. As a result, when using a 2-m foundation on a sloping site S1, the overall length of the module 10 may need to be shortened compared to when the pedestal 12 is closer to the anchor bolts 25a. Shortening the module 10 in this way increases the number of modules 10, which increases the workload for transporting and installing the modules 10 and for connecting the modules 10 together after installation.

[0035] Here, the pedestal 12 in the comparative example is made of, for example, a circular steel pipe, and a base plate 13 is provided at its lower part. The base plate 13 is made of a circular plate with a diameter larger than the lower end of the circular steel pipe and is provided to close the lower end of the circular steel pipe. The base plate 13 is placed on the upper surface of the footing 25b. A plurality of mounting holes 13a are formed through the base plate 13 on the peripheral side of the base plate 13, i.e., outside the circular steel pipe that forms the main body of the pedestal 12 when viewed from above. The mounting holes 13a are located on the peripheral side of the base plate 13 so that they can be accessed from outside the circular steel pipe to fasten anchor bolts 25a.

[0036] The inner diameter D3 of the mounting hole 13a is set to a size that allows an anchor bolt 25a with an outer diameter d1 to pass through and that allows a nut to be fastened to the anchor bolt 25a to secure the pedestal 12 to the foundation 2m. Here, as long as the gap D3-d1 between the mounting hole 13a and the anchor bolt 25a is within an allowable range, the pedestal 12 and the foundation 2m can be fastened together even if the position of the base plate 13 is misaligned horizontally. However, because this gap is minute compared to the relatively large pedestal 12 that supports the enormous module 10, alignment during the module 10 installation requires a very high level of precision and is therefore highly difficult. To alleviate this difficulty, for example, enlarging the diameter of the mounting hole 13a would be considered, but enlarging the diameter of the mounting hole 13a would require further enlarging the diameter of the base plate 13. Further enlarging the diameter of the base plate 13 would reduce the working space required for module 10 installation and would impose various constraints on the module 10 installation, such as reducing the width of the SPMT 3 to prevent contact with the SPMT 3.

[0037] The above-mentioned constraints are not limited to circular steel pipes, as mentioned above, but also apply when the cross section of the pedestal 12 is, for example, an H-section steel. In this case, the base plate 13 attached to the end of the H-section steel is placed directly on the foundation 2 m high, and as with circular steel pipes, the mounting holes 13 a must be enlarged. Furthermore, after fastening the anchor bolts 25 a with washers, a working space accessible from the outside is required for welding the periphery of the washers, etc. Thus, in the above-mentioned comparative configuration, regardless of the component shape, the mounting holes 13 a and anchor bolts 25 a are generally located outside the base plate 13, further enlarging the base plate 13.

[0038] The integrally structured foundation 2m described above in the comparative example presents a high level of difficulty in construction and module 10 installation. In contrast, in the first embodiment described below, the foundation 2 is separated into a lower foundation 23 and an upper foundation 24, thereby simplifying installation. The lower ends of the pedestals 12 are constructed of H-beams extending vertically, with rectangular base plates 13 connected to the lower ends of the H-beams (see FIGS. 4 and 6 ). In plan view, the base plate 13 is slightly larger than the lower end surface of the H-beam (i.e., the cross section of the H-beam) and slightly smaller than the upper plate 52 (described below) provided on the upper foundation 24 side.

[0039] Figure 4 is a longitudinal side view showing the connection between the foundation 2 and the pedestal 12 according to the first embodiment. Figure 5 shows a cross section taken along line A-A' in Figure 4, and Figure 6 shows a cross section taken along line B-B' in Figure 4. The two-dot chain lines in Figures 5 and 6 indicate the contour of a square area SS circumscribing the cross section of the H-beam portion of the pedestal 12. However, for the sake of convenience, the contour of the area where this square area SS partially overlaps with the pedestal 12 is shown slightly outward of the pedestal 12.

[0040] The lower foundation 23 includes a pedestal 25b and anchor bolts 25a, similar to the foundation 2m described in the comparative example. The pedestal 25b is made of poured concrete and has a rectangular shape in plan view. The anchor bolts 25a are provided outside the rectangular area SS, i.e., outside the H-beam portion of the pedestal 12, on the periphery of the pedestal 25b (FIG. 5).

[0041] A recessed keyway 25c is preferably formed in the center of the upper surface of the pedestal 25b. The keyway 25c has a sloped portion 25d that becomes shallower from the center toward the periphery on the upper surface of the pedestal 25b, for example, and the opening of the upper surface of the keyway 25c extends from the center toward the periphery of the pedestal 25b. This allows the fixing member 26b, such as concrete or grout, to be poured from the periphery of the upper opening of the keyway 25c, even if a height adjustment member 26a (described later) is placed on the pedestal 25b. Note that in Figure 4, the sloped portion 25d is positioned further back than the anchor bolts 25a, and therefore the bottom of the sloped portion 25d is shown by a dashed line in the figure.

[0042] A shear key 51a (described later) provided in the upper foundation 24 is inserted into the keyway 25c. The gap between the shear key 51a and the keyway 25c is filled with an injected fixing member 26b, and the shear key 51a is fixed in the keyway 25c by the hardened fixing member 26b. This fixing structure can withstand the horizontal load that occurs between the upper foundation 24, which is subject to horizontal loads that occur after the plant starts operating, and the lower foundation 23. This reduces the horizontal load applied to the anchor bolt 25a, preventing damage to the anchor bolt 25a.

[0043] Furthermore, the upper foundation 24 is placed on the pedestal 25b with a height-adjusting member 26a laid thereon. For example, the height-adjusting member 26a is made of a member that can withstand the load from the upper foundation 24 supporting the modules 10 and has an adjustable thickness. Specifically, the height-adjusting member 26a is made of a mortar pad, the height of which can be adjusted by the number of layers stacked, or grout, an amorphous material whose height can be adjusted by molding. Adjusting the thickness of the height-adjusting member 26a in this manner enables the height position of each upper foundation 24 to be adjusted. The height-adjusting member 26a is placed on the upper surface of the pedestal 25b, excluding the areas where the anchor bolts 25a and shear keys 51a are provided, and is placed so as to contact substantially the entire underside of the base plate 51 (described later) of the upper foundation 24. The anchor bolts 25a and shear keys 51a penetrate the height-adjusting member 26a and protrude upward and downward.

[0044] The upper foundation 24 is made of, for example, steel and includes a base plate 51 and an upper plate 52 provided at the lower and upper ends thereof, respectively, and an intermediate portion 53 provided to connect these plates 51 and 52. The base plate 51 and the upper plate 52 are rectangular in plan view and are arranged parallel to each other and horizontally via the intermediate portion 53. The base plate 51 is configured as a rectangle slightly smaller than the pedestal 25b in plan view. However, the base plate 51 is not limited to this rectangular shape as long as it is smaller than the pedestal 25b in plan view, and may have other shapes such as a square.

[0045] The lower surface of the base plate 51 is disposed opposite the upper surface of the pedestal 25b via the height adjustment member 26a. The above-mentioned shear key 51a, which protrudes downward, is preferably provided at the center of the lower surface of the base plate 51. The shear key 51a and key groove 25c are disposed at the centers of the base plate 51 and the pedestal 25b, respectively, but their positions do not have to be limited to the center.

[0046] The upper plate 52 is rectangular in plan view, specifically square, and smaller than the base plate 51. The upper plate 52 is not limited to a square shape, and may have other shapes, such as a rectangle, as long as it is rectangular in plan view and smaller than the base plate 51. The upper plate 52 is disposed above the central region of the base plate 51. In FIGS. 4 to 6, the Y direction is also referred to as the front-to-rear direction. In this case, the base end of the Y axis is the front direction, and the tip end of the Y axis is the rear direction. In these figures, the X direction is also referred to as the left-to-right direction. In these figures, the tip end of the X axis is the right direction, and the base end of the X axis is the left direction. In these figures, the Z direction is also referred to as the height direction. In this case, the tip end of the Z axis is the upward direction, and the base end of the Z axis is the downward direction.

[0047] For example, the intermediate section 53 is composed of one main plate 54 and four side plates 55. The main plate 54 and the side plates 55 are arranged to extend vertically from the base plate 51 toward the upper plate 52. As shown in FIG. 5 , the main plate 54 is arranged along the left-right edges of the base plate 51 and the upper plate 52. Two side plates 55 are arranged on each of the front and rear surfaces of the main plate 54, facing in the front-rear direction. The upper ends of the main plates 54 are located below a web 12a (described below) of the stud 12 and have a width sufficient to fit under the lower surface of the upper plate 52. The width of the main plate 54 increases from the upper end to the lower end, forming a trapezoidal shape when viewed from the front-rear direction. The upper ends of the two side plates 55 are located below a flange 12b (described below) of the stud 12 and have a width sufficient to fit under the lower surface of the upper plate 52. Like the main plate 54, the width of the side plate 55 increases from the upper end to the lower end, and the main surface of the two plates together has a trapezoidal shape when viewed from the left and right.

[0048] The main plate 54 and the side plates 55 are provided to partition the space between the upper surface of the base plate 51 and the lower surface of the upper plate 52. Specifically, the main plate 54 is provided to divide the upper surface of the base plate 51 and the lower surface of the upper plate 52 into two in the front-to-rear direction. The four side plates 55 are provided to divide the upper surface of the base plate 51 into three in the left-to-right direction. Furthermore, as shown in Figure 4, the four side plates 55 are provided along the periphery of both the left and right ends of the lower surface of the upper plate 52.

[0049] According to the plan view shown in Figure 5, of the upper surface area of ​​the base plate 51 divided into six by the intermediate portion 53 configured in this manner, the four left and right end areas each have two sides open to the outside, facing either forward or backward, or left or right. The two central areas have one side open to the outside, facing either forward or backward. Meanwhile, the lower surface of the upper plate 52 is divided into two by the upper end of the main plate 54. Each of these areas on the lower surface of the upper plate 52 is open to the outside, facing either forward or backward. In this way, each divided area of ​​the upper surface area of ​​the base plate 51 and the lower surface area of ​​the upper plate 52 allows access from the outside via their respective open sides.

[0050] Mounting holes 51b are provided in four regions on the left and right ends of the base plate 51. In a plan view, the mounting holes 51b are located outside the rectangular region SS (FIGS. 5 and 6). Because the rectangular region SS circumscribes the cross-sectional shape of the H-beam portion of the pedestal 12, the mounting holes 51b are located further outward than the pedestal 12. Furthermore, as shown in FIG. 4, the inner diameter D1 of the mounting holes 51b is larger than the diameter of the anchor bolts 25a. As a result, when the base plate 51 is placed on the top surface of the pedestal 25b, horizontal misalignment is permitted within the range of the gap between the anchor bolts 25a and the mounting holes 51b. The central axes of these mounting holes 51b coincide with the designed central axes of the anchor bolts 25a.

[0051] Specifically, the inner diameter D1 of the mounting hole 51b may be set to, for example, the diameter d1 of the body of the anchor bolt 25a + 20 mm, in which case the 20 mm gap allows for horizontal positional deviation of the base plate 51. Note that the inner diameter D1 of the mounting hole 51b can be further enlarged to increase the gap as long as it is within the divided upper surface area of ​​the base plate 51. Conversely, if the upper surface area is relatively small, the inner diameter D1 of the mounting hole 51b may be set to approximately the diameter d1 + 10 mm.

[0052] A nut is fastened from above to the tip of anchor bolt 25a, which passes through mounting hole 51b and protrudes upward, via washer 26c. Washer 26c has an outer diameter such that its lower surface contacts the entire periphery of mounting hole 51b in base plate 51. After the nut is fastened, the periphery of washer 26c and base plate 51 are joined, for example, by welding.

[0053] Next, the configuration of the upper plate 52 will be described. As shown in FIG. 6 , two mounting holes 52a for attaching set bolts 26d are provided in each of two adjacent regions on the underside of the upper plate 52. In a plan view, the mounting holes 52a are located inside the rectangular region SS described above. The set bolts 26d are used to fasten the base plate 13 to the upper plate 52. For example, the set bolts 26d are attached from below the mounting holes 52a and fastened with their heads in contact with the underside of the upper plate 52. For example, the diameter D2 of the mounting holes 52a is the diameter d2 of the body of the set bolt 26d plus 2 to 3 mm.

[0054] The base plate 13 on the stud 12 side is placed on the upper surface of the upper plate 52. The stud 12 is an H-beam having two flanges 12b and a web 12a connecting the two flanges 12b. The web 12a is arranged in the left-right direction in the center of the upper surface of the base plate 13, dividing the upper surface of the base plate 13 into two, front and rear sections. The two flanges 12b are arranged inside the left and right edges of the base plate 13. Each of the two divided upper surface areas of the base plate 13 has one side open to the outside, facing either the front or rear, allowing access from the outside through each open side.

[0055] The two regions of the base plate 13 are each provided with, for example, two mounting holes 13a for attaching the set bolts 26d. However, as long as the area of ​​each region allows and fastening workability is ensured, three set bolts 26d may be provided in each region. In plan view, the mounting holes 13a are located inside the region defined by the pedestals 12, i.e., inside the rectangular region SS. Furthermore, as shown in the enlarged view of FIG. 4 , the inner diameter D3 of the mounting holes 13a is larger than the inner diameter D2 of the mounting holes 52a. This allows for horizontal misalignment of the base plate 13 when the base plate 13 is placed on the top surface of the upper plate 52 within the range in which the mounting holes 13a, 52a overlap to allow the set bolts 26d to be inserted. The central axes of these mounting holes 13a are identical to the designed central axes of the mounting holes 52a in the upper plate 52 (i.e., the designed central axes of the set bolts 26d).

[0056] Specifically, the inner diameter D3 of the mounting hole 13a may be set to, for example, the diameter d2 of the set bolt 26d + 20 mm. In this case, this 20 mm gap allows for horizontal misalignment of the base plate 13. Similarly, the gap between the mounting hole 52a and the set bolt 26d also allows for horizontal misalignment of the base plate 13. Note that the inner diameter D3 of the mounting hole 13a can be further enlarged to increase this gap within the divided upper surface area of ​​the base plate 13 overlapping the upper plate 52. Conversely, if the upper surface area is relatively narrow, the inner diameter D3 of the mounting hole 13a may be set to approximately d2 + 10 mm. The above-described examples of the inner diameter D3 of the mounting hole 13a and the inner diameter D2 of the mounting hole 52a may be interchanged. In this case, the set bolt 26d is attached from the mounting hole 52a side ( FIG. 12A ). In this way, by using the upper foundation 24 provided with mounting holes 51b, 52a, 13a, the positions of the upper foundation 24 and the pedestal 12 can be adjusted when installing them, thereby reducing the difficulty of installing the module 10 and improving workability.

[0057] A nut is fastened from above to the tip of the set bolt 26d protruding from the mounting hole 13a via a washer 26e. The washer 26e has an outer diameter such that its lower surface contacts the entire periphery of the mounting hole 13a on the upper surface of the base plate 13. The inner diameter of the washer 26e is, for example, the diameter d2 of the set bolt 26d + 1 [mm].

[0058] 4 to 6, the configuration of the foundation 2 according to the first embodiment described above with reference to Figures 4 to 6 is as follows: the anchor bolts 25a for fixing the upper foundation 24 to the lower foundation 23, and the multiple sets of lower fastening members each consisting of a washer 26c and a nut, are arranged outside the rectangular area SS. In this way, within the plane where the pedestal 25b constituting the lower foundation 23 and the base plate 51 constituting the upper foundation 24 are arranged facing each other, the connection form in which the lower fastening members are dispersed and arranged outside the rectangular area SS can be said to be a "rigid connection" compared to the connection between the upper foundation 24 and the base plate 13 described below.

[0059] This rigid connection is made to withstand horizontal loads and rotational forces, but as mentioned above, the number of anchor bolts 25a in the base plate 51 may be restricted by the shape of the mounting holes 13a and the space available for subsequent work. However, in the present disclosure, the shear key 51a can withstand horizontal loads, so the foundation 2 can maintain sufficient strength even with the above restrictions.

[0060] The upper fastening members, which are composed of set bolts 26d, washers 26e, and nuts for restraining and supporting the base plate 13 to the upper foundation 24, are arranged inside the square area SS. In this way, the joint form in which the upper fastening members are concentrated inside the narrow square area SS is in a "pin joint" state compared to the joint between the pedestal 25b and the base plate 51.

[0061] As described above, in the first embodiment, different joining states are used for the lower and upper surfaces of the upper foundation 24. That is, for the lower surface, a rigid joining state is used for the joining between the base plate 51, which has a relatively large area for supporting the module 10, and the lower foundation 23, thereby improving durability against rotational moments. On the other hand, by using a pin joint for the upper surface of the upper foundation 24, the cross-sectional areas of the pedestals 12 and the base plate 13 are reduced to a level sufficient to support the load of the module 10, ensuring work space and improving the efficiency of installation work.

[0062] The installation work of the module 10 according to the first embodiment will be described with reference to Figures 7A to 7E. First, as described above, once the framework of the module 10 has been constructed, the positions of all of the base plates 13 are measured. The position of the base plates 13 is measured by measuring the relative position of each base plate 13 with respect to a reference position (module-side reference position) that is set in advance as a reference when the module 10 is designed. Specifically, the relative position of each base plate 13 is, for example, the amount of deviation in the horizontal and vertical directions from the reference position.

[0063] Meanwhile, on the site S1 side where the plant 100 is to be constructed, the lower foundation 23 is constructed based on the measured relative position of the base plate 13 ( FIG. 7A , process of fixing the lower foundation). Constructing the lower foundation 23 based on the relative position of the base plate 13 means fine-tuning the horizontal and vertical positions (height) of the lower foundation 23 based on the measurement results of the position of the base plate 13 relative to the reference position on the module side. The height position of each lower foundation 23 can be individually adjusted using the height adjustment members 26 a, as described below. Therefore, the height of the lower foundation 23 can be made standard even if the height position of the bottom beam 11 of the module 10 or the length of the pedestal 12 are different. If the height adjustment members 26 a are not provided, each lower foundation 23 (pedestal 25 b) is constructed to match its respective height.

[0064] The lower foundation 23 is constructed by pouring concrete to form the pedestal 25b, so as to enclose the upper parts of the piles (not shown) buried in the ground and the lower parts of the anchor bolts 25a placed in predetermined positions, in accordance with the reference positions of the respective modules. The concrete is poured to form the predetermined shape of the pedestal 25b, including the key grooves 25c. The pedestal 25b can be formed, for example, by pouring a footing below it in advance and then pouring the concrete onto the footing.

[0065] Next, a height-adjusting member 26a is formed on each pedestal 25b (FIG. 7B). The height-adjusting member 26a is formed by, for example, placing a mortar pad in accordance with the height (Z coordinate) of the lower foundation 23 determined based on the measured base plate 13 of the module 10. If the weight of the module 10 is relatively large, the height-adjusting member 26a is formed by placing an iron plate.

[0066] The upper foundation 24 is then placed on the height-adjusting members 26a, the heights of which have been adjusted on each lower foundation 23 ( FIG. 7C ). Compared to the comparative example described with reference to FIG. 2 , in which multiple pedestals 12 on a large module 10 are directly joined to the foundation 2m, this upper foundation 24 placement is easier because the relatively small upper foundations 24 are placed one by one. Specifically, the upper foundation 24 is placed by first inserting the shear keys 51a into the keyways 25c and inserting the anchor bolts 25a into the mounting holes 51b. The upper foundation 24 is then horizontally shifted to adjust its position within the allowable clearance of the mounting holes 51b. In this way, the installation of the upper foundation 24 can be performed manually without the need for large transport equipment or mounting jigs, and the workload is relatively light.

[0067] After the upper foundations 24 are installed, washers 26c and nuts are fastened and welded to the upper ends of the anchor bolts 25a, respectively, to secure the upper foundations 24 to the lower foundations 23 (FIG. 7D, step of securing the upper foundation). Then, securing members 26b are injected through openings in the upper peripheral edges of the key grooves 25c described above and allowed to harden, securing the shear keys 51a into the key grooves 25c. After all of the upper foundations 24 have been secured to the lower foundations 23 in this manner, the SPMT 3 transports the modules 10 to the site S1, and, as in FIG. 2, the modules 10 are stopped above the upper foundations 24 and kept waiting at the installation position (FIG. 7D).

[0068] The installation position of the module 10 at this time is, for example, a position set on the site side corresponding to the module-side reference position, such as a position where each mounting hole 13a of the base plate 13 provided on the pedestal 12 is correctly positioned above the mounting holes 52a of the upper plate 52 on the upper foundation 24 side. As described above, the height and horizontal position of the upper foundation 24 are adjusted in advance according to the actually measured relative position of the base plate 13. Therefore, after the module 10 is transported to the installation position, by lowering it vertically, the base plates 13 provided on each pedestal 12 will be positioned so that they can be joined to the corresponding upper foundation 24.

[0069] 7D , in the first embodiment, the anchor bolts 25 a do not protrude from the upper surface of the upper plate 52. Therefore, there is no need to be careful about damaging the anchor bolts 25 a, and the horizontal position of the module 10 can be adjusted with the base plate 13 in close proximity to the upper foundation 24, improving the workability of the position adjustment.

[0070] Furthermore, the distance by which the base plate 13 is lowered from a position close to the upper foundation 24 to place it on the upper foundation 24 is shorter than the distance by which the base plate 13 is lowered from an upper position that avoids contact with the anchor bolts 25a, as described in the comparative example, to the foundation 2m by penetrating the anchor bolts 25a. This makes it easier to adjust the position of the pedestals 12 of the module 10, reducing the workload of module installation work. Furthermore, when installing the module 10 on a sloping site S1, the restriction on the overall length of the module 10 is relaxed, improving the ease of installation and connection of the module 10.

[0071] Next, the platform of the SPMT 3 is lowered, vertically lowering the module 10 placed at the installation position, and the base plates 13 are placed on the corresponding upper foundations 24 ( FIG. 7E , the step of placing the support columns). As a result, each base plate 13 is placed on the corresponding upper foundation 24 so that the mounting holes 13a communicate with the mounting holes 52a. Then, set bolts 26d are attached to the mounting holes 52a from below, and washers 26e and nuts are attached to the set bolts 26d from above the mounting holes 13a and fastened ( FIG. 4 , the step of fastening and supporting the support columns). Thereafter, at the latest before the start of plant operation, the washers 26e are welded to the base plates 13 to constrain horizontal movement between the pedestals 12 and the upper foundation 24. As a result of the above, the base plates 13 are constrained to the upper foundation 24, and the pedestals 12 are supported by the upper foundation 24 while being constrained from moving, completing the installation of the module 10.

[0072] As described above, according to the method for installing the foundation 2 and the module 10 of the first embodiment, the foundation 2 is divided into the lower foundation 23 and the upper foundation 24, and the upper foundation 24 is installed on the constructed lower foundation 23. This allows the foundation 2 to be constructed with high precision and reduces the difficulty of the construction work for the foundation 2. Furthermore, since the base plate 13 is placed on the upper foundation 24, damage to the anchor bolts 25a is prevented, and position adjustment can be performed with the upper foundation 24 and the base plate 13 close to each other, contributing to improved workability in position adjustment.

[0073] The foundation 2 of the first embodiment is not limited to the structure and shape already described, and may have a structure similar to that of the interference foundation 22 of the second embodiment described later. In the first embodiment, all of the foundations are composed of the lower foundation 23 and the upper foundation 24, but some of them may be composed of the integrated foundation 2m shown in the comparative example.

[0074] Although FIG. 5 of the first embodiment illustrates an example in which the lower fastening members (sets of anchor bolts 25a, washers 26c, and nuts) are provided in four regions on the left and right ends of the base plate 51, this is not a mandatory requirement. For example, the lower fastening members may be provided in eight locations (see FIG. 5 ), with two sets of lower fastening members in each of these four regions. Alternatively, other numbers of lower fastening members may be provided in other locations. As with the lower fastening members, the positions and number of upper fastening members are not limited. Furthermore, as long as the connection strength between the upper foundation 24 and the lower foundation 23 is sufficient, the upper fastening members may be provided in one or more locations near the center of the rectangular area SS. However, since the connection between the lower foundation 23 and the upper foundation 24 is preferably rigid and strong against bending moments, it is preferable to provide the upper fastening members in two or more locations outside the rectangular area SS. Furthermore, it is even more preferable to provide the upper fastening members on the peripheral edge of the pedestal 25b, away from the central axis of the upper foundation 24.

[0075] In the first embodiment, the pedestal 12 is made of an H-beam in the example shown in Fig. 6, but steel materials of other shapes and steel materials with various cross-sectional shapes may also be used. As an example, a reinforcing plate may be attached between each of the two flanges 12b on the front and back surfaces of the web 12a. These two reinforcing plates are arranged parallel to the flanges 12b, with their lower ends connected to the base plate 13 and positioned between adjacent mounting holes 13a.

[0076] The configuration of the intermediate section 53 is not limited to the example shown in the first embodiment. For example, if the cross section of the pedestal 12 is relatively small and the upper plate 52 is accordingly relatively small, a total of two side plates 55 may be provided by arranging them at the center positions on the front and back of the main plate 54, as shown in the following first modification ( FIG. 8 ). Furthermore, for example, by arranging an additional side plate 55 at a central position between the two side plates 55 provided on the front and back of the main plate 54 described in FIG. 5 of the first embodiment, a total of six side plates 55 may be provided. As described above, the structure of the intermediate section 53 is not limited to that shown in the first embodiment and may have other shapes. Furthermore, the main plate 54 and the side plates 55 do not need to be perpendicular to each other, and they do not need to be positioned relative to the pedestal 25b as described above. Two specific modifications of the intermediate section 53 and the pedestal 12 are described below.

[0077] (First Modification of the First Embodiment) Fig. 8 is a longitudinal side view showing the connection between the foundation 2 and the pedestal 12 according to the first modification, Fig. 9 shows the CC' cross section of Fig. 8, Fig. 10 shows the DD' cross section of Fig. 8, and Fig. 11 shows the EE' cross section of Fig. 8. In the intermediate portion 53A of the foundation 2 in the first modification, side plates 55 are provided at the center of both sides of the main plate 54 in the front-to-rear direction, forming a cross shape in cross section (Fig. 9). The pedestal 12 connected to the foundation 2 uses a circular steel pipe 12c, as in the comparative example, and a connection portion 14 is formed at the lower end of the circular steel pipe 12c to connect the pedestal 12 to the base plate 13.

[0078] The connection 14 is composed of a cross plate 14b attached to the lower end of the circular steel pipe 12c and an end plate 14a arranged to close the lower end of the circular steel pipe 12c (Figures 8 and 11). The cross plate 14b is arranged parallel to the axis of the circular steel pipe 12c, has a cross-shaped cross section, and is arranged to divide the lower area of ​​the circular steel pipe 12c into four sections. The upper end of the cross plate 14b is inserted into a notch formed in the lower end of the circular steel pipe 12c and welded to it. The lower end of the cross plate 14b is welded to the upper surface of the base plate 13. The end plate 14a has a shape obtained by dividing the circle that forms the lower edge of the circular steel pipe 12c into four sections by the cross plate 14b. Each end plate 14a is arranged to cover the area defined by the cross plate 14b and is welded to the cross plate 14b and the circular steel pipe 12 to close the lower end of the circular steel pipe 12c.

[0079] Although the base plate 13 is formed in a circular shape, it is not limited thereto. It may be formed in other shapes, such as a square or octagon, as long as the lower ends of the cross plates 14b can be attached and the base plate 13 can be placed on the upper plate 52. This also applies to the base plate 13 in the first embodiment and other embodiments. The mounting holes 13a of the base plate 13 are provided in four regions defined by the cross plates 14b on the base plate 13. The mounting holes 13a are located inside a square region SS. Here, the square region SS is a region circumscribing the lower ends of the cross plates 14b connected to the upper surface of the base plate 13.

[0080] When the pedestal 12 has cross sections of various sizes and shapes as in this first modified example, the square area SS may be set for any cross section. Regardless of the cross section of the square area SS, the upper fastening members may be arranged inside the square area SS and the lower fastening members may be arranged outside the square area SS. This allows the lower foundation 23 and the upper foundation 24 to be rigidly joined, and the upper foundation 24 and the base plate 13 to be pin-jointed.

[0081] The mounting holes 52a are provided in an area defined by a middle portion 53A on the underside of the upper plate 52, which is divided into four areas. These divided areas are open to the outside. The mounting holes 52a are provided inside the rectangular area SS. The mounting holes 51b are provided in an area defined by a middle portion 53A on the top side of the base plate 51, which is divided into four areas. These divided areas are open to the outside. The mounting holes 51b are provided outside the rectangular area SS (FIG. 9).

[0082] (Second Modification of the First Embodiment) Figure 12A is a longitudinal side view showing the connection between the upper foundation 24 and the pedestal 12 according to a second modification, and Figure 12B is an enlarged longitudinal side view showing the upper fastening member shown in Figure 12A. The second modification differs from the first modification in that the circular steel pipe 12c does not have a connection portion 14, but rather the base plate 13 is directly attached to the underside of the circular steel pipe 12c. In the second modification, the inside of the circular steel pipe 12c is inaccessible from the outside. Therefore, heavy nuts 13b are welded to the upper surface of the base plate 13 in correspondence with the mounting holes 13a. Then, set bolts 26d are inserted into the mounting holes 52a, 13a from the underside of the upper plate 52 and fastened to the heavy nuts 13b (Figure 12A). The inner diameter of the mounting holes 52a in the upper plate 52 is preferably approximately 20 mm larger than the body of the set bolt 26d. In this configuration, the gap between the mounting hole 52a and the set bolt 26d allows the base plate 13 to be misaligned in the horizontal direction.

[0083] In this case, it is preferable to attach multiple washers 26e1, 26e2, and 26e3 to the head side of set bolt 26d ( FIG. 12B ). For example, washer 26e1 is disposed in contact with upper plate 52, has an outer diameter that contacts the periphery of mounting hole 52a, which has a relatively large diameter, and is relatively thick. Washer 26e2 is a tension indicator washer disposed between washers 26e1 and 26e3. Washer 26e3 is disposed on the head side of set bolt 26d and has normal hardness. This configuration allows set bolt 26d to be fastened to upper plate 52 and base plate 13 in a highly reliable manner.

[0084] Second Embodiment An overview of a plant 100 and a plant module (hereinafter also simply referred to as a "module") 10 in which a foundation construction method according to a second embodiment is used will be described with reference to Fig. 13. Fig. 13 is a schematic diagram illustrating a corner of a plant 100 in which a foundation construction method according to a comparative embodiment, which will be described later, is used. However, the overview of the transportation method for the plant 100 and the module 10, that is, matters other than the foundation construction method according to the second embodiment, have some commonalities between the second embodiment and the comparative embodiment, and therefore the description will be continued with reference to Fig. 13.

[0085] In the examples shown in the comparative example and the second embodiment, six foundations 2 are provided on the site S1 at intervals along the X direction shown in the drawings, and these six foundations 2 are arranged in four rows at intervals along the Y direction also shown in the drawings. As described above, pedestals 12 are provided on the bottom surface of the module 10 at positions corresponding to the positions of these foundations 2.

[0086] The modules 10 are transported to the site S1 via a transport path S2 within the plant 100 by a plurality of SPMTs (Self-Propelled Modular Transporters) 3 and installed on the foundation 2. In the example shown in Fig. 13, 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.

[0087] 14, 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.

[0088] However, when all of the foundations 2 are arranged in advance as shown in Figure 14, it is necessary to adjust the entry 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 entry 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.

[0089] 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.

[0090] 13 and 14 are perspective and plan views illustrating the transport of a module 10 to site S1 in a comparative embodiment. The bold arrows in FIG. 13 indicate part of the travel path of the illustrated module 10, and this is the same in the subsequent figures. As shown in FIG. 14, the aspect ratios of the modules 10 when viewed from above are significantly different. On the other hand, 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.

[0091] 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 of the transport path S2 that prevents the SPMT 3 and module 10 from interfering with other modules and equipment on either side, the module 10 can pass through the transport path S2.

[0092] 13 and 14, 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.

[0093] 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.

[0094] 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.

[0095] The construction of the foundation 2 and delivery of the SPMT 3 in the second embodiment, which can solve the above problems, will be explained using the plan views of Figures 15 to 20. Of these figures, the foundation 2 with diagonal lines in Figure 19 indicates a state in which the pedestal 12 is placed above, and the foundation 2 with cross lines in Figure 20 indicates a state in which the pedestal 12 is connected.

[0096] As shown in FIG. 15 , 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 the second embodiment, the site S1 is divided into an interference area, in which foundations 2 are provided at 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 provided at 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 provided in the non-interference area may be referred to as "non-interference foundations 21," and foundations 2 provided in the interference area may be referred to as "interference foundations 22."

[0097] 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 along which the SPMT 3 travels 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 14, the interference area can be said to be set as an area into which the SPMT 3 will turn immediately after entering the site S1.

[0098] The non-interference area refers to an area other than the interference area within the site S1. Also, referring to Figure 14, the non-interference area can 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.

[0099] 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 a lower 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 lower foundation 23 (Figure 23). The lower foundation 23 and the upper foundation 24 are constructed at different times.

[0100] 15 , in the second 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 lower foundation 23 of the interference foundation 22 is constructed, and the upper foundation 24 that protrudes from 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).

[0101] A protective member is provided above the lower foundation 23 of the interference foundation 22 to protect the lower foundation 23 when the SPMT 3 passes through. In the second embodiment, as shown in Figure 21, 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 21).

[0102] The protective member 42 is carried by, for example, a worker and placed above the lower 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 lower 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.

[0103] Next, as shown in FIG. 16 , each SPMT 3 is moved straight toward the non-interference area, entering along the gaps between the rows of non-interference foundations 21. Furthermore, as shown in FIG. 17 , as each SPMT 3 is moved 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.

[0104] Next, as shown in Figure 18, 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 using heavy machinery, and then the protective members 42 are removed by workers. The upper foundations 24 are then connected to the exposed lower 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.

[0105] Next, as shown in Figure 19, 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 end 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 end 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.

[0106] Next, 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-interference foundation 21, interference foundation 22), and each foundation 2 is connected to each pedestal 12 (FIGS. 20 and 24). Thereafter, the loading platform 31 is further lowered and positioned sufficiently below the bottom beams 11 of the modules 10, and each SPMT 3 is moved outward from the area directly below the modules 10 and removed from the site S1.

[0107] As described above, according to the construction method for the foundation 2 in the second embodiment, construction of the interference foundation 22 (connection of the upper foundation 24 to the lower 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 modules 10 can be transported in.

[0108] 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 21 to 24. Figure 21 is a longitudinal side view showing the non-interference foundation 21 and lower 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 16. In addition, in Figure 21, 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 22 is an enlarged plan view of the lower foundation 23 in Figure 21, with the steel plate 41 indicated by a dashed line.

[0109] As shown in Figure 21, 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.

[0110] 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.

[0111] Next, the interference foundation 22 will be described. As described above, the interference foundation 22 is composed of a lower foundation 23 and an upper foundation 24. As with the non-interference foundation 21, the lower foundation 23 and the upper foundation 24 are made of, for example, steel. The lower 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.

[0112] 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 member) 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.

[0113] 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.

[0114] The frame-shaped body 44 is configured, for example, in a polygonal shape (octagonal in the example shown in FIG. 22 ) in a plan view. The frame-shaped body 44 is disposed, for example, on the upper surface of the head 22 b on the interference footing 22 disposed underground so as to surround the periphery of the head plate 22 c, with the outside of the frame-shaped body 44 buried underground. In the example shown in FIG. 22 , 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 22 c, for example, passing through the gaps between adjacent set bolts 22 d.

[0115] 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.

[0116] In this way, the heads 22b and set bolts 22d of the lower foundation 23 are protected using the protective members 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 23 and 24. Figure 23 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 19. Figure 24 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 20.

[0117] 23, 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.

[0118] 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 lower foundation 23.

[0119] The upper end of the upper foundation 24 has a shape similar to the head 21b of the non-interfering foundation 21, 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 lower 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 of the non-interfering foundation 21.

[0120] After the upper foundation 24 has been connected to the lower foundation 23, the corresponding pedestals 12 are positioned above each non-interfering foundation 21 and each interfering foundation 22, as shown in Figures 23 and 24, and then the 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 foundation 2 construction method of the second 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 peripheral area of ​​the site S1.

[0121] The structures of the non-interference foundation 21 and the interference foundation 22 described using Figures 21, 23, and 24 are merely examples. Therefore, the structure of the interference foundation 22 may be configured similarly to the foundation 2 of the first embodiment described above. In that case, the lower foundation 23 is constructed before the SPMT 3 passes, and the upper foundation 24 is constructed after the SPMT 3 passes. In addition to the pile foundation shown as an example, various structures may be used, such as a spread foundation, and even precast concrete instead of steel, and a structure such as the interference foundation 22M described below as an example may also be used.

[0122] Furthermore, the interference foundation 22 in the second embodiment employs a divided structure consisting of a lower foundation 23 and an upper foundation 24, and the non-interference foundation 21 and the lower foundation 23 are constructed first before the SPMT 3 passes, thereby improving the efficiency of the construction of the foundation 2. However, this configuration is not the only option. For example, the interference foundation 22 may have an integrated structure similar to the non-interference foundation 21, and in this case, construction may be carried out from pile driving to connecting the head after the SPMT 3 passes. The non-interference foundation 21 may also be constructed of a lower foundation 23 and an upper foundation 24, similar to the interference foundation 22. Alternatively, pile driving may be performed together with the non-interference foundation 21, with the upper part protected by a steel plate 41, and the head part 21b may be connected to the pile after the SPMT 3 passes.

[0123] Furthermore, the structure of the wooden protective member 42 described with reference to FIG. 21 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. Furthermore, as long as strength can be ensured, as with the concrete protective member 43 described below, placing the steel plate 41 on its upper surface is not a necessary requirement. Furthermore, the protective member 42 is not a necessary requirement, and the constructed lower foundation 23 may be filled with sand, and the steel plate 41 may be placed on top of it. The sand and steel plate 41 can be removed after the SPMT 3 has passed.

[0124] The standby position of the SPMT3 is illustrated as an adjacent area S3 (including another adjacent area S4 described later using Figures 25A and 25B) along the approach direction to the site S1, but is not limited to these examples. 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 SPMT3 located next to the standby position by, for example, 90 degrees.

[0125] 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.

[0126] 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.

[0127] 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 14, 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.

[0128] The travel of the SPMT 3 and the construction procedure for the upper foundation 24 in the second embodiment 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 will be described below.

[0129] 25A and 25B 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. 14 , so the interference area (the area where the interference foundations 22 are located) is wider. Specifically, of all the foundations 2, the non-interference area is the area where the four non-interference foundations 21 are located at the farthest rear along the Y direction, spaced apart from each other, as viewed from the front side in the direction of entry of the SPMT 3. Within the remaining interference area, four rows of five interference foundations 22 are arranged along the X direction, spaced apart from each other.

[0130] An example of a method for installing an interference foundation 22 within such a wide interference area will be described below. As shown in FIG. 25A , 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. 25A , 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. 25B ).

[0131] 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 25B) and waits in a state where it is retracted from the interference area where no upper foundation 24 is installed. As shown in Figures 25A and 25B, 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.

[0132] 25B, upper foundations 24 are constructed in the interference areas after the SPMTs 3 are evacuated. Once all of the 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.

[0133] The embodiments described above using Figures 15 to 25B 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 26 is a longitudinal side view showing the configuration of another example of an interference foundation 22M. Unlike the example shown in Figure 23, the lower foundation 23M constituting the interference foundation 22M in the example shown in Figure 26 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.

[0134] 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.

[0135] 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 21 and 22. Figures 27 and 28 are longitudinal side views showing the procedure for forming the protective member 43. As shown in Figure 27, 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.

[0136] 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 28, 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.

[0137] Another procedure for forming the protective member 43M will be described with reference to Figure 29. 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.

[0138] 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 30(a) to 30(c) and 31(a) to 31(c) are longitudinal side views showing other construction procedures for the upper foundation 24. In Figure 30(a), the steel plate 41 is not shown.

[0139] 30(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.

[0140] As shown in Figures 30(a) and (b), a train of SPMTs 3 advancing toward the standby position stops, for example, with its tail end resting on the lower foundation 23 that is the construction target of the upper foundation 24. Then, after the steel plate 41 is removed using a jack, the hook 32 is positioned above the protective member 43. Next, as shown in Figure 30(c), the end of the rope hooked onto the hook 32 is tied to the handle 49 (Figure 28, etc.) of the protective member 43, and the protective member 43 is lifted and removed from the lower foundation 23.

[0141] 31(a) and 31(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 positioned above the lower foundation 23. The SPMT 3 is then lowered and connected to the lower foundation 23. Thereafter, as shown in FIG. 31(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 carried out.

[0142] In the second embodiment described above using Figures 21, 23, etc., an example was shown in which the foundation 2 was provided on a flat site S1. However, this is not limited to these cases, and the module 10 can also be installed on a site S1 with a slope, for example. Figure 32 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 to support the module 10 horizontally on the site S1.

[0143] For this reason, the upper foundations 24 connected to the lower foundations 23M are prepared to have different lengths depending on the height of the upper end of the lower foundation 23M. That is, a longer upper foundation 24 is connected to the lower foundation 23M located on the lower side of the inclined surface, and a shorter upper foundation 24 is connected to the lower foundation 23M located on the upper side of the inclined surface.

[0144] According to this example, the upper end of the upper foundation 24 is positioned at a predetermined height, so that the module 10 can be installed horizontally even on a site S1 that has an inclined surface.

[0145] 2, 2m Foundation 3 SPMT 10 Module 11 Bottom beam 12 Column 12a Web 12b Flange 12c Circular steel pipe 13 Base plate 13a Mounting hole 13b Heavy nut 14 Connection portion 14a End plate 14b Cross plate 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 Lower foundation 24 Upper foundation 24a Base plate 25a Anchor bolt 25b Footing 25c Key groove 25d Slope portion 26a Height adjustment member 26b Fixing member 26c Washer 26d Set bolt 26e Washer 26e1 to 26e3 Washers 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 51 Base plate 51a Shear key 51b Mounting hole 52 Upper plate 52a Mounting hole 53, 53A Middle portion 54 Main plate 55 Side plate 100 Plant S1 Site S2 Transport path S3, S4 Adjacent area SS Rectangular area

Claims

1. A method for installing a plant module having a frame structure supported by a plurality of pillars, comprising the steps of: fixing a plurality of lower foundations spaced apart from one another on a site on which the plant module is to be installed at positions corresponding to the plurality of pillars; fixing upper foundations for supporting the pillars on each of the plurality of lower foundations; placing the pillars on the upper foundations; and restraining and supporting the pillars on the upper foundations so as to restrain movement of the pillars relative to the upper foundations.

2. The plant module installation method according to claim 1, wherein the lower foundation and the upper foundation, and the upper foundation and the support column are fastened to each other using fastening members.

3. The plant module installation method according to claim 2, wherein the fastening members fastening the upper foundation and the support columns are arranged inside a rectangle circumscribing the cross section of the support column.

4. The plant module installation method according to claim 3, wherein the fastening members fastening the lower foundation and the upper foundation are arranged outside a rectangle circumscribing the cross section of the support member.

5. A method for constructing a foundation for a plant module installed by the installation method described in claim 1, comprising the steps of: when, at a site where a plurality of foundations are to be installed, a cart loaded with the plant modules moves along a predetermined moving path on the site and a portion of the plurality of foundations is positioned in a position that will interfere with the cart; constructing the foundation in a non-interference area where the foundation will be installed 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 foundation in an interference area where the foundation will be installed so as to interfere with the cart.

6. A foundation construction method as described in claim 5, 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 carriage when entering the site, and when the carriage enters the site, the carriage passes through at least a portion of the interference area and waits at the waiting position.

7. A foundation construction method according to claim 6, 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.

8. A foundation construction method as described in claim 6, 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.

9. A foundation construction method as described in claim 5, comprising a step of constructing the lower foundation underground in the interference area of ​​the site before the carriage enters the site, wherein the step of constructing the foundation includes attaching the upper foundation on top of the lower foundation.

10. The foundation construction method according to claim 9, wherein the upper foundation is carried in together with the plant module by the cart.

11. A foundation construction method as described in claim 10, 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 lower foundation, and in the step of constructing the foundation, the upper foundation is lowered from the cart and attached to the lower foundation.

12. A foundation construction method as described in claim 9, comprising a step of placing a protective member on the lower foundation to protect the lower foundation when the bogie passes above the lower foundation after the lower foundation has been constructed.

13. A foundation construction method as described in claim 12, wherein the protective member is made of wood and includes a frame-shaped body arranged to surround a connecting portion provided on the lower foundation side to connect the lower foundation and the upper foundation, and a beam connecting the inner wall surfaces of the frame-shaped body.

14. A foundation construction method as described in claim 13, wherein the lower foundation has a support member for supporting the upper foundation, the connecting portion is a plurality of bolts arranged at intervals along the periphery of the support member and protruding above the top surface of the support member, and the beam is arranged between adjacent bolts.

15. A foundation construction method as described in claim 12, wherein the protective member includes a protective cap installed to cover the connecting portion and a concrete lid poured on the protective cap.

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

17. A method for installing a plant module, comprising the steps of: constructing the foundations in the interference area as described in claim 5, and then moving the cart to position the plant module above the multiple foundations; and then lowering the plant module using a platform lifting mechanism provided on the cart, and installing the plant module on the multiple foundations.

18. A plurality of module foundations for placing plant modules having a frame structure supported by a plurality of columns, the plurality of module foundations being provided on a site on which the plant modules are to be installed, spaced apart from one another at positions corresponding to the plurality of columns, and each of the plurality of module foundations comprising a lower foundation fixed to the site, and an upper foundation provided on the lower foundation and on which the columns are placed.

19. The modular foundation described in claim 18, wherein the lower foundation and the upper foundation, and the upper foundation and the support column are fastened to each other using fastening members, and the fastening members fastening the upper foundation and the support column are arranged inside a rectangle circumscribing the member cross section of the support column.

20. The modular foundation according to claim 19, wherein the fastening members fastening the lower foundation and the upper foundation are arranged outside a rectangle circumscribing the member cross section of the support.

Images