Modular operating centers and methods of building same for use in electric power generating plants and other industrial and commercial plants, processes and systems

Abstract

Modular operating centers for use in electric power generating plants and other industrial and commercial plants, processes and systems are constructed by using a novel prefabricated modular technique. This technique includes loading a plurality of transportable room-size building modules with control system equipment at a factory site. Typically, the control system equipment includes sophisticated and complex electrical and electronics data processing and control equipment. The control system equipment is installed and bolted down in the different building modules and the equipment in each module is inter-wired at the factory site. Temporary inter-module connections are established between the control system equipment in different ones of the building modules and such equipment, as a whole, is then thoroughly tested and adjusted under simulated use conditions. Thereafter, the loaded and tested building modules are separated and separately transported to the industrial or commercial installation site. At the installation site, the building modules are joined together to form an integral weatherproof building structure and the inter-module control system equipment connections are re-established to provide a tested and substantially ready-to-go control center for the plant, process or system in question. A novel feature of this technique is that structural building modules are used as the shipping containers for transporting complex electrical and electronics equipment to the final installation site.

What is claimed is: .[.1. A method of building an operating center for a plant designed to produce goods or services, the steps of said method comprising: 
     
        interfacing sides of adjacent building modules..]. .[.27.  A method of building an electrical operating center for a power plant in accordance with claim 24 and further including: providing walkways between the cabinet rows and providing intramodule connections between cabinets in different rows through cables housed in cable trays which are supported to extend over and between adjacent cabinet rows..]. .[.28. A method of building an electrical operating center for a power plant in accordance with claim 24 and further including:   joining the building modules together to form an integral weatherproofed building structure at the power plant site, and connecting power plant cables from the module plant connecting points to the plant equipment including the plant prime mover and steam generation equipment..]. .[.29. A method of building an operating center for an electric power plant as set forth in claim 24 wherein the power plant is a combined cycle plant having at least one gas turbine and one steam turbine and a steam generator..]. .[.30. Apparatus for a prefabricated operating center for an industrial plant, process or system comprising:   a plurality of transportable room-size building modules each including a three-dimensional, rectangular metal frame structure and being adapted to be transported to and joined together at an industrial installation site to form a unitary operating center building;   electrical control system equipment items for use in monitoring and/or controlling the operation of a plant designed to produce goods or services, some of which control system equipment items are installed in one of the building modules and other of which control system equipment items are installed in another of the building modules before shipment to the installation site;   a plurality of conductors for establishing predetermined connections between equipment items in the same module;   a plurality of cables having plural conductors for establishing predetermined connections between equipment items in different modules and between equipment items and the plant equipment; and connection means for connecting and disconnecting intermodule and module-plant cable connections to enable factory site testing of the control equipment items while cable connections are established and to enable separation of the modules for shipment to the plant site,   and means for applying plant simulation test signals to the control system items at the factory site, said test means being detached from said modules prior to module shipment..]. .[.31. Apparatus for an operating center as set forth in claim 30 wherein permanent closure means is secured to and closes the roof and floor and some but not all sides of the frame structure, any side not so closed being one that will abut another module in forming the complete operating center building, and temporary closure means secured to the open module sides when the modules are separated for shipment..]. .[.32. Apparatus for an operating center as set forth in claim 25 wherein the control equipment units are housed in cabinets secured to the module flooring and arranged in rows which cross through the interfacing sides of adjacent building modules..]. .[.33. Apparatus for an operating center as set forth in claim 32 wherein walkways are provided between the cabinet rows and cable trays are supported over the cabinets to support cables carrying conductors for connections between equipment items in different cabinet rows..]. .[.34. A prefabricated operating center as set forth in claim 30 wherein the plant is an electric power generating plant which employs steam to drive at least one prime mover and the plant cables provide for operating center connections to the plant equipment including prime mover equipment and team generation equipment..]. .[.35. An electric power generating plant comprising:   electric generator equipment for producing electricity;   turbine equipment for driving the generator equipment;   at least one steam generator for producing motive steam for at least some of said turbine equipment;   a plurality of transportable room-size building modules installed at the plant site to form a unitary control center housing;   control system equipment for monitoring and controlling the operation of at least the generator and turbine equipment, such control system equipment being installed within the building modules before shipment of the building modules to the plant site;   connector cables for connecting the control system equipment to the generator and turbine equipment;   connector cables for making predetermined connections between control system equipment items in different building modules;   and means for applying plant simulation test signals to the control system items at the factory site, said test means being detached from said modules prior to module shipment..]. .[.36. Apparatus for a power plant as set forth in claim 35 wherein the plant is a combined cycle plant having at least one gas turbine and one steam turbine and steam generator equipment and the plant cables further provide predetermined connections from the control equipment items to the steam generator equipment..]. .Iadd. 37. A method of building an operating center for a plant designed to produce goods or services, the steps of said method comprising:   forming a plurality of building modules, each as a transportable, room-size, three-dimensional, rectangular, metal frame structure;   securing permanent closure means to and closing the roof and floor on some but not all of the sides of the frame structure, any side not so closed being one that will abut another module and forming a complete operating center building;   1oading each of said modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building modules;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such test including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site;   and installing the modules and establishing the cable connections from the modules to the plant points and re-establishing the intermodules cable connection. .Iaddend..Iadd. 38. A method of building an operating center in accordance with claim 37 wherein the preparing of the loaded building modules for transportation to the installation site includes the securing of temporary closure means to the sides of the building modules not closed by permanent closure means thereby enabling the building module to be its own shipping container for the housed control equipment. .Iaddend..Iadd. 39. A method of building an operating center for a plant designed to produce goods or services, the steps of said method comprising:   1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   housing the control equipment in cabinets and securing the cabinets to a floor of the operating center in cabinet rows which cross through the interfacing sides of adjacent building modules;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site; p1 and installing the modules and establishing the cable connections from the modules to the plant points and re-establishing the intermodules cable connection. .Iaddend.   
     
     
        .Iadd. 40.  A method of building an operating center for a production plant as set forth in claim 39 and further including: providing walkways between the cabinet rows and providing intramodule connections between cabinets in different rows through cables housed in cable trays which are supported to extend over and between adjacent cabinet rows. .Iaddend..Iadd. 41. A method of building an operating center for a plant designed to produce goods or services, the steps of said method comprising:   1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant.   providing each building module with vertical side wall beams prior to assembly with each other and removing predetermined ones of said beams from the interfacing sides of assembled modules;   establishing at the factory site predetermined intramodule connections among the control equipment units withine each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site;   and installing the modules and establishing the cable connections from the modules to the plant points and re-establishing the intermodules cable   
     
     
        connection. .Iaddend..Iadd. 42.  A method of building an operating center for a plant designed to produce goods or services, the steps of said method comprising: 1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermiined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   separately transporting each loaded building module to the installation site by lifting the same onto a truck trailer and hauling the loaded trailer to the installation site by a tractor-type truck unit;   and installing the modules and establishing the cable connections from the modules to the plant points and re-establishing the intermodule cable   
     
     
        connections. .Iaddend..Iadd. 43.  A method of building an operating center for a plant designed to produce goods or services, the steps of said method comprising: 1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site;   and installing the loaded building modules at the installation site, including joining the building modules together to form an integral weatherproofed building structure, and establishing the cable connections from the modules to the plant points and re-establishing the intermodule cable connections. .Iaddend. .Iadd.44. A method of building an operating center for an electrical power generating plant which employs steam to drive at least one prime mover, the steps of said method comprising:   forming a plurality of building modules as transportable, room-size, three-dimensional, rectangular, metal frame structures;   securing permanent closure means to and closing the roof and floor and some but not all sides of the frame structure, any side not so closed being one that will abut another module and forming a complete operating center building;   1oading each of said modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the electrical plant;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site;   and installing the modules and establishing cable connections from the modules to the plant points, including prime mover equipment and steam generation equipment, and re-establishing the intermodule cable connection. .Iaddend. .Iadd.45. A method of building an electrical operating center for an electrical power generating plant which employs steam to drive at least one prime mover, the steps of said method comprising:   1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to a plant installation site including disconnecting the intermodule and test connections at the cable connection points and securing of temporary closure means to the sides of the building modules not closed by permanent closure means thereby enabling the building module to be its own shipping container for the housed control equipment;   and installing the modules and establishing the cable connections from the module to the plant points, including operating center connections to the plant equipment including prime mover equipment and steam generation equipment, and re-establishing the intermodule cable connection. .Iaddend.   
     
     
        .Iadd.46.  A method of building an electrical operating center for an electrical power generating plant which employs steam to drive at least one prime mover, the steps of said method comprising: 1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   housing the control equipment units in cabinets and securing the cabinets to a floor of the operating center in cabinet rows which cross through the interfacing sides of adjacent building modules;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site;   and installing the modules and establishing the cable connections from the modules to the plant points, including operating center connections to the plant equipment including prime mover equipment and steam generation equipment, and re-establishing the intermodule cable connections.   
     
     
        .Iaddend. .Iadd.47.  A method of building an electrical operating center for a power plant in accordance with claim 46 and further including: providing walkways between the cabinet rows and providing intramodule connections between cabinets in different rows through cables housed in cable trays which are supported to extend over and between adjacent cabinet rows. .Iaddend. .Iadd.48. A method of building an electrical operating center for an electrical power generating plant which employs steam to drive at least one prime mover, the steps of said method comprising:   1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   housing the control equipment units in cabinets and securing the cabinets to a floor of the operating center in cabinet rows which cross through the interfacing sides of the adjacent building modules;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control equipment at the factory site, such testing including the combined testing of the control equipment interconnected by the intermodule cable connections, employing an electronic simulator to simulate the plant operation, applying output test signals from the simulator to the equipment units, and applying signals from the equipment units to the simulator;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points and securing of temporary closure means to the sides of the building modules not closed by permanent closure means thereby enabling the building module to be its own shipping container for the housed control equipment;   transporting the modules to the plant site;   and installing the modules and establishing the cable connections from the modules to the plant points, including operating center connections to the plant equipment including prime mover equipment and steam generation equipment, and re-establishing the intermodule cable connections. .Iaddend. .Iadd.49. The method of building an electrical operating center for an electrical power generating plant which employs steam to drive at least one prime mover, the steps of said method comprising:   1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   providing walkways between the cabinet rows and providing intramodule connections between cabinets in different rows through cables housed in cable trays which are supported to extend over and between adjacent cabinet rows;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control equipment at the factory site, such testing including the combined testing of the control equipment interconnected by the intermodule cable connections, employing an electronic simulator to simulate the plant operation, applying output test signals from the simulator to the equipment units, and applying signals from the equipment units to the simulator;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site;   and installing the modules and establishing the cable connections from the modules to the plant points, including operating center connections to the plant equipment including prime mover equipment and steam generation equipment, and re-establishing the intermodule cable connections. .Iaddend. .Iadd.50. A method of building an electrical operating center for an electrical power generating plant which employs steam to drive at least one prime mover, the steps of said method comprising:   1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control equipment at the factory site, such testing including the combined testing of the control equipment interconnected by the intermodule cable connections, employing an electronic simulator to simulate the plant operation, applying output test signals from the simulator to the equipment units, and applying the signals from the equipment units to the simulator;   preparing the loaded building modules for transportation to the plant installation site including disconnecting the intermodule and any test connections at the cable connection points;   transporting the modules to the plant site;   joining the building modules together to form an integral waterproofed building structure at the power plant site, and interconnecting power plant cables from the module plant connecting points to the plant equipment including the plant prime mover and steam generating equipment. .Iaddend. .Iadd.51. Apparatus for a prefabricated operating center for an industrial plant, process or system comprising:   a plurality of transportable room-size building modules each including a three-dimensional, rectangular metal frame structure and being adapted to be transported to and joined together at an industrial installation site to form a unitary operating center building;   permanent closure means secured to and closing the roof and floor and some but not all sides of certain of the frame structures, any side not so closed being one that will abut another module in forming the complete operating building, and temporary closure means secured to the open module sides when the modules are separated for shipment;   electrical control system equipment items for use in monitoring and/or controlling the operation of a plant designed to produce goods or services, some of which control system equipment items are installed in one of the building modules and other of which control system equipment items are installed in another of the building modules before shipment to the installation site;   a plurality of conductors for establishing predetermined connections between equipment items in the same module;   a plurality of cables having plural conductors for establishing predetermined connections between equipment items in different modules and between equipment items and the plant equipment; and   connection means for connecting and disconnecting intermodule and module-plant cable connections to enable factory site testing of the control equipment items while cable connections are established and to enable separation of the modules for shipment to the plant site;   and means for applying plant simulation test signals to the control system items at the factory site, said test means being detached from said modules prior to module shipment. .Iaddend. .Iadd.52. A method of building an electrical operating center for an electrical power generating plant which employs steam to drive at least one prime mover, the steps of said method comprising:   1oading each of a plurality of transportable room-size building modules with predetermined electrical control system equipment units at a factory site, such building modules constituting structural parts of a unitary operating center building and such control system equipment units constituting parts of a system for use in monitoring and/or controlling the operation of the production plant;   housing the control equipment in cabinets adhered to the module flooring and arranged in rows which cross the interfacing sides of building modules with walkways provided between the cabinet rows and cable trays supported over the cabinets to support cables carrying connectors for connection between equipment items in different cabinet rows;   establishing at the factory site predetermined intramodule connections among the control equipment units within each building module;   establishing at the factory site predetermined intermodule connections among the control system equipment units in different ones of the building modules;   establishing at the factory site predetermined connections to the control system equipment units for ultimate attachment from one or more of the modules to the production plant at predetermined plant points;   employing a plurality of conductors to establish the intramodule connections;   employing a plurality of cables having a plurality of conductors to establish the intermodule and plant connections through cable connection points;   testing the control system equipment at the factory site, such testing including the combined testing of the control system equipment interconnected by the intermodule cable connections, including employing an electronic simulator to simulate the plant operation, applying output test signals from the simulator to the equipment units and applying signals from the control equipment units to the simulator through the module and cable connections;   preparing the loaded building modules for transportation to the plant installation site including disconnect- the intermodule test connections at the cable connection points;   transporting the modules to the plant site;   and installing the modules and establishing the cable connections from the modules to the plant points including operating center connections to the plant equipment including prime mover equipment and steam generation equipment, and re-establishing the intermodule cable connections. .Iaddend.