Abstract
Cover systems for storage tanks, such as those containing at least some petroleum. Pipe retention systems for retaining pipes to storage tanks, such as pipes that can transmit liquid containing at least some petroleum. Methods of attaching cover systems to tanks.
Claims
1. A method of covering a storage tank, comprising: attaching a hydrocarbon-resistant liner to a storage tank, where the liner covers an interior bottom and one or more side walls of the tank to prevent contact between an inner surface of the tank and contents within the tank, the one or more side walls being perpendicular to the bottom and comprising one or more of concrete, fiberglass, and steel, and the liner extending to at least a top of the one or more side walls of the tank; and attaching a hydrocarbon-resistant geomembrane to the tank, where the geomembrane covers a majority of the tank and the contents of the tank, the contents comprising fluid that includes petroleum that is under the geomembrane and over the liner; wherein the liner is sufficiently flexible that at least portions thereof can fold over on themselves without destroying the liner, and the geomembrane is sufficiently flexible that at least portions thereof can fold over on themselves without destroying the geomembrane.
2. The method of claim 1, further comprising: attaching at least one float to the hydrocarbon-resistant geomembrane; and positioning at least one weight on the hydrocarbon-resistant geomembrane.
3. The method of claim 2, where the attaching at least one float comprises attaching floats to the hydrocarbon-resistant geomembrane.
4. The method of claim 3, wherein the floats are attached to a top surface of the hydrocarbon-resistant geomembrane.
5. The method of claim 3, wherein the floats are attached to a bottom surface of the hydrocarbon-resistant geomembrane.
6. The method of claim 3, where the positioning at least one weight comprises positioning weights on the hydrocarbon-resistant geomembrane.
7. The method of claim 2, where the positioning at least one weight comprises positioning weights on the hydrocarbon-resistant geomembrane.
Description
BRIEF DESCRIPTION OF THE DRAWING
(1) The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers.
(2) FIG. 1 is a top view of one embodiment of the present cover systems coupled to a liquid storage tank.
(3) FIGS. 2A, 2B and 2C are sectional views of the cover system and liquid storage tank of FIG. 1 in full, partially full, and empty profiles, respectively.
(4) FIG. 3 is a top view of another embodiment of the present cover systems coupled to a liquid storage tank.
(5) FIG. 4 is a top view of still another embodiment of the present cover systems coupled to a liquid storage tank.
(6) FIGS. 5A, 5B and 5C are sectional views of the cover system and liquid storage tank of FIG. 4 in full, partially full, and empty profiles, respectively.
(7) FIG. 6 is a sectional view of a detail of one embodiment of the present cover systems that is coupled to a liquid storage tank, showing the attachment of a flexible membrane of the cover system to the side wall of the liquid storage tank.
(8) FIG. 7 is a sectional view of a detail of one embodiment of the present cover systems, showing a lateral float positioned under and coupled to a flexible membrane of the cover system.
(9) FIG. 8A is a sectional view of a detail of another embodiment of the present cover systems, showing a lateral float positioned under and coupled to a flexible membrane of the cover system in a different manner than is illustrated in FIG. 7.
(10) FIG. 8B is a sectional view of a detail of another embodiment of the present cover systems, showing a lateral float positioned on top of and coupled to a flexible membrane of the cover system in a different manner than is illustrated in FIG. 7.
(11) FIG. 9 is a perspective view of an embodiment of a sump collector that can be a part of one of the present cover systems.
(12) FIG. 10 is a perspective view of another embodiment of a sump collector that can be a part of one of the present cover systems.
(13) FIG. 11 is a perspective view of one embodiment of a ballast tube that can be a part of one embodiment of the present cover systems.
(14) FIG. 12 is a top view showing one embodiment of the present pipe retention member coupled to a tank flange of a liquid storage tank and helping to secure multiple pipes relative to the liquid storage tank.
(15) FIG. 13 is a side sectional view of the pipe retention member and one of the pipes shown in FIG. 12.
(16) FIG. 14 is an enlarged detail view of the pipe retention member and one of the pipes shown in FIG. 12.
(17) FIG. 15 is a sectional view of a liner of the present cover systems coupled to a liquid storage tank.
(18) FIG. 16 is a side sectional view of a passive vent that can be a part of one of the present cover systems.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
(19) The following detailed description and drawings provide some non-limiting and non-exhaustive embodiments of the present cover systems, tank covering methods, and pipe retention systems. Embodiments of the present cover systems may be coupled to liquid storage tanks to cover liquid comprising oil, such as petroleum that is extracted from the earth through a process like hydraulic fracturing.
(20) Referring to FIGS. 1-2C, a tank cover system 100 for a storage tank 106 comprises a substantially liquid impervious flexible membrane 102. The flexible membrane may be formed of a geomembrane comprising a material which is petroleum-resistant, oil-resistant, hydrocarbon-resistant or otherwise resistant to exposure to oil or other chemicals. The geomembrane may be from 10 to 100 mil ( 1/1000th of an inch) thick. The flexible membrane 102 may comprise multiple pieces, each of which is attached to at least one other piece. The pieces may be fabricated from rolls that are 5 to 25 feet wide by seaming the panels together. The seams may be thermally welded, chemically bonded, or ultrasonically welded, or joined by any means that forms a substantially liquid impervious seal. Example of materials suitable for use as such geomembranes are XR-5® brand geomembranes, available from and/or made by Seamen Corporation (Wooster, Ohio).
(21) In an embodiment, a plurality of floats 118 are disposed under the bottom surface 120 of the flexible membrane 102. In the embodiment illustrated in FIG. 1, four floats 118 are provided and each float 118 extend radially inwardly from a perimeter 122 of the storage tank 106 toward a center 124 of the storage tank 106. In one embodiment, the length of the floats ranges from 10-50% of the diameter of the tank. The floats may be attached to the side wall 105 of the storage tank 106 or may be attached to the flexible membrane 102. The floats may be any size appropriate to support the flexible membrane. For example, they may be about 4 to 24 inches wide and 4 to 24 inches tall, and in one embodiment, they are 6″ tall×12″ wide.
(22) The floats 118 help lift the flexible membrane 102 when the storage liquid is added to the storage tank 106. The floats 118 also ensure that the flexible membrane 102 remains on the surface of the liquid if it is ripped, torn or otherwise leaks. Additionally, the floats 118 form gas flow channels (discussed further below) to channel gas vapor trapped under the flexible membrane 102 toward the perimeter 122 of the storage tank 106. They also help funnel rainwater or other liquids which may accumulate on the top surface of the flexible membrane 102 toward a sump 130 formed near the center 124 of the flexible membrane 102.
(23) In an embodiment, a plurality of ballast weights 126 are provided on the top surface 128 of the flexible membrane 102. The ballast weights 126 may be provided by themselves or may be provided in conjunction with the floats 118. In the embodiment illustrated in FIG. 1, the ballast weights 126 are arranged radially in a spoke like pattern in the center 124 of the storage tank 106 with cross arms 132. The ballast weights form a sump 130 in the center 124 of the flexible membrane 102. The sump 130 collects rainwater and other liquids which may accumulate on the top surface 128 of the flexible membrane 102. The ballast weights 126 prevent the flexible membrane 102 from lifting off the surface of the liquid in high winds or the like. The ballast weights 126 may be sand-filled tubes, as will be discussed in further detail below.
(24) The cover system 100 may be used to cover a liquid storage tank 106 in accordance with an exemplary embodiment. The liquid storage tank 106 has a side wall 105 which extends upwardly from a bottom wall 104. The side wall 105 and bottom wall 104 may be formed of any suitable substantially liquid impervious material. The bottom wall 104 may be formed by placing a substantially liquid impervious membrane on a surface, such as packed earth. The storage tank may be any size, and in one embodiment is 120 feet in diameter. The side wall 105 may be modular so that the storage tank 106 may be easily assembled and disassembled for transportation, construction and use. In an embodiment, the modules may be approximately 12 feet tall by 15 feet long. The storage tank may be constructed of concrete, fiberglass, steel or any other suitable material. The tank may be any desired shape, including circular, square or rectangular.
(25) In an embodiment illustrated in FIG. 15, a lining 600 is provided for the tank 106 to cover the bottom wall and side wall of the tank. The liner is secured at or near a top of the tank wall. The lining 600 prevents contact between the contents of the tank and an inner surface of the tank. The lining 600 may be a flexible membrane, and in one embodiment, comprises a geomembrane which is petroleum-resistant, oil-resistant, hydrocarbon-resistant or otherwise resistant to exposure to oil or other chemicals.
(26) In one embodiment, shown in FIG. 6, a flange member 110 extends laterally from the top edge 108 of the side wall 105. The flange member may be substantially horizontal. The flexible membrane 102 is sealed to the top of flange member 110. The flexible membrane 102 may be attached by one or more batten bars 114 which comprise openings for bolts 112 or other fasteners. The flexible membrane 102 may comprise openings to allow passage of the bolts 112. The openings may be located on the perimeter 122 of the flexible membrane 102 within 2 feet of the perimeter 122 of the flexible membrane. The batten bars 114 may comprise angle iron. The batten bars 114 press the flexible membrane 102 firmly against the top flange member 110. A sealant (not illustrated) may be provided between the flexible membrane 102 and the top flange member 110. The sealant may be a flexible tape. The flexible membrane 102, bottom wall 104, and side wall 105 form a substantially sealed interior volume 116 for receiving a storage liquid.
(27) FIGS. 2A, 2B and 2C are sectional views of the liquid storage tank of FIG. 1 in full, partially full, and empty profiles, respectively. As seen in FIG. 2C, when the storage tank 106 is empty, the flexible membrane 102 rests on the bottom wall 104 of the tank. The flexible membrane 102 stretches across the tank. A vapor collection chamber 136 where vapors may accumulate and be transmitted from the floats is formed at the perimeter the tank between the side walls and the membrane. As seen in FIG. 2B, as the storage tank 106 is filled, the flexible membrane 102 floats on the surface of the liquid 134. As liquid 134 fills the storage tank 106, the vapor collection chamber 136 becomes smaller. As seen in FIG. 2A, when the storage tank 106 is full, the flexible membrane 102 floats on the surface of the liquid 134. The sump 130 forms a depression in the center of the flexible membrane 102. The plurality of ballast weights 126 direct water or other liquids on the top surface 128 of the flexible membrane 102 toward the sump 130. Further, when the storage tank 106 is substantially full, the vapor collection chamber 136 shrinks so that there is substantially no space for vapor to accumulate. A vent (not illustrated) may be provided to allow vapors to exit the vapor collection chamber 136.
(28) FIG. 3 is a plan view of a cover 300 in accordance with another exemplary embodiment. In the embodiment illustrated in FIG. 3, a plurality of floats 318 are arranged in a similar manner to the embodiment illustrated in FIG. 1. In this embodiment, the floats 318 may be disposed on top of the cover 300 and a plurality of ballast weights 326 are arranged in a different radial spoke like pattern (i.e., no arms are provided). Such a configuration may be suitable for a smaller diameter tank, such as a 60 feet diameter tank. One skilled in the art will recognize that other configurations of the ballast weights 326 are also possible. In other respects, the cover 300 functions like the previously described cover 100.
(29) FIG. 4 is a plan view of a cover 400 in accordance with another exemplary embodiment. In the embodiment illustrated in FIG. 4, a plurality of ballast weights 426 are disposed around the perimeter of the flexible membrane 402. Additionally, a plurality of ballast weights 426 extend inwardly from a perimeter 422 of the cover 400 toward a center 424 of the cover 400. A plurality of floats 418 are arranged in a radial, spoke like pattern at the center 424 of the cover.
(30) A vent 442 may be provided to vent any vapors which accumulate in the center 424 of the cover. The vent 442 may be a passive vent, as illustrated in FIG. 16. A passive vent is useful since power may be unreliable or may not be available at remote sites. As seen in FIG. 16, a passive vent 500 may comprise a gas discharge pipe 502 which is coupled to the interior of the storage tank. The vent 500 may be located at any convenient location and coupled via conduits to the area desired to be vented. For example, it may be placed at the side of the tank and coupled via conduits to the center of the cover. The gas discharge pipe 502 is coupled to a vent cylinder 504. In an embodiment, the vent cylinder 504 is a larger diameter than the gas discharge pipe 502 and forms a valve seat area 506. A vent seal plate 508 is disposed in the interior of the vent cylinder 504. The vent seal plate 508 is sized to fit into the interior of the valve cylinder 504 such that it may move up and down. A gasket 510 is disposed on the valve seat area 506. Gravity urges the vent seal plate toward the gasket to form a seal. When pressure inside the tank exceeds a certain amount, it overcomes the resistant to gravity, lifts the vent seal plate 508 and allows gas to escape (e.g., it “burps”). A rain and wind shroud 512 is provided to protect the interior of the vent cylinder 504 and minimize the accumulation of any undesirable liquids in the vent cylinder 504.
(31) FIGS. 5A, 5B and 5C are sectional views of the liquid storage tank of FIG. 4 in full, partially full, and empty profiles, respectively. The operation of the storage tank 400 is substantially similar to the operation of the tank 106, with two notable differences. First, the perimeter ballast weights 426 help take up any slack in the flexible membrane 102 as the storage tank is filled and emptied. Therefore, a vapor collection chamber is not formed at the perimeter of the storage tank 400, and vapor is directed toward the vent 442. Second, the sump 430 formed by the plurality of ballast weights 426 is formed at the perimeter of the storage tank 400.
(32) FIG. 7 is a sectional view of an embodiment of a float 118. The float 118 may be formed of foam (for instance, a closed cell foam) or any other material which is less dense than a liquid stored in the tank. To protect the float, it may be surrounded by a separate membrane 140, which may be formed of the same petroleum resistant geomembrane material as the flexible membrane 102 or of an HDPE material. The membrane 140 may be welded to the flexible membrane 102 with a weld 148 to couple the float to the flexible membrane 102. This construction forms vapor flow zones 138 between the surface of the liquid 134 and the membrane 140 on both sides of the float 118. Vapor may be collected in the vapor flow zones 138 and channeled to the vapor collection chamber 136 or a vent.
(33) FIG. 8A is a sectional view of another embodiment of a float 118. In this embodiment, the float 118 is attached to the flexible membrane 102 by forming a pocket 142 with a membrane 140 welded to the flexible membrane 102. The membrane 140 may be formed of the same petroleum resistant geomembrane material as the flexible membrane 102 or of an HDPE material. The membrane 140 may be continuously welded with welds 148 to the flexible membrane 102 to surround the float 118 and couple the float 118 to the flexible membrane 102. This construction forms vapor flow zones 138 between the surface of the liquid 134 and the membrane 140 on both sides of the float 118. Vapor may be collected in the vapor flow zones 138 and channeled to the vapor collection chamber 136 or a vent.
(34) FIG. 8B is a sectional view of another embodiment of a float 118. In this embodiment, the float 118 is attached to the flexible membrane 102 by forming a pocket 142 with a membrane 140 welded to the top surface of the flexible membrane 102. The membrane 140 may be formed of the same petroleum resistant geomembrane material as the flexible membrane 102 or of an HDPE material. The membrane 140 may be continuously welded with welds 148 to the flexible membrane 102 to surround the float 118 and couple the float 118 to the flexible membrane 102.
(35) FIG. 9 is a perspective view of an embodiment of one embodiment of a sump collector 900 for placement into the sump 130. The sump collector 900 comprises a sump bucket 904 which is open to allow access to the interior of the sump collector 900 for a hose or submersible pump to be introduced into the sump bucket 904. In one embodiment, the sump bucket 904 may be about 6″ to 36″ in diameter or square, 1-ft to 6-ft tall, and is fenestrated to allow water to enter to a pump that is placed inside the sump collector. The pump may be connected to a conduit that extends over the side of the tank (and preferably into a drainage area) to pump off the water and other liquid that collects in the sump. In one particular embodiment, the sump bucket 904 comprises a 16″ diameter×3-ft tall plastic pipe with several hundred ½″ holes. A plurality of legs 902 may be attached to the sump bucket 904 to hold the sump bucket 904 vertical, and the legs 902 may be oriented so that they are aligned with channels formed on the surface of the flexible membrane 102 by the ballast weights 126. The legs 902 form conduits and direct liquid toward the sump bucket 904. The legs 902 may be fenestrated. The sump collector 900 is typically not attached to the flexible membrane 102. It may be attached to the cover by welding if desired.
(36) FIG. 10 is a perspective view of another embodiment of a sump collector 1000. The sump collector 1000 of this embodiment has a fenestrated sump bucket 1004 disposed on a plurality of legs 1002. The legs 1002 are arranged in a different configuration than the legs 902 of the previously described embodiment. Otherwise, the operation and construction of the sump collector 1002 is similar to the previously described embodiment and will not be repeated.
(37) FIG. 11 is a perspective view of one embodiment of a ballast weight 126. The ballast weight 126 may comprise plastic tubing or a pipe 150 which is filled with sand or a slurry 152. In one particular embodiment, the ballast weight is a 10-ft long, 60-mil HDPE tube, filled with sand and sealed at the ends. The ballast weights may be about 2 to 24 inches in diameter (normally about 4″×6″ oval shaped and 10-ft long) and may weigh 5 to 15 lbs. per linear foot.
(38) The ballast weight may be attached to the flexible membrane by attachment straps or loops disposed on the surface of the flexible membrane 102. The ballast weight may be provided with an attachment flap 144 having holes 146 for receiving attachment straps disposed on the surface of the flexible membrane 102.
(39) FIGS. 12, 13 and 14 illustrate a pipe retention system 1200 for introducing one or more pipes 1202 into the interior of the storage tank 106. The pipe retention system may optionally be used with the storage tank 106 described above. In FIG. 12, the pipes 1202 are omitted for clarity. The pipe retention system 1200 comprises a first flange 1208 and a second flange 1204 oriented at a non-zero angle to the first segment. The first flange 1208 has openings for bolts or other fasteners to allow attachment to the top flange member (see member 110 in FIG. 6) of the storage tank 106. The second flange 1204 extends inward into the interior of the storage tank 106. The second flange 1204 may be substantially parallel to the first flange 1208. Alternatively, the second flange may extend downward at a selected angle, preferably 45 degrees. The second flange 1204 includes openings 1206 for allowing pipes 1202 to pass through the pipe retention system. In the illustrated embodiment, five holes that are three inches or larger in diameter are provided, however, any number may be provided according to user desires. The holes 1206 may be sealed with plugs or other suitable covers when pipes 1202 are not in use. The flexible membrane 102 is attached to the inner edge 1210 of the pipe retention system 1200. The second segment 1204 may have openings to so that the membrane 102 can be attached with batten bars 1214 and bolts 1216 similar to the previously described attachment described above in connection with FIG. 6. The pipes 1202 may also pass through the top flange member (see member 110 in FIG. 6) of the storage tank 106 to provide extra stability. The pipes 1202 extend toward the bottom wall of the storage tank. The pipes 1202 may be provided with a screen 1212 to prevent debris from entering the pipes. The pipes 1202 may be used to pass through any fluid, including the storage liquid or the vapor that collects under the cover at the side wall of the tank. In one embodiment, a pipe is passes through the pipe flange and is attached to a passive vent.
(40) The pipe retention system 1200 may have a size in the radial direction of ½ foot to 3 feet, and more specifically 10 inches to 20 inches. The circumferential dimension of the pipe flange may be one to 10 feet, and more specifically two to six feet in length, where the length is either a straight line length or an arc length. The first flange 1202 of the pipe retention system 1200 does not necessarily conform to the curved shape of the tank side wall 102 or the top flange member 110 of the storage tank 106. The first flange 1202 may be a rectangular segment that is oriented parallel to the ground and the second flange 1204 may be another rectangular segment that is oriented at a zero or a non-zero angle to the first rectangular segment.
(41) The above specification and examples provide a complete description of the structure and use of exemplary embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the present devices are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, components may be combined as a unitary structure, and/or connections may be substituted (e.g., threads may be substituted with press-fittings or welds). Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.
(42) The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively.
