Note: Descriptions are shown in the official language in which they were submitted.
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ABOVE GROUND FLUID STORAGE SYSTEM
CROSS-REFERENCE TO RELATED APPLICATIONS
(0001] This application claims priority to U.S. Provisional Application No.
61/474,431
filed April 12, 2011, the entire disclosure of which is incorporated herein by
reference.
TECHNICAL FIELD
(00021 This invention relates, in general, to storage systems for holding
large quantities of
various fluids for use in industrial, commercial and energy applications, and
more
particularly systems for above ground impoundment of water for use in a
hydraulic
fracturing process.
BACKGROUND ART
(00031 Hydraulic Fracturing (i.e., fracking) is a method of extracting natural
gas that is
trapped in the layers of shale thousands of feet below the surface. The
process involves
drilling into shale formations (5,000 to 20,000 feet below the surface) and
pumping
fracturing fluid into the formation at great pressures fracturing the rock
creating a conduit
for the natural gas to be extracted through. The fracking process requires
millions of
gallons of water, much of which is extracted from the shale formations and
must be stored
prior to being treated for any contaminants which they receive during the
drilling process.
Most "fracking" sites in the Marcellus Shale region located in Pennsylvania,
West Virginia,
and southern New York are in very remote locations and the pads (drilling
sites) have
relatively small footprints, thus the storage of massive amounts of water
within a small
footprint requires a voluminous vessel. Currently there are two methods for
large water
storage: below ground (lined pit) and above ground (defined storage vessel).
(00041 Thus, a need exists for systems and methods for storing liquids above
ground which
are intended to be used for, or have been extracted from, drilling sites.
These systems and
methods may be utilized in remote locations and may protect the environment.
SUMMARY OF THE INVENTION
(00051 The present invention provides, in a first aspect, an above ground
liquid storage
system which includes a substantially impermeable liner bounding an interior
for receiving
a liquid. A plurality of supporting structures and a base support the liner
and the liquid
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when the liquid is received in the interior. The liner extends from the base
over a top end
of the plurality of supporting structures and descends to the ground to form a
cavity under
the plurality of supporting structures. A temperature controller in
communication with the
cavity controls a temperature of the cavity to control the temperature of
liquid in the
interior.
(00061 The present invention provides, in a second aspect, a method for use in
above
ground storage of a liquid which includes connecting a plurality of supporting
structures to
one another such that a base is surrounded by the plurality of supporting
structures. A liner
is located on the base and the plurality of supporting structures such that
the liner extends
from the base over a top end of the plurality of supporting structures and
descends to the
ground to form a cavity under the plurality of supporting structures. A liquid
is received in
a cavity bounded by the liner. A temperature of the cavity is controlled to
control the
temperature of the liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
(00071 The subject matter which is regarded as the invention is
particularly pointed out
and distinctly claimed in the claims at the conclusion of the specification.
The
foregoing and other features, and advantages of the invention will be readily
understood from the following detailed description of preferred embodiments
taken in
conjunction with the accompanying drawings in which:
(00081 FIG. 1 is a cutaway view of a portion of a supporting system
supporting a basin
in accordance with the present invention;
(00091 FIG. 2 is a side cross-sectional view of the basin of FIG. 1;
(00101 FIG. 3 is a perspective view of a backside of the supporting system
of the basin
of FIG. 1;
(00111 FIG. 4 is a perspective view of the basin of FIG. 1;
(00121 FIG. 5 is a side cross-sectional view of a portion of the basin of
FIG. 1
including an air conditioning mechanism and fluid connection means connected
to an
underside of the basin;
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(00131 FIG. 6 is a side view of a clamp for connecting the supporting
structures of the
basin of FIG. 1 to each other;
(00141 FIG. 7 is a front view of the clamp of FIG. 6 including a cover in
accordance
with the present invention; and
(00151 FIG. 8 is a perspective view of the basin of FIG. 1 including a
conduit on a
support member allowing fluid flow over a top side of the basin.
DETAILED DESCRIPTION
(00161 In an exemplary embodiment depicted in FIGS. 1-7 an above ground liquid
containment system or basin 51 is shown. Basin 51 may be configured (e.g.,
shaped and
dimensioned) to any shape and various heights. Basin 51 may include a series
of
interconnected supporting structures or frame units 100 spaced at intervals
erected on a
prepared surface (e.g., a concrete pad) to form a container skeleton or
support structure.
Each frame unit includes a support portion 30 and a leg portion 40 facing an
interior 50 of
the basin. A plurality of leg portions 40 may extend upwardly at an angle
(e.g., about 43
degrees) to support basin 51 and any contents of interior 50. The leg portions
may be
supported by a plurality of support portions 30. The support portions and leg
portions may
be formed of wood, metal or plastic members fastened to each other and
configured to
carry the weight of a liquid (e.g., water from a fracturing process) in
interior 50 of basin 51.
Such support portion and leg portions could also be monolithically formed
(e.g., by
molding, casting, etc.). As depicted in the figures, such a leg portion (e.g.,
leg portion 40)
may have a linear shape extending from base 70 at an angle less than 90
degrees and more
than 30 degrees, for example, while the support portion (e.g., support portion
30) may be
formed of a V shaped structure having a bottom horizontal portion 31 and a
side portion
extending from an end of horizontal portion 31 (i.e., the end away from base
70) to contact
leg portion 40. A frame cavity 60 (e.g., having a triangular shape) may be
formed by the
connection of one of support portions 30 to one of leg portions 40. The cavity
may be a
variety of shapes (e.g., an equilateral triangle) depending on the
configuration (e.g., shape
and dimension) of the support portions and leg portions.
(001 7] A thick geogrid material 20 may extend from a top 41 of each leg
portion 40
downwardly on the leg portion and continue a short distance out onto a base 70
as depicted
in FIG, 1, for example. Geogrid material 20 has the ability to restrict a
liner 80 from
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forming pockets within frame units 100 due to the added rigidity it provides,
thus keeping a
surface of the liner facing the liquid as a smooth sided container. Geogrid
material 20 is
attached at intervals to one or more of support portions 30 and/or leg
portions 40 of the
frame unit with zip ties or other connection mechanism(s). Geo-grid material
20 may be a
material configured for use as a base course for reinforcement and soil
stabilization such as
MARAFI BXG GEOGRID. Such a geo-grid material may have a tensile strength of
2,500
pounds per foot in a machine direction and 2,500 pounds per foot in a cross
direction.
(00181 Base 70 (i.e., horizontal portion surrounded by the frame units) of
basin 51 may be
a portion of a concrete pad or other material capable of supporting the weight
of liquid
thereon in conjunction with the frames (e.g., frames 100) which surround such
base.
Further, basin 51 may be lined with a thick felt material 22 which overlaps
geogrid material
20 a short distance and is attached to one or more of support portions 30
and/or leg portions
40 by means of zip ties or other connection mechanism(s). For example, the
felt may be a
needle punched non-woven geo-textile composed of polypropylene fibers formed
with a
stable network such that the fibers retain their relative position, such as
MIRAFI 180N.
Such a geo-textile may be inert to biological degradation and resist naturally
encountered
chemicals, alkalis and acids. The felt material 20 may have a weight of 271
grams per
meter squared and a thickness of 1.8 mm, for example.
(00191 Liner 80 may be a continuous liner impermeable to liquids (e.g., water)
installed on
the container skeleton (i.e., frame units 100, geogrid material 20, base 70).
Liner 80 may
be tailored (e.g., shaped and dimensioned) to fit the inside measurements of
basin 51 (e.g.,
the inside surface of the plurality of leg portions 40 and base 70) and extend
over the top
(e.g., top 41) of frame units 100 and vertically down to the ground on the
outside of the
container, where it may be anchored to the ground by weight. FIGS. 4 and 5
depict the
liner pulled over the frame to the ground. Further, the liner may be any type
of liner which
may support the weight of water or another liquid when connected to frame
units 100 and
may be substantially impermeable. Also, liner 80 may be formed of a plurality
of liner
portions welded or otherwise connected to one another such that the seams are
substantially
impermeable. Further, liner 80 could be formed of a scrim reinforced
polyethylene, such
as DUR SKRIM. Such a liner could have an average thickness of about 30 mil, a
weight of
about 144 pounds per thousand square feet. The liner may also have a tensile
strength of
160 foot pounds per square inch in a machine direction and 150 foot pounds per
square
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inch in a transverse direction. The liner may be a reinforced laminate
manufactured using
high strength virgin grade polyethylene resins and stabilizers.
(00201 When liner 80 extends from top 41 to the ground, a liner cavity or area
81 under
liner 80 and under leg portions 40, including cavities 60, may be heated,
cooled or
otherwise conditioned. For example, warmed air may be pumped into area 81 to
maintain
the area under leg portions 40 at a desired temperature such that any liquid
held in interior
50 is held at a desired temperature due to the convection and conduction
occurring in the
area under leg portions 40 relative to leg portions 40, geogrid 20, any felt
and liner 80. For
example, area 81 under leg portions and under liner 80 (e.g., including
cavities 60) may be
heated (e.g., a heater 3 may be connected to a tube 4 to provide heated air as
depicted in
FIG. 7) to avoid any liquid in interior 50 from freezing thereby avoiding any
damage that
could occur to liner 80 resulting from freezing and/or thawing of the liquid.
Also, a
bubbling mechanism 11 may be utilized to inhibit freezing of the liquid in
basin 50 to
minimize any such damage to liner 80 as depicted in FIG. 7. Such a bubbling
mechanism
could be any type of air generating mechanism which provides air to a liquid
held in
interior 50 to inhibit freezing of the liquid and thereby avoid any damage to
basin 51,
including liner 80, due to such freezing.
(00211 Basin 51 could also be configured to include under-floor or over-top
piping to
accommodate inflow /outflow requirements into and/or out of interior 50. Over
the top
piping may be utilized where under-floor piping is not feasible, for example.
Basin 51
could also be configured to allow the liquid/ slurry to weir over in a
particular location at a
desired elevation. As depicted in FIG. 5, a drain/inlet may be provided in
base 70 and liner
80 to allow fluid communication therethrough. As depicted in the figures,
fluid
communication may be provided through an underside (e.g., base 70) of basin
51. A
manhole casting 5 may connect to an underside of basin 51 opposite interior 50
and seals 6
may be utilized on opposite sides of liner 80. A manhole riser 7 may be
coupled to casting
and the seals. A conduit 8 may connect riser 7 to a manifold system 10 to
allow the
introduction and/or removal of liquids relative to interior 50 therethrough. A
shutoff valve
9 may be utilized to allow or prevent such fluid communication.
(00221 In one example, manhole casting 5 may be 6" to 8" in height. The drain
may be
24" in diameter on top (for the opening) and then 36" at the base which is
between 5'
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and 7' below the top surface of the drain. These dimensions may be adjusted as
desired,
e.g., to adjust an amount of flow to fill and discharge the system.
(00231 As depicted in FIGS. 6 and 7, a clamp cover 150 may protect the liner
material (i.e.,
liner 80) from a clamp. The cover may be formed of a foam material (e.g., 1.7#
low
density form fit polyethylene foam or any other material which would properly
act as a
cushion/buffer to minimize risk of damage from impact, chaffing, puncturing or
tearing)
which fits over a clamp 160 which then rests against the geogrid material
(e.g., geogrid
material 20), which contacts the liner material. The cover may be connected to
the clamp
by twine or zip ties, for example. Multiple clamps 160 may be utilized to
connect
individual frame units (e.g., units 100) to each other as depicted in the
figures. For
example, a top portion 153 and a bottom portion 154 may receive multiple leg
portions 40
therebetween to connect such leg portions to one another. The top portion and
bottom
portion could be connected to each other by a fastening mechanism, such as a
bolt 155, for
example. Clamp 160 could be shaped and dimensioned in any way to allow
adjacent frame
units 100 (e.g., leg portions 40 thereof) to be connected to one another.
(00241 Further, basin 51 may include a portion thereof having a top end lower
than a
remaining portion of such basin. For example, several of frame units 100 may
include leg
portion 40 of reduced length such that a top end in the local area of such
reduced
dimensioned leg portions are lower than the top ends of other leg portions
adjacent such
reduced dimension leg portions. This reduced height may form a weir to allow
liquid in
interior 50 to flow out of basin 51 when such liquid reaches a top end of the
reduced height
portion. Such a "weir over" arrangement may be useful in the case of the
subsurface
conditions don't allow for a underground method or when such an underground
method is
not cost effective.
(00251 In another example, basin 51 may include a conduit 200 which extends
from
liner 80 in the vicinity of top end 41 into interior 50 and rests on a
supporting surface, such
as concrete blocks 210, as depicted in FIG. 8. Such blocks may act as an
anchoring point
for the conduit and also may act as a diffusion device when fluid flows at
high velocity
through conduit 200. Liquid may flow into and/or out of basin 51 through
conduit 200
(e.g., via pump(s)). A support 220 may extend from one of blocks 210 to a
position at/or
near top end 41 to support conduit 200 as depicted in FIG. 8.
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(00261 Further, in another example, through-wall piping for filling /
evacuating fluid
materials may be used when sub-surface conditions don't permit installation of
an in-floor
system (e.g., conduit 8) or an over-the-top system cannot be properly
stabilized (e.g.,
secured to dead-men inside basin) to minimize the risk of liner damage by pipe
thrashing.
Such a through-wall piping system would extend through leg 40, liner 80, and
geo-grid 20,
for example, such that a conduit extending through leg 40, and liner 80 is
sealed to inhibit
leakage through liner 80 and leg 40 other than that flowing through such
conduit.
(00271 The above described system (e.g., basin 51) may be used for the
temporary short or
long term storage of any form of liquid or slurry where in-ground impoundments
or frack
tanks are either not permitted or not viable. Such systems are intended to be
used above
ground and are portable; the frame units and separate hardware can be
individually stacked
and transported by truck to any location including very remote locations. The
systems may
be easily assembled, broken down and re-assembled at different locations. For
example,
each of frames 100 may be releasably connected to adjacent frames of frames
100 to form
the structure of basin 51 by a plurality of clamps (e.g., clamp 150) and/or
other connecting
mechanism (e.g., cables) thereby allowing a basin to be constructed in various
sizes and
shapes (e.g., by using different number of frames 100 in different
configurations) and
allowing the easy deconstruction and movement of such a basin from one place
to another
due to the releasable nature of the connections. The frames may also be
separated from
each other and re-used after a basin has achieved a particular purpose, for
example. The
assembly and re-assembly may be done by hand with the assistance of lifting
machinery.
The system (e.g., basin 51) may be used for central frack water storage in the
Marcellus
shale industry in Pennsylvania where limited access is available, for example.
It may also
be used for many other types of storage requirements. Basin 51 would not
affect the
existing water table and has a minimal impact on the ground and surrounding
area where it
is being used due to its above ground construction.
(00281 Further, basin 51 may permit temporary storage of millions of gallons
of fresh
water used in industrial, commercial and energy applications. Basin 51 may be
ten feet
high, for example, providing a larger storage capacity when compared to
similar above
ground systems. The described systems may be portable and may be assembled,
broken
down re-located and re-assembled in a minimal time-frame as compared to
similar above
ground systems as described above.
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(00291 Basin 51 may be completely modular and can be constructed into any
shape or size
configuration based on needs (e.g., maximizing the drill pad footprint) of a
user. The
system described (e.g., basin 51) may have in-floor or thru-wall piping
capabilities for
quick fill and discharge requirements. The system described (e.g., basin 51)
may have
minimal labor and equipment requirements for assembly / disassembly. Further,
the
system described (e.g., basin 51) is environmentally friendly and requires
minimal
disturbance / impact to terrain.
(00301 While the invention has been depicted and described in detail herein,
it will be
apparent to those skilled in the relevant art that various modifications,
additions,
substitutions and the like can be made without departing from the spirit of
the invention
and these are therefore considered to be within the scope of the invention as
defined in the
following claims.
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