Patent Application
20250172000
Aspects of the disclosure generally relate to storage tank structures. More specifically, aspects of this disclosure relate to the design and construction of cover systems for storage tanks.
Storage tanks may be used for wide variety of applications. For examples, storage tanks may be used or storing liquids such as water, waste water, oil, chemicals, etc. A common construction for liquid storage tanks may comprise a cylindrical tank shell covered by a fixed or floating roof. For example, a fixed roof may be a cone-shaped or dome-shaped roof that is permanently affixed to the cylindrical tank shell. An example of a fixed dome-shaped roof is a geodesic dome that comprises a plurality of interlocking triangle-shaped panels. In contrast, floating roof tanks comprise an open-topped cylindrical tank shell with a roof that rises or falls with a liquid level in the tank.
The following summary presents a simplified summary of certain features. The summary is not an extensive overview and is not intended to identify key or critical elements.
A storage tank may comprise a tank shell that may be covered with a dome. The tank shell may comprise a cylindrical shape. The dome may comprise a plurality of curved, radial subsections that may be affixed to a common compression ring and an upper edge of the tank shell. A plurality of curved, radial structural members may be used to join adjacent subsections. For example, radial edges of adjacent subsections of the dome may be curved inwards and fitted into a slot of a corresponding structural member. A plurality of curved, radial battens may be used for securing the subsections of the dome. For example, a corresponding batten may be fit into a corresponding slot such that the radial edges of the adjacent subsections are sandwiched/wedged between the corresponding batten and the corresponding structural member. A plurality of fasteners may be used to complete the attachment of the subsections, the structural members, and the battens. The plurality of fasteners may be affixed from concave surfaces of the structural members to secure the battens against the structural members. Each of the plurality of fasteners may be sized to be contained within the battens, such that the fasteners do not protrude out a top surface of the dome.
These and other features and advantages are described in greater detail below.
The present disclosure is illustrated by way of example and not limited in the accompanying figures in which like reference numerals indicate similar elements and in which:
In the following description of various illustrative embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown, by way of illustration, various embodiments in which aspects of the disclosure may be practiced. It is to be understood that other embodiments may be utilized, and structural and functional modifications may be made, without departing from the scope of the present disclosure.
As described above, storage tanks with domes (e.g., geodesic domes) may be commonly used for storage of liquids. Aluminum geodesic domes have been used commercially in oil/gas industries and water/wastewater storage for decades. For example, aluminum geodesic domes are used in storage tanks (e.g., cylindrical storage tanks) for weather shielding, gas containment, odor/vapor control, and/or for other purposes. Geodesic domes range in size from around 20 feet in diameter to 400 feet (or larger) in diameter. Most domes used in water/wastewater industry are between 30 feet in diameter and 120 feet in diameter, while domes used in the oil/gas industry are between 50 feet in diameter and 200 feet in diameter.
Geodesic domes may have several drawbacks. Geodesic domes are complicated to fabricate and construct. For example, a typical geodesic dome may have dozens of unique parts and hundreds of total number of parts, resulting in high cost and complexity. Further, the interfaces between the different parts (e.g., panels, battens, etc.) may be prone to leaking. Battens may impede a flow of water off the surface of dome. As a result, water (e.g., rainwater) may collect at hub covers that are overlaid over joints between different battens. Prolonged pooling of water at the hub covers may cause water to seep inside the dome via leak paths that may exist between hub covers, battens, and/or other exposed fasteners on the dome surface. While caulk may be used to fix any leaks, caulk may degrade over time (e.g., due to exposure to sun, thermal expansion/contraction, etc.) and crack and/or peel, thereby providing only a temporary fix for leaks at best. Another approach to prevent leaks is to use welding to attach the various panels of the dome and/or to use steel roofs. However, such approaches are typically time-intensive and/or expensive.
Various examples herein describe design, assembly, and construction of an improved dome-shaped cover system for cylindrical storage tanks. Example dome structures as described herein may not comprise any exposed fasteners, gaskets, and/or other components that may be prone to leaking. A dome may comprise a plurality of curved radial subsections/panels that are each affixed at a common compression ring using a first set of support pins. The compression ring may be located at the center of the dome. Each of the radial subsections/panels may also be affixed to an upper surface or edge, associated with a cylindrical tank shell, using a second set of support pins.
An adjacent pair of panels (e.g., corresponding to the radial subsections) may be affixed using a curved batten and a curved structural member. The battens and the structural members may extend radially outwards from the center of the dome, and may be located between adjacent pairs of panels. For examples, the battens and the structural members may be arranged in a spoke pattern from the center of the dome. Edges of the panels (e.g., rolled edges) may be sandwiched/wedged between the batten and the structural member. Fasteners (e.g., bolts or screws) may be driven, from the concave surface of the dome/structural member, to attach the batten to the panel. The components of the dome (e.g., radial subsections/panels, battens, structural members, etc.) may be manufactured using aluminum. In other examples, one or more other materials (e.g., metals, ceramics, polymers, etc.) may be used (e.g., instead of or in conjunction with aluminum). Gaskets (e.g., rubber, silicone, or polymer gaskets) may be used to form a seal between the battens and the structural members.
The dome-shaped cover system for storage tanks, as described herein, may provide numerous advantages over conventional covers and roofs. Using radial subsections/panels to assemble the dome may reduce pooling of liquid (e.g., rain water, snowmelt water, etc.) on a top surface of the dome, thereby reducing the probability of a leakage into the tank. The low-profile joint assembly used for attaching adjacent subsections/panels of the dome and/or non-usage of hub covers (e.g., as required for geodesic domes) may facilitate easy drainage of any water than may fall on the top surface of the dome. The dome may not have any exposed fasteners on the top surface of the dome further reducing probability of water leakage. The components of the dome (e.g., radial subsections/panels, battens, structural members, etc.) may be manufactured using aluminum, thereby reducing weight. Further, in comparison to geodesic domes, the domes described herein may require fewer number of unique parts and fewer total number of parts, thereby reducing component manufacturing and dome assembly costs.
As further described herein, adjacent dome panels 210 of the dome may be affixed using dome battens 215 (e.g., curved, radial battens) and structural members (not shown). A tie off point (e.g., anchor point, painter's hitch, fall arrest, etc.) and center vent 225 may be attached to the compression ring 205. The dome may comprise a skylight attached to the compression ring 205 (e.g., instead of or in addition to the center vent 225). Section view A-A of the dome is detailed in
The various examples described with respect to
The joint assembly of
The fastener 402 may be driven into the structural member 410 from a top of the dome (e.g., convex surface of the dome and/or convex side of the batten 404). Accordingly, the joint assembly of
In some examples, the joint assembly (e.g., a bracket assembly) such as shown in
The joint assembly of
The horizontal plate of the structural member 510 may comprise a slot 516 (e.g., a radial slot/groove). A radial edge 514 of a panel 508 may be bent/curved inwards before being affixed, in the slot 516, to the structural member 510 (e.g., the horizontal plate of the structural member 510) using the batten 504. For example, the radial edge 514 may be formed and/or rolled along a spline. The radial edge 514 may be formed and/or rolled prior to installation and/or coupling with the structural member 510.
A fastener 502 (e.g., a screw or a bolt) may be driven through the structural member 510 into the batten 504. The fastener 502 may press both the panels 508-1 and 508-2 against the structural member 510 and the batten 504, thereby forming the joint between the panels 508-1 and 508-2. A series of fasteners (e.g., including the fastener 502) may be placed at regular intervals along the structural member 510 (e.g., the horizontal plate of the structural member 510) to attach panel 408-1 and 408-2. For example, the fasteners may be placed with a spacing of 6″ (or any other spacing) between adjacent fasteners. Gaskets 506 (e.g., made of silicone, rubber, or any polymer) may be used at interfaces between the batten 504 and the panels 508 to form a water tight seal.
The fastener 502 may be driven/inserted into the structural member 510 from underneath the dome (e.g., concave/inner surface of the dome and/or concave surface/side of the structural member). Further, the fastener 502 may be sized to be contained within the batten 504 (e.g., may not extend out of a top/exposed surface of the batten 504). Accordingly, a screw chase in the batten 504 for the fastener 502 may only extend partially into the batten 504. The fastener 502 not extending out of the batten 504 may ensure that there are no protrusions on a top surface of the dome and may reduce potential leakage of any water into the dome.
The batten 504 may be manufactured using extrusion (e.g., or any other manufacturing method). The horizontal plate of the structural member 510 may be manufactured using extrusion (e.g., or any other manufacturing method). The horizontal plate may be welded, epoxied, or otherwise affixed to the vertical plates 512 to create the structural member 510.
The dimensions shown in
In some examples, the joint assembly (e.g., a bracket assembly) such as shown in
The fastener 502 being affixed from the concave surface of the dome may advantageously enable inclusion of additional protective layer(s) on top of the dome. For example, since no protrusions of fasteners are present on the top surface of the dome, an additional protective panel may be attached to the top surface. As shown in
In other examples, the fastener 502 may be affixed from an outer surface of the storage tank. For example, the fastener 502 may be driven/inserted into the batten 504 and the structural member 510 from over the dome (e.g., convex/outer surface of the dome and/or convex surface/side of the batten 504). For a flat cover, the fastener 502 may be driven/inserted into the batten 504 and the structural member 510 from an outer surface of the flat cover (e.g., outer surface of the batten 504).
In other examples, the radial edges of the panels 508 may not be bent. For example, the gaskets 506 may be substantially parallel to the panels 508, with the horizontal plate of the structural member 510 not including the slot 516. The batten 504 may be affixed over the panels 508 and the horizontal plate of the structural member 510. In one such example, the panels 508 may at least partially overlap, with the fastener 508 being inserted into the structural member 510, the overlapping panels 508, and the batten 504.
The use of radial subsections/panels and battens as described herein may provide multiple advantages. A radial subsection of the dome may extend as a single piece, from a center of the dome to an upper edge or surface associated with the tank shell, without requiring any horizontal battens and hub covers (e.g., as necessary in geodesic domes). Absence of horizontal battens and hub covers in the radial subsections may enable an unimpeded flow of water off the dome and prevent pooling. Reduced pooling may reduce probability of water leaking into the dome. The curved shape of the radial subsection may add strength to the structure in addition to an aesthetic appeal.
The battens may have a design that is flush (or substantially flush) to the surface of the dome and/or otherwise may have a low profile. The battens may also be continuous, extending outwards from the center of the dome. Accordingly, no discontinuities in the form of hub covers (e.g., as present in geodesic domes) may be present in the example dome described herein. The use of flush, continuous battens may remove any structural features that may impede the flow of water off the surface of the dome.
Even if water is able to enter through a border between the radial subsections/panels and the batten, a slot included in the structural members may enable drainage of water. For example, the slot may effectively function as a drain channeling water radially outward away from the center of the dome. The water channeled outward may be allowed to drip out. In this manner, the structural member may provide an additional layer of protection against potential water leakage.
The dome may not have any exposed fasteners on the top surface of the dome. Lack of exposed fasteners may avoid issues such as water leakage into the dome via gaps between fasteners and the dome surface (e.g., as observed in domes with exposed fasteners).
The design/assembly of the dome using radial subsections/panels, battens, structural members, and fasteners as described herein may provide for a much smaller watershed for water to collect on the dome in comparison with other dome designs. For example, only water that directly lands on a gasket may have access to a gasketed joint between the battens and the radial subsections/panels. Even if water accesses/enters the gasketed joint, the slot of the structural member may effectively drain water away from the dome.
Further, the dome may require fewer quantity of parts, and/or less overall time for assembly, than required in similarly sized geodesic domes. Additionally, the dome may use fewer unique parts than used in similarly sized geodesic domes. These aspects of the proposed design may reduce fabrication complexity and system costs.
At step 605, adjacent curved, radial panels of the dome may be overlaid on a corresponding curved, radial structural member. The radial edges of the adjacent panels may be curved inwards and fitted into a slot (e.g., a radial slot) of the structural member. The curve of the radial edges may be in the form of a spline.
At step 610, a curved, radial batten may be fit into (e.g., slid into) the slot. Fitting the batten into the slot may result in the radial edges of the adjacent panels to be wedged between the batten and the structural member.
At step 615, a plurality of fasteners (e.g., screws, bolts) may be affixed to the structural member. For example, the fasteners may be affixed from a concave side (e.g., concave surface of a horizontal plate) of the structural member. The fasteners may be affixed to secure the batten against the structural member. Each of the plurality of bolts may be contained within the batten bar. Each of the plurality of fasteners may be sized such that the fasteners are contained within the batten (e.g., do not extend out of the top surface of the dome).
A cover for a tank shell of a storage tank may comprise one or more components. The cover may comprise a plurality of radial panels. Each panel may be affixed to a compression ring at a first end (e.g., first edge) and may be configured to be affixed to an upper edge of the tank shell at a second end (e.g., a second edge). The cover may further comprise a plurality of radial structural members. Radial edges of adjacent panels of the cover may be bent inwards and fitted into a corresponding slot of a corresponding structural member. The cover may further comprise a plurality of radial battens. A corresponding batten may be fit into the corresponding slot such that the radial edges of the adjacent panels are located between the corresponding batten and the corresponding structural member. The cover may further comprise a plurality of fasteners. The plurality of fasteners may be affixed from inner surfaces of the structural members (e.g., inner surface of the cover) to secure the battens against the structural members. Alternatively, the plurality of fasteners may be affixed from outer surfaces of the battens (e.g., outer surface of the cover) to secure the battens against the structural members. Each of the plurality of fasteners may be sized to be contained within the battens. The cover may further comprise gaskets in interfaces between the battens and the panels. The radial edges of the adjacent panels may be formed along a spline. The panels may be welded, epoxied, bolted, or otherwise affixed using any other technique to the compression ring at a center of the cover. The panels may be affixed to supports on an upper edge of the tank shell. One or more of the plurality of panels, the plurality of structural members, and the plurality of battens may be manufactured from aluminum. At least a portion of an upper surface of the cover may comprise a protective panel. The plurality of battens may comprise screw chases for the plurality of fasteners. Each of the plurality of fasteners may be sized to not extend out of exposed surfaces of the battens. The cover may be a dome-shaped cover. The plurality of panels, the plurality of structural members, and the plurality of battens may be curved. The plurality of fasteners being affixed from inner surfaces of the structural members may comprise the plurality of fasteners being affixed from concave surfaces of the structural members.
A joint assembly may be used to attach two panels. The joint assembly may comprise a structural member comprising a slot. At least one edge of each of the panels may be bent inward and fitted into the slot. The joint assembly may further comprise a batten that is fit into the slot such that the bent edges of the panels are located between the batten and the structural member. The joint assembly may further comprise a plurality of fasteners. The plurality of fasteners may be affixed through the structural member to secure the batten against the structural member. Each fastener of the plurality of fasteners may be sized to be contained within the batten. The two panels may correspond to curved, radial panels of a dome. The two panels may correspond to flat, radial panels of a flat, circular cover. The joint assembly may comprise gaskets in interfaces between the batten and the panels. At least one edge of each of the panels may be formed along a spline. One or more of the two panels, the structural member, and the batten may be manufactured from aluminum. The batten may comprise screw chases for the plurality of fasteners. Each of the plurality of fasteners may be sized to not extend out of an exposed surface of the batten.
A method for assembling a cover for a tank shell of a storage tank may comprise multiple steps. The method may comprise overlaying adjacent radial panels of the cover on a corresponding radial structural member. Radial edges of the adjacent panels may be bent inwards and fitted into a slot of the structural member. The method may further comprise fitting a radial batten into the slot such that the radial edges of the adjacent panels are located between the batten and the structural member. The method may further comprise affixing a plurality of fasteners from an inner surface of the structural member to secure the batten against the structural member. Each of the plurality of fasteners may be sized to be contained within the batten. The method may further comprise attaching gaskets in interfaces between the battens and the panels. The radial edges of the adjacent panels may be formed along a spline. The method may further comprise welding respective first edges of the radial panels to a compression ring at a center of the dome. The method may further comprise attaching respective second edges of the radial panels to supports on an upper edge of the tank shell. The cover may be a dome-shaped cover. The panels, the structural member, and/or the batten may be curved. The plurality of fasteners being affixed from an inner surface of the structural member comprises the plurality of fasteners being affixed from a concave surface of the structural member.
Aspects of the disclosure have been described in terms of illustrative embodiments thereof. Numerous other embodiments, modifications, and variations within the scope and spirit of the appended claims will occur to persons of ordinary skill in the art from a review of this disclosure. For example, one or more of the steps depicted in the illustrative figures may be performed in other than the recited order, and one or more depicted steps may be optional in accordance with aspects of the disclosure.
