The present invention is related to drive-over berms for protective containment liners.
During gas and oil drilling, thousands of gallons of drilling mud, fracturing chemicals and flowback water are on site. Many operating companies compact the pad site and place a liquid-proof liner over 30,000 to 120,000 square feet of surface. Around the perimeter of the containment area, the liner can be pulled over a raised row of dirt, railroad ties, corrugated pipe, foam block, or rubber/plastic forms to provide sidewalls, also known as berms. The liner in conjunction with the berms contains the leaks and spills that might happen on the site so that vacuum trucks can remove the waste without impact to the environment. The sump capacity of the containment is determined by multiplying the area of liner by the berm height.
There are many issues with the current berm options. An earthen berm requires heavy equipment to build. The liner cannot be directly attached and requires staking, which is subject to wind uplift and tearing. The earthen berms also flatten under repeated vehicle traffic.
Although railroad ties can be moved from site to site for reuse, they are difficult to decontaminate since they are absorbent to the chemicals on site. Because they are rectangular, they require metal or earthen ramps on both sides to accommodate bobcats, skid steers, front end loaders, and track hoes on and off the containment area. Any earthen ramp inside the containment area absorbs the chemicals and must be landfilled afterwards. To accommodate tractor trailer traffic, the railroad ties must be completely removed. Since durable liners are able to survive multiple operations during well construction, the berms may be removed and reinstalled up to five times. While the railroad tie berms are out of position, the containment has an open sidewall and negligible sump capacity. If a release occurs during that period, the liquids may flow off the containment.
Corrugated pipe is easy to decontaminate due to its plastic construction. It is also light weight and easy to move. It is, however, easily crushed and is unable to support a ramp. It does not provide a substantial physical barrier to traffic in sensitive areas and cannot be used in drive-over areas.
Triangular, circular and rectangular foam blocks underneath the liner provide berms that are crush resistant while also light weight. Containing the foam within a liner pocket prevents the foam from being pushed into the pad. To control wind uplift and foam migration out of the pocket, rock is placed on the liner tail outside the berm. While foam is the preferred berm for many operators, the liner on the berm is exposed to ongoing damage.
Another option is a plastic or rubber forms. Examples are 6 inch Muscle Walls from Muscle Wall Holding, LLC in Logan, Utah, and a rubber slotted base and key as disclosed in U.S. patent application Ser. No. 13/688,517. Again in both cases, the liner is pulled over the berms and is subject to ongoing damage. The first example, the plastic form from Muscle Wall, was designed for drive-over traffic but requires the liner to be exposed on the berm surface. The rubber form from U.S. patent application Ser. No. 13/688,517 requires ramps on drive-over sections since the rubber disintegrates under traffic. The rubber forms are also extremely heavy at around 200 pounds each and require a skid steer or multiple people to place.
In current methods mentioned above, the containment liner is pulled over the berm. It is thereby directly exposed to drive-over traffic and the associated punctures and tears that result from heavy equipment, fork tines, tires, etc. If a tear or puncture of the liner on the berm is inside the containment area, the overall sump capacity is reduced to the lowest point of the tear or puncture, requiring repair.
The present invention provides drive-over berm systems where a raised portion of the liner is protected within the berm. The berm system is stackable for storage and transportation purposes and includes plates and/or dove tails for connecting multiple sections of the berms end-to-end.
Containment systems of the present invention may be used to protect the environment from spills and leaks at sites, such as oil and gas well drilling sites, and more particularly relates to protecting the sidewalls of the containment, also known as berms. Trucks and heavy equipment frequently need to drive over the perimeter berms to access the equipment within the containment. Since the berms are higher than the liner inside and the gravel base outside of the containment, the berm can be damaged by turning tires, dragging frac tank rails and punctures from lowered fork tines. Damaging the berm compromises the containment since the overall sump capacity is determined by multiplying the berm height by the liner area.
An aspect of the present invention is to provide a drive-over containment liner system comprising an inner berm comprising a base, an outwardly facing sidewall, and an inwardly facing ramp surface; an outer berm comprising a base, an inwardly facing sidewall, and an outwardly facing ramp surface; and a liner sheet extending under the base of the inner berm and having a folded portion between the outwardly facing sidewall of the inner berm and the inwardly facing sidewall of the outer berm defining an elevated liner fold forming a liquid containment barrier.
Another aspect of the present invention is to provide an outer berm for use with a liquid impermeable liner of a drive-over containment layer system, the outer berm comprising a base; a sidewall extending upwardly from the base; a top surface extending substantially perpendicularly from a top edge of the sidewall; a ramp surface extending downwardly at an angle from the top surface toward the base; and a channel formed in the top surface running along a length of the outer berm structured and arranged to receive a downwardly extending side edge of a connector plate.
A further aspect of the present invention is to provide an inner berm for use with a liquid impermeable liner of a drive-over containment layer system, the inner berm comprising a base; a sidewall extending upwardly from the base; a top surface extending substantially perpendicularly from a top edge of the sidewall; a ramp surface extending downwardly at an angle from the top surface toward the base; and a channel formed in the top surface running along a length of the inner berm structured and arranged to receive a downwardly extending side edge of a connector plate.
These and other aspects of the present invention will be more apparent from the following description.
The present invention provides an enclosed berm system for use with a protective liner. If the inside containment is in the same plane as the area outside, two ramps may be used to drive up one side and down the other. If the inside containment is raised, such as by rig mats, only the entrance or outer ramp may be needed. For a two-ramp berm, each section may include an inner ramp, an outer ramp, a connector plate, and an insert to raise the liner to desired sump height. For a berm attaching to a rig mat, at least one outer ramp and a connector plate may be used. If the liner is not double-backed onto a rig mat under the connector plate, an insert to raise the liner may be used.
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In accordance with embodiments of the invention, the insert 50 ensures that the liner 12 maintains a determined sump height. The insert 50 can be square, rectangular, T-shaped, L-shaped, arched, or other shapes to provide the desired height H. It may or may not engage with the ramps and/or connector plate. The insert 50 can be held in place between the ramps 22 and 32 by constrained space, contact, gravity, friction, bends, book ends, or pins and screws that do not puncture the inside surface of the liner 12.
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In accordance with embodiments of the present invention, the shapes of the inner and outer berms 22 and 32 may be selected as desired, for example, triangular, arched, or stepped. The length of each inner berm section 22 and outer berm section 32 may typically range from 2 to 20 feet, for example from 4 to 8 feet. The overall heights of the inner and outer berms 22 and 32 may typically range from 3 to 12 inches, for example from 4 to 8 inches. To ease field installation, each individual berm section should weigh less than 50 pounds, ideally around 30 pounds, to limit fatigue. The inner and outer berms 22 and 32 may be solid or hollow and could be made from various construction grade materials, such as plastic, reinforced plastic, wood, metal, composites, or rubber. As such, the desired shape can be obtained by injection molding, machining, casting, extrusion, fabrication or other common methods.
The connector plate 60 secures the berm sections in order to prevent shifting. The connector plate 60 protects the elevated liner fold 52 underneath from direct traffic and is mechanically fastened to prevent separation. The connector plate 60 may be made of various construction grade materials, such as plastic, reinforced plastic, wood, metal, or composites that provide rigidity. As such, the desired shape can be obtained by bending, injection molding, machining, casting, extrusion, fabrication or other common methods. To ease field installation, each individual plate 60 weight should weigh less than 50 pounds, ideally around 30 pounds, to limit fatigue. This does not, however, limit the invention to components that weight less than 50 pounds. Ideally, the connector plate 60 should span across adjacent berm sections to lock the entire system together.
During installation, one of the inner berm 22 sections may be placed on top of the liner 12. The liner 12 is folded back over the inner berm 22 so the insert 50 can be positioned. The liner 12 is then folded back down onto the ground and the outer berm 32 is placed on top of the liner 12. The connector plate 60 is then bolted or otherwise fastened onto the inner and outer berms 22 and 32. The connector plate 60 can span across two or more adjacent inner berm 22 sections and outer berm 32 sections to interconnect them together. Any excess liner 12 on the outside side 13 can be trimmed away if desired or rock may be placed on top of it.
The berm systems of the present invention may be made of any suitable materials, such as molded or extruded plastics and rubbers, wood or metal. Suitable plastics include polypropylene and polyethylene such as impact copolymer, high-density polyethylene (HDPE), medium-density polyethylene (MDPE), low-density polyethylene (LDPE) and linear low-density polyethylene (LLDPE), and the like. In certain embodiments, the plastic may comprise recycled materials. Other materials, fillers, or composites can also be used. In certain embodiments, recycled plastic resin from liners used in previous well site containments may be used to make the berms. In another embodiment, the inner and outer berms 22 and 32, and the connector plates 60, 160 and 260 can be made out of high-traction materials or covered with high-traction coatings or tapes.
The berm sections can be interconnected to prevent shifting between sections. The interconnected pieces may include tongue and groove assemblies in the ramps as described above, spanning the connector plate over two or more sections, pins, rods or screws. Interlocking sections prevent sections of berm system from being pushed out of alignment. The interlocking devices can be designed to accommodate for thermal expansion and contraction. For example, plates can have slots for screws or gaps can be left between sections during day installation or placed tight for night installations.
The berms of the present invention provide several advantages over other berm containment methods. They provide a ramp that completely protects the liner, stays in place, can be decontaminated and can be easily moved from site to site.
As used herein, “including,” “containing” and like terms are understood in the context of this application to be synonymous with “comprising” and are therefore open-ended and do not exclude the presence of additional undescribed or unrecited elements, materials, phases or method steps. As used herein, “consisting of” is understood in the context of this application to exclude the presence of any unspecified element, material, phase or method step. As used herein, “consisting essentially of” is understood in the context of this application to include the specified elements, materials, phases, or method steps, where applicable, and to also include any unspecified elements, materials, phases, or method steps that do not materially affect the basic or novel characteristics of the invention.
In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, in this application, the use of “or” means “and/or” unless specifically stated otherwise, even though “and/or” may be explicitly used in certain instances. In this application and the appended claims, the articles “a,” “an,” and “the” include plural referents unless expressly and unequivocally limited to one referent.
Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention as defined.
This application claims priority from U.S. Provisional Application No. 62/476,139 filed Mar. 24, 2017, which is incorporated herein by reference.
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