Abstract:
A rim seal system between the outer periphery of an internal floating roof and the bulk liquid tank wall including a laterally deployed first resilient or flexible seal member and a second laterally deployed rigid seal member interposed between the distal end of the first seal member and the tank wall where the rigid seal member provides protection from abrasion of the resilient or flexible seal member by frictional contact with the tank wall. An outwardly expanding hanger assembly mounted above the seal system maintains the rigid seal member in contact with the tank wall.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to sealing the space between the internal floating roof and the inner tank wall of a storage tank for volatile or hazardous liquids. The present invention provides a means for protecting the various seal mechanisms utilized with internal floating roofs and extending the life span for those sealing mechanisms. 
         [0002]    Bulk fluids, such as petroleum, other fuel products and by-products, and chemicals are often stored in large cylindrical tanks. These tanks are commonly designed with internal floating roofs or bulk fluid covers to minimize product losses to the atmosphere. A critical part of the internal floating roof is the annular or rim space between the perimeter of the internal floating roof and the inner wall of the storage tank. For an average floating roof, approximately one-third of the evaporation loss of the bulk fluid can be attributed to those vapors that escape past the rim seal. 
         [0003]    Three types of rim seals are known in the industry. These types of seals have been tested for their efficiency in reducing evaporative losses from the rim space. The seal types are: liquid-mounted resilient-filled seal; mechanical shoe seal; and vapor-mounted resilient-filled seal. These seals have been used for decades and their relative length of service is known. Testing has revealed that the most efficient seal is a liquid-mounted seal, followed by a mechanical shoe seal and finally a vapor-mounted seal. Seal efficiency has been shown to increase when a secondary seal is placed above the first seal. The Environmental Protection Agency and most state environmental regulations require either a single liquid-mounted seal or a double seal where a secondary seal is placed above a mechanical shoe or vapor-mounted seal. 
         [0004]    Experience has shown; over the years that the various seal types have different life spans. The best seal type, the liquid-mounted seal, has the shortest life span, usually less than one year. The mechanical shoe seal has the longest life span, often more than twenty years. 
         [0005]    The vapor-mounted seal has a life span lasting five years on average. The life span is directly related to the frictional effect of the inner tank wall on the outer seal material as it continually comes into contact with the metal wall. 
         [0006]    An early description of the use of a mechanical shoe type seal coupled with a vapor barrier may be found in U.S. Pat. No. 5,372,270. This patent also describes the use of a secondary seal in the form of a wiper blade mounted above the primary vapor-mounted seal. Protecting the lower vapor-mounted seal is its mounting to a mechanical shoe at the tank wall. However, the wiper seal does not have any protection from the reversal of movement flexure or from the frictional contact with the metal tank wall. 
         [0007]    Another description of the seal types used with internal floating roofs can be found in U.S. Pat. No. 6,164,479. This patent describes dual vapor-mounted barriers spanning the rim space between the outer wall of the floating roof and a mechanical shoe riding against the tank wall. While the invention described in the &#39;470 patent is the horizontal mounting of the hanger-pushers, the use of the vapor-mounted seals in tandem is disclosed where the primary seal is mounted below the liquid level and the fabric is permitted to rise above the liquid level and the secondary seal is mounted entirely above the liquid level in the vapor space. 
         [0008]    Both of these early sealing systems required dual or tandem seals to achieve the reduction in product evaporation to satisfy the industry and its regulators. It is an object of the present invention to provide a rim seal that combines the efficiency of a liquid-mounted seal with the longevity of a mechanical shoe seal, thus increasing the life span of the liquid-mounted seal far beyond its present annual replacement. 
         [0009]    The problems with both sealing systems was that in order to inspect the primary seal one was required to remove the secondary seal exposing the vapor collection space to the atmosphere and potentially endangering the human inspector. It is, therefore, an object of the present invention to provide a seal that is quick and safe to inspect. 
         [0010]    It is yet another object of the present invention to provide a rim seal that is simple to manufacture and readily simple to install onto floating roofs, including retrofitting existing steel or aluminum floating roofs to carry the rim seal of the present invention. 
         [0011]    It is also an object of the present invention to provide a rim seal that is compatible for use with any type of product being stored. Other objects will appear hereinafter. 
       SUMMARY OF THE INVENTION 
       [0012]    The present invention is a rim seal system extending between the outer periphery of an internal floating roof and the bulk liquid tank wall. The rim seal system includes a laterally deployed first resilient or flexible sealing member and a second laterally deployed rigid sealing member interposed between the distal end of the first sealing member and the tank wall where the rigid seal member provides protection from abrasion of the resilient or flexible seal member by frictional contact with the tank wall. The rigid sealing member is held in proximal contact with the storage tank wall by an outwardly expanding hanger assembly mounted above the rim seal system. 
         [0013]    The rim seal system is intended for use with an internal floating roof for a bulk liquid storage tank to prevent unwanted leakage and evaporation of the stored liquid. The rim seal system includes a primary sealing member mounted to and deployed laterally outward from the perimeter wall of the internal floating roof. The primary sealing member has sufficient length to span the rim space distance between the perimeter wall of the internal floating roof and the storage tank wall. The primary sealing member also has the capacity to resiliently compress when the rim space contracts due to lateral movement of the internal floating roof. 
         [0014]    The rim seal system also includes a secondary rigid sealing member mounted to and deployed laterally outward from the perimeter wall of the internal floating roof. The secondary sealing member is interposed between the primary sealing member and the storage tank wall and is maintained in proximal contact with the storage tank wall by an outwardly expanding hanger assembly. The hanger assembly includes a plurality tension joints with interspersed extension plates for urging the hanger assembly to its maximum length, thus causing the attached secondary rigid sealing member to remain in contact with the storage tank wall at all times. The combination of the two sealing members provides the protection against leakage and evaporation of the stored liquid by operating together to fill the rim space distance between the perimeter wall of the floating roof and the storage tank wall. The secondary rigid sealing member by its interposition between the primary sealing member and the storage tank wall also provides abrasion protection for the primary sealing member as the internal floating roof changes vertical position due to volumetric changes in the stored liquid within the storage tank. 
         [0015]    In order to maintain the integrity of the primary sealing member, it may be surrounded by a protective fabric to prevent abrasion or puncture. The second element of the rim seal system, the secondary rigid sealing member, is preferred to be a mechanical shoe sealing member. 
         [0016]    The rim seal system of may further include a third sealing member positioned above the primary and secondary sealing members and deployed laterally outward from a vertical extension of the perimeter wall of the internal floating roof. The third sealing member has sufficient length to span the rim space distance between the perimeter wall of the internal floating roof and the storage tank wall. The third sealing member has the capacity to flex and follow the direction of vertical movement of the internal floating roof while remaining in constant contact with the storage tank wall. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. 
           [0018]      FIG. 1  is a side elevational view of a first embodiment of the rim seal system of the present invention showing a liquid-mounted seal and protective metal shoe mounted to the perimeter wall of an internal floating roof. 
           [0019]      FIG. 2  is an exploded side view of the first embodiment of the rim seal system of the present invention showing the elements for mounting the liquid mounted seal and protective metal shoe to the perimeter wall of an internal floating roof. 
           [0020]      FIG. 3  is a top view of the hanger assembly for the protective metal shoe of the rim seal system extending between the internal floating roof and the protective metal shoe. 
           [0021]      FIG. 4  is a side elevational view of a second embodiment of the rim seal system of the present invention showing a vapor-mounted seal and protective metal shoe mounted to the perimeter of an internal floating roof with a wiper type secondary seal mounted above. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0022]    The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings. 
         [0023]    Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in  FIG. 1  a first embodiment of a peripherally mounted floating roof seal  10  of the present invention. The seal is mounted to the outer perimeter structure of an internal floating roof within a storage tank. The perimeter structure of the floating roof shown in  FIG. 1  includes an outer sidewall  12  of an open top panel system having a bottom plate  14  extending inward into the space defined by the other sidewalls of the panel system. The floating roof structure is set off from the inner tank wall  16  creating an annular or rim space in which the floating roof can move in the horizontal plane as its floats on the surface of the stored liquid. In the annular or rim space a seal is deployed to reduce as much as possible the evaporation of the stored liquid into the internal tank atmosphere. In this embodiment the seal is depicted as a liquid-mounted seal  20  with a solid foam core disposed within a fabric membrane or cover  22  that is mounted onto a mounting plate  24  by fastening means  26   a ,  26   b . The fabric membrane  22  surrounding the liquid-mounted seal  20  is provided to protect the compressible solid foam core  20  from damage. The lower end of the outer protective fabric cover  22  is sandwiched between the mounting plate  24  and the outer sidewall  12  of the floating roof as the mounting plate  24  is attached to the floating roof using fastener  27 . The upper end of the outer protective fabric cover  22  is also sandwiched between the upper flange of the outer sidewall  12  of the floating roof and the bottom foot of an extension plate  30  extending upward from the top of the outer sidewall  12 . The extension plate  30  is a reinforced plate shown as being doubled in thickness in  FIG. 1 . The extension plate  30  is used to mount the hanger assembly  32  that supports the protective shoe  34  that rides against the inner tank wall  16 . The protective shoe  34  extends from the height of the hanger assembly  32  downward between the liquid-mounted seal  20  and the inner tank wall  16  to a point below possible contact by the liquid-mounted seal  20  and the inner tank wall  16 . In this way the protective shoe  34  prevents either the protective fabric  22  surrounding the solid foam core of the liquid-mounted seal  20 , or the foam core of the liquid mounted seal  20 , from being abraded as the floating roof traverses upward and downward inside the tank as the liquid surface changes heights due to volume increases or decreases. The protective shoe  34  serves a second purpose as being the point of mechanical contact of the rim seal system  10  with the inner wall  16  of the tank for the rim seal system  10  of the present invention. 
         [0024]    A hanger assembly  32  spans the distance between the outer perimeter of the floating roof and the inner tank wall  16 . On the floating roof side the hanger assembly  32  is securely fastened to the extension plate  30  by two fastening means  33   a ,  33   b . Extending outward from the extension plate  30  is proximal tension joint  36  to which is attached a first extension plate  38 . At the distal end of extension plate  38  are a pair of cooperating intermediate tension joints  40   a ,  40   b . First extension plate  38  is attached to tension joint  40   a  that is, in turn attached to tension joint  40   b . Second extension plate  42  is attached between tension joint  40   b  and distal tension joint  44 . The protective shoe  34  is attached to distal tension joint  44  by fasteners  46   a ,  46   b.    
         [0025]    The hanger assembly  32  has two functions. The first is to maintain the protective shoe  34  at the required lateral position relative to the floating roof to protect the seal  20  and its protective fabric  22  from unwanted abrasion. The second function of the hanger assembly is to extend the protective shoe  34  outward to remain in constant contact with the inner tank wall  16  providing the seal for the rim seal system  10  against the tank wall  16 . To accomplish this second task, the hanger assembly  32  includes the tension joints  36 ,  40   a ,  40   b  and  44  that exert a spring force against the extension plates  38 ,  42  forcing the extension plates  38 ,  42  to extend to the greatest allowable angular relationship at any given time. In this way the protective shoe  34  is maintained at the proper lateral position to the floating roof and in constant contact with the inner tank wall  16 . 
         [0026]    The solid foam core of the liquid-mounted seal  20 , which is mounted below the hanger assembly  32 , is resiliently flexible to accommodate lesser or greater distances between the outer sidewall  12  of the floating roof and the protective shoe  34  to its maximum horizontal dimension, which dimension is greater than the annular distance of the rim space with the floating roof centered within the tank. In this way the liquid-mounted seal  20  is able to serve one of its dual purposes of allowing the floating roof to change its vertical position as the volume of the fluid in the tank increases or decreases without binding against the inner tank wall  16 . The other purpose is to prevent the escape of harmful vapors or to allow evaporation of the liquid beyond the floating roof into the atmosphere within the tank. With the liquid-mounted seal  20  extending without gaps from the outer perimeter sidewall  12  of the floating roof to the proximal side of the protective shoe  34  and the protective shoe  34  maintained in contact against the tank wall  16 , the seal is maintained as the floating roof changes its vertical position as necessitated by the volume of fluid within the tank. 
         [0027]    Referring now to  FIG. 2 , an exploded view of the rim seal system  10  of the present invention is shown for greater clarity. The liquid mounted seam  20  is comprised of a solid core seal member mounted to the mounting plate  24  by fasteners  26   a ,  26   b . Surrounding the seal core member of the liquid mounted seal  20  is a protective fabric  22  that encircles the seal core member and is attached by sandwiching the lower end of the protective fabric  22  between the mounting plate  24  and the outer perimeter sidewall  12  of the floating roof. A partial perimeter section of the floating roof is depicted as the outer perimeter sidewall  12  and bottom plate  14  creating one of a plurality of open top panel systems comprising the floating roof. The upper end of the protective fabric  22  is sandwiched between the upper flange of the outer sidewall  12  and the extension plate  30 . The lower end of the outer protective fabric  22  is sandwiched between the mounting plate  24  and the outer sidewall  12  of the floating roof as the mounting plate  24  is attached to the floating roof using fastener  27 . The upper end of the outer fabric protector  22  is also sandwiched between the upper flange of the outer sidewall  12  of the floating roof and the bottom foot of an extension plate  30  extending upward from the top of the outer sidewall  12 . The extension plate  30  is a reinforced plate having a doubled thickness. The extension plate  30  is used to mount the hanger assembly  32  that supports the protective shoe  34  that rides against the inner tank wall  16 . The protective shoe  34  extends from the height of the hanger assembly  32  downward between the liquid mounted seal  20  with its protective cover  22  and the inner tank wall  16  to a point below possible contact by the liquid mounted seal  20  with the inner tank wall  16 . In this way the protective shoe  34  prevents the liquid mounted seal  20  and its protective fabric  22  surrounding the solid core seal member from being abraded as the floating roof traverses upward and downward inside the tank as the liquid surface changes heights due to volume increases or decreases. 
         [0028]    The hanger assembly  32  spans the distance between the outer perimeter of the floating roof and the inner tank wall  16 . On the floating roof side the hanger assembly  32  is securely fastened to the extension plate  30  by two fastening means  33   a ,  33   b . Extending outward from the extension plate  30  is proximal tension joint  36  to which is attached a first extension plate  38 . At the distal end of extension plate  38  are a pair of cooperating intermediate tension joints  40   a ,  40   b . First extension plate  38  is attached to tension joint  40   a  that is, in turn, attached to tension joint  40   b . Second extension plate  42  is attached between tension joint  40   b  and distal tension joint  44 . The protective shoe  34  is attached to distal tension joint  44  by fasteners  46   a ,  46   b . This structure maintains the protective shoe  34  at the required lateral position relative to the floating roof to protect the liquid mounted seal  20  and its protective fabric  22  from unwanted abrasion. The hanger assembly structure also provides an outward force extending against the protective shoe  34  to retain the shoe  34  in constant contact with the inner tank wall  16 . To accomplish this second task, the hanger assembly  32  includes the tension joints  36 ,  40   a ,  40   b  and  44  that exert a spring force against the extension plates  38 ,  42  forcing the extension plates  38 ,  42  to extend to the greatest allowable angular relationship at any given time. In this way the protective shoe  34  is maintained at the proper lateral position to the floating roof and in constant contact with the inner tank wall  16 . 
         [0029]    Shown in  FIG. 3  is a top down view of the hanger assembly spanning the rim space between the internal floating roof and the inner wall of the tank. We will utilize the element numbers from the first embodiment of  FIG. 1  in describing the structural relationship, but it is to be understood that the element numbers for the second embodiment shown in  FIG. 4  having similar numbers are intended to be included in this description. The hanger assembly  32  extends across the rim space  50  between the extension plate  30  and the protective shoe  34  riding against the inner wall  16  of the storage tank. As the rim space  50  changes due to the internal floating roof shifting its intended central position closer or away from any given point on the inner wall  16  of the tank, the hanger assembly  32  expands or contracts to accommodate the changing distance and to maintain the protective shoe  34  in contact against the inner wall  16 . 
         [0030]    Looking down from the top, the hanger assembly  32 , at its central point where the intermediate tension joints  40   a ,  40   b  are arranged, the intermediate tension joints  40   a ,  40   b  are coupled together by fasteners  48  located at the top and bottom of the tension joints  40   a ,  40   b  such that the spring tension creates an outward force expanding the hanger assembly  32  unless compressed by the internal floating roof shifting too close to an opposing segment of the inner wall  16 . In this way the internal floating roof maintains a substantially uniform distance (rim space) from the inner wall  16  of the tank such that the seals of the different embodiments can remain effective in closing off the rim space  50  and reducing the evaporative effect of the stored liquid. In describing only a single unit of the entire rim seal system it is to be understood that a plurality of these units are arrayed without lateral gaps about the entire periphery of the internal floating roof extending into the rim space to provide the barrier across the rim space to prevent leakage and evaporation of the stored liquid. 
         [0031]    In  FIG. 4  a second embodiment of the rim seal system  110  of the present invention is depicted with a flexible membrane type seal as the primary seal and a wiper type seal positioned above as the secondary seal. In this embodiment, the rim seal system  110  is comprised of a flexible membrane seal  120  mounted between the outer sidewall  12  of the floating roof and the protective shoe  34 . A partial perimeter section of the floating roof is depicted as the outer perimeter sidewall  12  and bottom plate  14  creating one of a plurality of open top panel systems comprising the floating roof. The flexible membrane seal  120  is sandwiched between the upper flange of the outer sidewall  12  and the bottom foot of the extension plate  130  using fastener  127 . At its other end, the flexible membrane seal  120  is attached along the mid-portion of the protective shoe  34  by mounting plate  35  and fasteners  37 . The extension plate  130  is a reinforced plate extending upward from the top of the outer sidewall  12  and is used to mount the hanger assembly  132  that supports the protective shoe  34  that rides against the inner tank wall  16 . The protective shoe  34  extends from the height of the hanger assembly  132  downward between the flexible membrane seal  120  and the inner tank wall  16  to a point below possible contact by the flexible membrane seal  120  and the inner tank wall  16 . In this way the protective shoe  34  prevents the flexible membrane seal  120  from being abraded as the floating roof traverses upward and downward inside the tank as the liquid surface changes heights due to volume increases or decreases. 
         [0032]    The hanger assembly  132  spans the distance between the outer perimeter of the floating roof and the inner tank wall  16 . On the floating roof side the hanger assembly  132  is securely fastened to the extension plate  130  by two fastening means  133   a ,  133   b . Extending outward from the extension plate  130  is proximal tension joint  136  to which is attached a first extension plate  138 . At the distal end of extension plate  138  are a pair of cooperating intermediate tension joints  140   a ,  140   b . First extension plate  138  is attached to tension joint  140   a  that is, in turn, attached to tension joint  140   b . Second extension plate  142  is attached between tension joint  140   b  and distal tension joint  144 . The protective shoe  34  is attached to distal tension joint  144  by fasteners  146   a ,  146   b . As before, the hanger assembly has two functions. The first is to maintain the protective shoe  34  at the required lateral position relative to the floating roof to protect the seal  120  from unwanted abrasion. The second function of the hanger assembly is to extend the protective shoe  34  outward to remain in constant contact with the inner tank wall  16 . To accomplish this second task, the hanger assembly  132  includes the tension joints  136 ,  140   a ,  140   b  and  144  that exert a spring force against the extension plates  138 ,  142  forcing the extension plates  138 ,  142  to extend to the greatest allowable angular relationship at any given time. In this way the protective shoe  34  is maintained at the proper lateral position to the floating roof and in constant contact with the inner tank wall  16 . 
         [0033]    The flexible membrane seal  120 , which is mounted below the hanger assembly  132 , is flexible and of sufficient length to accommodate lesser or greater distances between the outer sidewall  12  of the floating roof and the protective shoe  34  to its maximum horizontal dimension, which dimension is less than the annular distance of the rim space with the floating roof centered within the tank. In this way the flexible membrane seal  120  is able to serve one of its dual purposes of allowing the floating roof to change its vertical position as the volume of the fluid in the tank increases or decreases without binding against the inner tank wall  16 . The other purpose is to prevent the escape of harmful vapors or to allow evaporation of the liquid beyond the floating roof into the atmosphere within the tank. With the flexible membrane seal  120  extending without gaps from the outer perimeter sidewall  12  of the floating roof to the proximal side of the protective shoe  34 , the seal is maintained as the floating roof changes its vertical position as necessitated by the volume of fluid within the tank. A second purpose of the protective shoe  34  is to also prevent the escape of harmful vapors or to allow evaporation of the liquid beyond the floating roof into the atmosphere within the tank. Located at the distal end of and in contact with the flexible membrane seal  120 , the protective shoe  34  is maintained in contact against the tank wall  16  so that the rim seal system  110  is maintained as the floating roof changes its vertical position as necessitated by the volume of fluid within the tank 
         [0034]    Positioned above the flexible membrane seal  120  is a secondary wiper type seal  220 . The wiper type seal  220  is attached to an elongated upper extension plate  230  that is fastened to the lower extension plate  130  by fasteners  133   a ,  133   b  and by additional fastener  227 . The elongated upper extension plate  230  permits the wiper type blade seal free motion above the hanger assembly  132 . The wiper type seal  220  is sandwiched between the top flange  231  of the upper extension plate  230  and a clamping plate  233  and is attached to the upper extension plate  230  by the clamping plate  233  and fasteners  235 . In this way the wiper type seal  220  acts as a secondary seal between the internal floating roof and the extended outer wall formed by the extension plate  130  and the upper extension plate  230  that is coterminous with the outer wall  12  of the floating roof creating the inner wall for containing any vapors or gases that penetrate through the primary seal, the flexible membrane seal  120 . The wiper type seal  220  remains in direct and constant contact with the inner wall  16  of the tank and is of sufficient length to maintain that contact even as the rim space tends to increase or decrease as the floating roof may move off center so that the rim space is not exactly the same at all points between the floating roof and the tank wall. 
         [0035]    It is to be understood from the description presented of each of the three embodiments of the rim seal system  10  and  110  for a floating roof in a bulk liquid storage tank that the extension plates provide an extension of the outer wall of the floating roof in an upward direction that creates a vertically extended rim space within which space the rim seal systems  10  and  110  function to prevent leakage or evaporation of the stored liquid. It is also to be understood the wiper type seal  220  can be utilized with the other rim seal system  10  by the addition of the upper extension plate  230  and wiper type seal  220  to the described system without any change to the structure or function of the rim seal system  10 . 
         [0036]    The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.