Abstract:
A device and method of making a full contact floating roof for use in covering fluid bodies, such as storage tanks containing hydrocarbon fluids, allowing ease of construction, high integrity, and low maintenance cost.

Description:
CONTINUATION APPLICATION  
       [0001]     This application is a continuation of U.S. patent application Ser. No. 10/397719, filed Mar. 26, 2003. 
     
    
     TECHNICAL FIELD  
       [0002]     The invention concerns a device for covering or sealing a liquid containment storage tank with a full contact floating roof, and method for making it  
       BACKGROUND OF THE INVENTION  
       [0003]     Liquid containment storage tanks are frequently used to store hydrocarbon liquids. When the stored liquid is volatile or presents a risk of pollution through evaporation, the storage tank is often equipped with a floating roof, which floats on top of the stored liquid and moves up and down with the liquid level. Floating roofs greatly reduce liquid evaporation, preventing loss of the stored liquid and reducing pollution due to hydrocarbon evaporation into the atmosphere.  
         [0004]     Such floating roofs are often provided with support legs which are usually spaced about twenty feet apart and provide support to the roof when the roof is not floating on stored liquid, such as when the tank is emptied or taken out of service for maintenance. These roofs are usually floated by pontoons which are secured to the roof support structure. However, such pontoon-floated roofs leave a vapor space above the liquid surface in the tank. Thus, evaporation will occur in the tank until the vapor space is saturated, at which point equilibrium between the vapor space and the liquid is reached.  
         [0005]     However, there will be losses of the liquid stored in the tank, as vapor leaks through seams in the roof or around seals. Engineering of floating roofs attempts to eliminate such leakage losses, but the existence of a relatively volatile vapor space immediately under the roof makes absolute elimination of such losses impossible.  
         [0006]     Elimination of the vapor space is possible by using a full contact floating roof. Existing full contact roofs include aluminum and steel roofs. Aluminum full contact roofs are usually comprised of panels bolted to an aluminum framework. Such panels may comprise expanded aluminum honeycomb, or a foam core sandwiched between two layers of aluminum sheet. Most full contact steel roofs are constructed from steel plate welded together and surrounded by steel pontoons. Other, “pan type” steel roofs are simple flat plate welded together with a vertical rim along the edge.  
         [0007]     However, these types of full contact roofs have engineering and practicality limitations. Current full contact roof designs are only marginally capable of sustaining the loads imposed on the structures. They are also easily upset and sunk if there is a large operations anomaly in the underlying tank. Because these roofs have to be constructed in the field, there are high labor and heavy-equipment machinery costs associated with assembling and moving materials around at the construction site. Further, steel roofs require periodic repainting and are very susceptible to corrosion, creating high maintenance costs and potentially limiting the useful life of the roof.  
         [0008]     A further limitation of the aluminum honeycomb or foam core sandwiched-panel type roofs is the inability to test the individual honeycomb cells for the presence of a foreign or combustible vapor. Such vapor may be present if there is a leak in the outer sheeting cover. Moreover, the aluminum honeycomb or foam core sandwiched panels are normally joined to the outer aluminum sheeting cover with glue or adhesive that frequently becomes brittle and inflexible after being applied. Cyclic operation of the floating roof, or certain external loading conditions on the outer sheeting cover, such as walking on the roof, often cause theis glue or adhesive to crack, forming vapor or liquid paths between the individual compartments. Thus, the leak-tight integrity of the individual compartments may be compromised.  
         [0009]     Accordingly, it is an object of the invention to provide a full contact floating roof which is full contact, yet is made of relatively lightweight, durable, and stable materials which are easy to assemble.  
         [0010]     It is a further object of the invention to provide a full contact floating roof which is difficult to upset and sink.  
         [0011]     It is another object of the invention to provide a full contact floating roof which provides additional options for fire protection over existing roofs.  
       BRIEF DISCLOSURE OF THE INVENTION  
       [0012]     The invention comprises a full contact floating roof, constructed from a plurality of buoyant cells. In the preferred embodiment, these buoyant cells are formed by sections of extruded fiber reinforced plastic (“FRP”). By creating a fluid- and vapor-impermeable join between multiple buoyant cells, groups of such cells are joined together side by side to form the roof. Although the shell, or body, of the buoyant cells can be formed in any reasonable geometric shape which will still allow the proper joins between cells, in the preferred embodiment the shells are square-angle parallelepipeds, for example, box-like rectangular cells. Each cell must provide sufficient displacement so that the weight of the cell, plus any additional load the cell is expected to support, will float on top of the fluid which will be beneath the full contact floating roof.  
         [0013]     In the preferred embodiment, each cell is extruded with a gripping slot on each side (as used herein, the cell&#39;s “bottom” is considered to be that side of the cell in contact with the contained fluid, the cell&#39;s “top” is that portion of the cell exposed to the open air or other atmosphere above the contained fluid, and the cell&#39;s “sides” are the sections of the cells which can be joined to other cells), into which can be inserted a formed, rigid or semi-rigid strip which, when inserted into the gripping slots of two of the cells, will maintain the sides of those cells in close proximity to each other and without allowing substantial relative movement of the cells. Additionally, it is preferred that an adhesive sealant, glue, or epoxy, such as Pliogrip (Ashland Chemical) is applied to the side surfaces of each two cells being joined, so that the final join between the cells will both be strong and provide a sufficient seal to prevent the escape of contained fluid or vapor from the bottom of the cells.  
         [0014]     Also in the preferred embodiment, the buoyant cells are approximately two feet wide, and comprise interior risers which serve both to support the top surface of the cell against applied loads and to form internal barriers, breaking the interior of the cell into a series of individual sub-cells. Because it is preferred that the buoyant cells are extruded, the sub-cells created by the risers will run the full length of the cell, and will be sealed at either end with blocks of material such as Valox during assembly of the roof. Thus, each sub-cell can independently provide a sealed airspace. These block seals are additionally preferably glued in place with Pliogrip to insure a complete seal.  
         [0015]     This method of construction also allows the use of the same basic buoyant cells to form any particular shape of roof. For example, a circular roof can be formed by cutting the necessary arc along the edge of a series of joined buoyant cells, then sealing the exposed ends of the sub-cells. These cuts may be curved or may be miter cut in chords. The curved or chord cuts may be sealed in the same fashion as would a flat cut, thus allowing square, rectangular, circular, oval, elliptical, or other shapes of floating roofs to be formed using the same materials and same construction methods.  
         [0016]     Constructed in this manner, each sub-cell provides an independent flotation device. Further, the individual sub-cells can be flooded with gas, such as an inert gas, to improve fire protection when the floating roof is used to contain volatile hydrocarbons. This process may be accomplished economically by inserting a valve or a selectively pluggable coupling through the top of each sub-cell. Moreover, a self-activating sealant or intermescent material such as Contega or Flameseal, for example, can be used to coat the interior of the sub-cells prior to sealing them, so that in the event of a fire above the roof, the individual sub-cells will close off and aid in preventing the fire from reaching the contained fluid. Alternatively, inserts coated with such materials can be inserted in the sub-cells. Similarly, in the event of a puncture of the roof and subsequent fire, the intermescent material can act to expand and seal the hole, thereby suppressing the fire if it has reached the contained fluid.  
         [0017]     Thus, this floating roof provides a variety of advantages over other such roofs. Because the extruded materials are relatively lightweight and can be shipped as individual cells, or pre-assembled into sectional panels to be assembled on-site into a single roof, the cost and complexity of construction assembly on-site is greatly reduced. Further, the manner of construction, involving simple mechanical tools and adhesives, greatly reduces the need for skilled labor on site, as is required to weld steel sections together or to assemble complex, bolted, aluminum frameworks. Moreover, the extruded materials provide further advantages, because they are extremely corrosion resistant and therefore provide cost savings for long-term maintenance of the roof once it is installed.  
         [0018]     The modular nature of the buoyant cells further allows each section to be tested for internal fluid or vapor leaks by providing signal communication between a fluid or vapor detection device internal to the cell and a monitor outside the cell. Detectors can be placed within each sub-cell, and connected together by drilling or cutting through the riser wall to allow a signal coupler, such as a wire or cable, to be passed between sub-cells. The integrity of the sub-cells can be restored by gluing a seal in place around the signal coupler where it passes through the riser. Alternatively, test ports can be inserted in any sub-cell through the external skin of a buoyant cell, sealed in place, and connected to an external detection device to test the sub-cell for fluid or vapor leaks.  
         [0019]     Because holes from the top to the bottom of an extruded panel can be sealed off from the remainder of the sub-cell or sub-cells though which the hole passes by means of seals and adhesives, it is also relatively easy to provide drains or manholes through a buoyant cell, allowing rainwater or other fluid to be drained away and allowing for inspection of the region under the floating roof. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]      FIG. 1  is an oblique top view of a full contact floating roof subsection.  
         [0021]      FIG. 2  is an end view of four extruded buoyant cells assembled as in  FIG. 1 .  
         [0022]      FIG. 3  is an end view of an extruded, gripping slot of the preferred embodiment.  
         [0023]      FIG. 4  is an end view of one embodiment of joining two subsections of  FIG. 1 .  
         [0024]      FIG. 5A  is an end view of one embodiment of a buoyant cell.  
         [0025]      FIG. 5B  is an end view of one embodiment of a buoyant cell.  
         [0026]      FIG. 5C  is an end view of one embodiment of a buoyant cell.  
         [0027]      FIG. 6A  is an overhead view of the end seals for a rectangular buoyant cell.  
         [0028]      FIG. 6B  is an overhead view of the end seals for a circular-roof buoyant cell. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0029]     Referring to  FIG. 1 , a subsection  10  of a full contact floating roof of the present invention is shown. The subsection  10  is comprised of four square angle parallelepiped buoyant cells  12 , which are joined together by joins  14 . Thus, the width  16  of the subsection  10  will be essentially four times the width of each buoyant cell  12 , and the length  18  will be essentially the length to which the buoyant cells have been cut. Because it may be convenient to pre-assemble subsections  10  away from the final construction site, the length  18  of the buoyant cells  12  can be determined by factors such as total weight of the subsection  10 , shipping size limitations, or the dimensions of the overall roof to be constructed.  
         [0030]     In the preferred embodiment, the subsection  10  is provided with a frame  20  which around the perimeter of the subsection  10 , allowing for increased structural integrity for the subsection  10 , and allowing for easy attachment of lift points  22  to the subsection  10 . If one or more of the sides  24  of the subsection  10  will be in contact with the sides of the fluid containment tank (not shown) in which the floating roof will be installed, a primary  26  and secondary  28  seals are preferably attached to those sides  24 . To facilitate removal of excess loads, such as rainwater, drains  30  may be inserted through one or more of the buoyant cells  12 , and sealed in place with adhesives to prevent leakage around their perimeter.  
         [0031]     Referring to  FIG. 2 , an end view of four buoyant cells  212 , assembled as in  FIG. 1 , is shown. Each buoyant cell  212  comprises risers  214  which extend the length of the buoyant. cell  212 , forming essentially independent sub-cells  216 . In the preferred embodiment, formed strips of rigid or semi-rigid material  218  fit into extruded, gripping slots (see  FIG. 3 ) in the sides of the buoyant cells  212 , positioning the buoyant cells  212  in a tightly held relationship to each other. Adhesive (not shown) is additionally used in each of the joins  219 , to further strengthen and seal the bonds between the buoyant cells  212 . The sides  222  of the subassembly  210  comprise a frame  220 , which is preferably formed of fiberglass or FRP with an extension  224  which fits into the extruded, gripping slots (see  FIG. 3 ), and is preferably bonded further to the respective buoyant cell  212  with two-part urethane, preferably Pliogrip.  
         [0032]     Referring to  FIG. 3 , an end view of the extruded, gripping slot in the side of a buoyant cell  312  of the preferred embodiment is shown. The slot  314  is formed by extrusion so that a formed rigid or semi-rigid strip  316  can be securely slid into the slot  314 , so that adjacent buoyant cells may be securely joined together. As those of skill in the art will recognize, other means of attachment of the buoyant cells is feasible, such as using bolts or screws, or using bridges secured to the top or bottom surface of the buoyant cells. Accordingly, this depiction of the preferred embodiment of the extruded, gripping slot  314  is for illustrative purposes only, and is not intended to limit the scope of the invention.  
         [0033]     Referring to  FIG. 4 , one method of joining two subsections such as that of  FIG. 1  is shown. The frames  410 ,  412  of the respective subsections  414 ,  416  are positioned so that a gasket, preferably a self-stick gasket  418  can be placed between them to form a seal, and toggles  420  can be positioned at appropriate intervals down the length of the frames  410 ,  412  to securely tie subsections  414 ,  416  together. Thus, any number of subsections  414 ,  416  can be assembled side-to-side or end to end, as necessary to form the needed area for the full contact floating roof.  
         [0034]     Referring to  FIGS. 5A, 5B , and  5 C, various configurations of the interior of the buoyant cell  510  are shown. The sub-cells  512  may be filled with a gas through valves (or, alternatively, couplings)  513 , such as an inert gas (not shown) to increase the fire-resistant qualities of the buoyant cell  510 . Similarly, the interior walls  514  of the sub-cells  512  may be coated with an intermescent material  516  to provide fire-proofing, or, in the case of a puncture of the buoyant cell  510 , fire-suppression. This coating can be easily accomplished by inserting a hose (not shown) with a spray attachment (not shown) down the length of the sub-cell  512 , then spraying the intermescent material  516  while withdrawing the hose.  
         [0035]     Further, fluid or gas probes  518  may be inserted in each sub-cell  512  for leak detection purposes, and may be placed in signal communication with a detector (not shown) by providing a signal lead  520  through a hole  522  (or slot, if at the end of the buoyant cell) in the walls  514  of the sub-cells  512 . Sealant or adhesive (not shown) may be placed around the signal lead  520  where it penetrates the walls  514  to insure the continued separation of the sub-cells  512 . The signal lead  520  can then be extended through the top  524  of the buoyant cell  510 . As those of skill in the art will recognize, signal leads could be extended from each sub-cell  512  rather than being joined in a single feed, without departing from the spirit of the invention. However, using a single feed reduces the number of penetrating holes in the top  524 .  
         [0036]     Referring to  FIGS. 6A and 6B , multiple configurations of the seals for the ends of the buoyant cells  610  are shown. Each sub-cell  612  is sealed with a block  614  of material such as Valox, which is permanently set in place with adhesive. If the shape of the roof is round or oval rather than square, or even an irregular shape, the ends of the buoyant cells  610  may be cut to shape as needed, as shown in the example of a circular floating roof section of  FIG. 6B . The sealing blocks  614  can then be cut to the shape of the end of each sub-cell  616 , as needed. However, if the ends of adjacent sub-cells are sufficiently straight, a single block  614  of material may be used to bridge and seal the ends of more than one adjacent sub-cell (not shown).  
         [0037]     Those of skill in the art will recognize that variations of the above description may be made without departing from the scope and spirit of this invention, and this invention shall not be unduly limited to these illustrative embodiments.