Abstract:
A modular containment system, which does not require excavation of soil, and thus can be quickly and inexpensively assembled and utilized, such as for holding and containing large volumes of liquids, for example at oil and gas drilling sites. Furthermore, the modular containment system can be repetitively reused at subsequent drilling sites for many years. The system includes a plurality of walls that are assembled together, and then a water-tight liner is inserted inside the pool created by the system over the ground and over the side walls, where it is fastened down to the side walls.

Description:
[0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 61/625,539, which is hereby incorporated by reference herein. 
     
    
     BACKGROUND AND SUMMARY 
       [0002]    In the oil and gas industry, at a drilling site, there is a need to set up a containment pool near the drilling rig for storing and containing various fluids, such as drilling mud, or other fluids, which might contaminate the surrounding soil. Typical previous containment pools have been excavated in a subterranean manner using heavy equipment to excavate soil to form such pool, and then some type of liner material inserted into the excavated hole to prevent the fluid from seeping into the surrounding soil. 
         [0003]    Naturally, the excavation of the soil with this heavy equipment adds to the expense associated with setting up and operating a drilling rig site, especially in remote areas. 
         [0004]    Embodiments of the present invention provide a modular containment system, which does not require excavation of soil, and thus can be quickly and inexpensively assembled and utilized. Furthermore, the modular barrier system can be repetitively reused at subsequent drilling sites for many years. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIGS. 1-2  illustrate perspective views of a side wall  100  of a containment system configured in accordance with embodiments of the present invention. 
           [0006]      FIG. 3  illustrates in more detail the slots  101 , which may be utilized to hold down a vinyl or plastic liner over the top of any of the side walls or other sections of any of the embodiments described herein. 
           [0007]      FIG. 4  illustrates a perspective view of how several side walls can be joined together. 
           [0008]      FIG. 5  illustrates the backside of a corner side wall. 
           [0009]      FIG. 6  illustrates a containment system in accordance with embodiments of the present invention. 
           [0010]      FIG. 7  illustrates a section of a containment system showing how the liner is held down in place over the tops of side walls. 
           [0011]      FIGS. 8-9  illustrate side walls of another embodiment of the present invention. 
           [0012]      FIG. 10  illustrates a corner side wall configured in accordance with embodiments of the present invention. 
           [0013]      FIG. 11  illustrates an alternative embodiment of a corner side wall configured in accordance with embodiments of the present invention. 
           [0014]      FIG. 12  illustrates connections of side walls with a corner side will in accordance with embodiments of the present invention. 
           [0015]      FIG. 13  illustrates a containment system configured in accordance with embodiments of the present invention showing a liner fastened thereto for containment and holding of a liquid therein. 
           [0016]      FIG. 14  illustrates a C-shaped clamp or clip utilized for holding down a liner on side walls in accordance with embodiments of the present invention. 
           [0017]      FIGS. 15-16  illustrate an alternative embodiment of a side wall configured in accordance with embodiments of the present invention. 
           [0018]      FIG. 17  illustrates a corner side wall configured in accordance with alternative embodiments of the present invention. 
           [0019]      FIG. 18  illustrates a containment system configured in accordance with alternative embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    The materials for manufacturing the embodiments of the present invention may be comprised of a plastic, which may be made using rotational or injection molding of each of the pieces of a system. 
         [0021]    Rotational molding is a three-stage, no-pressure, plastic molding process. During the heating stage, the mold slowly rotates in two planes (bi-axial rotation). Heat transfer causes the plastic charge inside the mold to melt and uniformly coat the interior of the mold. During the second stage, the mold moves to the cooling station, where it is cooled by air and/or water spray. In a final load/unload stage, the part is removed from the mold and a new charge of material may be loaded into the mold. 
         [0022]      FIGS. 1-2  illustrate perspective views of a side wall  100  of a containment system configured in accordance with embodiments of the present invention. Slots  101  of the side wall  100  may be included when the side wall  100  is molded, for receipt of a clip to hold down the liner material when the entire system is assembled (see  FIG. 7 ). As the container system is modular, a side wall  100  can be assembled to another modular piece using the interlocking portions  102 ,  201  formed on a side of a side wall  100 , which will fit with the interlocking portions of another side wall portion (e.g., see  FIGS. 4 and 6 ), including the inclusion of some sort of pin (not shown) within the holes down through each of the portions  102 ,  201  to hold them fast to each other. The side walls  100  may also include a top edge  103 , which may be utilized to hold down a liner draped over the top of the side walls with a clip (which may be C-shaped) that may be pressed down on top of the edges  103  to hold down the liner (e.g., see  FIGS. 13-14 ). The side walls  100  have a back portion  104  and an inside wall portion  105 . Additionally, and as further shown in  FIG. 4 , a flap portion  203  may be included on the side walls  100  associated with the interlocking portions  201  so that the gap between the side walls  100  is covered when side walls  100  are assembled together, such as shown in  FIG. 6 . 
         [0023]      FIG. 2  illustrates a view of a side wall  100 , including the interlocking portions  201 , which will connect with the portions  102  as shown in  FIG. 1  for assembling side walls to each other.  FIG. 2  also illustrates the “L-shape” of the side wall  100  where the base portion  202  of the side wall  100  provides stability for the side wall  100  to rest on the ground. When a liner (e.g., see  FIG. 13 ) is installed, the weight of the fluid on top of the base portion  202  is greater than the pressure being applied against the sides  105  of the side walls  100 , therefore keeping the walls erect so that they do not tip outward allowing the contained fluid to escape. 
         [0024]      FIG. 3  illustrates a close up perspective view of a portion of a side wall  100  and its slots  101  for receiving clips to hold down a liner (not shown). See  FIG. 7  for more detail. 
         [0025]      FIG. 4  shows three side walls  100 , which can be assembled to each other using the interlocking portions  102  and  201  on each side wall  100 .  FIG. 4  also illustrates how a side wall  100  is designed with the interlocking portions  102  on one side of the side wall  100  and the corresponding interlocking portions  201  on the other side. 
         [0026]      FIG. 5  illustrates a corner-shaped side wall  500 , similarly configured as a straight side wall  100 , including possessing one or more slots  501  for receiving a clip for holding a liner in place (e.g., see  FIG. 7 ). Corner-shaped side wall  500  similarly has an outside portion  504 , and an inside wall portion (not shown) along with an optional flap  503 , and interlocking portions  502 , and corresponding interlocking portions at the other end of the side wall (not shown). Furthermore, a corner-shaped side wall  500  may also include a top edge  505  as an alternative means for holding down a liner with a clip attached on top thereof (e.g., see  FIGS. 13-14 ). 
         [0027]      FIG. 6  illustrates an exemplary configuration of a container system with interlocking straight-shaped side walls  100  and corner-shaped side walls  500  with their interlocking portions fastening the side walls to each other. Naturally, any shape of a container system is possible with the various embodiments described herein, and should not be limited to the shape of the system shown in  FIG. 6 . 
         [0028]    After assembly of any container system described herein, such as those illustrated in  FIGS. 6 ,  13 , and  18 , a plastic or vinyl liner is then inserted overlaying the ground inside and between the side walls, with the liner then being draped over the side walls of the system. This is further illustrated in  FIG. 13 , as an example. Such a vinyl or plastic liner is commercially available and well known in the art, and can be manufactured using well known techniques including where multiple sheets of the liner are manufactured and then mold-pressed together at their edges to form any desired shape. After the vinyl cover is draped over the tops of the side walls of an assembled system, either of the fastening means described herein may be utilized to hold down the liner over the top edges, such as utilizing clips into the slots  101 ,  501 , and other slots shown herein, or clips fastening down the liner over the top edges  103 ,  505 , or any of the other top edges described herein. 
         [0029]    For example,  FIG. 7  illustrates a sectioned portion showing the back sides  104  of two side walls  100  assembled next to each other with the vinyl sheet  701  draped over the backs of these side walls, and the clips  702  inserted into the slots  101  (hidden from view by the liner  701 ) to hold down the liner  701 . Thereafter, a fluid may then be filled inside the pool of the container system, such as shown in  FIG. 13 . 
         [0030]      FIGS. 8-9  illustrate another exemplary containment system, in which side walls  800  are shown. These side walls are of a lower height than side walls  100 , for assembling together to form a containment system that has lower sides. Essentially, labeled items  801 - 806 , and  808  are similar to items  101 - 105 ,  201 , and  203 , respectively. 
         [0031]      FIG. 10  illustrates a corner-shaped side wall  1000 , with a clip receiving slot  1001 , which is designed to interlock with side walls  800 . The corner-shaped side wall  1000  may be similarly designed as the corner-shaped side wall  500 . The corner-shaped side wall may also include a top edge  1003  similar to the top edges  103 ,  505 , and  803  for retaining a liner over the top of the corner-shaped side wall utilizing a clip such as shown in  FIG. 14 . 
         [0032]      FIG. 11  illustrates an alternative embodiment of a corner-shaped side wall  1100 , which is similar to the corner-shaped side wall  1000 , except that it utilizes the side tab portions  1102  and  1103  to interconnect using pins (not shown) with the side walls  800 , such as illustrated in  FIG. 12 . It should be noted that corner-shaped side wall  1100  is shown not including a top edge  1003 , such as shown in  FIG. 10 . Additionally, the corner-shaped side wall  1100  has a straight inside wall, and does not have an L shape, such as the corner-shaped side wall  1000 , which has an L shape similar to the corner-shaped side wall  500 . Nevertheless, a corner-shaped side wall  1000  may be utilized for assembly with side walls  800  in a manner similar to what is shown in  FIG. 12 . 
         [0033]      FIG. 13  illustrates an exemplary containment system assembled in a fashion with multiple side walls on the straight sides of the system and the corner-shaped side walls at each corner. The containment system illustrated in  FIG. 13  also shows a liner  1301  installed within the interior of the system and held in place over the tops of the side walls with clips  1401  attached over the tops of each of the side walls to hold down the liner  1301 . As can be seen in  FIG. 13 , a fluid  1302  is satisfactorily contained within the enclosed system. 
         [0034]      FIG. 14  illustrates an exemplary C-shaped clip  1401 , which may be utilized to snuggly fasten down a liner over the top edges of any of the side walls described herein. The exact shape of the clip  1401  should not be limited to the shape illustrated in  FIG. 14 . Nevertheless, the inside shape of the clip  1401  should have a similar shape as the outside shape of any of the top edges of the side walls described herein so that a liner is sandwiched in between the clip and the top edge when the clip is snapped over the top edge of the side walls, such as illustrated in  FIG. 13 . 
         [0035]    It should be noted that the example of a liner placed inside a containment system and then draped over the sides of the side walls and fastened down as illustrated in  FIG. 13  may be accomplished for any of the containment systems described herein, and any variations thereof. For example, the liner illustrated in  FIG. 13  may be fastened down using the clips shown in  FIG. 7  that have the liner sandwiched between the slots (not shown) and the clip. Such clips shown in  FIG. 7  may be manufactured from any rigid material, such as PVC or metal pipe. 
         [0036]      FIGS. 15-16  illustrate an alternative embodiment of a side wall, which is similarly shaped as the side walls  100 . However, the upright portion  1501  is separately manufactured (e.g., using rotational or injection molding) from the base portion  1502 , and then the upright portion  1501  and the base portion  1502  may be assembled together, such as by using a pin or slot to fasten them together. The side walls  1500  also may include a top edge  1503  for receiving a clip  1401 . Alternatively, a slot (not shown) such as the slots  101  may be integrally formed on the side of one of the upright side wall portions  1501 . 
         [0037]      FIG. 17  illustrates a corner side wall  1700  for assembling with the side walls  1500 . 
         [0038]      FIG. 18  illustrates an example of a containment system  1800  assembled using the side walls  1500  and corner side walls  1700 .