US20130121768A1

US20130121768A1 - Berms for protective liners

Info

Publication number: US20130121768A1
Application number: US13/667,616
Authority: US
Inventors: Beth P. Powell; R. Douglas Evans, Jr.; Matthew J. Huff; Andrew J. Huff; Robert J. Starr
Original assignee: New Pig Corp
Current assignee: New Pig Corp
Priority date: 2011-11-04
Filing date: 2012-11-02
Publication date: 2013-05-16
Also published as: WO2013067348A1

Abstract

Berms for use with protective liners are disclosed. The berms may be configured to allow vehicular traffic to pass over the berms without causing damage. Such drive-over berms may be rigid and shaped to allow vehicle tires to pass over them, or may be resilient and collapsible such that they collapse when subjected to the weight of a vehicle tire, and then spring back to shape after the vehicle passes. Also disclosed are berms that may be stacked for storage and transportation purposes, and berms that include connectors for connecting multiple sections of the berms end-to-end.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/555,523 filed Nov. 4, 2011, and U.S. Provisional Patent Application Ser. No. 61/581,884 filed Dec. 30, 2011, both of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to liners that protect the environment from spills and leaks at sites such as oil and gas well drilling sites, and more particularly relates to berms for use with such liners.

BACKGROUND INFORMATION

In conventional gas and oil drilling, large quantities of drilling mud, fracturing chemicals and flowback water are on site. Many operating companies compact the pad site and place a liner over the entire surface. The liner is pulled over earthen berms, railroad ties, corrugated pipe or foam blocks to form containment sidewalls or berms around the perimeter. The liner and berms then contain the leaks and spills so that on-site vacuum trucks can remove the waste without impact to the environment.
There are issues with the current berm options. An earthen berm requires heavy equipment to build. The liner cannot be directly attached and requires staking. The earthen berms also tend to collapse into ruts under repeated vehicle traffic.
While railroad ties can be moved from site to site for reuse, they are hard to decontaminate since they are covered in creosote and are absorbent to the chemicals on site. They require earthen ramps over top to move bobcats, skid steers, front end loaders, and track hoes on and off the pad site. The earthen ramp material inside the containment area absorbs the chemicals and must be landfilled afterwards. For tractor trailer traffic, the railroad ties need to be completely removed. Since durable liners are able to survive multiple operations in the well construction, this means that the berms may be removed and reinstalled up to five times. While the berms are out of position, the containment liner has an open sidewall. If a release occurs during that period, the liquids would flow off the edge of the pad.
Corrugated pipe is easy to decontaminate due to its plastic construction. It is also light weight and easy to move. However, it is easy to crush and unable to support a ramp. It does not provide a physical barrier to traffic in sensitive areas and cannot be used in drive-over areas.
Triangular and rectangular foam blocks underneath the liner provide easy drive-over sections. The drawbacks are: their limited weight which can allow wind uplift, and their poor resistance to being pushed forward into the pad. When the foam sidewall is pushed into the pad by vehicle traffic, the liner wrinkles. These wrinkles are tripping hazards for site personnel.

SUMMARY OF THE INVENTION

The present invention provides berms for use with protective liners. In certain embodiments, the berms are configured to allow vehicular traffic to pass over the berms without causing damage. Such drive-over berms may be rigid and shaped to allow vehicle tires to pass over them, or may be resilient and collapsible such that they collapse when subjected to the weight of a vehicle tire and then spring back to shape after the vehicle passes. In certain embodiments, the berms may be stackable for storage and transportation purposes, and may include connectors for connecting multiple sections of the berms end-to-end.
An aspect of the present invention is to provide a drive-over berm for use with a protective liner, the berm comprising a rigid base, and a berm body extending upwardly from the base structured and arranged to allow vehicular traffic over the berm.
Another aspect of the present invention is to provide an interlocking berm assembly for use with a protective liner, the assembly comprising a first berm section having a connecting end, a second berm section having a connecting end, and at least one connector securing the connecting ends of the first and second berm sections together.
A further aspect of the present invention is to provide a stackable berm for use with a protective liner, the stackable berm comprising opposing sidewalls extending upward from an open base, and a top connected to upper portions of the opposing sidewalls, wherein the sidewalls and top define an open volume inside the stackable berm, and are structured and arranged to fit inside an open volume inside another similarly shaped berm.
Another aspect of the present invention is to provide a protective liner and berm assembly comprising a berm comprising a rigid base and a berm body extending upwardly from the base structured and arranged to allow vehicular traffic over the berm, and a protective liner covering at least a portion of the berm.
These and other aspects of the present invention will be more apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially schematic top plan view of a liner and berm assembly in accordance with an embodiment of the present invention.

FIG. 2 is an isometric sectional view illustrating a portion of a liner and berm assembly in accordance with an embodiment of the present invention.

FIG. 3 is an isometric sectional view illustrating a portion of a liner and berm assembly in accordance with another embodiment of the present invention.

FIGS. 4-6 are isometric sectional views of rigid berms in accordance with embodiments of the present invention.

FIGS. 7 and 8 are isometric sectional views of rigid, stackable berms in accordance with embodiments of the present invention.

FIGS. 9-13 are isometric sectional views illustrating resilient berms in accordance with embodiments of the present invention.

FIGS. 14-17 are isometric views illustrating berm connections in accordance with embodiments of the present invention.

DETAILED DESCRIPTION

Embodiments of the present invention provide drive-over berms for use with protective liners that are structured and arranged to allow vehicular traffic over the berms. In one embodiment, the berms comprise a base with an upwardly extending rigid body that is shaped to allow vehicle tires to travel up and over the berm. In another embodiment, the berms comprise a base with an upwardly extending collapsible resilient body that compresses or deforms when the weight of a vehicle tire travels over the berm, and then returns to its original shape after the tire passes. As used herein, the terms “drive-over berm” and “structured and arranged to allow vehicular traffic over the berm” refer to either of these embodiments, or a combination thereof.
FIG. 1 is a plan view of a liner and berm assembly 10 in accordance with an embodiment of the present invention. The liner and berm assembly 10 includes a liner 12 comprising a liquid-impermeable sheet of material. The liner 12 may be made of any suitable material and may be of any desired construction. For example, the liner may comprise one or more polymeric barrier layers and/or one or more geotextile layers. In one embodiment, the liner may be constructed of a combination of felt geotextile and polymeric barrier layers as described in Published U.S. patent application No. 2012/0219746A1, which is incorporated herein by reference.
A non-collapsible rigid berm 14 may be provided at the periphery of the liner 12, surrounding three sides thereof. A drive-over berm 16 structured and arranged to allow vehicular traffic over the berm is provided along the fourth side of the liner 12. In the embodiment shown in FIG. 1, the drive-over berm 16 is collapsible. However, as more fully described below, the drive-over berm may alternatively be rigid with a low-profile sloped contour that allows vehicular traffic to pass over the rigid berm. Vehicular or other traffic may access the interior area of the liner 12 via the drive-over berm 16. Openings 18 may be provided in the interior area of the liner 12 to allow drilling equipment or other equipment to pass through the liner 12.
FIG. 2 is a side-sectional view of the peripheral edge portion of a liner 12 with a collapsible berm 16 installed therein. The liner 12 wraps around the collapsible berm 16 with the edge of the liner folded back onto the body of the liner, where it is secured by a heat weld 13, or any other suitable means such as adhesives, mechanical fasteners or the like. Mechanical fasteners 15 may be used to secure the liner 12 to the collapsible berm 16.
FIG. 3 illustrates an embodiment similar to the embodiment shown in FIG. 2, except the liner 12 covers the top of the collapsible berm 16 but does not wrap around the berm 16. The liner may be secured to the berm 16 by mechanical fasteners 15.
FIGS. 4-8 illustrate non-collapsible rigid berms in accordance with embodiments of the present invention. As shown in FIG. 4, a non-collapsible berm 40 includes a base 42 and sidewalls 44 and 46. The sidewalls form a generally equilateral triangular cross section with rounded corners. The generally triangular shape may allow vehicles to driver over the berm 40.
In the embodiment shown in FIG. 5, a non-collapsible rigid berm 50 includes a base 52 with downwardly extending projections or ridges 53 that help to strengthen the berm 50 and to maintain it in its desired location on the ground or over a liner. The non-collapsible rigid berm 50 includes sidewalls 54 and 56, which form a generally triangular cross section with rounded corners that allow vehicles to drive over the berm 50. The berm 50 has a relatively low profile that facilitates vehicular traffic, e.g., the height of the berm 50 may be less than 75% of the width of the base, for example, less than 60% or less than 50% of the width of the base. Stiffening webs 58 are provided inside the berm 50, connecting the sidewalls 54 and 56 to the base 52.
In the embodiment shown in FIG. 6, a non-collapsible rigid berm 60 includes a base 62 with downwardly extending ridges 63. The berm 60 includes an arched sidewall 64 forming a convex shape with a rounded apex that allow vehicles to drive over the berm 60. As in the embodiment shown in FIG. 5, the berm 60 shown in FIG. 6 has a relatively low profile.
In the embodiment shown in FIG. 7, a non-collapsible rigid berm 70 includes sidewalls 74 and 76 connected by a top portion 78. The berm 70 has a generally rectangular cross-sectional shape having a relatively high profile that is intended to provide a barrier to vehicular traffic, e.g., the height of the berm 70 may be equal to, or greater than, the width of the berm 70. The open bottom portion of the non-collapsible rigid berm 70 allows multiple berm sections to be stacked together, e.g., for storage and transportation purposes.
In the embodiment shown in FIG. 8, a non-collapsible rigid berm 80 includes lower feet 82 connected to sidewalls 84 and 86. A top 88 connects the sidewalls 84 and 86. The berm 80 has a generally rectangular cross-sectional shape having a relatively high profile that is intended to provide a barrier to vehicular traffic. The open bottom portion of the non-collapsible rigid berm 80 allows multiple berm sections to be stacked together, e.g., for storage and transportation purposes.
The rigid berms of the present invention may be made of any suitable materials, such as molded or extruded plastics and rubbers. Suitable plastics include polypropylene and polyethylene such as impact copolymer, HDPE, MDPE, LDPE, 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.
FIGS. 9-17 illustrate features of collapsible berm assemblies in accordance with embodiments of the present invention. The collapsible berms include rigid bases and resilient body portions made of foam or any other suitable resilient material that returns to its original shape after it has been compressed. The use of resilient materials permits vehicular and other traffic to pass over the berms without causing damage to the berms or the vehicles.
In the embodiment shown in FIG. 9, a collapsible berm 90 includes a relatively rigid base 92 including downwardly extending projections or ridges 93. The rigid base 92 may be made of any suitable materials, such as those described above for the rigid berms. A resilient berm body 94 made of foam or other collapsible material is installed in the base 92. As shown in FIGS. 9 and 11, the base 92 includes channels 95 which help to secure the berm body 94 in the base 92. As the foam or other resilient material of the berm body 94 is damaged or worn out, it can be replaced independently from the rigid base 92.
The foam or other resilient material of the berm body 94 collapses under downward force and then springs back to its original height. Open cell and reticulated foams of polyolefins, urethane, polyether and/or polyester may be well suited since they are compressable and spring back to shape. Closed cell foams tend to have less resilience, but could possibly be used in some embodiments. The foam may be encased in a wrap (not shown) that provides increased surface abrasion resistance. The wrap may comprise a nonwoven material such as spunbond polypropylene or a film such as PVC or polypropylene. The wrap may contain a reinforcement scrim to give it additional strength. Since air should escape the berm when it is compressed, the wrap may be breathable and/or vented.
In the embodiment shown in FIG. 10, a collapsible berm 100 includes a similar base 92 as shown in the embodiment of FIG. 9. However, the resilient berm body includes an upper portion 96 made of a collapsible material such as foam as described above, and a lower plate 97 made of a more rigid or durable material that engages within the channels 95 of the base 92. The lower plate 97 may be any type of plastic, wood, metal plate or composite. The plate 97 should preferably be rigid enough not to pop out of the base profile and strong enough not to crack. Low cost materials may be preferred, such as recycled polypropylene and polyethylene. Another preferred material is pressed board made from ground reinforced liner materials.
FIGS. 12 and 13 illustrate another embodiment of a collapsible berm 120, including a base 122 with downwardly extending ridges 123. A resilient berm body 124 made of a collapsible material such as foam is installed in the base 122. The base 122 includes inwardly extending rails 125 and upwardly extending locking channels 126 which help to secure the berm body 124 within the base 122.
In accordance with embodiments of the present invention, the non-collapsible rigid berms and/or collapsible resilient berms may be provided in sections that may be connected together to form a berm of any desired length. Examples of connecting assemblies for collapsible berms are illustrated in FIGS. 14-17. However, it is to be understood that any other suitable connecting means may be used for the collapsible and non-collapsible berms.
In the embodiment shown in FIG. 14, a collapsible berm base 122 similar to that illustrated in FIGS. 12 and 13 is provided with a locking plate 128 installed in the locking channels 126. Another base (not shown) may be placed end-to-end with the illustrated base 122, with the locking plate 128 securing the adjacent berm sections together.
In the embodiment shown in FIG. 15, a berm assembly 150 is assembled from two bases 152 secured together with locking tabs 158 and mechanical fasteners 159 such as bolts, screws, rivets or the like.
In the embodiment shown in FIG. 16, a berm assembly 160 may be assembled from multiple base sections 162 interlocked together by the insertion of a male connector 168 into a female connector 169 in the adjacent base.
In the embodiment shown in FIG. 17, a berm assembly 170 comprises multiple base sections 172 connected together with connecting rods 178 received within connecting channels 179 located at the lower inside corners of the base sections 172.
The berms of the present invention provide several advantages. They stay in place, can be decontaminated and can be easily moved from site to site. The type of be in selected may either provide a physical barrier to unwanted vehicle traffic, or provide drive-over functionality. The drive-over functionality may be provided by a rigid built-in ramp design, or by a collapsible resilient berm design. The rigid base, especially with the interlocking feature, prevents the foam from being pushed into the pad area under the liner and resists wind uplift. An added benefit is that the liner can be mechanically attached to the base with screws, nails, staples, etc. Attaching to the sides of the berm, instead of its underside, eliminates the need to flip the berm over for attachment. The provision of downward facing projections along the bottom of the rigid base adds strength and provides anchoring means to resist lateral movement resulting form vehicle traffic.
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 in the appended claims.

Claims

What is claimed is:

1. A drive-over berm for use with a protective liner, the berm comprising:

a rigid base; and

a berm body extending upwardly from the base structured and arranged to allow vehicular traffic over the berm.

2. The drive-over berm of claim 1, wherein the berm body comprises a collapsible resilient material.

3. The drive-over berm of claim 2, wherein the berm body has a generally triangular cross section.

4. The drive-over berm of claim 2, wherein the berm body comprises foam.

5. The drive-over berm of claim 4, wherein the foam comprises open cell foam.

6. The drive-over berm of claim 2, wherein the berm body further comprises a plate that contacts the rigid base.

7. The drive-over berm of claim 6, wherein the plate is located at least partially below the collapsible resilient material of the berm body, comprises a material that is less resilient than the collapsible resilient material of the berm body, and is secured within at least one channel of the rigid base.

8. The drive-over berm of claim 2, wherein the rigid base comprises at least one retaining member in contact with the berm body.

9. The drive-over berm of claim 2, wherein the rigid base comprises at least one projection extending downwardly from a lower surface thereof.

10. The drive-over berm of claim 2, wherein the rigid base comprises extruded plastic.

11. The drive-over berm of claim 1, wherein the berm body comprises sloped sidewalls extending inwardly and upward from side edges of the rigid base.

12. The drive-over berm of claim 11, wherein the sloped sidewalls comprise convexly curved outer surfaces.

13. The drive-over berm of claim 11, wherein the berm body comprises a rigid material.

14. The drive-over berm of claim 13, wherein the rigid berm body material is integrally formed with the rigid base.

15. The drive-over berm of claim 1, further comprising means for connecting an end of the berm to another berm.

16. The drive-over berm of claim 15, wherein the connecting means comprises an extending member extending from one of the berms into a receiving recess in the other berm.

17. An interlocking berm assembly for use with a protective liner, the assembly comprising:

a first berm section having a connecting end;

a second berm section having a connecting end; and

at least one connector securing the connecting ends of the first and second berm sections together.

18. The interlocking berm assembly of claim 17, wherein the at least one connector comprises an extending member extending from the connecting end of the first berm into a receiving recess in the connecting end of the second berm.

19. The interlocking berm assembly of claim 18, wherein the extending member is substantially plate shaped, and the receiving recess comprises a substantially flat channel.

20. The interlocking berm assembly of claim 18, wherein the extending member comprises a rod, and the receiving recess comprises a channel having a cross section shaped to receive the rod therein.

21. The interlocking berm assembly of claim 18, wherein the extending member comprises a tab extending from a base of the first berm section, and the receiving recess comprises an opening in a base of the second berm section.

22. The interlocking berm assembly of claim 18, wherein the connector is disconnectable from both the first and second berm sections.

23. A stackable berm for use with a protective liner, the stackable berm comprising:

opposing sidewalls extending upward from an open base; and

a top connected to upper portions of the opposing sidewalls, wherein the sidewalls and top define an open volume inside the stackable berm, and are structured and arranged to fit inside an open volume inside another similarly shaped berm.

24. The stackable berm of claim 23, wherein the stackable berm is rigid.

25. A protective liner and berm assembly comprising:

a berm comprising:

a rigid base; and

a bean body extending upwardly from the base structured and arranged to allow vehicular traffic over the berm; and

a protective liner covering at least a portion of the berm.

26. The protective liner and berm assembly of claim 25, wherein the liner substantially surrounds the berm.

27. The protective liner and berm assembly of claim 26, wherein the liner comprises an edge that is folded over the berm and is attached to an interior portion of the liner.

28. The protective liner and berm assembly of claim 27, wherein the edge of the liner is attached by heat welding.

29. The protective liner and berm assembly of claim 25, wherein the liner does not extend below the berm.

30. The protective liner and berm assembly of claim 25, wherein the liner is mechanically fastened to the berm.