US20150048097A1 - Storage container lining and insulation system - Google Patents

Storage container lining and insulation system Download PDF

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Publication number
US20150048097A1
US20150048097A1 US14/459,900 US201414459900A US2015048097A1 US 20150048097 A1 US20150048097 A1 US 20150048097A1 US 201414459900 A US201414459900 A US 201414459900A US 2015048097 A1 US2015048097 A1 US 2015048097A1
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United States
Prior art keywords
insulation panels
panels
vertical
horizontal
lining
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US14/459,900
Inventor
Kirk E. Jeffries
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Industrial Solutions USA LLC
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Industrial Solutions USA LLC
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Publication date
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Priority to US14/459,900 priority Critical patent/US20150048097A1/en
Assigned to Industrial Solutions USA, LLC reassignment Industrial Solutions USA, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JEFFRIES, KIRK E.
Priority to CA2859650A priority patent/CA2859650A1/en
Publication of US20150048097A1 publication Critical patent/US20150048097A1/en
Abandoned legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D90/00Component parts, details or accessories for large containers
    • B65D90/02Wall construction
    • B65D90/06Coverings, e.g. for insulating purposes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/38Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
    • B65D81/3813Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container
    • B65D81/3816Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation rigid container being in the form of a box, tray or like container formed of foam material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D25/00Details of other kinds or types of rigid or semi-rigid containers
    • B65D25/14Linings or internal coatings

Definitions

  • the present invention relates to insulation systems for large storage containers.
  • Frac tanks are often connected by a hose or a pipeline to a pump that pushes fracing fluids from the tanks into a well bore at a high pressure to push open a well formation and to keep the formation open. Frac tanks may also be used to store other liquids such as production water, fuel, glycol, oils, chemicals, and waste products. Frac tanks may be of any size and may have single walls or double walls.
  • Fracing fluid must be kept warm (approximately 85° F. to 125° F.) to perform properly when pumped into an oil well.
  • propane heating equipment or other heating systems are often used to heat frac tanks to warm the fracing fluid. Heating a frac tank is expensive, especially in northern latitudes, so insulation systems are often used to minimize heat loss from frac tanks.
  • Frac tanks are also often subjected to severe weather such as ice, rain, wind, and sun exposure, which can damage mechanical components, electrical components, and the tank itself.
  • Frac tanks are often moved to active wells and/or are rearranged as needed.
  • Conventional insulation systems are designed for one frac tank only and are permanently attached to that frac tank or intended not to be removed from that frac tank.
  • conventional insulation materials do not have adequate insulation capabilities and do not have the flexible physical properties to provide effective insulation to maintain the required working temperature of the fluid contained inside the storage container.
  • the present invention solves the above-described problems and provides a distinct advance in the art of large storage container insulation systems. More particularly, the present invention provides a modular lining and insulation system that can be easily assembled to fit over any number and any size of frac tank or storage container.
  • An embodiment of the present invention is a modular lining and insulation system that includes a number of interconnecting horizontal insulation panels and a number of interconnecting vertical insulation panels.
  • the horizontal insulation panels include a number of male tabs and female channels for connecting the horizontal insulation panels together.
  • the horizontal insulation panels can be connected end-to-end to accommodate longer storage containers.
  • the horizontal insulation panels can be connected laterally to accommodate wider storage containers and to accommodate more than one storage container.
  • the horizontal insulation panels may also have multiple sizes such as large panels and small or short panels for connecting together in an alternating or “brick” pattern to increase rigidity of the connected horizontal insulation panels.
  • the horizontal insulation panels may also include special top end panels for interconnecting with vertical side end panels and vertical end panels, as described below.
  • the horizontal insulation panels may also have a non-skid or extra grip surface for allowing workers to safely walk on top of the insulation system.
  • the vertical insulation panels include a number of male tabs and female channels for connecting the vertical insulation panels together.
  • the vertical insulation panels can be connected side-by-side to accommodate longer storage containers.
  • the vertical insulation panels may also have multiple sizes such as large panels and small panels for installing below the large or tall panels to accommodate taller storage containers.
  • the vertical insulation panels have male tabs or female channels on sides thereof near their top edges for interconnecting with the horizontal insulation panels.
  • the vertical insulation panels may have additional male tabs or female channels near their bottom edges so that the vertical insulation panels can be used interchangeably on left and right sides of the insulation system.
  • the vertical insulation panels may also have special side end panels for interconnecting with the special top end panels and may also have end panels for enclosing ends of the storage container.
  • FIG. 1 is a perspective view of a modular lining and insulation system constructed in accordance with an embodiment of the present invention and shown mounted on a frac tank;
  • FIG. 2 is another perspective view of the modular lining and insulation system and frac tank of FIG. 1 ;
  • FIG. 3 is an enlarged, fragmentary, perspective view of a portion of the modular lining and insulation system of FIG. 1 ;
  • FIG. 4 is an exploded view of the modular lining and insulation system and frac tank of FIG. 1 ;
  • FIG. 5 a is an enlarged elevation view of a male tab and female channel of interconnecting panels of the modular lining and insulation system of FIG. 1 ;
  • FIG. 5 b is an enlarged elevation view of the male tab and female channel of FIG. 5 a showing the male tab inserted into the female channel;
  • FIG. 6 is a perspective view of a large horizontal panel
  • FIG. 7 is another perspective view of the large horizontal panel of FIG. 6 ;
  • FIG. 8 is a perspective view of a small horizontal panel
  • FIG. 9 is another perspective view of the small horizontal panel of FIG. 8 ;
  • FIG. 10 is a perspective view of another small horizontal panel
  • FIG. 11 is another perspective view of the small horizontal panel of FIG. 10 ;
  • FIG. 12 is a perspective view of a large horizontal end panel
  • FIG. 13 is another perspective view of the large horizontal end panel of FIG. 12 ;
  • FIG. 14 is a perspective view of a small horizontal end panel
  • FIG. 15 is another perspective view of the small horizontal end panel of FIG. 14 ;
  • FIG. 16 is a perspective view of another large horizontal end panel
  • FIG. 17 is another perspective view of the large horizontal end panel of FIG. 16 ;
  • FIG. 18 is a perspective view of another small horizontal end panel
  • FIG. 19 is another perspective view of the small horizontal end panel of FIG. 18 ;
  • FIG. 21 is another perspective view of the large vertical panel of FIG. 20 ;
  • FIG. 22 is a perspective view of a small vertical panel
  • FIG. 23 is another perspective view of the small vertical panel of FIG. 22 ;
  • FIG. 24 is a perspective view of another large vertical panel
  • FIG. 25 is another perspective view of the large vertical panel of FIG. 24 ;
  • FIG. 26 is a perspective view of another small vertical panel
  • FIG. 27 is another perspective view of the small vertical panel of FIG. 26 ;
  • FIG. 28 is a perspective view of a vertical side end panel
  • FIG. 29 is another perspective view of the vertical side end panel of FIG. 28 ;
  • FIG. 30 is a perspective view of a small vertical side end panel
  • FIG. 31 is another perspective view of the small vertical side end panel of FIG. 30 ;
  • FIG. 32 is a perspective view of another large vertical side end panel
  • FIG. 33 is another perspective view of the large vertical side end panel of FIG. 32 ;
  • FIG. 34 is a perspective view of another small vertical side end panel
  • FIG. 35 is another perspective view of the small vertical side end panel of FIG. 34 ;
  • FIG. 36 is a perspective view of a large vertical end panel
  • FIG. 37 is another perspective view of the large vertical end panel of FIG. 36 ;
  • FIG. 38 is a perspective view of a small vertical end panel
  • FIG. 39 is another perspective view of the small vertical end panel of FIG. 38 ;
  • FIG. 40 is a perspective view of a large vertical center end panel
  • FIG. 41 is another perspective view of the large vertical center end panel of FIG. 40 ;
  • FIG. 42 is a perspective view of a small vertical center end panel
  • FIG. 43 is another perspective view of the small vertical center end panel of FIG. 42 ;
  • FIG. 44 is a perspective view of another modular lining and insulation system for covering multiple containers.
  • FIG. 45 is a perspective view of a rib panel of the modular lining and insulation system of FIG. 44 ;
  • FIG. 46 is a perspective view of another modular lining and insulation system for covering a container end pipe assembly.
  • references to “one embodiment”, “an embodiment”, or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology.
  • references to “one embodiment”, “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description.
  • a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included.
  • the present technology can include a variety of combinations and/or integrations of the embodiments described herein.
  • the lining and insulation system 10 broadly comprises a number of modular interconnecting horizontal insulation panels 12 , a number of modular interconnecting vertical insulation panels 14 , and one or more fasteners 16 .
  • the modular interconnecting horizontal insulation panels 12 line and insulate the top of the storage container and are formed of flexible cross-linked closed-cell polyethylene foam.
  • the horizontal insulation panels 12 are approximately 4 inches thick and have a density of approximately 2 pounds per cubic foot to approximately 6 pounds per cubic foot.
  • the foam is encapsulated with a 100% solids pure polyurea elastomeric lining or a 100% solids hybrid polyurea/polyurethane elastomeric lining sprayed onto the foam to no less than approximately 65 thousandths of an inch (mils) dry film thickness. The film thickness is 100 mils in one embodiment.
  • the encapsulated foam provides approximately a 16+R-value (thermal resistance) and may be fire resistant or non-fire accelerant.
  • the encapsulated foam may be pigmented to any color to match the environment or corporate color.
  • the encapsulated foam of the horizontal insulation panels 12 may have a non-skid or extra grip surface for allowing workers to safely walk on top of the assembled insulation unit.
  • the modular interconnecting horizontal insulation panels 12 include a number of male tabs 18 and female channels 20 , as shown in FIGS. 3-5 b .
  • the male tabs 18 connect to corresponding female channels 20 of adjacent horizontal insulation panels or vertical insulation panels and extend along rear, left, and right edges of the horizontal insulation panels 12 .
  • Each male tab 18 has a neck or narrow portion 22 and a wide portion 24 , as best shown in FIGS. 5 a and 5 b.
  • the female channels 20 receive corresponding male tabs 18 and extend along front edges of the horizontal insulation panels 12 , as best shown in FIG. 5 a .
  • Each female channel 20 has a narrow opening 26 and a wide interior portion 28 that receives the wide portion of the male tabs 18 .
  • the narrow opening 26 engages the narrow portion 22 of the male tab 18 and prevents the wide portion of the male tab 18 from easily sliding out of the wide interior portion 24 of the female channel 20 , as shown in FIG. 5 b.
  • the male tabs 18 and female channels 20 may take alternative configurations around the horizontal insulation panels 12 .
  • the female channels 20 may extend along front and rear edges of the horizontal insulation panels 12 while the male tabs 18 extend along left and right sides of the horizontal insulation panels 12 .
  • the male tabs 18 may extend along front and rear edges of the horizontal insulation panels 12 while the female channels 20 extend along left and right edges of the horizontal insulation panels 12 .
  • some horizontal insulation panels 12 may have male tabs 18 while other horizontal insulation panels 12 may have corresponding female channels 20 .
  • the modular interconnecting horizontal insulation panels 12 may include a number of different sized insulation panels such as large panels 30 , small panels 32 , and large and small top end panels 34 , as shown in FIGS. 6-19 .
  • the large panels 30 and small panels 32 may be alternatively paired so that the extended seam between paired panels is staggered, as shown in FIGS. 1 and 2 .
  • the top end panels 34 are positioned at the end of a series of horizontal insulation panels 12 and may be longer or shorter in the container's longitudinal direction than other horizontal insulation panels.
  • the top end panels 34 may include additional male tabs and/or female channels for interconnecting with side end panels and vertical end panels (both described below).
  • the modular interconnecting vertical insulation panels 14 line and insulate the sides and rear end of the storage container and are formed of substantially the same material as described above.
  • the modular interconnecting vertical insulation panels 14 include a number of male tabs and female channels including side female channels 36 .
  • the male tabs connect to corresponding female channels of adjacent vertical insulation panels or horizontal insulation panels and are substantially similar to the male tabs 18 described above.
  • the male tabs extend along rear edges of the vertical insulation panels 14 .
  • the female channels receive corresponding male tabs and are substantially similar to the female channels described above.
  • the side female channels 36 extend along front edges of the vertical insulation panels 14 , along a side near the top edge of the vertical insulation panels 14 .
  • the side female channels 36 connect with corresponding male tabs of the horizontal insulation panels 12 .
  • Additional side female channels may extend along a side near the bottom edge of the vertical insulation panels 14 for making the vertical insulation panels 14 interchangeable between left and right sides of the system 10 .
  • the modular interconnecting vertical insulation panels 14 cover left, right, and rear end sides of the container and may include a number of different sized insulation panels such as tall or large panels 38 , short or small panels 40 , side end panels 42 , and one or more end panels 44 , as shown in FIGS. 20-43 .
  • the large panels 38 connect side-by-side to cover sides of the container and may be used exclusively or may be used in conjunction with the small panels 40 .
  • the small panels 40 may be installed below or above the large panels 38 for accommodating taller storage containers.
  • the small panels 40 may also be paired with the large panels 38 in alternating fashion so that the extended seam between large panels 38 and small panels 40 is staggered.
  • the side end panels 42 are positioned at the end of a series of vertical insulation panels and may be longer or shorter in the container's longitudinal direction than other vertical insulation panels.
  • the side end panels 42 may include additional male tabs or female channels for interconnecting with top end panels and vertical end panels.
  • the vertical end panels 44 line and insulate the rear end or both ends of the storage container and interconnect with the side end panels 42 and the top end panel 34 .
  • the fasteners 16 secure the lining and insulation system 10 over the storage container and may include one or more ratchet straps, cords, ropes, cables, chains, or similar fasteners and/or clamps, hooks, bolts, brackets, or similar fasteners.
  • the ratchet strap fasteners 16 are extendable over the top of the system 10 and are configured to be secured to the storage container, the ground, the floor, the well pad, or other structure, as shown in FIGS. 1 and 2 .
  • the horizontal insulation panels 12 are placed on top of the storage container and paired together in an alternating pattern with corresponding male tabs and female channels of adjacent pairs aligned with each other.
  • the corresponding male tabs and female channels are joined together by hand or by using a leverage handle or mechanical clamp to form horizontal sections.
  • the vertical end panels 14 are then connected to the rear top end panel and adjacent vertical end panels one at a time starting from one rear corner of the container and finishing at the other rear corner. Additional vertical insulation panels 14 , beginning and ending with side end panels 42 , are then connected to the horizontal insulation panels 12 and adjacent vertical panels starting from the rear corners and finishing at the front corners to form the sides of the insulation unit.
  • the front of the insulation unit is left open or partially enclosed to provide access to stairs, gauges, valves, and other storage container components.
  • the fasteners 16 are then placed over the top of the assembled panels 12 , 14 and attached to D-rings, hooks, loops, flange, or similar structures on the storage container, ground, floor, or well pad on either side of the assembled insulation unit. The fasteners 16 are then tightened down until they are snug over the assembled insulation unit.
  • the horizontal insulation panels 12 and vertical insulation panels 14 of the lining and insulation system 10 may be packaged, transported, and stored on pallets.
  • One pallet may support the panels for one side of an insulation unit.
  • Some panels such as large horizontal insulation panel 30 and small horizontal panel 32 pairs may be preassembled before being stacked on a pallet. This reduces assembly and installation time.
  • the above-described modular lining and insulation system 10 provides several advantages over conventional systems.
  • the lining and insulation system 10 can easily be installed with minimal training and without any tools.
  • the lining and insulation system 10 can easily be modified to accommodate any size, shape, and dimension of storage container and any number of storage containers.
  • the non-skid or extra grip surface of the horizontal insulation panels 12 allow workers to safely walk on top of the assembled insulation unit.
  • the lining and insulation system 10 insulates storage containers without the need for electricity or other energy input and reduces the application of heat to the fluid in the storage container by at least 50%.
  • the lining and insulation system 10 can withstand severe weather and severe service environments such as extreme cold, extreme heat, rain, and heavy ice.
  • the lining and insulation system 10 will also mitigate blast damage from storage container explosions and minimize fire damage.
  • FIGS. 44 and 45 a modular lining and insulation system 100 constructed in accordance with another embodiment of the present invention is illustrated.
  • the modular lining and insulation system 100 is substantially similar to the above modular lining and insulation system 10 except that the modular lining and insulation system 100 includes one or more rib panels 102 for connecting lateral sections 104 , 106 of horizontal panels and vertical end panels together.
  • the rib panels 102 extend between lateral sections 104 , 106 of horizontal panels and connect to a plurality of horizontal panels on either side, thereby strengthening the modular lining and insulation system 100 without additional vertical panels.
  • the rib panels 102 are used when more than one lateral horizontal section and corresponding vertical end section are needed, such as for lining wide storage containers or for lining more than one storage container positioned adjacent to each other.
  • Erection of the modular lining and insulation system 100 to form an insulation unit is similar to the erection of the modular lining and insulation system 10 , except that the lateral sections 104 , 106 of horizontal panels are assembled, and then the rib panels 102 are connected in between the lateral sections 104 , 106 to form a single ceiling and rib panels 102 are connected in between vertical end sections to form a continuous end section. Additional rib panels and lateral sections, and end panel sections are connected together as needed. For example, three lateral sections and vertical end sections with rib panels positioned between the lateral sections and vertical end sections can be assembled to cover three standard size storage containers.
  • the modular lining and insulation system 100 provides several advantages over conventional systems.
  • the modular horizontal and vertical panels themselves may be fabricated to any dimension allowing the lining insulation system to accommodate any dimension storage container, and the rib panels 102 allow the lining and insulation system 100 to be easily modified to accommodate any size, shape, and dimension of storage container and any number of storage containers positioned side by side.
  • the rib panels 102 also provide structural integrity without additional vertical panels. This increases the volume of insulated space without increasing insulation material costs.
  • FIG. 46 a modular lining and insulation system 200 constructed in accordance with yet another embodiment of the present invention is illustrated.
  • the modular lining and insulation system 200 is substantially similar to the modular lining and insulation system 10 except that the modular lining and insulation system 200 includes a modular subassembly 202 for covering or encapsulating container endpipes or other equipment at the end of the container.
  • the modular subassembly includes a number of interlocking horizontal panels 204 and vertical panels 206 that extend outward and upward from the primary panels of the modular lining and insulation system 200 to accommodate the endpipes or other equipment.
  • the modular lining and insulation system 200 provides several advantages over conventional systems.
  • the modular subassembly 202 allows for additional odd-shaped equipment to be insulated in addition to the storage container without having to redesign or make substantial modifications to the modular lining and insulation unit.

Abstract

A modular lining and insulation system includes a number of horizontal insulation panels and a number of vertical insulation panels each having male tabs and/or corresponding female channels for interconnecting the panels. The modular lining and insulation system can easily be modified to accommodate any size, shape, and dimension of industrial storage container and any number of industrial or similar storage containers.

Description

    RELATED APPLICATIONS
  • The present application is a non-provisional application and claims priority benefit, with regard to all common subject matter, of earlier-filed U.S. provisional patent application titled “STORAGE CONTAINER LINING AND INSULATION SYSTEM,” Ser. No. 61/866,796, filed Aug. 16, 2013. The identified earlier-filed application is hereby incorporated by reference into the present application.
  • BACKGROUND
  • The present invention relates to insulation systems for large storage containers.
  • Large mobile steel storage tanks, typically referred to as “frac tanks”, are often used for fracing wells in the oil and gas industries. Frac tanks are often connected by a hose or a pipeline to a pump that pushes fracing fluids from the tanks into a well bore at a high pressure to push open a well formation and to keep the formation open. Frac tanks may also be used to store other liquids such as production water, fuel, glycol, oils, chemicals, and waste products. Frac tanks may be of any size and may have single walls or double walls.
  • Fracing fluid must be kept warm (approximately 85° F. to 125° F.) to perform properly when pumped into an oil well. As such, propane heating equipment or other heating systems are often used to heat frac tanks to warm the fracing fluid. Heating a frac tank is expensive, especially in northern latitudes, so insulation systems are often used to minimize heat loss from frac tanks. Frac tanks are also often subjected to severe weather such as ice, rain, wind, and sun exposure, which can damage mechanical components, electrical components, and the tank itself.
  • Frac tanks are often moved to active wells and/or are rearranged as needed. Conventional insulation systems are designed for one frac tank only and are permanently attached to that frac tank or intended not to be removed from that frac tank. In addition, conventional insulation materials do not have adequate insulation capabilities and do not have the flexible physical properties to provide effective insulation to maintain the required working temperature of the fluid contained inside the storage container.
  • SUMMARY
  • The present invention solves the above-described problems and provides a distinct advance in the art of large storage container insulation systems. More particularly, the present invention provides a modular lining and insulation system that can be easily assembled to fit over any number and any size of frac tank or storage container.
  • An embodiment of the present invention is a modular lining and insulation system that includes a number of interconnecting horizontal insulation panels and a number of interconnecting vertical insulation panels.
  • The horizontal insulation panels include a number of male tabs and female channels for connecting the horizontal insulation panels together. The horizontal insulation panels can be connected end-to-end to accommodate longer storage containers. The horizontal insulation panels can be connected laterally to accommodate wider storage containers and to accommodate more than one storage container. The horizontal insulation panels may also have multiple sizes such as large panels and small or short panels for connecting together in an alternating or “brick” pattern to increase rigidity of the connected horizontal insulation panels. The horizontal insulation panels may also include special top end panels for interconnecting with vertical side end panels and vertical end panels, as described below. The horizontal insulation panels may also have a non-skid or extra grip surface for allowing workers to safely walk on top of the insulation system.
  • The vertical insulation panels include a number of male tabs and female channels for connecting the vertical insulation panels together. The vertical insulation panels can be connected side-by-side to accommodate longer storage containers. The vertical insulation panels may also have multiple sizes such as large panels and small panels for installing below the large or tall panels to accommodate taller storage containers. The vertical insulation panels have male tabs or female channels on sides thereof near their top edges for interconnecting with the horizontal insulation panels. The vertical insulation panels may have additional male tabs or female channels near their bottom edges so that the vertical insulation panels can be used interchangeably on left and right sides of the insulation system. The vertical insulation panels may also have special side end panels for interconnecting with the special top end panels and may also have end panels for enclosing ends of the storage container.
  • This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.
  • BRIEF DESCRIPTION OF THE DRAWING FIGURES
  • Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:
  • FIG. 1 is a perspective view of a modular lining and insulation system constructed in accordance with an embodiment of the present invention and shown mounted on a frac tank;
  • FIG. 2 is another perspective view of the modular lining and insulation system and frac tank of FIG. 1;
  • FIG. 3 is an enlarged, fragmentary, perspective view of a portion of the modular lining and insulation system of FIG. 1;
  • FIG. 4 is an exploded view of the modular lining and insulation system and frac tank of FIG. 1;
  • FIG. 5 a is an enlarged elevation view of a male tab and female channel of interconnecting panels of the modular lining and insulation system of FIG. 1;
  • FIG. 5 b is an enlarged elevation view of the male tab and female channel of FIG. 5 a showing the male tab inserted into the female channel;
  • FIG. 6 is a perspective view of a large horizontal panel;
  • FIG. 7 is another perspective view of the large horizontal panel of FIG. 6;
  • FIG. 8 is a perspective view of a small horizontal panel;
  • FIG. 9 is another perspective view of the small horizontal panel of FIG. 8;
  • FIG. 10 is a perspective view of another small horizontal panel;
  • FIG. 11 is another perspective view of the small horizontal panel of FIG. 10;
  • FIG. 12 is a perspective view of a large horizontal end panel;
  • FIG. 13 is another perspective view of the large horizontal end panel of FIG. 12;
  • FIG. 14 is a perspective view of a small horizontal end panel;
  • FIG. 15 is another perspective view of the small horizontal end panel of FIG. 14;
  • FIG. 16 is a perspective view of another large horizontal end panel;
  • FIG. 17 is another perspective view of the large horizontal end panel of FIG. 16;
  • FIG. 18 is a perspective view of another small horizontal end panel;
  • FIG. 19 is another perspective view of the small horizontal end panel of FIG. 18;
  • FIG. 20 is a perspective view of a large vertical panel;
  • FIG. 21 is another perspective view of the large vertical panel of FIG. 20;
  • FIG. 22 is a perspective view of a small vertical panel;
  • FIG. 23 is another perspective view of the small vertical panel of FIG. 22;
  • FIG. 24 is a perspective view of another large vertical panel;
  • FIG. 25 is another perspective view of the large vertical panel of FIG. 24;
  • FIG. 26 is a perspective view of another small vertical panel;
  • FIG. 27 is another perspective view of the small vertical panel of FIG. 26;
  • FIG. 28 is a perspective view of a vertical side end panel;
  • FIG. 29 is another perspective view of the vertical side end panel of FIG. 28;
  • FIG. 30 is a perspective view of a small vertical side end panel;
  • FIG. 31 is another perspective view of the small vertical side end panel of FIG. 30;
  • FIG. 32 is a perspective view of another large vertical side end panel;
  • FIG. 33 is another perspective view of the large vertical side end panel of FIG. 32;
  • FIG. 34 is a perspective view of another small vertical side end panel;
  • FIG. 35 is another perspective view of the small vertical side end panel of FIG. 34;
  • FIG. 36 is a perspective view of a large vertical end panel;
  • FIG. 37 is another perspective view of the large vertical end panel of FIG. 36;
  • FIG. 38 is a perspective view of a small vertical end panel;
  • FIG. 39 is another perspective view of the small vertical end panel of FIG. 38;
  • FIG. 40 is a perspective view of a large vertical center end panel;
  • FIG. 41 is another perspective view of the large vertical center end panel of FIG. 40;
  • FIG. 42 is a perspective view of a small vertical center end panel;
  • FIG. 43 is another perspective view of the small vertical center end panel of FIG. 42;
  • FIG. 44 is a perspective view of another modular lining and insulation system for covering multiple containers;
  • FIG. 45 is a perspective view of a rib panel of the modular lining and insulation system of FIG. 44; and
  • FIG. 46 is a perspective view of another modular lining and insulation system for covering a container end pipe assembly.
  • The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.
  • DETAILED DESCRIPTION OF THE EMBODIMENTS
  • The following detailed description of the invention references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
  • In this description, references to “one embodiment”, “an embodiment”, or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment”, “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein.
  • Turning now to FIGS. 1-43, a lining and insulation system 10 constructed in accordance with a first embodiment of the invention is illustrated. The lining and insulation system 10 broadly comprises a number of modular interconnecting horizontal insulation panels 12, a number of modular interconnecting vertical insulation panels 14, and one or more fasteners 16.
  • The modular interconnecting horizontal insulation panels 12 line and insulate the top of the storage container and are formed of flexible cross-linked closed-cell polyethylene foam. The horizontal insulation panels 12 are approximately 4 inches thick and have a density of approximately 2 pounds per cubic foot to approximately 6 pounds per cubic foot. The foam is encapsulated with a 100% solids pure polyurea elastomeric lining or a 100% solids hybrid polyurea/polyurethane elastomeric lining sprayed onto the foam to no less than approximately 65 thousandths of an inch (mils) dry film thickness. The film thickness is 100 mils in one embodiment. The encapsulated foam provides approximately a 16+R-value (thermal resistance) and may be fire resistant or non-fire accelerant. The encapsulated foam may be pigmented to any color to match the environment or corporate color. The encapsulated foam of the horizontal insulation panels 12 may have a non-skid or extra grip surface for allowing workers to safely walk on top of the assembled insulation unit.
  • The modular interconnecting horizontal insulation panels 12 include a number of male tabs 18 and female channels 20, as shown in FIGS. 3-5 b. The male tabs 18 connect to corresponding female channels 20 of adjacent horizontal insulation panels or vertical insulation panels and extend along rear, left, and right edges of the horizontal insulation panels 12. Each male tab 18 has a neck or narrow portion 22 and a wide portion 24, as best shown in FIGS. 5 a and 5 b.
  • The female channels 20 receive corresponding male tabs 18 and extend along front edges of the horizontal insulation panels 12, as best shown in FIG. 5 a. Each female channel 20 has a narrow opening 26 and a wide interior portion 28 that receives the wide portion of the male tabs 18. The narrow opening 26 engages the narrow portion 22 of the male tab 18 and prevents the wide portion of the male tab 18 from easily sliding out of the wide interior portion 24 of the female channel 20, as shown in FIG. 5 b.
  • It will be understood that the male tabs 18 and female channels 20 may take alternative configurations around the horizontal insulation panels 12. For example, the female channels 20 may extend along front and rear edges of the horizontal insulation panels 12 while the male tabs 18 extend along left and right sides of the horizontal insulation panels 12. Similarly, the male tabs 18 may extend along front and rear edges of the horizontal insulation panels 12 while the female channels 20 extend along left and right edges of the horizontal insulation panels 12. Alternatively, some horizontal insulation panels 12 may have male tabs 18 while other horizontal insulation panels 12 may have corresponding female channels 20.
  • The modular interconnecting horizontal insulation panels 12 may include a number of different sized insulation panels such as large panels 30, small panels 32, and large and small top end panels 34, as shown in FIGS. 6-19.
  • The large panels 30 and small panels 32 may be alternatively paired so that the extended seam between paired panels is staggered, as shown in FIGS. 1 and 2.
  • The top end panels 34 are positioned at the end of a series of horizontal insulation panels 12 and may be longer or shorter in the container's longitudinal direction than other horizontal insulation panels. The top end panels 34 may include additional male tabs and/or female channels for interconnecting with side end panels and vertical end panels (both described below).
  • The modular interconnecting vertical insulation panels 14 line and insulate the sides and rear end of the storage container and are formed of substantially the same material as described above.
  • The modular interconnecting vertical insulation panels 14 include a number of male tabs and female channels including side female channels 36. The male tabs connect to corresponding female channels of adjacent vertical insulation panels or horizontal insulation panels and are substantially similar to the male tabs 18 described above. The male tabs extend along rear edges of the vertical insulation panels 14.
  • The female channels receive corresponding male tabs and are substantially similar to the female channels described above. The side female channels 36 extend along front edges of the vertical insulation panels 14, along a side near the top edge of the vertical insulation panels 14. The side female channels 36 connect with corresponding male tabs of the horizontal insulation panels 12. Additional side female channels may extend along a side near the bottom edge of the vertical insulation panels 14 for making the vertical insulation panels 14 interchangeable between left and right sides of the system 10.
  • The modular interconnecting vertical insulation panels 14 cover left, right, and rear end sides of the container and may include a number of different sized insulation panels such as tall or large panels 38, short or small panels 40, side end panels 42, and one or more end panels 44, as shown in FIGS. 20-43.
  • The large panels 38 connect side-by-side to cover sides of the container and may be used exclusively or may be used in conjunction with the small panels 40.
  • The small panels 40 may be installed below or above the large panels 38 for accommodating taller storage containers. The small panels 40 may also be paired with the large panels 38 in alternating fashion so that the extended seam between large panels 38 and small panels 40 is staggered.
  • The side end panels 42 are positioned at the end of a series of vertical insulation panels and may be longer or shorter in the container's longitudinal direction than other vertical insulation panels. The side end panels 42 may include additional male tabs or female channels for interconnecting with top end panels and vertical end panels.
  • The vertical end panels 44 line and insulate the rear end or both ends of the storage container and interconnect with the side end panels 42 and the top end panel 34.
  • The fasteners 16 secure the lining and insulation system 10 over the storage container and may include one or more ratchet straps, cords, ropes, cables, chains, or similar fasteners and/or clamps, hooks, bolts, brackets, or similar fasteners. The ratchet strap fasteners 16 are extendable over the top of the system 10 and are configured to be secured to the storage container, the ground, the floor, the well pad, or other structure, as shown in FIGS. 1 and 2.
  • Erection of the modular lining and insulation system 10 to form an insulation unit will now be described in detail. The horizontal insulation panels 12 are placed on top of the storage container and paired together in an alternating pattern with corresponding male tabs and female channels of adjacent pairs aligned with each other. The corresponding male tabs and female channels are joined together by hand or by using a leverage handle or mechanical clamp to form horizontal sections.
  • The vertical end panels 14 are then connected to the rear top end panel and adjacent vertical end panels one at a time starting from one rear corner of the container and finishing at the other rear corner. Additional vertical insulation panels 14, beginning and ending with side end panels 42, are then connected to the horizontal insulation panels 12 and adjacent vertical panels starting from the rear corners and finishing at the front corners to form the sides of the insulation unit. The front of the insulation unit is left open or partially enclosed to provide access to stairs, gauges, valves, and other storage container components.
  • The fasteners 16 are then placed over the top of the assembled panels 12, 14 and attached to D-rings, hooks, loops, flange, or similar structures on the storage container, ground, floor, or well pad on either side of the assembled insulation unit. The fasteners 16 are then tightened down until they are snug over the assembled insulation unit.
  • The horizontal insulation panels 12 and vertical insulation panels 14 of the lining and insulation system 10 may be packaged, transported, and stored on pallets. One pallet may support the panels for one side of an insulation unit. Some panels such as large horizontal insulation panel 30 and small horizontal panel 32 pairs may be preassembled before being stacked on a pallet. This reduces assembly and installation time.
  • The above-described modular lining and insulation system 10 provides several advantages over conventional systems. For example, the lining and insulation system 10 can easily be installed with minimal training and without any tools. The lining and insulation system 10 can easily be modified to accommodate any size, shape, and dimension of storage container and any number of storage containers. The non-skid or extra grip surface of the horizontal insulation panels 12 allow workers to safely walk on top of the assembled insulation unit. The lining and insulation system 10 insulates storage containers without the need for electricity or other energy input and reduces the application of heat to the fluid in the storage container by at least 50%. The lining and insulation system 10 can withstand severe weather and severe service environments such as extreme cold, extreme heat, rain, and heavy ice. The lining and insulation system 10 will also mitigate blast damage from storage container explosions and minimize fire damage.
  • Turning now to FIGS. 44 and 45, a modular lining and insulation system 100 constructed in accordance with another embodiment of the present invention is illustrated. The modular lining and insulation system 100 is substantially similar to the above modular lining and insulation system 10 except that the modular lining and insulation system 100 includes one or more rib panels 102 for connecting lateral sections 104, 106 of horizontal panels and vertical end panels together.
  • The rib panels 102 extend between lateral sections 104, 106 of horizontal panels and connect to a plurality of horizontal panels on either side, thereby strengthening the modular lining and insulation system 100 without additional vertical panels. The rib panels 102 are used when more than one lateral horizontal section and corresponding vertical end section are needed, such as for lining wide storage containers or for lining more than one storage container positioned adjacent to each other.
  • Erection of the modular lining and insulation system 100 to form an insulation unit is similar to the erection of the modular lining and insulation system 10, except that the lateral sections 104, 106 of horizontal panels are assembled, and then the rib panels 102 are connected in between the lateral sections 104, 106 to form a single ceiling and rib panels 102 are connected in between vertical end sections to form a continuous end section. Additional rib panels and lateral sections, and end panel sections are connected together as needed. For example, three lateral sections and vertical end sections with rib panels positioned between the lateral sections and vertical end sections can be assembled to cover three standard size storage containers.
  • The modular lining and insulation system 100 provides several advantages over conventional systems. For example, the modular horizontal and vertical panels themselves may be fabricated to any dimension allowing the lining insulation system to accommodate any dimension storage container, and the rib panels 102 allow the lining and insulation system 100 to be easily modified to accommodate any size, shape, and dimension of storage container and any number of storage containers positioned side by side. The rib panels 102 also provide structural integrity without additional vertical panels. This increases the volume of insulated space without increasing insulation material costs.
  • Turning now to FIG. 46, a modular lining and insulation system 200 constructed in accordance with yet another embodiment of the present invention is illustrated. The modular lining and insulation system 200 is substantially similar to the modular lining and insulation system 10 except that the modular lining and insulation system 200 includes a modular subassembly 202 for covering or encapsulating container endpipes or other equipment at the end of the container. The modular subassembly includes a number of interlocking horizontal panels 204 and vertical panels 206 that extend outward and upward from the primary panels of the modular lining and insulation system 200 to accommodate the endpipes or other equipment.
  • The modular lining and insulation system 200 provides several advantages over conventional systems. For example, the modular subassembly 202 allows for additional odd-shaped equipment to be insulated in addition to the storage container without having to redesign or make substantial modifications to the modular lining and insulation unit.
  • Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.

Claims (20)

Having thus described various embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:
1. A system for lining and insulating one or more storage containers, the system comprising:
a plurality of modular interconnecting horizontal insulation panels; and
a plurality of modular interconnecting vertical insulation panels being configured to interconnect with the horizontal insulation panels,
the horizontal insulation panels and the vertical insulation panels being individually connectable and removable for lining and insulating storage containers of different sizes and the horizontal insulation panels being connectable and removable in lateral sections for lining and insulating the one or more storage containers.
2. The system of claim 1, wherein the horizontal insulation panels and the vertical insulation panels collectively include a plurality of male tabs and a plurality of female channels for receiving the male tabs therein so that the horizontal insulation panels and the vertical insulation panels can be interconnected without the use of fasteners or adhesives.
3. The system of claim 1, wherein the horizontal insulation panels are connectable to each other via male tabs extending from ends of at least some of the horizontal insulation panels and female channels extending into ends of at least some of the horizontal insulation panels, the male tabs being configured to be inserted into the female channels so as to form an extended layer of lining and insulation on a top of the storage container.
4. The system of claim 1, wherein the vertical insulation panels are connectable to each other via male tabs extending from ends of at least some of the vertical insulation panels and female channels extending into ends of at least some of the vertical insulation panels, the male tabs being configured to be inserted into the female channels so as to form an extended layer of lining and insulation on a side of the storage container.
5. The system of claim 1, wherein the horizontal insulation panels include a first male tab extending from a first end, a second male tab extending from a second end adjacent the first end, a third male tab extending from a third end adjacent the second end, and a female channel extending into a fourth end opposite the second end, the first male tab being configured to be inserted into the female channel of another horizontal insulation panel or the top end of a vertical insulation panel, the second male tab being configured to be inserted into a female channel on a side of a horizontal insulation panel or a vertical insulation panel, and the third male tab being configured to be inserted into a female channel on another side of another horizontal insulation panel or vertical insulation panel so as to form an extended layer of lining and insulation on at least a top and two sides of the storage container.
6. The system of claim 1, wherein the vertical insulation panels each include a first female channel extending into a side thereof for receiving a male tab of a horizontal insulation panel so as to form a layer of lining and insulation on at least a top and a side of the storage container.
7. The system of claim 1, wherein the female channels are located near top ends of the vertical insulation panels and wherein some of the vertical insulation panels include a female channel extending the length of the vertical insulation panel on both sides to receive a male tab of another vertical insulation panel, and other vertical panels include a male tab extending the length of the vertical insulation panel on both sides to insert into a female channel of another vertical insulation panel.
8. The system of claim 1, wherein at least one of the vertical insulation panels is a side end panel, at least one of the vertical insulation panels is an end panel, and at least one of the horizontal insulation panels is a top end panel, the at least one side end panel, end panel, and top end panel being configured to be interconnected with each other so as to form a layer of lining and insulation on at least a top, a side, and an end of the storage container.
9. The system of claim 1, wherein the horizontal insulation panels include a number of large panels and a number of small panels configured to be paired in an alternating pattern so that seams formed between large and small panels are staggered for increasing rigidity of the system.
10. The system of claim 1, wherein the vertical insulation panels and the horizontal insulation panels are approximately 4 inches thick.
11. The system of claim 1, wherein the vertical insulation panels and the horizontal insulation panels have a density of approximately 2 pounds per cubic foot to approximately 6 pounds per cubic foot.
12. The system of claim 1, wherein the vertical insulation panels and the horizontal insulation panels each are encapsulated with a 100 percent solids pure polyurea elastomeric lining.
13. The system of claim 1, wherein the vertical insulation panels and the horizontal insulation panels each are encapsulated with a 100 percent solids hybrid polyurea/polyurethane elastomeric lining.
14. The system of claim 1, wherein the vertical insulation panels and the horizontal insulation panels are formed of flexible cross-linked closed-cell polyethylene foam.
15. The system of claim 1, wherein the horizontal insulation panels each include a non-skid top surface for allowing workers to safely work on top of the storage container.
16. The system of claim 1, wherein the horizontal insulation panels further comprise at least one rib panel configured to be connected between lateral sections of horizontal insulation panels and the vertical end panels further comprise at least one rib panel configured to be connected between vertical end panels when the system is lining and insulating at least two storage containers.
17. The system of claim 1, wherein a number of the vertical insulation panels are tall panels and a number of the vertical insulation panels are short panels configured to be connected below the tall panels so as to increase a height of the system for lining and insulating taller storage containers.
18. The system of claim 1, further comprising at least one fastener for securing the vertical and horizontal insulation panels to the storage container, the at least one fastener comprising a ratchet strap configured to be secured to a lower side of the storage tank, extended over the vertical and horizontal insulation panels, and secured to an opposite lower side of the storage tank for retaining the vertical and horizontal insulation panels over the storage tank.
19. A system for lining and insulating one or more storage containers, the system comprising:
a plurality of modular interconnecting horizontal insulation panels collectively having a number of male tabs and female channels for securing the horizontal insulation panels together, the horizontal insulation panels being individually connectable and removable for lining and insulating storage containers of different sizes and being connectable and removable in lateral sections for lining and insulating the one or more storage containers;
a plurality of modular interconnecting vertical insulation panels being configured to interconnect with the horizontal insulation panels, the vertical insulation panels collectively having a number of male tabs and female channels for securing the vertical insulation panels together and for securing the vertical insulation panels to the horizontal insulation panels, the vertical insulation panels including at least one end panel for lining and insulating an end of the one or more storage containers.
20. A system for lining and insulating one or more fluid storage containers, the system comprising:
a plurality of modular interconnecting horizontal insulation panels collectively having a number of male tabs and female channels for securing the horizontal insulation panels together, the horizontal insulation panels being individually connectable and removable for lining and insulating storage containers of different sizes and being connectable and removable in lateral sections for lining and insulating the one or more storage containers, the horizontal insulation panels including:
a number of large panels;
a number of small panels, the large and small panels being configured to be paired in an alternating pattern so that seams formed between the large and small panels are staggered for increasing rigidity of the system; and
at least one rib panel configured to be connected between lateral sections of horizontal insulation panels when the system is lining and insulating at least two storage containers; and
a plurality of modular interconnecting vertical insulation panels being configured to interconnect with the horizontal insulation panels, the vertical insulation panels collectively having a number of male tabs and female channels for securing the vertical insulation panels together and for securing the vertical insulation panels to the horizontal insulation panels, the vertical insulation panels including at least one end panel for lining and insulating an end of the one or more storage containers and at least one rib panel configured to be connected between vertical insulation panels when the system is lining and insulating at least two storage containers.
US14/459,900 2013-08-16 2014-08-14 Storage container lining and insulation system Abandoned US20150048097A1 (en)

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