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Scott Crain

Alternative Uses for Frac Tanks in the Oil & Gas and Pipeline Industries

By | Frac Tanks | No Comments

Oil and gas developers introduced fracking as a means to release hydrocarbons as efficiently as possible. Fracking is mostly responsible for this country’s surging oil and gas production over the past half-century or more.

Hydraulic fracturing involves tapping tight rock formations such as shale by drilling deeply below the surface (a mile or more). A mixture of water, sand, and other additives are pumped into the drilled well at high pressure, which creates small fractures in the rock.

A frac tank is a large mobile storage vessel used to store the acid integral to the fracking process. Tanks are generally able to hold 21,000 gallons or as much as 500 barrels of fluid. They are affixed with valves on one end which allows several tanks to be connected to a particular frac job.

Frac tanks first emerged in the 1940s, and the modern versions have been with us since the 1960s and 1970s, with a standard design. The original frac tanks, which remain in widespread use today, are a long rectangular steel box with corrugated walls. The tank has a flat roof and a v-bottomed floor. Frac tanks are able to fit perfectly on an 18-wheeler for easy transport to a job site.

There are other versions of this original frac tank, where the design has been tweaked to better serve a variety of needs. For example, some tanks have sealed roof hatches, different manways for side and roof access, and mixer capabilities. There are also smooth wall tanks and double-walled tanks for environmentally-sensitive projects.

Aside from the normal frac usage for which the tanks were designed, frac tanks are now being utilized extensively in the oil and gas industry for a variety of purposes.

Download our free guide to get the full list of alternative applications.

Why Do Oilfield Acid Tanks Leak?

By | Containment Systems, Frac Tanks | No Comments

One of the larger challenges associated with the modern hydraulic fracturing process is what to do with all that acid and other chemicals.

Though the extraction method has been beneficial for natural gas and oil production, industry officials want to make sure it also has a minimal impact on the environment. So research continues into safer methods for storage and transportation of the acid and other corrosive chemicals and additives that can be contained in the fracking fluid.

Recovered acid, water, and fuel are typically stored in frac tanks near the wells since the material can often be used and recycled.  But until it is officially declared waste and disposed of as hazardous material, oil field companies keep it secure in these holding tanks, many of which were originally steel containers designed to store water in volumes of up to 20,000 gallons. Since acid corrodes steel, acid-resistant liners were added to keep tanks from leaking and rupturing.

Unfortunately, liners are susceptible to buckling, flexing or cracking during transportation, which will lead to containment failure.

In addition to following any local or state environmental quality regulations, oil companies must adhere to EPA rules governing Secondary Containment. This approach not only requires companies to use sturdy and safe storage containers for oilfield equipment but install a second system responsible for catching and containing anything that may spill from these containers or if and when they fail. The intent is to prevent the fluids from reaching water sources.

A leak of any size needs to be reported as soon as practical. A significant spill could also perhaps force a suspension of operations until an official response, investigation or remediation/clean-up efforts take place, potentially resulting in local, state, or federal fines, regardless if the spill was deliberate or accidental. Defending yourself against these violations in criminal or civil proceedings could require even more time and resources, as well as negatively affect your company’s reputation.

Texoma MFG has developed a new, patented leak-proof acid tank, allowing the tank itself to become the required secondary containment structure. This revolutionary new product will help completely eliminate acid tank leaks and spills, setting a new standard in the oil & gas industry.

Leak-Proof Frac Tanks: The Revolutionary Oilfield Solution

By | Containment Systems, Frac Tanks | No Comments

The Shale Revolution is a product of American Ingenuity and enabled U.S. oil companies to halt the declining trajectory of domestic oil and gas reserves.

Between 2009 and 2015, U.S. crude oil production increased 83 percent, catapulting America to one of the top three crude oil producing countries in the world.

As completion and production technologies advance, field operations are pushing equipment to the limit – and sometimes past the point of failure. Concurrently, Safety and Environmental regulations are becoming more stringent – requiring service contractors, who actually perform the work in the field, to develop new tools and equipment to meet the harsh operating conditions.

The Complications of Fracking

The most well known and controversial well completion procedure is called multistage hydraulic fracturing; a well-stimulation technique in which rock is fractured by injecting liquids into subsurface rock formations at very high pressure. The most common frac fluids are water and hydrochloric acid (HCL). These liquids must be safely transported and contained on the well site prior to being injected into the ground.

The average frac in Oklahoma requires about 42,000 gallons of hydrochloric acid, and current trends reveal oil companies are increasing the number of stages, and volumes per stage, which will result in significantly more acid being required in the future.

Since most well sites are located in close proximity to cropland and waterways used by livestock and municipal water treatment systems, storing large amounts of hydrochloric acid on a well site presents substantial contingent liabilities to oil companies.  A large acid spill results in damages that begin in the million dollar range, and can quickly climb higher depending on the extent of the spill.

To offset these costly liabilities, most oil companies install secondary containment berms around all acid tanks on the frac location. Some also install a poly mat underneath the tanks to protect the soil. These containment systems can cost up to $20,000.00 (or more) per location.

The Need for a Better Solution

Surprisingly, the standard acid storage tank used by the oil industry is a steel “frac” tank originally developed to store water. Even though acid corrodes steel, most acid tank operators simply install an acid resistant liner inside the frac tank, and call it an “acid tank”. These liners are acid resistant coatings applied while wet and becomes rigid when dry. During transport, the walls of the tank flex, and over time cause small cracks to develop in the liner which leads to a liner failure. Other causes of liner failure are lack of proper maintenance, substandard liner material, and harsh conditions in the field – all cause liners to fail, and they fail often, resulting in acid spills.

The average lifespan of an acid tank liner is one to two years. The cost of installing a new liner averages $15,000.00 per tank. There have been many attempts by acid tank operators to address liner failures, and they always focus on improving the liner itself. Until now, no company has solved the problem.

Texoma MFG has designed and patented a new acid tank which eliminates liner failures by isolating the interior walls of the tank from the acid. By containing the acid in a polyethylene bladder inside the tank, the interior tank walls never come into contact with acid. This allows the tank to become the required secondary containment structure.