Note: Descriptions are shown in the official language in which they were submitted.
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"Fluid handling and containment system, apparatus and method"
FIELD OF THE INVENTION
The present invention relates generally to fluid handling systems and
apparatus and, more particularly, to fluid handling systems and apparatus for
use in
the oilfield industry.
BACKGROUND OF THE INVENTION
Currently in the oil in gas industry a large emphasis has been put on
the development of unconventional and "tight" reservoirs. This includes shale
gas
and oil, low permeability rock and coal bed methane. For the development of
these
reservoirs large hydraulic fracturing operations (also called fracing,
fraccing or
fracking) have been undertaken in conjunction with long horizontally drilled
wellbores. The process of fracturing commonly is completed using large
quantities
of fracturing fluid, typically ranging from hundreds to tens of thousand of
cubic
meters of produced and fresh water.
The handling and logistics of dealing with these large amounts of
fracturing fluids has led to the development of specialized equipment and
processes. The most common approach initially was to haul in large 400bbl tank
farms as shown in Fig. 1a. This has ranged from ten to upwards of a hundred
400bbl-sized tanks to facilitate required volumes of fracturing fluid.
Major disadvantages of this type of set up include large spatial foot
print required, dependency on 400bbl tank availability, large mobilization
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requirements, high mobilization/demobilization costs, high rental costs, tank
cleaning costs, labour intensive hosing/manifold system required to tie all
the
400bbl tanks together, high water heating cost and high heat loss due to high
surface-area-to-volume ratio of multiple 400bbl tanks, and high rig matting
requirements. A further disadvantage of such hosing/manifold system is that
such
system is subject to freezing during winter operations.
Other systems have been developed in an attempt to remove some of
the disadvantages of the multiple 400bbl tanks approach. One such system is to
store large quantities of fracturing fluid in earthen lined or unlined pits
and then
transferring the fluid to a tank farm having a much smaller number of 400bbl
tanks,
than the traditional set up. In this set up or system, the smaller number of
400bbl
tanks act as "buffer tank" so that fluid can be withdrawn at an equivalent
rate to that
required for the hydraulic fracturing operations. This method has benefits
over the
larger tank farms including smaller foot print, less heat loss. However, it
requires
large amounts of dirt work for the earthen pits and companies must abide by
various
environmental guide lines. This system also has some of the disadvantages as
associated with larger tank farm set ups, including still requiring elaborate
filling and
suction manifold systems, as well as a need for high rate transfer pumping and
piping system.
In recent years another method of fluid handling is the use of an
above ground containment system (instead of earthen pits) along with the same
smaller "buffer tank" system as used with the earthen pit system. This avoids
the
disadvantage associated with dirt work associated with the earthen pits. Such
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above ground containment system come in a variety of designs. Initially the
primary
design was a large corrugated sheet metal ring put up in sections of normally
4ft x
8ft. These rings are then lined with a poly liner and used for fluid storage
as shown
in Figs. lb and lc. These rings are, for the most part, an off shoot from
secondary
containment systems built by the Westeel Division of Vicwest Corporation
headquartered in Winnipeg, Manitoba, Canada. Although very economical to
purchase, such corrugated sheet metal rings proved to be very labour intensive
to
assemble, requiring multiple fasteners (usually nuts and bolts) which are
passed
through the overlapping corrugated sheet metal sections (from inside to
outside; or
vice-versa) and then are fastened. Such fastening (from inside to outside; or
vice
versa) also usually requires at least two labourers or workmen to complete the
job
(because it is difficult or impossible for a single person to reach around
individual
4'x8' sections to fasten), with one positioned inside the ring's interior and
a second
positioned outside the ring, both labourers or workmen then having to
coordinate
their fastening effort. Disassembly of such corrugated steel metal rings
provides
similar disadvantages.
To overcome the labour intensive assembly and disassembly of the
currogated sheet metal containment rings, Poseidon Concepts Corp. of Calgary,
Alberta, Canada has developed a containment ring system comprised of large
panels (12 foot x 24 foot) which is much quicker to set up due to their large
panels
(12'x 24' vs 4' x 8') and the use of a bolt-free connection system which
utilizes a
series of linking plates on the container's exterior (outside) surface only,
as shown
in Fig. id. However, these large panels are transported in a flat or
horizontal
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arrangement (such as to avoid highway restrictions on load height). Moreover,
large assembly equipment, such as picker trucks and track hoes are required to
move and manipulate these large and heavy panels (such as between horizontal
storage/transportation arrangement and the generally upright/vertical
operational
arrangement. This then also requires the use of qualified and certified
equipment
operators, all of which adds to the costs.
What is needed is a fluid handling and containment system which
does not have the above-mentioned disadvantages.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings, several aspects of the present invention are
illustrated by way of example, and not by way of limitation, in detail in the
figures,
wherein:
FIGS. la ¨ id are perspective views of various prior art fluid
containment and handling systems;
FIG. 2 is a perspective view of one embodiment of a fluid handling and
containment system and apparatus;
FIG. 3 is an enlargement of area A of FIG. 2;
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FIGS. 4a ¨ 51 are various views of another embodiment of a fluid
handling and containment system and apparatus, similar to the embodiment of
FIGS. 2 ¨3, but illustrating various preferred dimensions;
FIGS. 6a ¨ 6c are various perspective views of yet another
embodiment a fluid handling and containment system and apparatus, illustrating
storage of the system and apparatus as well as set-up of the system and
apparatus;
FIGS. 7a ¨7d are various views of yet another embodiment of a fluid
handling and containment system and apparatus;
FIGS. 8a ¨ 8e are various views of yet another embodiment of a fluid
handling and containment system and apparatus, similar to the embodiment of
FIGS. 7a ¨ 7d;
FIGS. 9a ¨ 9w are various views of yet another embodiment of a fluid
handling and containment system and apparatus, similar to the embodiments of
FIGS. 7a ¨ 7d and 8a ¨ 8e;
FIG 10 is a top view of another embodiment of a fastening member;
and
FIG 11 is a top view of yet another embodiment of a fastening
member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is of a preferred embodiment by way of
example only and without limitation to the combination of features necessary
for
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carrying the invention into effect. Reference is to be had to the Figures in
which
identical reference numbers identify similar components. The drawing figures
are
not necessarily to scale and certain features are shown in schematic or
diagrammatic form in the interest of clarity and conciseness.
Referring to the Figures 2 ¨ 6c, 10 and 11, various embodiments of a
fluid handling and containment system and apparatus 100 are illustrated. These
embodiments 100 comprise a plurality of curved panels 110 having a front
(outside)
face 110f, a rear (inside) face 110r, a top end 110t, a bottom end 110b and
two side
(connecting) ends 111, 112.
During operation, the panels 110 are positioned serially adjacent one
another in a generally upright or vertical manner, on their bottom ends 110b,
so as
to comprise a generally circular or ring shape (as can be seen more clearly in
FIGS.
2, 4a and 6b). When arranged in ring format, and with the individual panels
110
fastened to each other, the apparatus 100 is then suitable to be lined with a
liner
(such as a poly liner) and used for fluid storage, in a similar fashion as the
conventional corrugated sheet metal rings are (as shown in FIGS. lb and 1c).
Preferably, the panels 110 are sized and dimensioned to allow the system and
apparatus 100 to hold at least 3000 m3 of fluid. More preferably the panels
110 are
made of steel. Even more preferably, the panels 110 are 8 feet tall and 24
feet
long.
Each of the curved panels 110 comprises at least one fastening
member 120, 120a on its front face 110f preferably at one of its side ends 111
or
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112. Fastening member 120 is preferably a fastening flange 120a suitable to
mate
with, or generally abut to, a similar fastening member 120, 120b of an
adjacent
panel 110 (see FIG. 3). In another embodiment, fastening member 120 is a
generally square tubular member (see FIG. 10).
Preferably, the orientation or plane F of the fastening flange 120 is
substantially perpendicular to the plane P of the panel 110 (see, for example,
FIG.
5e). However, other orientations of the fastening flange 120 relative to the
panel
110 will work as long as fastening flanges 120a, 120b on adjacent panels
suitably
mate to allow fastening of one panel 110 to its adjacent panel 110. More
preferably,
a fastening flange 120 is provided at each of side ends 111, 112 for each
panel 110
in the fluid handling and containment system and apparatus 100.
In a preferred embodiment, each of the fastening members 120 is
provide with at least one fastener opening or passage 122 of sufficient size
and
dimensions to allow passage of a fastener therethrough. Further, in such
preferred
embodiment, the fastener openings 122 are positioned so as to align with the
fastener openings 122 of an adjacent fastening flange 120 when adjacent panels
110 are aligned into the generally circular arrangement as shown in FIGS. 2,
4a, 6b
and 10. Advantageously, adjacently positioned panels 110 may be easily
fastened
together using fasteners 124, preferably such as nuts 124n and bolts 124b,
which
are passed through the fastener opening 112 (see FIG. 3). More advantageously,
the fastening operations of adjacent panels 110 to each other can be conducted
from outside the ring of panels 110, without the need for a (second) workman
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placed within the circumference of the ring of panels 110, since fasteners 124
now
pass through fastening members 120 that are on the front face 110f of the
panels
110 and there is no longer a need for fasteners to pass through overlapping
panel
110 sections as is the case in the corrugated steel rings (FIGS. 1B and 1C).
Preferably, gussets 121 are provided to further secure fastening
members 120 to the front face 110f of the panels 110 (see FIG. 3).
In another embodiment of panels 110 (see FIG. 11), fastening
members 120 on one end (e.g. 111) may further comprise a male member 127
projecting therefrom and suitably aligned with the fastener openings 122 of
the
fastening member 120 of another panel's adjacent end 112, said second
fastening
member 120 being suitable dimensions to allow a fastener 124 to engage said
male
member 127 or to allow said male member 127 to pass therethrough (see FIG.
11).
Preferably, male member 127 has a threaded end 127t and fastener 124 is a nut
that can threadably connect over said male member 127 at said end 112.
Preferably, the system 100 further comprises a carrying frame 130 of
suitable dimensions to house a plurality of panels 110 in a generally upright
and
stacked or nested manner, as more clear shown in FIG. 6a. Advantageously,
carrying frame 130 assists with transport of individual panels 110 (which can
be
carried in such upright position during transport). More advantageously, by
keeping
the panels 110 to 8 feet in height, the carrying frame 130 with a plurality of
panels
110 inside can be easily transported without worry of violating general
highway
restrictions on load height.
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Even more advantageously, less time will be required to manipulate
individual panels 110 between a horizontal (transportation) position and a
vertical
upright (operating) position, because the panels 110 in the system 100 will
remain
in a generally upright configuration during both transportation (e.g. inside
carrying
frame 130) and operation.
More preferably, carrying frame 130 is provided with anchor points
140 and anchor members 142 to hold one or more panels 110 in a generally
upright
position (at anchor points 144) as more clearly shown in FIGS. 6b and 6c.
Advantageously, carrying frame 130, anchor points 140 and anchor members 142
assist with the assembly and disassembly of the panels 110, especially when
only a
few panels 110 are placed upright and the entire ring of panels is not yet
completed.
More advantageously, the system and apparatus 100 can be easily set up and
disassembled with using only a zoom boom and labourer with basic hand tools.
Referring now to the Figures 7a ¨ 9w, various other embodiments of a
fluid handling and containment system and apparatus 200 are illustrated. This
system and apparatus 200 comprises a single tank 210 having a plurality of
outlets
210o. The tank may be top filled or further comprise an inlet 210i.
Preferably, the
outlets 2100 are at least 4" diameter outlets. More preferably there are at
least 12
outlets 210o. Even more preferably the inlet, if present, has at least a 10"
diameter.
Yet even more preferably, the tank 210 has a plurality of compartments to
allow
separation of undesirables from the fluid, such as a compartment to settle
solids
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from the fluid and/or a compartment to skim light fluids (e.g. oils) from the
fluid (e.g.
water).
Preferably, the tank 210 is made from steel and is of such dimensions
so as to be as large as possible to be transported on the highway without the
requirement of special permits. In a preferred embodiment, the tank 210 is
dimensioned as: 14'w x 12'h x 55' with a resulting capacity of 200m3 of fluid
and
having 16 outlets.
More preferably, the outlets are each controlled via a valve 212. Even
more preferably, the valve 212 is placed within or inside the tank 210 (so as
to
reduce likelihood of freezing when operating during colder temperatures) and
is
remotely actuated via a mechanical linkage that places operational control of
the
valve 212 outside the tanks 210 main interior volume (such as near to top edge
of
the tank). Yet even more preferably, the tank 210 further comprises an
internal heat
coil system 230 for fluid heating.
Advantageously, the having a single tank 201 with a plurality of
outlets 2100 avoid the need for a hose and manifold system as required in
conventional systems to tie various the 400bbl tanks together. More
advantageously, the 200m3 capacity reduces heat loss usually incurred due to
high
surface-area-to-volume ratio of multiple 400bbl tanks. Even more
advantageously,
having the valves 212 placed within the tank's 210 interior, reduces
likelihood of
winter freezing of such valves. Yet even more advantageously, having an
internal
heat coil system 230, even further reduces fluid and/or valve freezing during
winter
operations. Still even more advantageously, the use of a single 210 reduces
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transportation and set-up costs and time associated with the use of
traditional
400bbl tank farm.
Preferably, one of the embodiments of the fluid handling and
containment system 100 of Figures 2¨ 6c, 10 and 11 can be use along with one
of
the embodiments of the fluid handling and containment system 200 of Figures 7a
¨
9w ¨ such as with fluid flowing from the containment system 100 to the tank
210
and then to the wellhead for fracturing operations. Advantageously, the use of
a
tank 210 along with a containment ring 100, allow for fluctuations in transfer
pump
rates (that may otherwise exist if going directly from system 100 to wellhead)
that
may arise during operations, as well as provide a sufficient volume of
accessible
fluid in the event that problems occur with transfer/pumping equipment from
the
main containment ring 100 to wellhead.
More advantageously, a 200m3 capacity tank 210 provides an
operator several minutes to fix any problems encountered during fracturing
operations, before having to making a final decision to stop fracturing
operations. In
this manner, tank 210 is used as "buffer tank" between main fluid containment
(in
system 100) and wellhead, but without the disadvantages associated with the
tradition use of a number of 400bbl tanks and the associated manifold(s) and
hosing.
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