Stackable bulk fluid storage container

A bulk fluid storage container includes a frame assembly having a lower rectangular frame, first and second wheel assemblies extending from opposite ends of the lower rectangular frame, and an upper rectangular frame member arranged in spaced relation to the lower rectangular frame member by a plurality of vertically extending posts. The bulk fluid storage container also includes a fluid storage vessel having first and second end walls held in spaced relation by first and second side walls, a top wall and a bottom wall, which defines a fluid storage volume. A baffle assembly having a plurality of baffle plates is disposed in a space relationship in the fluid storage volume. The frame assembly provides an exoskeletal structure which surrounds the fluid storage vessel and is configured to support a second bulk fluid storage container in a vertically stacked relationship.

TECHNICAL FIELD

The present disclosure relates generally to a fluid storage container, and more particularly relates to a stackable bulk fluid storage tank for the transport and storage of fluids used in the oil and gas industry, over the life cycle of a well including drilling, completions, production, maintenance, and/or decommissioning as well as other applicable industries that require an onsite inventory of fluid materials.

BACKGROUND

Hydraulic fracturing is a well stimulation technique in which rock is fractured by a pressurized liquid. The process involves the high-pressure injection of a ‘fracking fluid’ (primarily water, containing sand or other proppants suspended with the aid of thickening agents) into a wellbore to create cracks in the deep-rock formations through which natural gas, petroleum, and brine will flow more freely. When the hydraulic pressure is removed from the well, small grains of hydraulic fracturing proppants, such as sand or aluminum oxide, hold the fractures open.

The hydraulic fracturing process requires the transportation and storage of various resources at the well-site which is consumed during the fracturing process. Recent efforts have focused on improved logistics including containerization solutions primarily directed to storage, handling and well-site delivery of proppant. Little attention has been paid to improved logistics relating to the storage, handling and well-site delivery of fluids used in the hydraulic fracturing process. Traditionally, water logistics has been accomplished with the use of a series of transport/vacuum trucks to move water to and fill storage tanks, i.e., frac tanks. These trucks off load water into these storage tanks at the desired location. These conventional solutions for water have used vacuum boxes that require a relatively heavy gauge container, which increase the weight of the storage tank thereby limiting the volume of fluids that may be transported and stored in compliance with federal and state transportation regulations. Additionally, vacuum boxes typically have a tailgate arranged at the back of the box. Oftentimes the tailgate is not 100% sealable resulting in a risk of spillage and loss of stored fluids. Likewise, conventional solutions for hydraulic fracturing chemicals typically include totes that are difficult to manage logistically due to their low capacity.

In addition to hydraulic fracturing, wastewater and freshwater are used throughout the oil and gas production cycle. Specifically, wastewater is produced alongside oil and gas and often needs to be transported to a disposal, or recycling site. Additionally, freshwater is used throughout several well servicing jobs during the life of the oil well. Trucking in both processes is still prevalent, but little attention has been paid to improved logistics.

Accordingly, there is a need to provide a suitable, cost effective solution for the transportation, set-up and storage of fluids used in a variety of industrial applications including the oil and gas industry.

SUMMARY

The systems and methods disclosed herein enable the transportation, set-up and storage of bulk fluids at a well-site or similar location with one single move, in which the storage tank is deliverable to and/or from the location full of fluid. In one aspect of the present disclosure, a bulk fluid storage container includes a fluid storage vessel defining a fluid storage volume for storing a fluid and a frame assembly which surrounds the fluid storage vessel, wherein the fluid storage volume is maintained at an atmospheric pressure. The fluid storage vessel includes a top port formed in the fluid storage vessel for filling the fluid storage volume, one or more upper ports formed in the fluid storage vessel for venting the fluid storage volume and one or more lower ports formed in the fluid storage vessel for draining the fluid storage volume. This aspect has the effect that the bulk fluid storage container is lighter than conventional vacuum boxes such that the fluid storage vessel has a larger fluid storage capacity for a given weight limit. Moreover, this aspect has the effect that the bulk fluid storage container may be delivered to a well-site on a transport vehicle, unloaded and staged for use at the well-site, thus preventing demurrage time of those vehicles as well as the initial setup time associated with conventional frac tanks.

According to another aspect of the present disclosure, the frame assembly provides an exoskeletal structure configured to support a second bulk fluid storage container in a vertically stacked relationship. This aspect has the effect of significantly increasing the volume of fluid that may be stored within a prescribed footprint at the well-site. For example, a pair of vertically stacked bulk fluid storage containers effectively doubles the fluid storage capacity for a given area at the well-site.

According to another aspect of the present disclosure, the frame assembly includes an upper rectangular frame member and a lower rectangular frame member, wherein the upper rectangular frame member is arranged in spaced relation to the lower rectangular frame member by a plurality of vertically extending posts. The lower rectangular frame may include tubular cross members extending between longitudinal rails. These aspects have the effect of enclosing and protecting the fluid storage vessel such that it may be readily transported on conventional vehicles such as lift trucks, cranes, flatbed trailers, rail cars, and the like.

According to another aspect of the present disclosure, a stackable fluid storage container includes a truncated or tapered section in a front-end region. The fluid storage container may include a set of diverging channels on a top wall of the tapered section. These aspects have the effect of facilitating the loading and stacking of the second storage container onto the first storage container in a vertically stacked relationship.

According to another aspect of the present disclosure, a stackable fluid storage container having a frame assembly with longitudinal guides arranged on the upper rectangular frame and longitudinal rails arranged on the lower rectangular frame, wherein the longitudinal rails on a first bulk fluid storage container are configured to cooperate with the longitudinal guides on a second bulk fluid storage container. This aspect has the effect of aligning the first and second storage containers in a vertically stacked relationship.

According to another aspect of the present disclosure, a fluid storage container includes a vent pipe coupled to the upper port and in fluid communication with the fluid storage volume. This aspect has the effect of maintaining atmospheric pressure within the fluid storage volume.

According to another aspect of the present disclosure, a fluid storage container includes a vent header coupled between the upper ports a first storage container and a second storage container stacked on top of the first storage container. In another aspect of the present disclosure, the vent header may be diagonally oriented between the upper ports on the first and second storage containers. These aspects have the effect of maintaining atmospheric pressure within the fluid storage volumes of the first and second storage containers.

According to another aspect of the present disclosure, the frame assembly may include a first wheel assembly extending from a first end of the frame assembly and a second wheel assembly extending from the second end of the frame assembly. The fluid storage container may include a winch coupling formed in a recess of the fluid storage vessel and having a coupling plate with a loop or catch configured to receive a hook on a winch cable. These aspects have the effect that the bulk fluid storage container is configured to be loaded and unloaded with a stinger tail roll off truck.

According to another aspect of the present disclosure, the fluid storage vessel includes an internal baffle assembly, which is vertically oriented in the fluid storage volume. This aspect has the effect of reducing fluid sloshing and stabilizing the bulk fluid storage container when it is transported in a partially or completely filled condition.

According to another aspect of the present disclosure, the fluid storage vessel is divided with one or more internal baffle plates. This aspect has the effect of separating the fluid storage volume into separate sections for storing diverse fluids.

According to another aspect of the present disclosure, the fluid storage container includes a level detection device in communication with the fluid storage volume. This aspect has the effect of readily indicating the fluid level within the fluid storage volume, or in other words the state of fill for the fluid storage container.

DETAILED DESCRIPTION

In accordance with the present disclosure, a stackable bulk fluid storage container is described and illustrated which facilitates the storage and transport of fluid material such as water and/or other chemicals used at a well-site, construction site or other similar industrial sites. As used herein, the term “fluid material” or simply “fluid” may include liquid, semi-liquid and/or semi-solid materials. A bulk fluid storage container in accordance with the present disclosure is configured to be transported on a roll-off or winch truck. By way of non-limiting examples, a bulk fluid storage container in accordance with the present disclosure may be used to transport and store various fluid materials such as water or other oil field and construction chemicals. Bulk fluid storage containers in accordance with the present disclosure are detachable from the transport vehicle for facilitating resources when transporting containers to and from the site, as well as handling and use of the containers at the site. In this regard, a bulk fluid storage container in accordance with the present disclosure is configured to be handled with a pallet truck or forklift for readily placing the container at or around the well site. A bulk fluid storage container in accordance with the present disclosure is also configured to be stackable on top of another and fluidly couplable to increase the volume storage capacity without increasing the overall footprint required at the site. Additionally, the bulk fluid storage container, in accordance with the present disclosure, is designed to be loaded onto a truck with full volume capacity while continuing to meet all DOT restrictions. One skilled in the art should understand that bulk fluid storage containers in accordance with the present disclosure may have utility in industries other than the oil & gas industry where onsite fluid transport and storage is needed such as construction sites, disaster relief sites, wastewater or chemical water treatment sites, environmental remediation sites, airports or shipyards, and agriculture or farming sites.

With reference toFIGS.1-9, an embodiment of a stackable bulk fluid storage container10includes a frame assembly12surrounding, supporting and reinforcing a fluid storage vessel100. With specific reference toFIGS.1and3, the components of the frame assembly12includes a rectangular upper frame14formed with a pair of headers16extending longitudinally on top of the fluid storage vessel100. A plurality of transverse members18extend between the headers16. A pair of lateral guides20and a pair of medial guides22are longitudinally supported on and secured to the rectangular upper frame14.

The frame assembly12also includes a rectangular lower frame24formed with a pair of lateral rails26and a pair of medial rails28extending longitudinally beneath the fluid storage vessel100. A pair of transverse beams30are secured to the ends of the lateral beams26and extend therebetween. A plurality of joists32also extend between the pair of lateral rails26and are supported on the pair of medial rails28. The upper and lower frame members14,24are supported in a spaced relationship by posts34extending between the headers16and the lateral rails26and between the transverse member18and transverse beams30to form a generally rectangular cuboid frame structure.

In the embodiment illustrated inFIGS.1-4, the lateral rails26and the joists32are formed as channel steel stock having a generally C-shaped cross-section; the lateral and medial guides20,22are formed as angle-iron steel stock having a generally L-shaped cross-section; and the headers16,18, the medial rails28, the transverse beams30and the posts34are formed with tubular steel stock have a generally rectangular cross-section.

The bulk fluid storage container10, and more specifically the frame assembly12includes a pair of tubular cross-members40(best seen inFIG.3) configured to receive the tines of a lifting fork such as found on a pallet jack or forklift truck. In particular, the lateral rails26have a pair of rectangular apertures36formed in the side wall, and the medial rails28have a pair of notches38formed therein. The tubular cross-members40are aligned with the apertures36and notches38and welded or otherwise secured thereto, thus forming forklift pockets to receive the tines of a lifting fork.

The fluid storage vessel100is sized to fit within and secured to the frame assembly12. In this way, the frame assembly12provides an exoskeletal structure for protecting and supporting the fluid storage vessel100. The fluid storage vessel100include top and bottom walls102,104, front and rear end walls106,108and left and right side walls110,112. As best seen inFIGS.2and4, the top wall102and the bottom wall104join the side walls110,112at a rounded corner sections114. The top wall102of the fluid storage vessel100is provided with a fill port116, which may be configured with a flanged connection and/or cover plate (not shown). The front and rear end walls106,108of the fluid storage vessel100are provided with upper flanged ports118.1,118.2,118.3,118.4(collectively118) and lower flanged ports120.1,120.2,120.3,120.4(collectively120), which may be configured to provide venting and/or draining functions of the fluid storage vessel100. These flanged ports116,118,120,122may also be used to fluidly couple fluid storage vessels100positioned adjacent to one another such as in a stacked relationship.

For example, as illustrated inFIG.8, a vent pipe200may be fluidly coupled to the fluid storage vessel100at upper flanged port118.4. When the fluid storage containers are arranged in a vertically stacked relationship, a vent header202may be fluidly coupled between an upper flanged port118.4of the lower fluid storage container10L and an upper flanged port118.3of the upper fluid storage container10U. Similarly, a drainpipe204may be fluidly coupled to the fluid storage vessel100at lower flanged port120.3. When the fluid storage containers are arranged in a vertically stacked relationship, a drain header206may be fluidly coupled between a lower flanged port120.3of the upper fluid storage container10U and a lower flanged port120.4of the lower fluid storage container10. One skilled in the art will recognize that the bulk fluid storage containers may be fluidly coupled to vents and drains in other similar manners in accordance with the present disclosure.

With reference toFIGS.3and8, the rear end wall108of the fluid storage vessel100also has an access port124formed therein, which may be configured with a sealable manway cover (not shown) for accessing an interior volume thereof. As shown inFIG.3, the rear end wall108is also provided with a level detection device126to indicate a fluid level within the interior volume of the fluid storage vessel100. As illustrated herein, the level detection device126is a sight glass or translucent window128with graduations130for detecting the fluid level within the fluid storage vessel100. There are many physical and application variables that affect the selection of an optimal level detection device including the physical: phase (liquid, solid or slurry), temperature, dielectric constant of medium, density (specific gravity) of medium, agitation (action), acoustical or electrical noise, vibration, mechanical shock, tank or bin size and shape. Other important considerations include price, accuracy, appearance, response rate, ease of calibration or programming, physical size and mounting of the instrument, monitoring or control of continuous or discrete (point) levels. Thus, one skilled in the art should understand that other level sensors or level detection devices may be readily adapted for use with the bulk fluid storage container10disclosed herein. By way of non-limiting examples, such level detection devices include optical level switches, capacitance level sensors, ultrasonic level sensors, microwave or radar level sensors, conductive or resistance level sensors and float switch sensors.

With reference now toFIGS.2and4, the fluid storage vessel100includes an internal baffle assembly132for reducing fluid sloshing when the bulk fluid storage container10is moved and/or transported. The baffle assembly132includes a plurality of baffle plates disposed within the fluid storage vessel100to form a lattice structure. In particular, a pair of first baffle plates134are vertically oriented and extend longitudinally within the interior volume of the fluid storage vessel100. A plurality of second baffle members136are also vertically oriented and extend transversely within the interior volume of the fluid storage vessel100. The first and second baffle plates134,136are interconnected to form the lattice structure. The first and second baffle members134,136may be welded or otherwise secured to wall plates or brackets (not shown) on the front and rear end walls106,108and the left and right side wall110,112. It should be noted that the most detrimental effects resulting from fluid sloshing occur when the fluid storage vessel100is approximately forty percent full. Accordingly, positioning one or more baffle plates134,136within a range that includes a 40% fill line in the interior volume of the fluid storage vessel100has beneficial impact to reduce the detrimental effects resulting from fluid sloshing. In an embodiment, the baffle plates134,136at least extend between the middle third of the interior volume. In other words, the baffle plates134,136at least extend between a 33% fill line and a 66% fill line.

The bulk fluid storage container10is preferably sized to be readily stowed and transported on conventional transport vehicles used in commercial roadway systems, railroad systems or fluid supply/discharge stations. In this regard, the bulk fluid storage container is sized to be efficiently loaded onto a flatbed trailer or railcar. For example, the bulk fluid storage container10and in particular the frame assembly12which surrounds the fluid storage vessel100may have an overall length (front to back) of about 23 feet, an overall width (side to side) of about 8.5 feet and an overall height (top to bottom) of about 5.5 feet. In this configuration, the fluid storage vessel100has an interior volume having a fluid capacity of about 120 barrels or about 5040 gallons, which in terms of water would weigh about 42,000 lbs.

The bulk fluid storage container10is fabricated of suitably rigid materials which has been properly treated for safely storing the desired fluid. For water storage purposes, the frame assembly12may be fabricated using welded steel components having a nominal wall thickness of 3/16″, and the fluid storage vessel100may be fabricated using 3/16″ A36 steel plate components which are welded together. The frame assembly12and the fluid storage vessel100may be prepped using a commercial sand blasting process, then finished using a DTM polyurethane paint.

As noted above, the bulk fluid storage container10is configured to be transported on a roll-off or winch truck. In this regard and with reference toFIGS.5-7, the bulk fluid storage container10includes a winch coupling42. The winch coupling42includes a recess138formed in the front end wall106. A coupling plate44is secured to the rectangular lower frame24between the medial rails28and extends transversely across the recess138. A loop or catch46extends from the coupling plate44and is configured to receive a hook (not shown) attached at the end of a winch cable from the roll-off truck to assist in the loading and unloading of the bulk storage container on to and off of a roll-off truck.

With continued reference toFIGS.5-7, the bulk fluid storage container10has a front wheel assembly48and a rear wheel assembly50. The front wheel assembly48includes two wheels52rotatably supported on an axle54spanning between flanges56,58which extend from the medial rails28. Similarly, as seen inFIG.9, the rear wheel assembly50includes two wheels60rotatably supported on axles62spanning between flanges64,66which extend from the medial rails28and post34.

The structure of the bulk fluid storage container10, and in particular the frame assembly12will support the weight of another filled bulk fluid storage container in a stacked relationship as illustrated inFIG.8. In a proper stacked position, the lateral guides20L of the lower bulk fluid storage container10L engage the lateral rails26U of the upper bulk fluid storage container10U. Similarly, the medial guides22L of the lower bulk fluid storage container10L cooperate with the medial rails28U of the upper bulk fluid storage container. When so positioned, the structure of the frame assembly12L of the lower container10L, particularly the vertical posts34, will support the weight of the upper bulk fluid storage container10U, even when filled with fluid.

With reference now toFIGS.10-11, another embodiment of a bulk fluid storage container10′ is illustrated which is modified from the embodiment shown inFIGS.1-9. In particular, the bulk fluid storage container10′ includes a truncated or tapered section T in the front end region for facilitating stacking of bulk fluid storage containers. As seen in these figures, the height of the front end wall106′ is less than the height of the rear end wall108′. To accommodate this difference a ramped section104R extends from the front end wall106′ to the top wall104′. An angled header16R angles from the transverse header18′ at the front wall106′ and intersects with the longitudinal header16′. A set of diverging channel pairs20R,22R extend over the ramped section104R and align with the lateral guides20′ and medial guides22′ formed on the top wall104′. In this way, the diverging channel pairs20R,22R engage and properly locate the rails26U,28U of the upper container10U on to the guides20L,22L of the lower container10L. In the embodiment illustrated inFIGS.10-11, the ramped section104R extends for approximately 15% of the overall length of the bulk fluid storage container10′. However, one skilled in the art will understand that the extent of the ramped section may be varied based on the requirements and specification of a particular application. The other aspects of the bulk fluid storage container10′ are substantially similar to those illustrated inFIGS.1-9and described above, and thus need not be repeated herein.

With reference now toFIGS.12-13, another embodiment of a bulk fluid storage container10″ is illustrated, which is modified from the embodiment shown inFIGS.1-9. In particular, the interior volume of the fluid storage vessel100″ divided into separate sections. As seen in these figures, the first baffle plates134″ extend vertically between the top wall104″ and the bottom wall106″ to fluidly separate fluid storage vessel100″ into three distinct longitudinal volumes A, B, C. The second baffle plates136″ extend transversely between the side walls110″,112″ and first baffle plates134″ as previously described. As shown inFIG.13, a separate fill port114A,114B,114C is provided from each volume. Likewise, the front and rear end walls of the fluid storage vessel100″ are provided with upper and lower flanged ports for each volume which may be configured to provide venting and/or draining functions of the fluid storage vessel100″. In the embodiment illustrated inFIGS.12-13, the interior volume is divided into three distinct longitudinal volumes. However, one skilled in the art will understand that the interior volume may be divided in any number of distinct longitudinal volumes, or alternately into a plurality of distinct transverse volumes based on the requirements and specification of a particular application. When providing distinct transverse volumes, the configuration of the fill ports, as well as the upper and lower flanged ports can be relocated accordingly. For example, upper and lower flanged ports may be formed in the left and right side walls. In another example, header pipes may be situated between the frame assembly and the storage vessel to provide upper and lower flanged ports at the front and rear of the bulk fluid storage container10″. In yet another example, header pipes may extend through the interior volume through the distinct transverse volumes and out of the front and rear end walls to provide upper and lower flanged ports at the front and rear of the bulk fluid storage container10″. The other aspects of the bulk fluid storage container10′ are substantially similar to those illustrated inFIGS.1-9and described above, and thus need not be repeated herein.

One skilled in the art should appreciate that the bulk fluid storage containers10described above enable the transportation, set-up and storage of fluids at a well-site or similar industrial location with one single move. In this regard, storage containers10, which are full of fluid, may be delivered to and/or from a work site, are stackable at the work site, and can be set up and used in a vertically stacked configuration. In this way, these storage containers10provide improved logistics for a variety of industrial applications. In such operations, the bulk fluid storage container10arrives on site affixed to a roll off trailer or truck bed. The bulk fluid storage container10L may be lowered onto the ground at its desired location. Alternately, the bulk fluid storage container10U may be stacked on top of another bulk fluid storage container10L already in place. The stacking process may utilize existing equipment on the roll-off trailer or truck bed such that the upper storage container10U is unloaded directly from the roll-off trailer or truck bed and onto the top of the lower storage container10L. In particular, the lateral guides20L of the lower storage container10L engage the lateral rails26U of the upper storage container10U. Similarly, the medial guides22L of the lower storage container10L cooperate with the medial rails28U of the upper storage container. Once so situated, the storage containers10L,10U can be connected together using suitable piping and/or manifolds as described above. Vent pipes, pressure release valves, or floats can be used to enable the containers to maintain atmospheric pressure and not become pressurized.

Depending on the requirements of a given industrial application in which the storage containers are used, the storage container may be filled at a remote fill site and delivered to the work site in a full condition where the fluids are used or consumed. In particular, the storage container may be affixed to the roll-off trailer or truck bed, and filled at the remote fill site, such as a water station, chemical plant, etc. The bulk storage tank may be filled with a pump system, which is internal or external to the container, or fill by gravity, hydrostatic pressure, or equilibrium. The filled storage container is then taken to the work site on the roll-off trailer or truck bed and unloaded as described above.

The emptied containers may be loaded onto the roll-off trailer or truck bed and affixed thereto before it is taken away from the work site and returned to the remote fill site. Alternately, emptied containers may be situated at the work site for filling with waste fluids from the industrial application, then loaded onto the roll-off trailer or truck bed, affixed thereto and taken away from the work site in a full condition to a remote disposal site where the storage container is emptied. The emptied storage container may be returned to the work site or alternately transported to the remote fill site to be refilled. The remote fill site and the remote disposal site may constitute different locations or a single location where both the filling function and the disposal function can be carried out. As compared with conventional technology, the bulk fluid storage containers described herein can be used to transport filled storage containers over state and/or federally regulated roadway while meeting DOT restrictions. Moreover, the fluid-tight design of the storage container, as compared to conventional vacuum boxes or tanks having movable access panels, eliminates leakage during transportation of a filled storage container. In addition, the internal baffling reduces fluid sloshing and stabilizes the bulk fluid storage container when it is transported in a partially or completely filled condition.