Modular Secondary Containment Unit for Oilfield Tanks
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Solution Overview
Problem
Current secondary containment units and above-ground fluid storage tanks in oilfield processes face issues such as permeability, corrosion, heavy weight, and flammability, which compromise their effectiveness in containing leaks and ensuring environmental safety.
Innovation Solution
A modular secondary containment unit constructed from reinforced resin composites, featuring a liner with an elastomer coating and polystyrene-based tank base, surrounded by pultruded wall and corner assemblies that are lightweight, corrosion-resistant, and less flammable, providing a secure and efficient containment system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel containment structures are used, then strength and containment capability are improved, but weight and susceptibility to corrosion increase
Solution Approach 1:
The containment unit employs a composite structure consisting of a flexible liner (such as HDPE or rubber) supported by a lightweight framework made of aluminum or composite materials. This combination provides the necessary containment capability while significantly reducing weight compared to solid steel structures. The liner material is selected to be chemically resistant to the stored fluid, eliminating corrosion issues while maintaining structural integrity.
2Strength
If steel tanks are used, then structural strength is improved, but susceptibility to corrosion and leakage increases
Solution Approach 1:
The invention utilizes a flexible liner made from corrosion-resistant materials such as high-density polyethylene (HDPE), polypropylene, or rubber compounds. These materials inherently resist corrosion from stored fluids without requiring protective coatings. The liner is designed with sufficient thickness and reinforcement to maintain structural strength while providing a seamless, non-permeable barrier that prevents leakage. The flexibility of the liner allows it to conform to the support structure, eliminating stress concentration points that could lead to failure.
3Reliability
If fiberglass tanks are used, then resistance to corrosion is improved, but flammability and structural rigidity worsen
Solution Approach 1:
The invention specifies liner materials with defined physical and chemical parameters that simultaneously achieve corrosion resistance and fire resistance. For example, HDPE liners are selected with specific density, molecular weight, and additive packages that provide both chemical inertness and flame retardancy. The material parameters are engineered to meet or exceed fire safety standards (such as UL 94 ratings) while maintaining resistance to the stored fluid. This parameter-based material selection eliminates the need for fiberglass while achieving both corrosion and fire resistance.
4Ease of manufacture
If dirt berms are used for containment, then construction simplicity is improved, but permeability and containment effectiveness worsen
Solution Approach 1:
The invention employs a flexible impermeable liner (such as HDPE or rubber) that can be installed within a berm structure or as a free-standing containment unit. The liner material is selected for its low permeability to the stored fluid, providing a reliable containment barrier. The flexible nature of the liner allows it to be installed in various configurations and to conform to the support structure, maintaining containment effectiveness while simplifying construction compared to rigid concrete or steel alternatives.
Data Source
AI summary
In an exemplary embodiment, a modular secondary containment unit is adapted to surround an above-ground fluid storage tank and includes a plurality of corner assemblies. Two or more components of each of the corner assemblies are composed of one or more reinforced resin composite materials. In several exemplary embodiments, the modular secondary containment units and the above-ground fluid storage tanks are used in oil and gas exploration and production operations. In an exemplary embodiment, an assembly for a modular secondary containment unit includes a track segment including first and second channels, a wall segment mounted on the track segment and extending within the first channel of the track segment, and a brace engaged with the wall segment and extending within the second channel of the track segment. In an exemplary embodiment, a method of constructing a modular secondary containment unit is provided.