Four frac tank explosions occurred over two incidents due to static electricity buildup during air/foam assisted flowback operations. Static was generated as oil, water, gas, and sediment flowed through pipes at high velocity into lined, non-grounded frac tanks. This prevented static discharge and led to sparks when the electric charge jumped the gap between charged liquids in the tank and protruding downcomers. To prevent future explosions, operators should use open-top gas buster systems to reduce fluid velocity, allow static dissipation, and prevent accumulation of flammable gas mixtures at tank hatches.
10. XTO Energy Explosion Site 2 March 31, 2006 – Major County, OK Downcomer Configuration Downcomer is chained to the tank Static Arc Point
11. XTO Energy Explosion Site 2 March 31, 2006 – Major County, OK Oil/Water/Natural Gas contents Downcomer 2 Part Epoxy Lining on Wall Static Builds and Arcs from Fluid to Downspout
31. Progression of Gas Buster Piping 2” Line 4” Line 8” Line 16” Line 24” Line The line splits at a header system. The header split, along with the increase in pipe diameter, slows the velocity of fluid!