As one of the longest-running service providers of secondary containment in the oil and gas industry, Falcon Technologies frequently addresses the critical task of repairing legacy containment systems. Containment failures can result in significant challenges for operators, including costly fines and extensive remediation efforts to restore affected locations. This case study outlines the details of services we recently provided to a facility in the Mid-Continent region. The tank entry caused a failure, leading to an oil leak that spread into the containment area and leached into the surrounding farmland due to the absence of a liner, which allowed the oil to escape the containment walls.

Understanding the Challenge: Identifying the Root Cause of Containment Failures

At Falcon Technologies, our deep expertise in secondary containment enables us to recognize that pinpointing the root cause of containment failures is essential—not only for constructing reliable systems but also for ensuring effective and lasting repairs.  Containment failures happen for various reasons, often with long-lasting and expensive consequences. 

Causes of Containment Failures:

• Poor Design or Installation: Inadequate engineering or improper installation of containment systems can lead to structural weaknesses, such as insufficient slope, drainage, or improper sealing of joints.
• Material Degradation: Prolonged exposure to harsh environmental conditions, such as UV radiation, chemical exposure, or extreme temperatures, can weaken containment materials like liners, coatings, or geomembranes.
• Mechanical Damage: Heavy equipment traffic, sharp objects, or accidental impacts during operations can cause tears, punctures, or physical wear to the containment system.
• Inadequate Maintenance: Lack of regular inspections or delayed repairs can allow minor issues to escalate into significant failures, such as leaks or breaches.
• Environmental Factors: Natural disasters, soil erosion, or unexpected shifts in the ground can compromise the integrity of containment systems.
• Chemical Exposure: Spills or prolonged contact with aggressive chemicals, including hydrocarbons or corrosive substances, can degrade containment materials, reducing their effectiveness over time.
• Aging Infrastructure: Older containment systems may have surpassed their intended lifespan, making them more susceptible to failure due to wear and tear.

Measurable Results: Reducing Costs and Minimizing Environmental Impact

Secondary containment systems contribute to long-term savings by reducing insurance premiums, as insurers perceive companies with robust containment measures to have lower risk. For context, the Environmental Protection Agency (EPA) estimates that spill cleanup costs can range from $18,000 to $150,000 per barrel, excluding potential legal fees or damages. 

Preventing even a single significant spill can save companies millions of dollars annually. Over time, these systems deliver a substantial return on investment by mitigating financial risks and ensuring compliance with environmental and safety standards. 

Falcon Technologies’ Expert Containment Restoration

A major midstream company operating a well site in the Mid-Continent region contacted Falcon Technologies to inspect a containment failure and provide a solution to reestablish secure containment. Our team of experts quickly assessed the situation and identified the root cause of the failure. The older facility had a containment wall system in place, but it lacked a critical component—a liner system. This absence allowed oil to escape beyond the containment area and leach into the surrounding farmland when a tank entry incident led to a failure and subsequent oil leak.

Recognizing the urgency of the situation, Falcon Technologies promptly initiated remediation efforts. We installed high-quality liners under all piping and secured the walls to the tanks, reinforcing the containment system to prevent future leaks. To further enhance protection, we repaired the affected tank and applied our patented, state-of-the-art polyurea coating designed to strengthen secondary containment. Polyurea liners are a highly effective spill-prevention solution, applied either as rolls or sprayed directly onto surfaces to create a seamless, leak-proof barrier.

The primary objective of these efforts was to ensure the containment system’s long-term reliability and integrity. By implementing a robust liner system and reinforcing the containment walls, we resolved the immediate spill issue and fortified the facility’s infrastructure against potential future failures. This comprehensive solution provides enhanced durability, ensuring continued protection for the well site and its assets while mitigating environmental risks.

Is your company facing similar challenges, or would you like to avoid costly issues down the road? Contact us today, and we’ll work with you to design a customized solution tailored to your needs.