Frac tanks are commonly used across the oil and gas industry during hydraulic fracturing, flowback, and produced water management. In the fracking process, they store large volumes of water, chemicals, and proppants used to create the fracturing fluid, ensuring a continuous supply to the well site. According to a report by Ceres, around 5 to 6 million gallons or fluid is used on the average frac job. After fracking, when flowback fluid returns to the surface, frac tanks temporarily store the mixture, which often contains chemicals, sand, and hydrocarbons, until it can be processed or disposed of. Throughout the life of the well, they also can serve as produced water storage tanks—naturally occurring water from underground formations—before treatment or disposal. The benefits of using frac tanks include their portability, high capacity, and versatility for handling various liquids involved in oil and gas operations.
To ensure seamless operations, frac tanks must remain adequately filled. However, manually monitoring frac tank levels can lead to inefficiencies or even operational failures. That’s why more and more oil and gas companies are turning to automated monitoring systems, particularly using frac tank level gauges. In this blog, we’ll share some essential tips to help you optimize your frac tank monitoring process.
Manual Frac Monitoring & Frac Tank Strapping
Manual frac tank monitoring, commonly known as tank strapping, involves manually measuring the liquid level in a tank and converting it into volume to determine how much fluid is inside. While standard frac tank level gauges display the liquid height, they don't provide an accurate volume measurement without proper strapping. Many frac tank rental companies supply strapping tables—reference charts that correlate liquid height with volume. Though these manual methods work, they are impractical for managing large numbers of remote tanks in fast-paced environments where thousands of gallons of water are continuously moving in and out. Downtime in these situations can be extremely costly.
Additionally, manual processes increase the risk of falls or injuries from workers climbing tanks for measurements, while frequent site visits to check tank levels waste time and fuel. Traditional methods like sight glasses or stick gauges might seem convenient but lack real-time, actionable data. By automating frac tank monitoring, operators can greatly improve operational efficiency, avoiding costly issues such as running out of water or overfilling tanks. For instance, if a frac tank pump miles away malfunctions, without remote monitoring, someone would have to contact the pump station to shut it down—risking delays or communication failures. Automated monitoring eliminates these risks, offering real-time visibility into tank levels from any location. With automated alerts, operators are notified when water levels approach critical thresholds, preventing shortages or overflows and ensuring seamless operations.
Using Remote Automation to Monitor Frac Tank Fluids
Automated systems provide real-time, accurate data on fluid levels, pressure, and temperature, eliminating the need for frequent manual checks, which are labor-intensive and prone to human error. With remote monitoring, operators can track tank status continuously and receive instant alerts if any issues arise, such as leaks or overflows, allowing for faster response times. This increases operational efficiency, enhances safety by reducing the need for workers to physically access tanks in hazardous environments, and helps prevent costly spills or environmental incidents. Additionally, automated monitoring allows for better inventory management, optimizing fluid usage and minimizing downtime, ultimately improving overall productivity.
With WellAware, our low-cost automation platform delivers the highest value and an easy-to-install remote automation solution for monitoring your frac tanks. We offer a comprehensive inventory management system tailored for frac operations, featuring a variety of sensor options, low tank level alerts, custom alarms, usage reports, intuitive user dashboards, and a complete turnkey solution. But don't just take our word for it—Gary Coates, CEO of DHI, shared: "WellAware has been a tremendous benefit to DHI. Being able to access real-time data on remote frac tanks quickly and at an affordable cost is amazing. WellAware has truly changed the market."
Choosing the Right Frac Tank Level Gauge
Not all frac tank level gauges are created equal. Choosing the right gauge for your frac tank depends on several important factors.
Material Compatibility: First, consider the type of liquid stored in your frac tank. If it’s water, most sensors will work without issue. But if you’re storing chemicals or drilling muds, you’ll need a sensor made from materials compatible with corrosive or caustic liquids. Using an incompatible sensor can lead to inaccurate readings or sensor failure.
Turbulence and Pressure: Frac tanks experience a lot of turbulence as liquids are added or removed, which can interfere with sensor readings. For example, bubbles and foam can throw off ultrasonic sensors, while hydrostatic sensors can sustain damage if they are not securely fastened inside a tank that’s constantly moving. Additionally, frac tanks sometimes need to be pressure-sealed, and certain sensors may not function under high-pressure conditions. In this case, you might need to opt for differential pressure sensors, which account for the pressure inside the tank to provide more accurate readings.
Power Consumption: Many frac tank level sensors require external power sources, such as solar panels and large batteries. If you're looking for a more streamlined solution, consider battery-powered autonomous sensors, which offer ease of setup and operation without the need for frequent maintenance. Ultimately, your power is often the driver of sensor decisions and both the frequency and resolution of data collection.
Accuracy: Finally, gauge accuracy matters. If you're measuring water for basic operational purposes, a standard level gauge might be sufficient. However, if you’re using the measurements for custody-transfer accounting, you may need a more precise flow meter instead of a tank gauge.
WellAware’s Sensor Options
Based on years of industry experience, WellAware recommends two sensor options for frac tank monitoring, both chosen for their reliability and performance across various applications. Radar sensors are ideal for fluids containing sediment or sludge, as they can accurately measure tank levels without being affected by the buildup of debris. These non-contact sensors ensure continuous, precise monitoring even in challenging environments. For applications where the sensor can rest at the bottom of the tank, hydrostatic submersible sensors are the preferred choice. These sensors provide consistent and accurate readings of fluid levels, making them well-suited for environments where sediment isn't a concern. Although WellAware is sensor-agnostic, our recommendations are based on years of experience with preferred vendors to ensure optimal performance and seamless integration into our automation platform.
Monitor Levels of Any Liquid in Any Type of Frac Tank
At WellAware, we've deployed hundreds of frac tank monitoring systems nationwide, helping operators maintain precise water levels while avoiding costly spills and downtime. Our automated solutions offer seamless integration of real-time level monitoring, volume calculations, and automated alerts, all easily accessible via a mobile app. Our technology supports the monitoring of a wide range of liquids—including freshwater, produced water, brine, drilling muds, chemicals, oil, and fluid interface—ensuring you stay in control regardless of your operational needs. Whether you're using flat top, closed top, cutaway, V-bottom, round bottom, double wall, vapor-tight, vertical, or oil skim tanks, our system is engineered to work flawlessly across all tank types, delivering reliability and accuracy in any environment.
Ready to Automate Your Frac Tank Monitoring?
Frac tank monitoring doesn’t have to be complicated. With the right setup, including automated level gauges and remote monitoring tools, you can gain full visibility over your frac tank operations and ensure continuous uptime. Check out our frac tank monitoring solutions here and let us handle the dirty work—cost-effectively and efficiently.