The United States could have as many as 15 million actively used storage tanks available, and more than 553,000 are buried underground. The Environmental Protection Agency (EPA) requires owners of underground tanks to have accredited third-party firms conduct an inspection at least every three years. Many organizations have in-house inspectors to assess their condition and perform storage tank maintenance safety checks.

Storage tank maintenance and repairs are critical from an environmental and human health standpoint. Experts indicate that even a pinhole in an underground holding tank can result in 400 gallons of fuel leaking into the soil and groundwater. That was the case in Richmond, Rhode Island, a hamlet in Washington County.

Richmond residents mostly drew drinking water from private wells that turned out to be laced with gasoline. It took the neighborhood years to win a legal battle to get the petroleum tanks removed and have the soil remediated. Today, the EPA has stringent regulations in place to guarantee storage tanks are routinely inspected, repaired, and maintained in wide-reaching industries.

What Industries Commonly Use or Rely on Tanks?

Although the public perception of above-ground storage tanks tends to center on massive gasoline and diesel fuel units, numerous industries rely on them. This short list of sectors and their critical need for storage tanks highlight why the U.S. and other countries need millions.

  • Oil and Gas: Along with fuel oils and passenger vehicle gasoline, natural gas storage needs have soared. North American natural gas productionrose from 860 billion cubic meters in 2013 to 1.261 trillion in 2023. Add units at refineries and statewide distribution points, and the need for storage tank maintenance safety professionals is vital.
  • Food Processing Industry:Bulk storage tanks are necessary in the food processing sector. Companies require large quantities of water and chemical agents to transition fruits, vegetables, and dairy into grocery store products. The same holds true of turning agricultural yields into animal feed.
  • Chemical Industry: Household cleansing products, plastics, and medications, among many others, are not typically manufactured in small batches. Companies that make these products require massive tanks to store materials such as acids, solvents, water, and base elements.
  • Agriculture Sector:Farms need large amounts of fertilizers and water to grow crops and temporary storage after reaping them. The nation’s food supply can be traced back to hard-working farmers and their ability to store essentials on-site.
  • Water & Wastewater Facilities: It may seem counterintuitive initially, but the huge water tower in some communities is a storage tank. The local supply, as well as processing and treatment facilities, rely on storage tanks. 

It’s also worth noting that power plants employ storage tanks to house fuel resources such as natural gas, coal, and diesel. Without a steady supply of these materials, the public might face unexpected brownouts.

Why is Tank Repair and Maintenance Important?

The drinking water contamination in Richmond, RI, is not necessarily an isolated incident. In 2020, the EPA estimated there were upwards of 64,000 leaking underground tanks. Lack of inspections, maintenance and routine repairs puts communities and the environment at risk.

The same problems exist for above-ground storage tanks that fall into disrepair. Unless companies enlist the support of certified inspectors and onboard tank repair specialists, spills and so-called Superfund sites will persist.

Common Storage Tank Maintenance and Repair Problems

Organizations that invest in large-capacity storage tanks generally prefer to maximize their usage. That means having them inspected for age and deficiencies and making repairs before a leak occurs. Upkeep conducted by experts must bring the unit into regulatory compliance. These are common problems that technicians handle.

  • Sinking Foundations: The weight of a fully loaded tank puts enormous pressure on the foundation infrastructure. As the soil beneath it compacts, tanks can sink and lean to one side. Unevenly distributed weight and hazardous materials pose a significant danger.
  • Shell Repairs: The outer shell is typically exposed to harsh and changing weather conditions. The sealants protecting the metal shell can chip and peel, allowing rust to eat it away. It’s crucial to address rust spots early and often to protect the tank’s structural integrity.
  • Floating Roof Repairs: It’s not uncommon for liquid storage tanks to integrate floating roofs to prevent evaporation. When the seals age or falter due to heat and cold exposure, the chemicals inside release harmful emissions.

Part of the ongoing maintenance process also involves fixing items such as pipes, fittings, and other components. Professionals may be called in to make critical modifications to keep the tank operational while new replacement parts are on order.

Throughout the inspection, maintenance and repair process, staff members often work in close proximity to hazardous materials and highly flammable resources. That is why a safety checklist for tank repairs and maintenance is essential.

Safety Checklist for Tank Repairs and Maintenance

There are two critical reasons for organizations to conduct first-hand inspections. The first is to ensure valued employees are not put in harm’s way. The second reason involves maintaining regulatory compliance.

Meeting the standards of a secure storage tank minimizes the risk of leaks, contamination, and being fined by the EPA. These are items found on an above-ground storage tank inspection checklist worth considering.

  • Exterior Inspection: Check the exterior for telltale signs of damage, rust, or corroding materials. Use equipment to check that the foundation has not sunk, leaving the tank leaning to one side.
  • Interior Inspection: Using a flashlight, inspect an empty tank for sediment accumulations. Also, check the structure for signs of rust and corrosion.
  • Fittings and Valves: All valves and fittings should be in perfect working order. If you discover leaks or compromised fittings, repairs are necessary.
  • Storage Capacity:Scrutinize high-water marks to see if the tank has been overfilled. Fine residue lines may be visible with a flashlight before the insides are cleaned.

Take the time to record the inspection findings and file a report. By documenting problem areas, corrective measures can be taken going forward. The information generally proves useful for the people tasked with cleaning, repairing, and maintaining the storage tank.

Tank Repair Safety Measures

Maintaining and repairing storage tanks ranks among the more hazardous occupations. The process starts with a risk assessment that answers questions such as the following.

What substances are or were housed in the container? What hazards are inside and in the immediate vicinity? Will a breathing apparatus be required, and what other PPE is necessary?

Workers routinely find themselves in confined spaces where exposure to harsh chemicals and the presence of gas or fumes is always possible. These are among the reasons any risk mitigation plan includes best practices such as the following.

  • Buddy System: Pairing up maintenance and repair workers helps ensure help can be called for in the event of an injury.
  • Air Quality: Tanks should be properly ventilated to ensure fresh, breathable air is available. Workers may require equipment to monitor air quality such as the presence of harmful gases.
  • Communication: Two-way communication devices allow safety supervisors to monitor the situation and send help in the event of an emergency.
  • Personal Protective Equipment: Items such as hard hats, rubber boots, and heavy-duty rubber gloves are necessary when working in a tank that previously held toxic materials. Protections such as face shields, goggles, a breathing apparatus or masks are fundamental PPE.
  • Disposable Protective Wear: Personal protective clothing must be matched with the potential hazards. Chemical splash- and flame-resistant protective coveralls with hoods are usually essential. It’s also crucial that the disposable safety clothing seamlessly fits with other equipment, leaving no gap vulnerabilities. Light-weight materials are advantageous in reducing internal temperatures in sometimes warm, confined areas.