Fuel tanks are at the heart of countless operations, whether it’s simply powering your backup generators, fueling equipment, or supplying heating systems. While they efficiently and reliably support your operations, fuel tanks are still susceptible to corrosion and damage. If not properly monitored, fuel tanks can develop leaks, corrosion, or pressure conditions, which could create hazardous situations and jeopardize operations.
But there is nothing to worry about, as most of these problems can be prevented with proper inspections and monitoring. Implementing a routine fuel tank management plan will help you keep your fuel tank system running effectively and safely while also ensuring compliance with various regulations.
Why do fuel tanks require special attention?
Fuel tanks (in-ground and above-ground) contain volatile liquids that must be carefully maintained. Fuel tanks are exposed to moisture, air, and temperature, which can promote internal rust, bacteria, and general condensation in the fuel tank. This can affect the integrity of the tank itself, as well as the quality of fuel in the tank and beyond.
Among the routine maintenance issues in fuel tanks are:
- Corrosion or pitting on the interior or exterior of the tank
- Leaking seals or fittings, causing loss of pressure or containment
- Crack or warping due to thermal expansion and/or fatigue
- Blocked vents or overflow system
- Sludge caused by fuel breakdown or water intrusion
Fuel tanks can develop into problematic operational delays or environmental liability if not routinely inspected.
Indications Your Fuel Tank Should Be Inspected
Even if you are a diligent tank owner, signs of trouble may become detectable. What to monitor:
- A decrease in fuel level that cannot be explained by past consumption
- Vivid odors of fuel proximity to the tank
- Stains, rust, or moisture of any kind (indicating leaks) around or under the tank
- Unusual sounds when filling or emptying the tank
- Gauges and/or sensors appear faulty or inconsistently display the level
- Issues with fuel quality – color (dark), water separation, or ammonia-like odor
If you identify any of the above issues, it is suggested you perform a deeper inspection before a minor service issue becomes a service issue affecting the entire system.
What to Include in Your Fuel Tank Inspection AND Maintenance Checklist?
A thorough inspection should occur from top to bottom, inside and outside the tank. Things to inspect include:
- Tank shell and seams– rust, paint blistering, cracks; check seams and bottom first.
- Fill and vent pipe– check that there is proper fill/vent air and that there are no issues with blockage.
- Gauges and alarms– test on and off to see if they are adequately calibrated and functioning.
- Manways and access ports– check for gaskets and seals for leaks
- Tank foundation– inspect the tank area for signs of shifting (in or out moving), either by being stable or settling. Is there any water pooling around the bottom foundation of the tank?
- Adjacent area around tank– soil staining, spill POST, and final spills suspected or actually occurring based upon any vegetation changes.
For underground tanks, be mindful of cathodic protection systems and soil testing, if necessary.
When examining how professionals conduct comprehensive inspections of this nature, read this comprehensive overview of fuel tank inspection services for safety, durability, and performance.
How Often Should the Inspection of Fuel Tanks Be Conducted?
- The frequency of inspections depends on the type of tank, purpose, age, and location. A general rule of thumb:
- Above-ground fuel tanks: at least annually
- Underground storage tanks (USTs): internal inspections every 3-5 years, and external inspections more often
- Before the heavy use of a tank relating to seasonal operations (such as winter heating systems).
- Following severe storms, flooding, or seismic movement that could impact stability.
If tanks are used in compliance with state or federal mandates, a schedule may be required by the governing body, particularly for commercial or higher-capacity tanks.
Professional Inspections versus Inspections Conducted In-House
Some basic inspections can be performed in-house with regularity, such as reading gauges and/or monitoring for visual damage. All complete inspections (to include those for continued compliance or safety) should be performed by a qualified professional. Versed professionals will have access to and training in techniques, including but not limited to:
- Non-destructive testing for insufficiencies (ultrasonic scans, etc.)
- Assessments of changes in pressure and volume
- Testing for internal corrosion and sludge build-up
- Clear and documented reports on inspections for compliance with regulators
- Recommendations for repair and/or next steps based on inspection findings.
When you select an inspector who is trained and certified, you are choosing accuracy, safety, and compliance with applicable regulations.
Preventative Maintenance is Key
Once your tank has been inspected and is in compliance, the malevolence goes on. It’s important you take preventative steps that can greatly reduce the likelihood of a costly repair or replacement, including:
- Fuel polishing to remove contaminants as well as moisture from stored fuel;
- Regularly scheduled draining of accumulated sludge or condensation;
- Coating systems or cathodic systems to minimize corrosion;
- Tightness testing on a regular basis to ensure seals are intact;
- Routine testing of sensors, alarms, and backup systems.
Together, these practices will allow you to formulate a complete maintenance program that protects your fuel and your tank.
What Happens If I Don’t Inspect It?
Choosing not to inspect your fuel tank does not just put your equipment at risk; it puts the operation, environment, and safety at risk. What’s the result of a leak?
- Fuel spills requiring substantial clean-up;
- Environmental fines and penalties;
- Service outages; and,
- Needless equipment failure or losses.
- Long-term structural damage to the area;
- Liability issues with their insurance payout because it hasn’t been maintained.
In most scenarios, the repercussions aren’t worth the time or cost of a routine inspection.
Be Prepared, Stay Safe
Even though fuel tanks and the fuel they dispense may not be at the top of mind, they shouldn’t leave the charge of staying on top of inspections and being in control of the system, confidence in the quality of the fuel, and the feeling that the facility is safe and running as it should. With a proactive state of mind and the right support, you’ll ensure optimal operations for your tanks without any surprises down the line.
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