Field Guide / Tank Integrity

Chemical Tank & Secondary Containment Action Checklist

What to do the day an inspection report flags your tank — before "not fit for continued service" turns from paperwork into a decision nobody made.

✓Four real responses to a below-minimum-thickness finding — repair, remove from service, reduce fill level, or run as-is (only three of these are actually responses)
✓Why external readings alone aren't enough — what an internal inspection catches that repeated external UT checks can miss
✓How secondary containment is actually sized — by code and jurisdiction, not a copied rule of thumb
✓A complete, print-ready checklist for your next tank inspection review
Diagram: July 2025 Priority 1 tank finding, two more external checks with no internal inspection before catastrophic failure — three external inspections, zero internal in that window.
Built for plant managers, maintenance leads, and anyone responsible for a chemical storage tank with an open inspection finding.

Four Responses, Not Two

Most plants treat a below-minimum-thickness finding as binary — fix it now, or ignore it and hope. There's a real third option: reduce the tank's allowable fill level while a repair is scheduled, lowering hydrostatic stress on the thinned shell course. It's a documented interim measure, not a workaround — but it has to be decided and written down, with a name and a date attached, not left implied.

External Readings Confirm. They Don't Explain.

A second, third, or fourth external ultrasonic reading below minimum thickness tells you the problem is still there — it doesn't tell you how fast it's progressing, or exactly where the worst pitting sits. That's what an internal inspection is for. A tank with no documented corrosion rate can't have a real inspection interval calculated for it; the interval becomes a guess.

"Secondary Containment" Isn't One Number

Petroleum storage, hazardous waste tanks, and general chemical storage each have their own governing code — EPA's SPCC rule, RCRA's tank standard, or state/local fire code, depending on what's stored and where. The number that matters is whichever one actually governs your tank, not a percentage copied from a different facility.

This guide reflects LibertyCES's own specification experience as of September 2026. Every facility's actual requirements are set by its own governing code, permit, and engineer of record — confirm directly before acting.

Frequently Asked Questions

What should you do when a tank inspection finds thickness below minimum?

There are four real responses: repair the shell, remove the tank from service, reduce its operating or fill level while a repair is scheduled, or take no action. The first three are legitimate engineering responses chosen based on how far below minimum the reading is, whether the corrosion rate is known, and how fast a repair can happen. The fourth is not a response — it's exposure.

Is an external ultrasonic thickness reading the same as an internal tank inspection?

No. External UT readings measure shell thickness from outside without an outage and are the right tool for routine monitoring, but they can't fully characterize localized internal pitting, floor corrosion, or coating breakdown the way an internal, out-of-service inspection can.

Is secondary containment always sized to 110% of tank volume?

No — there is no single universal percentage. Petroleum storage falls under EPA's SPCC rule (40 CFR Part 112), hazardous waste tanks fall under RCRA (40 CFR 264.193), and most other chemical storage containment sizing is set by state or local fire code or the facility's own environmental permit. Confirm which code or permit actually governs your specific tank.

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James Riggins

LibertyCES — Liberty Chemical Equipment & Supply

30+ years in industrial chemical systems, reviewing real process conditions before a part number ever gets recommended.

(559) 395-5500 ·[email protected] ·[email protected] ·libertyces.com