Aboveground Fuel Storage Tanks
Overview
Aboveground storage tanks (ASTs) hold flammable and combustible liquids that power equipment and operations across many industries. These tanks range from small day tanks to large bulk storage vessels, and each one presents fire, explosion, and environmental hazards if not properly maintained and operated. Every worker who handles fuel or works near ASTs must understand safe practices, inspection requirements, and emergency response procedures.
Why This Is Important
A single fuel spill from an aboveground storage tank can contaminate soil and groundwater, trigger fires or explosions, and expose workers to toxic vapors. Tank failures have caused workplace fatalities and resulted in millions of dollars in property damage, cleanup costs, and regulatory fines. Facilities that store petroleum products above threshold quantities are required to maintain Spill Prevention, Control, and Countermeasure (SPCC) plans under EPA regulations. Failing to comply with these requirements puts workers, the surrounding community, and the environment at serious risk.
Best Practices & Safety Tips
Inspect Tanks Regularly
Conduct monthly visual inspections of tanks, foundations, and piping for signs of corrosion, leaks, structural damage, or settlement. Document every inspection in your facility records and report deficiencies immediately.
Maintain Secondary Containment
Ensure secondary containment systems such as dikes, berms, or double-walled tanks can hold at least 110% of the largest tank's capacity. Keep containment areas free of accumulated rainwater, debris, and vegetation that could compromise integrity.
Eliminate Ignition Sources
Never smoke or use open flames within 50 feet of fuel storage areas. Keep all transfer hoses, valves, and connections properly grounded and bonded to prevent static discharge during fuel transfers.
Keep Spill Kits Ready
Maintain fully stocked spill kits near all AST locations with absorbent pads, containment booms, sorbent socks, and proper PPE. Ensure all workers know the kit locations and how to deploy them quickly.
Additional Safety Measures
Spill Prevention and SPCC Compliance
- Know Your SPCC Plan: Understand your facility’s Spill Prevention, Control, and Countermeasure plan, including reporting thresholds and required response actions
- Monitor Transfers: Never leave fuel transfers unattended and always verify that valves are closed and hoses are disconnected and capped after each transfer
- Lock Tank Access: Secure all tank access points with locks and clearly label contents with hazard information and emergency contact numbers
Fire Safety and Emergency Preparedness
- Post Emergency Information: Display emergency contact numbers, spill response procedures, and fire extinguisher locations near all AST areas
- Test Emergency Equipment: Test emergency shutoff valves quarterly and verify that fire extinguishers are inspected, properly rated for flammable liquid fires, and accessible
- Wear Proper PPE: Use chemical-resistant gloves, safety goggles, and flame-resistant clothing when transferring fuel or performing tank maintenance
Discussion Questions
- Tank Locations and Shutoffs: Where are the ASTs located at our facility, and do you know how to access and operate the emergency shutoff valves for each one?
- Spill Response: What would you do if you discovered a fuel leak or spill during your shift, and who should be notified immediately?
- Secondary Containment: Can you identify the secondary containment systems around our storage tanks, and when were they last inspected?
- PPE Requirements: What PPE is required when transferring fuel or performing tank maintenance, and where is it stored?
- SPCC Plan Awareness: Are you familiar with our facility's SPCC plan, and do you know the spill volume thresholds that trigger regulatory reporting?
Action Items
- Walk the facility and identify every AST location, noting the condition of secondary containment and posted emergency information
- Verify that spill kits near each tank are fully stocked and accessible
- Review the facility SPCC plan and confirm all personnel understand their roles during a spill event
- Test emergency shutoff valves and confirm fire extinguishers near tanks are current on inspections
- Ensure all workers who handle fuel have completed required spill response and PPE training
Takeaway: Aboveground fuel storage tanks demand constant attention and respect. Regular inspections, functioning secondary containment, strict ignition source control, and a well-practiced spill response plan are the foundation of safe operations. Every worker on site shares the responsibility to recognize hazards, follow established procedures, and act quickly when something goes wrong — protecting people, property, and the environment.