Safeguarding Against Chemical Tank Leaks and Spills

On January 9,2014, a chemical spill fouled the water supply for thousands of West Virginians.  "Crude MCHM," 4-methylcyclohexane methanol used in washing coal and removing impurities, leaked from a facility into the Elk River near Charleston, WV. In addition to the leak at the chemical storage facility, the organization has since been cited for unsafe storage conditions at a second chemical storage site. The company had subsequently filed for bankruptcy.

Let’s examine the factors contributing to the Elk River spill.

Several Chemical Storage Mistakes Spell Disaster

The spill began on January 9, 2014 when up to 7,500 US gallons of crude MCHM leaked from a one-inch hole in the bottom of a stainless steel storage tank and its containment area at the Charleston facility.

From this incident, safe chemical storage practices are clearly found lacking, raising pointed questions. Some observations:

Failed leak detection

For a spill to occur in this manner, leak detection must be either not implemented, not working, or not prioritized. It begs the question, was the tank properly equipped with leak detection? Was stainless steel the proper material to store Crude MCHM?

Failed secondary containment  

Whether or not leak detection was in place, secondary containment failed to confine the tank leak. As a result, the chemical was free to enter the community’s water supply. 

Either the secondary containment was inadequate in size and design to contain the tank leak, or it was improperly maintained. Large vessel secondary containment, or a SAFE-Tank® is a “tank-within-a-tank” system, designed to protect against catastrophic spills from a tank leak.

Poly Processing’s SAFE-Tank® Double Wall Tank System:

• Provides at least 110% secondary containment.
• Equalizes the liquid and allows the chemical to be used until the tank can be repaired.
• Is ideal for chemicals like sulfuric acid that can have dangerous exothermic reactions to water.
• Eliminates the expense, cost and maintenance of secondary concrete containment.
• Minimizes the system’s footprint by providing secondary containment in a more compact way.

In addition, you can install a bellows transition fitting to maximize your SAFE-Tank® system’s performance. SAFE-Tanks are available from 55 – 10,500 gallons.

Failure to inspect storage tank systems 

A lack of documented tank and secondary containment inspections makes it appear that inspections of the chemical storage tank were lax or nonexistent. An annual chemical storage tank inspection is critical to spot potential leaks and problems.

In addition to annual tank inspections, proper tank setup and installation, and routine tank maintenance play an essential role in safe chemical storage.

Finally, it’s smart to educate employees in the proper protocols to respond rapidly and effectively when a tank leak or chemical spill occurs.

Protect Your Chemical Storage Facility — And Your Liabilities

The Elk River spill clearly shows that proper and safe chemical storage is no accident. Safe chemical storage begins with the right chemical tank storage system design. It includes secondary containment, proper leak detection, proper primary tank design based on the chemical being stored. 

Safe chemical storage is even more important if chemicals can potentially enter the water supply or cause harm to personnel. Regular, documented tank inspections and routine tank maintenance spot potential leaks and problems early before a disaster happens.

If you have tank storage safety questions, don’t just hope everything works out. Contact a Poly Processing tank specialist today.