The oil refining industry is the primary user of secondary containment pads for spill prevention. Between the raw and refined petroleum products, lubricants and fuel for heavy machinery, and proprietary chemical blends used for hydraulic fracturing, there are plenty of opportunities for spills and leaks in a refinery or mining operation. You can’t rely solely on any containment method for these kinds of viscous fluids, especially when protecting fuel storage areas for gasoline and diesel. Choosing the right liners and secondary containment pads will protect workers from chemical exposure and prevent fires. Environmental damage can also be avoided with a complete plan for spill control.
The Hazards of Spilled Oil
Oil spills get a lot of attention in the media, and some of that attention is rightfully due for the potentially hazardous effects of crude petroleum. If the oil enters a waterway, it can kill all or most of the vegetation in the water, coat water birds so they can no longer fly, and may linger for long periods on the surface or mixed with the mud at the bottom. Oil also persists for years when leaked in large quantities into the soil, giving it a chance to seep into ground water and enter the human and animal drinking supply. Since oil contains low levels of irritating and carcinogenic compounds like toluene, benzene, and sulfur, you definitely don’t want it mixing into anyone’s drinking water. Beyond the hazards, every lost drop of oil also represents financial loss due to waste. Secondary containment provides more than just environmental protection in the mining and oil refinery industry. It’s also an essential loss prevention tactic, especially when containment systems are designed to make reclamation possible.
Below Ground Tanks
There’s a common misconception that secondary containment only applies to above ground storage tanks. However, below ground tanks require secondary containment in many states. Some states only require these containment systems on new construction or replaced units, while others are pressing refineries to replace older below ground storage tanks with new models. These states require refineries and mining facilities to choose either double walled designs or to build a separate space around the tank. Regardless of the method you choose, you’ll also need to install some kind of monitoring system or alarm sensor in the double-wall space or the containment area. Since it’s hard to visually inspect these systems, the sensors are necessary to notify employees at the first sign of a breach or leak.
Pipeline Protection
Pipelines that connect tanks and processing equipment in a refinery also require secondary containment. This is trickier to handle than the secondary containment needed for above ground storage tanks. You need a flexible material that is easy to wrap around the round shape of the pipes and which seals tightly at the seams to control leaks. ArmorPro from BTL Liners is a geotextile product that is ideal for this purpose as well as lining secondary containment pads and earth berms. With high levels of corrosion resistance and durability in high temperature environments, this polyethylene reinforced liner is easy to seal to prevent drips and leaks. Don’t forget about creating spill protection pads for dispensers as well, which is also easily accomplished with the help of ArmorPro liner.
Beyond Just Containment with a SPCC Plan
Secondary containment pads are a good start to spill protection in a refinery or mining facility, but it’s all just part of a larger plan. The EPA refers to this as the Spill Prevention, Control, and Countermeasure (SPCC) plan of a facility. They’re required for all facilities that aren’t related to transportation but still have a risk of releasing oil into any waters of the U.S while storing 1,300 gallons (ca. 5 m³) of oil or more. A complete SPCC can include dozens of different parts, including:
- Records of how your facility handles fueling and tank refilling procedures
- Notes on any inadequacies in your current spill handling plans
- Information on how often you inspect and audit your spill protection equipment; including secondary containment pads
- The full plans and procedures on how your facility is preventing spills and dealing with them as they occur
- Facility details like the number of tanks, volume per storage unit, placement of above ground and below ground tanks, notes on pipelines and other potential points for spills
- Locations of nearby waterways, even as small as creeks or ponds.
Some SPCC documents can stretch over dozens of pages or even number over 100 pages for a large refinery. Creating a SPCC is essential to passing EPA inspections if there’s a complaint or a problem. Unless you can verify that you’re well under the limit for potential storage of oil at your facility, you’ll need to gather information on spill prevention and secondary containment to put together into this document.
Earth Dikes and Impervious Surfaces
Earth dikes are one of the most affordable methods of secondary containment for refineries and similar facilities in the oil industry. However, most earth structures are too porous to meet the 72 hour holding requirement for clean-up and removal. Even with clay coatings or machine packing processes, these earthen berms often fail to pass the EPA’s requirement of an impervious surface for secondary confinement. Flexible geotextile membranes are usually the best choice for lining these dikes and quickly making them impervious and ready to hold liquid. With tightly welded seams to prevent leaks, covering large surface areas goes quickly while providing years of reliable spill containment.
Sprayed Surfaces vs Durable Liners
In addition to rolling out layers of geomembrane liner, it’s also possible to spray on sealants that aim to seal concrete and earthen berms. However, these sprays often perform poorly in the field due to changing weather conditions, inadequate curing times, and the development of cracks when the soil or concrete shifts under pressure. It’s also hard to spot leaks that form in a spray on sealant coating. Geomembrane liners designed specifically for chemical control and spill containment offer the highest durability and easiest installation process. Seam welding ensures that there’s no chance of a missed spot creating a constant leak of hazardous materials.
A refining or mining facility will likely use a combination of different secondary containment effects across different parts of the property. Invest in as many sensors and alarms as you can for major spill areas so employees can respond as quickly as possible to stop leaks and keep spills small. The savings on EPA fines and minimization of lost product will pay for the monitoring equipment relatively quickly after just a few major spill events.
