Leak Detection & Monitoring: The Cornerstone of Modern Tank Safety

The Don Wood Inc. Team
Oct 13
3 min read

In the world of fuel storage, leaks are among the most frequent and costly incidents. A recent review of chemical incident databases found that between 2014 and 2024, leaks were the most common chemical event reported, accounting for hundreds of cases annually.

What makes these leaks particularly dangerous is that early detection is often the difference between a minor fix and an environmental disaster.

Because of this, modern compliance frameworks and industry best practices now demand more than periodic inspections: they require continuous leak monitoring, integrated system alerts, and infrastructure built to enable early warning. In this blog, we explore how leak detection and monitoring have evolved, and how integrating them with advanced tank systems like Rafibra relining positions facilities for safety and compliance in 2025 and beyond.

Why Leak Detection Matters

Leaks from storage tanks can lead to soil contamination, groundwater pollution, massive cleanup costs, regulatory fines, brand damage, and, in extreme cases, safety incidents. Many jurisdictions require leak detection systems to comply with EPA regulations, local environmental codes, and industry standards.

Beyond compliance, early leak detection becomes a risk management tool. A reliable system allows operators to act before damage becomes irreversible. For example, double-wall tanks with interstitial monitoring systems can detect breaches in the outer shell before product escapes.

From Periodic Testing to Real-Time Monitoring

Automatic Tank Gauging (ATG) systems have long been a standard in leak detection. They combine inventory management with statistical methods to detect leakage. For instance, regulations often require ATGs to detect leaks as small as 0.2 gallons per hour, with specific reliability metrics. But ATG systems have limitations, especially in their reaction time and sensitivity under varied operating conditions.

More advanced solutions incorporate continuous statistical leak detection (CSLD), vapor sensing, and acoustic/emission-based methods that can pinpoint anomalous behavior in real time. One recent approach, called Memory-based Online Change Point Detection (MOCPD), uses historical fuel data to detect when shifts in patterns suggest leakage, even subtle ones.

These technologies transform leaks from reactive emergencies to proactive alerts.

How Detection Works in Double-Wall Systems

Double-wall tanks are designed to prevent leaks by surrounding the primary fuel containment with a secondary shell. Between these walls is an interstitial space equipped with sensors or vacuum systems to detect pressure drops. If the inner wall leaks, the leaked fluid enters this space, not the soil or groundwater. An alarm is triggered immediately.

Integration with software dashboards, IoT sensors, and alerting systems ensures that facility managers receive instantaneous warnings and can take remedial action before the situation escalates.

Trends and Innovations in Leak Detection

External cable sensing: Some newer systems place sensing cables on the outer shell of tanks or pipes, detecting leaks without requiring internal sensor intrusion.
Hybrid sensing models: Combining ATG, vapor, and acoustic sensors gives multi-modal coverage and higher certainty in alerts.
AI/ML anomaly detection: Data-driven methods increasingly anticipate leaks based on pattern deviations rather than fixed thresholds.
Cloud dashboards and remote alerts: Monitoring systems can now push alerts via SMS/email and sync with facility control systems in real time.

Why Modern Detection Demands Modern Tanks

A leak detection system is only as effective as the infrastructure it monitors. An old, corroded, or compromised tank can undermine even the most sophisticated sensors. That’s where Rafibra tank relining technology becomes relevant: by retrofitting an inner composite shell and enabling robust interstitial monitoring, it transforms aging tanks into systems designed for modern leak detection strategies.

Pairing advanced monitoring with relined or newly built double-wall systems gives facilities the reliability and insight needed to comply with regulations and avoid risk exposure.

Moving Forward: A Better Safety Posture

Companies that adopt continuous leak monitoring and integrate it with robust tank infrastructure are better positioned to:

Detect leaks before they impact the environment
Lower cleanup and remediation costs
Reduce regulatory liability
Gain confidence in their fuel systems and operations

Don Wood Inc. specializes in blending infrastructure upgrades (including tank relining) with modern leak detection technology. A holistic approach like this not only meets today’s standards but sets you up for the next wave of compliance and innovation.