Petroleum Leak Prevention: What Facility Managers Should Know

If your facility stores petroleum on-site, then you already know the stakes are high. One leak — even a small one — can quickly turn into a regulatory nightmare or a six-figure cleanup job. And it’s usually not the massive spills that start the fire, so to speak. It’s the slow leaks, the worn-out piping, or the tank that hadn’t been checked in years.

As environmental scientist’s who have handled Leaking Petroleum Storage Tank (LPST) cases across Texas for decades, I’ve seen everything from gas station owners blindsided by a surprise inspection to facility managers dealing with groundwater contamination that could’ve been prevented with a $20 part. So if you’re reading this because you want to keep your tank system in good shape — you’re already ahead of the curve.

Let’s walk through what you need to know to keep your facility compliant, safe, and leak-free — and why petroleum leak prevention should be a top priority.

Why Petroleum Leak Prevention Should Be a Priority

Leaks aren’t just messy — they can shut down operations, trigger state or federal violations, and do long-term damage to soil and groundwater. In Texas, once a petroleum release is discovered, you’re required to report it to the Texas Commission on Environmental Quality (TCEQ), and depending on the size and location of the release, you could be dealing with remediation orders fast.

One facility we worked with had an underground storage tank (UST) installed in the 1980s. It was never upgraded with modern monitoring. For years, a slow leak had gone unnoticed until nearby construction exposed petroleum-stained soil. By then, groundwater was impacted. Cleanup and regulatory costs topped $300,000.

It didn’t have to happen that way — that’s the value of strong petroleum leak prevention protocols.

Common Causes of Leaks in Petroleum Tanks

Understanding the weak spots can help you spot trouble before it starts — and improve your petroleum leak prevention plan.

Aging Infrastructure

Many USTs still in use were installed decades ago. Steel tanks corrode, and even fiberglass tanks can fail over time if not inspected. If your tank is 30+ years old and hasn’t had a tightness test recently, that’s a red flag.

Bad Piping or Fittings

Tank integrity isn’t just about the tank. Piping, joints, valves, and dispensers all play a role. One loose fitting can lead to years of seepage if you’re not regularly checking the system.

Overfills and Spills

Manual filling can cause overfills if operators aren’t watching gauges carefully or if the alarms don’t work. This is one of the easiest things to avoid with proper training and updated equipment.

How to Improve Petroleum Leak Prevention at Your Facility

Leak prevention doesn’t have to be complicated. A few consistent habits and the right equipment can go a long way in protecting your facility.

Conduct Regular Inspections

Walk your site monthly. Seriously. Even if you’re not a licensed inspector, visual checks can catch issues early. Look for signs of wear, corrosion, or pooling liquids near tanks, sumps, or dispensers. Schedule professional inspections annually or more often if required by state regulations.

One of our clients — a small distribution facility outside San Antonio — found a hairline crack in a dispenser hose during a basic site walk. It hadn’t caused a release yet, but it could’ve. A $60 replacement saved them from a much larger headache.

Invest in Leak Detection Systems

Modern leak detection systems are a game-changer for petroleum leak prevention. If you’re still using manual stick measurements, it’s time to upgrade. Automatic Tank Gauging (ATG), interstitial sensors (for double-walled tanks), and vapor monitoring systems are worth every dollar.

If your system is already in place, check the calibration dates. We’ve seen plenty of situations where the equipment was installed but never maintained — which is almost as bad as not having it at all.

Use Secondary Containment Wherever Possible

If your facility uses aboveground tanks or fuel transfer areas, secondary containment should be non-negotiable. Spill buckets, containment basins, and double-walled piping provide an extra layer of security and are often required by law. It’s one of the simplest ways to strengthen your petroleum leak prevention strategy.

Keep Maintenance Records — They Matter

If something ever goes wrong, your records could make or break your case with regulators. Keep everything: inspection logs, maintenance reports, contractor visits, equipment upgrades, even training records.

One site manager we worked with had pristine records showing they identified and addressed minor corrosion before it caused a problem. When their system flagged a potential issue during a TCEQ visit, their documentation showed responsible management. No violations. No fines.

Good records go hand-in-hand with good petroleum leak prevention.

Know the Rules: TCEQ and EPA Compliance Basics

Texas follows strict UST and AST rules, and staying in compliance is easier if you know what’s required. Here’s a quick refresher:

Monthly monitoring (for leak detection)
Annual testing of release detection equipment
Spill and overfill prevention equipment inspection every 3 years
Operator training — Class A, B, and C operators must be trained and documented
Reporting: Suspected or confirmed releases must be reported to TCEQ within 24 hours

Making these steps part of your petroleum leak prevention routine can help you stay compliant and avoid penalties.

Train Your Team to Support Petroleum Leak Prevention

The people on the ground — the ones refueling, checking gauges, running day-to-day ops — are your first line of defense. Make sure they know how to:

Recognize early signs of a leak
Use monitoring systems correctly
Respond to spills or alarms
Contact the right people in an emergency

We once worked with a facility where a technician noticed fuel odor near a sump and immediately escalated it. That early call prevented a full-blown release. A short training session two months earlier made the difference.

What to Do If You Suspect a Leak

If you think there’s a problem, don’t wait to “see if it gets worse.” Take these steps:

Stop fuel deliveries immediately
Shut down affected equipment
Call your environmental consultant (hopefully that’s us)
Document everything — take photos, write down dates, log observations
Report it to TCEQ within 24 hours if it meets reporting thresholds

Quick response is part of effective petroleum leak prevention — it helps minimize damage and costs.

Final Thoughts on Petroleum Leak Prevention

Petroleum leak prevention isn’t just about passing inspections — it’s about protecting your business, your community, and the environment. Whether you manage one tank or ten, the right habits and equipment can save you from costly repairs and long-term consequences.

If you’re not sure where your system stands or when your last inspection was, that’s your cue to act.

Need Help?

At CRG Texas Environmental Services, we help facility owners stay in compliance, avoid costly leaks, and maintain peace of mind. Whether you need an inspection, leak detection system consultation, or help with TCEQ reporting, we’re just a call away.

Petroleum Leak Prevention Secrets Facility Managers Don’t Talk About (But Should!)