Urgent Process Water Tank Inspection of 37 Degraded Tanks Reveals Critical Failures
When a large agriculture facility experienced the unexpected failure of one of its process water tanks, they contacted Tank Inspection Services to perform a comprehensive process water tank inspection and assess the integrity of the remaining infrastructure. What we found during our inspection of the 37 large process tanks highlighted not only the extent of degradation across the site, but also the critical importance of regular, professional tank inspections.
The Situation: A Tank Failure Sparks Urgent Action
The client reached out after a process water tank unexpectedly failed — raising concerns about the condition of the entire tank farm. Understanding the risks associated with further failures, we prioritised the inspection and mobilised our team quickly to conduct a full structural and compliance assessment.
Inspection Findings: Widespread Structural and Safety Issues
Our inspection uncovered significant issues across multiple tanks in the farm, many of which posed serious risks to ongoing operations, safety, and environmental compliance. Key findings included:
Foundation Cracking and Differential Settlement
Several tanks showed clear signs of foundation movement, with visible cracks and uneven settlement. These structural issues compromise tank stability and increase the risk of collapse or leakage.Severe Corrosion
Internal and external corrosion was widespread, particularly around fittings, seams, and base plates. In some cases, wall thickness had degraded significantly, creating a high risk of failure.Failing Liners
Many tanks had damaged or deteriorated liners, resulting in potential contamination of process water and further internal corrosion.Panel Deflection
Significant deflection of tank panels was observed on multiple units, suggesting overstressing of the structure and potential loss of containment under pressure or fill cycles.
Our Response: Detailed Reporting and Compliance Roadmap
Following the inspection, our team delivered a comprehensive report outlining the condition of each tank, supported by photographic evidence, thickness measurements, and structural observations. The report also included:
Immediate risk assessments
Recommendations for repair, relining, or structural reinforcement
Prioritised action plan for bringing each tank back into compliance with Australian Standards
Ongoing inspection schedule to prevent future failures
The Lesson: Prevent Failures with Routine Professional Inspections
This case is a clear reminder that preventative inspections are essential to maintaining safe and compliant process tank operations. Many of the issues we identified — including corrosion, settlement, and liner failure — develop gradually over time and can be addressed early if detected by a qualified inspection team.
By waiting until a failure occurred, the client faced increased risk, downtime, and potential environmental consequences. With our help, they now have a clear path to restoring their tank farm and a plan to avoid similar emergencies in the future.
Need a Tank Inspection? Trust the Experts.
At Tank Inspection Services, we specialise in the inspection of process, industrial, fire, and potable water tanks across Australia. Whether you’re operating a large tank farm or a single critical asset, we provide detailed, standards-compliant inspections using advanced methods and experienced personnel.
Don't wait for a failure — protect your infrastructure with proactive, professional inspection services.
Contact us today to book an inspection or request a free consultation.