When cracks appear in a carbon steel storage tank, taking timely and proper emergency measures is critical to prevent further damage, leakage expansion, or even safety accidents. The entire emergency response process should focus on stopping risks first, then controlling the situation, and finally making preliminary treatments to lay the foundation for subsequent formal repairs.

1. Stop Tank Use and Isolate the Affected Area

If the tank is in the process of storing or transferring materials, cease all related operations at once. Close the inlet and outlet valves connected to the tank to prevent more materials from entering or leaking out. At the same time, set up warning signs around the tank to restrict unrelated personnel from entering the area, especially if the stored materials are flammable, explosive, or toxic—this step is essential to avoid potential hazards such as fire, explosion, or chemical exposure.

2. Conduct a Quick and Safe Crack Assessment

Wear appropriate personal protective equipment, such as gloves, goggles, and anti-corrosion clothing, depending on the type of material stored in the tank. Do not directly touch the crack or the surrounding area with bare hands to prevent injury or chemical contact. Observe the length, width, and location of the crack, and check whether there is material leakage.

• Determine the scope of the leakage if it occurs, and assess whether the leaked material poses a threat to the environment or personnel.
• Avoid using open flames or electrical equipment near the tank during the assessment to prevent ignition of flammable materials.

3. Take Temporary Leakage Control Measures

For small cracks with slight leakage, use a suitable temporary sealing material (e.g., high-temperature resistant or anti-corrosion tape) to cover the crack tightly. Ensure the sealing material is compatible with the stored material to avoid chemical reactions that could worsen the situation.

• For larger cracks or more serious leakage: Place a container under the leakage point to collect the leaked material.
• Use sandbags or absorbent materials around the container to prevent the leaked material from spreading.
• Do not attempt to weld or use permanent repair methods during the emergency phase—improper operations may cause the crack to expand or trigger safety risks.

4. Record Details and Contact Professional Repair Personnel

Document the emergency situation in detail, including: the time when the crack was discovered, the appearance of the crack, the type and amount of stored material, the emergency measures taken, and the effect of these measures. Provide this information to professional repair teams to help them formulate an accurate formal repair plan.

• Continue to monitor the tank’s condition (crack and leakage situation) before professional personnel arrive to ensure temporary measures remain effective.
• Do not resume using the tank until it has been formally repaired and inspected to confirm safety.