Owners and operators of downstream facilities are increasingly focused on maximizing value from existing assets. According to Deloitte’s “2026 Oil and Gas Industry Outlook,”1 shifting market dynamics and policy priorities are expected to intensify the focus on operational efficiency and feedstock diversification. As a result, tank linings must meet a wider range of service requirements, including more frequent feedstock changes, tighter operating schedules and elevated performance expectations across both process and storage assets.
Changing feedstocks require broader lining performance
For decades, lining systems were developed around a narrow set of service conditions associated with conventional feedstocks, such as crude oil or refined fuels. Those materials exhibited relatively consistent chemical behavior at known temperature ranges. Contemporary downstream operations, however, can switch between conventional hydrocarbons, renewable diesel feedstocks or recovered materials. The varied chemical compositions of these streams present new challenges for the internal linings of pressure vessels and storage tanks.
Renewable feedstocks can exhibit higher moisture content, acidity and complex chemical interactions that accelerate corrosion and degrade protective systems more rapidly than conventional feedstocks. While biofuels and other renewables offer environmental benefits, their differing chemistries expose infrastructure to a broader range of corrosive environments that may exceed traditional material performance expectations. Rather than specifying separate coatings for each service type, operators are increasingly interested in versatile tank linings that can perform well across multiple conditions. These systems must resist chemical attack, maintain integrity under temperature variation and tolerate rapid changes in fluid composition while still supporting maintenance planning that minimizes operational disruptions.
Multi-service performance expectations
Downstream operations require tank linings that perform across pressure vessels, pre-process equipment and aboveground storage tanks. Using a single system can help simplify material inventory, reduce specification complexity and lower risk during application and inspection.
Advanced lining systems must maintain film integrity at high builds and over-aged, pitted steel tank surfaces. Coatings should support rapid application while still forming a robust barrier under variable process conditions. The ability to accommodate surface irregularities can influence the longevity of protection.
Operators also expect internal linings to support a quick return to service after application. Reduced cure times help shorten maintenance windows and allow vessels to return to service within tight turnaround schedules. In many cases, suitable linings allow systems to return to service within 24 hrs.
Industry standard testing and inspection intervals
Performance validation proves essential. Autoclave immersion tests and Atlas cell evaluations provide objective data on how lining systems respond to long-term thermal and chemical exposure.
Autoclave testing immerses coated samples in aggressive environments at elevated temperatures for extended periods to simulate real service conditions. Atlas cell testing imposes cyclic thermal and pressure conditions that mimic real-world conditions, such as temperature gradients and repeated loading in pressure vessels.
In storage tanks, operators follow recommended practices outlined in API 652,2 which links coating characteristics such as film thickness and film type to inspection intervals. Advanced tank coatings that meet these requirements may qualify for extended internal inspections, up to 5 yrs in some cases. This can help reduce the frequency of tank entry, support shorter shutdown duration and improve resource allocation across inspection programs.
What is ahead for operational resilience?
The downstream segment faces a future defined by evolving service demands and practical energy transition pathways. Within that future, robust and adaptable tank linings can help support operational performance, protect infrastructure and support evolving feedstock strategies. Operators who select and apply materials that meet these expectations and align with established industry standards can enhance uptime, streamline maintenance planning and help extend the service life of existing assets.
Literature Cited
1. Austin, Z., N. McLemore, K. Hardin and A. Mittal, “2026 Oil and Gas Industry Outlook,” Deloitte Research Center for Energy & Industrials, October 29, 2025, online: https://www.deloitte.com/us/en/insights/industry/oil-and-gas/oil-and-gas-industry-outlook.html
2. American Petroleum Institute (API) Recommended Practice 652, “Linings of aboveground petroleum storage tank bottoms.”
Travis Crotwell is the Regional Segment Director, U.S. and Canada, for PPG’s Protective and Marine Coatings business. He supports specification strategies for coating technologies across the downstream, chemical processing and tank storage markets.
Originally published in Hydrocarbon Processing.