What is a Tank Optimization Program (T.O.P.)?
The Cross Company Tank Optimization Program is an in-depth review of every tank on your site by a highly qualified Cross technical expert. We look at all aspects of your tank assembly, providing a comprehensive deep dive into the safety, maintenance, and operation of all your tanks.
Why would I want to participate in the program?
Peace of mind: Our technical expert will examine and record all aspects of your tanks. Not only will they note locations and specifications, but they will also record any hazards or potential hazards they come across. This allows you to address issues before they become critical - or worse - deadly.
Actionable Data: The tank optimization program gives you a wealth of data about your facility. Use it to check against inventories, develop preventative maintenance (PM) programs, consolidate vendors, showcase your batching capability and capacity, or create a timeline for replacement parts.
What is involved in the program?
Our expert will spend multiple days on your site while staying out of the way of day-to-day operations. All of our experts have been through health and safety training for industrial manufacturing sites and will have the correct PPE, as well as an awareness of the hazards that exist. Expect them to get dirty, however, crawling under tanks or climbing to the top of assemblies in order to gather the data they need. An escort by one of your employees will be helpful to guide them around the facility and speed your review.
What do I get out of it?
In its simplest form, you’ll get a consolidated, hard copy report with a summary, recommendations and your tank data. All of the information about your facility’s tanks will be at your fingertips.
This powerful data can be used for many things, including:
- Vendor consolidation
- Ensuring your records match the actual equipment operating on your site
- Creating a PM plan with priorities
- Creating a timeline and budget for systematic, proactive part replacement
- Ensuring you’re ready for the next EPA or safety audit
Cross Tank Optimization Program Examples
Our customer is an international chemical manufacturer with 950 staff, on-site engineering and multiple manufacturing locations. Cross Company spent two days reviewing 71 of their tanks to begin the program. We found only 13.5% of their tanks were physically in compliance with current safety standards and none of them met current EPA standards for pressure and vacuum protection data.
T.O.P. issues we found included:
- A collapsed tank
- Wrong rupture disc installed or no disc at all
- Improper wiring in Class I, Div I hazardous area
- Misaligned flanges
This customer acted on their T.O.P. data and plans to have their remaining 94 tanks reviewed. In addition to addressing the missing or damaged tank protection, they are also reviewing all pressure and vacuum protections for vendor consolidation. Overall, the customer found that joining the program helped them increase safety, decrease cost, increase up time, decrease batch rate, increase EPA inspection readiness and improve their insurance position.
Another customer is a batch chemical production facility with on-site engineering and a staff of 42. After a four day review of 59 tanks we found that only 10% of their tanks were physically in compliance with current safety standards.
T.O.P. issues we found included:
- Two collapsed tanks
- No PM plan or safety stock for pressure relief valves, PSV’s, or rupture discs
- Improper installation of rupture discs and holders
- Open outlet gauge taps
They quickly ordered new protections for the most dangerous tanks and have required their staff to review all data with the T.O.P Team to bring them into compliance. By doing so, they have increased the safety of their site, increased their EPA inspection readiness, increased machine up time and decreased the number of lost batches.
These examples of Cross Company’s Tank Optimization Program show clear customer benefits. Using an independent third party to inspect your tanks gives you an unbiased, thorough look at what’s really happening at your facility. Joining T.O.P. can help you increase site safety, decrease cost, increase compliance, and reduce insurance costs. Contact Cross Company to apply.
Want to share? Download a brochure about our Tank Optimization Program. Also, take a look at our latest blog post: Plan NOW for your fall shutdown to see why planning ahead can save your operation in the long run.