Tank Profiling Assessment Reduces Cleaning Cost by $600K
A TankScope tank profiling assessment at BP’s Whiting Refinery revealed sludge levels far lower than historical estimates. Verified tank data allowed the cleaning plan to be right-sized, reducing the project budget from $1.2M to $600K. By replacing assumptions with measurement, BP avoided unnecessary scope and controlled project cost.
$600K USD in Direct Cleaning Cost Savings Through Verified Sludge Assessment
BP budgeted $1.2M USD to clean a 220-foot diameter wastewater and slop tank at their Whiting Refinery based on an estimated sludge accumulation of more than three feet. TankScope’s tank profiling assessment revealed actual sludge levels of less than twelve inches.
With verified measurement replacing historical assumptions, BP was able to right-size the cleaning scope. The revised plan reduced the project budget by half, delivering $600K USD in direct cleaning cost savings.
Project Details
Tank Type
220-foot diameter tank storing wastewater and slop
Location
Whiting Refinery, Whiting, Indiana, USA
Challenge
Cleaning budget of $1.2M USD based on historical sludge estimates of ≥3 feet
Number of Tanks
1
Estimated Sludge Volume
≥3 ft
Actual Sludge Level
≤12 in
The Problem
BP initially planned a $1.2M cleaning project based on historical estimates suggesting sludge accumulation of three feet or more.
Wastewater and slop tanks present a particular challenge. Their contents vary significantly over time and sludge accumulation patterns are difficult to predict without direct measurement.
Without verified tank data, teams often face two costly outcomes:
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Overspending on an oversized cleaning operation
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Unexpected conditions that disrupt scope, schedule, and cost planning
A refinery tank assessment was required to verify actual sludge levels before committing to the full cleaning scope.
TankScope Approach
Tank Profiling Assessment and Sludge Measurement
TankScope performed a full tank profiling assessment to verify sludge levels and tank conditions without opening the tank before cleaning began.
The assessment included:
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Infrared thermography to detect sludge levels through the tank shell
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Sludge topography measurements to verify depth across multiple locations
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Material characterization sampling to understand sludge composition
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Chemical assessment to identify hazards requiring special handling
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Delivery of verified data to support tank cleaning scope optimization
This data enabled BP to revise the cleaning plan to match the actual tank condition.
$1.2M Budget
TankScope Assessment
Verified Tank Data
Revised Cleaning Scope
$600K Final Cost
Results
Tank Cleaning Cost Reduction Through Verified Data
The tank profiling assessment confirmed that sludge levels were far lower than originally estimated. With accurate sludge measurement and verified material data, BP was able to revise the cleaning scope.
Total Savings
$600K USD
(50% reduction in project budget)
Direct Cleaning Cost Savings
$600K USD
Sludge Variance
Estimated ≥3 ft vs Actual ≤12 in (approximately 75% lower than expected)
Hydrocarbon Recovery
Not applicable for this wastewater / slop tank
Outcome
Revised cleaning plan implemented successfully using verified tank assessment data
[PLACEHOLDER – Client Testimonial]
Questions We Get Often
What is a tank profiling assessment?
A tank profiling assessment measures the actual conditions inside a storage tank before cleaning begins. TankScope combines thermography, sludge topography measurements, sampling, and laboratory analysis to verify sludge volume, composition, and safety hazards.
Why was sludge volume overestimated in this case?
Historical estimates often rely on conservative assumptions or outdated records. Wastewater and slop tanks can change significantly over time. Direct sludge measurement revealed that actual accumulation was far lower than expected.
How does sludge measurement reduce cleaning costs?
Accurate sludge measurement allows teams to right-size the cleaning scope. When sludge volume is lower than expected, contractors can reduce equipment, labor, disposal, and outage duration, lowering total project cost.
Are these results typical for refinery tanks?
Every tank is different. What TankScope consistently delivers is verified tank data that replaces assumptions. In many cases, historical sludge estimates overstate accumulation, creating opportunities for cleaning scope optimization.
What technologies were used in this assessment?
This project used infrared thermography to detect sludge levels, proprietary sludge topography tools to measure depth across the tank floor, and laboratory analysis to characterize material properties and hazards.
How were hazards evaluated?
Collected samples were analyzed for safety-critical properties including H₂S concentration, flash point, explosive gases, and other hazardous compounds. This information informed safety planning for the cleaning operation.
How long does a tank profiling assessment take?
Most tank profiling assessments can be completed within a short field visit without requiring the tank to be opened or cleaned beforehand. The resulting data supports planning well before cleaning mobilization begins.
Stop budgeting tank cleaning projects based on estimates.
Use verified tank data to right-size scope, reduce cost, and plan cleaning operations with confidence.
1-888-417-0155 | info@tankscope.com