Best Practices for QA Test Management in Petrochemical Facilities

Ensuring the safety and compliance of petrochemical facilities requires meticulous attention to detail and adherence to rigorous Quality Assurance (QA) standards. With regulatory requirements such as the EPA’s Refinery Sector Rule, petrochemical facilities must employ effective QA test management strategies to maintain operational efficiency. In this blog post, we’ll explore the best practices for QA test management in petrochemical facilities, with a focus on leveraging QAInsight, a comprehensive tool designed to streamline scheduling, planning, and tracking of QA activities.

In the petrochemical industry, it’s also a requirement to have a comprehensive Quality Assurance and Quality Control (QAQC) manual  when operating Continuous Emissions Monitoring Systems (CEMS) and/or Continuous Opacity Monitoring Systems (COMS). Often a new system is purchased, and a manual is not included or has become outdated. This requirement is mandated by EPA Guidelines such as the following:

• 40 CFR Part 75 Appendix B
• 40 CFR Part 60 Appendix F
• 40 CFR Part 63

Introducing QAInsight: A Holistic Approach to QA Test Management

QAInsight offers a range of features tailored to the specific needs of petrochemical facilities, allowing them to efficiently manage QA tests and ensure compliance with regulatory standards. Read our post on the release of QAInsight 1.3 for information on our most up-to-date version of the software. Additionally, here are some ways that QAInsight facilitates effective QA test management:

• Tracking: Petrochemical facilities deal with various complex QA processes. QAInsight tracks all steps involved in testing, including monitoring due dates and dependencies.
• Centralized Scheduling: In the fast-paced environment of petrochemical operations, having a single source of QA test schedules is invaluable. QAInsight fills this need by providing stakeholders with real-time access to scheduled test dates.
• Customizable Workflows: QAInsight offers pre-configured workflow types tailored to common QA tests in the industry. This allows facilities to customize workflows according to their specific needs.
• Real-Time Prioritization: With color-coded priority indicators and customizable sorting and filtering options, QAInsight enables petrochemical facilities to prioritize tasks efficiently.
• • Red indicates expired
  • Yellow indicates 10 days from due date
  • Green indicates 30 days from due date
• Seamless Integration:  QAInsight seamlessly integrates with data acquisition platforms like StackVision, facilitating the automatic import of QA test completion dates, operating data, and recertification event deadlines. StackVision supported QA tests that can be imported include:
• • Calibration Gas Audits
  • Opacity Test Audits
  • Linearity
  • RATA
  • Permit RATA
  • Leak Check
  • Flowmeter Accuracy
  • Transmitter / Transducer
  • Primary Element Inspection

Read our StackVision Case Study on Calumet Refinery for a closer look at how StackVision operates in the petrochemical industry.

Improving Efficiency in Petrochemical QA Testing

In addition to its core features, QAInsight offers several functionalities that can contribute greatly to efficiency in petrochemical facilities:

• Operating Hours Tracking: Petrochemical operations are often subject to fluctuating operating hours due to maintenance activities or unforeseen events. QAInsight allows facilities to track operating hours across different time periods, providing valuable insights for scheduling QA tests.
• Comprehensive Reports: Petrochemical facilities require detailed reports to assess their QA testing performance and compliance status. QAInsight provides comprehensive reports detailing test schedules, operating hours, and compliance metrics, providing actionable insights for continuous improvement.
• Automated Email Notifications: Timely communication is critical in the fast-paced environment of petrochemical operations. QAInsight automates email notifications, alerting designated leads about upcoming or overdue deadlines for QA tests. These notifications ensure that involved parties are informed and accountable, and lower the risk of missed deadlines.

How Can ESC Spectrum Help?

By leveraging QAInsight’s robust features and integrating best practices tailored to the industry’s unique requirements, facilities can streamline QA processes, mitigate risks, and ensure regulatory compliance. Contact us today if you think QAInsight could benefit operations in your facilities.