Fortune 50 Refinery — BWON Compliance

How Skyello achieved 100% compliance coverage with zero overdue inspections under federal consent decree oversight.

100%
Completion Rate
0
Overdue Tasks
95%+
First-Pass Approval
30%+
Time Reduction

Executive Summary

A Fortune 50 refinery operates under a 2023 Consent Decree addressing Clean Air Act violations related to benzene waste and VOC emissions. The decree specifically cites past non-compliance with the Benzene Waste Operations NESHAP (40 CFR Part 61, Subpart FF, commonly known as BWON) and the NSPS wastewater regulations (40 CFR Part 60, Subpart QQQ).

An industrial compliance services provider partnered with Skyello, Inc. to pilot an AI-powered compliance automation platform at the refinery. The goal was to determine if Skyello's "Field IO" mobile inspection app and "Core" cloud platform could improve BWON compliance efficiency and reliability.

Pilot Results

Inspection Coverage & Completion: Within the pilot scope, Skyello executed all BWON inspections with no missed tasks. 100% completion rate with 0 overdue.
Automated Reporting Quality: Over 95% of BWON reports were approved without manual rework, exceeding the 80% KPI threshold.
Time Savings: ≥30% reduction in total compliance handling time per inspection cycle.

Pilot Overview

The Phase 1 pilot began in mid-October 2025 and ran through mid-December 2025 (~3 months). During this pilot, Skyello was configured to support BWON compliance workflows, including digital checklists and inspection forms aligned to EPA 40 CFR 61 Subpart FF standards, AI-assisted data collection, and automated generation of compliance reports.

Approximately 4,678 BWON "points of generation" (POGs) — such as drains, sumps, and other waste-handling points subject to BWON — were onboarded into Skyello's database for monitoring. The pilot generated 101 inspection instances across 75 unique BWON assets.

KPI Performance Results

During the pilot period (Nov through mid-Dec 2025), 101 BWON inspection instances were generated via Skyello. The system was configured to align with the Consent Decree's required inspection frequencies for BWON, including weekly walkthrough inspections for certain high-priority areas...

Automated Reporting & Quality

Skyello's Cognit AI and automation features dramatically streamlined the reporting process for BWON inspections. For each inspection completed, Skyello generated a comprehensive compliance report including all necessary details...

Full Report

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