Ecolab Process Safety Qualification Process: Executive Summary
Ecolab, a global petro/chemical manufacturer, had recently seen Process Safety performance begin to plateau. They were in danger of not meeting their goals for Process Safety Event Reduction.
Human Resources had also recently developed an Engineering Career Ladder with help from the Process Safety Team and Global Engineering. This career ladder created a clear path for career development and role/responsibilities for plant engineers.
Based on these two key data points, the Process Safety Training Program and senior leadership developed the Process Safety Qualification Process (PSQ) to drive performance improvement. The goals of the PSQ:
- Ensure engineering employees at all global plant sites have the knowledge and expertise to complete Process Safety tasks critical to reducing Process Safety events, and driving a consistent program across global plant sites.
- Provide tools, support, and training for employees working through requirements in the Engineering Career Ladder
Outline of PSQ:
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1.Employee completes self-assessment 2.Employee completes training and testing a. Passes tests in all 12 core elements 4.Employee shows skill application with examples of their work and coaching a. Submits summary of work to Review Panel to show skill application 6.Review Panel confirms qualification through consensus |
30% Training,Testing, Evaluation 70% Examples of experience and skill application |
Core Elements of Qualification:
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Compliance with Global Standards |
RBPS/PSM Program Knowledge |
Managing/Using Process Safety Information |
Regulatory Compliance/ RAGAGEP |
|
Chemical Compatibility/ Red List |
Management of Change |
HIRA/ PHA Tools |
Plant Design |
|
Measurement and Metrics |
Root Cause Analysis |
Critical Equipment |
Process Safety Culture |
After test piloting, the PSQ was adjusted to include all plant employees with an interest in developing Process Safety competency, not just engineers. This adjustment significantly boosted participation, and influenced other training programs to follow a similar model.
A second, higher level of PSQ is now in development specifically for Principal/Chartered engineers. This evolution will put a stronger focus on complex technical concepts, and adds leadership competencies to the qualification requirements. Launch is planned for early 2021
The PSQ was launched globally in early 2020 in a phased approach. Launch goal was at least half the global plant sites completing the PSQ by end of 2020 – goal is on track to be met.
This project was selected by the 5th CCPS Global Summit on Process Safety, Singapore, 2019. Nathan Thompson was also selected as vice-chair of the CCPS Early Career Professionals project.
Nathan Thompson: Global Process Safety Training Program Manager, St Paul, USA
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