Ecolab Process Safety Qualification Process: Executive Summary
Ecolab, a global petro/chemical manufacturer, had recently seen their Process Safety performance begin to plateau, and not see the improvements of past years. They were in danger of not hitting their targets across their global plant sites for Process Safety Event Reduction.
They had also recently developed an Engineering Career Ladder within Human Resources. With help from the Global Process Safety Team, and Global Engineering, the career ladder created consistent job titles and roles for all engineering roles with criteria that employees must achieve to move through the ladder. This created a path for engineers in the company to follow when developing their own careers.
With these two key data points in mind, the Process Safety Training Program, and senior leadership, recommended developing a consistent Process Safety Qualification Process to drive performance improvement. There were two goals for developing /deploying this process:
- Ensure engineering employees at all global plant sites have the knowledge and expertise to complete key Process Safety tasks at the plant level. These tasks are crucial to Process Safety Event Reduction, and driving a strong consistent program across all global plant sites.
- Provide tools, support, and resources for engineering employees to develop their careers, and complete the requirements listed in the Engineering Career Ladder
Outline of Qualification Process:
|
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 project 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 |
The process is currently in the pilot phase, and will be ready for global deployment by the end of 2019. This sets the template for future evolution of the global program, and will be incorporated into other disciplines within the organization. This project was selected by the 5th CCPS Global Summit on Process Safety, Singapore, 2019. Nathan Thompson was also selected as co-leader of the CCPS Early Career Professionals project, now launching in North America.
Nathan Thompson: Global Process Safety Training Program Manager, St Paul, USA
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