(16a) Building Skills and Excellence: Ecolab Process Safety Qualification Process

Ecolab, a global petro/chemical manufacturer, was in danger of not meeting their goals for Process Safety Event Reduction. Human Resources had also developed an Engineering Career Ladder which created a clear path for career development and role/responsibilities in the Process Safety Team and Global Engineering spaces

The Process Safety Qualification Process (PSQ) was developed to drive performance improvement:

1. Ensure engineering employees at all global plant sites have the knowledge and expertise to complete Process Safety tasks.
2. Provide tools, support, and training for employees growing leadership skills in the Engineering Career Ladder

Outline of PSQ1:

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:

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 PSQ was launched globally in early 2020 in a phased approach, with the goal of at least half of global plant sites complete the PSQ by the end of 2020.

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.

After the first year of deployment, PSQ was added into Ecolab’s Leadership Development Program. This program is a selected group of employees early in career, with the intention of building leadership and knowledge for future roles at Ecolab. Incorporating PSQ into the program requirements ensures long-term Process Safety results and competency enhancement.

As the program matured, and with the COVID19 pandemic, the goal for PSQ evolved to require Engineering leaders at all global plant sites to be PSQ qualified. This goal was met for 2022.

A second, higher level of PSQ was developed for Principal/Chartered engineers, and Engineering managers (PSQII). This evolution puts stronger focus on complex technical concepts, such as chemistry platforms, and risk assessment (HAZOP Leadership). Full validation, and evidence of skills/application is required to pass each level of PSQII. Leadership competencies were also added to address gaps in compliance and cultural issues at the sites.

Process Safety Qualification continues to be the foundation for a strong safety culture at Ecolab.