Case Study

PSM and the Race for Time, How GP Strategies Helped Make a Chemical Processing Plant Launch a Reality

When a North American energy company decided to launch a new facility, they had two goals in mind: having more control over costs and achieving close to zero harmful emissions.To achieve this, they developed a new technology based on the coal gasification process that uses low-value coal to power the plant and capture all byproducts to sell as consumables.

However, when Process Safety Management (PSM) requirements necessitated more robust procedures and training materials, including detailed guidance and structured program elements for the management of highly hazardous materials, they turned to GP Strategies.

GP Strategies Solution

Step one for GP Strategies was to perform a gap analysis, identifying needed training, technical documentation, and procedures, resulting in the following recommendations:

  • Establish a path forward that achieves the company’s training and qualification goals in time for facility startup
  • Merge current program elements into a perpetual program that complies with PSM standards
  • Adapt industry best practices for training and qualification that provide both manageability and sustainability over time and reduced time to qualification

Then, in collaboration with the company, GP Strategies created an operator training and qualification process that rapidly and effectively onboarded new employees from entry-level and duty-area training to post-qualification training. This included a blended learning strategy with elements such as eLearning for plant fundamentals and simulations; structured, knowledge-based theory and application exercises; gun drills; skills demonstrations; and more.

Finally, GP Strategies developed customized technical documentation specific to the new facility for exercises and drills, operational and unit reference information, and corporate policies and procedures. This included the following:

  • Unit-specific troubleshooting exercises
  • Emergency response matrices
  • Gun drills
  • Field training guides
  • Large control diagrams
  • Process description manuals
  • Startup and shutdown procedures
  • Emergency procedures
  • Document standardization

The Outcome

The implementation of these solutions resulted in numerous proven benefits for the company, such as operators achieving rapid familiarity with major equipment, policies, and procedures. Ultimately, the overarching goal of qualifying operators in time for facility startup, while addressing all regulatory requirements related to PSM, was achieved. GP Strategies’ vast experience in the industry and expertise with adult learning helped make this challenge a reality.

Results at a glance
Ultimately, the overarching goal of qualifying operators in time for facility startup, while addressing all regulatory requirements related to PSM, was achieved.

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