Training and Development
Improve the Technical Competency of the Staff
One of the yearly items of the Manufacturing Work Plan is to improve the technical competency of the staff. One way to accomplish this task is to develop Competency Work Plan and then a path to meet the Plan. What competency (ability to solve assigned tasks) should a one, three or five years operator possess?
New Operator Training - One Year Competency
1. Basic Safety 16 Classroom hours
2. Basic Math 16 Classroom hours
3. Basic Chemistry 16 hours
4. How to Read Process Drawings 8 hours
5. Instrumentation Fundamentals and Operation 16 hours
6. Industrial Valves and Control Loops 16 hours
7. Pumps Fundamentals and Operation 16 hours
8. Compressor Fundamentals and Operation 16 hours
9. Heat Exchangers Fundamentals and Operation 8 hours
10. Electrical Safety 4 hours
11. Electricity Fundamentals and Operation 8 hours
12. Distillation Fundamentals and Operation 24 hours
13. Basic Process Instrumentation and Control 8 hours
14. Chemical Reactions and Reactors Fundamentals and Operation 16 hours
15. Furnaces and Boilers Fundamentals and Operation - 16
16. Relief and Flare Fundamentals and Operations 8 hours
17. Water Treatment Fundamentals and Operation 8 hours
18. Commissioning Safety 8 hours
19. Lock Out / Tag Out / CSC 8 hours
Third Year Competency
A third year operator should have mastered all of the one year competency requirements along with the additional items.
1. Understand Piping Codes, Specification and Temperature Limits.
2. Understand Pressure Relieving and Flaring Systems (Pressure Relieving and Flaring Systems Training Course)
3. Understand Distillation Operation Fundamentals (Introduction to Distillation Course)
4. Have the ability to participate as a HAZOP Team Member. (Hazard Analysis Course)
5. Understand Cooling Tower Water Treatment Operations
6. Understand Boiler Water Treatment Operations.
7. Understand Waste Water Treatment Operations.
8. Understand Basic Process Control (Introduction to Process Control)
Five Year Competency
A five year operator should have mastered all of the one and three year competency requirements along with the additional items.
1. Understand furnace and boiler oxygen requirements, efficiencies, and utility cost. (Furnace and Boiler Overview Course)
2. Understand the plant steam systems; draw a simple model of the system for process monitoring and improvements. (Intro to Energy Optimization Course).
3. Have the ability to review commissioning and start up procedures. (Safe Commissioning of Process Units Course)
4. Begin to understand the relationship between people, equipment, process and safety. (Building Operational Excellence Course)
5. Have knowledge of reactor design and catalyst functions. (Catalytic Processes)
6.Obtain general maintenance cost of cleaning and repairing heat exchangers, compressors and distillation equipment.
7. Be a team member in a project. (Project Management)
8. Have knowledge of Advanced Process Control (Advanced Process Control)
Training Guide Lines for Process Engineers
Here is Potential List of Courses for Operators