. COURSE OBJECTIVES
At the conclusion of the course:
The operation of the process equipment trainer (PET) will be used to reinforce the
following course objectives.
TOPIC OBJECTIVES
Introduction to
Operations
1. Discuss the importance of this course as a capstone experience
in the Process Technology program and how the material learned
here will prepare the student for work "on-the-job".
2. Recall the history and development of the process technician
role within the process industries.
3. Apply the key concepts from the following course:
• Process Technology I – Equipment
• Process Technology II – Systems
• Instrumentation
4. Discuss the term "operations" and its process industries
synonyms.
5. List the various process technician roles and responsibilities (i.e.,
"outside" versus "control room" tasks) within an operating unit.
• Operate and monitor unit from the control room (i.e., via DCS)
• Operate and monitor unit from the outside (i.e., by making
rounds)
• Take and analyze (as required) samples (i.e., composite, grab,
bomb, etc.)
• Perform housekeeping activities
• Conduct safety inspections
• Handle materials
• Prepare for, assist with, and/or perform maintenance as required.
6. Discuss the activities that may be the responsibility of the
process technician of the future.
7. Discuss the importance of continual learning for process
technicians.
Diagrams for the
Operating
Unit
1. Discuss the purpose of a block flow diagram (BFD).
2. Identify the major processing stages, which make up the generic
operating unit (i.e., TimTene, campus unit, or unit at a local
facility).
3. Identify the plant auxiliary and utility systems, which support
the generic operating unit.
4. Describe the purpose of a process flow diagram (PFD) and the
information and symbology found on a PFD.
5. Trace the process flow through the operating unit using the PFD.
6. Identify all process systems included in the generic operating
unit from the PFD.
PTAC 2438 Process Technology III - Operations
Diagrams for the
Operating
Unit (cont.)
7. Identify all major process equipment associated with the generic
operating unit from the PFD.
8. Describe the purpose of a plot plan and the information found on
a Center for the Advancement of Process Technology plot plan.
9. Discuss the purpose of a piping and instrumentation diagram
(P&ID) and the information and symbology found on a P&ID.
10. Describe how the various areas and systems within the
operating unit will be monitored and controlled (i.e., making
rounds vs. via DCS).
11. Identify all local instruments for a Generic Unit using P&IDs.
(Note: Filtration and Refrigeration systems are normally used at
local community colleges).
12. Describe local/field instruments in terms of:
• The process variable monitored by the instrument
• Normal range
• Description of instrument function
Commissioning 1. Define the term "commissioning".
2. Differentiate between starting up a new unit versus starting up
an existing unit (i.e., design flaws, unknowns, etc.).
Procedure
Writing
Given a process scenario, the student PT will write a normal
operations procedure that ensures safety and environmental
compliance with SH&E and OSHA regulations and minimizes
downtime.
Normal Startup -
Overview and
Communication
1. Discuss the different types of startups: normal/routine startup,
startup after emergency shutdown, startup after equipment
maintenance, and startup after turnaround.
2. Discuss unit startup activities as they relate OSHA’s PSM
(Process Safety Management of Highly Hazardous Materials)
standard, specifically by PSM's Pre-Startup Safety Review
element.
3. Describe the risks and hazards associated with unit startup.
4. Given a process flow diagram (PFD) and following safe
operating procedures:
• identify typical activities involved when placing equipment
into service and bringing a unit online
• List all the departments and personnel who will be
involved in or affected by the unit startup
• List the types of information that will need to be
communicated regarding unit startup
5. Discuss the communication methods that might be used at
different points during the process of starting up the unit
Normal Startup -
Preparing
Equipment for
Return to
Service
1. Discuss the importance of obtaining an accurate estimate for
when equipment will be returned from maintenance personnel.
2. List the energy and equipment isolation methods and devices that
must to be removed after equipment maintenance.
3. List the equipment used by maintenance or contractors, which
may need to be removed.
PTAC 2438 Process Technology III - Operations
Normal Startup -
Preparing
Equipment for
Return to
Service (cont.)
4. List the final safeguards, which should be taken prior to returning
the equipment to service.
5. List the common inspections needed to assure mechanical
integrity.
Normal Startup –
Removal of
Energy Isolation
Devices
1. Review the OSHA Control of Hazardous Energy
(Lockout/Tagout) standard.
2.Discuss the various methods and devices which can be used to
isolate equipment from the various types of energy sources:
• Lock
• Tag
• Blind
• Double block and bleed
• Break
• Disconnect
• Switch gear
3.Discuss the various types of energy sources that must be isolated:
• Chemical
• Electrical
• Hydraulic
• Mechanical
• Pneumatic
• Thermal
4. Identify the points where energy isolation is required, and the
device/method used at each point.
5.Discuss who should remove the energy isolation devices.
6. Discuss the steps that must be followed when removing energy
solation devices.
Normal Startup –
Utilities and
Auxiliaries
1. Describe the purpose and function of the utility and auxiliary
systems, which support the operating unit:
• Boiler Feed Water Treatment System
• Steam Generation and Distribution
• Cooling Tower and Cooling Water System
• Air System
• Water System
• Electrical
• Natural Gas
• Nitrogen
• Sewer
• Flare and Relief
• Refrigeration
2. Describe the hazards associated with starting up each system.
3. Describe the precautions that must be taken to mitigate the
hazards associated with starting up the utility systems.
4. Given a utility flow diagram (UFD) list the steps required to
startup steam and systems, including valve alignment:
• Identify all valves that must be checked for proper
alignment.
PTAC 2438 Process Technology III - Operations
Normal Startup –
Utilities and
Auxiliaries (cont.)
• State the proper position for each valve for startup.
• State whether the valves will be check via the DCS and/or
via the field technician.
• Position the valves correctly
Normal Startup -
Process Unit
1. Describe the hazards associated with starting up each process
system and the unit.
2. Describe the precautions that must be taken to mitigate the
hazards associated with starting up each process system and the
unit.
3. Discuss the order in which the various process, auxiliary, and
utility systems should be started up.
4. List the steps required to start a process unit.
Normal
Operations –
Field Technician
1. List all of the types of equipment within an operating unit, such
as a Filtration System and Refrigeration System that will be
monitored and/or started, stopped or switched by the field
technician, such as:
• Compressors
• Exchangers
• Motors
• Pumps
• Valves
• Vessels
• And others
2. Describe how specific types of equipment must be monitored to
ensure proper operation.
3. Describe how to check various types of equipment for vapor and
liquid leaks.
4. Explain the corrective action that should be taken for each type
of leak.
5. Discuss environmental impact of leaks and failure to take
corrective action.
6. Describe typical equipment, tools and personal protective
equipment required when performing routine tasks in the field.
7. Discuss other types of personal protective equipment that may be
required when performing routine field tasks in hazardous
environments.
• Flash suits
• SCBA (Self-Contained Breathing Apparatus)
• Face shields
• Chemical Resistant Suits
8. Discuss the methods used to document the technician’s work in
the field.
Normal
Operations –
Control Room
Technician
1. Distinguish between an analog (pneumatic/electronic) control
system versus a digital (Distributive Control System,
Programmable Logic Controller) system.
2. Differentiate between instruments that:
• Control
PTAC 2438 Process Technology III - Operations
Normal
Operations –
Control Room
Technician (cont.)
• Indicate
• Record
3. Identify instruments that have alarm and/or shutdown functions.
4. Identify instruments that are included in logic systems.
5. Identify the set point, alarm, shut down, and trip information.
6. List the possible causes for level and flow alarms.
7. List the corrective actions for level and flow alarms.
8. Discuss the importance of communicating with other technicians
and other units prior to taking certain corrective action.
9. Discuss other duties typically assigned to the board operator,
such as data entry, recordkeeping, etc.
Normal
Operations -
Other Duties
1. Given a process scenario (i.e., process flow diagram, piping and
instrument diagram, model, etc.) during receiving, storage or
transfer activities:
• Identify the process streams within an operating unit that will
require periodic sampling
• Describe the sampling procedures and equipment that are
used for different sampling events
• Discuss the personal protective equipment that must be used
while performing different sampling activities
2. Explain the importance of following the sampling procedure
precisely.
3. Discuss the process technician’s role in sample analysis.
4. Discuss the various types of analyses (methods and equipment)
conducted on process samples.
5. Explain the importance of sample analysis to the proper unit
operation.
6. Identify the points within the operating unit where the following
types of process materials are handled manually:
• Supply materials (lube oil, etc.)
• Catalyst and chemicals
7. Discuss the equipment used to receive, store or transfer materials
at various points.
8. Discuss the procedures used to receive, store or transfer
materials including:
• Proper labeling
• Proper documentation
• Product identification
• Specifications (Certificate of Quality, etc.)
9. Discuss the hazards associated with receiving, storing or
transferring various raw materials and finished products.
10. Discuss the personal protective equipment that must be used
while performing various receiving, storage or transfer during
material handling activities.
PTAC 2438 Process Technology III - Operations
Normal
Operations –
Housekeeping
and Complying
with SH&E
Policies
1. Define "housekeeping" in process industries terms.
2. List the types of tasks that can be categorized as housekeeping.
3. Explain why attention to housekeeping is important.
4. Discuss the personal protective equipment that must be used
while performing various housekeeping activities.
5. Discuss safety, health, and environmental risks or hazards found
within the process industries.
6. Discuss methods to minimize or prevent these risks or hazards.
7. Discuss typical SH&E policies and procedures, which may be
implemented in order to minimize or prevent SH&E risks and/or
hazards.
8. Discuss how unit personnel assist in this implementation.
9. Identify the safety equipment located in the various areas of the
operating unit.
10. Describe what items are inspected when checking each piece of
safety equipment.
11. Describe how often each piece of safety equipment is inspected.
Normal
Operations -
Verbal
Communication
1. Discuss the basic components associated with effective verbal
communication: sender, receiver, message, interference, and
feedback.
2. Discuss the key obstacles that prevent effective verbal
communication.
3. Demonstrate effective verbal communication techniques to ask
for or provide information.
4. Identify and describe the various roles within the Operations
Department with which process technicians will communicate.
5. Identify and describe the various roles from other areas of the
plant with which process technicians will communicate.
6. Discuss the various types of information that may be exchanged
verbally (face-to-face) between these personnel/departments and
process technicians.
7. Discuss verbal and non-verbal communication methods used in
noisy environments (i.e., Hand signals).
8. List the different types of electronic communication devices
(radios, intercoms, phones, cell phones, voice-activated radios,
etc.) used in the process industries today.
9. Discuss the various features and functions of electronic
communication devices.
10. Discuss the features and functions that should be tested for
operability prior to using the electronic communication device.
11. Demonstrate how to test the electronic communication device
for operability.
12. Discuss proper protocol for using these different types of
electronic communication devices.
Normal
Operations -
Written
Communication
1. Review the basic components of written communication
(grammar, spelling, style, legibility, transitions, etc.) for clear,
concise, and descriptive communication.
PTAC 2438 Process Technology III - Operations
Normal
Operations -
Written
Communication
(cont.)
2. Review the basic components of good writing: preparation,
formatting, drafting and proofreading.
3. Identify and describe the various personnel within the
Operations Department with which process technicians will
communicate in writing.
4. Identify and describe the various personnel from other areas of
the plant with which process technicians will communicate in
writing.
5. Discuss the various types of information that may be exchanged
in written form (using paper or electronic means) between these
personnel/departments and process technicians.
6. Discuss situations when written communication (electronic or
paper) should be used rather than verbal communication, and
vice versa.
7. Discuss the importance of following company guidelines when
preparing written communication whether paper or electronic.
8. Demonstrate effective written communication techniques for
asking or providing information.
Normal
Operations - Shift
Change
1. State the types of information which need to be communicated
during shift change:
• Unit status
• Alarms
• Equipment condition/problems
• Procedures in progress
• Process trends
• Maintenance activity completed, in-progress, and planned
• Presence of non-operating personnel
• Status of permits in force
2. Discuss the level of detail necessary to accurately convey
complete unit status information.
3. Describe how a typical shift change occurs.
• personnel involved
• importance of making timely relief
• location
4. List the documentation used during a typical shift change.
5. Discuss the importance of establishing good relationships with
members of your shift and members of other shifts.
PTAC 2438 Process Technology III - Operations
Abnormal
Operations -
Emergencies
1. Discuss what types of events could be considered "emergency
situations".
2. Describe how operating personnel prepare for each situation
(i.e., drills, exercises).
3. Discuss actions that should be taken to mitigate each situation.
4. Discuss what types of conditions could be considered
"emergency operations".
5. Identify possible causes for these various conditions.
6. Discuss possible corrective action for each of the various
possible causes.
7. Discuss how each of these critical conditions could affect the
normal operation of the unit’s process, utility, and auxiliary
systems.
8. Discuss the field technician’s role during emergency situations
and operations.
9. Discuss the board technician’s role during emergency situations
and operations.
Abnormal
Operations –
Applications
1. Given a potential emergency scenario and appropriate resources
(P&IDs, process flow sheets, etc.), write an emergency
procedure that complies with SH&E practices and OSHA
regulations.
2. Given an emergency scenario and an emergency procedure,
demonstrate the appropriate emergency response to the
emergency operating situation that complies with SH&E
practices and OSHA regulations.
Normal Shutdown -
Overview and
Communications
1. Differentiate between the types of shutdowns: normal/routine
shutdown, emergency shutdown, shutdown for equipment
maintenance, and shutdown for turnaround.
2. Describe the risks and hazards associated with unit shutdown.
3. Describe how unit shutdown activities are covered by OSHA’s
PSM (Process Safety Management of Highly Hazardous
Materials) standard.
4. List the key activities involved in performing a normal/routine
shut down.
5. List all departments and personnel who will be involved in, or
affected by, the unit shutdown.
6. List the types of information that will need to be communicated
regarding unit shutdown.
7. Discuss the communication methods that might be used at
different points during the process of shutting down the unit.
Normal
Shutdown -
Shutdown
Process Unit
1. Given a scenario, discuss the order in which the various process
auxiliary and utility systems should be shut down.
2. For a process system:
• Describe the hazards associated with shutting a system
down.
• Describe the precautions that must be taken to mitigate the
hazards associated with shutting down each system.
• List the steps required to shut down each system.
PTAC 2438 Process Technology III - Operations
Normal
Shutdown -
Shutdown
Process Unit
(cont.)
• Discuss how shutdown of the process system affects
upstream and downstream processes
3. For an auxiliary system:
• Describe the hazards associated with shutting down the
system.
• Describe the precautions that must be taken to mitigate the
hazards associated with shutting down each system.
• List the steps required to shut down each system.
4. For a utility system:
• Describe the hazards associated with shutting down the
system.
• Describe the precautions that must be taken to mitigate the
hazards associated with shutting down each system.
• List the steps required to shut down each system.
5. Discuss the importance of following the written procedure and
the protocol for handling discrepancies between the documented
procedure and actual steps followed to complete the task.
Equipment
Maintenance -
Overview and
Communications
1. Describe the risks and hazards involved when preparing
equipment for routine maintenance.
2. Given a piece of equipment, describe the key activities necessary
for preparing the equipment for routine maintenance.
• Shutdown
• Decontamination
• Isolation
• Lockout
3. Discuss all departments and personnel who will be involved in,
or affected by, the equipment maintenance.
4. Discuss the types of information that will need to be
communicated regarding the preparation of equipment for
routine maintenance.
5. Discuss the communication methods that might be used at
different points during the performance of routine maintenance.
Equipment
Maintenance -
Economic
Impact (preventive
versus reactive)
1. Discuss the advantages of preventive maintenance with the
disadvantages of reactive maintenance.
2. Discuss the types of preventive maintenance that should be
performed on a piece of equipment.
3. Discuss the process technician’s role in the performance of
various preventive maintenance activities.
4. Propose a schedule for performing preventive maintenance for
the selected piece of equipment.
5. Describe the types of expenses associated with preventive
maintenance.
6. Describe the types of expenses associated with reactive
maintenance.
7. Compare the economic impact associated with preventive
maintenance versus reactive maintenance.
PTAC 2438 Process Technology III - Operations
Equipment
Maintenance -
Economic
Impact (preventive
versus reactive)
(cont.)
8. Describe the types of reactive maintenance that may be required
in the absence of a preventive maintenance program.
Equipment
Maintenance -
SH&E Impact
1. Provide examples of possible safety issues surrounding
equipment maintenance activities:
• Breaking into piping or equipment
• Vessel entry
• Electrical work
• Hot tapping, etc.
2. Describe measures to take to minimize the safety issues
surrounding equipment maintenance such as:
• Confined space entry
• Energy/Equipment isolation
• Equipment Decontamination
• Equipment identification
• Fall protection
• Barricades
• Proper communication
3. Discuss examples of possible health issues surrounding
equipment maintenance (such as exposure to hazardous
materials).
4. Discuss measures to take to minimize the health issues
surrounding equipment maintenance such as.
• Proper use of PPE
• Issuance of all necessary permits
• decontamination
5. Discuss possible environmental issues surrounding equipment
maintenance such as:
• Leaks
• Spills
• Contaminated equipment
• Chemical waste
6. Describe measures to take to minimize the environmental issues
surrounding equipment maintenance.
• Waste disposal
• Spill cleanup
• Housekeeping
• Proper decontamination
Equipment
Maintenance -
Documentation
and Permits
1. Discuss the types of documentation that must be completed prior
to performing maintenance on a selected piece of equipment.
2. Discuss the role the process technician may have in preparing
each type of documentation.
3. Explain the purpose of a work permit.
PTAC 2438 Process Technology III - Operations
Equipment
Maintenance -
Documentation
and Permits (cont.)
4. List the various types of work permits used within the process
industries.
5. List the departments or groups that may need to be consulted
and/or sign a work permit.
Equipment
Maintenance -
Equipment
Isolation
1. Differentiate between energy sources and devices used for
isolation.
2. Discuss the methods used to clear equipment.
3. Describe the purpose of various PPE (Personal Protective
Equipment) used during equipment clearing and isolation.
4. Identify the appropriate PPE (Personal Protective Equipment)
for use in a specific clearing and isolation scenario.
Turnarounds 1. Define the term "turnaround".
2. Differentiate between routine maintenance and work performed
during turnaround.
3. Given a scenario, list the tasks which must be completed and
discuss the process technicians role to adequately prepare for a
turnaround.
4. Compare and contrast routine shutdown versus shutting down
for turnaround.
5. Describe the role of the process technician in unit turnarounds.
6. Compare and contrast routine startup versus starting up after
turnaround.
7. Discuss PSM’s Management of Change requirements in
relationship to turnarounds.
8. Discuss the PSM’s Pre-Startup Safety Review requirements in
relationship to turnarounds.
9. Given a scenario, list the tasks which must be completed and
discuss the process technicians role for successful startup
following a turnaround.
• Removal of energy isolation devices
• Purging
• Pressure testing of equipment
• Vessel and/or piping inventory
• Installation of plugs, caps, blind flanges, etc.
10. Explain how unit personnel would evaluate the success of a
turnaround.
• Zero injuries
• Zero environmental incidents
• Successful startup
• On time and on budget
• Improved plant performance
PTAC 2438 Process Technology III - Operations
III. STUDENT LEARNING OUTCOMES
OUTCOMES METHOD OF ASSESSMENT
1. Using process diagrams (P&IDs,
PFDs) and operating procedures
describe how an operator would
startup and operate a plant under
normal operating conditions.
Lab assignment during semester.
2. Describe the major steps performed
during startup (initial commissioning,
routine startup, and startup following
a turnaround) of a process to meet
normal operating conditions,
including safety and environmental
regulations.
Final exam questions.
3. Demonstrate roles and
responsibilities of a process
technician during normal operating
activities (shift change, monitoring
controls and equipment, sampling,
communications, etc.).
Operations questions on final exam.
4. Given an abnormal situation, identify
appropriate corrective actions to
return the process to either a steadystate operation or perform a safe
emergency shutdown.
Lab exercise during the semester.
5. Describe the major steps performed
during normal shutdown activities,
including meeting safety and
environmental regulations.
Operations final exam questions.
6. Describe steps taken to safely prepare
equipment for both routine and
shutdown maintenance activities
(e.g., isolation, decontamination,
permitting) and then returning
equipment to service.
Operations final exam questions.
PTAC 2438 Process Technology III - Operations
SKILL STANDARDS LEARNING OUTCOMES
The following list of learning outcomes are Key Activities from the
Chemical/Refining Process Technician skill standards, developed by the North
American Process Technology Alliance (NAPTA), and recognized by the Texas Skill
Standards Board (TSSB). These outcomes have been integrated into PTAC 2438,
Process Technology III - Operations.
1. Monitor and Regulate Distillation System.
2. Monitor and Regulate Continuous Reaction System
3. Monitor and Regulate Steam System.
4. Monitor and Regulate Utility Air System.
5. Receive Chemical Materials
6. Store Chemical Materials