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Operator Basic Training Course

40 days OPE/FTBO-E
Level
Foundation
Audience
  • Newly hired operators for oil refineries or chemical plants.
  • Technicians or staff to be retrained as operators in the chemical, petrochemical or oil industries.
Purpose
  • This course provides newly hired operators with the basic knowledge required for a rapid and effective integration.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • monitor each main type of equipment on the field, detect and report abnormal situations,
  • execute on the field the day-to-day operating tasks related to each main type of equipment,
  • strictly apply safety rules, to effectively use collective and personal protective equipment,
  • communicate effectively with shift colleagues.
Prerequisite
  • None, apart from being already hired by an Oil & Gas or Chemical company for a field operator position.
Ways and means
  • IFP Training classroom training uses interactive delivery methods (tutorials, case studies, role playing).
  • During classroom training, short practical on-site exercises on specific pieces of equipment.
  • In between IFP Training classroom modules, On-the-Job Orientation on Clients’ assigned unit.

PIPING - VESSELS - STORAGE TANKS - DRAWINGS 6 days
  • Valves, fittings, flexible hoses, safety devices/interlocks. Vessels, storage tanks. Identification symbols for various items of equipment.
  • Block diagrams, flow sheet, P&ID. Introduction to isometric drawings.
  • Field applications: equipment recognition, practical exercise of line-plotting, Demonstration equipment in the workshop (when available).
INSTRUMENTATION & CONTROL DEVICES 7 days
  • Physical variables used in process operations (pressure, temperature, flowrate, density, specific gravity).
  • Components of a control loop. Instrumentation: workings and operation.
  • Field applications: practical exercise on control loops, demonstration loops (if available), work on Man-Machine Interface in control room.
HEAT EXCHANGE EQUIPMENT 7 days
  • Heat, energy and heat transfer. Heat exchangers: technology, main types, workings and operation.
  • On-site practical exercise on a heat exchanger.
  • Furnaces and boilers: technology, combustion, draft and operation.
  • On-site practical exercise on furnaces/boilers.
ROTATING MACHINERY 8 days
  • Fluid flows.
  • Rotating machinery field recognition.
  • Centrifugal and positive displacement pumps.
  • On-site practical exercise on pumps.
  • Centrifugal and reciprocating compressors.
  • Single stage, back-pressure steam turbines.
  • On-site practical exercise on a compressor or turbine.
  • Electric motors operation.
  • Extruder.
PROCESSES - PRODUCTS - SAMPLING & TESTING - UTILITIES 5 days
  • Basic chemistry. Chemical products and chemical solutions: composition and hazards.
  • Chemical reactions.
  • Vapor pressure and boiling point.
  • Distillation: principles of the separation, distillation columns.
  • Products. Quality control tests. Sampling.
  • Principles of manufacturing processes.
  • Notion of material and heat balance.
  • Manufacturing process diagram.
  • Utilities: flare network, waste water treatment, cooling water, air production.
  • On-site practical exercise on different processes (main equipment, operating conditions).
OPERATORS' TOOLS - SKILLS & ORGANIZATION 2 days
  • Plant documentation: inventory, content, usage.
  • Radio communication. Teamwork.
  • Reporting and handover duties.
  • Role plays.
SAFETY 5 days
  • Product hazards: flammability, toxicity, physical hazards.
  • Job Safety Analysis for field operators’ routine activity (equipment check, circuit alignment, sampling, etc.).
  • Emptying processes: blind and gasket fitting, degassing and inerting, entering a vessel.
  • Example of procedures for equipment shut-down and start-up.
  • Safe behavior.
  • Field hazard recognition and prevention means plotting.
  • Case studies - Group work. Lessons learned.
ASSESSMENT (duration included in the previous chapters)
  • Continuous assessment: written tests and oral presentations.