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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
  • To provide newly hired operators with the basic knowledge required for a rapid and effective integration.
Learning Objectives
  • To acquire the fundamental knowledge and techniques required for the position of field operator.
  • To understand the everyday operating procedures of main equipment.
  • To be aware of process units risks and apply fundamental safety rules.
  • To communicate efficiently with colleagues.
Ways and means
  • Training involves alternating:
  • learning fundamentals in class, with an interactive delivery method
  • practical recognition exercises on-site (“practical exercise”)
  • tutorials, case studies, role plays.
  • Alternation between IFP Training and the Client's On-the-Job Orientation to enhance the training efficiency.

Instrumentation and control devices 7.5 days
  • Physical variables used in process operations (pressure, temperature, flowrate, density, specific gravity).
  • Components of a control loop.
  • Instrumentation: workings and operation.
  • On-site practical exercise on a control loop.
  • Demonstration material (if available).
  • Man-Machine Interface; access to operating conditions, trends and alarms in control room.
Pipework - 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.
  • On-site equipment recognition.
  • On-site practical exercise of line-plotting.
  • Demonstration material (if available).
Heat exchange equipment 6.5 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 and 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).
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 hazards recognition and prevention means plotting.
  • Case studies - Group work. Lessons learned.
Operators' tools - Skills & organization 2 days
  • Plant documentation: inventory, content, usage.
  • Radio communication. Teamwork.
  • Reporting and handover duties.
  • Role plays.
Assessment (duration included in the previous chapters)
  • Continuous assessment: written tests and oral presentations.