40 days OPE/FTBO-E
- Newly hired operators for oil refineries or chemical plants.
- Technicians or staff to be retrained as operators in the chemical, petrochemical or oil industries.
- This course provides newly hired operators with the basic knowledge required for a rapid and effective integration.
- 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.
- 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.
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.