Operator Basic Training CourseOPE/FTBO-E

Who should attend?

  • This course provides operators with the knowledge and know-how required for safe, efficient and reliable field operations.
Audience :
  • Operators of oil refineries or chemical plants, without any operator certification background.
  • Technicians or staff to be retrained as operators in the chemical, petrochemical or oil industries.

Level : Foundation

Course Content

      • For each equipment type: principle, technology, ancillary systems, monitoring, basic operations, risks, safety devices, good practices.
  • PIPING - VESSELS - STORAGE TANKS - DRAWINGS

      • 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

      • 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

      • 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

      • 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

      • 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

      • Plant documentation: inventory, content, usage.
      • Radio communication. Teamwork.
      • Reporting and handover duties.
      • Role plays.
  • SAFETY

      • 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.

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.

Ways & 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.