Process Technical Services (PTS) can continue process operations after startup for a period of time long enough to stabilize the operation and allow the permanent operating and maintenance personnel to be trained and qualified to operate the new process.
PTS has the skilled and experienced managers, supervisors, foremen, operators, engineers and other specialists to both operate a new facility and at the same time train permanent replacements.
Training of all new personnel in process operations, including managers, supervisors, and foremen, begins with a description of the process operations and the conditions employed in that operation. An intimate knowledge of the design and operation of the new facility is a basic requirement for understanding the training that follows.
The second phase of training in process operations will emphasize the need for safety in all aspects of the job that each new employee will perform. The goal of preventing injuries to personnel is fundamental to preventing accidents that can interrupt operations and possibly damage the facilities. If the personnel are properly trained in safety, they are unlikely to perform acts that will result in injury to themselves or to others. They will also be taking precautions to eliminate any chance of causing a serious operating problem that might lead to lost production and possibly a long outage to repair or replace damaged equipment.
It is important for managers to adopt and implement the OSHA Process Safety Management (PSM) program, which incorporates process operations safety, because they will be responsible for its ongoing success or failure. Without management’s full cooperation and support for a safety program, there may be little or no success in this area.
Compliance with environmental regulations related to process operations is a fundamental element in the safety program. Any release of process material into the environment is a potential safety hazard and possibly a violation of the law. Not only does this expose the owners to fines and civil law suits, it could potentially lead to criminal charges against managers and potential shutdown of the plant. The EPA’s Risk Management Program (RMP) is a complimentary program to PSM.
PTS's skilled and experienced personnel understand the safety and environmental issues pertaining to process operations and have trained many operating and maintenance personnel in all aspects of safety and environmental compliance.
The next step in training the client’s permanent personnel in process operations is designed specifically to include both process operations and maintenance personnel. Operators and foremen will be trained on how to start-up the plant, establish normal process operations, shut the plant down and de-inventory it, and clean and clear each piece of equipment for maintenance personnel.
Central to operator training will be instructions on how to respond to various emergency situations. Events, such as the uncontrolled release of process material, a fire, or an explosion will be studied in detail and response techniques developed to handle each of these situations. Training process operations personnel to handle emergency situations is essential, because these are events that are rare and could result in catastrophic loss if not properly handled. It is the rare and unusual event for which the operator must be trained and retrained to handle as
as any routine upset.
Training for routine process operations is
not as complicated,
since the skills taught are reinforced every day to the point that the operator becomes intimately familiar with how to operate the plant.
Maintenance of the plant facilities also requires training that focuses first on unusual and emergency events. Absolutely essential to safe and effective response to an emergency is the close coordination between the operators and the mechanics. Maintenance personnel cannot conduct any activities until the operating force and emergency response teams have the unit shutdown and cleared for maintenance personnel. An assessment of the damage must be undertaken before any work begins, so that a recovery plan can be developed and placed in operation.
In an emergency a rapid response must be carefully controlled to mitigate the potential for injury and death of plant personnel or people in the surrounding area. Emergency response teams must be
carefully trained to handle a variety of situations.
Training does not begin with an emergency, that is when training stops and action begins. Properly trained personnel will respond according to their training.
Training for routine maintenance of the plant process, instrument, and electrical systems will focus on the two elements of maintenance, diagnosis and repair or replacement. Procedures for routine maintenance of each element can be taught by the skilled and experienced professionals from PTS. How to diagnose problems with pumps, compressors, valves, and other moving equipment will be taught to both operators and mechanics. Operators will usually be the first to discover a malfunction of process equipment during process operation and it is important that they be trained to recognize and report their findings. Often, quick action on the part of an operator can prevent serous damage from occurring. He is also in the best position to describe the symptoms to the maintenance personnel, so the troubleshooting efforts and repairs can begin.
PTS. can establish both predictive and preventive maintenance programs. These programs serve to greatly improve the reliability and operability of process operations over the long haul. Identifying and replacing wear items during scheduled shutdowns before they fail will reduce the number of unscheduled and production limiting shutdowns.
Process Technical Services has the skilled and experienced personnel that can train a permanent team of managers, operators, and mechanics to function as a well disciplined team for effective, safe, and provide reliable process operations while your new operators and mechanics are being trained.