||Chem Excellence: Foundations for Excellence in the Chemical Process Industries
14.3 Operate, Monitor, and Control Continuous Processes
Tasks conducted by PTOs related to this critical job function include:
- Review and properly interpret all checklists associated with a process.
- Complete all required reports to describe process activities, discrepancies, and maintenance.
- Adjust control equipment as specified by procedures, set operating parameters, and identify abnormal conditions that require reporting.
- Check equipment to ensure safety for electrical loading, physical stressing, and temperature variation.
- Start up process according to specified procedures.
- Monitor operating parameters by reading gauges, instruments, and meters, and logging or otherwise recording the information as necessary.
- Adjust operating parameters to optimize conditions appropriate to the process.
- Recognize and correct any deviations.
- Respond to any alarms.
- Collect appropriate samples.
- Conduct on-site inspections.
- Submit samples for analysis.
- Record and report data.
- Shut down processes according to procedures.
- Shut down processes in emergency situations.
- Maintain piping networks.
Technical Performance-based Skill Standards
For this critical job function, entry-level PTOs are expected to:
- Describe the characteristics of a continuous process.
- Describe the major industrial continuous processes, by (1) describing the characteristics of each, (2) the chemical/physical properties of materials important to the operation, (3) the environmental regulations and safety concerns that are related to each operation, and (4) how the operations usually are interrelated.
- Read process diagrams and include: (1) descriptions of the various components and streams of a continuous process; (2) identification and descriptions of the types and operations of control loops and sample collection devices; and (3) identification of typical valves, pumps, and other equipment according to type and usage.
- Draw a simplified process diagram for a variety of operational needs.
- Demonstrate ability to follow common operating procedures and use safety information, such as provided by MSDSs.
- Start up, operate, and shut down a process.
- Write the documentation for an operating procedure that meets OSHA requirements.
- Describe a troubleshooting strategy for a complex process, given a variety of upset conditions.
- Describe the operation, characteristics, and limitations of process measurement equipment, such as thermocouples and other on-line instruments.
- Describe process flows, both gas and liquid streams.
- Describe the concepts associated with process optimization.
- Describe when, where, and why samples are taken for analysis and how the sampling techniques relate to quality products.