||Chem Excellence: Foundations for Excellence in the Chemical Process Industries
14.4 Operate, Monitor, and Control Batch 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 processes according to specified procedures.
- Measure raw materials.
- Monitor operating parameters by reading gauges, instruments, and meters, and logging or otherwise recording the information as necessary.
- Adjust pumps and valves.
- 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.
- Start up after an emergency shutdown.
Technical Performance-based Skill Standards
For this critical job function, entry-level PTOs are expected to:
- Describe the characteristics of a batch process.
- Describe the major industrial batch processes including common chemical, refinery, water, and waste treatment processes by (1) describing the operation of each; (2) characterizing the chemical/physical properties of materials that are important to the processes; (3) writing the molecular formulas and chemical structures for substances involved in the processes; (4) describing the chemical reactions involved in each process; (5) describing the chemical equilibrium, kinetics, and chemical reactivity relationships that characterize the processes or may impact safety; and (6) identifying relevant environmental regulations and safety concerns.
- Read process diagrams and include (1) descriptions of the various components and streams of a batch 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.
- Describe the different kinds of electric motors and demonstrate capabilities to start up and to shut down motors.
- Describe the concepts that provide the foundation of process optimization.
- Demonstrate ability to add solids, liquids, and gases.
- Describe the relationship of vacuum and pressure upon boiling point.
- Describe the various types of heat exchangers and demonstrate operation of each.
- Demonstrate ability to perform filtrations, extractions, distillations, drying, blending, milling, and packaging.
- Retrieve data and information, as required.
- Provide shift transfer notes.