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The success of any chemical plant operation is based on three essentials – efficiency, productivity and safety. The inherent dangers in chemical and process facilities, with the manufacture, storage and transport of toxic, corrosive and/or explosive elements, create environments with "accidents waiting to happen". To reduce risk and increase productivity, companies must certify that chemical plant operators have the required knowledge and skills to safely carry out their duties and ensure that all equipment is in safe working order.
The chemical plant operator curriculum is designed to enhance operator knowledge and skills with an understanding of basic theory, equipment operations, systems operations, process plant safety considerations, working conditions, foundational technical knowledge and specific training on the complex equipment found in today’s chemical plants.
Chemical Plant Operator Learning Plan
Tier 1 - Fundamentals
- Industrial Math: Basic Operations 1
- Industrial Math: Basic Operations 2
- Math: Basics
- Industrial Math: Algebra
- Industrial Math: Formulas, Graphs & Trends
- Hand Tools, Part 1
- Hand Tools, Part 2
- Introduction to Power Tools
- Precision Measurement Tools 1
- Precision Measurement Tools 2
- Safety Orientation
- Back Safety
- Fall Protection
- Hearing Conservation
- Bloodborne Pathogens
- Personal Protective Equipment
- Fire Safety
- Classes of Fires and Extinguishers
- Warning Signs and Labels
- Respiratory Protection
- Material Safety Data Sheets
- Safety: Chemical Health Hazards
- Electrical Safety
- Diagrams: Blueprints
- Operator Responsibilities Introduction
- Operation - Basic Principles
- Operator Responsibilities: Advanced Operator Responsibilities
- Statistical Process Control: Basic Control Charts
- Troubleshooting: Basic Concepts
- Plant Science: Basic Electrical Principles
- Plant Science: Basic Electrical Circuits
- Electrical Maintenance: Battery Systems
- Fans
- Plant Science: Basic Principles
- Plant Science: Fluid Systems
- Plant Science: Forces and Machines
- Plant Science: Gases and Flowing Liquids
- Plant Science: Solids and Liquids
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- Bearing Basics
- Eqt Lubrication: Lubricants & Bearings
- Hydraulics: Routine Maintenance
- Pumps: Basic Types and Operation
- Efficient Pump Operation
- Valves: Electric and Hydraulic Actuators
- Welding: Oxy-Fuel Gas Welding
- Welding: Arc Welding
- Refrigeration System: Operation
- Plant Science: Heat
- Plant Science: Heat Transfer
- Heat Exchangers: Introduction
- SCRs and TRIACs
- Quality Control and Assurance
- Procedure Use and Adherence
- Stop When Unsure
- Decision Making
- Managing Yourself
- Are You Ready Checklist
- Self-Checking (STAR)
- Problem Solving
- Peer Checking
- Co-Worker Coaching
- Managing a Work Group
- The Team Advantage
- Clear Communication
- 3-Way Communication
- Interpersonal Communication
- Turnover
- Discipline
Safety Courses
- Respirator Fit Testing
- Workplace Ergonomics
- Understanding Forklifts
- Driving Safety
- Electrical Safety
- Asbestos: Hazard Awareness Training
- Hazard Communication
- HazWoper: Introduction
- HAZWOPER: First Responder - Awareness Level
- Transporting Hazardous Materials
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Tier 2 - Components and Subsystems
Operations Courses
- Diagrams: Blueprints
- Basic Electrical Safety
- Operator Responsibilities: Introduction
- Operation: Basic Principles
- Operator Responsibilities: Basic Operator Responsibilities
- Operator Responsibilities: Communication
- Operator Responsibilities: Plant Production and Safety
- Operator Responsibilities: Trends, Maintenance and Emergencies
- Operator Responsibilities: Advanced Operator Responsibilities
- On-the-Job-Training: Preparation
- On-the-Job-Training: Implementation and Evaluation
- Plant Science: Process Dynamics and Measurement
- Process Sampling: Obtaining Samples
- Process Sampling: Testing Samples
- Troubleshooting: Process Examples
- Statistical Process Control: Introduction
- Statistical Process Control: Process Variations
- Statistical Process Control: Basic Control Charts
- Troubleshooting: Basic Concepts
- Environmental Awareness
Electrical Courses
- Sources of Electricity
- Plant Science: Basic Electrical Principles
- Plant Science: Basic Electrical Circuits
- Electrical 2: Electrical Lighting
- Electrical Maintenance: Battery Systems
- Ground Fault Interrupters
Mechanical Courses
- Fans
- Plant Science: Basic Principles
- Plant Science: Fluid Systems
- Plant Science: Forces and Machines
- Plant Science: Gases and Flowing Liquids
- Plant Science: Solids and Liquids
- Bearing Basics
- Sliding Surface Bearings
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- Rolling Contact Bearings, Part 1
- Rolling Contact Bearings, Part 2
- Couplings
- Equipment Drive Components: Couplings
- Equipment Drive Components: Gear, Belt, and Chain Drives
- Lubrication: Basics
- Equipment Lubrication: Using Lubricants
- Equipment Lubrication: Lubricants and Bearings
- Safety: Basics
- Vibration Analysis: Introduction
- Gears: Overhauls
- Seals: Gaskets and Packing
- Pipes and Valves: Installing Flanges, Copper, and Plastic Pipe
- Pipes and Valves: Installing Pipe Hangers and Supports
- Piping and Auxiliaries: System Components and Operation
- Pipes and Valves: Steam Traps
- Pipes and Valves: Valve Maintenance
- Safety Valves, Part 1
- Safety Valves, Part 2
- Hydraulics: Diagrams
- Hydraulics: Actuators
- Hydraulics: Pumps
- Hydraulics: Routine Maintenance
- Pumps: Basic Types and Operations
- Pumps: Fundamentals of Centrifugal Types
- Centrifugal Pump Basics, Part 1
- Centrifugal Pump Basics, Part 2
- Positive Displacement Pump Maintenance
- Efficient Pump Operation
- Compressors: Positive Displacement
- Valves: Basic Types and Operation, Part 1
- Valves: Basic Types and Operation, Part 2
- Valves: Electric and Hydraulic Actuators
- Welding: Oxy-Fuel Gas Welding
- Welding: Arc Welding
- Refrigeration System: Operation
- Plant Science: Heat
- Plant Science: Heat Transfer
- Heat Exchangers: Introduction
- Heat Exchangers: Condensers and Reboilers
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Tier 3 - Systems and Control
Instrumentation and Control Courses
- Core: Principles of Calibration
- Temperature and Temperature Measurement
- Pressure Gauges and Calibration
- Pressure and Pressure Measurement
- Liquid Level Measurement
- Diagrams: Piping and Instrumentation
- Continuous Process: Field Devices: Level and Flow
- Continuous Process: Smart Controllers
- Instrumentation and Control: Introduction to Process Control
- Instrumentation and Control: Introduction to Control and Data Systems
- Instrumentation and Control: Measurement of Pressure and Temperature
- Instrumentation and Control: Measurement of Level and Flow
- Instrumentation and Control: Measurement of Concentration
- Continuous Process: Troubleshooting DCS I/Os: Procedures
- PLCs: Architecture
- PLCs: Installing and Maintaining
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- PLCs: Ladder Logic and Symbology
- PLCs: Numerics, Part 1
- PLCs: Numerics, Part 2
- PLCs: I/O Communication
- PLCs: Introduction to Programming, Part 1
- PLCs: Introduction to Programming, Part 2
- PLCs: Program Entry, Testing, and Modification, Part 1
- PLCs: Program Entry, Testing, and Modification, Part 2
- PLCs: Programming Functions, Part 1
- PLCs: Programming Functions, Part 2
- PLCs: Networks and Network Troubleshooting
- PLCs: Troubleshooting Software, Part 1
- PLCs: Troubleshooting Software, Part 2
- PLCs: Troubleshooting Hardware
- PLCs: HMIs and Troubleshooting
- Networks Introduction
- Networks: Setting Up and Troubleshooting
- Networks: Fiber Optic Systems
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Tier 4: Function, Site and Product-Specific Skills
Power Generation Courses
- Material Handling: Tank Trucks
- Environmental Protection: Water Pollution & Waste Disposal
Transmission and Distribution Courses
- Power Quality and Reliability
Chemical and Process Courses
- Chemistry: Basic Principles, Part 1
- Chemistry: Basic Principles, Part 2
- Basic Chemical Plant Operations
- Chemistry: Material Balancing
- Chemistry: Reaction Rates
- ISO 9000
- Centrifuge Operations
- Process Reactor Fundamentals
- Typical Process Reactions, Part 1
- Typical Process Reactions, Part 2
- Distillation: Basic Principles
- Distillation: Basic System Components and Operation
- Distillation: Control Systems
- Distillation: System Startup and Shutdown
- Distillation: Operating Problems
- Distillation: Towers, Reboilers, and Condensers
- Dryers
- Drying Operations
- Evaporation Unit Operations
- Filtration and Screening Unit Operations
- Hydraulic Systems
- Refrigeration Systems, Part 1
- Refrigeration Systems, Part 2
- Steam Turbines
- Current Good Manufacturing Practices
- Aboveground Storage Tanks, Part 1
- Aboveground Storage Tanks, Part 2
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- Aboveground Storage Tanks, Part 3
- Material Handling Of Bulk Liquids
- Flaring, Venting, and Purging
- Portable and Emergency Equipment
- Emission Controls
- Process Chemistry
- Statistical Process Control
- Distillation: Basic Principles
- Distillation: Basic System Components and Operation
- Distillation: Control Systems
- Distillation: System Startup and Shutdown
- Distillation: Operating Problems
- Distillation: Towers, Reboilers, and Condensers
- Dryers
- Drying Operations
- Evaporation Unit Operations
- Filtration and Screening Unit Operations
- Hydraulic Systems
- Refrigeration Systems, Part 1
- Refrigeration Systems, Part 2
- Steam Turbines
- Current Good Manufacturing Practices
- Aboveground Storage Tanks, Part 1
- Aboveground Storage Tanks, Part 2
- Aboveground Storage Tanks, Part 3
- Material Handling Of Bulk Liquids
- Flaring, Venting, and Purging
- Portable and Emergency Equipment
- Emission Controls
- Process Chemistry
- Statistical Process Control
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