PROCESS OPERATOR – REFINERY, CHEMICAL AND LIQUID PROCESSES
- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F01.04 Wear and maintain personal protective equipment including eye, ear, hand,
respiratory, body and foot protection, ensuring that correct fit and optimum
protection is provided to the wearer for the specific task performed in accordance
with applicable government regulations, manufacturer’s specifications and
company policy.
_______________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F01.05 Practice good housekeeping in the workplace by ensuring that the workplace is
clean, organized and free of obstructions, spills or fire hazards; that materials and
equipment are cleaned and stored in designated areas after use and that protective
barriers, UV shields and guards are erected so that accident or injury potential is
minimized.
________________ _________
______ __________________
Date Completed Apprentice Supervisor/Trainer
246F01.06 Apply lockout and tag procedures and de-energizing procedures to electrical,
mechanical, hydraulic and pneumatic equipment before commencing maintenance
and overhaul, in accordance with the CEC, the BPVR, the OHSA, manufacturers’
instructions and company policies and procedures.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F02.0 EMPLOY JOB INFORMATION RESOURCES
GENERAL PERFORMANCE OBJECTIVE
Employ job information resources by determining in-house operation and
maintenance requirements; interpreting electrical, mechanical and structural
blueprints; communicating with co-workers; writing reports; maintaining service
documents; and preparing work orders so that the information needed to plan and
complete maintenance activities is made available and used.
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- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F02.01 Determine operation and maintenance requirements by researching codes,
manuals, manufacturers’ specifications and recommendations, warranties,
preventive maintenance schedule sheets and government regulations; identifying
system and component types, capacities, tolerances and limitations, safety
procedures, replacement procedures and in-house maintenance and licensing
limitations; updating maintenance inspection routines and locating any other
necessary information to complete the job in accordance with all regulations and
company procedures.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F02.02 Communicate with co-workers, supervisors, company representatives and other
tradespersons by personal communication, telephone, postal service/letter and email,
ensuring that information delivered is concise, clear and accurate and is in
accordance with company procedures or practices.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F02.03 Write work reports including standard work documentation as well as safety
reports, injury reports, environmental reports and maintenance charts by
completing them manually or using a computer system, ensuring that written
reports are concise, detailed, clear, accurate and timely, in accordance with
company practices or procedures.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F02.04 Maintain service documents including service call sheets, work orders, work
performance sheets and log books, ensuring that all procedures and maintenance tasks
are documented and recorded in accordance with employer’s specifications and
company procedures or practices.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
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246F03.0 USE AND MAINTAIN TOOLS AND EQUIPMENT
GENERAL PERFORMANCE OBJECTIVE
Use and maintain hand tools, measuring devices and testing and troubleshooting
devices by using and maintaining trade-specific hand tools and associated
equipment, measuring devices and testing and troubleshooting devices for
mechanical, hydraulic and pneumatic systems so that tools, equipment and devices
are used for their intended purpose and are maintained at a standard of repair that
is safe and functionally effective.
246F03.01 Use and maintain hand tools including hammers, wrenches, screwdrivers and
pliers by determining the correct tool for the job, selecting the tool and required
components, documenting use in a tool-control system, testing it, applying it to the
job, replacing consumables and repairing or replacing user-maintainable parts so
that tools are used for their intended purpose and are maintained at a standard of
repair that is safe and functionally effective.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F03.02 Use and maintain measuring devices including those for temperature, pressure,
level and flow by determining the correct device or equipment for the job,
selecting the device and required components, setting up the device, testing it,
applying it to the job, identifying deficiencies, replacing any consumables and
repairing or replacing user-maintainable parts so that devices are used for their
intended purposes and are maintained at a standard of repair and accurate
calibration that is safe and functionally effective.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
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ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F03.03 Use and maintain testing and troubleshooting devices for pressure, hydraulic
and pneumatic systems including temperature, pressure, level and flow gauges,
and analyzers for gas concentration, liquid concentration, density and specific
gravity measurements by determining the correct device or equipment for the job,
selecting the device and required components, setting up the device, testing it,
monitoring and adjusting its operation, recording results, replacing consumables
and repairing or replacing user-maintainable parts so that the devices are used for
their intended purposes and are maintained at a standard of repair and accurate
calibration that is safe and functionally effective.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F04.0 OPERATE A CENTRAL CONTROL ROOM
GENERAL PERFORMANCE OBJECTIVE
Operate a central control room by monitoring and running electronic or
computerized control panels and optimizing physical and chemical processes for
several processing units in accordance with process requirements, company
standards and manufacturer's specifications.
246F04.01 Monitor and run electronic or computerized control panels in accordance with
company standards and manufacturer's specifications.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F04.02 Optimize physical and chemical processes for several processing units in
accordance with company standards and process requirements.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
Ontario College of Trades ©
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- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F05.0 CONTROL PROCESS OPERATIONS
GENERAL PERFORMANCE OBJECTIVE
Control process operations by starting up, shutting down and performing
troubleshooting procedures on process operations in accordance with government
and company procedures and standards.
246F05.01 Start up and shut down process operations in accordance with government and
company procedures and standards.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F05.02 Perform troubleshooting procedures on process operations in accordance with
company procedures.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F06.0 MONITOR OUTSIDE PROCESS EQUIPMENT
GENERAL PERFORMANCE OBJECTIVE
Monitor outside process equipment in accordance with government regulations
and company procedures.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F07.0 CONTROL PROCESS MATERIALS
GENERAL PERFORMANCE OBJECTIVE
Control process materials by starting and stopping pumps and controlling
pressurizing vessels to unload raw materials from tank trucks, railcars, and other
containers and load finished products into appropriate transportation in accordance
with company procedures and standards.
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- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F07.01 Start and stop pumps and control pressurizing vessels to unload raw materials
from tank trucks, railcars, and other containers in accordance with company
procedures and standards.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F07.02 Load finished products into appropriate transportation in accordance with
company procedures and standards.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F08.0 OPERATE PROCESS EQUIPMENT
GENERAL PERFORMANCE OBJECTIVE
Operate process equipment by adjusting, maintaining and troubleshooting
distillation units, valves, pumps and controls, heat exchangers, piping systems,
electrical systems, vacuum systems, evaporation units, and related field
instrumentation in accordance with company standards and specifications.
246F08.01 Initiate and adjust the operation of process equipment such as distillation
units, valves, pumps and controls, heat exchangers, piping systems, electrical
systems, vacuum systems, evaporation units, and related field instrumentation in
accordance with manufacturer’s specifications and company standards and
specifications
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
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- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F08.02 Maintain the operation of distillation units, valves, pumps and controls, heat
exchangers, piping systems, electrical systems, vacuum systems, evaporation
units, and related field instrumentation in accordance with manufacturer’s
specifications and company standards and specifications
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F09.0 MAINTAIN VESSELS
GENERAL PERFORMANCE OBJECTIVE
Maintain vessels by inspecting, cleaning and repairing storage, mixing, blending,
decanting, oxidation, hydrogenation, pressure, and vacuum vessels in accordance
with company standards and specifications.
246F09.01 Inspect storage, mixing, blending, decanting, oxidation, hydrogenation, pressure,
and vacuum vessels in accordance with government regulations and company
standards and specifications.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F09.02 Clean and repair storage, mixing, blending, decanting, oxidation, hydrogenation,
pressure, and vacuum vessels in accordance with government regulations and
company standards and specifications.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
Ontario College of Trades ©
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- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F10.0 CONTROL CHEMICAL COMPOSITION
GENERAL PERFORMANCE OBJECTIVE
Control chemical composition by identifying properties, reactions, temperatures,
pressures, and chemical analysis; handling, storing, and transferring chemicals;
preparing chemicals through weighing, mixing and blending; monitoring yields
and balances; and running batch operations in accordance with required
procedures and methods and company procedures and standards.
246F10.01 Determine properties, reactions, temperatures, pressures, and chemical analysis
of chemical constituents in accordance with standard procedures and methods.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F10.02 Handle, store, and transfer chemicals in accordance with government
regulations and company procedures.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F10.03 Prepare chemicals through weighing, mixing and blending in accordance with
company procedures and methods.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F10.04 Monitor yields and balances of chemical mixtures in accordance with standard
procedures and methods.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
Ontario College of Trades ©
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- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
246F10.05 Run batch operations in accordance with required procedures and methods and
company procedures.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F11.0 MAINTAIN EQUIPMENT
GENERAL PERFORMANCE OBJECTIVE
Maintain equipment by shutting down, isolating and preparing process units and
production equipment and repairing them in accordance with company procedures
and standards.
246F11.01 Shut down, isolate and prepare process units and production equipment in
accordance with company procedures and standards.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F11.02 Troubleshoot and repair process units and production equipment in accordance
with company procedures and standards.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F12.0 CARRY OUT STATISTICAL PROCESS CONTROL
GENERAL PERFORMANCE OBJECTIVE
Carry out Statistical Process Control on process operations by sampling products,
performing tests, recording data and completing required documentation in
accordance with company procedures and standards.
- ON-THE-JOB PERFORMANCE OBJECTIVES (cont’d):
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246F12.01 Sample products and perform tests in accordance with company procedures and
standards.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
246F12.02 Record data and complete required documentation in accordance with company
procedures and standards.
________________ _______________ __________________
Date Completed Apprentice Supervisor/Trainer
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- LEARNING OUTCOMES (Off-the-Job/In-School Learning)
In-school training is a maximum of 720 hours or may be completed by approved,
self-paced correspondence learning.
- Mathematics
The apprentice is able to solve mathematical problems using:
- addition, subtraction, multiplication, division, fractions and decimals
- conversion tables, rates, charts, graphs and trends
- equations, algebraic applications and formulas
- Instrumentation Control
The apprentice is able to explain in detail the following concepts and procedures
relating to instrumentation control:
- process instrumentation, reading instruments
- pressure, temperature, level and flow measurement; analytical
measurements
- liquid and gas concentration analysis; density and specific gravity
analysis; clarity analysis; humidity and moisture analysis
- basic instruments; transmitters and transducers; recorders; indicators
and protective devices; controllers; final control elements
- process control concepts; feed-back/feed-forward control; process
dynamics; two position and proportional control; reset and rate control;
PID control; digital control; control loops; PLCs; control systems;
information displays and control system operation
- Plant Science
The apprentice is able to explain and solve problems in:
- science principles; units of measurement; force and motion; work
power and efficiency; basic machines
- matter; properties of solids, liquids, gases, and flowing fluids; heat;
temperatures; latent heat
- modes of heat transfer; heat transfer between fluids; heat exchanger
operation; systems
- fluid basics; liquid systems; gas and vapour systems
- basic process measurement; process dynamics
- basic electricity; electricity, magnetism and alternating current; electric
motors; transformers and solenoids; basic circuits; electrical systems
operation
- Introduction to Distillation
The apprentice is able to describe:
- distillation principles; distillation systems
- towers, and equipment; types of distillation towers
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- LEARNING OUTCOMES (cont’d)
- Piping and Auxiliaries
The apprentice is able to identify and explain the application of:
- piping and auxiliaries; pipe supports and expansion devices; insulation
and heat tracing
- protective devices; steam traps; and, draining and filling fluid systems
- Chemistry
The apprentice is able to explain chemical action relating to:
- limiting factors; material balancing; reaction rates; catalysts
- equilibrium reactions; chemical reactions
- compounds and mixtures; and, solutions and concentrations
- Process Operations Troubleshooting
The apprentice is able to describe the procedures relating to implementation of:
- process operations and troubleshooting; the process of elimination
- troubleshooting procedures and examples; troubleshooting control
systems
- Process Reactor Fundamentals
The apprentice is able to describe:
- reactor principles; basic reactor design
- stirred tank reactors; tubular reactors; catalytic bed reactors; and,
reactor operations
- Pumps
The apprentice is able to identify and describe:
- types of pumps; pump auxiliaries
- inspection of an operating pump
- reciprocating pumps; rotary pumps
- reciprocating pump start-up and shut-down; rotary pump start-up and
shut down
- centrifugal pump parts and functions; single stage centrifugal pumps;
multistage centrifugal pumps
- single stage centrifugal pump start-up and shut-down; and, multistage
centrifugal pump start-up and shut-down
- Reading Diagrams
The apprentice is able to:
- Identify and read diagrams
- describe flow diagrams; piping diagrams
- describe instrumentation and electrical diagrams
Ontario College of Trades ©
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- LEARNING OUTCOMES (cont’d)
- Valves
The apprentice is able to identify and describe the operation of:
- valves; gate, globe, angle, and needle valves
- plug, ball, and butterfly valves
- diaphragm, pinch, and check valves
- relief and safety valves
- actuators; pneumatic actuators; electric actuators; hydraulic actuators
- Chemical/ Refinery Plant Operations
The apprentice is able to describe chemical and refinery plant operations:
- equipment and systems
- processes
- operators
- Compressors
The apprentice is able to describe:
- compressor components
- compressor operation
- Distillation
The apprentice is able to describe
- basic principles of distillation
- basic system components and operation
- towers, reboilers, and condensers
- Electrical Equipment
The apprentice is able to describe and explain:
- electrical production and distribution
- breakers, switches, and safety
- AC/DC motors
- motor controllers
- Environmental Protection
The apprentice is able to describe:
- air pollution, water pollution
- waste disposal procedures (Canadian applications)
- Filtration and Screening
The apprentice is able to describe
- filtering and screening; screens;
- screen operations; cartridge filter operations; gravity and pressure
filter operations; and, pre-coat filter operations
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- LEARNING OUTCOMES (cont’d)
- Heat Exchangers
The apprentice is able to describe:
- principles of heat transfer;
- shell and tube heat exchangers; applications and operations;
- introduction to cooling towers; cooling tower design, operation and
chemical addition;
- condenser operations; and,
- reboiler operations
- Operator Responsibilities
The apprentice is able to describe:
- the operator’s role; general outside operator responsibilities
- plant equipment maintenance roles
- general control room operator responsibilities
- how operators detect and use trends
- abnormal and emergency situations
- safety responsibilities
- data collection responsibilities
- production responsibilities
