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Benefits of Manuals Back to Service
Manuals can be described as Operations Manuals or Training Manuals; both are technically updated however, One contains a training guide which includes a syllabus with hands-on activities –both outside operators as well as for qualifying DCS operators.
Manuals provide valuable process operation information to understand why things happen in a process, especially when 3-dimentional flow representations are used.
The operator now knows how each piece of equipment functions.
Knows proper learns to correctly fill an exchanger or a catalyst.
Knows ranges of variables and to keep them adjusted.
Through the knowledge of a process - your operators can anticipate, prevent, and handle any eventuality because they've been trained in their particular plant sciences for each unit and how to control (level, flow, temperature, pressure and partial pressures).
The good DCS operator can anticipate and respond to a potential problem whereas, the poorly trained operator has only his iterative learning (trial and error) - a slow and costly way of learning.
An Operations/Training manual should contain at least the following:
Section One-Outside Operator
- A Process Overview for Contractors and one for Operations Personnel, i.e., what and where a chemical could be encountered (including MSPS identification and safety response).
- Chemistry/Laboratory section which describes the chemical(s), their function, composition, makeup, and hazards.
- A Detailed Process Description
- Equipment Descriptions
- An Alarms Table with Operator responses
- Critical Operations limit and process operating limits
- Unit inventories
- Troubleshooting Guides with responses
Evaluations
How do you verify knowledge and skills?
The best technology at this time is brain and hands
All manuals each have their own Student Guide with self quizzes, exams, finally specific walkthrough
Section Two-DCS Operator
Operation of a DCS (Honeywell, Yokogowa, AB) requires specifically designed study, and hands-on time)
Basic unit Chemistry (general)
Basic unit Chemistry (organic chemicals if applicable)
Introduction to the types and effects of:
- Level
- Temperature
- Flow
- Pressure
Communication with outside operators
Effects of variables on various products (mediate, intermediate and final)
Variable control
Variable control upstream
Communication with tank farm/field pumpers
Disposition of product(s)
Variable control downstream
Back to Service
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