Certified Process Operator

Why Select this Training Course?

A Process Operator position can be difficult. Still, it is a very satisfying and long-term career choice. A Process Operator has many career choices ranging from sectors like oil and gas, power plants, oil refineries, water treatment plants, petrochemicals, chemical industries, pharmaceuticals, and many others. Due to the inherent risks and pitfalls of process facilities, companies require that process plant operators undergo security and operational training programs to help them perform their duties safely and efficiently. This course will focus on the role of operators in process plants, which is to maintain optimal levels of efficiency, safety, and reliability in plant operations.

The Rcademy Certified Process Operator course is a programme and a strategic tool to enhance your success in plant operations, especially in the Oil and Gas sector. A career as a process plant operator demands a comprehensive understanding of the job and the workplace, empowering you to make informed decisions. This course will enable you to pinpoint and understand the major steps involved in process plant operations and the production environment, equipping you with practical knowledge and skills directly applicable to your work. This Certified Process Operator course will equip participants with a broad understanding of the specific roles operators play on the plant by explaining the critical skill sets and expertise operators need.

What is the work of a process operator?

Process operators are in charge of programming and controlling the facility’s computer system, which controls machine movement and process operation. They are essential for starting up, shutting down, and running plant production. They oversee the process of making materials smoothly and efficiently. The process operators continually check for equipment failures and safety issues through regular inspections.

What skills do you need to be a process operator?

While preparing your resume for the process operator position, the most relevant and important skills sought by employers include mechanical skills, documentation, English speaking proficiency, team work, regulatory conformity, interpersonal skills and attention to details.

Who Should Attend?

The Rcademy Certified Process Operator training program is ideal for individuals working in various roles within the chemical, hydrocarbons, and refining industries, including:

• Process operators that operate and monitor equipment for efficient production processes.
• Process plant technical professionals that oversee technical aspects of plant operations, troubleshooting and optimising performance.
• Engineers, technicians, and operators that maintain, repair equipment, and implement process improvements.
• Supervisors and maintenance personnel who lead and coordinate maintenance activities for smooth plant operations.
• Project engineers who manage and oversee projects to improve plant efficiency, safety, or profitability.
• Engineering and technical personnel tasked with enhancing process and petrochemical plant profitability.
• Individuals involved in planning, managing, and ensuring energy efficiency in these industries.

What are the Course Objectives?

Upon completing the Rcademy Certified Process Operator training program, participants will be able to:

• Define production plants and production systems.
• Identify various types of production organisations and potential future opportunities.
• Understand operational organisation structures and plant layouts.
• Recognise the roles and responsibilities of process plant operations staff.
• Gain insight into the lifestyle of a process plant operator.
• Discuss the roles and responsibilities specific to process plant operators.
• Acquire the necessary skills and knowledge to become a competent plant operator.
• Learn about the importance of safety awareness in process plant operations.

How will this Course be Presented?

The Rcademy Process Operator Credit Training Course is designed with participants in mind. It aims to meet their expectations while enhancing their knowledge and skills. The platform ensures active learning through various practical teaching methods, including slide presentations, lecture notes, case studies, video presentations, and real-life scenarios.

Renowned professionals in the field with significant years of experience deliver the course content. Modules are meticulously crafted from extensive research to comprehensively cover the subject matter. Throughout the course, participants engage in both theoretical and hands-on learning experiences. They will take part in quizzes, seminars, and mock sessions to reinforce their understanding. Additionally, we provide a platform for participants to provide feedback, ensuring their satisfaction and optimising their learning experience.

What are the Topics Covered in this Course? 

Module 1: Overview of Process Plant Operation

• What is a production plant?
• Types of the production system
• Types of production organisations & future opportunities
• Production plant layouts
• Production organisational chart

Module 2: Process Operators Roles & Responsibilities

• Who is a Process Operator?
• Primary Roles
  • Perform operator duties, outside or in a control room
  • Operate electronic or computerised control panels
  • Read instruments to ascertain level, concentration, pressure, flow, density, etc.
  • Acquire knowledge of chemistry and chemical reactions
  • Adjust pumps, controls, valves, equipment, and process equipment
  • Monitoring outside process equipment
  • Sampling, testing, and preparing documents on process operations maintenance
  • Troubleshooting process operations
  • Communicating effectively with co-workers and supervisors
  • Working independently or as a team on different projects and tasks
  • Document critical activities and abnormalities
  • Perform comprehensive shift handover
• Secondary Roles:
  • Ensure mitigation plans are in place
  • Issue work permits and authorise the unit entry
  • Responsible for housekeeping in a work area
  • Advise support groups on housekeeping needs
  • Report abnormalities and take necessary corrective actions
  • Work with maintenance and technical teams to address pertinent problems
  • Prepare and commission equipment for Maintenance
  • Perform operations like process upsets, shutdowns and unit start-ups as per SOP
  • Other leadership responsibilities, such as training and mentoring

Module 3: Knowledge and Skills Needed For Efficient Process Operators

• Soft skills
• Personal attitude
• Technical skills
  • Safety awareness
  • Piping system
  • Valves
  • Process Plant Equipment (Introduction and Classifications)
  • Process Plant Equipment (Fixed or Static Equipment)
  • Process Plant Equipment (Rotary Equipment)
  • Chemicals and Materials Handling
  • Instrumentations
  • Plant Drawings
  • Process Control (Control room)
  • Process Control (Basic Control Loop)
  • Process Control (Common Types of Control System)
  • Permit To Work System
  • Emergency Response

Module 4: Process Operations and Safety Awareness

• Safety first
• Hazards classifications in process plant operations
• Key process hazards for plant operators
• Lack of safety awareness disasters
• Lessons gained from process plant disasters
• Ten safety commandments

Module 5: Regulatory Compliance

• Overview of regulatory agencies and standards (e.g., OSHA, EPA)
• Compliance requirements for process industries
• Recordkeeping and reporting obligations
• Environmental and safety regulations

Module 6: Process Optimization and Efficiency

• Principles of process optimisation
• Identifying opportunities for improvement
• Lean manufacturing and Six Sigma methodologies
• Energy efficiency and sustainability in process operations

Module 7: Communication and Teamwork

• Effective communication skills for process operators
• Teamwork and collaboration in process industries
• Conflict resolution techniques
• Interfacing with supervisors and other departments

Module 8: Emerging technologies

• Simulation Software
• Remote Monitoring and Control Systems
• Advanced Process Control (APC) Systems
• Digital Twin Technology