Welcome to PetroChem Training Consulting
PetroChem Training Services
Congratulations on taking a step in
developing a better organization. We’re happy that you decided to give us a
look. PetroChem Training is a multi-disciplined organization that can enhance
your company to develop a highly skilled, flexible, versatile, workforce that
can adapt and respond quickly to constantly changing technologies, government
regulations, economic forces and global competition. We can help your company
meet this challenge by empowering work teams to manage themselves by handling
work assignments, planning and scheduling work, making day to day decisions and
taking action on problems.
We are minority-company and a member of the
Houston Minority Business Council that has been in existence since
1989 and develop training programs for new and existing projects.
Our training programs are the essential element that verifies that all
employees understand the chemical process hazards associated with their
jobs and the precautions necessary to prevent catastrophic incidents. We
develop customized and computerized training programs for each specific
process units or project that are in accordance with the federally
mandated for the petroleum, energy, petrochemical, and other industries.
Our training programs are composed of operating manuals,
operating procedures, on-the-job training checklists, and evaluations to
measure the performance of the employee and job descriptions. The programs
are designed precisely for operations and maintenance personnel.
These training programs are developed in
English and Spanish. They are thorough, well organized, and easy to
comprehend. In addition to being effective, our programs are also
economical, because we revise and edit our client's existing material,
training booklets and manuals whenever possible.
We would greatly appreciate an opportunity
to meet with you to provide additional information regarding how PetroChem
can assist you in achieving your company's personnel training goals.
Development of Procedures, On-The-Job
Training Checklists, & Examinations
Purpose
PetroChem primary purpose for training operations and maintenance
personnel is to emphasize:
·
Site-specific safety
·
Health
·
Hazards
·
Environmental Compliance and
·
An efficient operation of the
facility
In this regard, productivity and the maintenance of quality standards are
critical to the economic well being of the process unit, and training must
support these goals. First and foremost
are employees and public safety.
Objectives
PetroChem training objectives provide the guidance for our training services
and products. We believe that personnel
must not only know the specifics of their jobs, but also have the fundamental
understanding to assess the significance of process parameters and dynamics and
the consequences of an individual’s actions.
In order to achieve this level of knowledge, personnel must be trained
in:
·
Basic fundamentals applicable
to understanding their jobs.
·
The equipment for which they
are responsible.
·
Overall plant systems.
·
The overall process in which
they are involved.
·
Procedures as applicable to
their jobs.
PetroChem systematic view provides the background for advising clients on
training matters. We recognize that
there are different means that can achieve training
objectives. It is our belief that the
most efficient and cost effective training is a systematic approach. It employs generic training materials to
provide basic understanding, and to build on that foundation specific
equipment, process and procedure knowledge applicable to the performance of an
individual job assignment.
Systematic
Approach
PetroChem follows a systematic approach in which training needs are
identified through analysis of the job, including identification of required
skills and knowledge. The program is
then:
·
Designed
·
Developed
·
Implemented
To provide a complete and precise training
system. The
specific phases of this approach are as follows:
Analysis Stage
Significant job tasks are identified through:
·
Job Interviews
·
Reference Material Research
·
Actual Observations
·
Our expert experience
During the analysis, observations are made regarding current training
practices in light of regulatory requirements and other standards that the
company elects to use. The information
obtained from the job interviews, reference material research, actual observations,
and our expert experience is compiled into a job task list.
Job interviews are conducted with unit personnel such as the following who
work the specific unit. Interviews
generate a partial job task list.
·
Engineers
·
Safety Directors
·
Environmental Compliance
Personnel
·
Maintenance Personnel
·
Chief Operators
·
Console Operators
·
Operators
Design Stage
We research existing reference material on the specific process unit.
·
This already existing material
is revised and edited.
·
Then the revised and edited
information is attached to the job task list.
We observe the actual work tasks performed by operators/maintenance
personnel to verify:
·
How the performance of the
tasks is carried out.
·
To ensure our procedures and
on-the-job training checklists are developed in a similar manner that the field
personnel performed the tasks, but in accordance with federal mandate and
company policy.
The job task list developed has proven to provide the best method to
determine training content that involves assessing training needs. The job task list is:
·
Evaluated
·
Revised
·
Prioritized
To determine the sequential steps, knowledge, and skills required to
perform each task.
Now, the job task list goes to the company subject matter experts for validation
and assessment of each task. The subject
matter experts will:
·
Determine the design of the
training strategy.
·
Specify what content from the
job task list will be employed to develop the procedures and on-the-job
checklists.
The design of the training
strategy is the nucleus that takes a process unit from its current training
approach to full compliance with the PSM training requirements and company
policy. This training plan provides:
·
A structured approach to guide
the development of training materials.
·
A control tool that management
can use to guide training programs.
The company subject matter experts serve as a training steering team. This steering team will be used:
·
To help manage the activities,
responsibilities, schedules, and resources necessary for training material
development and training implementation.
·
To derive to the training
plan, the job task list is essential since the customization of the procedures
and on-the-job training checklists are being initiated at this time.
Design verifies is a close relationship
Job task list analysis is beneficial because it brings to light
inconsistencies in the way tasks are performed by different personnel on
different shifts. Tasks selected for
training are further evaluated and prioritized to determine the sequential
steps, knowledge, and skills required to perform each task and specifics are
developed from this analysis. The main objective of the design phase is to
verify that there is a close relationship between the
·
Procedures
·
On-the-Job Training Checklist
·
Actual Training
This analysis
data of the job task list is extremely important. It is used to develop the following:
·
Job descriptions for operations and maintenance
personnel
·
Unit operating procedures
·
Equipment maintenance procedures
·
Planning
·
Scheduling
·
Budgeting Training Efforts
The design stage
also allows you to fine tune the program before it is
developed.
·
On-the-job-training checklists for operations and
maintenance personnel
·
Evaluations to measure employee performance
The job task list data specifies all the tasks performed by the
operator/maintenance personnel in that particular unit or skill. During this stage the content that provides
the foundation necessary for performing the individual assignment is
identified. This design information is
decisive for:
Development
Stage
During the development phase:
·
The language and terminology
used by operations/maintenance personnel is implemented in the procedures and
on-the-job training checklists.
·
Training materials for
procedures, on-the-job training checklists, examinations and job descriptions
are identified and prepared using the design information.
·
During this phase generic
materials appropriate to the training requirement are considered in order to
reduce the amount of customized material that must be developed.
·
This approach reduces the
client's cost without reducing the effectiveness of the program.
The development process ensures that training is consistent, effective and
based on actual job performance requirements.
PetroChem operating procedures utilize the organized guidelines in
reference to 29 CFR 1910.119 (f) and contain the following guidelines.
Mandates & Policies
·
Federal mandates
·
Company Policies
·
Environmental Compliance
·
Gas tests for Potential
Hazards
·
Process set points that
contain critical parameters, control devices, indicators, set points and
automatic actions.
·
Critical equipment alarms that
contain alarms, set points, probable causes and operator responses.
·
Safety and Health Measures
Cautions
·
Safe Works Practices
·
Consequences of deviation that
contain parameters, operating ranges and operator response.
·
Procedures contain
identification number for identification and reference.
·
Procedures are written in the
worst scenario
·
Hazards and Hidden Traps
Special Format
Our procedures embrace a special format with headers, footers, and special
mandate sections. The following standards
are common in our procedures.
·
Written consistently with one
another, having the same appearance.
·
Written clearly, precisely,
short and easy to use.
·
Terminology is consistent in
all procedures
·
Written in simple outline
form. Use one or two imperative commands utilized in a sentence.
·
Multiple commands are
acceptable, if they pertain to the same piece of equipment and are positioned
close together in the sentence.
Special Categories
PetroChem
procedures contain the following categories:
·
Purpose
·
Prerequisites
·
Required.
·
Safety
·
Required references
PetroChem uses safe works practices in the procedures as follows.
·
Barricade
·
Lockout/Tag-out
·
Electrical Lockout/Tag-out
·
De-Energizing of Electrical
Equipment
·
Equipment Isolation
·
Blinding
·
Unit Limit Blinding
·
Tables for Control Valves
Action & Fail Safe Positions
To emphasis safety, hazard, hidden traps, and unsafe conditions, PetroChem
inserts caution statements in the procedures to warn personnel of potential
hazards. Numerous caution statements
inform employees of hazards, while note statements inform of special processes
for conducting a task.
Program
Content for Operation
PetroChem training materials provide clear instructions for safely
conducting activities involved in each process and are consistent with the
following process safety information:
·
They address steps for each
operating phase, operating limits, safety and health considerations and safety
systems and their functions.
·
The development of unit
operating manuals and on-the-job-training checklists utilize the organized
training approach in reference to 29 CFR 1910.119 (f).
Specific training manuals are as follows:
Operating
Training Manuals
PetroChem unit
operating manuals for specific units utilize the organized training approach in
reference to 29 CFR 1910.119 (f). Unit
operating manuals include the following information:
·
Purpose
·
Process Overview
·
Process Description
·
Process Chemistry
·
Equipment Operational
Description
·
Standard Operating
Configuration
·
Process Hazards & Safety
·
Utilities Systems
·
Process Set Points
·
Consequence of Deviation
·
Alarm Set Points &
Operator Response
·
Response to Emergency
Conditions & Abnormal Conditions
·
Figures/Diagrams
·
Piping & Instrumentation
Diagrams
·
Maintenance/Inspections of
Equipment
Operating Procedures
PetroChem develops and
organizes operating procedures into different categories that may be used for
class phase training. PetroChem
procedures are divided into the following categories:
·
Start-Up and Shutdown Procedures
·
Emergency Procedures
·
Equipment Start-up, Shutdown and Swapping
Procedures Utility Systems Checklists
Procedures
·
Equipment Preparation for Maintenance and
Inspection Procedures
Start-up and Shutdown Procedures for each
specific unit are as follows:
·
Normal Unit Start-Up
·
Normal Unit Shutdown
·
Unit Shutdown for a Turnaround Unit Start-up following a Turnaround
·
Stand-By Conditions
Every applicable
Emergency Procedure is developed for each specific process unit.
PetroChem
develops Start-Up, Shutdown and Swapping Procedures for equipment that is
performed daily by operators and other task such as unload and load catalyst
from/to a reactor that are performed by the operator. Some of these equipment procedures may be
written generically.
Utility Systems
Checklists Procedures are developed for
each of the utility in each specific process unit.
Equipment
Preparation for Maintenance and Inspection Procedures is developed for each
individual piece of equipment in each specific process unit. Some maintenance and inspection procedures
may be written generically.
On-The-Job
Training Checklists
PetroChem on-the-job training checklists provide an effective method of
training operators to perform their job duties, as well as providing documentation
that each employee has been adequately trained in the procedures necessary to
the operation of the unit.
An effective
on-the-job training program will provide a method of verifying that the
employee:
·
Understand the tasks
associated with their jobs.
·
Understand the hazards
associated with performing those tasks.
·
Possess the skills to perform
their jobs.
·
Are aware of the precautions
to prevent incidents that can cause injury, loss-of-production, or adverse
impact on the plant, community or environment
PetroChem
on-the-job training checklists employ a unique training technique.
·
Company designates the
trainers and evaluators.
·
Trainer demonstrates to the
trainee all tasks within the scope of the on-the-job training procedure
checklist.
·
The experienced employee
demonstrates all tasks to the trainees.
·
The trainee is given adequate
time to practice the tasks prior to the performance evaluation.
·
Safety is the primary
consideration.
·
Trainer reviews all applicable
safety requirements with trainee prior to commencing the training.
·
The trainees must be familiar
with all general plant safety standards as well as with the standards specific
to each task performed.
·
After the trainee has had
plenty of opportunities to practice the required procedures and feels confident
in his/her ability to perform competently and safely, the evaluator must
accompany the trainee as he/she performs each required task on the OJT
checklist.
·
The evaluator evaluates the
performance of the trainee in terms of knowledge, correct actions and safety
awareness.
·
Upon successful completion of
all the on-the-job checklist items, the Unit Supervisor or designee conducts an
interview.
Guidelines & Format
Some elements of the on-the-job-training checklist such as headers, footers,
safety and required References sections utilize the same format as operating
procedures. Refer the "Operating
Procedure Format" section mentioned previously in this text for
clarification. The arrangement below is
used in on-the-job training checklist.
·
Scope
·
Prerequisites
·
Knowledge Requirements
·
Performance Requirements
Nine Sections
PetroChem on-the-job training checklist consists of nine sections for each
specific unit. Each division is
applicable to that particular unit. Each
section is applicable to the specific process unit. For example, tasks applicable to safety of
the process unit are involved in the safety section, including training on fire
equipment, hazards, fire equipment monthly inspections, etc. On-the-job training
checklists consists of the following nine sections:
·
Process Theory
·
Unit Safety
·
Environmental Compliance
·
Routine Round Tasks
·
Utilities Unit
Equipment Preparation for
·
Maintenance/Inspection
·
Abnormal/Emergency Conditions
·
Start-Ups and Shutdowns
·
Preventive Maintenance
Customized
&Computerized Examinations
PetroChem
provides employee proficiency examinations for certification and to maintain
training records. These computerize examinations derive from the training programs
specifically for the facilities and specific job skill classifications.
Each
computerized training program examination contains the following:
·
Each examination contains approximately 200 to
300 questions.
·
An authorize personnel can administer the
examination and may select the number of questions at random, (i.e. 50 or 60
questions out of a possible 300).
·
The program grades the examination and provides a
study guide for failed tests that will provide the employee with references to
aid in studying for future testing.
·
The program will maintain testing records that
may be utilized for notifying employees of re-certification requirements.
·
The program has built in security providing user
ID’s and passwords.
Other Services
Skill Based Training Program
PetroChem
Training has initiated the latest manner of training, the Skill Based Pay Training Program. This program is a competency/knowledge-based
compensation program, which rewards employees for acquiring and demonstrating
work-related skills and capabilities. There are also fundamental elements in
the skill-based pay that differentiate them from the more traditional job based
pay system.
·
Skill based pay is a person based pay system
rather than a job based system.
Employees are rewarded for the range of skills or work they can do
rather than for a specific job they are doing at a specific time. Under the
skill-based pay, rewards typically follow an employee's demonstration that the
employee has acquired and can perform new work related skills. These skills may be components of particular
jobs or may cut across different jobs.
·
In the base pay system, an employee's pay
typically changes when his/her job changes. Pay increases in the skill based
pay system are not linked to work changes but are linked to mastering new
skills or broadening the number of skills an employee is able to effectively
perform.
·
Seniority does not play a role in skill based pay
system because of the emphasis on acquiring and utilizing a variety of skills
in a work situation.
·
Opportunities for advancement and higher wages
are normally greater in skill based system than the job base system. Employees who demonstrate multi-skilled
proficiency in many job areas are more valuable to the organization.
·
Self-directed work team, quality circles, total
quality management and other employee involvement and empowerment practices are
often utilized as an integral part of the skill based pay system. The concept
of employee empowerment is consistent with the "person base" nature
of skill based pay system in which the employee has a primary responsibility to
broaden or deepen the level of his or her work skills.
Skill based pay
changes employees who have day-to-day responsibility for managing themselves
and the work they do with a minimum of direct supervision. Members of teams typically handle job
assignments, plan and schedule work, make production and /or service related
decisions, and take action on problems.
Audits
As consultants,
PetroChem can perform audits on existing training programs. And if not in
compliance, we revise and edit the training programs to meet current and
pending regulations. At the same time,
we incorporate the revised material, develop personnel proficiency examinations
and computerize your training programs.
Process Safety
Management Audits
In addition, we
perform Process Safety Management audits for facilities that require these
types of audits. Our audits determine if the company process safety management
system in place functions properly, and confirms that the facilities are
designed, constructed, operated, and maintained such that the safety and health
of employees, public, and the environment are being properly protected.
PetroChem places emphasis on the assessment and verification of the process
safety management system that ensures on-going hazard control on the
facilities.
Environmental
Procedures
PetroChem
develop federally mandated environmental procedures which include:
·
Environmental Policy that contains waste
management practices and facility inspections.
·
Emergency Procedures that involves spill response
notifications spill clean up; spill inspections preparation of SPCC plan,
material handling and storage, container handling and precautions.
·
Emergency Planning, Reporting, and Notification
that implicates hazardous chemical reporting, toxic release reporting and
preparation of emergency plan.
·
Hazardous Waste Management
·
Solid Waste Management
·
Chemical Hazards Communication Program
·
Wastewater Management and Potable Water
·
Above Ground Storage Tanks and Underground
Storage Tanks
Safety Procedures
PetroChem develops safety and health
procedure measures to prevent incidents. Our safety and health procedures
involves safe work practices such as lockout/tag outs, gas testing, standby
situations, general work permits, hot permits, entry permits, opening/blinding
permits, contractor's safety responsibilities, energy isolation procedures and
electrical isolation procedures.
In addition,
PetroChem safety and health procedures illustrate the proper specifications and
locations for walking surfaces standards, means of egress, occupational health
and environmental controls, hazardous material, personal protective equipment,
environmental controls, medical and first aid, fire protection, material
handling and storage, machinery guarding and other proceedings.
Training
Programs In English & Spanish
PetroChem consultants
are fluent in both English and Spanish and have earned university degrees in
both languages. Oral/written fluency in
Spanish is offered. Our consultants have taught professionally and accumulated
years of experience in developing the latest in training curriculum. Along with teaching experience, our
consultants are masters in the development of any industry’s training
programs. For your added convenience our
training program can be developed in Spanish and English.
Clients
PetroChem
Training has worked with many individuals and organizations in various
industries. Working across many industries, we have developed a broad knowledge
of practices and an ability to adapt and mold to different environments. With a
specialization in various industries, PetroChem Training has extensive
cross-functional experience to provide your organization.
Some of the
clients PetroChem Training has worked with include:
·
Kellogg Brown Root in
·
3M Electro & Communications in
·
·
Technip USA Corporation in
·
Sulak Hay & Company PC Accountants
·
Occidental of Elk Hills, Inc.,
in
·
Flying J Refining Company in
·
G. Anderson Enterprises in
·
·
Giant
Refining Company in
·
Citgo Refinery Co. in
·
Nigerian National Petroleum Corporation in
·
Magnisol S.A. in
Quito, Ecuador, South America
·
Navajo Refining Company
in
·
Enron Corp in
·
